Efficiency Improvement in Sugar Mills; The Role of High-Pressure Boiler Technology in Cogeneration

Abstract

Pakistan’s electricity shortage has had a significant impact on its economic growth, people’s livelihoods, and industrial operations. Currently, thermal methods like oil and gas satisfy around 67% of its electricity needs, with hydropower generating 30% and nuclear means generating only 3%. Bagasse, a solid waste produced during sugar production, accounts for only 0.9% of Pakistan’s energy production. However, by implementing co-generation retrofits, bagasse’s capacity can increase up to 3000 MW. Sugarcane is a significant crop in Pakistan, and sugarcane crushing mills have been utilizing boiler technology for many decades as a means of generating steam and producing electricity. The process of cogeneration, which uses bagasse to generate steam and produce electricity, has several advantages, including reducing reliance on fossil fuels, providing a reliable source of electricity, and a source of revenue for sugarcane mills. High-pressure boilers have several advantages, including higher energy efficiency, higher electricity generation, less wear and tear on equipment, lower installation and maintenance costs, and a smaller footprint. As most sugar mills are in rural areas so we can also use this as a benefit and & provide electricity to remote areas. A case study related to JDW Sugar mill has been added at the end to compare the results of High- and Low-pressure boilers. From the results, it is clear that if we want to have highly efficient Cogeneration scheme in Sugar mills, we need to shift urgently towards High pressure boilers.

Keywords

• bagasse
• sugar mills
• high pressure boiler
• cogeneration