Transition of the Pakistani Sugar Industry to World

© Kashif Export Co. 2018

PSST

52nd Annual Convention

Karachi, 1st to 2nd October 2018

Transition of the Pakistani Sugar Industry to World Technology Leadership

2005 -> 2018

by

Kashif Naseem1, Dr. Boris Morgenroth2, Pedro Avram2 and Harjeet Singh Bola3

1Kashif Export Co. (Int’l) Ltd., United Kingdom

2IPRO Industrieprojekt GmbH, Germany

3IPRO INDIA Pvt. Ltd., INDIA


Introduction

• In 2005, the sugar cane price was RS 40/Maund and sugar at Rs 26/kg

• The majority of the industry are still bread and butter, bagasse balanced factories:

• Average factory size: below 10,000 tcd

• Low pressure boilers with less than 25 bar

• Steam drives for mills

• Average steam on cane: 48 - 60%

• High internal power consumption of more than 20 kWh/t cane

• POL in Cane: 10.5 - 11%

• Sugar Recovery: 8 - 8.5%

• Sugar yield per hectare: 3 t/ha

• R1 colour: 60 - 70 ICUMSA

• Laboratories run with antique equipment

• Sugar cane is purchased based on quantity not quality

• Cogeneration is of no interest

• Cut to crush time ranging from 5 - 15 days


Integrated Beet and Cane Sugar Processing & Cogeneration

• Combined sugar beet + sugar

cane factory

• High pressure boiler and turbine

65 bar

• Cogeneration

• Dual-use moving bed diffuser

• Falling-film evaporators in all

effects

• CIP system for heaters and

evaporators

Almoiz Sugar Industries Ltd

Unit 1

• Continuous cascade and conventional pans for raw sugar house

• Integrated refinery

• Energy efficient sugar process including utilization of vapors from all

effects


• Operation with 0.5-0.7 bar absolute pressure for last effect

• Optimum usage of heating with condensate

• Stepwise flashing of condensate by ‘condensate cigars’

• Seed Cooling Crystallizer Plant

• High level of automation

• Very efficient design

Integrated Beet and Cane Sugar Processing & Cogeneration

Almoiz Sugar Industries Ltd Unit 1


Modern technologies

• Very good heat transfer

• High heat transfer coefficient

• Small Δ T possible

• Low sucrose inversion

• High operational flexibility

• Lower color formation in comparison to conventional Robert evaporators

• Low space demand

• CIP (Clean In Place) stands for quick cleaning of tubes without opening the evaporator

FALLING FILM EVAPORATORS


Modern technologies

CASCADE CONTINUOUS PANS

• Small hydrostatic head over the calandria

• Easy to bypass any of the compartments for cleaning

• Equipped with stirrers - high heat transfer co-efficient

• Allows very good energy economy by using 3rd to 5th vapor

• Lower color formation & sugar losses


Modern technologies

SEED COOLING CRYSTALLIZER

• Increased sugar recovery by reduction of C- molasses purity

• Seed quality improvement

• Reduced seed development time and increased strike speed

• Improved centrifugal performance due to crystal uniformity

• Lesser sugar recirculation in the process

• Easy implementation in existing plants


Modern technologies

FULLY AUTOMATED PAN OPERATION

• Exhaust steam saving of 4 – 5% on cane possible

• Saves 2 - 5 tons water per batch

• Man power optimization

• Almost no false grain formation

• Shorter pan strikes

• Better pan capacity utilization

• Less recirculation due to better CV of sugar crystals

• Less sugar color due to shorter boiling time

• Less vapors to the condensers: savings in injection water & pump power


Modern technologies

DIRECT CONTACT JUICE HEATERS

• DC heaters are inexpensive and easy to integrate with low space demand

• Allow an approach temperature of 1.5 – 2 K while tubular or plate heaters require 4 – 8 K

• Almost no cleaning or down time

• Constant performance

• High load flexibility with minimum performance change

• Drawback is the water dilution and 2 - 3% o.c. increase in steam demand but it is compensated to some extent by shifting vapour bleedings


Challenges and Opportunities

• In 2010-11 sugar cane price was RS 126/Maund and sugar at Rs 68/kg

• Pakistan is facing a severe energy shortfall of approx 7000 MW

• PSMA and especially the JDW group are lobbying for a more favourable cogeneration policy than the ‘take and pay’ policy

• Pakistan Sugar industry has the ability export approx. 3000 MW power

• Coal + Bagasse Policy: - Rs12/kWh levied with international coal price

• 2013-2017: Bagasse Upfront Tariff - Power purchase price Rs11.74/kWh on 132KV line

• Bagasse has become a commodity

• Steam Saving has been recognized as an essential feature for cogeneration


Present Day Pakistan

• Sugar Cane Price at Rs180/Maund Sugar at approx Rs 48

• Approx. 10 factories with steam on cane below 38%

• Approx. 10 factories with cogeneration boilers at 67 bar and 110 bar

• Over 100 FFE’s Installed in Pakistan

• Higher levels of automation

• R1 quality of <45 ICUMSA being produced by approx 20% of the

industry

• 20% of the industry adopting international Laboratory routines and

equipment

• Leading groups looking towards cooperative farming

• Awareness of benefits of planning and proper engineering

• But this is only 20% of the Industry!


KPI Present/Future Pakistan cane sugar

Typical Best unconstrained future

Factory capacity t/day < 10.000 > 20.000

Cane crushing

Sugar production

t/year < 1 Million

< 110.000

> 2 Million at 100 days

> 220.000 at 11 % Pol rec.

Laboratory

control

Antique ICUMSA

Cane yield t cane/ha maunds/acre

50 – 120

~ 500 - 1250

> 120 (actually 11 – 14 % Pol)

-> 13 – 16 % Pol in future

Sugar yield t sugar/ha 6 - 15 17 – 19 at better cane quality

Sugar quality col.

Sediment

IU

mg/kg

22 - 45 R1

37 – 70 R2

6.5 - 15

9 - 30

< 35 R1

< 45 R2

< 7 R1

< 7 R2

Process steam

requirement

% on cane 35 - 65

(raw/refined

sugar)

27 – 32

(raw/refined sugar)


KPI Present/Future Pakistan cane sugar

Typical Best unconstrained future

Power

requirement

kWh/t

cane

14 – 25

Turbine

drives

12 – 14 (26 – 28)

Turbines (electrified drives)

Power export kWh/t

cane

0 – 35 (in

season)

100 – 145 using all bagasse

-> improvement with HP

boilers coming up

Sugar recovery %

% Pol

81 – 87

9 – 11.4

89 – 91 (actually low purities)

11.6 – 14.6

Molasses purity % 33 - 40 30 – 32 (all refractometric)

Effective Season

length at full

crushing

days 50 - 130 > 130; cogen, sugar beet

other countries: 180 – 330

days

Personnel persons 500 - 1200 ~ 150 - 180 + services


• Lab routines: Follow ICUMSA rules and switch to refractometric Brix

measurement!

• Apply modern process technology

• Accept transfer of technology where relevant

• Improve equipment layout

• Improve automation

• As a result decrease steam usage per ton of cane to levels of <32%

• Obtain better payment terms from the Government per cogenerated

kWh in order to finance the necessary investments

• Reduce Cut to Crush time

• Improvements in agriculture -> cane quality payment is a must!

• Create therefore a substantial additional source of income, like it has

been done since decades in Brazil, Guatemala, Mauritius, Reunion,

amongst others!

Challenges to the sugar mills


IPRO Industrieprojekt GmbH

Documents

Transition of the Pakistani Sugar Industry to World