Technologies For Exporting Electricity

of 100 kWh/T of Clean Cane

While Producing White Sugar

A SUCCESS STORY

Speaker : Anurag Goyal At : 29th ISSCT, 7 Dec 2016, Chiang Mai, Thailand
ISGEC Heavy Engineering Ltd, India
 AUTHORS
Hasan Mushrif
Chairman & Managing Director

Mahesh P Joshi
General Manager

Milind P Chavan
Production manager
Sar Senapati Santaji Ghorpade Sugar Factory, India

Anurag Goyal
Isgec Heavy Engineering Limited, India
Email id: goyalsap08@gmail.com

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 OBJECTIVE
To set up a green field integrated sugar complex with
eco-friendly plant configuration and zero liquid discharge for
sustainable socio-economic development of rural area for:

o Production of plantation white sugar with high process

efficiencies
o Fuel grade ethanol with zero liquid discharge.
o High milling efficiency RME>96.5%,
o Low power consumption of i.e. <33.5 kW/T of cane,
including sugar, co-gen, distillery.
o Minimum process steam consumption to achieve
surplus power of minimum 100 kW/t cane for export.

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 CHALLENGES
• The Indian regulations require that a new sugar plant has
minimum aerial distance of 15 kM. from any of the
existing sugar plants.

• The land area available with us was on hill terrain and

could not accommodate the entire complex on a single
hillock. We had to spilt the plant on two adjacent hillocks
with a elevation difference of 40 m and horizontal
distance of 500 m.

• This was a challenge for us. But after discussion with our
engineering team, it was decided to put Mill on lower
hillock and rest of plant at the upper hillock.

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 PLANT VIEW

Process
plant
Cogen
plant
40 meter
elevation
difference
Mill
section

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 OVERVIEW OF PROJECT
Sar Senapati Santaji Ghorpade
Project Promoter
Sugar Factory
Sugar plant capacity 3500 tcd, expandable to 5000 tcd
Process Double sulphitation
Process steam consumption Less than 32% on cane
Co-gen plant capacity • 120 t/h, 110 bar, 540°C boiler
• 23 MW triple extraction cum
condensing turbo generator
Distillery Plant 35 kL/day with Zero liquid Discharge
Distillery boiler 10 t/h, slop incineration boiler
Sugar Complex power cons. 33.5 kW/t of cane
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 METHODOLOGY :
SELECTION OF MILL

• Minimum no. of cane preparatory

Higher devices with high PI>89
efficiency • Low speed milling achieve high
with less RME>96.5 @low power consume.
power cons.
• Use of planetary gear boxes to
minimise transmission losses

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 METHODOLOGY : SELECTION OF MILL
• Juice extraction section consumes 50% of total power
and hence require greater attention for selection of mill
configuration.
• Two stage cane preparation i.e. cane cutter & heavy
duty fiberizor, with energy-efficient flux-compensated
magnetic-amplifier rotor starters selected to achieve
higher P.I. (89+) at lower power.
• Low-speed milling (12.0 m/min roller speed) comprising
4 mills of size 915 mm x 1980 mm (36”x78”), each mill
with toothed roller pressure feeder, foot-mounted
planetary gear box and AC VFD drive, selected to
achieve higher Reduced mill extraction > 96.50% & at
lower power consumption (12 kW/T of cane)
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 3D VIEW OF THE MILL AT OUR PLANT

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 SITE PHOTOGRAPH OF MILLING TANDEM

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 TREND: STEAM CONSUMPTION

Our Target
32% on cane

Present : 35-37%
on cane

In 2000’s : 50% on cane

In 1980’s : 55% on cane

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 METHODOLOGY : STEAM
SAVING IN PROCESS HOUSE

• Heat recovery of SO2 gas

for sulphur melting
Eliminating the • Use of high temperature
use of live condensate for sugar wash in
steam high grade C/f
• Use of non condensable in
online molasses conditioners

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 STEAM SAVING IN PROCESS
HOUSE SULPHUR MELTING
• Sulphur got melted at 140°C temperature and about
0.3-0.5 % live steam (7 bar pressure) is used for sulphur
melting

• Sulphur burning is exothermic reaction and liberate

9726 kJ/kg energy. This thermal energy is used in small
re-boiler to generate steam, which is utilize for sulphur
melting.

