Raw sugar factory and refinery practice at Central Azucarera Don Pedro, Incorporated (CADPI, Inc.) : Special topic: Problems encountered and proposed solutions in boiler softening facilities and power house

Date

10-2011

Degree

Bachelor of Science in Chemical Engineering

Major Course

Major in Sugar Technology

College

College of Engineering and Agro-Industrial Technology (CEAT)

Adviser/Committee Chair

Jerico Z. Alcantara

Abstract

The 35-day Summer Practicum held from April 13-MAy 24 in Central Azucarera Don Pedro Incorporation (CADP Inc.) in Barangay Lumbangan, Nasugbu, Batangas is part of the curriculum of B.S. Chemical Engineering (BS ChE) major in Sugar Technology (SUTC) students of UPLB. The mill practice allowed the students to observe and familiarize themselves in actual raw sugar manufacturing and refining relate the theories and principles of Chemical Engineering and Sugar Technology in actual factory operations gain hands-on experience in conducting sugar laboratory analysis increase understanding of pollution control by observing the plant's waste water treatment facility determine possible causes of sucrose losses and account them in sugar factory control understand the reasons behind the common problems encountered in factory operations and to determine the effect on the plant of increasing efficiency in the Boiler and Power House by studying CADPI's water treatment and water softening facility. It is estimated that there are 556,000farmers and 25,000 sugar mill workers in the sugar industry here in the Philippines. Filipinos consume about 150,000 tons of raw sugar every month and is present in every Filipino home. Bagasse is a by-product of sugar cane. It is what remains after the juice is extracted. A sugar factory produces nearly three tons of bagasse for every ten tons of sugar cane crushed. Since it is a by-product of sugar production, the bagasse produces sufficient energy to supply the needs of the entire plant with energy to spare. in the factory, all the energy required comes from the Boiler which is the steam generating station of the plant. The energy stored in the bagasse as fuel is transferred to water inside the boiler, which transforms it to live steam. The steam at elevated pressure and temperature is distributed to the turbine and steam engines where the heat is transformed to mechanical energy. The mechanical energy equivalent of the heat produced is partnered to a generator in the Power House that converts the mechanical energy to electrical energy. Cogeneration is the simultaneous production of energy, such as the heat energy from the Boilers and electricity from the Power House, from one source- the bagasse. It is important to have a cogeneration plant due to cheap electricity produced from the bagasse fuel in the production of steam in the Boiler to run the turbo generator sets in the Power House. A great advantage of sugar factories is that they are a self-reliant operation and in complete control of power generation and maintenance because purchased power is sometimes interrupt and expensive. To this end, it is very fitting that this special topic studies both the Boilers and Power House. At the end of the operation, if the sugar factory has excess bagasse, the factory can be said to be efficient in their generation and utilization of energy. More excess bagasse can be available if the factory can further reduce its live steam and exhaust steam demand or increase steam production per unit of bagasse. A good treatment of the water used in the Boiler Department does not cost. Rather, it saves money in terms of prolonged equipment life, energy savings, and most importantly, the assurance of dependable operation. The knowledge of complete boiler system and accurate make-up water analysis ate important considerations in the treatment of the boiler feed water. Efficiency of the Power House can be attained by increasing boiler efficiency reduction of prime mover live steam consumption with increasing pressure and superheat of the live steam and increased turbine stage installation of more efficient evaporator schemes continuous vacuum pans, crystallizers and energy efficient devices and installation of equipment and devices which will increase the capacity of the mills, Boiling House and Refinery with little effect on steam or power requirement. These will result in bagasse savings. Controlling boiler operation losses include monitoring combustion losses boiler chemistry control and maintain fuel quality, excess air, and boiler exit gas temperature. Turbine system losses can be minimized by proper operational practices. In energy utilization, the objective is not only to lower their production cost, but also to have extra fuel off-season operation. The performance of the Boiler directly affects the performance of the Power House. To ensure maximum efficiency of the Power House, optimal performance of the Boiler is expected.

Language

English

Location

UPLB Main Library Special Collections Section (USCS)

Call Number

LG 993.5 2011 E62 /T47

Document Type

Thesis

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