PASSION for PROGRESS Slide 0 - Thermal EnergyPASSION for PROGRESS BMA company profile © BMA...

PASSION for PROGRESS BMA company profile © BMA – CONFIDENTIAL –

Without verbal explanation the information on this document is incomplete.

Without verbal explanation the information on this document is incomplete

Slide 1PASSION for PROGRESS BMA company profile © BMA – CONFIDENTIAL –


Challenges by

transferring proven efficient design

from beet to cane

BSST - ATM, 20.10.2016, Derby / UK

Dr.-Ing. Andreas Lehnberger

BMA Braunschweigische Maschinenbauanstalt AG

Braunschweig, Germany



Slide 2

Challenges by transferring proven efficient

design from beet to cane based on practical experience

■ Production of beet and cane sugar

■ Potential technology transfer from beet to cane ready to use?

■ Evaporation equipment

Falling film evaporator

■ Sugar boiling equipment

Batch pans

Continuous boiling with VKT

Seeding procedure

■ Conclusion



Slide 3

Production of beet and cane sugar



Slide 4


■ Cane sugar factories

Build decades ago

Especially in areas with low level of infrastructure development:

bagasse used only for cane sugar production

Low investment in equipment and maintenance

high workload

low chemical usage

carbon steel



Slide 5


■ Beet sugar factories in Europe

Build decades ago

Production relies 100 % on primary energy

Continuous extensions and upgrades for efficient operation

High product quality and reduce maintenance

low workload

highly automated process

chemical usage

equipment from stainless steel



Slide 6

Beet and cane sugar processes

■ Cane and beet sugar processes look at a first glance totally different

Different technical and technological consultants networks

Low exchange of knowledge, experiences and approaches

Dedicated equipment suppliers with only few overlapping

■ Recent development in cane sugar factories

Cogeneration and power export to the grid

New target: maximise bagasse use for power generation

Gives a good opportunity to investigate the high efficient processes of

the beet sugar industry suitable for the cane sugar industry



Slide 7








Batch pans


Seeding procedure

■ Conclusion



Slide 8

Cane Beet

Morphology of raw material Mechanical cell opening Cell opening by scalding

Equipment for extraction Diffuser or mills Extraction tower

Juice characteristics Reduced sugars Bad tasting components

Juice purification Liming,

sulfitation,

clarifying

Liming,

carbonation,

filtration

Properties of the juice Saturated with carbonates,

sulfates, phosphates

High amount of reduced

sugars

Low pH

Low hardness

No suspended solids

Thermostable

Potential technology transfer from beet to

cane ready to use?

Different chemical processes - no potential of technology transfer



Slide 9

Cane Beet

Evaporation Heat transfer

Temperature difference is the driving force

Pan boiling Crystallisation

Supersaturation is the driving force

Potential technology transfer from beet to

cane ready to use?

High potential of technology transfer



Slide 10








Batch pans


Seeding procedure

■ Conclusion



Slide 11

Challenges in the evaporation station

■ No difference between “cane” and “beet”

Heat transfer

Concepts of energy schemes

■ Major concerns of the cane sugar industry regarding falling film evaporators

Scaling

Always an issue in the cane sugar industry

Not in the beet sugar industry due to the use of anti-scaling agents

Cleaning

Performed regularly

Requires proper design for chemical and cleaning by high pressure water jet

Non-condensables

Larger quantity in the cane as in the beet sugar industry

Requires proper extraction, vacuum tight vapour lines and valves

Practical experience shows reliable solutions



Slide 12


Huge reduction of the steam consumption has been proven

■ Very common in “cane”

● 4 effect evaporation station

with Roberts

● Batch pans on 2nd vapour

● 43 % steam requirement

■ Up-to-date concept

● 5 effect evaporation station

with falling film evaporators

● Batch pans on 3rd vapour

● 32 % steam requirement

-25 %



Slide 13


Some figures of an installation

■ Evaporation plant with FFEs

3x 4000 m² + 2x 1000 m²

■ Scaling consequences

Crushing capacity drops from 7500 to

7000 tcd within 21 days

Specific steam consumption

increases from 30 to 33 % o.c.