• About 1.3 kW/Ton of cane extra power can be generate, to

avoid 0.5 % live steam for sulphur melting through waste
heat recovery system.
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 STEAM SAVING IN PROCESS
HOUSE SULPHUR MELTING

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 STEAM SAVING IN PROCESS
HOUSE: MOLASSES CONDITIONING
• Earlier Live steam at 1500C
was used for molasses
conditioning, that lead to
caramalisation of sugar and
higher colour load in process
house.

• Now 3rd effect vapour (1000C)

is used in specially designed
on line conditioners, which
eliminates live steam
consumption.
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 METHODOLOGY : STEAM
SAVING IN PROCESS HOUSE

Selection of • Quintuple evaporator system

equipment to • Heat recovery of LP exhaust condensate
suit • Use of direct-contact juice heaters
Extensive • Use of a condensate flash heat recovery
system
vapour
• Use of continuous pan
bleeding

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 METHODOLOGY: QUINTUPLE
CONFIGURATION
• Quintuple configuration evaporator is selected with
1st and 2nd effect as long tube evaporator and rest are
down take less Robert’s type evaporator.

• Maximum vapour bleeding from V2, V3 & V4 vapours, to

reduce steam consumption at 1st effect.

• Long tube evaporator for 1st and 2nd effect, to achieve

lower Δ T so that higher vapour temperature of 2nd/3rd
effect is maintained at more than 1000C for pan boiling.

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 METHODOLOGY: QUINTUPLE
CONFIGURATION

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 QUINTUPLECONFIGURATION:
VAPOUR BLEEDING PATTERN

1st Effect 2nd Effect 3rd Effect 4th Effect 5th Effect
S.K. FFE Robert’s Robert’s Robert’s
(2800 m2) (3000 m2) (1200 m2) (600 m2) (600 m2)

CJ- II CJ-I SJ-II RJ-II RJ-1st

heating heating heating heating heating

SJ-II ‘B’ Pan

heating Condenser
boiling

‘A’ &‘C’ ‘A’ &‘C’

Pan Grain
boiling boiling

Melter
Pan +Molasses
washing
conditioner

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 PRESSURE AND TEMPERATURE
PROFILE AT EVAPORATOR

400
350 128.2 Temperature(degC)
300 Pressure (kPA)
119.6
250 250.3
112.1
200 199.6
100.3
150 151.2 87.2
105.2
100
61.3
50 61.4
20
0
LP steam V1 V2 V3 V4 V5

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 STEAM SAVING IN PROCESS HEAT
RECOVERY OF LP CONDENSATE

• Normally, LP exhaust condensate at 1200C is pumped

to boiler feed water tank where it flashes in atmosphere
through a vent, thereby cooled down to 100°C.

• This condensate is again pumped to a de-aerator,

where LP steam is used to heat the feed water to
118-120°C.

• Extra D.M. water is require to maintain vented out

vapour deficiency.

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 STEAM SAVING IN PROCESS HEAT
RECOVERY OF LP CONDENSATE
In this plant, New system is adopted: Pumping of LP exhaust
condensate directly to a de-aerator at 120°C. The following
are the major savings/benefits observed:

• Saving of D.M. water as vapour venting in feed tank is

avoided so load on DM plant thereby raw water
consumption & chemical load decreases.

• Steam saving: Negligible steam requirement in De-aerator

as high temperature condensate directly pumped to
De-aerator & less quantity of low temperature D.M. water.

• Avoids double pumping of condensate transfer.

