Low steam % cane – Almoiz Industries’ road to success

Energy conservation is an integral part of steam, power, fuel and water management in the sugar industry and energy conservation within a sugar mill has become more important globally in the context of both thermal and electrical energy. Sugar mills that can be operated at high pressure with co-generation will be more profitable and viable, as these have an ability to optimize the process steam and electrical power. Therefore, high-pressure boilers (65 bar, 500°C), evaporators (with a complete set of falling film), high-pressure turbines, electrically driven mills (with compact planetary gears and flexible couplings), continuous vacuum pans, an automated process house and molasses conditioners were installed at Almoiz industries unit 2 at Mianwali (Pakistan), which was established in 2014. This industrial unit is an excellent adaptation of advanced technologies and modern equipment, making it a state-of-the-art facility having high energy-efficiency values. The reduced steam % cane and in-house power consumption per tonne of cane was achieved to improve export of electricity by using the saved bagasse. A complete set of falling-film evaporators was installed; all vapours from the 1st effect to the 5th effect, including condensate, were used for heating of juice and boiling massecuites to reduce steam consumption per tonne of cane. Water consumption is most critical. The pan station, evaporators operation and juice heaters were automated. Heat loss was reduced significantly by proper insulation of equipment and pipelines. Initially steam % cane was somewhat high, but by taking corrective measures and optimization of system operations, the steam % cane with a refinery was reduced to less than 35% within three years. Key words Co-generation, reduced steam % cane, bagasse saving, boiler efficiency, steam consumption per kWh