2008 lawlor workshop.pdf
TRANSCRIPT
ISSCT Workshop 200830 June to 4 July
ISSCT Workshop 200830 June to 4 July
Warren LawlorJuly 2008
Contents
BackgroundVenueTechnical SessionsVisitsConclusion
Background
ISSCT Congress every 3 yearsWorkshops held between CongressesWorkshops:
Less formalMainly slide show presentationsDiscussion encouragedIncludes site visits
Workshop theme:Design, Manufacturing and maintenance of sugar mill equipment
Background
Workshop held in conjunction with SIMTEC:
(Symposium and Technology Exhibition on the Sugar & Alcohol Industry)
Venue
Brazil
Venue
Peracicaba, Brazil
Venue
The Old Sugar Mill, Peracicaba, Brazil
Technical Sessions
Four technical sessionskeynote addressPresentationsDiscussion
Over 25 presentations4 Site visits
1. Overview of Brazilian Industry (Edgard Gomes Beauclair of STAB)
Sugar Cane In Brazil 20076 million hectares470 million tonnes of cane29 million tonnes of sugar17 billion liters of ethanol83 tonnes sugarcane per hectare
1. Overview of Brazilian Industry (Edgard Gomes Beauclair of STAB)
Brazillian Plants357 plants produce sugar, ethanol, and some cogeneration88 more mills planned by 2010 (US$ 17 Billion)
20551%
19849%
22753%
20047%
25255%
20345%
27757%
21043%
30458%
21742%
33460%
22540%
0
100
200
300
400
500
600
Million tonnes
2005/06 2006/07 2007/08 2008/09 2009/10 2010/11
For Ethanoll
For sugar
403
559521
487455427
1. Overview of Brazilian Industry (Edgard Gomes Beauclair of STAB)
Increase of 30 millions t/year
1. Overview of Brazilian Industry (Edgard Gomes Beauclair of STAB)
Environmetal issuesCane for ethanol is not replacing food production (previously unproductive land)New cane land not within Amazon region
Amazon forest
Pantanal wetlands Atlantic coastal forest
1. Overview of Brazilian Industry (Edgard Gomes Beauclair of STAB)
SummaryBrazilian industry is focused on sugarcane as an energy cropProducts include:
Ethanol from juice productsEthanol from biomass (Hydrolysis)Biodiesel from biomassElectricitySugar products
BioedieselPlant
Barralcool Mill(First in Brazil to produce sugar, ethanol, electricity and biodiesel)
2. Factory and factory system design (Jose Oliverio of Dedini)
Vision for future of sugar industrySustainable development based on producing biofuels and bioenergy from sugarcane.
Vision of sugarcane as energyOne tonne of sugar cane = 1.2 barrels of oil(1/3 bagasse, 1/3 trash, 1/3 sugar)Bioelecticity from bagasse, trash, dunderBioethonol from juice, bagasse and trashBiodiesel from integrated sugar and bioethanol mill
2. Factory and factory system design (Jose Oliverio of Dedini)
Traditional Technology
PRODUCT FLOW
HIGH ORESSURE STEAM FLOW (DRIVING PURPOSE)LOW PRESSURE STEAM FLOW (THERMAL PURPOSE)
ELECTRICITYGENERATION
(TURBOGENERATOR)
CANE RECEPTION/PREPARATION EXTRACTION
SURPLUS BAGASSE
BAGASSE
JUICE SUGARPROCESS
SUGAR
MOLASSES
STEAMGENERATION
(BOILER)
PRODUCT FLOW
