EXPANSION AND EXPANSION AND MODERNIZATION OF THE MODERNIZATION OF THE

SUGAR INDUSTRY IN SUGAR INDUSTRY IN GUYANAGUYANA

ContentContent

IntroductionIntroductionExpansion of cane cultivation and sugar Expansion of cane cultivation and sugar productionproductionDesign capacity of new factoryDesign capacity of new factoryValue added productsValue added productsCogenerationCogenerationChallengesChallengesEquipment installed at SWRIIEquipment installed at SWRII

Guyana Sugar Corporation (GuySuCo) has embarked on expanding sugarproduction by modernizing Skeldon Sugar Estate. The new, 350 TCH, state of the art factory will commence VHP sugar production during the second half of 2008.

In addition to sugar production, 12 MW of co generated power will be madeavailable to the national grid.

Equipments of major interest are:Equipments of major interest are:

Heavy Duty Hammer ShredderHeavy Duty Hammer Shredder350 TCH, Cane Diffuser350 TCH, Cane DiffuserNew Generation SRI ClarifierNew Generation SRI ClarifierEvaporator Floor Evaporator Floor -- Quintuple arrangement of Semi Quintuple arrangement of Semi ––KestnerKestner & & Roberts Evaporators. Roberts Evaporators. Pan stage Pan stage -- Continuous Vacuum PansContinuous Vacuum PansC C –– MassecuiteMassecuite Vertical Continuous Crystallizers with Vertical Continuous Crystallizers with ReheaterReheater..Curing station Curing station –– Batch & Continuous CentrifugalsBatch & Continuous CentrifugalsRotaryRotary-- Louver type sugar dryer with water injection for final Louver type sugar dryer with water injection for final moisture setting.moisture setting.Boilers Boilers -- Two boilers Two boilers –– capacity, 125 tonnes of steam /unit @ 54 capacity, 125 tonnes of steam /unit @ 54 bar pressure.bar pressure.Molasses StorageMolasses Storage-- Use of geoUse of geo--textile material (bladder)textile material (bladder)

Power plant Power plant –– Two T/A sets of 15 Two T/A sets of 15 MW /unit, Three diesel/HFO MW /unit, Three diesel/HFO generating sets with a total generating sets with a total capacity of 10 MW.capacity of 10 MW.Total power plant capacity of Total power plant capacity of 40MW.40MW.

Sugar has been an integral part of Sugar has been an integral part of GuyanaGuyana’’s history.s history.

In 1976, nationalization took effect and In 1976, nationalization took effect and formed Guyana Sugar Corporation Inc formed Guyana Sugar Corporation Inc (GUYSUCO)(GUYSUCO)

Although GovernmentAlthough Government--owned, GUYSUCOowned, GUYSUCOoperates as an independent, profitableoperates as an independent, profitablecommercial organization. Policy iscommercial organization. Policy isdetermined by the Board of Directorsdetermined by the Board of Directorsappointed by the Minister of Agriculture.appointed by the Minister of Agriculture.Since 1990, GUYSUCO has beenSince 1990, GUYSUCO has beenmanaged on contract by Booker Tate Ltd.managed on contract by Booker Tate Ltd.

The Corporation operates five sugarThe Corporation operates five sugarEstates and eight factories, four in the Estates and eight factories, four in the Demerara region, the birth place of Demerara region, the birth place of world renowned world renowned ““Demerara SugarDemerara Sugar””, , and four in the east of the country onand four in the east of the country onthe banks of the Berbice and the banks of the Berbice and Corentyne Rivers.Corentyne Rivers.

Map indicating the locations of sugar estates in Guyana

Drainage is by a complex system of Drainage is by a complex system of canals and sluices, which is essential canals and sluices, which is essential to ensure effective cultivation. Guyana to ensure effective cultivation. Guyana is unique in having most of itis unique in having most of it’’s sugar s sugar cane transported on water ways rather cane transported on water ways rather than by road or rail.than by road or rail.

