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Conceptual design of a cane white sugar factory offering maximum

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Conceptualdesignof a canewhite sugarfactory
offering maximum cogeneration*
Caracteristicasde un ingenio produciendo azricar blanco con alta eficiencia energetica

Pedro Avram-Waganoff and Thomas Stark

Reprintfromvol. 126(2001)720-729 VerlagDr.AlbertBartensKG,Lückhoffstr.

16,D-14129Berlin
Conceptualdesignof a canewhite sugar factory
offering maximum cogeneration*
Caracteristicasde un ingenio produciendo azücar blanco con alta eficiencia energetica
Pedro Avram-Waganoff and Thomas Stark
The increasingmarket demand for white sugar of high quality has
led to the developmentof microfiltration and other techniquesena-
bling the juice purification and sugar crystallization processesin
cane sugar factoriesto be greatly simplified, When thesetechniques
are applied together with high-pressuresteam generatorsand con-
densing-extractionturbogenerators,wholly electrified drives and
single-linecontinuousprocessstations,the resultantwhite sugarfac-
tory can saveat least40Voof the availablebagasseduring a 150 day
crop, while still exporting approx. 35 kwh of electrical power per t
of cane.The excessamount of bagassecan be baled during the crop
and be employed for firing the power station during the off-season'
generatingan additional 77 kwh/t electricalpower' In total, approx.
I l2 kWh/t of cane can be generatedfor export to the grid on a year-
round basis,without employing any additional fuel or sophisticated
methodslike bagassegasification.
The paper shows the conceptualdesign of such a factory, including
an overall layout, summary tables and schematicsof the mass and
heat balances,short descriptionof the main processfeaturesand cost
estimatefor a plant of 24,000 t/d capacity. At current world market
white sugar prices and assuming US$40 net revenue per MWh ex-
ported, the amount of export power generatedwill add approx ll%
to the annualrevenueof the factory due to salesof sugar and molas-
ses.In a number of cane sugar producing countriesthis could be an
attractive proposition.
1 Introduction
Demandfor "white sugar"with color levelsof 100 I.U. (or less)has
continuously grown in most countriesof the world' With the advent
of ultrafiltration membranes(now proven in industrial scalefor over
6 years at Puunene,Hawaii) combined with efficient short retention
clarifiers and separateclarification of filtrate and retentateit should
be possibleto reducecolor and turbidity levels enteringthe sugarend
of a cane sugar factory to such a degree that direct production of
good quality white sugar is practicablewithout refining steps' This
should be even easier with diffuser factories, as the raw juice from
diffusers has levels of suspendedsolids that are 10 times lower than
juice from mills, as well as lower starchand gum levels (Rein' 1999)'
In order to increasecane sugar factory productivity, cogenerationof
electricity from surplusbagassehas been proven to be a commercia-
ble viable option in severalcountrieslike Mauritius, Guatemalaand
Hawaii for many years.In order to maximize their cogeneratlonpo-
tential the energy efficiency of most cane sugar factories has to be
improved markedly. The techniquesof how to accomplish this are
alreadyavailable,as summarizedby Bullock (1999) and discussedin
detail by Wunsch and Avram-Waganoff (1999).
This paper presentsthe conceptual design of a large (24'000 t/d)
modern cane sugar factory incorporatingthe following features:
- Single-line continuous process stations where possible (econo-
mies of scale).
- Proven modern technologies offering high sugar yield and/or high
energy efficiency (like diffusers,falling-film evaporators,contin-
uous evaporatingcrystallizers(pans) etc.).
2
La demandacrecientede azicar blanca de alta calidad ha propiciado
el desarollode las t6cnicasde microfiltraci6n y otras de tal manera
que es posible simplificar los procesosde la clarificaciön del jugo y
en la casade cocimienlosde ingenioscafleros.Aplicando estastecni-
cas en conjunto con calderasde alta presiön y turbogeneradoresde
condensacidn-extracci6n, impulsiones totalmenteelectrificadasy lf-
neasde procesosencillas,es posible ahorraraprox. el 40 Vodelbaga-
zo disponibledurante unazafra de 150 dias' Alavez se puedenex-
portar ("cogenerar")35 kWh por toneladade cafraprocesada.El ba-
gazo sobrantese puede embalar en pacas durante la zafra y es em-
pleado como combustibleen las calderasel resto del afro,generando
adicionalmente77 kWh/t cafra. O sea en total se pueden generar
ll2 kwh^ cafla para exportar a la red, sin emplear combustibleadi-
cional o metodossofisticadoscomo gasificacidndel bagazo'
El presenteaftfculo muestra el diseflo concepcionalde un ingenio
con estascaracteristicas,incluyendo el arreglo de la planta, tablas y
esquemasresumiendolos balancesde masay de energia,descripci6n
principalesy estimaci6nde los costosde un in-
de las caracter(sticas
genio de 24.000tld de capacidad.En base a los precios actualesde
azücar blanca y melaza y asumiendo US$ 40 de entrada neta por
MWh exportado se obtendränaprox. ll Vo de entradasadicionales
por encima de las ventasde azücary melaza'Parauna seriede paises
productoresde azücarde cafraesta deberiaser una propuestalntere-
sante.
- High quality white sugarproduction without sulphitationor refin-
tng.
- High-pressureboilers and extraction-condensingturbogenerators
