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Johann F. Görgens - One of the best experts on this subject based on the ideXlab platform.

  • assessment of the thermodynamic performance improvement of a typical Sugar Mill through the integration of waste heat recovery technologies
    Applied Thermal Engineering, 2019
    Co-Authors: Eunice Sefakor Dogbe, Mohsen Ali Mandegari, Johann F. Görgens
    Abstract:

    Abstract The cogeneration system is the most inefficient unit a typical Sugar Mill. This paper evaluates the improvements in the exergy performance of a Sugar-Mill cogeneration system, through the integration of the absorption heat pump (AHP) and the organic Rankine cycle (ORC) technologies for waste-heat recovery. The cogeneration system was simulated in Aspen Plus® process simulator and its thermodynamic performance determined through exergy analysis. In addition to providing an alternative cooling for the Mill, the AHP integration minimized the irreversibility of the deaerator, Sugar-drying unit and the overall system by 51%, 76% and 0.14%, respectively, saving 0.83% of total bagasse combusted. The ORC increased the cogeneration system’s exergy efficiency by 1.7% by generating “green” electricity up to 10% of the cogeneration capacity. The AHP and ORC were economically feasible with payback periods of 8.3 years and 6.3 years, respectively. This paper provides basis for waste-heat recovery based exergy improvement studies in other process industries.

  • disturbance modelling through steady state value deviations the determination of suitable energy indicators and parameters for energy consumption monitoring in a typical Sugar Mill
    Energy, 2019
    Co-Authors: Thobeka Mkwananzi, Mohsen Ali Mandegari, Johann F. Görgens
    Abstract:

    Abstract The growing emphasis in alternative revenue streams, from the conversion of Sugarcane bagasse into energy co-products has prompted a desire by the Sugar factories to achieve higher levels of energy efficiency. This study presents a comprehensive overview of the parameters whose steady-state deviation leads to excess energy use in Sugar Mills. The effect of eight operating parameters on the defined energy indicators was investigated, using a MATLAB simulation of a 250-tonne per hour Sugar Mill. The captured energy trends were used to develop energy prediction models based on the parameters whose steady-state offsets resulted in excess energy use. High prediction accuracies of over 95% were obtained when the developed energy prediction models were validated for seasonal cane quality and evaporator heat transfer coefficient variations. Increased A-massecuite recycling had a more pronounced effect on the energy used per kilogramme of water in the evaporator unit as compared to the crystallisation unit. Of the eight parameters, elevated imbibition water use and A-massecuite recycling had a cumulative percentage effect of 79% on the overall steam used per tonne of cane and Sugar produced. Hence increasing the syrup concentration, decreasing imbibition water use and massecuite recycling are preferred operational strategies for improved energy-efficiency in a Sugar Mill. Overall, this study strengthens the existing literature by illustrating an approach for developing suitable energy indicators for excess energy use monitoring in Sugarcane Mills.

  • Exergetic diagnosis and performance analysis of a typical Sugar Mill based on Aspen Plus® simulation of the process
    Energy, 2018
    Co-Authors: Eunice Sefakor Dogbe, Mohsen Ali Mandegari, Johann F. Görgens
    Abstract:

    Abstract The Sugar industry is the second largest agro-industry in the world, with more than 80% of Sugar produced from Sugarcane. Sugar Mills are energy-intensive and historically not designed to be energy efficient, even though they may be energy self-sufficient. This study presents a comprehensive exergy analysis of cane Sugar production processes to identify inefficient components for improvement. The exergy analysis was based on rigorous mass and energy balances calculated from an Aspen Plus® simulation of a typical 250 ton per hour Sugar Mill, along with an appropriate exergy methodology. The exergy analysis of the cogeneration system, which has been found to be the principal Sugar Mill exergy destruction unit, is conducted separately and will be presented in a subsequent paper. The overall Sugar Mill irreversibility and functional exergy efficiency were 217.3 MJ per ton of cane crushed and 9.7%, respectively. The evaporation unit generated the highest irreversibility of 100 MJ/ton of cane, while crystallization unit had the lowest functional exergy efficiency of 9.6% and the highest potential for improvement of 47.0 MJ/ton of cane. The exergetic performance of the Mill may be improved by adopting a single stage crystallization with an integrated biorefinery.

