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The Digital Sugar Mill
Seminar on Sugar & Ethanol Automation
Process House Automation
Mr. Israr Hussain
General Manager (Production)
Habib Sugar Mills
Process House
Automation
Agenda
Introduction
Automation Strategy
Role of Automation in Sugar Processing
Scope of Automation
Automation for Utilities
System Architecture
HMI Displays
Maintenance
Impact of Automation
Falling Film Evaporators Automation
Continuous/Batch Pan Automation
Remelt Phosphatation Process Automation
Multi-Bed Filters Automation
Skills and Training
Conclusions
3
Introduction
Worldwide sugar factories are being modernized and automated in responseto the need for efficient production and the ability to compete globally.
Continuous control and precise handling of all parameters is required toensure consistent product quality and reduce production costs.
Automation Strategy
Selection of automation strategy:
Centralized Control System (CCS)
Decentralized Control System (DCS)
Which strategy to choose?
Automation Strategy
Merits and Demerits:
Correct selection of automation equipment
Correct selection of instruments
Right automation partner
Choose wisely
Role of Automation in Sugar Processing
Key issues:
Perishable raw material
Heat sensitive product
pH sensitive product
Flow Rate
Fuel and Energy
Impact of operating parameters on sugar recovery and quality
Role of Automation in Sugar Processing
Impact of Operating Parameters on sugar recovery and quality:
Flow Rate pH TemperatureRetention
TimeLevel
IndicationPressure Vacuum
Automation for Utilities
Control of Key Parameters in Boiler Operations
Drum LevelSteam
PressureSteam
TemperatureSteam
QuantityFeed Water
TemperatureFlue Gas Analysis
Flue Gas Temperature
System Architecture
HMI Displays
HMI Displays
HMI Displays
Maintenance
Monitoring
Temperature PressureAxial Floats of
Rotors
Impact of Automation
Implementation of a need-based process control system leads to:
Capacity Optimization
Improved Plant Efficiency
Reduced Energy Cost
Improved Product Quality
Reduced Production Cost
Reduced Maintenance Cost
Reduced Down Time
Man-Power Savings
Falling Film / Conventional Evaporators Automation
Feed juice enters at the top of the tubes through distributors and flows down with the tube walls as a thin film. Since the film ismoving in the direction of gravity, a finer and faster moving film results, yielding high heat transfer coefficient and reducedcontact time. The flow of vapors and juice maybe concurrent or countercurrent where the liquid is drawn from bottom and vaporfrom the top. Forced circulation is applied.
Automation of Falling Film Evaporators is critical in the sense that its malfunction can cause accidents. We should understand thecriticality and dangers of this process and ensure safe and reliable operation through automating the process including:
Juice Flow
Juice Level
Emergency Hot Water
Sugar Losses through inversion
Salt Scaling
Caramelization in case of dry tubes
Falling Film / Conventional Evaporators Automation
Better control of these parameters affects sugar recovery and quality.
The way an evaporator plant works has a crucial impact on heat economy of thesugar factory.
Continuous / Batch Pan Automation
Efficient crystal growth requires accurate monitoring and control of all parameters (throughautomation) of the concentration of sugar solution in each compartment of the continuous vacuumpan.
Each compartment of the continuous vacuum pan is controlled through individual set points in orderto establish the required Brix profile along the pan.
The continuous vacuum pan permits constant level of vapor bleeding from the operator station. Thisresults in more even running of evaporator station and consistent dry substance content of the thickjuice.
The low massecuite level above calandria keeps the heating steam pressure. Moreover, circulation andhomogeneity of the massecuite improved. The heating steam can therefore be taken from adownstream effect of the evaporators station and fully used in upstream effect.
Remelt Phosphatation Process Automation
Monitoring and control of:
Liquor Flow Rate
Liquor Brix
Liquor Heating
Process Chemical Dosing
pH Control
Level Control
Retention Time
Continuous and precise monitoring and control of all the parameters is required to ensure consistentproduct quality and sugar losses.
Multi-Bed Filters Automation
Monitoring and Control
Flow Rate PressureBackwash
CycleLevel
Indicators
Skills and Training
Present day process control systems are interactive
It is imperative that Automation Solution Providers also facilitate the training andguidance for Sugar Mill operators, through:
Training Modules
Operational Support
Operational Manuals
Conclusions
22
The surest mantra to achieve cost reduction in the shortest time
Return on Investment can be phenomenal and quick
Move towards becoming internationally competitive
Question & AnswersThank You for Your Valuable Time