Transcript
The Digital Sugar Mill
Seminar on Sugar & Ethanol Automation
Overview of Sugar Process, Evaporator and Pan Automation
Mr. Zia Baloch
Almoiz Industries Ltd.
The Importance of Automation
In Sugar Industry
Agenda
Introduction to Sugar Industry Process
Key Benefits and Improvement in KPI’s in Sugar process by Automation
AL-Moiz Rockwell PlantPAx Automation Project Briefing & System Architecture
Introduction to Evaporation in Sugar industry
Evaporator’s Automation Controlling parameters and Key benefits
Al-Moiz Evaporator HMI
Introduction to Pan Automation
Pan Automation Key Benefits
Al-Moiz Pan Automation HMI
Conclusion
3
Introduction
Sugar Plant automation solution is designed to help the Sugar industry to get more out of each stage of the process
It spans across the process, right from cane unloading to sugar bagging and beyond, to give the sugar plant the best performance, the best quality, reliability and the best delivery. In short the most value.
Sugar Process – Graphical Representation
Sugar Process – List View
Cane YardWeighbridgeCane UnloadingCane PreparationMilling & Juice ExtractionJuice Heaters & ClarificationEvaporationPan/CrystallizationSugar Driers Bulk Sugar HandlingUtilities Management
Key Benefits of Sugar Plant Automation
Safety of Man & Machine
Efficient use of plant equipment
Significantly less power and utilities consumption
Use of modern maintenance techniques leading to higher plant availability and lower maintenance
costs
Better cane management logistics
Better Production to Manpower ratio
Superior and Consistent Quality
An Integrated Plant Operation philosophy
Improvements in KPI’s
Improved Recovery
Reduction in Manpower (30% to 40%)
Savings in Steam consumption by up to 5%
Savings in Electrical Power consumption by 5 to 10%
Increased percentage extraction
Improved reliability in plant operation
Reduction in Sugar ICUMSA by 10 to 20 units
Project Briefing
Client Name: Al-Moiz Industries
Project Name: Rockwell PlantPAx System (Distributed Control System)
Control Processors & I/Os
Central Control room Panels Area
Areas Covered in Rockwell PlantPAx Project
Evaporator
Boiler
Defecation
Mill House
Juice Heater
Batch Pan
Continuous Pan
Process House
Talo Floc
Turbine
Condenser
Sugar Process – Areas (Evaporator & Pan)
Introduction to Evaporator in Sugar Industry
The purified juice is a sugar solution containingapproximately 14% sugar and 1% non-sugars. Itis now necessary that this solution is thickenedup into a syrup by boiling off excess water in aseries of connected vessels.
Under automatically controlled conditions eachsubsequent evaporator operates underdecreasing pressure with the last one beingunder almost a total vacuum. This "thick juice"leaving the evaporator station has a dark yellowto light brown color and contains approximately60% sugar.
Falling Film Evaporator Automation Components
Field Instruments
Control Hardware
Control Software
Falling Film Evaporator Automation Components
Level Transmitter
Circulation Flow meter
Calandria Temperature Transmitter
Calandria Pressure Transmitter
Separator Pressure Transmitter
Separator Temperature Transmitter
Circulation Pressure Transmitter
Cone Temperature Transmitter
Emergency ON/OFF Valve
Circulation Pumps Delivery ON/OFF
Valves
Level Control Valve
Temperature Gauge for Separator
Compound Gauge for Separator
FFE Control Hardware & Software
FFE can be controlled using DCS
Hardware & Software is provided by Service provider along with Services
for commissioning
FFE Control Strategy
Cone Level must be controlled
Circulation juice Pump should be operated in auto mode
ON/OFF circulation pumps delivery line valve should be operated as per pumps
operation
Emergency valve must follow the process conditions
Circulation Juice Flow must be maintained by using Pumps VFDs control
Evaporator Controlling Parameters Temperature Control
Level Control of each Evaporator
Vacuum
Circulation Juice Flow control
Pumps Control
Emergency Valve control
Emergency Water Tank Level Control
Pressure and temperature of exhaust steam
Clear Juice Tank Level Monitoring
Brix of syrup
Flow of condensates from calandrias
Evaporator Automation Benefits
Regulated feed to each Evaporator
Maintain level in Evaporator
Syrup Brix Control
Steam temperature do not exceed 125 – 130C
Less scale formation due to even juice level
Due to controlled steam temp the efficiency of system is higher
Sugar Process – Areas (Evaporator & Pan)
Introduction to Pan AutomationSyrup from the evaporators is sent to
vacuum pans, where it is furtherevaporated, under vacuum, to supersaturation. Fine seed crystals are added,and the sugar “mother liquors” yields asolid precipitate of about 50 percent byweight crystalline sugar.
Fine clarified liquor is boiled to white sugarin a series of vacuum pans similar to thoseused in sugarcane processing.
Fine grains (sanding or fruit sugars).
Why Batch Pan Automation
The boiling of Massecuite in Batch Pan is very critical operation
Because the super saturation of boiling liquid inside the pan should be
maintained within a very narrow range
Ineffectiveness of operator to do so will leads to extra water drink to
dissolve false grain
Key Benefits of Pan Automation
Decrease of boiling time
Reduction of sucrose in final molasses
Narrow range of crystal size
Easy operation even by untrained operators
Key parameters protected by password
Pan Automation
Proven performance and reliability in sugar applications worldwide
High Availability
Robust design, High degree of protection
Worldwide service
Low initial investment due to module design
Easy expendability
Question & AnswersThank You for Your Valuable Time
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