Avr 08

XXIInd Symposium. MASS AND ENERGY BALANCE AND THE PERFORMANCE OF SUGAR FACTORIES AND REFINERIES.

 

Welcome AVH Mauritius

 

The symposium presentation papers will be published on the AVH website: http://www.associationavh.com/us/

 

Intro Book of Abstracts AVH 2015

 

Contents

First day: 25/02/2015

 

9:00 – Opening of Symposium, Holiday Inn, Room Mon Trésor AB

Mr Jacques Marrier d’UNIENVILLE, CEO, Omnicane Group, Mauritius

Mr Sébastien LAVOIPIERRE, Chief Operations Officer – Industrial activities Alteo Group, Mauritius

Mr Jean Claude AUTREY, General Secretary, ISSCT, Mauritius

Prof. Mohamed MATHLOUTHI, Association AVH, Reims, France

 

Session I: Mass balance and yield of sugar factory and refinery

Chair: Lindsay Fayolle, OMOL, MU

9:30: – Different alternatives of sugar refining and the control of colour, Sébastien Schellen, DeSmet Engineers & Contractors, Waterloo, Belgium

10:00 – Improving the yield in boiling workshop through viscosity depressing in pan and mixers.

François GHIGNY, Green Europe, Gouvy, Belgium

10: 30 – Coffee Break, Posters and Exhibitors

 

Session II : Energy balance in sugar factories and refineries

Chair : Maciej STARZAK, SMRI, Durban, RSA 

11:20 – Improving energy balance in an integrated cane sugar complex: Omnicane as example,   Gérard Chasteau de Baylon, Omnicane, MU

11:40 – Maximizing Power Export by Reducing Steam Consumption and Implementing Heat Recovery Systems, Field St J. Vawda A.S, Sarir E.M, Carbo-Solutions International, USA

12:00Energy balance in sugar mill and refinery: Latest heat circuit model, Dr G.S.C. RAO, Global Cane Sugar Services PVT Ltd, New Delhi

12:30 – Lunch

 

Session II: Energy balance in sugar factories and refineries Workshop

Moderator: Tiranjiv PARSAN, Alteo Group, MU 

14:00 – Falling film evaporator in cane sugar industry, another way to save energy, Xavier LAMBLIN, Fives Cail, Villeneuve d’Ascq, France

14:10 – Control of the energy concept in sugar factory by use of a reliable assessment, Sébastien SCHELLEN, DeSmet Engineers & Contractors, Waterloo, Belgium

14: 20 – Optimization of energy production through water treatment by organic technical aids, François GHIGNY, Green Europe, Gouvy, Belgium

14:30 – Discussion

15: 00 – Transfer and Visit of the Sugar Museum & Factory (L’AVENTURE DU SUCRE)

19:30    Symposium Dinner at RESTAURANT LE FANGOURIN

 

Second day: 26/02/2015

Session III: Modeling of Sugar processes to increase performance

Chair : Philippe REISER, CEDUS, Paris

9: 00 – Mass and Energy Balance Modelling of a Sugar Mill, A comparison of MATLAB™ and SUGARS™ simulations,  Maciej STARZAK and Steve DAVIS, SMRI Durban, RSA

9: 30 – Process Modelling Using Sugars™ – Cane Factory, Warner WEISS, Sugars International LLC, Denver, USA 

10: 00 – Control of Crystallization using ANSYS Software, Thierry MARCHAL, Wavre, Belgium 

10: 30 – Coffee Break, Posters and Exhibitors

 

Session IVa: New Trends in designing sugar mills and refineries

Chair: Mohamed MATHLOUTHI, Association AVH

11: 20 – Challenges in transfering proven efficient design from beet to cane based on practical experience, Andreas LEHNBERGER, BMA, Braunschweig, Germany 

11: 50 – Modeling of sugar cane mill using“CAMEIO” Plant Managing Solutions Software , Alain BELOTTI, Fives Sugar Consulting, Fives Cail, Villeneuve d’Ascq, France

12:30 – Lunch

 

Session IVb: New Trends in designing sugar mills and refineries

Chair: Gilles SCHREVEL, R.T. Tienen, Belgium

14:00 – Role of Indian Sugar Industry in achieving best operating performance & efficiency, M.S. SUNDARAM, JP Mukerji & Associates PVT Ltd.