HIGH ORESSURE STEAM FLOW (DRIVING PURPOSE)LOW PRESSURE STEAM FLOW (THERMAL PURPOSE)
PRODUCT FLOW
HIGH ORESSURE STEAM FLOW (DRIVING PURPOSE)HIGH ORESSURE STEAM FLOW (DRIVING PURPOSE)LOW PRESSURE STEAM FLOW (THERMAL PURPOSE)LOW PRESSURE STEAM FLOW (THERMAL PURPOSE)
ELECTRICITYGENERATION
(TURBOGENERATOR)
CANE RECEPTION/PREPARATION EXTRACTION
SURPLUS BAGASSE
BAGASSE
JUICE
SURPLUS BAGASSE
BAGASSE
JUICE SUGARPROCESS
SUGAR
MOLASSESMOLASSES
STEAMGENERATION
(BOILER)
2. Factory and factory system design (Jose Oliverio of Dedini)
Traditional Technology Optimised
BAGASSE
JUICEJUICE
CANE RECEPTION/PREPARATION EXTRACTION
ELECTRICITYGENERATION
(TURBOGENERATION)
STEAMGENERATION
(BOILER)
BIOETHANOL
STILLAGE
SUGAR
MOLASSES
SUGARPROCESS
BIOETHANOLPROCESS
BIOELECTRICITY
BAGASSE
JUICEJUICE
CANE RECEPTION/PREPARATION EXTRACTION
ELECTRICITYGENERATION
(TURBOGENERATION)
STEAMGENERATION
(BOILER)
BIOETHANOL
STILLAGE
SUGAR
MOLASSES
SUGARPROCESS
BIOETHANOLPROCESSB
AGASSE
JUICEJUICE
JUICEJUICE
CANE RECEPTION/PREPARATION EXTRACTION
ELECTRICITYGENERATION
(TURBOGENERATION)
STEAMGENERATION
(BOILER)
BIOETHANOL
STILLAGE
BIOETHANOL
STILLAGE
SUGAR
MOLASSES
SUGAR
MOLASSES
SUGARPROCESS
BIOETHANOLPROCESS
BIOELECTRICITY
2. Factory and factory system design (Jose Oliverio of Dedini)
Future (Electricity optimised)
2. Factory and factory system design (Jose Oliverio of Dedini)
Future (Ethanol optimised)
2. Factory and factory system design (Jose Oliverio of Dedini)
Future (Biodiesel optimised)
LAND
RESOURCES
SYSTEMS
MANAGEMENT
BIODIESEL
CANE
GRAIN
INTEGRATED FARMING
SUGARCANE+
GRAIN
OIL
GRAIN MEAL
BIOELECTRICITY
BIOETHANOL
STILLAGE
BIODIESEL
GLYCERIN
SUGARCANE+
GRAININTEGRATEDPROCESSES
MILL
TECHNOLOGY OPTIMIZATION TO INTEGRATED BIODIESEL
PRODUCTION3rd GENERATION
TECHNOLOGY OPTIMIZATION TO INTEGRATED BIODIESEL
PRODUCTION3rd GENERATION
LAND
RESOURCES
SYSTEMS
MANAGEMENT
BIODIESEL
CANE
GRAIN
INTEGRATED FARMING
SUGARCANE+
GRAIN
OIL
GRAIN MEAL
BIOELECTRICITY
BIOETHANOL
STILLAGE
BIODIESEL
GLYCERIN
SUGARCANE+
GRAININTEGRATEDPROCESSES
MILL
LANDLAND
RESOURCESRESOURCES
SYSTEMSSYSTEMS
MANAGEMENTMANAGEMENT
BIODIESELBIODIESEL
CANECANE
GRAINGRAIN
INTEGRATED FARMING
SUGARCANE+
GRAIN
OILOIL
GRAIN MEALGRAIN MEAL
BIOELECTRICITYBIOELECTRICITY
BIOETHANOLBIOETHANOL
STILLAGESTILLAGE
BIODIESEL
GLYCERIN
BIODIESELBIODIESEL
GLYCERINGLYCERIN
SUGARCANE+
GRAININTEGRATEDPROCESSES
MILL
TECHNOLOGY OPTIMIZATION TO INTEGRATED BIODIESEL
PRODUCTION3rd GENERATION
TECHNOLOGY OPTIMIZATION TO INTEGRATED BIODIESEL
PRODUCTION3rd GENERATION
TECHNOLOGY OPTIMIZATION TO INTEGRATED BIODIESEL
PRODUCTION3rd GENERATION
TECHNOLOGY OPTIMIZATION TO INTEGRATED BIODIESEL
PRODUCTION3rd GENERATION
2. Factory and factory system design (Jose Oliverio of Dedini)
Vision for future of sugar industry
5. Concept of an energy efficient 6000 t/day sugar factory (Boris Morgenroth)
