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EXTRACTION (MILLING)
bagasse
Cane Preparation Mill No 1 Mill No. 2 Juice Mixing Mixed juice Brix 13 to15 Purity 80 to 90 Mill No. N water Exhaust Section Counter-current Extraction 3 to 5 Mills
COMMON NOMENCLATURE IN EXTRACTION Cane; Raw material fed to the milling station Imbibition water; Water added in the exhaust section for washing out and recovering most of the sucrose in cane. Common numbers are 20 to 35 % on cane. Absolute juice; total weight of cane minus the weight of present fibre. A common relation between both is 86 to 14 % on cane. Fibre; The lignocellulosic structure giving strength to the cane to keep itself erected. Common values are 12 to 14 % on cane.
Mixed juice; Juice coming off the milling station and going into the purification station. The weight of mixed juice produced per unit time, is quite similar to that of cane ground per same unit time, in many healthy installations . Bagasse; Is the lignocellulosic residue left frrom cane after the juice extraction in the milling station. Most of its components are fibre, between 45 and 47 % on wet bagasse, and moisture , between 49 and 51 % on wet bagasse. From 2 % to 4 % may be soluble solids, mainly sucrose . Fundamental Equationof milling is: Cane + Imbibition Water = Mixed Juice + Bagasse.
15 ton of cane
Bagasse
It is the natural fuel in processes of production of sugar and ethanol. Enough for fulfilling whole demands. Reaching in practice, in addition, a balance between produced and burned bagasse, through control of boilers efficiency. Surplus bagasse without a goal, is as bad as not enough bagasse.
Bagasse
In Cuba, when producing in a campaign, 6 million ton of sugar, there are ground 50 million ton of cane, with a bagasse production of 15 million ton, out of which, 95 % is burned, going the difference to derivatives. This 15 million ton bagasse, are equivalent to 3 million ton fuel oil.
Bagasse
32-36 kW-h /tc for fulfilling whole demand of the factory. For 3000-3500 tc per day, 150 (ton/hour), power generation is of the order of 5000 kw (including the mills). Energy reserves due to co-generation plus surplus bagasse may grow up to 10000 kw (70 kw-h/tc) as per Mauritius Island experience
Through changes in steam generation parameters, and with efficient use of steam in process, which in general mean investments, there are reached surplus of the order of 70-80 kw-h per ton of cane, i.e. for a factory grinding 150 ton per hour, it is not impossible to deliver to the grid 12000 kw with proved technologies (Mauricio Island and Hawaii).
In Operation Today
1) BackPressure Turbines To the Grid 10/15 kw/tc-h 2) Cond.-Extr. Turbines Mauricius Island 70 kw/tc-h In development at present 3) Combined Cycle, GT + gasifying 240 kw/tc-h
Different Approaches
ExtractionCondensing Turbines
A main drawback is the seasonal character of cane sugar processing all over the world and the scale economy of Rankine cycle. Possible sizes are not enough efficient, and very expensive per kw to operate 60 to 70 per cent time with fossil fuels. It is possible only in very small countries and where very efficient cane harvest wastes use are reached or with energy canes
-Following bagasse gasification; It is almost ripe the technology. After this, semi or commercial tests. It will be ready in a few years. Through bagasse hydrolysis, the fuel can be fed directly to the combustor. It is now at bench scale level, then semi or com mertial tests. May be ready in ten years.
Operation plus maintennance cost of a hydroelectric plant in Brazil is of the order of US $0.001/kw-h, while capital cost US$ 0.06/kw-h
In a conventional fossil fuel plant these costs are 0.005 and 0.025 respectively and that of fuel 0.02 for a total of US $ 0.05 per kw-h
Gasification; operation plus maintennance costs 0.005, capital cost 0.025, fuel 0.02 for a total of US $ 0.05 per kw-h.