14: 20 – Techno-economically viable options for chasing energy efficiency in a stand-alone sugar refinery, Alan Fraser, Sven Prigge, PGBI, RSA, , M. Reza LAULLOO, Durrah Sugar, KSA

14: 40 – Reduced losses and increased capacity from accurate and real-time process information, Amélia de Andrade Ferraz and Bjarne Christian Nielsen, Neltec Denmark

15: 00 Concluding Remarks, Mohamed MATHLOUTHI, Association AVH

15h30 – 18h30 – Transfer and visit of Omnicane Refinery, La Baraque

18: 30 – Dining Buffet, offered by Omnicane Milling Operations, Ltd

At Hotel Holday Inn Airport

 

Paper # 1

Different alternatives of sugar refining and the control of colour

Sébastien Schellen

 De Smet Engineers & Contractors, Waterloo, Belgique

DSEC presents a predictive model for the optimization of complete sugar processes which has been validated in beets and cane sugar factories as well as in raw sugar refineries. The  innovation  of  DSEC’s  model  is  its  capability  to  follow the  colour  and  the  purity  of  process.  While traditional  commercial  software  uses  arbitrary  ratios  to  define colour and purity, it is essential for DSEC to consider precise and in-plant  validated  equations  of  crystallization  and  centrifugation operations to guarantee the end-sugar colour, opening the way to mastering and optimizing the heart of the process, especially in raw sugar refineries.

It provides therefore more accurate performance predictions in terms of product quality and utilities consumption. It allows an in-depth audit of existing factories so as to identify possible process bottlenecks as well as potential energy efficiency increases. One of the major interests of this model based on Matlab / Simulink® software is its capability to simulate the complete plant in one integrated calculation tool considering also the cogeneration and plant utilities. Thanks to its friendly presentation similar to a process flow diagram the model gives an easy overview on all streams’ physical data and provides the basis of design for all key equipments. By simulating different technological solutions DSEC is able to propose reliable technical and economical analysis leading to profitable investment decisions.

 

Paper # 2

Improving the yield in boiling workshop through viscosity depressing in pan and mixers 

François GHIGNY

Green Europe, Belgium

Sugar rich syrup is boiled to obtain a massecuite. Thereafter, the massecuite is subjected to at least one stage of continuous mixing under vacuum to promote crystallization of the massecuite. The crystallized massecuite is then centrifuged to separate the crystals from the mother liquor. The mother liquor drained in the first discharge of centrifugal is called poor runoff (lower purity) and a second discharge consisting in washing water is called rich runoff (higher purity). Substantially all of the runoffs is recycled to the continuous mixing stage under vacuum. Accordingly, the massecuite and the crystals are subjected to a treatment having continuity during mixing under vacuum to maintain homogeneity of the sugar crystals.

In the sugar manufactures, the crystallization processes are often a delicate and a bottle neck steps. Control of sugar crystallization is crucial to produce a large number of crystals at the desired size in a shortest delay.

The costs reduction objectives are the key of success for the productivity improvements.

The adjunction of fluidizing additives in the massecuite induces a crystal growth kinetic effect by reducing the viscosity , as  well as inclusions. In the meantime, bubbles release is improved by an active-surface reaction. We developed an FDA approved and green technology fluidizing additive which increases sugar recovery in poor runoffs  without interfering on the sugar quality.

 

Paper # 3

Improving energy balance in an integrated cane sugar complex:

 Omnicane as example

Gérard Chasteau de Baylon

Omnicane, La Baraque, Mauritius

 

Paper # 4

Maximizing Power Export by Reducing Steam Consumption and Implementing Heat Recovery Systems

Field St J. Vawda A.S, Sarir E.M,

Carbo-Solutions International, USA

info@nullcarboua.com

In the early days of the cane sugar industry, sugar factories were designed to be energy self-sufficient with sugar being the primary product. Medium pressure boilers serving the electrical and heating needs of the sugar factory were the order of the day and there was no incentive to conserve bagasse.  However, since the 80s, there was a slow trend to keep sugar mills profitable by adding various by products, like alcohol, paper, board and speciality chemicals from bagasse and molasses. More recently, sugar factories began cogenerating for export to the local grid. In this paper we shall be focus on:

  1. The implication of energy improvement
  2. Guidelines for improving thermal efficiency.
  3. The economic justification for investing in energy efficiency.

