MiBs (Miwa Intermittent Boiling System) for Batch Vacuum Pan. Marubeni Plant Engineering Corp. Miwa Electric Industrial Co., Ltd
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1 MiBs (Miwa Intermittent Boiling System) for Batch Vacuum Pan Presented by Yukio Tanaka 13/Aug/2015 Marubeni Plant Engineering Corp. Miwa Electric Industrial Co., Ltd 1 1
2 Boiling Pan Business Summary l Developed and evolved Intermittent Boiling System and Consistency Meter based on accumulated know-how during a half a century (50 years) of Product development, sales, service and maintenance work involvement l On the basis of above experience; we are conducting Boiling Operation Consulting for the purpose of "long-term operation of the factory, better productivity and Panman s skill up 1973~ 1974~ 1984~ PCS for Entire Sugar Process Control 2008 Boiling Operation Consulting 2011 MiBs (Miwa Intermittent Boiling System) 1967 Automatic Boiling Pan System Consistency Meter Intermittent Boiling System 2 2
3 Miwa Intermittent Boiling system (MiBs) Operation Panel Printer PLC Wireless Control Room I/O Stirrer M Air Leak CV Cooling water Vuccum CV Vacuum Pump Local Panel Break Valve Temp Seed Cleaning Water Steam Syrup Water Flow Flow CV CV Gas Vent Calandria Press Exhust Valve Strike Receiver Level Consistency CV Flow Steam Intermittent Boiling gives supersaturating operation (shorten boiling cycle, Save material / energy) and high quality product 3 3
4 Our achievement from Japanese mills by MiBs l Refined Sugar yield increased by 2.3% : product/massecuite l Raw sugar yield increased by 2.1% : Recovery ratio of solid in massecuite l Crystallization time was reduced by 5% l Reduction of the consumption of steam, re-melting and wash water 4 4
5 Continuous Boiling in Batch Vacuum Pan Feed Syrup and Water are continuously supplied by using PID controller to control the Syrup valve and Water valve Step Supply Condence and seeding Growing Standby Growing Com_ plete Boil Down Finish Growing 1 Growing 2 Consistency Meter Seeding Stanby Program Setting1 Program Setting 2 Wait Seed V Steam V Water V Syrup V T1 T2 PID Control Pan Level Level Setting 5 5
6 Intermittent Boiling in Batch Vacuum Pan Feed Syrup and water are intermittently supplied to the solution, controlled by MiBs, by opening & closing the Syrup valve and Water valve Step Supply Condence and Seeding Seeding Standby Growing by Water Growing Growing by Syrup Comp _lete Boil Down Finish Consistency Meter Seeding Seeding Standby Wait Time Consistency Setting Seed V Steam V Water V Syrup V T1 T2 T2 T3 On-off Control Pan Level Level setting 6 6
7 Main difference Crystal Mother Liquor Droplet Gathering Droplet False Grain Growth Crystal Labile labile C onsistency Growth Limit Point IntermiDent Boiling system Interm ittent C ontrolb oiling S ystem Intermediate Metastable C ontinuous C ontrolb oiling S ystem Con?nuous Boiling system Intermediate Metastable Tim e - Metastable zone: nearest saturation; existing crystals increase in size but new crystal cannot form - Intermediate zone: new crystals can be formed but only in the presence of existing crystals - Labile zone: existing crystals grow; And new crystals can form even in the absence of existing crystal seeds 7 7
8 Merits of Intermittent Boiling l Reduction of False Grains, Twin Grains and Clustered Grains Fine Crystal l Raise Market Value of the product l Improve Color Value l Shorten Curing time, l reduce washing water l Reduce sugar dust -> less Dryer fan and Cooler breakdown l Better Sieve process l Better Packing speed (Refinery) Twin Grains Clustered Grains 8 8