Emerging technologiesDiffuser technology & return of clarifier underflow to diffuserFalling Film EvaporatorsIncreased 5th effect vapour temperature (0,15 bar (a) to 0,55 bar (a))Vapour bleeding from all effectsAll pans are supplied with vapour 3 of ~ 100 °CContinuous pans for A, B and C productA-Seed cooling massecuite plant A Syrup wash for A-Sugar Stepwise flashing of condensates and reuse of flashUsing condensate for pre-heating of limed juiceHigh g factor continuous centrifugalsHigh pressure boiler and turbineHigh level of automation
5. Concept of an energy efficient 6000 t/day sugar factory (Boris Morgenroth)
Results (Benchmarking):
Steam demand: 26 – 34 % on cane (raw / refined)Power demand: 25 – 32 kWh/t canePower export: 90 – 125 kWh/t cane at 14 % fiber on cane
Extraction recovery: ~ 98 %
Overall recovery: ~ 87 %
Sugar color: < 35 - 45 IU
6. Simple innovative, proven equipment and processes for improving energy efficiency (Bruce Moor of Bosch)
Modifications can be made to an existing “80’s” factory for efficiency improvements:
High pressure boilersContinuous pans using V2 or V3DiffusersMud recycle to diffuserElectric drives on shredder and millsIncreased boiler efficiency (air heaters / economisers)Long tube rising film evaporators
Result:Export power potential increased from 10.7 MW to 47.7 MW
7. Fives Cail equipment and designs for reduced maintenance and improved efficiency (Simon Trancart of Fives Cail)
In line whole stick shredderPower reduced by 15 to 20% compared to traditional knives and shredder.
7. Fives Cail equipment and designs for reduced maintenance and improved efficiency (Simon Trancart of
Fives Cail)
MillMax 3 roll mill12% lower capital cost40% lower maintenance cost30% lower power consumption compared to 4 roll mill
11. Development of pinionless mill (DK Goel from ISGEC)
ISGEC has developed a range of mills up to 340 t/h
11. Development of pinionless mill (DK Goel from ISGEC)
Stress distributionPinionless vs conventional
11. Development of pinionless mill (DK Goel from ISGEC)
DisplacementPinionless vs conventional
11. Development of pinionless mill (DK Goel from ISGEC)
Shear force and bending moment diagramPinionless vs conventional
11. Development of pinionless mill (DK Goel from ISGEC)
Drive efficiency
88%
Not Applicable
Not Applicable
95%
96%
96%
Pinionless Drive
76%Total Drive Efficiency
92%Mill Roll Crown pinion5
97%Tail Bar/Rope Coupling4
92%Reduction Gearing3
96%AC Motor2
96%VFD1
Conventional DriveEquipmentSl No
11. Development of pinionless mill (DK Goel from ISGEC)
In operation
13. High Pressure Cogeneration (AK Subramanian of ISGEC)
13. High Pressure Cogeneration (AK Subramanian of ISGEC)
Reason45 bar to 105 bar = 32% more power generation per tone of bagasse
FeaturesPressurised feedwater (220 Deg.C)Travelling grate (alternative fuels)Electrostatic precpitatorsOn line steam and water analysis
Claims65 bar to 105 bar 10% increase in capital costAll boilers with pressure greater than 45 bar require dedicated water circuit.
