In the year 2010 Mehran Sugar Mills Ltd. (MSM) obtained services from IPRO to increase the plant capacity from 7,300 to 9,000 tcd. During the plant audit IPRO identified various operational and equipment inefficiencies. In the refinery section for MSM used to add approx. 400 t/d movement water to the pans. There were four batch vacuum pans of 60 t capacity and 242m 2 heating surface each. The MSM team wanted to add a fifth pan to reach the target capacity of 9,000 tcd but IPRO emphasised the idea to optimize the operation of the pans by cutting the unwanted water addition with modern pan automation. The addition of a new pan would have been a costly affair and the inefficiencies would have remained in the system. Eventually, MSM management agreed and IPRO implemented a pan plus automation system.
It was a first of its kind project in Pakistan. Various issues faced during the implementation were successfully resolved with the support of MSM team. The major challenge was training the pan operators to operate the pans from the control room instead of standing in front of the pans. It took roughly two seasons to complete the project but the efforts of IPRO and MSM teams eventually paid off when MSM achieved the target capacity.
By operating the floating calandria types pans with the pan plus automation system MSM cut down the pan movement water by more than 70%. And it helped MSM to acheive more than 11,000 tcd during the crushing season 2015-16 with the existing four pans after resolving additional bottlenecks in other process ares. Apart from the pan capacity optimization, the pan plus automation system helped significantly reduce the process steam demand of the plant
Robert and Kestner evaporates allow steam saving only down to a level of approx. 40% stem on cane. Below this level, falling film evaporates become essential. Further, to target a stem demand of less than 32% on the cane, it is a must to operate a complete falling film evaporation plant.
The first ever complete falling film evaporation plants in the cane sugar industry have been commissioned in India at Shree Renuka, Athani and in Pakistan at Almoiz, both in 2007 based on IPRO design. Both the plants achieved the best steam performance in their respective country and set benchmarks. Since this time, a boom of installations of falling film evaporators followed.
More than 220 FFE plus falling film evaporators designed by IPRO or under IPRO license are operational in cane sugar plants today. They depict our immense experience and trust clients place in IPRO’s engineering and design. Already many sugar plants have been revamped by integration of FFE plus falling film evaporators to improve the steam economy.
Chandigarh - 160036, INDIA