Photo 2 Photo 2 -- Cane transport to factoriesCane transport to factories

Expansion of Cane Cultivation and Sugar ProductionExpansion of Cane Cultivation and Sugar Production

In 2001 Agriculture Improvement Plan In 2001 Agriculture Improvement Plan (AIP) was introduced to boost the cane (AIP) was introduced to boost the cane production. production.

The decision taken to embark on The decision taken to embark on Skeldon Sugar Modernization Project Skeldon Sugar Modernization Project ( SSMP) was aimed at reducing the ( SSMP) was aimed at reducing the production costs.production costs.

The Chinese contractor, CNTIC tradingThe Chinese contractor, CNTIC tradingCo. Ltd., was selected by international Co. Ltd., was selected by international tender was selected for the construction tender was selected for the construction of the factory and the cogeneration plant of the factory and the cogeneration plant on turnon turn--key basis. key basis.

Booker Tate Ltd. was appointed to manage the Booker Tate Ltd. was appointed to manage the successful completion of this project. successful completion of this project.

Bird’s eye view of the new factory

SWR II FactorySWR II Factory

SWR II FactorySWR II Factory

SWR II FactorySWR II Factory

The project agricultural expansion stated The project agricultural expansion stated in 2000, when completed the cane in 2000, when completed the cane production area for the new factory will production area for the new factory will cover 13,000 hectares of which cover 13,000 hectares of which approximately 25% will be with private approximately 25% will be with private farmers. farmers. In addition, the land preparation of the In addition, the land preparation of the cane expansion area will be done in a cane expansion area will be done in a manner to initiate introduction of large manner to initiate introduction of large scale mechanical harvesting scale mechanical harvesting

Skeldon Sugar Modernization Project Skeldon Sugar Modernization Project -- New Factory StatisticsNew Factory Statistics

Sugar production Sugar production 116,000 116,000 ts/yts/yCane consumption Cane consumption 1,115,000 1,115,000 tc/ytc/yCane processing rate Cane processing rate 8,400 8,400 tc/dtc/dHourly processing rate Hourly processing rate 350 350 tchtchSugar production 35.5 Sugar production 35.5 tchtchPol extracting Pol extracting 97.0097.00Overall recovery Overall recovery 85.5%85.5%Boiling house recovery Boiling house recovery 88.10 %88.10 %

Skeldon Sugar Modernization Project Skeldon Sugar Modernization Project -- New Factory New Factory Statistics continuedStatistics continued…………

Sugar quality Pol Sugar quality Pol –– 99.30 %99.30 %Colour Colour -- <1,350 icumsa<1,350 icumsaMoisture Moisture -- , 0.18%, 0.18%Grade Grade –– VHPVHP

Steam pressure Steam pressure 54 bar54 barBoiler capacity Boiler capacity 2X 125 ts/h2X 125 ts/hBoiler efficiency Boiler efficiency 86.0%86.0%Steam temperature Steam temperature 485 deg C485 deg CPower generation capacity (steam) Power generation capacity (steam) 2x15 MW sets2x15 MW setsPower generation capacity (diesel) Power generation capacity (diesel) 2X2.5 MW & 1X5.0 2X2.5 MW & 1X5.0 MW sets MW sets Total generating capacity Total generating capacity 40 MW 40 MW Export capability Export capability 25 MW25 MW

With the completion of the new factory, GUYSUCO will become With the completion of the new factory, GUYSUCO will become the owner of a modern, statethe owner of a modern, state--ofof--thethe--art sugar factory that will art sugar factory that will be in contrast to our existing factories.be in contrast to our existing factories.

The technologies and equipment new to Guyana that will be The technologies and equipment new to Guyana that will be found in the factory are:found in the factory are:

An improved automated punt dumper for offloading cane.An improved automated punt dumper for offloading cane.Heavy duty cane shredder to increase extraction.Heavy duty cane shredder to increase extraction.Air supported belt conveyers (AeroAir supported belt conveyers (Aero--belts) throughout the belts) throughout the factory. factory. Cane diffusion targeting an extraction of 97.0 % .Elimination ofCane diffusion targeting an extraction of 97.0 % .Elimination ofmud filters by addition of mud to the diffuser.mud filters by addition of mud to the diffuser.New generation SRI juice clarifier and usage of lime New generation SRI juice clarifier and usage of lime saccharate for pH control.saccharate for pH control.Double magma system for VHP grade sugar production. Double magma system for VHP grade sugar production. Quintuple evaporator station.Quintuple evaporator station.

