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Sugar cane bagasse drying - A review

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 Sugar cane bagasse drying - a review

By Juan H. Sosa-Arnao1, Jefferson L. G. Corrêa2, Maria A. Silva3 and Silvia A. Nebra4

1
Mechanical Engineering Faculty, State University of Campinas - Unicamp P.O. Box 6122, CEP 13083-970,
Campinas - SP, Brazil, E-mail: jhsosa@fem.unicamp.br
2
Food Science Department. Federal University of Lavras - UFLA,
CEP 37200-000, Lavras – MG, Brazil, E-mail: jefferson@ufla.br
3
Chemical Engineering Faculty, State University of Campinas - Unicamp, P.O. Box 6066, CEP 13083-970,
Campinas - SP, Brazil, E-mail: cida@feq.unicamp.br
4
Interdisciplinary Center of Energy Planning, State University of Campinas,
Rua Dr. Shigeo Mori, 2013 - Cidade Universitária - 13083-770 Campinas, SP, Brazil, E-mail:
silvia.nebra@pesquisador.cnpq.br

Abstract

Sugar cane bagasse is the only fuel used in the sugar-alcohol industry in Brazil, the world's leading sugar cane producer. The sugar-
alcohol industry produces cogenerated electrical energy for its own consumption and the surplus is sold to the market. Improving
the use of bagasse in furnaces is currently an important industrial strategy. The topic has aroused great interest due to an increase in
the cogeneration level in recent years. This work reviews the state of the art of sugar cane bagasse drying.

Introduction exhaust and the turbine efficiency.

The export of surplus electricity from sugar industry cogeneration is
becoming the norm in many parts of the world. Cogeneration systems
are composed of a steam generation system, steam turbines and, of
course, the process plant that acts as the condenser for the LP exhaust
steam. The need to keep generating beyond the end of crop means
that many systems also have water cooled condensers, typically inte-
grated with a turbine which is then a pass-out condensing machine.
The steam generation system is the principle source of losses
from modern cogeneration stations. It has a boiler, an air pre-heater,
an economiser and sometimes a bagasse dryer. The bagasse dryer,
like the pre-heater and economiser, increases the steam generation
efficiency but it only becomes a significant influence when flue gas
is used as the heat source for drying, the steam generation efficiency
being directly related to the final gas temperature.
It must be remembered that, even though bagasse drying is a
means of making more energy available from the cogeneration sta-
tion, the net increase in electricity generation depends on the charac-
teristics of the entire plant, which is also a function of mainly the tur-
bine inlet steam condition, the temperature and pressure of the
Arrascaeta and Friedman1,2 have presented the state of art of sugar
cane bagasse drying until 1987. However, despite the importance of
bagasse drying in recent years, it has not been sufficiently discussed.
The aim of this work is to present a review of the most important dry-
ing systems (whether reported in the literature or not) and a discus-
sion of their main characteristics.
Advantages of drying sugar cane bagasse
When the boiler efficiency is determined based on the Higher
Heating Value - HHV, it is possible to perceive that a critical aspect
is the bagasse moisture content.3 This value represents about 14.79%
of total heat losses, since the typical boiler efficiency is about
65.83%.
Don et al.4 according Upadhiaya5 reported that the HHV of brix-
free, ash free and moisture-free bagasse is 19605 kJ by kg of dry
bagasse, but if its moisture content is 50%, in the same conditions of
brix and ash, the LHV becomes 7929 kJ by kg of wet bagasse.
The reduction of cane bagasse moisture increases the LHV, and at
the same time, the volume of the boiler exit gases is reduced.
 Table 1. Industrial bagasse drying systems

Type and size Capacity Year Plant, location Reference Remarks

[t/h]

