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.