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 STEAM SAVING IN PROCESS
DIRECT CONTACT JUICE HEATER
Can operate at lower Δ T 2-
30C, so 2nd effect vapour
is used for sulphited juice
2nd heating to heating up
to 1040C and clear juice
heating.
Dilution due to water
addition in direct contact
heater, reduced Brix of
sulphited juice so higher
settling rate of mud is
achieved in settler/clarifier.
(The juice Brix are higher
due to high sugar
recovery)
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 STEAM SAVING IN PROCESS
COND. FLASH HEAT RECOVERY
• Normally hot condensate is vented out to atmosphere
from over head tank, which is loss of water as well as
loss of energy.

• Hot condensate of different temperature recovered from

evaporation, juice heating and pan boiling is sent to
common condensate flash recovery system and flash
vapour is used in evaporator bodies corresponding to
their vapour/temperature.

• About 2.0-2.5 % steam reduction due to utilisation of

flash vapour at evaporator.

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 STEAM SAVING IN PROCESS
COND. FLASH HEAT RECOVERY

3D Model of Common Condensate

flash recovery system

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 STEAM SAVING IN PROCESS
CONTINUOUS VACUUM PAN
• Vapour requirement at pan station has been
reduced to 18 % on cane by introducing a specially
designed continuous pan, common for B & C
massecuite boiling. This pan has multiple vapour
entry so that same vapour pressure can be
maintained throughout the calandria.

• Vapour at two different pressure (1.55 and 1.05 bar)

is used for low grade massecuite boiling without
effecting crystal growth.

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 STEAM SAVING IN PROCESS
CONTINUOUS VACUUM PAN

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 STEAM SAVING IN PROCESS
CONTINUOUS VACUUM PAN

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 WORKING RESULTS OF
2014-15 & 2015-16
Bagasse
Cane crushed Process steam
moisture
Week (t) % cane
(%)
Feb-15 Jan-16 Feb-15 Jan-16 Feb-15 Jan-16
Week-1 4522 5568 48.9 49.57 33.03 31.60
Week-2 4678 5700 48.8 49.72 31.46 30.42
Week-3 4655 5476 48.9 49.57 31.54 32.15
Week-4 4459 5756 48.9 49.65 31.97 30.91
Week-5 -- 5710 -- 49.65 -- 30.59
Average 4578 5718* 48.9 49.62 31.99 30.95

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 WORKING RESULTS OF
2014-15 & 2015-16
After successful trial season 2014-15, few balancing
equipment we added only in the process house, to
enhance crush rate to 5500 TCD

Plant achieved season average Reduced mill

extraction of 96.89% in 2014-15 and 96.6 % in 2015-
16, which is the one of the best efficiency from a 4 mill
tandem. Power consumption of the mill section was
only 11.5-11.8 kW/T of cane.

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 CO-GENERATION PLANT:
SELECTION OF POWER CYCLE
• Thermodynamically, the energy recovery from the
Rankin cycle depends upon the steam temperature,
but any increase in steam temperature must be
accompanied by an increase in steam pressure to
ensure optimum extraction of useful energy from the
working medium

• We selected 110 bar cycle as its power generation

potential is about 33% more than 45 bar cycle.

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 CO-GENERATION PLANT:
SELECTION OF POWER CYCLE
45bar/ 66bar/ 87bar/ 110 bar/ 125bar/
Parameter Unit
440°C 485°C 515°C 540°C 548°C
105
Feed water 150 (with 1 170 (with 1 220 (with 2 240 (with 3
°C (without HP
temperature HP heater) HP heater) HP heater) HP heater)
heater)
Steam/fuel
- 2.29 2.39 2.42 2.59 2.68
ratio
Steam
bar
parameters at 42 / 435 63 / 480 84 / 510 107 / 535 122 / 543
/°C
turbine inlet
Gross power
MW 22.3 23.2 25.6 27.0 27.8
output *
Specific steam
kg/kW 4.5 4.3 3.9 3.7 3.6
consumption

Plant efficiency % 19.4 21.0 23.5 26.5 28.3

*For 100 TPH steam and 0.1 bar 100 % condensing turbine
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 CO-GENERATION PLANT:
SELECTION OF POWER CYCLE
Power generation / Ton of baggase
40%
36%
35% 33%

30%
25% 21.40%
20%
Power generation /
15% 11.40% Ton of baggase
10%
5%
0%
0%
45 bar 67 bar 87 bar 110 bar 125 bar

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 CO-GENERATION PLANT:
SELECTION OF BOILER DESIGN
• Travelling grate boiler has much better results on burning of
bagasse as well as variety of biomass fuels and fossil fuels.

