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Energy performance comparisons and enhancements in the sugar cane industry
KTH, School of Industrial Engineering and Management (ITM), Energy Technology.ORCID iD: www.0000-0001-8091-8767
KTH, School of Industrial Engineering and Management (ITM), Energy Technology.
KTH, School of Industrial Engineering and Management (ITM), Energy Technology.
2019 (English)In: Biomass Conversion and Biorefinery, ISSN 2190-6815, E-ISSN 2190-6823, Vol. 9, no 2, p. 267-282Article in journal (Refereed) Published
Abstract [en]

In this study, energy-related operational parameters for modern and traditional (conventional) sugar mills are analyzed, with the goals of identifying improvements in energy efficiency and potential for surplus electricity export. Results show that the power- to-heat ratio of modern and traditional mills is clearly distinct, lying in the ranges of 0.3–0.5 and 0.04–0.07, respectively. Modifications under consideration for the traditional mills include the following upgrades: electric drives and higher capacity back-pressure turbine (case 1); high-pressure boiler, condensing extraction steam turbine and electric drives (case 2); and improvements in case 2 plus bagasse drying (case 3). The thermodynamic impact of these modifications shows that more power is generated as the modification becomes more advanced. Case 1 exhibits a modest increase in cogeneration efficiency (4%) as compared to the base case, while the cogeneration efficiency increase is more marked for cases 2 and 3 (21% and 31%, respectively). Surplus power was studied in a regional context, where it was found that the contribution of 19 retrofitted sugar mills in nine Brazilian regions could supply 30% or more power as compared to current installed power capacity. The economic analysis showed that levelized cost of electricity (LCOE) was lowest for case 1 (11 USD/MWh) and highest for cases 2 and 3 (58 USD/kWh).

Place, publisher, year, edition, pages
Springer Berlin/Heidelberg, 2019. Vol. 9, no 2, p. 267-282
Keywords [en]
Sugarcane; Traditional mills; Modern mills; LCOE; Energy performance; Model
National Category
Energy Engineering
Research subject
Energy Technology
Identifiers
URN: urn:nbn:se:kth:diva-207111DOI: 10.1007/s13399-018-0349-zISI: 000468144300003Scopus ID: 2-s2.0-85065905311OAI: oai:DiVA.org:kth-207111DiVA, id: diva2:1095860
Note

QC 20190910

Available from: 2017-05-16 Created: 2017-05-16 Last updated: 2019-09-10Bibliographically approved
In thesis
1.
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2. Process Utility Performance Evaluation and Enhancements in the Traditional Sugar Cane Industry
Open this publication in new window or tab >>Process Utility Performance Evaluation and Enhancements in the Traditional Sugar Cane Industry
2019 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

The need to achieve sustainable development has led to devising various approaches for the efficient utilization of natural resources. Renewable energy technology and energy efficiency measures feature prominently in this regard, and in particular for industries such as sugar production:  the sugar cane industry’s eponymous feedstock is a renewable resource, and mills have potential for increased energy savings via improvements to cogeneration units, electric drive retrofitting, and other measures.  The overall objective of this research work is to investigate different approaches of efficiency improvements for enhancing sugar cane conversion, thereby increasing the services obtained including surplus electric power delivery. Traditional sugar cane mills, i.e. those that lack modern components such as high-performance boilers and electric drives, are the focus of this investigation. 

System simulations show that modern mills generate more electrical power as compared to traditional mills, with power-to-heat ratios nearly one order of magnitude higher (i.e. 0.3-0.5).  Comparison of the thermodynamic performance of three retrofits showed that such modifications could raise the performance of traditional mills to approach those for their modern counterparts. Results for a base case traditional plant show that losses related to mechanical prime movers are high, since the mills and shredder are driven by steam and generate excess mechanical power. When considering press mill stoppages, steam is wasted during the ensuing fuel oil-fired start-up period. CO2emission for such transient conditions can be decreased owing via bagasse drying and storage. 

 

In studying both energy and water impacts, a comparison of four technological improvements demonstrates benefits outside the crushing season for three scenarios: recovery of excess wastewater for enhanced imbibition; recovery of waste heat for thermally-driven cooling; and pelletization of excess bagasse. The fourth option, involving upgrading of the mill’s cogeneration unit, is advantageous for continuous surplus power supply.

Place, publisher, year, edition, pages
KTH Royal Institute of Technology, 2019. p. 120
Series
TRITA-ITM-AVL ; 2019:21
Keywords
Sugar cane, energy saving, heat loss, steady state, transient state, CO2 emission; absorption chiller, pellet, bagasse drying, energy perfor-mance, traditional mills, modern mills, waste water, surplus power
National Category
Energy Engineering
Research subject
Energy Technology
Identifiers
urn:nbn:se:kth:diva-251736 (URN)978-91-7873-231-9 (ISBN)
Public defence
2019-08-20, F3, Lindstedtsvägen 26, KTH, Stockholm, 10:00 (English)
Opponent
Supervisors
Funder
Sida - Swedish International Development Cooperation Agency
Available from: 2019-05-24 Created: 2019-05-20 Last updated: 2019-05-24Bibliographically approved

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