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This study is a comparison of four technological improvements proposed in previous works for the Cuban sugar mill Carlos Balino. These technological options are: (1) utilization of excess wastewater for enhanced imbibition; (2) utilization of waste heat for thermally driven cooling; (3) utilization of excess bagasse for pellets; and (4) modificatio...
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... However, they can be bulky, require regular maintenance, and have lower overall efficiency compared to more advanced technologies. [4]. conditions. ...
... These technologies will enhance productivity, reduce downtime, and improve overall efficiency. 4. Energy Efficiency and Sustainability: Future sugar cane mill drive technology will focus on energy efficiency and sustainability. ...
... Energy recovery systems and waste heat utilization techniques will also be explored to maximize energy efficiency. [4]. 5. Remote Monitoring and Optimization: Remote monitoring and optimization capabilities will enable operators to monitor and control sugar cane mill drives from a centralized location. ...
Problem to deal with: Literature review of innovative mechanical transmissions in sugar cane mills and the studies that have been carried out in recent years. • Aims: Conduct a literature study on sugarcane mill drives that involves compiling and reviewing relevant research papers, articles, reports and publications that focus on the various aspects of mechanical mill drive systems. • Methodology: Literature search using academic databases, industry publications, and relevant conferences or symposium proceedings to obtain a comprehensive 4th International Scientific Convention UCLV 2023 Central University "Marta Abreu" of Las Villas "Trends in mechanical design for power transmissions in sugarcane mills" 2 4th International Scientific Convention UCLV 2023 Central University "Marta Abreu" of Las Villas "Trends in mechanical design for power transmissions in sugarcane mills" overview of the current research and developments in the field of sugarcane mill drives. • Results and discussion: The results show that the future of sugar cane mill drive technology lies in advanced gear designs, direct drive systems, automation, digitalization, energy efficiency, and remote monitoring. • Conclusions: Overview of the present and future trends in sugar cane mill drive technology. These contribute to increased productivity, sustainability, and profitability in the sugar cane processing industry. Resumen: • Problemática: Revisión bibliográfica de las transmisiones mecánicas innovadoras en los molinos de caña de azúcar y los estudios que se han realizado en los últimos años. • Objetivo: Hacer un estudio bibliográfico sobre los accionamientos de los molinos de caña de azúcar, que implica recopilar y revisar trabajos de investigación, artículos, informes y publicaciones relevantes que se centran en los diversos aspectos de los sistemas de accionamiento mecánico de los molinos. • Metodología: Búsqueda de literatura utilizando bases de datos académicas, publicaciones de la industria y actas de congresos o simposios relevantes para obtener una descripción general completa de las investigaciones y desarrollos actuales en el campo de los accionamientos de los molinos de caña de azúcar. • Resultados y discusión: Los resultados muestran que el futuro de la tecnología de los accionamientos de los molinos de caña de azúcar radica en diseños avanzados de engranajes, sistemas de accionamiento directo, automatización, digitalización, eficiencia energética y monitoreo remoto. • Conclusiones: Panorama general de las tendencias presentes y futuras en la tecnología de accionamiento de los molinos de caña de azúcar. Su contribución al aumento de la productividad, sostenibilidad y rentabilidad en la industria azucarera.
... The results show that using bagasse for electricity production optimizes the NPV and GHG emissions. A comparative analysis of four technologies in a Cuban sugar plant shows the potential of technological improvements to upgrade energy efficiency and sugar yields while reducing GHG emissions and economic costs [28]. ...
Renewable energy and energy efficiency are essential for a transition to cleaner and sustainable energy. Photovoltaic and wind turbine systems introduce operation, control, protection, and planning issues, particularly affecting frequency stability in the grid. In contrast to more widespread wind turbines and photovoltaic systems, biomass based electricity systems are more stable with no negative impacts on the grid stability. The efficiency of bagasse boilers is essential to guaranteeing adequate economic profit and environmental performance in sugar plants. To realize universal access to affordable, reliable, and modern energy services by 2030 (SDG 7), the use of renewable energy sources in energy mixing and energy efficiency must increase globally. Sugar plants include cogeneration systems to provide heat and electricity to the process and frequently sell an electricity surplus to the grid, which depends on their energy efficiency. Boilers are an essential component of cogeneration systems in sugar plants, and their efficiency is crucial to guarantee electricity surplus. Therefore, this study assessed a bagasse boiler to optimize its operational efficiency. To this end, the exergy assessment and multiobjective optimization based on a genetic algorithm are used. The results show that the exergy efficiency of the boiler improved by 0.8% with the optimization, reducing bagasse consumption by 23 t/d.