for maximum electricity generationfor year-roundoperation.
- Baling of the excess bagasseduring the crop and employing it
during the rest of the year.
- Simplified layout with a significant part of the equipment placed
outside.
- White sugar storagepartly in bulk (in 2 large cylindrical silos of
85,000 t capacity each) and partly in bags.
The main body of the paper presentsthe basedata employed for de-
signing the factory, tabular resultsof the mass and heat balancesfor
the main processstationand basic flow diagramsof juice extraction'
clarification, evaporationand the sugar boiling house. Further, two
simplified schematicsshowing the operationparametersof the steam
boilers and turbogeneratorsduring the crop and during the rest of the
year are included. Finally an investmentcost summary shows the re-
sult of detailed price estimatesof the necessarymechanical equip-
ment plus pro-rata estimatesfor other costs and an overall layout
drawing how the factory could look from the air and its total land
reoulrements
+ ExtendedversionofaposterpaperPresentedatthe24thlSSCTCongressinBrisbane,Sept
t6-23,2001
Table l: Base data Juice Extraction (two lines):
24,000 üd
Cane preparationwith 2 sets of knives and heavy-duty Tongaat-
Cane processingcapacity
Crop length 150 days/year type shredders; continuous cane diffusers; single dewatering
Sucrose content of cane 14.50Voon cane mills; all drives with electric motors
Fibre content of cane 13.007o on cane For further details, please refer to Table 2 (Mass balance), Figure
Trash content 5.00Voon cane max. I (Basic flow schemejuice extraction and clarification) and to
Temperature of cane 25.00'c
'72.00"c Figure 6 (Factory layout).
Temperature in the diffuser
Power station (two lines):
Circ. juice 150.007o on cane
Heat losses extraction l0.00Va High-pressure boilers (two lines): demineralisation plant for
Imbibition water 260 007o on fibre make-up water; baling of excessbagasse;extraction-condensing
Bagassehumidity 50 00Vo turbines:year-roundcogeneration:
Raw juice quantity 106.807o on cane power export durrng crop: 126,000MWh (150d/a)
Raw juice purity 84 00Vo
power export outside of crop: 278,000MWh (200d/a)
Raw juice temperature (after diffuser) 6 5 . 0 0" c
0.30 7o on cane
For further details, please refer to Figures 4 and 5 (Steam boilers
CaO consumption
Sugar (pol) losses and turbogenerators)and to Figure 6 (Factory layout).
Sugar (pol.) extraction 0 25Vo on cane Juice purificatlon (two lines):
Sugar (pol.) filter cake 0.03 % on cane Simple lime defecation;short retention clarifiers for limed juice;
Sugar (pol ) undetermined losses 0.25 7o on cane separate filtrate clarifier; microfiltration with membranes; juice
Dry substancecont. of filter cake 30.O0Vo
softening (optional)
Purity of thin juice 85.00Va
For further details, please refer to Table 2 (Mass balance), Figure
Dry substance c o n t o f t h i c kj u i c e 72.00Va
Purity of molasses 32.007a I (Basic flow schemejuice extraction and clarification) and to
White sugar color 90-110 r u. Figure 6 (Factory layout).
White sugar M.A. 0 60mm Evaporation station (one line):
White sugar C V 28.00Va Five effect evaporator station; pre-evaporator in parallel with 3'd
effect; vapor bleeding from all effects; falling-film plate evapora-
tors; wide gap plate juice heaters;reservebodies for cleaning
2 Results and discussion For further details, please refer to Table 3 (Mass and heat bal-
ance),Figure 2 (Evaporationflow scheme)and to Figure 6 (Fac-
2.1 Base data tory layout).
Sugar crystallization (one line)'.
Tables I and 2 show relevant base data employed for carrying out the
3-product-whitesugar scheme; special seed magma produced in
technological calculation and process layout design of the factory.
batch evaporating crystallizers; continuous evaporating crystal-
The figures given are realistically attainable, provided the factory is
lizers for all main products; 2"d and affinated 3'd sugars are dis-
properly supervised and controlled, logistics of cane harvesting and
solved and mixed with thick juice giving "standardliquor" for 1"
transport guaranteea steady supply of freshly-cut cane with trash and
product feed; large capacity batch centrifugals for l" product sug-
foreign matter content below 5Vo.
ar; continuouscentrifugalswith dissolving device for other sug-
ars; vertical cooling crystallizersfor 3'dproduct massecuite;fluid-
2.2 Main process features
ized-bed white sugar drier; sizer-typesugarprescreeners.
The technologicalcalculationsand basic design of the processsta- For further details, pleaserefer to Figure 3 (Mass and color bal-
tions were basedon the basedata and assumptionslisted in Table 1. ance) and to Figure 6 (Factory layout).
Due to spacelimitations here only a summarylist of the main process White sugar bagging and storage:
steps is presented. Due to equipment size limitations and operation 170,000t stored in bulk in 2 cylindrical silos with air condition-
reliability 2 parallel lines for juice extraction, clarification, steam ing; automatic sugar filling and reclaiming; sugar grading in siz-
and power generation were chosen. The rest of the factory is sized er-type screeners;4 bagging lines for 50 kg bags; 50,000 t in 50
for single line operation whereby the equipment chosen represents kg bags on wooden pallets in 2 conventionalstores
the upper limit of what is currently available from reputed machinery For further details,pleaserefer to Figure 6 (Factory layout).
suppliers.