KEYWORDS: bagasse, high pressure boilers, multiple effect evaporators, heat exchangers, co-generation

 

Paper # 5

Energy balance in Sugar Mill and Refinery- Latest heat circuit model

Dr. G.S.C. Rao and A.K. Srivastava

Global Canesugar Services Pvt. Ltd., New Delhi-110001, India

Sugar cane crop is most efficient in converting the solar energy into bio-mass and if the sugar extraction   process can be optimize to consume just 30 KW/ton of cane, electrical power and 34% steam on cane. One ton cane processed can replace > 120 KWh power generated from fossil fuel. World is looking for renewable source of energy to replace fossil fuel and sugar industry can play  a major role in it by exporting the surplus power.  So saving in energy for sugar extraction has become important.

To maximise the export of “cane-power many technologies in the heat circuit designs have been introduced especially in the last decade to reduce the steam consumption from 45% on cane to 34 % on cane in Indian Sugar Industry for the production of plantation white sugar. Each 1% saving of process steam demand can increase the exportable power by 3% in a bleed cum extraction-condensing TG set.

This presentation describes the latest heat loops with maximising the use of waste heat of vapour condensate, condensate flashing, Non condensable gasses etc for various heating purpose. Pan boiling has been shifted to continuous boiling using second /third vapour of a Quintuple effect evaporator.

Direct contact heating for various heating, molasses conditioning, low grade vapour for melting and Melt concentrator integration system has been described for optimising the steam requirement for refinery. The above energy economy measures has reduce the steam demand around 0.1-0.15 tons/ ton RSO in the refinery. Integration of melt concentrator for miscellaneous heating and recovery boiling     has brought the steam consumption 0.80 Ton /Ton RSO.

Presenters had implemented many above describes loops /equipments in sugar plants and also in annexed and stand alone refineries in India.

 

Paper # 6

Falling Film Evaporators in cane sugar industry, another way to save energy

Xavier Lamblin

Fives Group, Sugar/Bioenergy

The falling film evaporator has been widely used in the beet sugar industry for more than 30 years. This technology has been adapted and optimized for cane sugar factories addressing the increased risks of incrustation of the juice distribution system and heating surface due to an increased scaling propensity of cane juice. The developments carried out by Fives on falling film evaporator permitted the elimination of these problems. Falling film evaporators are characterized by the simplicity of installation and maintenance. The absence of a hydrostatic head means that for the same thermal power, lower ΔTs are possible, especially for intermediate and last effects of the evaporator station. Thus, reconfigurations of the bleedings may be possible, achieving lower steam consumptions than can be obtained with different evaporator technologies.

 

Paper # 7

Control of the energy concept in sugar factory by use of a reliable assessment

Sébastien Schellen

 De Smet Engineers & Contractors, Waterloo, Belgique

In a sugar factory or refinery, the energy is one of the major operational costs. Moreover, in cane sugar mills, energy could become a profitable income. Controlling the energy is a big challenge of the sugar industry while this concept is bounded through the complete process. In order to get reliable investment plans, it is absolutely essential to have a reliable and fully-integrated model. DSEC presents this assessment which is able to show the links between the four main energy levels starting from primary energy consumption to the deteriorated calories:

  • T > 130°C : acting on the cogeneration
  • 100°C < T < 130°C : optimizing juice/liquor concentration
  • 65°C < T < 100°C : controlling the consumptions especially for the crystallization
  • T > 65°C : recovering the energy

For each energy level our model is able to compute the wanted energy savings but thanks to all the links between the energy levels, it will also expose the impact on the complete process.

The presentation illustrates some improvements opportunities done in several plants. The numerous audits done by DSEC in worldwide sugar plants reinforce the credibility of the proposed process solutions. It will also expose the methodology of DSEC to make a profitable investment plan starting from a complete audit of the plant, analyzing different scenarii and finally integrating an accurate CAPEX/OPEX study.

 

Paper # 8

Optimization of energy production through water treatment by organics technical aids

François GHIGNY

Green Europe, Gouvy, Belgium

This paper deals with polyamine technology in boiler systems. We will give experimental examples to evidence the advantages of this technology (economy, health and environment friendly) as well as the ease of application.

Polyamines are efficient by a combination of 3 actions: pH control in feed water and condensates, filming protection of the feed tank, the boiler and condensate lines and the dispersion of scale forming salts. Polyamines do not increase the total dissolved solids level in the boiler, which reduces blow down and leads to lower water and energy costs. Dispersants in polyamines help in removing previously formed scale in the boiler, which is favourable to increase heat transfer coefficient and decrease energy consumption.

One of the most important properties of polyamines is the creation of a mono-molecular protective layer in the feed tank, the boiler and the condensate lines. This prevents corrosion and extends equipment life. This protective property allows running with minimum treatment during system shut down. In addition, the dosing of chemical directly into the make-up instead of feed water provides reduced dosage volume and less cost.

