The Sugar Process:Automation or Optimization

THE AUTOMATORS

The Sugar Process Continuous Flow Process

Highly Regulated Operating Conditions Seasonal Operation

Limited Resources Budgetary Limitations Personnel Limitations Remote Locations

New Challenges Shrinking Margins due to Globalization

THE AUTOMATORS

Is Automation Needed? Example 1

The Drum Level in a 2.4MPa 80TPH boiler can be controlled manually. However, the risk of losing control is high and the cost of instruments for this loop is too small compared to the damage caused by the loss of control. It is, therefore, better to automate this action.

Example 2Starting and stopping of the Screened Juice Pumps in the Mill House can be done manually. The cost of isolating valves at the suction and delivery sides of the pumps is too high to justify automating this action.

THE AUTOMATORS

Why Automate? Reduce Losses

Capacity Energy Materials Mechanical Failures

Maintain Quality Unbiased Analyses Independence from Manual Skill

NOT TO REDUCE MANPOWER

THE AUTOMATORS

Suggested Optimizations Mill House

Cane Feeding (Capacity Enhancement) Milling and Imbibition (Extraction Improvement) Crushing Rate Optimization (Process Balance)

Boilers and Steam Management Heating, Clarification and Evaporation Raw Pans (Batch or Continuous)

Brix/Super-saturation Control in Batch Pans Brix and Boiling Rate Control in Continuous Pans

Remelting and Refining Powerhouse (Load-shedding)

THE AUTOMATORS

Control Systems Discrete Controllers and Recorders

Low Cost in case of Few Loops Poor Analysis Tools Difficult to Maintain

PLC / Multi-Loop Controllers + SCADA Availability and Maintainability Issues Good for Machine Level or Area Wide Control

Distributed Control Systems Easy to Implement and Maintain Suitable for Plant Wide Control

THE AUTOMATORS

MILL HOUSE Starting point of the Sugar Plant, providing:

Juice to the Process House Bagasse to Boilers (at low moisture/ sugar traces) Exhaust Steam to the Evaporators

Irregularities in the Mill House mean Boiler and Steam Pressure Disturbance Evaporation Process Mismanagement Low or Poor Crushing for hours High Maintenance Costs Reduced Extraction Reduced Energy Efficiency

THE AUTOMATORS

Mill House Automation Results

Year Plant Setting Achievement

1997/98

Shahtaj Shredder with 2 Cutters, 5 Mills Capacity enhanced to 11,000 from 8,500Pol down to 1.8

2003 JDW-1A Shredder with 3 Cutters, 6 Mills Capacity enhanced to 8,500 from 6,5002004/

05JDW-1B Shredder with 3 Cutters and

Motorized Pressure Feeders on Mill 1/Mill 6

Never operated Manually. Capacity 14,000 TCD

2006 JDW-2 Fibriser, 5 Mills Capacity enhanced to 10,000 from 7,000

2007 Al-Abbas Fibriser, 5 Mills, 1 on Motor Capacity enhanced to 7,500 from 5,500Pol down to 1.6

2008 JDW-3 Shredder with 2 Cutters, 6 Mills Never operated Manually. Capacity 15,000 TCD

2011 Noon Shredder with 2 Cutters, 4 Mills Capacity enhanced to 9,000 from 7,0002013 Khairpur Shredder with 2 Cutters, 4 Mills Capacity enhanced to 7,000 from 5,0002015 Chaudhry Shredder with 2 Cutters, 5 Mills Capacity enhanced to 10,000 from 9,000

Pol down to 1.6

2015 Sheikhoo Unigrators with 2 Cutters, 7 Mills, 3 on Motor

Capacity enhanced to 16,000 from 13,500Pol down to 1.8

THE AUTOMATORS

CANE FEEDING

65.5100.01.000

60.9PVSVHLOP

CANE CUTTER 2Motor Load

(Amps)

RUNState

13.5019.000.963

14.08PVSVHLOP

SHREDDERTurbine NP

(kg/cm²)

RPM 975.5

MAIN CARRIERSpeed Control

REMOTE853

57.54849

SPPVOP

CASMD

Load 107.3

3.00

63.892.85

SPPVOP

Cane Weight(Tons)

AUTOMD

Cane Flow(T/Hr)

P C ELEVATORSpeed Control

REMOTE1323

88.021324

SPPVOP

CASMD

Load 81.70

12.0018.000.951

12.53PVSVHLOP

MILL 1Turbine NP

(kg/cm²)

RUNState

65.00

40.3270.08

SPPVOP

Chute Height(%)

AUTOMD

80.0120.00.913

82.3PVSVHLOP

CANE CUTTER 1Motor Load

(Amps)