9 Merits of Intermittent Boiling l Increase in yield due to higher crystal ratio in Massecuite l Shorter Boiling Time l Less number of Boiling Batches l Lower Purity in Final Molasses l Reduction of Steam Consumption l Due to less number of boiling batches, Non- Sucrose% become less 9 9
10 Japanese Sugar Factories (RefineryBeet) l Refinery sugar 9-companies (12-factries) l Beet sugar 3-companies (8-factries) ALL use Intermittent Boiling Miwa/Yokogawa Others Beet (8-factories) Refinery (12factories) 10 10
11 Japan Okinawa Sugar Factories (Raw Sugar) (Raw l sugar Sugar 15-companies (18-factories) 7 factories use Intermittent Boiling (Others by ManualContinuous Boiling in Batch Pans) Miwa/Yokogawa Others OKINAWA () () Raw sugar (7factories) 11 11
12 User Friendly System Operation Panel PLC Printer PLC Operation Touch Panel Operation Operation beside Pan Flexible Programming Simulator function Boiling data back up Integration with DCS Wireless I/O Stirrer Cooling water M CV Air Leak Vacuum Pump Vuccum CV Local Panel Break Valve Temp Seed Cleaning Water Steam Syrup Water Flow Flow CV CV Gas Vent Calandria Press Exhust Valve Strike Receiver Level Consistency Steam CV Flow 12 12
13 Field Operation panel & Consistency Meter 13 13
14 Boiling Operations consulting for MiBs l Professional Team onsite consulting l To enhance Panman s skill and improve productivity; l Boiling Operation Technical Seminar/Workshop l Hands-on guidance Total 7 working days l Expected outcome l Enhanced Panman s Skill l Better quality of the product l Enhanced entire plant capacity l Cost Reduction 14 14
15 Our Professional Team Miwa Electric Industrial Co., Ltd Sinmei-Cho, Tomakomai-shi Hokkaido, Japan TEL: FAX: MIWA ELECTRIC INDUSTRY 15 15
16 Sample Computation of Benefits Sample'Computation Rated&Capacity Raw&Sugar&Yield Production&Period Yield&Improvement Yield&Increase Daily&Yield&Increase Total&Yield&Increase 1=LKG&bag price&per&lkg&as&of&june&2015 Increase&in&Raw&Sugar&Sales Mill&share&(30%) &&&&&&&&&&&&&&&&& 10,000 TCD 100 kg/ton=cane 180 days 2.1% 2.1 kg/ton=cane &&&&&&&&&&&&&&&&& 21,000 kg&per&day &&&&&&&&&&&& 3,780,000 kg/season 50 kg/lkg=bag 1600 PhP/LKg=bag &&&&&&&& 120,960,000 PhP/season &&&&&&&&&& 36,288,000 PhP/season 16 16
17 Sample Computation of Potential Power Generation Energy'Consumption'Savings 5% steam(consumption(at(vacuum(pan 115 ton1steam/hr 5%(reduction 5.75 ton1steam/hr steam(generation((assumption) 1.98 ton1steam/ton1bagasse surplus(bagasse 2.90 ton1bagasse if(surplus(bagasse(is(used(in(power(generation((using(existing(system) power(generation(per(ton1steam( 59 kwh/ton1steam 30 kwh/ton1bagasse from(saved(bagasse,(we(can(generate 87 kwh/ton1surplus(bagasse for(the(season (((((((((((((((((((( 373,829 kwh at(fit((php6.63/kwh) ((((((((((((((((( 2,478,488 PhP/season if(surplus(bagasse(is(used(in(power(generation((using(mid1pressure,(cest(system) power(generation(per(ton1steam( 109 kw/ton1steam 55 kw/ton1bagasse mid1pressure,(cest(system(power(generation from(saved(bagasse,(we(can(generate((((((((((((((((((((((((((( 160 kwh/ton1surplus(bagasse for(the(season (((((((((((((((((((( 690,634 kwh at(fit((php6.63/kwh) ((((((((((((((((( 4,578,901 PhP/season 17 17
18 MiBs will contribute to the better operation in the factory. END 18 18
19 Contact Information Please feel free to contact us at any time if you are interested in MiBs Technologies. CETI Philippines, INC. Ms. Maria Loudel Dario Mobile:
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