 

Paper # 9

Mass and Energy Balance Modelling of a Sugar Mill,

A comparison of MATLAB™ and SUGARS™ simulations.

Maciej STARZAK and Steve DAVIS

Sugar Milling Research Institute, Durban, South Africa

Abstract

The Sugar Milling Research Institute in Durban (South Africa) is undertaking broad techno-economic modelling of the sugarcane biorefinery as a basis for selecting products and processes with the highest potential for successful implementation. Although most of the fundamental processing steps involved in bio-refining are well-known, there is a need for a methodology capable of evaluating the integrated processes to identify the optimal set of products and the best route for producing them. The approach adopted at SMRI is a case study modelling of pre-selected plant configurations involving mass and energy balances of individual units constituting the biorefinery. A sugar-ethanol-cogeneration was chosen for the starting scenario.

In the presented study we report on a MATLAB™ model of the sugar mill only, putting special emphasis on the method of boiling house modelling. A flowchart illustration of the Weiss model of massecuite centrifuging along with a matrix representation of the respective mass and energy balances will be discussed in detail.  The results of MATLAB™ simulations for the entire mill will be compared with those obtained for the same mill configuration using SUGARS™ software.

 

 

Paper # 10

Process Modelling Using Sugars™ – Cane Factory

L. Warner Weiss

 Sugars International LLC, Denver, Colorado USA

The Sugars™ for Windows® program has been used since 1986 by sugar companies, engineering firms and equipment suppliers in more than 40 countries to model sugar processes to improve and designing factories and to evaluate equipment.  Thousands of processes have been modeled with Sugars.  It does the complete mass, energy and color balance for sugar processes of almost any configuration.  Development of the program began in 1984 and the first versions were sold in 1986 to two beet sugar companies operating in the United States.  The earliest version was a DOS program that required users to create text files to describe their models. Since that time, it has evolved into a full Windows program with a graphical interface provided by Microsoft Visio®.  Now, Sugars includes ethanol as a component property and XML data import and export can be added as an option.  The model of a cane factory is illustrated using the latest version of the program.

 

Paper # 11

Towards the Control of Crystallization Using ANSYS Software,

Thierry Marchal

ANSYS, Inc.Wavre, Belgium

Crystallization is a delicate process driving the success, or failure, of the entire sugar manufacturing activity.  It is essential to carefully monitors local parameters such as the temperature, rate of evaporation or the local kinematics of the reacting fluid to ensure a good quality of sugar.  In today’s economy facing new regulations, quality is not good enough anymore: it needs to be completed by high productivity.

In collaboration with industrial partners, we have developed a 3D transient, non-isothermal model of the crystallizer.  Different configurations of the device were considered to investigate various operating conditions and crystallizer tanks geometries in order to identify the ones the most likely to yield concrete productivity improvement such as a reduction by a factor two of the heating process without compromising with sugar quality.

The first results have been successfully validated with observations made with operating crystallizers; they provide valuable insights on how to modify the device and improve the operating conditions leading to an efficient crystallization process.  The introduction of multiphase modeling will be the necessary next step to refine the model and reach quantitative validation of the calculated trends.

Crystallizer

 

Paper # 12

Challenges by transferring proven efficient design from beet to cane based on practical experience

Lehnberger, Andreas,

BMA Braunschweigische Maschinenbauanstalt AG 

Braunschweig, Germany

In the past, development in beet and cane sugar factories took place separately. Both industries used to rely on their local sugar institutes and technologists, who were best aware of the local economic conditions. One major difference between the cane and beet sugar industries is the energy supply issue: The cane sugar factories are self-sufficient in energy by burning bagasse, whereas the beet sugar factories need to buy their primary energy.

Since the beginning, the beet sugar industry was driven by improving energy efficiency. Nowadays cane sugar factories are keen on improving their energy efficiency, too. Additional revenue shall be generated by selling power to the grid.

Recently, efficient designs proven in the beet sugar industry have been successfully transferred to cane sugar factories. The challenges in designing efficient sugar mills are explained especially for the sections Evaporation and Sugar Boiling.

