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