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Elspec Equalizers for Sugar Industry

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Elspec Equalizers for Sugar Industry Powered By Docstoc
					Elspec Equalizers for Sugar
Industry
Daniel L.K. Ching




                              1
  Sugar Mills- Fertile Ground for
  Equalizers
• Huge MVar
  requirements can be
  expected in Sugar
  Mills.
• Equalizers Enhance
  Generator Capacities
  and improve power
  quality of Sugar Mills
• Expect repeat orders
  from Sugar Mills.
                                    2
SAMPLE FLOW DIAGRAM
OF A TYPICAL SUGAR MILL




                          3
Major Steps in Sugar
Processing
• Milling Process - Cleaning and Juice Extraction by
  shredding and pressing.
• Purification of Juice – Clarification (use of lime and
  chemicals) and vacuum evaporation.
• Crystallization in vacuum pans producing
  Messecuite.
• Centrifugal process to separate raw sugar from
  molasses.
• Drying and Packaging.
                                                           4
 Power Generation in Sugar
 Mills



• Sugar Mills generate their steam and
  power by burning bagasse.
• Steam is generated in the boilers. They
  are used in refining process and to run
  steam generators.

                                            5
Power Generation in Sugar
Mills
• Sugar Mills with
  refineries need more
  power and steam. Diesel
  generators are sometime
  used for augmentation.
• Numerous Steam
  Turbine and sometimes
  Diesel Generators are
  connected in parallel.


                            6
    Major Loads in a Sugar Mill

• Conveyor drive
  systems
• Centrifugal Baskets
• Pumps, compressors
• Mill loads such as
  cane cutters or
  knives, cane mill etc.


                                  7
Centrifugal Baskets – Important
Machine in Sugar Processing

• Machine that separates
  raw sugar or refined
  sugar from molasses.
• Revolves 1000-1200 rpm
  per process.
• Runs as required by the
  process.
• A Sugar Mill may have 6
  to 24 or more depending
  on the sugar mill’s
  capacity.
                                  8
 Centrifugal Baskets– Characteristics
• Would run every few minutes
  as the process dictates.
• Driven by large motors from
  100HP (75kw) to 150 HP
  (112kW).
• Old Systems are started
  Direct-on line (2 speed), DC
  Drive or driven by VFD’s
  (current fed- regenerative or
  voltage fed).
• Very Inductive During
  Starting.
                                        9
Centrifugal Baskets- Source of
Power Quality problems
• Huge kVa and Kvar demands during starting may
  create PQ problems in terms of voltage dips &
  frequency variations.




                                              10
Centrifugal Baskets- Source of
Power Quality problems
• Logged Data obtained from a Centrifugal basket
  driven by a VFD




                                                   11
Centrifugal Baskets- Source of
Power Quality problems
• An Example of Centrifugal Basket coupled to a
  Regenerative Drive




                                                  12
 Centrifugal Baskets- Source of
 Power Quality problems




• Another Centrifugal Basket driven by a regenerative drive. Take
  note on the impact on frequency by the demand of the starting load.   13
    Impact of Centrifugal Baskets
    on a Sugar Mill
•   Low Power Factor
•   Unstable
    Frequency
•   Must generate
    power at higher
    voltage (higher kW
    consumption)
•   Low efficiency
•   High Losses
•   Forced load
    scheduling
•   Increase CO2
    emissions
•   Occurrence of
    Voltage Dips that
    may trip sensitive              14
    equipments
Without EQ, plant engineers had used conventional
means but they can never improve their powerhouse PF




They tried manual banks but these would constantly be
damaged. Conventional Automatic banks are likewise
useless in their quest to improve their PF              15
With EQ, we can see a marked reduction on power demand !




                                                      16
• Enhanced
  Generator            Other Benefits
  capacities.
• Increased
  generator rigidity
  by having stable
  generated
  frequency and
  voltage.
• Energy/ fuel
  savings
• Reduces steam
  demand, thus
  improve
  productivity
• Increased
  efficiency
• Better PQ                             17
Tips when qualifying a Candidate
• High %THD in Current may indicate presence of fast
  changing loads
• Using a
handheld RMS
Power Analyzer
may help in
qualifying




                                                       18
Summary
• Sugar Mills can
  never improve
  their Power
  House Power
  Factor without
  Equalizer.
• Equalizer is the
  only Solution !

                     19

				
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posted:8/31/2011
language:English
pages:19