  • economic and environmental assessment of cellulosic ethanol production scenarios annexed to a typical Sugar Mill
    Bioresource Technology, 2017
    Co-Authors: Mohsen Ali Mandegari, Somayeh Farzad, Johann F. Görgens
    Abstract:

    Abstract In this work different biorefinery scenarios were investigated, concerning the co-production of bioethanol and electricity from available lignocellulose at a typical Sugar Mill, as possible extensions to the current combustion of bagasse for steam and electricity production and burning trash on-filed. In scenario 1, the whole bagasse and brown leaves is utilized in a biorefinery and coal is burnt in the existing inefficient Sugar Mill boiler. Scenario 2 & 3 are assumed with a new centralized CHP unit without/with coal co-combustion, respectively. Also, through scenarios 4 & 5, the effect of water insoluble loading were studied. All scenarios provided energy for the SugarMill and the ethanol plant, with the export of surplus electricity. Economic analysis determined that scenario 1 was the most viable scenario due to less capital cost and economies-of scale. Based on Life Cycle Assessment (LCA) results, scenario 2 outperformed the other scenarios, while three scenarios showed lower contribution to environmental burdens than the current situation.

  • techno economic assessment of integrating methanol or fischer tropsch synthesis in a south african Sugar Mill
    Bioresource Technology, 2015
    Co-Authors: Abdul M Petersen, Somayeh Farzad, Johann F. Görgens
    Abstract:

    Abstract This study considered an average-sized Sugar Mill in South Africa that crushes 300 wet tonnes per hour of cane, as a host for integrating methanol and Fischer–Tropsch synthesis, through gasification of a combined flow of Sugarcane trash and bagasse. Initially, it was shown that the conversion of biomass to syngas is preferably done by catalytic allothermal gasification instead of catalytic autothermal gasification. Thereafter, conventional and advanced synthesis routes for both Methanol and Fischer–Tropsch products were simulated with Aspen Plus® software and compared by technical and economic feasibility. Advanced FT synthesis satisfied the overall energy demands, but was not economically viable for a private investment. Advanced methanol synthesis is also not viable for private investment since the internal rate of return was 21.1%, because it could not provide the steam that the Sugar Mill required. The conventional synthesis routes had less viability than the corresponding advanced synthesis routes.

Paul Turnbull - One of the best experts on this subject based on the ideXlab platform.

Jyoti Menghani - One of the best experts on this subject based on the ideXlab platform.

  • tribological behavior of Sugar Mill roller shaft in laboratory simulated conditions
    Wear, 2013
    Co-Authors: Amol Kakade, S Ingole, Dhananjay V Bhatt, Jyoti Menghani
    Abstract:

    Abstract Wear is often observed on top roll shaft journal surface. Sugar Mill roller shafts are made up of carbon steel EN8. The friction and wear behavior of carbon steel EN8 was investigated under dry, lubricated, and contaminated sliding conditions. Sugar cane juice, bagasse, and water were used to simulate the contaminated service conditions. A reciprocating pin on disk tester was used to carry out friction and wear tests. EN8 was flat surface whereas E52100 bearing ball was counterface. The friction characteristics were examined at a constant applied load and sliding speed. It was observed that the coefficient of friction and wear volume increased when the shaft material was slid in contaminated test conditions. The volumetric wear was determined to analyze the wear resistance of the shaft material in the extreme service environment. Optical and scanning electron microscopy study showed sever wear in dry and contaminated test conditions. It was observed that the cracks initiated on the surface are consequences from the tribological phenomenon at the sliding interface.