 

Paper # 13

Modelling of cane sugar plant using “CAMEIOTM” Plant Managing Solutions software

Alain BELOTTI

Fives Sugar Consulting 

Villeneuve d’Ascq, France

A lot of modelling tools, ‘’homemade’’ or available on the market, are used by consultants, engineering companies, and sugar plants for sizing and balancing in the context of new project, investment, or operation optimization. The complexity of the process in a sugar plant resulting from the interaction between multiple streams (mass, heat, electricity, revenues) makes it difficult to reach the mandatory consolidation of the various balances, and thus the substantiated conclusions.

To answer the need to globally, quickly and accurately model a cane sugar plant with all its streams, Fives Sugar Consulting has developed a new methodological approach through a service/advice that relies on a team of experts and on a « homemade » software solution gathering more than 200 years of expertise: « CAMEIO™ Plant Manager Solution ». Thanks to this software combined with our expertise, we can model on a techno-economical basis various scenarios of a complete sugarcane plant with different technologies, varying raw materials and products prices, and then we accompany our clients to select the best scenario regarding CAPEX and ROI.

« CAMEIO™ Plant Manager Solution » can also be applied for existing plant through a periodical monitoring and comparison between actual and optimized settings at a given time with corresponding products prices and raw material characteristics. Using this model, we compare various combinations of settings in order to select the combination that leads to the maximum revenues and profits. The repetition of this settings optimization for each period of the campaign leads at the end to an additional revenue for the plant without any installation of new equipment.

 

Paper # 14

Role of Indian Sugar Industry in Achieving Best Operating Performance and Efficiency

M S Sundaram

J P Mukherji & Associates Pvt Ltd

Pune, India

The Indian share in the global sugar production has risen from 5% to 15% during the last five decades. Simultaneously, the Country has positioned itself as one of the most technically efficient sugar industries of the world.

In the present socio economic scenario, Sugar Industry in India face many challenges due to excess sugar production, low global prices of Sugar, higher prices of raw materials, etc. which have an unfavorable impact on the profitability of operations.

In spite of above adversities, the Sugar Industry in India has emerged as a successful business model, due to technical innovation, intelligent solution & knowledge sharing/ performance benchmarking accomplished by Premier Sugar Institutes & Knowledge Centers in the Country.

Indian factories have achieved lowest downtime by implementation of modern preventive maintenance strategies & spares inventory management, coupled with cane management & transportation techniques. Efficient cane preparation, latest development in milling technology, mill automation etc; have improved milling efficiency. Instrumentation, factory management & control strategies, controls based on monitoring of factory intermediates have led to improvement in Factory recovery, reducing sugar loss. Proper quality control, continuous monitoring of critical control parameters has enabled factories to manufacture high quality Product Sugar. Elaborate schemes have been implemented to reduce overall steam consumption to levels, which are unmatched world over. Cogeneration schemes with pressure & temperature rating ranging from 45 bara/450 0C to 125 bara/540 0C coupled with electrical energy saving measures in factory operations has resulted in highest electrical power export. On Pollution Control front, Air pollution control measures such as ESP, Biomethanation/ Incineration Techniques etc have enabled factory to attain stringent emission control norms. Water recycling & conservation measures have ensured Sugar Factories to attain “Zero Effluent Discharge” benchmark.

 

Paper # 15

Techno-economically viable options for chasing energy efficiency in a stand-alone sugar refinery

Alan Fraser, Sven Prigge, PGBI, RSA

M. Reza LAULLOO, Durrah Sugar, KSA

The efficient use of energy has become a key focus in modern industry, ostensibly to reduce greenhouse gases but primarily because it makes good business sense. With the reality of limited capital available for efficiency projects in our industry, the focus needs to be on low cost options for chasing energy efficiency. This paper revisits a variety of process techniques, both systems and operational practices that the refiner can consider to reduce the energy bill.”

 

Paper # 16

Reduced losses and increased capacity from accurate and real-time process information

By Amélia de Andrade Ferraz and Bjarne Christian Nielsen

 Neltec Denmark

When speaking about the efficiency of a factory or refinery, it is always necessary to focus on sugar losses – both known and unknown sugar losses.

Obviously both types of loss need to be as small as possible. The known losses should be well identified and controlled. Sugar sent to molasses gives a significant contribution to the sugar losses. Over-washing and centrifugals that are not well trimmed send good sugar to the recovery house where some of it ends in the molasses. These losses can be greatly reduced by having detailed and timely information about the performance of the centrifugals.

This paper presents data from different sugar factories worldwide, where the use of online colour information measured after the centrifugals allowed a significant reduction in good sugar sent to the recovery house. The amount of sugar sent to molasses was reduced and the production rate was increased.

 

Exhibitors AVH 2015

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