'[
able 2: Mass balancejuice extraction and juice purification
Total Total Dry Sucrose Non- Water Dry Purity Tempe- Specific Heat
mass mass substance content sucrose substance rature heat content
content capaclty
Units qo o.c. tlh Eao.c. Eao-c Eao.c. Vaoc Vo Vo "C kJ/(kg K) kJ/100kgc

Cane r00 00 1,0000 25.07 1 45 0 10.57 7 49 3 25.0',7 51 84 25.00 3 60 9,000

Imbibition water 33.80 338.0 3 38 0 90 00 4 . 18 t 2 , 7t 6
Press water 42.63 426.4 043 42.21 1.00 70.00 4.10 12,235
Wet bagasse 69.63 6964 13.93 0.25 1368 55-'71 20 00 70 00 3.98 19,399
Pressedbagasse 27 00 270.0 13.50 0.25 t3 25 13.50 50 00 70 00 4 10 7,'749
Sugar lossesin extraction 025
Raw juice 10680 1,068.0 1 69 6 1 42 5 2.'71 89 84 15.88 84 00 65.00 3 85 26,'727
CaO + HrO to limed juice 3.74 31-4 0.30 000 030
SO, 0.00 0.0 000 0.00 000
Filter cake 1.93 1 94 0.58 0.03 0.55 l 35 30.00
Sweet-off water - evaporation 3.00 3 00 0.00 000
Undetermined losses 033 33 o.25 025 0.00 0.08
'77
Thin juice 111.28 1,112-8 16.44 13 9',7 2.47 94 84 14 85.00
Purification effect 918
Thin juice to melter station 3.93 39.3 0.58 0.49 009 335 14.77 85.00
Thinjuice to evaporatorstation 107 35 1,073.5 1 58 5 13.48 2 38 9t.49 1417 85.00
Thick juice 22.02 220 2 15.85 I 3.48 2 38 6.17 7200 85.00
Water evaDoration 85 33 853.3 8 53 3
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 Shredded
cane P=l=
q d l 4
1007025"C d s l d
I