Counter current flow 1.4 1910 Palo Alto Sugar Factory Donaldsonville, Louisiana 6 Pilot scale
Rotary dryer (three) 30 1976 Atlantic Sugar Association, Florida 10 GIT = 218 ºC
Rotary dryer 3.6mx12 m 50 1976 St. Mary Sugar Co., Louisiana 2 GIT = 315°C
Rotary dryer 35 1979 Waialua Sugar Co., Hawaii 16 GIT = 244°C
Pneumatic dryer (five) 5 1980 Açucareira Santo Antonio, Brazil 12 GIT = 300°C
Pneumatic dryer 12 Açucareira Santo Antonio, Brazil 12 GIT= 330°C
Pneumatic dryer 30 Açucareira Santo Antonio, Brazil 12 GIT= 300°C
Pneumatic dryer 25 1981 Barra Grande sugar factory, Lençois Paulistas, SP, Brazil 7 GIT = 300°C
Pneumatic dryer (six) 4.7 Cruz Alta Plant, Olímpia, SP, Brazil 12 GIT = 259°C
Pneumatic dryer (six) 5 Cruz Alta Plant, Olímpia, SP, Brazil 12 GIT = 239°C
Pneumatic dryer (six) 6.1 Cruz Alta Plant, Olímpia, SP, Brazil 12 GIT = 257°C
Rotary dryer 3.6mx9m 65
10.7 1980 Davies Hamakua Sugar Co., Paauilo - Hawaii 16 Pellets
Rotary dryer 4.2mx9 m 72 1980 Hilo Coast Processing Co., Pepeekeo, Hawaii 16
Pneumatic dryer Paia Factory of HC&S Co., Maui, Hawaii 16
Pneumatic dryer 24 1982 Central Azucarero Don Pedro, Batangas, Philippines 2
Rotary dryer 3.6mx12 m. 45 Central Aidsisa, Bacolod, Philippines 2 GIT=258°C
Rotary dryer 2.4mx15.7 m 13 Central Victoria, Bacolod, Philippines 2

Pneumatic dryer 2 1980 Sugar Research Inst., Mackay, Queensland, Australia 11 Pilot scale
Pneumatic dryer 1983 Chun Cheng Sugar Factory, China 2 Pilot scale
GIT = 140°C
Pneumatic dryer 0.5 1983 Central Pablo Noriega, Quivicán, Cuba 2 Pilot scale
GIT = 200°C
Through circulation (moving) 3.8 1983 Usina Paraiso Alagoas Pernambuco - Brazil 20 Industrial
prototype
Pneumatic dryer 7 1983 Central Pablo Noriega, Quivicán, Cuba 2 GIT = 300°C
Solar 2.7 1983 Consuelo factory, Dominican Republic 17 H y b r i d
active/passive system
Pneumatic dryer 7.5 1984 Usina Itajubara – GIJS, Maranhão – Brazil 41 GIT = 330°C
Rotary 14 1985 Industry Zaio, Morocco 26 GIT = 220°C
Dryer
3mx 16m
Pneumatic dryer 10 1985 ICINAZ 21 GIT = 250°C
Pneumatic dryer 22 1986 CAI Jesus Rabi, Calimate – Matanzas, Cuba 25
Pneumatic dryer 13 1989 Ingenio Ñuñorco, Tucuman, Argentina 28 Industrial
scale Prototype
Pneumatic 17 1993 Ingenio Ñuñorco, Tucuman, Argentina 13 Industrial
prototype
dryer
Pneumatic 38 2003 Ingenio Ñuñorco, Tucuman, Argentina 29 Industrial
prototype
dryer
Hybrid 2003 Ingenio Leales, Tucuman - Argentina 30 Industrial
prototype
dryer
Pneumatic dryer 28 2003 Cia. Agroindustrial de Goiana - CAIG - Açúcar e Álcool – GIJS, Brazil 41 building

