Transcript Slide 1

S.U.D.S
2003 to 2009
From 5 Raw Sugar Factories to one
CANE – FLEXI Factory/Industry.
ASSCT –CAIRNS 2007
GUY MAUREL
TECHNICAL MANAGER
S.U.D.S
Mauritius Island showing
the cane cultivated areas .
B.VUE FUEL
MDA
MEDINE
B.CHAMP
6 SUGAR MILLS +/-5 MTONS CANES
4 COAL/BAG
P.PLANTS
2 BAG ONLY
P.PLANTS
Cane prod:1,6-1,7 Mts
SAVANNAH
Below an aerial view of
Savannah factory and the
power plant under
construction.
S.U.D.S –Societe Usiniere du Sud-created in 2003.
• SUDS was officially registered in 2003 following the merger of
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assets from five sugar mills to handle all canes from the south of
the Island [30 %].
Purpose was to reduce production costs in order to meet the
challenge of the world market on sugar prices .
The Mauritian sugar industry had a preferential price for its raw
sugar from the ACP protocol.
The uncertainty of this special price both in time and value was the
motivation to re-engineer and re-think about the SI in Mauritius.
The Industry had to find ways to reduce its cost of production
&develop new by-products from Cane in order to increase its
revenue and bring the SI into the 21st century .
Threats & opportunities of SUDS
• THREATS
• Reduction in the sugar price on export
• Reduction on the area of land under
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cane cultivation in Mauritius.
Unfavourable Forex
Small ‘old’ sugar mills
Labour intensive factories with low
automation.
Increasing production costs
Decreasing sugar revenue
High cost of Fossil fuels for energy
• OPPORTUNITIES
• Centralisation of milling activities ,one
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‘high capacity’ efficient mill
High tech fully automated factory to
decrease labour .
New market for refined sugars
New markets for special sugars &
sugar derived products
Increasing demand for Fuel alcohol
Energy production from Bagasse from
Co-Gen by using high pressure boilers
& steam turbines .
The Choice offered to SUDS in this difficult &
changing context .
• Do nothing and wait –would mean
bankruptcy in the short term.
• Invest heavily in the CANE industry and
take the challenge of the opportunities of
this changing industry .
• S.U.D.S opted for the challenge .!!
S.U.D.S Objectives for the period 2005-2010.
• Centralisation of milling activities in one 10,000 t/day mill operating
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180 days /year
Construction of a 100 MWe Bagasse / Coal power plant operating
year round to supply 650 GWe to the grid [175 GWh from Bagasse]
Construction of a 600 t/day sugar refinery operating all year round
Construction of an Alcohol [Fuel alcohol] distillery of 90,000 l/day
operating all year round from cane molasses ,with a potential
production of 30 M Litres /year .
Possibility to produce – Liquid fertilisers from Vinasse
Special sugars for markets
Rum and other drinking alcohol
2006- SUDS production from Cane
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Cane production
Mills in operation
Raw sugar
Special sugars
Refined sugar
Fuel alcohol
Molasses
Electricity ‘export’ to Grid
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1,600,000 tons
Four
160,000 tons
13,000 tons
Nil
Nil
45,000 tons
63 GWh [crop only]
Rose Belle
175 000 t
Riche En Eau
280 000 t
Closed 2002
Closed 2006
Britannia
180 000 t
Mon Trésor
250 000 t
Closed 2003
Closed 2006
275 000 t
Savannah
Up-graded
2006/07
1 680 000 t
Union
520 000 t
Will close 2007
(includes B.Ombre
& St Felix)
2009 - SUDS production from Cane
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Cane production
Mills in operation
Raw sugar
Special sugars
Refined sugar
Fuel alcohol
Molasses
Electricity ‘export’ to Grid
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1,680,000 tons
One
Nil / on demand P.W.S
13,000 tons
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13,5 M litres [all yr round]
Nil
172 GWh[bagasse]
450 GWh[Coal]
• 160,000 tons [all yr round]
The main steps to change five small raw sugar mills
into one Big ,modern ‘flexi –factory’ for the
production of :
• Raw sugar
• Plantation white sugar [PWS]
• Refined granulated sugar
• FUEL alcohol / Liquid fertilisers
• Electricity through Co-generation from
bagasse and /or Coal all year round .
SUDS restructuration plan
for the South of the island [Savannah mill]
Sugar & By-products.
• Simultaneous closure of both R E E and M T M D mills
after 2006 crop season & U S A mill the year after.
• Maintaining cane receiving platforms at the closed
mills
• Transfer of all the canes from the receiving platforms
to the upgraded Savannah mill by large payload lorries
(25 tonnes canes capacity), mainly during night hours
• Increase in capacity of the Savannah mill from 150
tonnes canes per hour to 425 tonnes canes per hour
(this will be done in two successive steps during the
2005-2006 and 2006-2007 intercrops)
Proposed restructuration plan
[ continued]
• Installation of juice sulphitation & syrup clarification
plant inside the factory for PWS production as from
2007 crop .[In view of the future sugar refinery]
• Installation of an AA alcohol distillery ,90,000 lts/day
,from molasses,in 2008 .Fuel alcohol for cars.
• Installation of a 600 t/day sugar refinery as from 2009
,operating all year round using PWS as input .
• Construction of warehouses to stock PWS / refined
sugar ,and an alcohol farm tank of 10 Mlts capacity .
SAVANNAH FACTORY UPGRADING FROM 150 TO 425 TCH
• Installation of a larger capacity cane shredder to guarantee optimal cane
preparation
• Installation of a cane diffuser followed by two stages of dewatering mills
to guarantee optimal sucrose extraction and 47% bagasse moisture
• The cane diffuser shall minimize the power requirement of the factory and
hence favour maximum power export by the nearby Power Plant
• Installation of quintuple evaporators to minimize exhaust steam
consumption of the factory and hence maximize power export by the
Power Plant
• Introduction of modern continuous boiling pans to minimize bled steam
consumption and favour automation of the Sugar Boiling process
• Installation of continuous centrifugals to minimize peak power demands
and ensure regular, optimal sugar quality
• The upgraded mill is also be fully automated in order to reduce the
possibility of human errors during processing, thus guaranteeing optimal
performance at all stages of sugar manufacture
Plan dif cx
NEW 10,000 TS /DAY Diffuser under
construction
New 45 X 90 de-watering mill & G.Box
New Clarifier & flash tank
New Kestners [1&2] under
construction .
Below new SS tubes for above .
New CVP – [A&C]
New ‘A&C’ centrifugals-Vertical ‘C’ crystalliser & massecuite
reheater.