Sugar Automation Packages- Boiler drum level & Combustion control system

• In boiler house instrumentation, 2 important aspects of boiler operations are considered.  Firstly, we look at the safety point of view and try to stabilize the boiler operations by using a 3-element Drum Level Controls System. In this case, apart from the drum level, the quantity of feed water and the quantity of steam generated are also measured. The control algorithm is then smart enough to maintain the drum level within specified limits.  This also reduces any fluctuations in the boiler operation, both in terms of steam generation and feed water demand. However, we treat this system as the most important parameter from the safety point of view of the boiler operations.
• The second aspect is the Combustion Control System for automatic control of bagasse feeding to the boiler, concerning the demand for steam. The offered system essentially works on steam pressure as the master parameter for sensing of steam demand fluctuations. Based on the changes in the steam demand, the firing of bagasse to the boiler is controlled by controlling bagasse feeding and FD air to the furnace. In conventional systems, the control of feeding speed used to be achieved by the method of motor speed control. However, we have found out that by controlling the sliding doors to the bagasse feeding chutes, the problems related to the choking of bagasse due to moisture content are taken care of. With these controls, it is possible to achieve 10 to 15% of savings on bagasse and paybacks for such a system are typically less than a crushing season.

Automatic Cane Feeding Control System

• This system ensures the complete sequencing & maintaining of ratios for the cane carriers, fiberiser, leveller, mills & GRPF system. Donevely chute level measurement & the RPM is also a part of the package. Current measurement is used for the measurement of loads on the mills, and the speeds are controlled by using a fully automatic speed control mechanism. The system ensures consistency on the mill controls and avoids choking / breakage in the entire system.

Imbibition water control

• In this case we measure the quantity of bagasse / load on the mill. This is then correlated with the quantity of imbibition water required to be added in proportional to the mill load. Use of moving parts in the sensor is avoided to have better performances of the system and we measure either chest back pressure or electrical current required to drive the mill. Electromagnetic flow meter is used to measure the quantity of imbibition water and Globe control valves controls the addition. Special interlocks are provided to cut-off the water in case of either mill trip or there is no bagasse on the mill. The benefits of the system will be quantifiable in terms of consistency in the juice brix and will also avoid unnecessary excess imbibition water (which needs to be evaporated later) when there is no bagasse in the mill or the mill trips. This will reduce usage of water too.

Juice flow stabilization system for mixed juice and clarified juice

• The system essentially comprises of Electromagnetic flow meters for measurement of  juice flow to the juice heaters / first body evaporator. The juice tank will have a level transmitter to measure the level of juice. This transmitter will have a special flush diaphragm to avoid any choking during the level measurement. The flow of juice will be controlled by a specially designed control valve on the juice by-pass line back to the juice tank. The principle of operation of the system is same for mixed juice and clarified juice. However, it is possible to set the flow rate for clarified juice to first body evaporator if there are fluctuations on the last body evaporator brix. The control system will operate in a normal case purely on a set point provided on to the controller. Whenever the level  goes below the limits, necessary correction for set point / tripping of pump will be initiated by the controller.

Lime Sulphitation pH Control

• Lime sulphitation pH control involves using milk of lime and sulphur dioxide (SO2) to adjust and maintain the pH of sugarcane juice, aiming for optimal clarification and sugar purity.
• Here the juice flow rate, the lime dosing and the pH of final juice is measured in control system. The probe selection for pH measurement is extremely critical as the parameter requires regular maintenance/cleaning and recalibration. In such case an automatically retractable pH probe can be selected which can be cleaned by water jet based on a programmed time interval from the controller. The final control is achieved by control of milk of lime quantities and also the sulphur burner secondary air.

Steam Flow Stabilization

• This solution consists of control of vapour to the PAN section, irrespective of the fluctuations in evaporation rates. The package consists of bleeding of exhaust steam or venting of the vapour depending on the fluctuations. The benefits of the system includes vent & vapour control, steady steam/ vapour flow to PANs irrespective of evaporation rates, no fluctuations of steam pressure to the PANs, hence consistent PAN boiling and improvement in sugar quality.

PAN Automation

• Specialized control systems designed for automation of both batch & continuous pans.
• The system includes special automatic cleaning type probes for brix measurement and measurement of flow for hot water and massecuits / syrup. The entire system can be operated from a PC for multiple number of Pans. The system also includes non-contact level measurement for batch pans and vacuum controls. The benefits of the system include consistency in pan boiling & improvement in sugar crystal formation.