Remembering that the specific heat of water vapour is almost twice
that of other gases, the heat losses by exit flue gas are also reduced.
Water vapour reduction also decreases the load of induced draft fans5.
Boulet6 stated that drying the sugar cane bagasse could reduce air
pollution and air demand in the furnace. Nebra7 concluded that pneu-
matic drying is a good choice even when combustion gases coming
from an air pre-heater are used (GIT 180°C). Bailliet8 stated that the
main advantage of sugar cane bagasse drying over the air pre-heater
is the substantial increase in bagasse "burnability". Hence, bagasse
drying is definitely a good course of action for mills producing large
amounts of it with moisture above 50%.
Marquezi and Nebra9 have shown that bagasse drying can save
more energy than the air pre-heater. Drying sugar cane bagasse in an
integrated system makes possible to obtain exit gases from the steam
generation system at a lower temperature1,11. The use of bagasse
dryer could reduce the temperature of the boiler exit gases from 300
to 140°C, increasing the steam generation system efficiency from
54% to 69%10. Currently there are bagasse dryers with even better
 Figure 1a. Pneumatic dryer (Santo Antonio
Factory)12
performances, capable of reducing the GOT to about 75°C12, 13, 14.
Energetic and exergetic analysis of a steam generation system has
shown that bagasse drying improves the energetic efficiency from
71.44% to 84.98%, simultaneously increasing the exergetic efficien-
cy by 3.14%15.
State of the art of sugar cane bagasse drying
Industrial-scale systems
Professor Kerr6, in 1910, was the first researcher to report sugar cane
bagasse drying using boiler exit gases. The dryer was of the counter-
current type. Hot drying gas entered the dryer at the bottom, travel-
ling along a zig-zag path to the top, where it was drawn off by a fan.
Bagasse entered at the top and worked its way down a series of
inclined pivoted shelves. The dryer was made of steel and measured
1.2 m x 1.8 m in cross-section and 6.0 m in height. Moisture content
was reduced from 54.3% to 46.4% (all moisture content figures are
wet basis). Gas inlet temperature (GIT) was about 245°C, and gas
Figure 1b. Pneumatic dryer (Barra Grande
Factory)7
outlet temperature (GOT) 104°C.
Few articles about bagasse drying were published from 1910 to
1970. Alternative energy sources such as sugar cane bagasse were not
regarded as important in Brazil during that period due to the low
price of fossil fuels. The energy crisis of the 1970's compelled plants
to focus on further reducing bagasse moisture by drying it with flue
gases. Consequently, boiler efficiency was improved, and emissions
of particulates and CO2 were reduced. Table 1 presents a compre-
hensive list of bagasse drying systems installed in various sugar
industries around the world. These systems are also discussed below.
During the fuel crisis of 1972-73, Furines10 studied the viability
of bagasse pre-drying by boiler exit gases. This author tested three
rotary-drum type dryers using boiler exit gases at a GIT of 218°C to
process bagasse obtained from 8000 t/day of sugar cane. Moisture
content was reduced from 54% to 46%. Total fuel oil consumption,
originally 1.62 gal/t of sugar cane, dropped to 1.01 gal/t in 1976.
Kinoshita16 reported four systems using boiler exit gases to dry
cane bagasse in Hawaii. Three of them were rotary-drum type dryers,
and the fourth was a flash dryer composed of a pneumatic dryer and
a cyclone. The author compared the increase in electric energy
brought by the dryers and the electric energy consumed by them, and
found a ratio of 2.7 to 3.7 for the rotary drum type and 1.5 for the
flash type.
Correia12 described the use of pneumatic dryers in Brazil and their
advantages over rotary drum dryers (Figure 1a). He reported an
increase of 16% in steam generation resulting from a decrease in
moisture content from 50% to 38%. Soon afterwards, the Cruz Alta
sugar cane company installed new sugar cane mills using that system.
Even though waste gases are the main heat source for drying
sugar cane bagasse, a solar dryer has been reported in the scientific
literature as also adequate. It had a low initial cost, and low operat-
ing and maintenance requirements17. This belt dryer processed 2.7 t/h
of bagasse and reduced moisture from 50% to 33%.
Massarani and Valença18,19,20 studied bagasse drying in a moving
bed dryer which they developed from laboratory scale to pilot scale.
The laboratory dryer had a cross-section of 0.40 m x 0.50 m, and 2 m
height; the pilot moving bed dryer had a cross section of 2 m x 0.5 m
and 6.0 m height. The pilot dryer processed 3.8 t/h achieving a mois-
ture reduction from 55.0% to 35.2%.
Salermo and Santana21 worked with a dryer made up of a flu-
idized bed, a pneumatic duct and a cyclone. The system processed 10
t/h of sugar cane with exit gases at 250°C. The moisture content was
reduced from 47% to 35%.
Nebra and Macedo7 studied an industrial pneumatic dryer (Figure
1b), and found that the most significant moisture content reduction
took place in the cyclone. This dryer processed 20.4 t/h of bagasse,
and reduced moisture content from 50% to 23.2%22, with a GIT of
300°C. Nebra23 was the first researcher in Brazil to study a cyclone
as a dryer. It is important to note that the cyclones in systems such as
that of Salermo and Santana21 were designed to work as gas cleaners,
not as dryers.
Arrascaeta et al.24 patented a dryer that elutriates sugar cane
bagasse and separates the particles into coarse and fine particulate
fractions. This classification allows the use of feeders and burners
specifically adjusted to each size fraction. Consequently, different
sizes of bagasse could be used as fuel and as raw material for paper
