Information. Design and construction. of plants, machinery and. equipment for the. sugar industry, starch industry, chemical industry

Transcription

1 Information 40/2002 Design and construction of plants, machinery and equipment for the sugar industry, starch industry, chemical industry and food industry Environmental engineering Drying

2 Preface Dear Readers, Permit us to cast a brief glance back at last year and an optimistic view to the future: After several years of decline in your orders and consequently in our activities, last year eventually scored a noticeable increase in turnover. Considering the rather rigid market segment we are working in, this certainly is an improvement in our position in this market. We thank you for the trust you have put in our company and are grateful for your continued support. The restructuring measures we launched in our company last year are being supported, and even refined and perfected, by all our employees. BMA s full know-how is now available for each and every task and to each and every person. Additional intensive talks and discussions shall now convey and impart these positive effects to our old and our new partners in the whole world. Several weeks ago, we started to ask your opinion on the quality of our services and products. The BMA management requests your eager participation in this campaign, which we would like to be a permanent one. Give us your opinion! Your satisfaction and your benefit from our labours always come first. We have the firm intention to become even quicker and better in many respects. We expect that this issue of BMA Information, in its 40th year, will again attract great attention worldwide, and as usual it covers the previous year s technical highlights and most interesting events at BMA. We would be delighted if this new forward motion will contribute to maintaining your highly esteemed interest in our company. Yours sincerely, Braunschweigische Maschinenbauanstalt AG Dr. Rolf Mayer Frank Lohrer

3 BMA, SUGAR-Division 12 Fluidized-bed steam dryer for pressed pulp 15 BMA modernizes Moroccan beet raw sugar factory 16 Countercurrent cossette mixer upstream of horizontal extractor 7 Expansion of press station at Munzel sugar factory 8 Crystallization? Benefit from BMA s know-how 11 Vertical cooling crystallizers 12 Vacuum pans and centrifugals for Russia 13 BMA batch centrifugals of the B-series 14 New 2nd-white sugar drying and cooling plant at Ochsenfurt 16 Fluidized-bed sugar cooler for Monitor Sugar BMA, STARCOSA-Division 18 Jet extractor for the wheat starch industry 18 Plant for the production of crystalline fructose 19 New dextrose monohydrate plant for Pure Chem, Thailand BMA, TAG DRYER-Division 20 SBS-dryer in Meppel 22 Prilling tower for plastic additives 22 Potato flakes dried on TAG drum dryers 22 Preserving sugar production process BMA, Nederland 23 Process optimization by problem analysis 24 news & personalities 1

4 Fluidized-bed steam dryer for pressed beet pulp SUGAR-Division Steam dryer of size 10 at Klein Wanzleben By tradition, Braunschweigische Maschinenbauanstalt AG are manufacturers and suppliers of plants, machinery and equipment for industrial-scale processing of renewable raw materials, and one essential item in BMA s line of supplies and services is the drying technology, which is found in BMA machines in a large range of applications and principles. BMA dryers are available for the sugar and starch industries and the food industry in general and for the production of aromas and chemical products. In March 2001 BMA acquired an exclusive worldwide licence covering the manufacture and sale of a high-capacity fluidizedbed steam dryer for the sugar industry. Of this type of dryer, which Niro A/S had hitherto been selling to the sugar industry as well, 12 units are installed at European and US sugar factories. Only a few months after the know-how had been taken over, BMA received an order from Nordzucker AG, Braunschweig, Germany, for the supply of a fluidized-bed steam dryer (FSD) for pressed sugar beet pulp, which will go on stream at the Uelzen sugar factory in the 2002 campaign. In Nordzucker AG, BMA won the support of a customer, together with whom, and on the strength of an excellent partnership relation and certainly due to the closeness of the factory sites, BMA has over many years been able to realize a great number of innovative and successful reference projects. This dryer, which is presently being manufactured at BMA s shops, has been subjected to progressive development in several respects. This refers, in particular, to its drying capacity which at a water evaporation of 50 t/h in the new size 12 unit is 25% higher than that of previous plants. As compared with conventional hightemperature pulp dryers, the fluidized-bed steam drying technology has the essential advantage that more than 90% of the energy introduced can be recovered, which means a substantially reduced environmental impact. Technologically, the drying plant has the following components: Fluidized bed with product inlet and outlet Cyclone dust separator Heat exchanger to superheat the circulation steam by means of heating steam Fan with drive Distribution plate to distribute the circulation steam in the cellular fluidizing bed. Details of the fluidizedbed steam dryer 2

