Use of Modern Technologies for Better Boiling House Efficiency by Mohammad 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 MILLSREPORTED MILLS Installed Installed Capacity(tcd.) Nos. Installed Capacity(tcd.) Capacity Used (tcd.) % Utilization , ,800170, , ,300125, , ,100159, , ,600220, , ,800123, , ,300126, , ,300178, , ,800159, , ,800132, Punjab

History of Sugar Industry YEAR SUGAR MILLSREPORTED MILLS Installed Installed Capacity(tcd.) Nos. Installed Capacity(tcd.) Capacity Used (tcd.) % Utilization , ,200107, , ,40089, , ,90089, , ,700110, , ,90081, , ,90066, , ,90088, , ,50094, , ,90077, Sindh

History of Sugar Industry YEAR SUGAR MILLSREPORTED MILLS Installed Installed Capacity(tcd.) Nos. Installed Capacity(tcd.) Capacity Used (tcd.) % Utilization ,600425,32011, ,600215,5005, ,600527,72014, ,600527,72017, ,600522,6009, ,600522,60012, ,600522,60014, ,600522,60013, ,600421,72013, KPK

History of Sugar Industry YEAR SUGAR MILLSREPORTED MILLS Installed Installed Capacity(tcd.) Nos. Installed Capacity(tcd.) Capacity Used (tcd.) % Utilization , ,320288, , ,200220, , ,720263, , ,020348, , ,300214, , ,800207, , ,800282, , ,900265, , ,420223, 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 Avenues Evaporation Season average Syrup Brix Highest = 67.44%. Lowest= 54.61%. Season 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 Avenues Crystallization 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.

THANKS