90"c 7 4 " cI

Pos,4
05
ill extracton
Juice Pos,4,05
l
(diituser)
P0s,4,02070"C
waler
70"c

Rawjuice -l wetbagasse
I 00flers
106,8%65"C b9.b7o /U"U
27Aa/o50%o12a

Lrnng
rn/n 35la/o 85"C
14240k 70"c
117
Pos6,030Condensate
ll
Clarifier
VaporlV
P0s,6050 82'C P0s,6,280
319% 97'C
Vaporlll
P0s,6060 88',C
Pos6271Vapor
ll
Vaporll
P0s,6070 99"C
Pos6270Vapor
lV

fierI
Clar Rotary
i,090
Pos,l vacuum
filters
424Yo 1 0 1 ' , C 19,17o 221T075"C

CIPWater
Pos124 CIPEffluent
12.4ya) 123.3109 6 ' C \2.40/a)

Regenerant Juice softening(optional) B-Molasses

to
Pos6,121 ization
crysta
B-Molasses 1 1 1 , 6 %9 1 ' C (7,0%)

P0s.6,230
Vaporlll
99'C

juice
Thin to
pre-evap0rar0r
1074lo 107"C
Pos6250Vapor
I

Fig. l: Basic flow schemeof juice extraction and clarification; mass quantitiesinTo oncane

2.3 Technological calculations

One of the main design targets of the investigated case was to obtain
the lowest possibleprocesssteamconsumptionin order to be able to
create a sizable bagassesurplus for cogenerating electrical power for
sale to the public utility. On the other hand due to having chosen 2
cane diffusers for the sake of high sugar extraction and lower power
consumption than 2 conventional milling tandems (Rein, 1999) "hot"
raw juice at 65 'C is obtained.This fact limits the use of low temper-
ature vapors and therefore a process steam demand of 30.4Voon cane
(304 t/h) was the lowest value that could be obtained. In the case of
factories with milling trains, where mixed juice temperatures are
normally around 35 oC the process steam demand can be reduced to
values of approx. 25Voon cane (Wunsch and Avram-Waganoff, 1999)
without much difficulty.
A singleJine 5-effect evaporatorstation with falling-film plate tech-
nology was chosen becauseit representsa cost-effective solution and
is also being applied increasinglyin the cane sugar industry (Rlval-
land, 2000) Total installed heating surface is 48.000 m2, distributed
as follows: Pre-evaporatorwith 5,500 m2, lu, 2ndand 3'defffects with
12,000m'z,4theffect of 5,000 m2 and 5'heffect with 1,500m'zheating
surface.
Heating of diffuser circulationjuice is performed with 4'hand 3'd va-
pors. Heating of limed juice consecutivelywith condensate,4'h, 3'd
and 2"d vapors whilst heating of clarified juice is done with 3'd, 2"d
and 1" vapor. The evaporating crystallizers are heated with "pre-
evaporator" vapor. This vessel is connectedsteam-wisein parallel
with the 3'd effect but juice-wise it receives clarified juice with
l4.87o rds. Thereforeit can cope easierwith any demandfluctuations
from the crystallization station All of the above is shown in Table 3
as well as in the flow schemesFigure 1 and Figure 2.
Another important design target was the production of white sugar
with color levels of 90-1 10LU without employing sulphitation or

