Projects & Case Studies
Plant revamp JDW Sugar Mills Ltd, Pakistan
In the year 2010, JDW Sugar Mills Ltd (JDW) a 20,000 tcd cane sugar plant with backend refinery obtained services from IPRO to bring down high steam consumption (52.60% on cane) of the plant along with capacity increase and cogeneration. During the plant audit IPRO identified various operational and equipment inefficiencies and suggested to reach the target in two phases to lower the investment burden and to use savings of first phase as investment for second phase.
Pan capacity optimization with Pan Automation System
A case study on the implementation of pan automation system in Mehran Sugar Mills Ltd. by joint efforts of IPRO and IPRO INDIA. It helped the Client increase the pan station capacity with modern pan automation system.
Engineering Group References
Competence and routine world wide
Bunge- Unidade Pedro Afonso, Brazil
Capacity ~24,000 t/day (cane)
Steam demand ~ 33 % on cane
Extraction Cane diffuser
Sugar quality < 150 IU (Phase II)
Boiler pressure 65 bar
Almoiz Industries Ltd, Pakistan
Capacity ~8,500 t/day (cane)
~ 4,000 t/day (beet)
Steam demand ~ 36 % on cane
Extraction Cane & Beet diffuser
Sugar quality < 45 IU
Boiler pressure 65 bar
Nordzucker AG, Klein Wanzleben, Germany
Capacity ~ 14,000 t beet/day
Steam demand ~ 19 % on beet
Sugar in beet: ~ 17,7 %
Sugar storage 2 x 60.000 t silos
Employees ~ 145
Sugar quality < 45 IU
Arengo 316 (Pty) Ltd, South Africa
Capacity ~ 300,000 l/day
~ 90,000 m³/year
DDGS drying by superheated steam
2nd feed stock sugar beet
Co-product DDGS ~4,000 t/year
Golden Sugar Refinery, Nigeria
Capacity ~ 2,400 t/day
Steam demand ~ 85 % on raw sugar
Sugar recovery > 98 %
Feed stock raw sugar (VHP)
Sugar quality < 45 IU
Steam generation GT HRSG
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Optimization of existing process & equipment
Whenever there is a discussion concerning the plant performance improvement or capacity increase, usually the first idea is to install energy saving/ additional equipment or implementation of modern technologies. Only a very few sugar factories consider to look inside to find the inefficiencies and bottlenecks in the existing process and equipment, but most sugar factories consider to go for new equipment for performance and capacity increase. Implementation of new equipment is not a bad idea, but it is an expensive approach.
Transition of Pakistan Sugar Industry
Transition of Pakistan Sugar Industry
IPRO Group’s contribution to enhance the efficiency
Scenario of Pakistan Sugar Industry till year 2005
Process steam demand 48-65 % on cane
Sugar losses 2.5-3 % on cane
Boiler pressure <25 bar Refined sugar colour 45-70 IU Power export Nil
Boiler capacity : A limitation in capacity expansion?
Sugar factories have often plans to expand the plant capacity but, in many cases, the boilers do not have sufficient capacity to handle the increased crushing capacity. In this case, the investment required to increase the plant capacity will be too high in one go when considering the big investment on a new boiler and turbine .
All Skills in One Hand
IPRO INDIA provides a complete solution for Sugar Industries from initial planning to delivery and installation to after-sales project monitoring and servicing.
Consultation
- Pre-investment Studies
- Plant Analysis
- Expert Advice
Project Planning
- Basic Evaluation
- Economic Feasibility Study
- Site Survey
Design
- Conceptual Design
- Basic Design
- Detail Design
Project Monitoring
- Implementation Planning
- Site Supervision