RUNState

55.080.0

0.538

70.8PVSVHLOP

CARDING DRUMMotor Load

(Amps)

RUNState

AUX. CARRIERSpeed Control

REMOTE328

22.8332

SPPVOP

CASMD

Load 53.2

288.7PV3157Tot

Ratio0.900

Ratio0.625

Main 23.85Exhaust 1.19

PRESSURE (Kg/cm²)

Mixed Juice 62.05Clear Juice 58.80

TANK LEVEL (%)

Flow (m³/Hr) 302.8Total (m³) 3234

MIXED JUICE97.831287

IMBIBITION WATERFlow (m³/Hr)

Total (m³)CANE FEEDING

THE AUTOMATORS

CANE FEEDING: Advantage Enhancement of Crushing Rate—up to 15% Regulation of Bagasse Supply to Boilers Improvement in Mill 1 Extraction Reduction in Damage to Mechanical

Assemblies of Mill 1, Cane Carries, Shredder and Cutters

Regular and lowered Energy Consumption at the above devices

THE AUTOMATORS

MILLINGMain 23.85Exhaust 1.19

PRESSURE (Kg/cm²)

Mixed Juice 62.05Clear Juice 58.80

TANK LEVEL (%)

Flow (m³/Hr) 302.8Total (m³) 3234

MIXED JUICE97.831287

IMBIBITION WATERFlow (m³/Hr)

Total (m³)MILLING

12.0018.000.951

12.53PVSVHLOP

MILL 1Turbine NP

(kg/cm²)

RUNState

65.00

40.3270.08

SPPVOP

Chute Height(%)

AUTOMD

14.0018.001.031

14.94PVSVHLOP

MILL 2Turbine NP

(kg/cm²)

RUNState

50.00

48.9048.77

SPPVOP

Chute Height(%)

AUTOMD

14.0018.001.000

13.51PVSVHLOP

MILL 3Turbine NP

(kg/cm²)

RUNState

50.00

44.7652.55

SPPVOP

Chute Height(%)

AUTOMD

15.0018.001.256

16.71PVSVHLOP

MILL 4Turbine NP

(kg/cm²)

RUNState

40.00

78.9872.80

SPPVOP

Chute Height(%)

AUTOMD

15.0018.001.000

12.53PVSVHLOP

MILL 5Turbine NP

(kg/cm²)

RUNState

45.00

11.7922.78

SPPVOP

Chute Height(%)

AUTOMD

Speed ControlREMOTE

783805

SPPV

CASMD

Speed ControlREMOTE

14501427

SPPV

CASMD

Speed ControlREMOTE

10961089

SPPV

CASMD

Speed ControlREMOTE

11251099

SPPV

CASMD

Speed Control

13231323

SPPV

MANMD

LOCAL

INIT

60.00

83.2362.05

SPPVOP

MJ Tank Level(%)

AUTOMD

Juice Pumps

0.00 RPM

Load 68.71223

97.87

73.8697.83

SPPVOP

Imbibition(m³/Hr)

CASMD

Imbibition Pumps

35.31086 RPM

Load 0.00

Dilution(Percent)

27.50 55.6

BAGASSE ELEVATORRUN

LoadState

83.7RUN

LoadState

MAIN BAG. CARRIER

THE AUTOMATORS

MILLING: Advantage Improved Extraction at all Mills Reduced Bagasse Moisture and Pol Maintained Overall Extraction Results at

Variable Crushing Rates Reduction in Damage to Mechanical Assemblies

of Mills, Inter-carriers, and Pumps Sustained Steam Consumption at Different

Crushing Rates

THE AUTOMATORS

Crushing Rate Optimization Under Crushing

Loss of Production Energy Losses

Over Crushing Saturation in Boiling House Increased Steam Demand Boiler Inefficiencies Millhouse Stoppages Loss of Production Energy Losses Equipment Damages

THE AUTOMATORS

THE AUTOMATORS

Crushing Rate Optimization

Other Optimizations in Sugar Plant Boilers

Efficiency Enhancement Pressure Stability

Evaporators Steam Economy Syrup Brix Improvement

Continuous Pan Uninterrupted Brix control for B & C Sugar Boiling Correlated Molasses and Massecuite flows for regular Vapor consumption Minimal Water Addition

Sugar Refinery Remelter Stabilization Maintained pH Control Deep Bed Filters

Batch Pan Reduced Strike Time Manual Washing

THE AUTOMATORS

THE AUTOMATORS

Boiler: 20~25 BAR Steam Class

THE AUTOMATORS

Mill House: Milling Control

THE AUTOMATORS

Evaporators: Falling Film

THE AUTOMATORS

Continuous Pans: C Sugar