r P o s I 030
965 687
16 470rds 231a/o
rds
Pos 10020
Fig. 2: Evaporationflow schemewith maximum cogeneration;mass quantitiesin 7o on cane
refining steps like decolorization and recrystallization. Starting from
raw juice color levels of 10,000-12,000I.U. it should be possibleto
reduce the color of the "thin juice" entering the evaporator station to
a level of 4,000 LU. by the steps enumeratedearlier, respectively
shown in Figure 1. Simple lime defecationis followed by sedimenta-
'l2O
tion in 2 short retention clarifiers (each sized for t/h of juice).
The mud juice is desweetenedin 4 rotary filters of 110 m2 areaeach
and resulting filtrate is sent to a separateflotation clarifier. Retentate
from the ultrafiltration membranes is also sent to this clarifier for
treatment. Therefore the clarified filtrate is recycled to the main lim-
ing tank due to its higher load of nonsugarsand colorants.
Clarified juice from the main clarifier is pumped to the ultra- respec-
tively microfiltration plant (ultrafiltration refer to pore sizes between
0.01 and 0.1 pm while microfiltration refers to pore sizes between
0.1 and 1 pm) Based on long-term experiencein Hawaii and many
trials at different cane sugar areas, the French Company Applexion
recommendsa pore size of 0.1 pm as a good compromise.Ceramic
membranes with this pore size can give a 5OVoreduction in color of
clarified juice, besides removing over 90Voof the turbidity and over
5OVoof dextran and starch. Other workers have found that advanced
spiral-type polymeric membranes capable of resisting 100'C are
more cost effective than ceramic membranes and can be even used
for purifying raw juice that had been previously mechanically fil-
tered through a screen with a slit opening of 50 pm (Martoyo et al.,
2000). For price estimation purposesa ceramic type membranein-
stallationcomposedof 21 skids, of which I 8 are working while 3 are
in the cleaning mode during 3 hours has been included. The price for
this installation is approx. US$7.4mn and it is included in Station 6
Juice purification (see Table 4).
6
r P o s 11l 6 0
it--"" _l
I
:
;oor
Pos I 0 4 0 P o s .9 , 0 5 0 Pos 9 060
41,9 285 233
37,9%rds 557%rds 680%rds
The clarified and ultrafiltered juice ("thin juice") with a color level
of 4,000 I.U. enters the short-retention falling-film plate evaporator
station described above. Due to the relatively low temperatures
(uice temperaturein the first effect is 12l "C and in the pre-evapora-
tor 107 'C) and short retention time (approx. 20 min for the whole
station) a 7O7oincreasein color in thick juice is estimated. As shown
in Figure 3, thick juice with 4,560 I.U. color is mixed with dissolved
2nd sugar and affinated 3'd sugar giving a "standard liquor" of
3,120[.U. which feeds the first product evaporating crystallizer. Due
to the previous removal of dextran, gums and waxes as well as at
least 5OVoof the macromolecular colorants a 2.5Vo color retention in
the white sugar crystals is estimated. With modern large capacity
batch centrifugals and washing with high purity syrup followed by
hot water a centrifugal yield of 45.87o (mass of sugar related to
massecuite)and a white sugar color of 9G-110 I.U. is ensured.For
2ndand 3'd products higher color retention levels (3.0% and 5.OVore-
spectively), due to the lower purities, are assumed.
All products are crystallized in continuous evaporating crystallizers.
Large vertical tower units (VKT's) are availablefor 280 t/h (1"'prod-
uct), 130 t/h (2"d product) and 75 t/h for 3'd product. To ensure good
C.V. values, seed magma with uniform crystal size is crystallized in
dedicated batch evaporating crystallizers for each product.
2.4 Power station and cogeneration
From the total of 210 üh (27Voon cane) bagasseavailable during the
crop only 140 t/h is required for firing the boilers. For design purpos-
es a specific steam generationof 2.3 t steam per t bagassewas as-
sumed. Steam production required for process, deaerator and con-
 Thinjuice Steamconsumption Evap. Heatingsteam
0,58 4,000 3 94
049 I Product 7.41 742 Tooc
148 ll Product 2.20 220 o/ooc
85.0
lll, Product 119 1 1 9 o/oo C,
Total 10,80 1 00 1 0 8 2 o/o O C,

Highwashsirup
1 12 1,149 1 44
098

Evap.
+ AC", =l )(to/^ | 7 41
I Productmassecuite
2538 3,741 27 89
22.38 Color retention

ll Productfeed solution
1198 7,823 15,01
9.04

ll Productmassecuite ll, Productsugar

1 19 8 9,388 12,81 5 58 282 564
9,04 530 -^ctu =

Run off
1 90 8,044 2 38
143
752 8 00

lll Productsugar
272 1,040 r

Run off
R C T
s
p

Fig. 3: Mass and color balance, sugar boiling; three product white sugar scheme
(7o); r Dry substancecontent (7o); C Color (IU);
? euantity, total (Voon cane); R Dry substance (Eoon cane);S Sucrose (Voon cane);p Purity
CY Centrifugal yield (mass of sugar/massof massecuite)

densation part of the turbogenerators during the crop is 324tlh at
85 bar. 525
'C. 2 boilers (of 180 t/h maximum capacity each) and
2 condensing-extraction turbines driving generators capable of pro-
ducing 33.4 MW each are foreseen. During the crop 150.5 t/h of ex-
haust steam at2.5bar (abs.)is extractedfrom each unit for process
purposes and 12tlh at 0.06 bar for condensation and return to the
boiler feedwater system (see Fig. 4).
After the crop the same units operate in wholly condensation mode'
Each turbine can absorb rreatly lO2 t/h of 85 bar steam and condense
it at 0.120 bar absolutepressure.The maximum possible electrical
generationis 30 MW eachunder thesecircumstances(seeFig' 5)'
During the crop (150d/a) the sugar factory requires approx. 31 MW'
so thai there is a remainderof 35 MW for export' i.e.35xl5ox24
= 126,000 MWh. The excessbagasse(128-132 t/h, depending on the
specific steam consumption ofthe boiler) is baled during the crop and
siored in rectangularpiles outside' A paved area of 64,000 m2 has
 162!n
Variant1: Crop operation
(150 days/yead
Steamboilers