production, particle boards, furfural and other products. This dryer
had a capacity of 7 t/h. In 1986, Arrascaeta et al.25 described an indus-
 Figure 1c. Pneumatic dryer (Ñuñorco indutry)29
trial-size pneumatic dryer that processed 22 t/h of bagasse with a
moisture content of 48%. Outlet moisture content was 21%.
Gamgami26 according van der Poel et al.27 reported a rotary
bagasse dryer installed in the Zairo sugar factory in Morocco. It
processed 14 t/h of bagasse with moisture content of 53%. Outlet
moisture content was 40%, and GIT was 220°C.
Aralde et al.28 worked with a pneumatic dryer installed at Ñuñor-
co sugar cane mill in Tucumán, Argentina, in 1989. This dryer
processed 13 t/h of bagasse with moisture content of 53%. Outlet
moisture content was between 40% and 43%, and GIT was 291°C.
Paz et al.13 also described an industrial-size pneumatic dryer. This
was a modified version of the dryer described by Aralde et al.28
(Ñuñorco mill). It performed satisfactorily, processing 17 t/h of
bagasse with an inlet moisture content of 54% and an outlet moisture
content of 40%. GIT was 320°C.
Colombres29 reported data of a pneumatic dryer (Figure 1c) with
bagasse capacity of 38 t/h at a moisture content of 52%. Outlet mois-
ture content was 38%, and GIT was 280°C. This was the biggest
Figure 1d. Pneumatic dryer (Leales industry)30
pneumatic dryer reported so far. This dryer was also installed at
Ñuñorco mill, in Argentina.
Saab30 reported a hybrid drying system composed of three types
of dryers -- rotary, pneumatic and cyclonic -- installed at Leales
Sugar mill in Tucumán, Argentina (see Figure 1d). Technical data
about this system are not available.
Morgenroth and Batstone31 proposed an innovative technology:
steam drying. Drying by superheated steam is a known process, but it
had not been applied for cane bagasse previously. The authors present-
ed calculations about their proposal, adapted from beet pulp drying, to
be introduced in a factory, showing the theoretical possibility of an
attractive increase in boiler efficiency and cogeneration. Afterwards
they reported data about a prototype steam dryer tested with whole
sugarcane with 70% moisture to be used for animal feed. The prototype
was of fixed bed type, with evaporation capacity of 0.3 t/h and inlet
superheated steam at a temperature of 180ºC. The outlet bagasse had
10% of moisture content. The feeding and discharge systems, key
design aspects, were carefully developed in the drying system.
Experimental systems
Meirelles32 studied the use of a fluidized bed dryer for a sugar cane
bagasse of unusual characteristics: very high inlet moisture (71 to
91%) and small particle sizes (0.51 to 1.02 mm). Meirelles found that
a mixer was required to achieve fluidization. During the drying
process, bagasse agglomeration was reduced and the dried particles
were elutriated.
Researchers at the Faculties of Mechanical Engineering and
Chemical Engineering at State University of Campinas (UNICAMP)
have been working on drying of agricultural residues in cyclones33.
Nebra et al.34 presented a review of the drying process in cyclones,
including part of the work by the UNICAMP researchers. Corrêa et
al. 35,36,37 presented theoretical and experimental data on bagasse dry-
ing in a cyclone that underwent geometric changes in order to work
as a dryer. These authors worked with bagasse with inlet moisture
content from 48 to 78% (w.b.); bagasse mass flow in the range of
0.0017 to 0.012 kg/s; GIT 210°C; and air flow rate of 7.8x10-2 kg/s.
They succeeded in reducing bagasse moisture content by 74% along
a particle residence time of 5 to 23 seconds. A pilot-scale system was
used in this experiment. The cyclone was 1.0 m in height. It must be
pointed out that cyclonic dryers allow a longer residence time than
other pneumatic types.
Barbosa and Menegalli38 and Barbosa39 studied sugar cane
bagasse drying kinetics in a pneumatic dryer (initial moisture content
36% to 82%). They found that the most significant moisture reduc-
tion happened in two places: the acceleration zone at the pneumatic
duct, and the cyclone. This pilot-scale system measured 0.075 m in
diameter and 3.0 m in height; bagasse mass flow varied from 0.0034
to 0.017 kg/s, air mass flow from 0.028 to 0.048 kg/s, GIT from 120
to 233°C, and final moisture content from 21.3% to 78.9%.
Alarcón and Jústiz40 also worked with a pneumatic dryer. Coarse
particles were removed in the beginning of the drying process, and
the smaller particles remaining in the dryer had their moisture con-
tent reduced from 50 to 30%. GIT was in the range of 240 to 270°C.
Bigger particles were used as raw material in the paper and pharma-
ceutical industries and smaller ones were burned to generate
thermal energy.
Conclusions
The first industrial bagasse dryer was of the rotary type. Many other
types have since been experimentally studied and used in industries,
such as fluidized and solar dryers. At present, pneumatic dryers are
most often used in factories because of their low price and small
space requirements.
Bagasse dryers undoubtedly promote energy savings that increase
the efficiency of the steam generation system. With the current
increase in export cogeneration in most Brazilian factories, the
bagasse dryer could become an important element of the system,
even though studies about trade-off between the air pre-heater, the
economizer and the drier are necessary, taking into account costs and
energy consumption, aiming to determine the best seating arrange-
ment between these pieces of equipment.
Acknowledgements
The authors wish to thank CNPq (Proc. 142135-2003-8; and Proc.
305720/2003-1) and FAPESP (Proc. 2001/14302-1) for their financial support.
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