Broadbent C54 batch Broadbent C54 batch fugalsfugals in HG curing in HG curing stations. Broadbent SP continuous fugal in LG stations. Broadbent SP continuous fugal in LG curing station.curing station.Fletcher Smith continuous vacuum pans for Fletcher Smith continuous vacuum pans for boiling all grades of boiling all grades of massecuitesmassecuites..Continuous vertical crystallizers.Continuous vertical crystallizers.Single pass, self cleaning, high pressure and Single pass, self cleaning, high pressure and high efficiency boilers. high efficiency boilers. Use of electrostatic precipitators for pollution Use of electrostatic precipitators for pollution control to meet World Bank standards.control to meet World Bank standards.Condensing turbines for power generation Condensing turbines for power generation during off season. during off season. All electric drives to reduce energy consumption. All electric drives to reduce energy consumption. Central control rooms with PLC based DCS Central control rooms with PLC based DCS control systemscontrol systems. .

We have established two packaged products in the We have established two packaged products in the Caribbean and other counties including USA, Caribbean and other counties including USA, Australia and UK. These products are the Australia and UK. These products are the DEMERARA GOLD and DEMERARA BROWN DEMERARA GOLD and DEMERARA BROWN sugars. sugars.

We are currently producing approx. 7000t of We are currently producing approx. 7000t of packaged sugar but the market is demanding packaged sugar but the market is demanding more of these two products. more of these two products.

As such, work has started on the construction of a As such, work has started on the construction of a new pant at Enmore to produce approx. demand new pant at Enmore to produce approx. demand 80,000 80,000 tonnestonnes/year at Enmore Sugar Estate/year at Enmore Sugar Estate

The plant is expected to be operational by The plant is expected to be operational by September 2009. September 2009.

VALUE ADDED PRODUCTS

Cogeneration of electricity, ethanol and refined Cogeneration of electricity, ethanol and refined sugar production sugar production

The cogeneration facilities will supply 10MW of The cogeneration facilities will supply 10MW of power to the national grid. power to the national grid.

The generation of electricity from The generation of electricity from bagassebagasse, will , will reduce the emission of green house gases reduce the emission of green house gases and the project has qualified for the carbon and the project has qualified for the carbon credits under the World Bank Community credits under the World Bank Community Development Carbon Fund. Development Carbon Fund.

With the successful completion of SSMP, plans With the successful completion of SSMP, plans are in hand to produce ethanol as well as are in hand to produce ethanol as well as refined sugar. refined sugar.

The ChallengesThe ChallengesExpansion of the cane cultivation under Expansion of the cane cultivation under adverse weather conditions. adverse weather conditions.

Increase in demand for cane supply Increase in demand for cane supply coupled with decrease in availability of coupled with decrease in availability of cane cutters.cane cutters.

Training of factory personnel to Training of factory personnel to understand the new technology and to be understand the new technology and to be competent to operate the fully automated competent to operate the fully automated plant. plant.

In the past the sugar industry in Guyana In the past the sugar industry in Guyana has been very fortunate with abundance has been very fortunate with abundance

of labour for manual tasks.of labour for manual tasks.

However, this has changed and we are However, this has changed and we are now experiencing severe labour now experiencing severe labour shortage especially in the harvesting shortage especially in the harvesting dept. dept.

This obviously has a negative impact on This obviously has a negative impact on cane supply to the factories. cane supply to the factories.

With the introduction ofWith the introduction of““Bell LoadersBell Loaders”” the industry is less dependent on the industry is less dependent on manual labour for cane cutting.manual labour for cane cutting.

The total number of bell loaders in the The total number of bell loaders in the industry at present is 59.industry at present is 59.

