Plant Revamp - JDW Sugar Mills Ltd, Pakistan

Plant revamp

A case study of JDW Sugar Mills Ltd, Pakistan

ü Steam demand reduction from ~53% to ~33% on cane

ü Plant capacity increase from 20,000 tcd to 24,000 tcd

A decade ago, feasibility studies for plant revamps to increase the capacity and reduce process steam demand was uncommon in Pakistan. In the year 2010, IPRO got an order from JDW Sugar Mills Ltd, a 20,000 tcd cane sugar plant with backend refinery, for a feasibility study. A plant audit with the focus on a reduction of the process steam demand to ~36% from as high as ~53% on cane was carried out. Initially, increasing in the crushing capacity was not a target. A decade ago, only the steam demand target was quite ambitious for a cane sugar factory with backend refinery operation.

To make this project commercially viable, it was very important to focus on process optimization, improvement of equipment capacity utilization and debottlenecking. During the plant audit, various operational and equipment inefficiencies were identified. It was planned (as per standard strategy of IPRO), to reach the target in multiple steps to ease the investment burden and to give JDW Sugar personnel a time for learning about and to get acquainted with new methods and technologies.

For the execution of plant audit recommendations, JDW Sugar decided to go for modern equipment of IPRO design. In the first step, IPRO designed falling film evaporators for 1st effect, pan automation for refinery pans and direct contact heaters for clear juice and molasses conditioning, which were implemented along with process optimization measures. With these changes, the process steam demand reduced to approx. 45% on cane with a slight increase in plant capacity to 20, 500 tcd.

In the subsequent steps, falling film evaporators for 2nd and 3rd effect, pan automation for raw house pans and DCHs for raw house molasses conditioning, along with further process optimization measures, were implemented. After the realization of all the steps, process steam consumption reduced to ~33% on cane (with backend refinery). Moreover, plant crushing capacity increased to 24,000 tcd with better equipment capacity utilization.

It was a “first of its kind” project in Pakistan at that time. After successful results, many sugar factories, including JDW Sugar group for their other factories, adopted the same strategy and ever since IPRO has continuously been supporting the sugar factories in Pakistan to achieve ambitious targets. We carryout 30 – 40 studies worldwide every year.

IPRO INDIA

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Sugar Factory Equipments

IPRO INDIA’s we offer energy saving and modern sugar factory equipments for the sugar industry i.e. Falling Film Evaporator, Direct Contact Heaters, Condensate Flashing System, Pan Automation System, Condensers, Carbonatation System, Cascade Continuous Pan etc. which are a part of highly efficient modern sugar factories.