13. High Pressure Cogeneration (AK Subramanian of ISGEC)
13. High Pressure Cogeneration (AK Subramanian of ISGEC)
13. High Pressure Cogeneration (AK Subramanian of ISGEC)
15. Selection use and maintenance of process pumps (Michael Yang of Sulzer)
Pump selection criterion should be based on lifecycle cost – not capital costSelection criteria should include:
Pump material and shaft sealing arrangementPump efficiencyMaintenance costQuality
15. Selection use and maintenance of process pumps (Michael Yang of Sulzer)
Capital cost is significant for pumps < 10 kWOver 150 kW capital cost is negligible
15. Selection use and maintenance of process pumps (Michael Yang of Sulzer)
Variable frequency drive vs. valve control25 to 30% energy saving (If highly throttled)(Sulzer has software available to analyze pumping systems and determine savings)
20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett)
Examples: TH Cylindrical continuous pan
20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett)
Examples: Rock and sand removal
20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett)
Examples: Two roll mill
20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett)
Examples: Bosch chainless diffuser
20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett)
Examples: Fives Cail multitube sugar drier
20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett)
Examples: Cane cleaning
20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett)
Examples: BMA OVC
20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett)
… if you are building, expanding or modifyinga sugarcane factory, and you are installing:
•Knives and a heavy duty shredder rather than an in-line, whole-stick shredder, or•A tandem of 4-roll mills rather than a diffuser, 2-roll mills or both, or•Robert evaporators on 1st and 2nd effects rather thanlong-tube film or plate, or•Batch pans rather than continuous pans on all boilings, or•Lower pressure boilers (< 45 bar) rather than high pressure boilers (> 86 bar) …
20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett)
22. SRI swirl spreaders (Anthony Mann and Geoff Kent of SRI)
Bagasse distribution
22. SRI swirl spreaders (Anthony Mann and Geoff Kent of SRI)
SRI Swirl Spreader SystemSwirl spreadersModifications to air distribution system
22. SRI swirl spreaders (Anthony Mann and Geoff Kent of SRI)
Benefits10% increase in boiler capacityImproved flame stabilityReduces sensitivity to bagasse moisture
24. Jigger systems to improve vacuum pan performance (Ross Broadfoot of Queensland University of Technology)
Incondensible gasses used as “jigger steam”
•Improves circulation (20%)
•Improves heat transfer (5 to 30%)
•Shorter cycle times
•Reduced calandria pressure
•Applicable to Batch and Continuous pans
24. Jigger systems to improve vacuum pan performance (Ross Broadfoot of Queensland University of Technology)
Laser drilled stainless steel tubingHoles of 0.2 mm diameter 100 000 holes per meter
24. Jigger systems to improve vacuum pan performance (Ross Broadfoot of Queensland University of Technology)
Air test after 15 000 hours of operation
Site VisitsTGM: Gearbox and Turbine manufacturer
Wide range of conventional and planetary gearboxesFrom 85 kNm to 4000 kNm capacityWide range of turbines up to 250 MW
Site VisitsUsina Mandu Sugar Factory and distillery
12 000 tc/dA lot of TGM equipment
Site VisitsDedini
One of 6 large manufacturing facilities visitedDesign and construction of complete sugar factories and distilleriesServices:
SugarBrewariesMiningSteel
Site VisitsUsina Da Barra white sugar factory and distillery
38 000 tc/d (3 lines)Produces:
White, amorphous and liquid sugar
Conclusion
Well attended62 participants15 countries
Increased focus on energy productsDriving innovation
Brazillian industry has a forward looking vision
Thinking bigThinking energy
Exciting times for the Sugar Industry worldwide
Acknowledgements
All presenters at the 2008 ISSCT WorkshopBooker Tate Limited
Obrigado / Thank youVisit our website
www.booker-tate.co.uk
Obrigado / Thank youVisit our website
www.booker-tate.co.uk