• The boiler is equipped with environmentally friendly

electrostatic precipitators for limiting particulate emission,
and a closed and energy-efficient dense-phase fly-ash
handling system.

• Adoption of lower flue gas velocities across heating

surfaces reduces draft losses, hence reduce ID, FD & SA
fan power consumption.

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 CO-GENERATION PLANT:
HEAT & MASS BALANCE
To feed
Steam Extraction To To Power
Condition water
Gen. to process distillery condenser generation
heating

t/h t/h t/h t/h t/h MW

Designed 120 64 8.0 27 21 23
Season
113 57 -- 26 30 23
2014-15

Season
120 73 -- 27 20 23
2015-16

In year 2015-16, the sugar plant operated for 158 days and the
co-generation plant operated for a further period of 50 days
using saved bagasse as fuel.
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 STEAM GENERATION PLANT

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 POWER TURBINE

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 POWER SAVING: USE OF VARIABLE
FREQUENCY DRIVE
Variable frequency drives installed in 53 nos.
mill, process & co-gen plant)
Load for operating motors 6056 kW
Load for standby motors 1120 kW
Total Load 7176 kW
Running load of motor without VFD 4481 kW
% consumption of connected load 75%
Actual running load of motor with VFD 4056 kW
% consumption of connected load 67%
Power saving 425 kW

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 RESULTS: POWER EXPORT
Description Unit Value
2014-15 2015-16
Cane crushed t 477,000 8,00,057
Bagasse % cane % 28 28.5

Steam consumption % 32 31

Moisture of bagasse % 48-49 48-49

Feed water temperature °C 210-220 210-220
Steam temperature °C 540 540
Steam pressure bar 110 110
Season days 122 158
Bagasse saved
t 7000 39,850
(during harvest)

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 RESULTS: POWER EXPORT
POWER EXPORT IN THE HARVEST
Parameters Unit 2014-15 2015-16
Power generation in the harvest kWh 61,900,000 81,886,960
Power required for sugar + co-gen kWh 16,529,000 24,375,250
plant & other facilities
Power export to Grid kWh 45,371,000 57,511,710
POWER EXPORT IN THE OFF–SEASON
2015 2016
No of days days 7 50
Power generation in the off- season kWh 3,445,000 27,600,000
Auxiliary power consumption kWh 310,000 2,208,000
Power export in the off-season kWh 3,135,000 25,392,000

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 RESULTS: POWER EXPORT

POWER EXPORT PER TONNE OF CANE

2014-15 2015-16
Total power export (during the
kWh 48,506,000 82,903,700
harvest + off-season)

Total cane crushed tonne 477,000 8,00,507

Power export kWh/t 101.60 103.57

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 CONCLUSION

• Higher efficiencies (RME > 96.5%) with low speed milling

cane be achieved with proper integration and selection of
equipment.

• Steam consumption less than 31% on cane while

maintaining high process efficiency (RBHR > 91%).

• 29% on cane steam consumption is also achieved for

many days during the crop 2015-16.

• More than 100 kW per tonne of cane, power export has

been achieved along with high efficiency and throughput
from well designed sugar complex.

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 ACKNOWLEDGEMENT

We are sincerely thankful to Isgec Heavy

Engineering Limited and its team for whole-hearted
support during the establishment of the project and
the operation of the plant.

We are also thankful to our technical team for their

dedication to operate plant with highest efficiencies.

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Thank You