Performance analysis and electricity potential for Nzoia sugar factory

Abstract

Kenyan sugar factories are facing challenges in the market from low cost sugar producers as a result of high cost of production. As a result, a number of factories have closed down while operating factories are struggling with cash flow problems. Diversification into both ethanol and export cogeneration is a promising solution to the challenges. In this study, the feasibility of export electricity generation for a Nzoia sugar factory in Western Kenya is undertaken. The 3000 tons of cane per day crushing capacity (TCD) factory has effective generation capacity of 2.8 MW for own internal consumption against installed capacity of 7 MW. The study showed that the factory can develop a continuous power plant of 15 megawatts (MW) but modernization of the factory is necessary to reduce steam consumption mainly by replacing steam turbine drives with electric drives, increase generation efficiency by use of a condensing extraction turbine. The three boilers which are over 30 years old should be replaced with more efficient modern boilers of steam pressure between 45–60 bars. A well negotiated power purchase agreement that captures the challenges facing the factory should then be signed with a utility company to avoid the challenges in implementation due to external factors.

Keywords

• Cane sugar production
• Cogeneration
• Electricity generation
• Sugar production
• Nzoia Sugar Company Ltd