SUGAR PLANT AUTOMATION
MILL HOUSE BOILING HOUSE REFINARY CENTRIFUGE CO-GENERATION
SKM Tycon Automation
Sugar Plant Overview
SKM
Tycon Automation
Mill House Automation
ACFC-Auto Cane Feed Control Preparatory Device Load Control
Belt Carrier & Cane Carrier Cascade Control
Mill Load Control
Chute Level Control Mill Load Control
Imbibitions Water Control
Water Flow Control w.r.t Crushing Rate
JFS-Juice Flow Stabilization
Tank Level Control Juice Flow Control
SKM
Tycon Automation
ACFC Screens
SKM
Tycon Automation
Mill Load Control Screens
SKM
Tycon Automation
Mill House Motor Locations & Control
SKM
Tycon Automation
Parameters For ACFC Unit 1&2
SKM
Tycon Automation
Parameters For Mill House Unit 1&2
SKM
Tycon Automation
Boiling House Control
Raw Juice Heater Temp Control Defecator Raw Juice Clarifier Defecated Juice Heater Temp Ctrl. Quad Body Bricks/Level Control Evaporator Continuous Pan/Batch Pan
Temp & Bricks Control
Molasses Conditioner
Bricks & Temperature Control
SKM
Tycon Automation
Quad Bodys Screen
SKM
Tycon Automation
Evaporating Station Screen
SKM
Tycon Automation
Batch Pan Screens
SKM
Tycon Automation
Continuous Pan Screens
SKM
Tycon Automation
Molasses Conditioners Screen
SKM
Tycon Automation
Refinery
Raw Sugar Melter
Temperature & Brix Control
Melt Clarifier
Flow, Chemical Dosing & Brix Control
Multi Bed Filters
Filtration & Auto Backwash Cycle
Ion Exchange Columns Control Brine Recovery System
SKM
Tycon Automation
Melting Station
SKM
Tycon Automation
Melt Clarifier Screen
SKM
Tycon Automation
Clarifier System
SCS-Syrup Clarifier System
Temperature Control Chemical Dosing Control
FCS-Filtrate Clarifier System
Temperature Control Chemical Dosing Control Temperature Control pH Control
SRT-Short Retention Tank
Dosing & pH Control (with JFS)
SKM
Tycon Automation
FCS Screen
SKM
Tycon Automation
CO-Generation
CONTROLS Boiler Drum Level Control Furnace Draft Control Combustion / Fuel Feeder Control O2/CO2 Control Atemperator Temperature control Deareator Level and Pressure Control PRDS & DSH Control Turbine Hot well level controller INTERLOCKINGS Interlocking of various equipments and devices Safety Interlocks Various devices control and interlocking such as Feed-water Pump, ID/FD Fans, Fuel Feeders MONITERING Interfacing to the Energy meters for the Load Monitoring Monitoring of various parameters of the Boiler and Turbine such as temperature and pressure, level, speed, load and frequency etc.
SKM Tycon Automation
Boiler Control & Monitoring
SKM
Tycon Automation
Water & Steam System
SKM
Tycon Automation
Deaerator System
SKM
Tycon Automation
PRDS Control
SKM
Tycon Automation
Combustion Control
SKM
Tycon Automation
Turbine Control & Monitoring
SKM
Tycon Automation
References For Sugar
Titawi Sugar: (Unit of Mawana Sugar) Centralised Control For
Unit1: Mill House, Boiling House, Continuous & Batch Pan, Molasses Conditioners, SCS, FCS,Boilres(1,2 & 3) Unit2: Mill House, Boiling House, Continuous & Batch Pan for Refined & Raw Sugar, SCS, FCS, Juice Heaters
Bajaj-Kinauni: Refinery, Syrup, Filtrate, & Melt Clarifier Renuka Sugar: ION Exchange (Athani) , Brine Recovery (Haldia) Bharat Sugar: Refinery DSM Sugar: Mill & Plant Drives, (SRT, JFS.(Mansoorpur / Asmoli / Rajpura)) JK Sugar: Mill & Plant Drives Kesar Sugar: Mill & Plant Drives, Fcs Palia Sugar: Centrifugal M/c Automation Balrampur Sugar: Fcs , Scs. Chemical Systems pvt. Ltd: FCS, SCS, MCS, MS, SRT, JFS, Ion Exchange, BRC, MBF Mawana Sugar: Boiling House, Refinery (Mawana). Shakti Sugar: Refinery. Assalaya Sugar- (Sudan) Cogeneration 13 MW Ugar Sugar: Fcs , Scs , Mcs. Bajaj Sugar: . Upgradation of Mill House and Boiler. AMC for Clarifier and Refinery: UDSM Shamli, Seohara, Oudh, Harinagar, Riga, Bardoli, Nanglamal, Titawi, Bajaj Kinoni.
SKM
Tycon Automation
Control Structures For Titawi Sugar
SATCOM Internet Firewall
DELHI
ADDITIONAL HARDWARE / SOFTWARE REQUIRED
485 TO 232 CONVERTOR
LOGGER
TSC / MAWANA
SQL Server
Boiler SCADA
Clarifier SCADA
Pc : INTERNET CONNECTIVITY Software : Web server Connectivity
TCP/IP MODBUS
ETHERNET BACKBONE
10Base2 or 10BaseFL
Approx 250 m
ETHERN ET MB+ BRIDGE
BOILER 1 BOILER 1&2 MODBUS
MILL MODBUS
PAN MODBUS
CLARIFIER MODBUS
ETHERNET MODULE / WEB SERVER MODULE
SKM
TITAWI CONTROL AND MONITORING ARCHITECTURE FUTURE PLAN
Tycon Automation
Control Structures For Titawi Sugar
SKM
Tycon Automation
Mill House Control System
Boiling House Control System
CASE STUDY Sugar Centrifuge
DC Drive Application
Sugar Centrifuge
Regenerative DC Drive
Centrifuge
Operation principle
Centrifuge separates particles from basic liquid The operation is cyclic, most motor power is needed for accelerating and decelerating Regenerative brake is needed
Centrifuge
What is actually being controlled?
The processing sequence duty cycle
Speed Control
Special requirements of the application?
High inertia to be accelerated and decelerated Regenerative drive for the efficient braking Often a part of the multiple drive system Demanding environment High reliability
Sugar Industry
RPM 1200 kW 800 300 200 400 100 Charging 0 -100 -200 -300
Centrifuge process cycle
Spinning
Speed (RPM) Power (kW)
+
Ploughing
3 -
Time 5
Benefits Centrifuge
Process Benefits
Optimum centrifugal speed gives high production of the right quality Increased production capacity No harm from the dusty environment Low energy consumption with regenerative unit = Cost of power per batch is minimised