Ross Broadfoot - One of the best experts on this subject based on the ideXlab platform.

  • Industrial decision support requirements and expectations for a Sugar Mill crystallisation stage
    IECON 2011 - 37th Annual Conference of the IEEE Industrial Electronics Society, 2011
    Co-Authors: Roland Dodd, Andrew Chiou, Ross Broadfoot
    Abstract:

    This paper describes the fundamental requirements and expectations for the development of a knowledge based supervisory support system (KBSSS), to provide industrial decision support, for a Sugar Mill crystallisation stage. This paper puts into context the rationale for such a system. The increasing need and importance of providing industrial decision support in the industrial Sugar Mill setting are also detailed. The primary topics of this paper will focus upon: (1) a review of Sugar Mill industrial decision support, (2) unrealized expectations, and (3) requirements for decision support; all pertaining to Sugar Mill crystallisation stage operations.

  • composite process models used in stock tank quantity prediction for Sugar Mill crystallization stage knowledge based supervisory support
    Proceedings of the Institution of Mechanical Engineers Part I: Journal of Systems and Control Engineering, 2010
    Co-Authors: R Dodd, Andrew Chiou, Ross Broadfoot, Xing Yu
    Abstract:

    The present paper proposes the component process models for a knowledge-based supervisory support system designed to provide expert knowledge in the control and management of a Sugar Mill crystallization stage. Forecasting stock tank quantities, within the Sugar factory crystallization stage, is beneficial to ensure that there are sufficient quantities of stock materials to allow completion of production schedules without disruption. It is shown that integration of projected vacuum pan feed rates with syrup rate production models and vacuum pan phase detection models allows forecasting of stock tank quantities for syrup and molasses in order to work towards the goal of forewarning of potential problems with the current operating strategies and advising corrective procedures. These industrial process models form an integral part of an overall pan stage knowledge-based supervisory support system to assist in providing a better decision-making strategy for crystallization stage operations.

  • a smart supervisory control system framework for a Sugar Mill crystallisation stage
    International Conference on Industrial Informatics, 2008
    Co-Authors: Roland Dodd, Andrew Chiou, Ross Broadfoot
    Abstract:

    This paper discusses the framework of an expert advisory system designed to provide expert knowledge in the control and management of a Sugar Mill crystallization stage. The Smart Supervisory Control System (SSCS) is fundamentally a hybrid fuzzy logic based expert system that incorporates fuzzy logic, explanatory capabilities and dynamic interrelational process models of the crystallisation stage. The primary topic of this paper will be a description of the framework of the SSCS system with focus on: (1) modular design, (2) system layering, and (3) system features.

Amol Kakade - One of the best experts on this subject based on the ideXlab platform.

  • tribological behavior of Sugar Mill roller shaft in laboratory simulated conditions
    Wear, 2013
    Co-Authors: Amol Kakade, S Ingole, Dhananjay V Bhatt, Jyoti Menghani
    Abstract:

    Abstract Wear is often observed on top roll shaft journal surface. Sugar Mill roller shafts are made up of carbon steel EN8. The friction and wear behavior of carbon steel EN8 was investigated under dry, lubricated, and contaminated sliding conditions. Sugar cane juice, bagasse, and water were used to simulate the contaminated service conditions. A reciprocating pin on disk tester was used to carry out friction and wear tests. EN8 was flat surface whereas E52100 bearing ball was counterface. The friction characteristics were examined at a constant applied load and sliding speed. It was observed that the coefficient of friction and wear volume increased when the shaft material was slid in contaminated test conditions. The volumetric wear was determined to analyze the wear resistance of the shaft material in the extreme service environment. Optical and scanning electron microscopy study showed sever wear in dry and contaminated test conditions. It was observed that the cracks initiated on the surface are consequences from the tribological phenomenon at the sliding interface.

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