COGENERATION ENHANCEMENT USING LOW PRESSURE VAPOUR FOR CRYSTALLISATION By: VIVEK VERMA

MISSION STATEMENT Dedicated for Sustainable Environment Development to Unlock Perpetual Food and Energy Resources.

HIGHLIGHTS Dhanalakshmi Srinivasan Sugars Pvt. Ltd. (DSSPL), Tamilnadu 3500 TCD Plant Current Steam Consumption 31-32% on cane Power export 100-105 kWh/Ton of cane Sugar Colour < 35 IU Modern boiling house with FFEs, DCH, SCP® for all Massecuite 2 roller 4-mill tandem plant 40% savings on power consumption by AC-VFD Motors Fully automated Sugar and Co-Generation units with DCS controls

BOILING HOUSE CONFIGURATION Quintuple Evaporator Station with seven identical Tubular FFEs (1500 m2) Total HS = 10,500 m2 [9000 m2 - operation and 1500 m2 – in standby] Condensate Flash Vessel System DCH for Raw, Defecated and Clear Juice & Syrup heating Single Floating Evaporator for cleaning all effects Working temp. range: 125°C to 75°C All massecuite boiling through SCP® using 4th effect vapour

OPERATING SCHEME AT DSSPL

OPERATING PARAMETERS Sr. No. Effects Operating Pressure (bar A) Operating Temp. (0C) Operating ∆T 1 1st Effect 1.8–1.9 118-120 6-80C 2 2nd Effect 1.3-1.4 110-112 8-90C 3 3rd Effect 0.9-1.0 98-102 7-100C 4 4th Effect 0.6-0.65 93-96 5-70C 5 5th Effect 0.35-0.40 75-78 12-150C

BLEEDING ARRANGEMENT Sr. No. Description Configuration Operating Temperature 1 MJ 1st Heating Pan Vapour 54-57 0C 2 MJ 2nd Heating 5th Effect 74-77 0C 3 DJ 1st Heating 4th Effect 86-89 0C 4 DJ 2nd Heating 3rd Effect 96-99 0C 5 DJ 3rd Heating 2nd Effect 107-110 0C 6 CJ 1st Heating 7 All Pans (A, B, C & R) 93-96 0C

CRYSTALLISATION & STEAM CONSUMPTION Evaporator bleeding for Pan Boiling directly effects the steam demand. Present design of pans prevent it to be operated with low pressure vapour. SCP® is the solution for reducing steam demand. Shifting of vapour for pan boiling to later effects indirectly helps in rising the liquor brix close to saturation alongwith direct steam saving. Crystallisation using later effect drives evaporator sizes identical ; only the single evaporator is required as standby.

EVAPORATION LOAD DISTRIBUTION Conventional Plant DSSPL, Tamilnadu

EFFECT OF CRYSTALLISATION ON STEAM Steam Consumption

CONVENTIONAL PAN 40% 35% 10% 5% Effect – I 115°C Steam 45% on Effect – II 105°C Effect – III 90°C Effect – IV 75°C Effect –V 55°C Steam 45% on Cane - 120°C 40% 35% 10% 5% Condensate

VERTICAL CONTINUOUS VACUUM PAN(SCP®) Effect – I 115°C Effect – II 105°C Effect – III 95°C Effect – IV 80°C Effect – V 55°C Steam 35% on Cane - 120°C 32% 28% 20% 18% 2% Vapours 15% Condensate

CRYSTALLISATION SECTION 3 Nos. of Vertical Continuous Vacuum Pan (SCP®) for all Massecuite boiling. Capacity of SCP®A – 50 TPH, B – 20 TPH, C – 15 TPH, R1 – 25 TPH and R2 – 20 TPH. Molasses Conditioner for AH, BH, CL R1 molasses of direct contact heating type. 2 Nos. of Seed Crystallizer of 20T for A and B Seeds. 2 Nos. of Grain Crystallizer of 30T for B and C Grain. 5 Nos. of supply tanks of 2 for syrup & melt and 3 for molasses storage.

COLOUR VALUE OF VARIOUS STREAMS S. No. Descriptions Colour Value(IU) 1. Primary juice 26500 2. Mixed Juice 28540 3. Clear juice 15458 4. Syrup 15750 5. “A” M/c 9200 6. “B” M/c 15040 7. “C” M/c 20453 8. R1 M/c 950 9. R2 M/c 1150 10. A Heavy 15304 11. B Heavy 22680 12. C Light 24540 S. No. Descriptions Colour Value (IU) 13. Final Molasses 28400 14. R1 Mol. 1023 15. R2 Mol. 1437 16. Raw Melt 570 17. Clear Melt 342 18. B & C Melt 4550 19. C Seed 2400 20. C fore Sugar 3715 21. C after Sugar 3180 22. R1 Sugar 24 23. R2 Sugar 41 24. Blended 34

COGEN EFFICIENCY COMPARISION DSSPL, Tamilnadu Conventional Plant

COGENERATION Particulars Unit SEASON WISE 2014-15 2013-14 2012-13 2011-12 2010-11 2009-10 Plant Crushing Rate MT 3200 3000 2000 1600 2200 1900 Power Consumption kWh/T 29.40 30.84 30.79 32.13 32.63 38.17 Sugar Colour IU 33.93 MONTH WISE Jan-2016 Feb-16 Mar-16 Apr-16 Power Generation kWh/T 135.96 128.11 135.85 135.35 Power Consumption 32.5 29.81 31.86 30.14 Power Export 103.46 99.3 103.99 105.21

PLANT VIEWS

RESULTS Sr. No. Descriptions/Parameters Value 1. Crushing Capacity 3500 TCD 2. Cane Crushed (MT) 5.0 Lakh 3. Bagasse % Cane 27.5 4. Fibre % Cane 13.10 5. Steam Consumtion of the Plant 31-32% on cane 6. Total Heating Surface Area of FFEs 10,500 m2 7. A Masseciute (%) cane 29 8. B Massecuite (%) cane 11 9. C Massecuite (%) cane 8.5 10 Refined Sugar (R1) (%) cane 28 11. Refined Sugar (R2) (%) cane 21 12. Sugar Colour < 35 IU 13. Power Export 100-110 kWh/Tons

CONCLUSION Enhanced Power Generation (100 - 105 kWh/T) by crystallization with 4th effect Falling Film Evaporator using innovative approach and efficient technologies.

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