The document discusses automation in the sugar production process. It provides an overview of the key stages in sugar production from cane unloading to bagging. It then discusses in detail the automation of evaporation and pans using the example of a project at Al-Moiz Industries. Automation provides benefits like improved recovery rates, reduced costs and manpower, and consistent quality. The evaporation and pan automation controls critical parameters like temperature, level, flow and pressure to optimize efficiency.

1. The Digital Sugar Mill
Seminar on Sugar & Ethanol Automation

2. Overview of Sugar Process,
Evaporator and Pan Automation
Mr. Zia Baloch
Almoiz Industries Ltd.

3. The Importance of
Automation
In Sugar Industry
Agenda
Introduction to Sugar Industry Process
Key Benefits and Improvement in KPI’s in Sugar process by Automation
AL-Moiz Rockwell PlantPAx Automation Project Briefing & System Architecture
Introduction to Evaporation in Sugar industry
Evaporator’s Automation Controlling parameters and Key benefits
Al-Moiz Evaporator HMI
Introduction to Pan Automation
Pan Automation Key Benefits
Al-Moiz Pan Automation HMI
Conclusion
3

4. Introduction
Sugar Plant automation solution is
designed to help the Sugar industry
to get more out of each stage of
the process
It spans across the process, right
from cane unloading to sugar
bagging and beyond, to give the
sugar plant the best performance,
the best quality, reliability and the
best delivery. In short the most
value.

5. Sugar Process – Graphical Representation

6. Sugar Process – List View
Cane Yard
Weighbridge
Cane Unloading
Cane Preparation
Milling & Juice Extraction
Juice Heaters & Clarification
Evaporation
Pan/Crystallization
Sugar Driers
Bulk Sugar Handling
Utilities Management

7. Key Benefits of Sugar Plant Automation
Safety of Man & Machine
Efficient use of plant equipment
Significantly less power and utilities consumption
Use of modern maintenance techniques leading to higher plant availability and lower maintenance
costs
Better cane management logistics
Better Production to Manpower ratio
Superior and Consistent Quality
An Integrated Plant Operation philosophy

8. Improvements in KPI’s
Improved Recovery
Reduction in Manpower (30% to 40%)
Savings in Steam consumption by up to 5%
Savings in Electrical Power consumption by 5 to 10%
Increased percentage extraction
Improved reliability in plant operation
Reduction in Sugar ICUMSA by 10 to 20 units

9. Project Briefing
Client Name: Al-Moiz Industries
Project Name: Rockwell PlantPAx System (Distributed Control
System)

11. Control Processors & I/Os

12. Central Control room Panels Area

13. Areas Covered in Rockwell PlantPAx Project
Evaporator
Boiler
Defecation
Mill House
Juice Heater
Batch Pan
Continuous Pan
Process House
Talo Floc
Turbine
Condenser

14. Sugar Process – Areas (Evaporator & Pan)

15. Introduction to Evaporator in Sugar Industry
The purified juice is a sugar solution containing
approximately 14% sugar and 1% non-sugars. It
is now necessary that this solution is thickened
up into a syrup by boiling off excess water in a
series of connected vessels.
Under automatically controlled conditions each
subsequent evaporator operates under
decreasing pressure with the last one being
under almost a total vacuum. This "thick juice"
leaving the evaporator station has a dark yellow
to light brown color and contains approximately
60% sugar.

16. Falling Film Evaporator Automation Components
Field Instruments
Control Hardware
Control Software

17. Falling Film Evaporator Automation Components
Level Transmitter
Circulation Flow meter
Calandria Temperature Transmitter
Calandria Pressure Transmitter
Separator Pressure Transmitter
Separator Temperature Transmitter
Circulation Pressure Transmitter
Cone Temperature Transmitter
Emergency ON/OFF Valve
Circulation Pumps Delivery ON/OFF
Valves
Level Control Valve
Temperature Gauge for Separator
Compound Gauge for Separator

18. FFE Control Hardware & Software
FFE can be controlled using DCS
Hardware & Software is provided by Service provider along with Services
for commissioning

19. FFE Control Strategy
Cone Level must be controlled
Circulation juice Pump should be operated in auto mode
ON/OFF circulation pumps delivery line valve should be operated as per pumps
operation
Emergency valve must follow the process conditions
Circulation Juice Flow must be maintained by using Pumps VFDs control

20. Evaporator Controlling Parameters
Temperature Control
Level Control of each Evaporator
Vacuum
Circulation Juice Flow control
Pumps Control
Emergency Valve control
Emergency Water Tank Level Control
Pressure and temperature of exhaust steam
Clear Juice Tank Level Monitoring
Brix of syrup
Flow of condensates from calandrias

21. Evaporator Automation Benefits
Regulated feed to each Evaporator
Maintain level in Evaporator
Syrup Brix Control
Steam temperature do not exceed 125 – 130C
Less scale formation due to even juice level
Due to controlled steam temp the efficiency of system is higher

23. Sugar Process – Areas (Evaporator & Pan)

24. Introduction to Pan Automation
Syrup from the evaporators is sent to
vacuum pans, where it is further
evaporated, under vacuum, to super
saturation. Fine seed crystals are added,
and the sugar “mother liquors” yields a
solid precipitate of about 50 percent by
weight crystalline sugar.
Fine clarified liquor is boiled to white sugar
in a series of vacuum pans similar to those
used in sugarcane processing.
Fine grains (sanding or fruit sugars).

25. Why Batch Pan Automation
The boiling of Massecuite in Batch Pan is very critical operation
Because the super saturation of boiling liquid inside the pan should be
maintained within a very narrow range
Ineffectiveness of operator to do so will leads to extra water drink to
dissolve false grain

26. Key Benefits of Pan Automation
Decrease of boiling time
Reduction of sucrose in final molasses
Narrow range of crystal size
Easy operation even by untrained operators
Key parameters protected by password

27. Pan Automation
Proven performance and reliability in sugar applications worldwide
High Availability
Robust design, High degree of protection
Worldwide service
Low initial investment due to module design
Easy expendability

29. Question & Answers
Thank You for Your Valuable Time