1. Josef Merkl AGRANA Zucker GmbH A-3430 Tulln, Reitherstraße 21-23
Reduction of energy consumption by the Austrian sugar factories in the period 1990 – 2002
Josef Merkl
AGRANA Zucker GmbH
A-3430 Tulln, Reitherstraße 21-23
T / TL / Merkl

2. Manufacturing process for sugar production
Reduction of energy consumption by the Austrian sugar factories in the period 1990 – 2002
Introduction
Manufacturing process for sugar production
Energy consumption of Austrian sugar factories
Measures to reduce energy consumption (1990 – 2002)
Evaluation of energy requirements
Evaluation of future savings potentials
T / TL / Merkl

3. Manufacturing process for sugar production
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4. Process sections and energy consumptions
Section for sugar production
Beet intake, beet storage, beet processing, juice extraction, pulp pressing, juice purification including lime kiln, evaporation and crystallization, sugar storage and shipping, boiler system for steam production, turbines, water and waste water networks
Section for production of dried pulp
Pulp drying station, pellet station and storage of animal feed
Energy consumption for sugar prodction
Including power station
Energy consumption for pulp drying
T / TL / Merkl

5. Heat distribution – Material separation system
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6. Energy consumption
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7. CO2 – Emissions (Campaign)
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8. CO2 – Emissions (Year)
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9. Electrical power consumption 1990 - 2002
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10. Survey AGRANA factories 1990 – 2002
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11. Sugar factory Hohenau
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12. Measures Hohenau factory 1990 - 2002
Steam boiler and pulp drying converted to natural gas operation (1990)
New extraction tower (1991)
Evaporation station renewed to a 6-stage operation (1997)
Waste heat utilization (1998 – 2000)
New pulp presses
Modernization of vacuum pans
Modernization of juice purification (2001 – 2002)
T / TL / Merkl

13. Sugar factory Leopoldsdorf
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14. Measures Leopoldsdorf factory 1990 - 2002
Steam boiler and pulp drying converted to natural gas operation (1990)
Beet washing house (1991)
Modernization of Evaporation station (1993)
Optimization of juice purification (1994)
Lengthening of an extraction tower (1996)
New pulp presses (1997)
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15. Sugar factory Tulln
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16. Measures Tulln factory 1990 - 2002
Steam boiler and pulp drying converted to natural gas (before 1990)
Optimization of slicing machines
Evaporation station renewed to a 5-stage operation (before 1990)
Optimization sugar end and heat exchangers
Reduction of lime utilization
New pulp presses
T / TL / Merkl

17. Benchmarking: Energy consumption for sugar production (Südzucker-AGRANA-Group)
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18. Benchmarking values (by IPRO Industrieprojekte GmbH)
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19. Benchmarking values (by IPRO Industrieprojekte GmbH)
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20. Benchmarking of electrical power consumption 2002 (21 factories in 7 European countries)
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21. Benchmarking of electrical power consumption 2002
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22. Evaluation of the future savings potentials and their efficiency
Hohenau
Further modernization of the pulp press station (33% DS) – investment costs recouped after 62 years
Leopoldsdorf
Increase of the evaporation station – investment costs recouped after 38 years
Tulln
Enlarge extraction tower – investment costs recouped after 23 years
T / TL / Merkl