161121 SIMPAG1606-03 Sugar - Siemens Global Website speed of single-stage steam turbines is notably...

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The powerful potential of sugarcaneTurning biomass into profit with Siemens steam turbines

Published by Siemens AG 2016

Power and Gas Division Steam Turbines Freyeslebenstrasse 1 91058 Erlangen, Germany

For more information, please contact our Customer Support Center.

Phone: +49 180 524 70 00 Fax: +49 180 524 24 71 (Charges depending on provider) E-mail: [email protected]

Article-No: PGSU-B10015-00-7600 Printed in Germany Dispo 34808 BR 1116.10 TB.I1116 V1

Subject to changes and errors. The information given in this document only contains general descriptions and/or performance features which may not always specifically reflect those described, or which may undergo modification in the course of further development of the products. The requested performance features are binding only when they are expressly agreed upon in the concluded contract.

Creating green, CO₂-neutral energy from bagasse requires the highest levels of efficiency. The goal of any plant is to extract as much natural energy as possible, whether that energy is sugar itself or steam and power to be sold to the grid. By choosing and using the right equipment, manufacturers can reap huge financial rewards and feel good about running a sustainable operation that is fit for the future. Cogeneration – the ability to create two forms of energy from a single fuel source – has many benefits, both on a local and global level.

A taste of independenceCreating your own source of energy from bagasse

Bagasse is the residual fiber left over from the sugarcane extraction process. Instead of treating it as waste, sugar mills can repurpose it to produce heat and electricity, in turn boosting independence and profit without creating more greenhouse gases.

The benefits of cogeneration

Increase profitabilityTake advantage of domestic resources to increase your profits and boost your competitiveness. There are many successful subsidiaries operating around the world.

Renewable and CO₂-neutralBagasse is renewable and does not emit greenhouse gases.

Support the national gridSell power back to the grid and contribute to the bioenergy targets of your country.

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The powerful potential of sugarcane

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A surge of power The right turbine for your plant

With over a century of experience in turbine technology, Siemens has delivered solutions for a wide range of purposes. For the sugar industry, turbines of up to 50 MW are the most relevant. Whether you run a small, medium, or large mill, we have the best-fitting and easily maintainable solution to match your needs.

Your benefits at a glance

Enhanced efficiencyWith their improved blade and seal concept, Siemens steam turbines are highly efficient in operation. Each turbine is characterized by a simple modular construction that provides flexibility and ease during configuration and maintenance, ensuring maximum output in the least time possible. The result is more energy produced and fed into the grid, and thus more profit.

Rely on our proven portfolioFor small sugar mills, there is the SST-60. For larger sugar mills, we have the popular SST-300. Whatever size mill you operate, we have a proven, easily main-tainable turbine that is ready to fulfill your needs.

For most mills, the popular SST-300 is the ideal choice. Turn to the last page of this brochure to learn more.

Proven reliability and availabilityCalling on a century of turbine devel-opment, all Siemens turbines guaran-tee a long life cycle of 200,000 hours. High availability is the result of a proven design, comprised of pressure blades with reliable root clamps and maintenance-free bolts. By lowering maintenance costs and being ready to crush whenever necessary, your mill will become more sustainable and profitable.

Minimal inspection requiredAll Siemens turbines feature a compact design and simple layout. This signifi-cantly reduces the cost and time associated with construction, inspection, and maintenance, enabling sugar producers to run a more efficient and independent plant.

Power output in MW of our steam turbines

L

0 30 60 90 120 150

SST-600

SST-500

SST-400

SST-300

SST-200

SST-150

SST-111

SST-110

SST-060

SST-050

SST-040 0.45–0.7

up to 0.75

up to 6

up to 8

up to 12

20

10

50

65

100

150

2,000 tons of sugarcane crushed per day (tcd)

up to

5 MWS

Small sugar mills


up to

52 MWL

Large sugar mills

up to

20 MW


M

Medium-size sugar mills

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Part-load operation In order to harvest as much sugarcane as possible during the production season, steam turbines must operate with high reliability and availability. Each day offline can cause huge losses. Not every mill always runs under full load, and bagasse can differ in its moisture and ash content, resulting in an inconsistent steam parameter. To solve this, part-load operation optimizes the efficiency and power output of the turbine if there is not enough sugarcane to crush. This feature ensures consistent results from season to season.

Homogeneous geometrical casing design This innovative design approach means Siemens turbines provide distinct benefits.

• Quick start times (up to 50 percent faster)

• Fast load changes – full load or partial load

• High efficiency

Back pressure or condensing Siemens turbines are available for back pressure or condensing operations in single- or multistage designs. To meet your specific needs, they can also be equipped with single extraction options, or multiple controlled (pass-out) and uncontrolled (bleeding) extraction options.