P o s .1 6 0 1 0

Turbogenerators
162Vh
Pos 18010
85bar 85bar,525'C
525'C
Pos 18.020

Maximumpossible
electricitygeneration
334MW

I Evaporator

Pos 18.040

Fig.4: Steam boilers and turbogenerators,crop operation

101,MVh
Variant2: Out-of-cropoperation
10164Vh
(200 days/year)
Steam boilers

TI u , 'ih^^ö^ö/ät^re
vvvvr rvr qrvi v

Pos.18010
85bar,525"C

Pos 18.020

Maximumpossible
electricitygeneration
30 MW

L Evaporator 10164vh
4 94 ' C
17826Vh
4 94 ' C
Pos 18.040

Steamto
oeaeralor

Boilerfeedwater
system(deaerator)

Fig.5: Steam boilers and turbogenerators,out-of-crop operation

been foreseen for storing up to 470,000 t of surplus bagasse pro-
duced during the crop. This amount can be used up during 200 dla
generating 30 MW per turbogenerator, giving an amount of
278,000MWh of export power (58 MW x2OOx24)'
Relating the above figures to the amount of cane processedthe ex-
port power during the crop is equivalent to 35 kwh/t of cane while
the amount exported after the crop is approx. 77 kWh/t cane, giving
a total of I 12 kwh/t on a year-round basis' This figure could only be
improved significantly by employing more efficient bagasse com-
bustion techniques (like gasification) but these are not yet available
for an industrial scale operation.
2.5 Investment costs and return'on-inYestment
The cost of the sugar factory described above and shown in Figure 6
amounts to a grand total of US$l98mn including lOVofor contingen-
cies and unforeseen such as land costs, permits, duties etc.

8
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\ _ / \ L

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tr m rEEEEE
I
BAGGED SUGAF
STOFE

tr trtrTtrT' ffiNSON

tr l-1"."*.trIItro l
T I r Weighingand storage 1 4 Syrup,run-otfand sugar

tr trtrTtrTtrT T of cane
Unloadingot cane 15
h a n d l i n ge q u i p m e n t
Sugar baggingand storage

tr TtrTtrtrtrtrtr 4
Cane preparation
Juice extraction
Handlingand storage 1 7
16
equipment
Steam production
Water treatment{or steam

tr T T T T T t r Ttr
5
of bagasse production
o Juice purification 18 Turbogenerators

T T t r t r T T I trT
7 Milk of lime station 19 Electricalequipment
8 F i l t e ra n d m u d 20 Measuringand control
handling equipment

T t r T T T T t r Ttr I
10
Evaporation
Condensate
recirculation
21 Coolingpond and cooling
towers
Processwater system
11 Crystallization and 23 Waste water treatment
condensation 24 Molassesand chemicalstorage
12 Coolingcrystallization tanks
13 Centrifugation 25 Compressedair supply

