Energy Efficiency in IPPC installations, 21.-22.

October 2004 in Vienna Austria Trend Parkhotel Schnbrunn

VEREIN DER ZUCKERINDUSTRIE

Innovative examples of energy efficiency in the German sugar industry - dewatering and drying process for sugar beet pulp Dipl.-Ing. Christian Vo Dr.- Ing. Joachim Wieting

Sdzucker AG for the German Association of Sugar Industry

U MWELT B UNDES A MT, Berlin

Postfach 33 00 22, D-14191 Berlin Tel. 030/ 8903-2829

Werk Warburg, D-34414 Warburg Tel. 05641/ 9413 Christian.Voss@Suedzucker.de

joachim.wieting@uba.de

Structure

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1. Introduction (targets and development of the specific energy requirement) 2. Mechanical dewatering process for sugar beet pulps in the sugar industry as regards energy 3. Drying processes (drum drying, low temperature drying and evaporation drying) 4. Energy aspects of pulp drying 5. Comparison of energy consumption and the economics of different types of installations with examples 6. Characterisation of the technology economic and ecological aspects

Background and Motivation

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With the finalisation of the Council Directive 96/61/EC concerning Integrated pollution prevention and control, the so-called IPPC Directive, the concept of an integrated approach to reduce environmental pollution is being pursued at European Community level for the first time, with all installations covered by the directive now requiring permits. The EU Commission is supporting the implementation of the directive as part of its exchange of information by having leaflets compiled on the best available techniques (BAT) by the European Integrated Pollution Prevention and Control (IPPC) Bureau in Sevilla, Spain.

Background and Motivation

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The food, drink and milk BREF gives information at community level on the best available techniques in the sugar industry to help promote the use of these techniques and to support the member countries effectively in their efforts to protect the environment.

The efficient use of energy in the industry

helps avoid and/or control emissions in the air, in water and in the ground as far as possible. The formulation of the directive into a new VDI guideline in Germany will set out primary and secondary control measures and new reduced emission figures for production technology.

Introduction

precautions in the interest of the climate

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Agreement between German sugar industry and the government board signed on 19.12.2000:
Reduction of the specific CO2 emissions of 41 45 %

by 2005/06 Base year 1990: CO2 emissions/beet Target year 2005/06: achieved 2000/01: 148 kg/t 81 87 kg/t 84 kg/t with 288.5 kWh/ton of beet

Target achievement:

almost 100 %

Introduction
Specific energy consumption in the German sugar industry

VEREIN DER ZUCKERINDUSTRIE

125 kWh / 100 kg beets 100 75 50 25 0 1950 1960 1970 year 1980 1990 current 1996: 30,6 basis 1990: 35,6

ABL DDR / NBL D, ges

target 2005 : 29 2000 2010

ABL = old Federal states NBL = new Federal states D = Germany as a whole

Introduction
Specific energy consumption in the German sugar industry

VEREIN DER ZUCKERINDUSTRIE

Since 1990 > 300 Million have been invested in projects for combined heat and power generation (CHP). Degree of efficiency of heat and power combinations > 90 % re-use of the heat several times normalf = 7 8 Future: physical limits increasing technical expenditure (costs) marginal energy savings
______________________________________________________ Personal remarks on sugar market regulation

Introduction
Energy conversion in a beet sugar factory and VDI extra edition 2594

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Main flows of energy and technical processes are more closely interlinked than in any other sector of industry.

Amount of energy used Sugar production : Dried pulp production 2 : 1

VDI-Guideline 2594 Emission reduction in pulp drying plants in the sugar industry, First printed August 2004

Energy aspects

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of the dewatering process for beet cossettes Production of dried pulp with 90 % dry substance and 10 % water from extracted cossettes with 10 (- 14) % dry substance and 90 % water in 2 dewatering stages: mechanical thermal approx. 3.000 100

Amount of energy used kWh/t water approx. 30 1 Target: :

To remove as much water as possible mechanically.

Energy aspects

of the dewatering process for beet cossettes

VEREIN DER ZUCKERINDUSTRIE

State of the art:

Spindle presses horizontal/vertical

pulp inlet screen ring, axially relocatable for pressing pressure variation

press water collector

pulp outlet

Energy aspects

VEREIN DER ZUCKERINDUSTRIE

of dewatering process for beet cossettes

Quantity of material pressed out depends on capacity of presses Hardening with calcium ions (gypsum), Development by Sdzucker (SZ):
34 3,4 3,2 3 2,8 2,6 2,4 2,2 2
82 84 86 88 90 02 92 94 96 98 00

Dry-substance content in Press-pulps in %

32 30 28 26 24 22 20
80

Campaign
Dry-substance content in % Watercarying in kg Water/kg Dry-substance content

SZ-Pressing target before drying: 32.5 % dry substance in the pressed pulp

Water carrying in kg Water/ kg Dry-substance content

Energy aspects

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of dewatering process for beet cossettes

Other mechanical dewatering processes % dry substance in the pressed pulp Diffusive dewatering: 65 in combination with evaporation plant to concentrate the press water Disadvantage: no suitable separation of solids/liquids High-pressure, multi-layer pressing: 50 Filter band press: 300 bar; 15 min. pressing time Disadvantage: no suitable filter cloth quality no reliable control of the 300 hydraulic control loops Extraction under alkaline conditions Pilot installations in France, Germany and England 45 50

