The document discusses automation strategies for sugar processing. It outlines the key benefits of automation including improved efficiency, quality, and reduced costs. Specific systems that can be automated are falling film evaporators, continuous vacuum pans, remelt phosphatation, and multi-bed filters. Correct selection of automation equipment and partners is important. Operator training is also key to leveraging new automation systems.

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

2. Process House Automation
Mr. Israr Hussain
General Manager (Production)
Habib Sugar Mills

3. Process
House
Automation
Agenda
Introduction
Automation Strategy
Role of Automation in Sugar Processing
Scope of Automation
Automation for Utilities
System Architecture
HMI Displays
Maintenance
Impact of Automation
Falling Film Evaporators Automation
Continuous/Batch Pan Automation
Remelt Phosphatation Process Automation
Multi-Bed Filters Automation
Skills and Training
Conclusions
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4. Introduction
 Worldwide sugar factories are being modernized and automated in response
to the need for efficient production and the ability to compete globally.
 Continuous control and precise handling of all parameters is required to
ensure consistent product quality and reduce production costs.

5. Automation Strategy
 Selection of automation strategy:
 Centralized Control System (CCS)
 Decentralized Control System (DCS)
 Which strategy to choose?

6. Automation Strategy
 Merits and Demerits:
 Correct selection of automation equipment
 Correct selection of instruments
 Right automation partner
 Choose wisely

7. Role of Automation in Sugar Processing
Key issues:
Perishable raw material
Heat sensitive product
pH sensitive product
Flow Rate
Fuel and Energy
Impact of operating parameters on sugar recovery and quality

8. Role of Automation in Sugar Processing
Impact of Operating Parameters on sugar recovery and quality:
Flow Rate pH Temperature
Retention
Time
Level
Indication
Pressure Vacuum

9. Automation for Utilities
 Control of Key Parameters in Boiler Operations
Drum Level
Steam
Pressure
Steam
Temperature
Steam
Quantity
Feed Water
Temperature
Flue Gas
Analysis
Flue Gas
Temperature

10. System Architecture

11. HMI Displays

12. HMI Displays

13. HMI Displays

14. Maintenance
Monitoring
Temperature Pressure
Axial Floats of
Rotors

15. Impact of Automation
 Implementation of a need-based process control system leads to:
 Capacity Optimization
 Improved Plant Efficiency
 Reduced Energy Cost
 Improved Product Quality
 Reduced Production Cost
 Reduced Maintenance Cost
 Reduced Down Time
 Man-Power Savings

16. Falling Film / Conventional Evaporators Automation
 Feed juice enters at the top of the tubes through distributors and flows down with the tube walls as a thin film. Since the film is
moving in the direction of gravity, a finer and faster moving film results, yielding high heat transfer coefficient and reduced
contact time. The flow of vapors and juice maybe concurrent or countercurrent where the liquid is drawn from bottom and vapor
from the top. Forced circulation is applied.
 Automation of Falling Film Evaporators is critical in the sense that its malfunction can cause accidents. We should understand the
criticality and dangers of this process and ensure safe and reliable operation through automating the process including:
 Juice Flow
 Juice Level
 Emergency Hot Water
 Sugar Losses through inversion
 Salt Scaling
 Caramelization in case of dry tubes

17. Falling Film / Conventional Evaporators Automation
 Better control of these parameters affects sugar recovery and quality.
 The way an evaporator plant works has a crucial impact on heat economy of the
sugar factory.

18. Continuous / Batch Pan Automation
 Efficient crystal growth requires accurate monitoring and control of all parameters (through
automation) of the concentration of sugar solution in each compartment of the continuous vacuum
pan.
 Each compartment of the continuous vacuum pan is controlled through individual set points in order
to establish the required Brix profile along the pan.
 The continuous vacuum pan permits constant level of vapor bleeding from the operator station. This
results in more even running of evaporator station and consistent dry substance content of the thick
juice.
 The low massecuite level above calandria keeps the heating steam pressure. Moreover, circulation and
homogeneity of the massecuite improved. The heating steam can therefore be taken from a
downstream effect of the evaporators station and fully used in upstream effect.

19. Remelt Phosphatation Process Automation
 Monitoring and control of:
 Liquor Flow Rate
 Liquor Brix
 Liquor Heating
 Process Chemical Dosing
 pH Control
 Level Control
 Retention Time
 Continuous and precise monitoring and control of all the parameters is required to ensure consistent
product quality and sugar losses.

20. Multi-Bed Filters Automation
Monitoring and Control
Flow Rate Pressure
Backwash
Cycle
Level
Indicators

21. Skills and Training
 Present day process control systems are interactive
 It is imperative that Automation Solution Providers also facilitate the training and
guidance for Sugar Mill operators, through:
 Training Modules
 Operational Support
 Operational Manuals

22. Conclusions
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The surest mantra to achieve cost reduction in the shortest time
Return on Investment can be phenomenal and quick
Move towards becoming internationally competitive

23. Question & Answers
Thank You for Your Valuable Time