However, at Skeldon the mechanizationHowever, at Skeldon the mechanizationefforts have been taken another stepefforts have been taken another stepforward with the introduction of modifiedforward with the introduction of modified““John DeerJohn Deer”” mechanical cane mechanical cane harvesters.harvesters.The mechanically harvested cane wouldThe mechanically harvested cane wouldbe in be in ““billetbillet””. .

An improved automated punt dumper for offloading An improved automated punt dumper for offloading cane at SWR 11. cane at SWR 11.

Heavy duty cane shredder for increased Heavy duty cane shredder for increased polpol extractionextraction

The shredder is located between feed and discharge Aerobelt conveyors. The second belt commences below the outlet of the shredder housing. There are 235 hammers mounted; it is rotating in flow direction at 900 rpm. The motor operates at 13.8 kV and 3.000 kW.

Air supported belt conveyers (Aero belts) throughout the factoryAir supported belt conveyers (Aero belts) throughout the factory..

Aerobelts are rubber conveyer belts, where upper belt trunk travels on an air cushion, which is an air film provided by two blowers. The returning trunk travels on idlers. The two transition points are rollers, the upper (head) roller is equipped with a VFD motor with gearbox for operating a belt at a designated speed.

Cane Diffusion PlantCane Diffusion Plant

Diffusers.Diffusers.A 9.000 m wide trough with fixed perforated bottom, with drag chA 9.000 m wide trough with fixed perforated bottom, with drag chain and scrapers, the averageain and scrapers, the averagespeed of the chain is 0.9 m/min. underneath the perforated platespeed of the chain is 0.9 m/min. underneath the perforated plate there are 12 collecting traysthere are 12 collecting traysfor collecting percolating juice for recirculation and an additifor collecting percolating juice for recirculation and an additional tray at the entry foronal tray at the entry forcollection of the draft juice. Unit is totally enclosedcollection of the draft juice. Unit is totally enclosed

Inside view of the cane diffuser

New Generation SRI ClarifierNew Generation SRI Clarifier

The SRI clarifier at Skeldon is designed on the principles of quiet multipoint Juice entry and multipoint clarified juice take off.

Evaporator stationEvaporator station

Pans

Juice heaters 2, 3

Diffuser

VHP sugar handling

1A 1B 2A 1B 3 4 5

Pans

Juice heaters 1, 2, 3

Scalding juice heaters To condenser

Juice heaters 1, 2, 3

Press water drum

Syrup pumpClear juice

Evaporator station. Juice and Vapour Flow

Pan Stage Pan Stage -- Fletcher Smith continuous vacuum pansFletcher Smith continuous vacuum pans

Pan stage. CVPs for boiling all grades of massecuites

Continuous vertical crystallizersContinuous vertical crystallizers

Broadbent C54 batch fugal in HG curing stations. Broadbent SP coBroadbent C54 batch fugal in HG curing stations. Broadbent SP continuous ntinuous fugal in LG curing station.fugal in LG curing station.

High Grade Curing - Broadbent C54 Low Grade Curing – Broadbent

High pressure boilersHigh pressure boilers

The plant has two boilers that are fuelled mainly by bagasse. They also have the capacity to burn “Heavy Fuel Oil” as an auxiliary fuel supply. Each boiler has a steam out put capacity of 125 tch at 5400 kPa and 485 degrees. The boilers are fitted with economizers and air heaters as integral part of the heat recovery system. The boilers are also fitted with primary, secondary and induced air fans. The bagasse firing equipment consists of rotary drum feeders and an atomizing oil burning system capable of delivering 65% MCR.

The electrostatic precipitator (ESP) is fitted in the final stages of the flue gas path. The electrostatic precipitator electrically charges the ash particles in the flue gas to collect and remove them. The unit comprises of a series of parallel vertical plates through which the flue gases pass. Central between the plates are charging electrodes which provide the electric field.

Electrostatic Precipitators (ESP)

Condensing turbines for power generation Condensing turbines for power generation during off season during off season

All electric drives to reduce energy consumption

Independent power station with automatic load following capacity.

Station

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