Sugar Technologist || Process & QC Chemist || Process Engineer || SUGARS™ (Process modeling and simulation) || Sugar, Ethanol & Sugar by-products.
🚀 Achieving 20% Steam Savings in the Indian Sugar Industry: A Game-Changer! 🌱 The Indian sugar industry has immense potential for energy optimization, and reducing steam consumption is a critical area for improvement. Reducing steam consumption to 20% on cane is a game-changer for the Indian sugar industry, enabling cost savings, higher bagasse savings , and environmental sustainability. With proper bleeding schemes and advanced technologies, this ambitious target is achievable for modern sugar mills. Key Strategies to Achieve this Target: 1. Vapor Bleeding Optimization: Use vapor bleeding from evaporators (1st Vapor use in place of HP steam, multi stage juice heating use later vapor preheating juice & 5th & 6th vapor for crystallization). Tailor bleeding rates to match heating and evaporation demands efficiently. 2. Implementation of Falling Film Evaporators: Improves heat transfer efficiency, multi effect evaporator goes up to 7th to 8th effect, reducing steam consumption in juice concentration. 3. Efficient Vacuum Pan Operations: Integrate automated vacuum pans that utilize low pressure vapors from evaporators for pan boiling. By using an energy efficient pan which operates at low pressure vapor. Optimize crystallization to ensure consistent energy efficiency. 4. Process optimization: Syrup brix up to 76_78% minimize sugar recirculation using slurry for grain preparation. Minimize water consumption in the pan by improving crystallization. Other Useful Technologies: 1. High-Pressure Boilers and Turbines: Use boilers with pressures of 105 bar or higher. Install condensing or back-pressure turbines for efficient cogeneration. 2. Mechanical Vapor Recompression (MVR): Employ MVR to compress low pressure vapor to high pressure vapor, reducing steam consumption. 3. Heat Recovery Systems: Recover heat from condensates, flue gases, and exhaust streams for reuse. Use condensate flashing systems for additional energy recovery. Use condensate for juice heating, send cool condensate from the process. 4. Automation and Process Monitoring: Use of modern control systems like DCS/SCADA to optimize steam usage across processes. Adopt IoT-based systems for real-time energy monitoring and control. Conduct regular energy audits to identify areas of improvement. Benefits of Achieving 20% Steam Consumption: Fuel Savings: Reduced bagasse usage enables higher power export. Cost Efficiency: Minimized energy costs boost profitability. Sustainability: Lower greenhouse gas emissions contribute to environmental goals. Join the Movement! Together, we can transform the sugar industry into a more efficient and sustainable sector. Let's innovate, implement, and inspire! 💡 Have you implemented steam-saving measures in your mill? Share your experience below! #SugarIndustry #SteamEfficiency #EnergyOptimization #Sustainability #Innovation
MVR is the best solution currently we have and is really efficient option to reduce steam consumption of existing plants as well as for new plants.. we have supplied many MVR to distilleries as well as a recent commissioning in renowned sugar factory and all our commissioned plants are running very efficiently with less steam.. MVR not only reduces steam consumption but also reduces Co2 emission and soft water requirement of the plant and increases overall efficiency…
Let's see the nunbers and products. Also it's important kwh/t cane. Real Mills with less stream consumption it's 28 to 31%
No water should be added in the pan. With DSEC batch pan automation no water is added. We achieved it in several beet and cane factories ( Thailand, Europe, Mauritius, Algeria,…)
MVR 🤘🤘👍
Very good achievement Energy saving is a key to success in sugar industries
Great achievement. At the same time as cost of production of Sugar decreased , part of the gain may be used to Raise Sugar Cane price as former is not able to continue Sugar Cane Agriculture .
Which are products of this mills? Refined sugar? With distillery?
Insightful
Operations Engineer at ASR Group
3wExcellent!👏🏽 which mill is this being targeted?