Steam extraction During controlled and uncontrolled extraction, steam is released from various stages of the turbine and used for industrial processes, or sent to boiler feedwater heaters to improve overall cycle efficiency. To ensure you have a tailor-made turbine solution, Siemens provides controlled and uncontrolled extrac-tion when you need it. Our experts will help you find the optimum balance between high efficiency and low cost.

Boost the efficiency of your business Flexible solutions for tailored performance

Our tailor-made solutions aim to boost output while reducing costs and resources used. This allows sugar producers to be more independent, sustainable, and profitable.

CondensingApplication Condensing turbines are most commonly found in electrical power plants. These turbines receive steam from a boiler and exhaust it to a condenser. The exhausted steam is at a pressure well below atmospheric, and is in a partially condensed state, typically of a quality near 90 percent.

When to applyRequires a bigger investment but is more efficient. Applicable if feed-in tariff is high and there are good subsidies.

Back pressureApplication Back pressure turbines are most widely used for process steam applications. The exhaust pressure is controlled by a regulating valve, which adapts to the needs of the process steam pressure.

These are commonly operated where large amounts of low-pressure process steam is needed.

When to applyMore cost-effective but less efficient, applicable if the government gives no subsidies and power price is very low.

Single-stage turbinesThe speed of single-stage steam turbines is notably higher than the speed of the driven equipment and they are therefore equipped with integral gearboxes. Integral gearing keeps the turbine relatively small, enabling minimal floor space requirements. Another advantage is that they allow the turbine rotor to oper-ate at high speed, which is key to superior efficiency.

Multistage turbinesSiemens’ multistage steam turbines are designed with a customized steam path. The portfolio uses reaction blade technology. The fixed casing design of the pre-designed machines enables high performance at lower cost together with short delivery lead and commission-ing times.

Depending on a customer’s specific requirements, either condensing or back pressure turbines can be used in the sugar-making process. Both turbine types have a long and proven track record in the industry, and each provides a tailored solution that can support any plant.

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Our recipe for success In today’s sugar industry, increasing compe-tition and the need for higher efficiency means producers are looking for new ways to achieve long-term success. And this is exactly where Siemens comes in. With unparalleled understanding of sugar pro-duction, a global footprint, and the most extensive range of products, solutions, and services, we are here to help you succeed.

Siemens has been developing solutions for the sugar industry for well over half a century. We are very familiar with the processes and objectives involved, as well as the challenges that producers face. Our work aims to boost output with reduced expenditure and resources, allowing you to acquire greater independence, sustainability, and profit in the future.

Siemens: fueling the future of sugarTradition meets innovation

Your proven global partnerThe wider Siemens world provides 360-degree support for any plant. With an industry-specific portfolio ranging from automation, instrumentation, drive technology and low-voltage switchgear, as well as global services throughout the entire life cycle of the plant, we cover every area of your sugar production to ensure that processes are efficient, coordinated, and centralized.

If preferred, we remove the need to deal with third parties and provide everything from under one roof; at the same time we can provide single components only, such as the steam turbine. We are as flexible as you need to be. When you choose Siemens, you have access to many different components, such as boilers and condensers. With a rich history that dates back over a century and new innovations in the making, the Siemens name will be your trusted partner now and in the future.

Generators made with generations of expertise Siemens offers a comprehensive portfolio of generators for the 25 to 2,235 MVA power range. They achieve efficiency levels of up to 99 percent. The design of our generators benefits from more than 150 years of experi-ence in development and production since Werner von Siemens invented the electrical generator in 1866. Generators of our SGenTM series are in operation around the globe, with an installed fleet of more than 2,500 units. Assembly and testing specialists accompany our generators from the plan-ning stage to destination, where they put them into operation for you. In addition, our specialists service generators from around the world and perform upgrades and repairs – even for components from other manufac-turers.

What you get when you choose Siemens• Years of proven experience in the industry

• Specialist support from start to finish

• An all-in-one solution for any plant

• Cost-effective packaging

Our boiler partnersWhen you choose Siemens, you gain access to several leading boiler producers. To help you understand what is on offer, consider one of our partners, NEM Energy BV, a subsidiary of Siemens (NEM). NEM creates custom-made heat recovery steam genera-tors (HRSGs), industrial and utility boilers, and related equipment. With over 80 years of experience and 815 HRSGs installed across six continents, NEM is a leading solutions provider for refineries, the petro-chemical industry, and more. NEM provides various types of steam generators using gaseous, liquid, and solid fuels which in-clude biomass such as sewage sludge and sugarcane residues. By choosing NEM, you can further enhance your plant and benefit from the specialist support of Siemens.

