Use of Modern Technologies

for Better Boiling House Efficiency

byMohammad Awais Qureshi

Advisor Shakarganj Mills Limited

Industry Scenario

History of Sugar Industry

Operation Levels

Non-Sharing of Technical Data

Lack of Critical Analysis

Long Term Vision

History of Sugar Industry

YEAR

SUGAR MILLS REPORTED MILLS

InstalledInstalled

Capacity(tcd.)Nos.

Installed Capacity(tcd.)

Capacity Used (tcd.)

%

Utilization

2010-11 46 372,100 31 256,800 170,719 66.48

2009-10 46 372,100 29 223,300 125,000 55.98

2008-09 42 345,100 34 278,100 159,600 57.39

2007-08 42 345,100 38 303,600 220,028 72.47

2005-06 41 341,100 31 243,800 123,490 50.65

2004-05 39 321,100 29 228,300 126,939 55.60

2003-04 39 321,100 31 259,300 178,881 68.99

2002-03 39 321,100 32 250,800 159,451 63.58

2001-02 38 319,600 27 229,800 132,459 57.64

Punjab

History of Sugar Industry

YEAR

SUGAR MILLS REPORTED MILLS

InstalledInstalled

Capacity(tcd.)Nos.

Installed Capacity(tcd.)

Capacity Used (tcd.)

%

Utilization

2010-11 34 173,200 28 159,200 107,348 67.43

2009-10 34 173,200 24 138,400 89,661 64.78

2008-09 33 165,200 27 147,900 89,807 60.72

2007-08 33 165,200 28 157,700 110,652 70.17

2005-06 32 162,200 28 148,900 81,184 54.52

2004-05 32 162,200 27 151,900 66,792 43.97

2003-04 32 162,200 23 127,900 88,433 69.14

2002-03 32 162,200 23 130,500 94,441 72.37

2001-02 31 159,200 26 138,900 77,795 56.01

Sindh

History of Sugar Industry

YEAR

SUGAR MILLS REPORTED MILLS

InstalledInstalled

Capacity(tcd.)Nos.

Installed Capacity(tcd.)

Capacity Used (tcd.)

%

Utilization

2010-11 8 52,600 4 25,320 11,445 45.20

2009-10 8 52,600 2 15,500 5,847 37.72

2008-09 8 52,600 5 27,720 14,086 50.81

2007-08 8 52,600 5 27,720 17,279 62.33

2005-06 7 38,600 5 22,600 9,203 40.72

2004-05 6 28,600 5 22,600 12,026 53.21

2003-04 6 28,600 5 22,600 14,861 65.76

2002-03 6 28,600 5 22,600 13,012 57.57

2001-02 6 28,600 4 21,720 13,523 62.26

KPK

History of Sugar Industry

YEAR

SUGAR MILLS REPORTED MILLS

InstalledInstalled

Capacity(tcd.)Nos.

Installed Capacity(tcd.)

Capacity Used (tcd.)

%

Utilization

2010-11 88 597,900 63 441,320 288,496 65.37

2009-10 88 597,900 55 377,200 220,235 58.39

2008-09 83 562,900 66 453,720 263,672 58.11

2007-08 83 562,900 71 489,020 348,183 71.20

2005-06 80 541,900 64 415,300 214,122 51.56

2004-05 77 511,900 61 402,800 207,514 51.52

2003-04 77 511,900 59 409,800 282,138 68.85

2002-03 77 511,900 60 412,900 265,974 64.42

2001-02 75 507,400 57 400,420 223,942 55.93

Pakistan

Efficiency Avenues

Clarification

Evaporation

Crystallization

Centrifugation

Cooling Crystallizers

Energy Management

Sanitation

Efficiency Avenues

Clarification

The basic need revolves around proper

instrumentation and control of basic

parameters.

Efficiency AvenuesEvaporation

Season 2002-03 average Syrup Brix Highest = 67.44%.Lowest = 54.61%.

Season 2010-11 average Syrup Brix Highest = 67.29%.Lowest = 53.97%.

Desired Syrup Brix Level Above 68.00%.

Efficiency Avenues

Evaporation

Efforts of Industry From Roberts to Kestner And falling films As an episode to improve efficiency Reduce condenser load Reduce steam consumption Extend capacity of Sugar Mills

(6,000 to 7,000 tcd, Uttarpardesh, India)

Efficiency AvenuesCrystallization

Batch followed by Continuous Vacuum Pans are seen in the local Sugar Industry.

Active operations did arrange gage-ts like mechanical circulators, Jiggers steam and above all vapors from the lower effect of evaporators.

Recent development of V K Ts for raw sugar boiling has not found its way in the Country.

Additional boiling needs

Efficiency Avenues

Centrifugation

Importance of equipment. Low grade continuous centrifugals. No appreciate able improvement for the last

half a century. Static approach during half a century.

(K11 and K12 rule this area) Operational parameters of raw station.

(Pugmills, Wash Water and Temperature)

Efficiency Avenues

Cooling Crystallizers

U-type open crystallizers to Cassette Coolers. Introduction of vertical crystallizers. Development of vertical cooling crystallizers

with provision of slowly lowering and lifting cooling blocks with hydraulic cylinders.

Elimination of stirring operation.

Efficiency Avenues

Energy Management

Role of boiling house operations. Judicial use of vapours through recycling. Minimum use of water

(during dilution, pan boiling and centrifugation) Recycling of surplus water in the factory. Steam consumption indicated by Mr. Sajid Naqvi Most of the Mills in Pakistan = 55–57% Mills practicing steam saving measures = 50-52% Mills having modern technologies = 42-45% Modern Mills in other Countries = 35-40%

Efficiency Avenues

Sanitation

This is a hidden corner in sugar industry, which if not given proper attention, can result in loosing efficiencies

Sanitation both at mills and boiling house need proper attention.

Efficiency Expectations

Role of operating department

Build a team of dedicated & competent engineers.

Chart down history of operations, critically analyzed, determine the ultimate goals and chalk out operational plans with in the resources / means available.

Short term and long term goals are a must for any good organization.

Efficiency Expectations

Difficulties to Technologists

Quick turnover of the operational staff in non- continuity of crushing rates do lead to in-efficiency and no proper Planning.

Sharing of Technical Informations at Plant, National & International level, do help the managements in arriving at logical decisions

KISS Slogan

Overriding considerations at all times should be

1. Low capital / operating costs and simplicity

2. KISS Slogan, Keep it simple, Stupid

Concluding Remarks

This talk is just a bird eye view of better boiling house efficiencies.

The learned speakers in their deliberations will throw detailed light on important avenues like evaporations, crystallizations and centrifugation etc.

The purpose of Workshop can only be achieved if the experience of various delegates are shared in this forum.

Concluding Remarks The clarity of subject can only be achieved when

a chance of thorough discussion is provided both to delegates and the speakers.

In one of the International Workshop, we did listen from Mr. B.S.Purchase, Director of Sugar Research Institute, Darban, that no question is a silly question.

There is always a hidden logic behind each question

what ever comes to the mind must be posed to the speaker for the necessary clarifications.

THANKSTHANKS