... The factory has poor steam efficiency averaging 580 tons per ton of sugarcane milled or 58% of cane milled which implies wasteful use of bagasse energy resources. Efficient sugar factories have average steam consumption of about 40% cane milled in addition to efficient steam to electricity conversion systems with less internal or process use hence excess generation to support export of power to the electricity grid [11,88]. More boiler fuel feedstock can be by collection and transport, of cane trash and tops from the field to the sugar factory for use in steam and power generation in higher steam pressure and temperature [1] although this implies more costs in transport and handling of extra biomass but will lead to more steam and power generation [13,88]. ...
... Efficient sugar factories have average steam consumption of about 40% cane milled in addition to efficient steam to electricity conversion systems with less internal or process use hence excess generation to support export of power to the electricity grid [11,88]. More boiler fuel feedstock can be by collection and transport, of cane trash and tops from the field to the sugar factory for use in steam and power generation in higher steam pressure and temperature [1] although this implies more costs in transport and handling of extra biomass but will lead to more steam and power generation [13,88]. ...
Sugar industries have huge potential to contribute to the sustainable energy transition through electricity generation and production of biofuels. Sugar-producing countries generate huge volumes of sugarcane bagasse as a byproduct of sugarcane production. In this study, the performance of an operating traditional sugar factory is analyzed for electricity generation and export potential. The study presents characteristics and energy potential of modern and traditional sugar factories. The challenges facing a traditional sugar mill are inefficient boilers, less efficient and back pressure steam turbines, and wasteful and inefficient use of steam turbine drives as prime movers instead of modern electric drives for the mills and cane knives. Others are the use of inefficient and energy intensive cane mill rollers instead of the diffusers which have low energy requirements. It was demonstrated that the cogeneration potential of sugar factory is quite significant but currently underutilized. Sugar factories can make significant contribution towards mitigation of greenhouse gas emission mitigation through supply of green electricity to the public grid. The study showed that the factory uses very old and inefficient boilers aged over 39 years which contributes to poor performance and low electricity generation capacity. Modernization is required to increase the generation and electricity export capacity through investment in new and modern high-pressure boilers, replacement of inefficient back pressure boilers (BPSB) with more efficient condensing extraction turbines (CEST), and reduction of factory steam consumption by electrification of mills and cane knife turbine drives among other measures. This study showed that the 3,000 TCD factory can invest in a 15 MW power plant based on current average factory performance indicators and more if the throughput and overall performance is close to design parameters.
... The target of self-sufficiency is impossible to attain using normal production, demonstrating the need to build new sugar mills [28]. Technology that improves the energy and water use efficiency in traditional sugar mills, as noted by Birru et al. [29], can be implemented. (2) Development of downstream industry. ...
Indonesia is the fourth most populated country in the world with an annual population growth rate of 1.3%. This growth is accompanied by an increase in sugar consumption, which is occurring at an annual rate of 4.3%. The huge demand for sugar has created a large gap between sugar production and demand. Indonesia became the world's largest sugar importer in 2017-2018. Sugarcane farmers have an important role in sugar production. They are facing problems with declining sugarcane productivity and arable land decreasing. We aimed to understand the sugar production issue in Indonesia and to examine options to increase sugar production. To achieve these aims, a framework consisting of four steps was developed: Analysis of the current situation; problems identification; resolution; and delivering programs; and strategies. The main problems in sugar production in Indonesia were identified, including a stagnation in sugarcane harvest area, low sugarcane productivity, lack of good varieties, and inefficient sugar mills. Based on the identified problems, strategies to increase production were created. Two approaches need to be executed simultaneously: An increase in sugarcane planting area, and an increase in productivity and sugar yield. The first approach in increasing sugar production is the exploration of new sugarcane planting areas outside of Java both on existing agricultural land and in new areas. A land suitability analysis for the whole country was conducted based on a semi-detailed soil map. The main priority for development was the existing agricultural area via an integration system or existing crop exchange. The second approach is restructuring sugar factories through the revitalization of existing sugar mills and investment in the construction of new mills. The challenges that need to be addressed include land availability, provision of high-yielding varieties, and improving the efficiency of sugar mills. General strategies and medium-term programs are presented and discussed. These efforts, if well-executed, will boost Indonesia's sugar production to meet its domestic demand by 2025, achieving competitiveness in the world market by 2045.