Each step of the sugar production process must run smoothly. Siemens has a proven portfolio of steam turbines, from small to large, so you can choose a precise solution for your plant.

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Global expertise, local solutionsOur latest references at a glance

1. Sucrerie de Wonji Shoa, Ethiopia

2. Simbhaoli Sugar Ltd., India

3. Shivratna Udyog Pvt. Ltd., India

4. Shree Krishna Khandsari, India

5. Gammon India Ltd., India

6. NSL Sugar Ltd., India

7. Ponni Sugars, India

8. Mitr Phol, Thailand

9. Khanh Hoa (Cam Ranh), Vietnam

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Powering innovation

Simbhaoli Sugars Ltd.

India

Year: 2013

Steam turbine: SST-300

Power output: 18 MW

Speed: 6,800 rpm

Inlet steam pressure: 87 bar(a)

Inlet steam temperature: 510 °C / 950 °F

Exhaust steam pressure: 0.1 bar(a)

Capacity: 5,000 tcd

There’s more to Simbhaoli Sugars Ltd. than the name suggests. The company specializes in sugar, of course, but also liquor, technology consultancy, co-generated power, extra neutral alcohol (ENA), ethanol, and bio-manure. As India’s largest integrated sugar refinery, it is a pioneer of innovative refinery processes, backed by the power of the SST-300.

Becoming self-sufficient

Sucrerie de Wonji Shoa

Ethiopia

Year: 2013


Power output: 31.5 MW

Inlet steam pressure: 62 bar(a) / 899 psi


At Sucrerie de Wonji Shoa, a sugar mill located 100 km east of Addis Ababa in Ethiopia, self-sufficiency is a key objective. After processing sugarcane, the remaining bagasse is used as fuel for the boiler. The mill operates with a capacity of 31.5 MW, which produces enough energy to fully cover the demand for electricity and process steam.

Looking for a partner

Shivratna Udyog Pvt. Ltd.

India

Year: 2015


Power output: 12 MW

Speed: 8,300 rpm



Exhaust steam pressure: 3 bar(a)

Capacity: 2,500 tcd

When Shivratna Udyog Pvt. Ltd. start-ed looking for a new steam turbine, quality and reliability were top priori-ties. “We found Siemens to be always approachable, quality-conscious, safety-conscious, and customer-orient-ed throughout the execution of the project. We are very much satisfied (…) and would recommend other prospective customers to prefer Siemens over other options,” com-mented the plant’s general manager.

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22.4 million*

operating hours

11,800 MW*

fleet experience in all regions

100*

SST-300s installed in sugar mills in Southeast Asia, Africa, and Latin America

*as of 2015

The SST-300 – a success story around the world

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The powerful potential of sugarcaneThe powerful potential of sugarcane

NSL Sugar Ltd. (NSL) is one of the most efficient integrated sugar companies in southern India. To help boost this status, the company turned to a Siemens SST-300 steam turbine in 2010. S.C. Gupta, consultant at NSL Sugar Ltd., said: “We are highly satis-fied with the support provided by Siemens … [the team] completed the project on time, and certain activities were completed ahead of schedule.”

There on time

NSL Sugar Ltd.

India

Year: 2010


Power output: 35 MW

Speed: 6,800 rpm




Capacity: 7,500 tcd

Founded in 1973, Shree Krishna Khand-sari Sugar Mills began life crushing 200 tcd. Since installing the SST-050 turbine in 2005, its output has reached 1,100 tcd. Today, the plant is totally independent from the state grid, which is plagued by frequency fluctuations and power outages. Calculations show that by using the SST-050, the company saves 1.8 million Indian rupees per month compared to other options.

Freedom to grow

Shree Krishna Khandsari Sugar Mills

India

Year: 2005


Power output: 2 MW

Exhaust pressure: 1.5 bar(a)

Capacity: 1,100 tcd

Upping the power

Gammon India Ltd A/c. Pravara Renewable Energy Ltd.

India

Year: 2012


Power output: 30 MW

Speed: 6,800 rpm




Capacity: 5,000 tcd

Operating as a subsidiary of Gammon Infrastructure Projects Limited, Pravara Renewable Energy Ltd. owns and operates a bagasse-fuelled cogenera-tion power project that processes roughly 5,000 tcd. By choosing Siemens and installing an SST-300 steam tur-bine in 2012, the plant now operates at a capacity of 30 MW.

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Located in the Cam Lam district in the coastal Khanh Hoa province, Khanh Hoa handles roughly 3,000 tcd. In the late 90s the plant was looking for a reliable, high-quality steam turbine solution to power production into the future. Since choosing the SST-300 from Siemens, the plant has not per-formed a major overhaul or changed any major parts in the past 17 years.