■ Cleaning of evaporators

After 21 days: 1st, 2nd, 3rd effect

After 10 days: 4th, 5th effect

Easy access to tubes for mechanical

cleaning



Slide 14


Extraction of non-condensable gases

■ Collected in the heating chamber

■ Concentrated in vents

Adjusted to approx. 1 % (w/w)

Ensures temperature loss below 0.25 K

■ Adjusted by measurement

■ Air leakages into underpressured vapour

has to be avoided



Slide 15








Batch pans


Seeding procedure

■ Conclusion



Slide 16

Challenges in the sugar boiling

Batch pan operation

■ Vacuum pans are evaporators

■ Heat transfer rules are the same in “beet” and “cane”

■ Crystallisation takes place by supersaturation

■ Highly efficient steam consumption requires pan operating

at low steam temperature

■ A-pans with powerful agitators

Excellent circulation

High heat transfer

Works with 3rd vapour

Even 4th vapour is possible



Slide 17



■ A-VKT runs identical in cane as in beet sugar factory

Technology

Automation

■ Operation at low temperature

3rd vapour – 91 °C

4th vapour – 84 °C

■ Steam requirement 28 % o. c. at 1.7 bar abs. / 115 °C

■ Non-condensables must be directed to the condenser

Entire steam and vapour system operates under vacuum

Heating of continuous pans became more stable

Reduction of water addition to boiling



Slide 18


Seeding procedure

■ Proper crystal formation is the most

critical process in crystallisation

■ Preparation of excellent seed material

with 100 µm from slurry by cooling

■ Well-established in the beet sugar

production

■ Cane sugar industry hasn’t taken

advantage of the seeding procedure yet

■ Improved sugar quality

Low aggregates

Good CV



Slide 19


Seeding procedure

■ Latest results of cane sugar boiling

Crystal formation and growing fully automated

Uniform crystal size distribution

Higher yield with reduced energy consumption

■ Works in cane sugar factory like in the beet sugar factory – no difference



Slide 20








Batch pans


Seeding procedure

■ Conclusion



Slide 21

Conclusion■ Cogeneration and power delivery to the grid are the major issues in a

today’s cane sugar factory

■ Therefore energy efficiency is mandatory

■ The technology knowhow of the highly efficient beet sugar industry offers

a good opportunity for a technology transfer

Evaporation with minor adjustments:

Scaling and cleaning

Extraction of non-condensables

Sugar boiling

Agitation is essential

3rd and 4th vapor is possible (vacuum tight system)

Vertical continuous boiling with VKT offers the same energy performances as in

beet sugar production

Seeding based on beet sugar process

Improved reliability in production thanks to the automated process



Slide 22

Conclusion

More and more interactions are occurring between

the cane and the beet sugar industries

Take the chance to discover more about

the potential of technology transfer !

©CEDUS, 2011©CEDUS, 2011



Slide 23

Thank you for your attention!



Slide 24

Back up



Slide 25

New Configuration Season 2013/14

■ Two new BMA falling film evaporators were added before season 2013/14

2 x 4000 m²

■ Updated 5-effect falling film evaporation plant

FFE1 – 4000 m²

FFE2 – 4000 m²

FFE3 – 4000 m²

FFE4 – 4000 m²

FFE5 – 1000 m²

Spare bodies for cleaning1x 4000 m²: FFE3 and FFE41x 1000 m²: FFE5 (former FFE4)



Slide 26

Operating figures

■ Season 2013/14

Cane crushing (average without stoppages) 9200 tcd



Slide 27

Operating figures

■ Season 2013/14


Steam consumption (average without stoppages) 28.1 % o.c.

(with clean heating surfaces of evaporators down to 27 % o.c.)



Slide 28

Operating figures

■ Season 2013/14


Steam consumption (average without stoppages) 28.1 % o.c.

■ Cleaning of evaporators in season 2013/14

1st and 2nd effect: up to 40 days of operation

3rd and 4th effect: up to 20 days of operation

5th effect: each 10 days of operation

■ Comparison to the season 2012/13

Steam production remaining at average 104 t/h (maximum 110 t/h)

Increased steam efficiency from 30 to 33 % o.c. to 28.1 % o.c.

Increased crushing capacity by approx. 30 %

Surplus bagasse is used for power production during off-season

PASSION for PROGRESS Slide 0 - Thermal EnergyPASSION for PROGRESS BMA company profile © BMA...

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