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Fig. 6: Overall layout of a white sugar factory with cogeneration facilities of 24,000 t/d; total factory site area: 3'7 ha (600 m x 675 m)
Table 4: Total investment costs (US$) of a white sugar factory with 3 Conclusion
cogenerationfacilities of 24.000 t/d capacity
In view of the increasingattractivenessof cogenerationto a number
Station Mechanicalequipmentcosts US$
of cane sugarproducing countriesit seemsworthwhile to look at en-
I Weighing and storageof cane 780,000 ergy-efficient integrated factories. In addition advances in mem-
2 Unloading of cane 880,000
brane separationtechniques make it possible to produce high quality
3 Cage preparation 1,925,000
4 Juice extraction l 0,r 00,000 white sugar without refining steps.Available "big" sizes and good
5 Handling and storageof bagasse I ,910,000 reliability of sugar machinery make it feasible to design large facto-
6 Juice purification 9,630,000 ries with a minimum amount of equipment. The paper shows the de-
7 Milk of lime station 80,000 sign of a24,000 t/d cane sugarfactory producing high quality white
8 Filter mud handling 100,000 sugar and exporting substantial amounts of electrical power at the
9 Evaporation 7,120,000
same time. Even at world-market prices this approach should be in-
10 Condensaterecirculation I 15,000
ll Sugar boiling station and condensers 5,925,000 teresting to a number of cane sugar producers.
12 Crystallizer station 2,650,000
l3 Centrifugal station 3,160,000
14 Syrup, run-off and sugar handling equipmenl 2,120,000 References
l5 Sugar bagging and storageequipment 16,025,000 I R e i n , P W . ( 1 9 9 9 ) : I n t S u g a r J l 0 l , 1 9 2 - 2 3 4 ( a l s o p r e s e n t e d a t t h e M e e t i n g i n S e p t
16 Steam production 16,450,000 1998 of the Sugar TechnologistsAssociation of India)
l'7 Water treatment for steam production 970,000 2 Bullock, G E. (1999): Proc S Afr Sugar TechnologistsAssociation 73,197-198
l8 Turbogenerators 7,210,000 3 Wunsch, H.; Avram-Waganoff, P (1999): Z Zuckerindustrie 124, 451455 (also
publishedin Proceedingsof the ISSCT XXII Congressat New Delhi)
t9 Electrical equipment seebelow
4 Rivalland,,r.F.R (2000): Proceedingsof ISSCT Workshop Cogenerationin Mauri-
20 Measuring and control equipment seebelow
tius, October 2000 ("Improvements in exhaust steam economy with the installation of
2l Cooling pond and cooling towers 590,000 falling film plate evaporatortechnology")
22 Processwater system 375,000 5 Martoyo,7., Bochtiar, A , Hiruo, M , and Nagase, Il (2000): Z Zuckerindustrie 125
a-) Waste water treatment 1 , I1 0 , 0 0 0 787-792
1A
Molassesand chemical storagetanks l ,r 30,000
25 Compressedair supply 210,000
Sum of mechanical equipment costs approx. 507o 90,565,000

Civil works and buildings approx.20% 36,000,000 Konzeptioneller Entwurf einer Rohr-Weißzucker-
Electrical equipment approx 7,59o l 3,500,000 Fabrik mit maximaler Elektroenergieerzeugung (Zu-
Measuring and control equipment approx 4Vo 7,250,000
Piping/Insulation approx 9o/o l 6,000,000 sammenfassung)
Erection and commissionning approx.37o 5,300,000 Die steigendeNachfrage des Marktes nach Weißzucker hoher Quali-
Engineering and supervision approx 6,50/o 1I,650,000 tät hat zur Entwicklung der Mikrofiltration und anderer Verfahren
Sum (Base costs) l00%o 180.265.000 geführt, die zur Vereinfachung der Extraktreinigung und der Kristal-
lisation in Rohrzuckerfabriken beitragen. Werden diese Verfahrens-
Contingencies / Unforeseencosts approx. ll%o 18,035,000
weisen mit Hochdruck-Dampferzeugern und Entnahme-Kondensati-
Total factory costs 198,300,000 onsturbinen einerseits sowie elektrischen Antrieben anstelle von
Dampfantrieben und kontinuierlichen einstrassigen Prozessschritten
andererseitskombiniert, entsteht eine Weißzucker-Fabrik, die bei ei-
nem Elektroenergie-Export von ca. 35 kWh/t Rohr während der
All major items of equipmenthave been dimensionedto fit the tech-
Kampagne(150 d/a) mindestens40 Vo der verfügbarenBagasseein-
nological calculationsand the proposedlayout. Each individual item
spart. Die während der Kampagne zu Ballen gepressteUberschuss-
was priced, but one cannot give a guaranteeof completeness,as this
bagassewird in der Nebensaisonals Brennstoff eingesetzt.Auf diese
representsthe result of basic engineeringwork only.
Weise können zusätzlich 7'7 kWhJt Rohr generiert werden. Bezogen
The cost summary sheet (Table 4) shows the sum of all machinery
auf einen Bilanzzeitraumvon einem Jahr lässt sich somit insgesamt
items plus pro-rata additions for civil works (buildings, paved sur-
eine Exportenergie von 112kWh/t generieren, ohne zusätzlichen
faces,roads etc.) electricalequipment,measuringand control equip-
Brennstoff oder aufwändige Verfahren wie die Gasifizierung von
ment incl. automation,piping and insulation, erection and commis-
Bagasseeinzusetzen.
sioning as well as all engineeringservicesincluding supervisionof
Der Artikel gibt einen konzeptionellen Uberblick solch einer Fabrik
all constructionand installation activities.
inkl. Gesamtlayout, Tabellen und Schemata sowie Massen- und
Income from sale of products is expectedto be:
Wärmebilanzen, gefolgt von einer kurzen Prozessbeschreibungund
Kostenermittlung, basierend auf einer Verarbeitungskapazität von
Sugar:
2 4 , 0 0 0V d x ' 1 4 . 5 %x 8 6 V ox 1 5 0d x $ 2 6 4 = $ 1 1 8 , 5 1 4 , 8 8 0 (83 3Vo) 24,000t/d. Bei Annahme eines Ertrags von 40 US$ pro exportierter
MWh erhöht die zusätzliche Export-Elektroenergie bei den derzeiti-
Molasses: gen Weißzucker-Weltmarktpreisen den jährlichen Umsatz einer Fa-
24,000 tldx 4.31ox 150 d x $50 = $ '7,740,000 (5 4Va) brik um ca. ll%o, bezogen auf den Erlös von Ztcker und Melasse.
Diese Aussicht könnte für eine Reihe von Rohrzucker produzieren-
Export-power:
den Ländem interessantse1n.
24,000 tld x 150 d x I 12 kWh/t x $0 04 =$ 16.128.000 (113qa)