Energy aspects

VEREIN DER ZUCKERINDUSTRIE

of dewatering process for beet cossettes Combination of electroporation and alkaline extraction
Alkaline extraction results in increased deposits of calcium ions

and thus to a definite increase in the pressability of the extracted cossettes

- Dry substance (DS) content of extracted cossettes : 40 - 45 % (an increase of approx. 10 % DS) Opening the cells by electroporation to prepare for deposit of

calcium ions
- opening the cell membranes by high voltage impulses high voltage impulses: a voltage of several hundred kV for the duration of approx. 1 sec low energy demand: approx. 1 kWh/t beet

Energy aspects

of dewatering process for beet cossettes

VEREIN DER ZUCKERINDUSTRIE

Changes in the mechanical properties of beet due to electroporation Electroporation increases the flexibility of the cossettes considerably and
enables them to stand up to heavier mechanical stress.

Energy aspects

VEREIN DER ZUCKERINDUSTRIE

of dewatering process for beet cossettes

be et s

Possible configuration of electroporation and extraction*

electroporated beets

electroporation

electroporated and alkalined cossettes slicing machine lime

mash
* patent

applied for juice towards juice purification

Drying process

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Start-up line 1,5 bar

85 bar DU 2 VD 2-7 Heating oil Generator Generator Steam turbine

85 25

25 3

3 bar 3 bar VD 1

4,5 MW

Gas turbine

Boiler

14,7 MW

25 bar

3,3 bar

VT 1

VT 2

DU 1

DU 3

Steam system of a sugar factory with steam drying

Drying process

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Legend: 1 2 3 4 5 6 7 8 9 10 Cossette feed screw in cell 1 Stationary guide vanes Cylinder with cyclone effect Cyclone over cell 16 for separating entrained cossettes Steam inlet into cyclone Stationary guide vanes for steam return Superheater for secondary steam Blower fan for creating fluidised bed Generated steam exit Feed screw for cossette output from cell 16

Steam system of a sugar factory with steam drying

Energy aspects of cossettes drying

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In order to consider the energy aspects of the installations described, the general data of the factories with both direct and indirect dewatering systems have been standardised as follows: Beet processing 10.000 tons/day . Length of campaign (season) 90 days p.a. Mass flow of pressed pulp: 160 kg/t beet processed = 66,7 tons/h Dry substance content of the pressed pulp 31 % Dry substance content of the dried pulp 90 % Steam consumption of a sugar factory for 200 kg/t processed beet = 83.4 t/h Live steam pressure 85 bar Live steam temperature 525 C Thermal value of the fuel 40.195 kJ/kg

Energy aspects of cossettes drying

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Electrical energy demand of the sugar factory without drying 10.4 MW = 24.96 kWh/t beet processed Complete crystallisation of the thick juice in the beet . campaign
These norms pre-suppose that the factories have the following technical installations:

A steam generator with 85 bar and 525 C. A corresponding back pressure turbine 3 bar back pressure to supply the evaporation station or 3 bar back pressure and 25 bar extraction pressure to supply the steam dryer.

Summary of the examples of installations

Steam High dryer temperature dryer Total electric energy demand Total fuel energy Total electric energy obtained MW 11.55 11.20 MW 73.72 111.83 MW 11.48 11.66

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Low/high Factory temperature without dryer a dryer

12.10 104.80 11.66 1,695 3,661

10.40 67.13 11.66 1,048 2,264

Total energy costs /h Total energy costs 103 per campaign /a

1,182 1,780 2,532 3,845

Summary of the examples of installations

VEREIN DER ZUCKERINDUSTRIE

Additional energy costs in comparison to a factory without dryers for the individual variations:
High temperature dryers Low/high temperature dryers Steam dryers
comparison to lower fuel costs in operation)

1.581 103 1.397 103

268 103

Operation related costs (higher investment costs of installations in

High temperature dryers Low/high temperature dryers Steam dryers

388 103 p.a.

460 103 p.a. 554 103 p.a.

Summary of the examples of installations

VEREIN DER ZUCKERINDUSTRIE

Investment costs plus net running costs of the dryer for the individual variations:
High temperature dryers Low/high temperature dryers Steam dryer 38.4 Mio. 40.7 Mio.

40.9 Mio.

Characterisation of the technology:

At the present time steam drying is the best available technique for new sugar factory construction or for complete reconstruction of energy production and heat control systems. However, it cannot be integrated easily into a normal existing factory.

Advantages achieved by steam drying

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Main achievement - Improvements for the environment with regard to emissions and energy consumption:
Emissions are avoided by direct primary use of energy for drying. No application of steam-volatile and odorous vapours. Energy consumption 30% less than in a factory with direct drying.

Inter-media effects
Transfer of the exhaust fumes into the effluent (approx. 1.200 m3
effluent with a chemical oxygen requirement of 1.500 mg/l and a NH4content of 25 mg/l).

VEREIN DER ZUCKERINDUSTRIE

THANK YOU
In conclusion we should like to thank all those who participated the members of the VDI working group 2594, the participating companies in the Sugar Association and all of you for your attention. THANK YOU