SUMMARISING
STEAM AND POWER GENERATION Base: 1000 kg of cane Sugar; Bagasse; 80 to 140 kg 260 to 320 kg 2.0 and 4.0 kg/kg sugar Steam; 380 kg to 600 kg 2.7 to 7.0 kg/kg sugar Energy; 3700 to 7400 kcal/kg sugar 15.5 to 31.0 MJ /kg sugar common value 4500 kcal/kg sugar 18.8 MJ/kg sugar
STEAM GENERATION Characterizing SG Efficiency, specification of Gross Calorific Value, or Nett Calorific Value as a function of % moisture(W) . metric units NCV = 4250-4850*W/100 kcal/kg (Hugot) english units 1.8*(kcal/kg) = Btu/lb NCV = 7650-8730*W/100 Btu/lb (Hugot) 1.0 kW-h = 3.6*106 watt-seg (joule) = 860 kcal; 1.0 kcal = 4.186 kj
Bagasse with 50 % moisture NCV = 1825 kcal/kg GCV = 2300 kcal/kg Eff. defined as the % of freed heat from the bagasse, leaving with the steam (enthalpy of steam less enthalpy of fed water, times steam rate, divided by the Caloric Value of one mass unit of bagasse. GCV Efficiency of best bagasse boilers 67.5 % NCV Efficiency of these units, (2300/1825)*67.5 = 85 %
Furnace Water walls Screen Superheater Water Evaporation Bundle Economizer Air Pre-heater
Sensible heat carried by gases leaving, 12-30 % Non complete combustion, 2-12% Excess air over the minimum necessary, including air infiltration Conduction and convection through walls 2% Water Extractions
Burning in pile; Horse shoe Cell Spreader stoker (grate) oscillating travelling Suspension firing
COMBUSTION / STOICHIOMETRY
Bagasse (dry) analysis, changed to ashes free Carbon 47.0/0.975 = 48.2 % Hydrogen 6.5/0.975 = 6.7 Oxygen 44.0/0.975 = 45.1 Ashes 2.5 ----Dividing by the MW of each element it is reached a pseudostructural formula, with which it is easier to do the combustion calculations using the moles approach.
Stoichiometry Equations
(/100)C4.02H6.7O2.82 ; Excess air % bagasse ; Base of Calc. + 4.285(1.0 + /100)*(/100) O2 oxygen in air + 16.12 (1.0 + /100)*(/100) N2 nitrgen coming with air
COMBUSTION PRODUCTS
4.02*(/100) CO2 + (3.35*( /100)+ BC*(hum/100)/18)H2O Carbon anhydride + water from water due to combustion moisture of fuel. 4.285(/100)*(/100)O2 non-used oxygen in gases + 16.12 (1.0 + /100)*( /100) N2 nitrogen in gases +
..LAST COMMENTARIES
AFTER STOICHIOMETRY, IT IS POSSIBLE TO BUILD MOLAR AND ENERGY BALANCES, AND AFTR THIS , ADDING DETAILS OF CONFIGURATION, TO BUILD THE WHOLE MODEL OF STEAM GENERATION
AFTER THE ADDEQUATE PROCEDURES THE REST OF THE WHOLE PROCESS ENGINEERING MAY BE MODELED, REACHING THE WHOLE PROFILE OF ENERGY TRANSFORMATIONS.
Another example; pumping cooling water to vacuum pans condensers. Evaporation in pans 18% cane = 180 kg / ton cane, need of cooling water 60 times, head 20 m, taking to English system =180*60 *20 *2.204 *3.28 *300/3600/550 = 237 hp or 176 kW. 176/300 = 0.6 kW-h/tc
Total Mechanical Energy Demand (different of installed power) is of the order of 32 to 36 kW-h( 115 to 130 mJ) per ton (metric) of cane Irrelevant of type of prime mover; steam or electric, it is a number slightly different Note: metric ton may be identified also by Tonne.
With a total, general distribution, just for giving an approximate idea as follows
1.3 1.7 kW-h per ton cane (one machine) Shredders 1.5 2.5 kW-h per ton cane,
depending on design
Change coefficient 0.134 by 0.1 for crusher (two rolls) For mills with pressure feeders (Walker), multiply power demand by 1.1 For losses in gearing use 2.0 % in closed reducers with oil bath, and 8 % in open gearing. In combined gearing
eff. in transmision=(1-0.02)*(0.92)=0.90 Energy demand at exit prime movers = = energy demand at exit of speed red./ eff.