Gross income = $ 142,382,880 (100Ea)

For the above calculation "world-market" prices were assumed.In
order to obtain an investment-return rate (IRR) of at least 16%oa net
revenue of approx. US$33mn/a has to be attained.This requires a
detailed operating and financial cost analysis which is beyond the
scope of this paper In many countrieshowever considerablyhigher
prices are paid for white sugar, making the described factory a
worthwhile proposition.
Conception d'une fabrique de sucre blanc offrant un
maximum de cog6ndration (Rdsumd)
La demande croissante du march6 pour du sucre blanc de haute qua-
Iit6 a conduit au d6veloppement de la microfiltration et ä d'autres
techniques permettant de simplifier grandement 1'6puration du jus et
le processusde cristallisationdu sucre dans les sucreriesde canne
Quand on applique ces techniques simultandment avec des g6n6ra-
teurs de vapeur ä haute pression et des turbogdnerateursavec extrac-
tion de condensat,des transmissionscomplötementElectrifideset des
ateliers de processuscontinus en une seule ligne, I'usine de sucre

l0
blanc qui en r6sulte peut dconomiser au moins 40 Vo de la bagasse
disponible au cours d'une campagnede 150 jours, tandis que I'on
peut encore exporter environ 35 kwh d'6nergie 6lectrique par t de
cannes. L'excddent de bagasse peut Ctre mis en ballots pendant la
campagne et €tre utilisd pour alimenter la centrale dlectrique en in-
tercampagne et produire ainsi une dnergie dlectrique additionnelle de
77 kWWt. Au total, on peut produire environ ll2 kwh/t de canne
pour le r€seau extdrieur sur base annuelle sans utiliser de combusti-
ble additionnel ni mdthodes sophistiqu6escomme la gaz6ification de
la bagasse.
Author's address: Dipl.-Ing. Pedro Avram-Waganoff and Dipl.-Ing. Thomas Srart, IPRO Industrieprojekt GmbH, Celler Straße 67,38114
Braunschweig, Germany; e-mail: Avram@ ipro-bs.de, Stark @ipro-bs.de
Cet article montre la conception d'une telle sucrerie, incluant une
dispositiond'ensemble,des tableauxr6sum6set des schdmasde bi-
lan de masseset de calories, une courte description des caractdristi-
ques principales du processus et une estimation des coüts pour une
usine d'une capacitl de 24 OO0t/j. Aux prix actuels du march6 mon-
dial du sucre blanc et en supposant un revenu net de 40 US$ par
MWh vendu au r6seau, le montant pour cette 6nergie export6e pro-
duite ajoutera environ ll Vo au revenu annuel de la sucrerie prove-
nant de la vente du sucre et de la m6lasse. Pour de nombreux pays
producteursde sucre de canne,ceci peut constituerune proposition
s6duisante.
lt
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