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S.U.D.S 2003 to 2009

S.U.D.S 2003 to 2009. From 5 Raw Sugar Factories to one CANE – FLEXI Factory/Industry. ASSCT –CAIRNS 2007 GUY MAUREL TECHNICAL MANAGER S.U.D.S. Mauritius Island showing the cane cultivated areas . Below an aerial view of Savannah factory and the power plant under construction. B.VUE.

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S.U.D.S 2003 to 2009

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  1. S.U.D.S 2003 to 2009 From 5 Raw Sugar Factories to one CANE – FLEXI Factory/Industry. ASSCT –CAIRNS 2007 GUY MAUREL TECHNICAL MANAGER S.U.D.S

  2. Mauritius Island showing the cane cultivated areas . Below an aerial view of Savannah factory and the power plant under construction. B.VUE FUEL MDA B.CHAMP MEDINE 6 SUGAR MILLS -+/-5 MTONS CANES 4 COAL/BAG P.PLANTS 2 BAG ONLY P.PLANTS Cane prod:1,6-1,7 Mts SAVANNAH

  3. S.U.D.S –Societe Usiniere du Sud-created in 2003. • SUDS was officially registered in 2003 following the merger of assets from five sugar mills to handle all canes from the south of the Island [30 %]. • Purpose was to reduce production costs in order to meet the challenge of the world market on sugar prices . • The Mauritian sugar industry had a preferential price for its raw sugar from the ACP protocol. • The uncertainty of this special price both in time and value was the motivation to re-engineer and re-think about the SI in Mauritius. • The Industry had to find ways to reduce its cost of production &develop new by-products from Cane in order to increase its revenue and bring the SI into the 21st century .

  4. THREATS Reduction in the sugar price on export Reduction on the area of land under cane cultivation in Mauritius. Unfavourable Forex Small ‘old’ sugar mills Labour intensive factories with low automation. Increasing production costs Decreasing sugar revenue High cost of Fossil fuels for energy OPPORTUNITIES Centralisation of milling activities ,one ‘high capacity’ efficient mill High tech fully automated factory to decrease labour . New market for refined sugars New markets for special sugars & sugar derived products Increasing demand for Fuel alcohol Energy production from Bagasse from Co-Gen by using high pressure boilers & steam turbines . Threats & opportunities of SUDS

  5. The Choice offered to SUDS in this difficult & changing context . • Do nothing and wait –would mean bankruptcy in the short term. • Invest heavily in the CANE industry and take the challenge of the opportunities of this changing industry . • S.U.D.S opted for the challenge .!!

  6. S.U.D.S Objectives for the period 2005-2010. • Centralisation of milling activities in one 10,000 t/day mill operating 180 days /year • Construction of a 100 MWe Bagasse / Coal power plant operating year round to supply 650 GWe to the grid [175 GWh from Bagasse] • Construction of a 600 t/day sugar refinery operating all year round • Construction of an Alcohol [Fuel alcohol] distillery of 90,000 l/day operating all year round from cane molasses ,with a potential production of 30 M Litres /year . • Possibility to produce – Liquid fertilisers from Vinasse • Special sugars for markets • Rum and other drinking alcohol

  7. Cane production Mills in operation Raw sugar Special sugars Refined sugar Fuel alcohol Molasses Electricity ‘export’ to Grid 1,600,000 tons Four 160,000 tons 13,000 tons Nil Nil 45,000 tons 63 GWh [crop only] 2006- SUDS production from Cane

  8. Riche En Eau 280 000 t Closed 2006 Rose Belle 175 000 t Closed 2002 Britannia 180 000 t Closed 2003 Mon Trésor 250 000 t Closed 2006 275 000 t Savannah Up-graded 2006/07 1 680 000 t Union 520 000 t Will close 2007 (includes B.Ombre & St Felix)

  9. Cane production Mills in operation Raw sugar Special sugars Refined sugar Fuel alcohol Molasses Electricity ‘export’ to Grid 1,680,000 tons One Nil / on demand P.W.S 13,000 tons 160,000 tons [all yr round] 13,5 M litres [all yr round] Nil 172 GWh[bagasse] 450 GWh[Coal] 2009 - SUDS production from Cane

  10. The main steps to change five small raw sugar mills into one Big ,modern ‘flexi –factory’ for the production of : • Raw sugar • Plantation white sugar [PWS] • Refined granulated sugar • FUEL alcohol / Liquid fertilisers • Electricity through Co-generation from bagasse and /or Coal all year round .

  11. SUDS restructuration planfor the South of the island [Savannah mill] Sugar & By-products. • Simultaneous closure of both R E E and M T M D mills after 2006 crop season & U S A mill the year after. • Maintaining cane receiving platforms at the closed mills • Transfer of all the canes from the receiving platforms to the upgraded Savannah mill by large payload lorries(25 tonnes canes capacity), mainly during night hours • Increase in capacity of the Savannah mill from 150 tonnes canes per hour to 425 tonnes canes per hour(this will be done in two successive steps during the 2005-2006 and 2006-2007 intercrops)

  12. Proposed restructuration plan [ continued] • Installation of juice sulphitation & syrup clarification plant inside the factory for PWS production as from 2007 crop .[In view of the future sugar refinery] • Installation of an AA alcohol distillery ,90,000 lts/day ,from molasses,in 2008 .Fuel alcohol for cars. • Installation of a 600 t/day sugar refinery as from 2009 ,operating all year round using PWS as input . • Construction of warehouses to stock PWS / refined sugar ,and an alcohol farm tank of 10 Mlts capacity .

  13. SAVANNAH FACTORY UPGRADING FROM 150 TO 425 TCH • Installation of a larger capacity cane shredder to guarantee optimal cane preparation • Installation of a cane diffuser followed by two stages of dewatering mills to guarantee optimal sucrose extraction and 47% bagasse moisture • The cane diffuser shall minimize the power requirement of the factory and hence favour maximum power export by the nearby Power Plant • Installation of quintuple evaporators to minimize exhaust steam consumption of the factory and hence maximize power export by the Power Plant • Introduction of modern continuous boiling pans to minimize bled steam consumption and favour automation of the Sugar Boiling process • Installation of continuous centrifugals to minimize peak power demands and ensure regular, optimal sugar quality • The upgraded mill is also be fully automated in order to reduce the possibility of human errors during processing, thus guaranteeing optimal performance at all stages of sugar manufacture

  14. Plan dif cx

  15. NEW 10,000 TS /DAY Diffuser under construction

  16. New 45 X 90 de-watering mill & G.Box

  17. New Clarifier & flash tank

  18. New Kestners [1&2] under construction . Below new SS tubes for above .

  19. New CVP – [A&C]

  20. New ‘A&C’ centrifugals-Vertical ‘C’ crystalliser & massecuite reheater.

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