Overview

Sugar companies around the world rely on Sugars to make improvements to their factories. Sugars is a powerful tool to analyze and improve sugar factories and refineries. Because of its flexibility, it can calculate the material, heat and color balances of most sugar processes regardless of the process technique, or equipment used. Sugars has modeled thousands of processes for major sugar companies including both beet and cane factories and refineries in various parts of the world. These processes cover everything from simple evaporators and complex boiling schemes, to complete factories with sophisticated molasses desugarization systems. Sugars is used for beet and cane factories and refineries to:

Predict Operating Results

Sugars does material, heat and color balances

A Sugars model is made for an existing sugar process, factory, or refinery and the model is used by Sugars to simulate the process. The results from the simulation and actual process data are compared to verify the accuracy of the model. When the accuracy of the model is verified, changes can be made to the model to see if the performance of the process will improve by making the changes. Sugars predicts the change in operating results by doing the complete mass, heat and color balances while considering all changes in vapor-liquid, sucrose solubility and crystallization.

Make Investment Decisions

Sugars calculates net process revenues

Net process revenue is the difference in revenues from all products (sugar, molasses, bagasse, pulp, etc.) and the cost of all consumables (cane, beet, raw sugar, steam, water, chemicals, etc.). Net process revenue differences between original and changed processes are used to make decisions about investing financial resources to make the process changes and equipment purchases.

Revisions to a factory or refinery involving either changes in the process flows or equipment require capital investment by management. Using Sugars, management can quickly evaluate these changes and look at the net process and revenues generated by the factory for each of the proposed changes. Many times, within minutes management can evaluate the economics of an investment, and at the same time, evaluate the affect of the proposed change on the other areas of the process.

Provide Process Information

Sugars provides information about the process that can't be measured

Some flow streams in a factory cannot be monitored either because of their location, or because the data to be measured is not measurable with current instrumentation. Simulation can be used to determine some of the characteristics of these flow streams by inference from other flow streams that can be measured and checked against the results from simulation. Results from a Sugars simulation give full details about every flow stream in the process. This information may be necessary when designing equipment for the process, or to develop a more thorough understanding of the process.

Design Factories

Sugars can be used in the design of new factories

New factory designs are greatly enhanced with modeling and simulation. Building a computer model of a proposed factory allows alternate designs to be tried quickly and easily. The simulation results are used to see the advantages or disadvantages of the different alternatives. Changing the routing of a process flow stream is simply a matter of clicking on the flow stream with a mouse and moving it to another destination. Changing equipment simply requires changing the performance data for the station in the model and running another simulation to see the results.

Reconcile Data

Sugars can help to reconcile factory data

Factory data can be reconciled using simulation by comparing measured and simulated values. Data that is not consistent can be disregarded; thus, the integrity of measured data is improved with simulation. Crosschecking measured values can be helpful for identifying faulty measuring devices and reconciled data can result in management reports that are more accurate.

Increase Yield

Sugars can evaluate process or equipment changes to increase yield

Sugar yield can be increased by process and/or equipment changes. Change in the performance of equipment can be entered into the model and simulation done to evaluate the change in sugar production. Process changes, such as imbibition water for mills, filter press performance, different boiling schemes, and centrifugal performance can be modeled and simulated to evaluate how the sugar production would change. Molasses desugarization, ion exchange, membrane filtration, etc all can be modeled and simulated to evaluate their affect on the sugar yield.

Train Process Engineers

Sugars is used to train process engineers by helping them
learn the operating characteristics of the process

Process engineers can learn about the process while building the Sugars model that is used to simulate the performance of a factory, or refinery. Then, as changes are made to the process, the process engineer can observe the results from the changes and gain valuable operating experience that might otherwise take years to acquire from actual factory operations.

Reduce Energy

Sugars can help reduce energy consumption

Energy savings can come from many sources. Modeling and simulation allow rapid evaluation of each alternative to arrive at process and/or equipment changes that can reduce energy consumption of a factory. For example, bleed vapor for a pan, heat exchanger surface area, heat exchanger location in the process, wash water use (or syrup) for a centrifugal, imbibition water for a mill, or draft for a diffuser. These and other areas of the process can all affect the energy consumption and their impact can be quickly evaluated with simulation.

Evaluate R & D Projects

Sugars can be used to evaluate the economics of proposed projects

Research and development projects can be modeled and simulated before funds are committed. The expected performance of the new process or equipment is entered into the model and a simulation is made to evaluate its effectiveness for improving factory operations. Projects that show significant potential financial gains can be given a higher priority than those that are less attractive.


Operating Features

Sugars is the world's most widely-used sugar process simulator. Sugar companies use it to build models of their factories and refineries to realistically simulate their behavior. Users can quickly analyze hundreds, or even thousands, of design variations and refine their designs until the performance of their process is optimized. What used to take weeks, or even years, to analyze and test can now be done in hours using Sugars. Users have dramatically reduced the time and cost of making process improvements, while significantly improving the performance of their factories. Sugars is revolutionizing sugar process design for sugar companies, engineering firms and consultants.

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