Award-winning energy saving

Mitr Phol

Thailand

Year: 2010


Power output: 26 MW

Established in 1946 as a small family business, Mitr Phol is now a global enterprise with footprints in China, Laos, Australia, and elsewhere. The company has cared for the environ-ment for over 55 years, and has re-ceived prestigious national and inter-national awards for its energy-saving efforts along the way. Today, the plant is powered by an SST-300 from Siemens.

Future-proof production

Khanh Hoa (Cam Ranh)

Vietnam

Year: 1999


Power output: 25 MW

Speed: 7,161 rpm

Inlet steam pressure: ≤ 46 bar(a) / 667 psi

Inlet steam temperature: ≤ 450 °C / 842 °F

Exhaust pressure: 2.5 bar(a) / 36.3 psi

Capacity: 3,000 tcd

Fuelling world firsts

Ponni Sugars

India

Year: 2010


Power output: 19 MW

Speed: 6,800 rpm




Capacity: 2,500 tcd

This sugar mill has a special place in history: it was the first to successfully produce newsprint from sugarcane bagasse. It continues to pioneer firsts in the industry, such as using alterna-tive fuel in its boilers. In 2010, the plant chose Siemens to deliver an SST-300 turbine, which today gener-ates 19 MW of power – enough to keep the innovations coming.

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SST-300Made with best-in-class technology and 20 years of development expertise, the SST-300 is a versatile and proven turbine solution. In the last decade alone, it has been installed in over 500 industrial and power applications across the world. All components and auxil-iaries, including the lubricating oil system,

Siemens SST steam turbinesA solution for every sugar mill

Power output: up to 45 MWSpeed: up to 12,000 rpm

Uncontrolled extractions (up to 6):Pressure up to 60 bar(a) / 870 psi

Controlled extraction possible (single or double, adaptive stage, nozzle control, throttle control):Pressure up to 25 bar(a) / 362 psi

Live steam conditions (nozzle or throttle control):

• Pressure up to 120 bar(a) / 1,740 psi

• Temperature up to 540 °C / 1,004 °F

Exhaust steam pressure:

• Back pressure up to 16 bar(a) / 232 psi

• District heating up to 3 bar(a) / 43 psi

• Condensing up to 0.25 bar(a) / 3.6 psi

Exhaust

Rotor and reaction blading Gearbox

Turbine casing

Base frame

are mounted on a common base frame. The turbine can be configured with either an upward, downward, or axial exhaust orienta-tion, and can also accommodate multiple extraction/steam induction points. Its com-pact design and simple layout significantly reduces the cost and time associated with construction, inspection, and maintenance.


Uncontrolled extractions:Pressure up to 25 bar(a) / 365 psi

Controlled extraction possible (up to 4):Pressure up to 16 bar(a) / 230 psiTemperature up to 350 °C / 560 °F

Live steam conditions (nozzle or throttle control):

• Inlet pressure up to 110 bar(a) / 1,595 psi

• Temperature up to 520 °C / 970 °F




SST-200The SST-200 is a single casing steam turbine in packaged and skid-mounted design. The back pressure and condensing turbines, with and without extraction or bleed points, are characterized by a robust layout. For generator drive an epicyclic gearbox com-bined with the generator is preferred, since this provides high efficiency together with a very compact arrangement.

Back pressure and condensing turbines are available with upward or downward exhaust and with internally controlled extraction and the possibility of several bleeds allows the selection of optimal solutions for the indus-trial applications.

The turbine casing and casing components are designed to permit short start-up times. The entire package is assembled and wired in the workshop prior to delivery.


Uncontrolled extractions:Pressure up to 25 bar(a) / 365 psi

Controlled extraction possible (up to 4):Pressure up to 16 bar(a) / 230 psiTemperature up to 350 °C / 560 °F

SST-150The SST-150 is a single-casing steam turbine, providing geared drive to a 1,500 or 1,800 rpm generator. The turbine is packaged in a skid-mounted design (can also be with separate oil system). This is a very compact arrangement which provides high efficiency in power generation and mechanical drive applications. The pre-designed turboset

enables early planning of the turbine build-ing layout, saving time for the customer. The turbine is used for both back pressure or condensing applications with internally controlled extraction and scope for several bleeds. Both back pressure and condensing turbines are available with upward or down-ward exhaust.

Inlet steam parameter:

• Inlet steam pressure up to 103 bar(a) / 1,495 psi

• Inlet steam temperature up to 505 °C / 940 °F




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161121 SIMPAG1606-03 Sugar - Siemens Global Website speed of single-stage steam turbines is notably...

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