... Sugarcane is one of the most productive resources in terms of harvesting in solar energy [2] and is widely cultivated around the world. Brazil has the largest sugarcane production share in the world and harvested over back pressure steam turbines to use the exhaust steam for the evaporation and crystallization process [7]. This causes more bagasse fuel to be burned than is required to satisfy the mills own needs during the harvest season because there is no heat duty of sugar evaporation in the off-season. ...
In Tanegashima, an isolated island in Japan, a 1500 ton/day sugar mill produces raw sugar and residual bagasse simultaneously. The bagasse is burned to generate steam that drives power turbines, but the bagasse boiler burns more bagasse than that is required. Accordingly, the process has a high temperature flue gas and a sizeable amount of unused heat at around 200 °C is exhausted from the sugar mill. Conversely, many other factories on the island burn imported oil in package boilers to generate process steam at temperatures up to 120 °C, all year around. To resolve this spatial and seasonal mismatch, we employ a thermochemical energy storage and transport system that uses a zeolite steam adsorption and desorption cycle. We introduce a basic design of a heat discharging device (a “zeolite boiler”) that features a moving bed with an indirect heat exchanger. The zeolite boiler's performance is predicted by an in house designed simulation model that includes empirical equilibrium adsorption kinetics and a heat transfer model of the exotherm for zeolite 13X adsorbing water vapor. The effects of the mass flow rates of zeolite and injected steam are computed and suggest that optimal conditions to produce 800 kg/h of steam could decrease fuel consumption by the existing oil-fired package boiler of 23.2%. We then design an advanced zeolite boiler to recover the zeolite's sensible heat, which would otherwise be wasted. Employing this economizing process yielded a total decrease in fuel consumption of 29.6%.
Malaysia’s energy intensity (GWh/GDP) shows an increasing trend since the 1990s, leading to the government’s efforts to promote energy efficiency via policies such as the National Energy Efficiency Action Plan (NEEAP), which includes the Energy Performance Contracting (EPC) initiative. This paper reviews recent publications in industrial Combined Heat and Power (CHP) with a focus on international case studies relevant to Malaysian industries that use industrial steam and highlights trends within the research area. It also provides the basis for more case studies to be performed in the Malaysian industry to improve energy efficiency while also supporting further academic research in the area. Additionally, the paper documents the importance of data collection and analysis as well as demand forecasting, not only for a better understanding of industrial energy systems but also to increase profitability since system loads may vary throughout a typical year. A multi-criteria and comprehensive approach is recommended in future case studies to ensure energy efficiency, economic returns and environmental impact are considered to ensure long-term sustainability. A summary of barriers to CHP implementation in the industry is also included to provide a broad understanding of industrial CHP.
Mexico is the sixth-largest producer of sucrose worldwide. Therefore, evaluating the environmental impacts of Mexican sugar and proposing impact mitigation strategies is of high importance since this would support better environmental performance and foster competition within the sector. However, the technological variability that occurs between farms and sugar mills, together with the different types of sugar that are produced, makes it difficult to identify a single agro-industrial production system for sugar production, that represents the entire sector. Environmental improvement strategies identified for one system are specific and have a low level of applicability to others. Therefore, the aim of this study is to develop a life cycle assessment study of nine representative sugar production systems in Mexico, considering 1 ton of sugar as a functional unit while also considering the types of sugar and technological level. The nine sugar life cycle systems analyzed were classified as follows: standard conventional (SC), standard semimechanized (SSM), standard mechanized (SM), refined conventional (RC), refined semimechanized (RSM), refined mechanized (RM), muscovado conventional (MC), muscovado semimechanized (MSM) and muscovado mechanized (MM). The results showed that conventional systems demonstrated a better environmental performance for all the impact categories analyzed, primarily because they have a lower energy requirement in cultivation and irrigation, require less fertilizers and applied pesticides, and in the industrial stage, require less chemicals for clarification. Regarding the types of sugar, Muscovado presented the lowest environmental impacts in all the categories analyzed, since it only requires one crystallization and centrifugation process, followed by drying, which is associated with lower requirements for electricity, heat, and steams. The results would suggest that the strategic avenues for further improving the environmental profile of sugarcane production and processing could include a) continued pursuit of high yields, which is an important determinant of the environmental impacts of agricultural products, b) precision application of fertilizers to reduce the potential for losses to the environment and c) maximizing the utilization of coproducts to increase environmental credits.
