2008 lawlor workshop.pdf

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