5 Balance of fluidized-bed steam dryer of size 12 Water evaporation 50,000 kg/h Steam 70,710 kg/h Heating steam 70,110 kg/h 26 bar abs. 231 C Ejector steam 600 kg/h 26 bar abs. 231 C Vapour 50,600 kg/h 3.8 bar abs Condensate 70,110 kg/h Benefits Most energy-saving method of pulp drying Water evaporation up to 50 t/h Use of standard motors for the fan wheel Optimized flow pattern BMA can provide every pulp drying technology Pressed pulp 75,000 kg/h 30 % DS 50 C Dried pulp 25,000 kg/h 90 % DS Fan power required 1,062 kw In the BMA fluidized-bed steam dryer, these components are extremely compact. In addition to the energy that the heat exchanger transfers to the circulation steam, further energy is transferred into the bed via heating panels. This direct contact of the pressed pulp with the heating panels provides for most efficient heat transfer. The bed of fluidized pressed beet pulp forms in an annular space surrounding the central heat exchanger. The stream of circulation steam required for this purpose is generated by a fan arranged below the heat exchanger. The diagram shown above is a typical balance of a size 12 fluidized-bed steam dryer operating at an absolute heating steam pressure of 26 bar. At a water evaporation of 50 t/h, the dryer can therefore process 75 t/h of pressed pulp containing 30% dry substance into dry pulp containing 90% dry substance. BMA s progressive development of the dryer is focussed, in the first place, on improving its availability during the campaign. Essential modifications, besides other design details, are: Fan drive and bearing modifications allowing the use of a standard motor and permitting motor repairs without the need to open the dryer New diameter/height ratio optimizing the fan rotor for the operating point Most advanced numerical computation methods to improve the degree of fluidization required for pressed pulp drying Design and size of inlet and outlet locks, based on the proved operating principle, adapted to the size 12 dryer to cope with the higher pulp throughput

6 SUGAR-Division Two feeder screw conveyors to supply the pressed pulp into the first bed cell to reduce the danger of choking in this area. A size 12 fluidized-bed steam dryer can process all the pressed pulp resulting from a beet slice rate of 10,000 t/d into dry pulp. For smaller drying capacities BMA can supply sizes 8 and 10, the design of which has also been optimized. The diagram below shows the water evaporation capacities of the different dryer sizes subject to the heating steam pressure. This new product and the order placed for it will both challenge and stabilize BMA s highly qualified technological and technical capabilities. Considering the great interest, worldwide, in the fluidized-bed drying technology for pressed pulp, it is of great importance that BMA has the certification for manufacture according to AD Code of Practice HP 0 and to ASME with U stamp for pressure vessels, and is thus qualified for the realization of complete FSD projects. Fluidized-bed steam drying, in addition to high-temperature and low-temperature drying, now enables BMA to offer a complete range of new and conventional pressed pulp drying technologies. For the customer this opens up the possibility to choose one technology and the associated equipment from this range and to have it optimally adapted to his specific requirements such as the sugar factory s processing rate or energy balance. BMA is the customer s competent partner in providing advisory services to elaborate an economically and technically perfected solution. Dr. Lothar Krell Water evaporation vs. heating steam pressure Water evaporation (t/h) Size 12 Size 10 Size Heating steam pressure, absolute (bar) 4

7 BMA modernizes Moroccan beet raw sugar factory In the spring of 2001, BMA was awarded an order from Cosumar, Compagnie Sucriere Marocaine et de Raffinage S.A., Morocco, for conversion of the Sidi Bennour beet sugar factory to the production of white sugar. The order covers the supply of the complete white sugar station, as well as equipment required for modernization of the existing raw-sugar, low-raw sugar and evaporator stations. BMA will supply the following equipment: one vertical 4-chamber vacuum pan for continuous production of 2nd-white sugar massecuite one batch pan for the production of seed magma three batch centrifugals for 2nd-white massecuite, for 1,750 kg/charge each one fluidized-bed dryer/cooler for 2nd-white sugar, plus ancillary equipment such as filters and conveyors two continuous centrifugals of type K 2300 M for raw and low-raw massecuite one vertical 3-chamber vacuum pan for continuous production of low-raw massecuite one vertical cooling crystallizer, equipped with oscillating cooling tubes, for low-raw massecuite one falling-film evaporator providing 3,000 m² heating surface various mixers, pumps, heat exchangers, tanks and ancillary equipment Benefits Engineering and equipment from one single source Optimized energy economy Short construction time Integration of locally manufactured equipment The time between the day the contract was signed in May 2001 and the scheduled commissioning at the end of April 2002 left less than 12 months for engineering, manufacture of the equipment and assembly/erection. This is an extremely short time for a project of this size. Cosumar s and BMA s project teams were constantly exchanging planning documents via the Internet, thus enabling the partners on the other side to continue their work without delays. Part of the equipment was fabricated by Moroccan companies under the supervision of BMA. The equipment supplied by BMA is assembled and erected in conformity with the schedule established by the customer and BMA, and this work is supervised by BMA personnel. After numerous orders for centrifugals and massecuite pumps, BMA now has been awarded a contract for a major project in Morocco. Steffen Kaufmann / Bernd Stolte A contract is signed by Carl-Gerrit Deilmann, Mohamed Lazaar and Mohamed Jawad Khattabi (from left) The contract also covers extensive design and engineering work for incorporation of the new equipment into the existing factory. Another task, in addition to the conversion to white sugar production, is to improve the energy economy of the factory. The ambitious goal is not to allow the factory s steam consumption for white sugar production to rise beyond that for raw sugar production. During erection 5

8 BMA countercurrent cossette mixer upstream of horizontal extractor SUGAR-Division Circulation juice % o.b. Press water Installation of the cossette mixer Cossettes Defoamed juice 80% o.b. Fresh water Gas Optimization Raw juice of the horizontal extractor Wet pulp For the 2001 campaign, another BMA countercurrent cossette mixer installed upstream of an RT drum extraction plant has successfully been commissioned at the Coruche sugar factory of Sociedade de Desenvolvimento Agro-Industrial S.A. (DAI), Portugal. The design capacity of the mixer is 6,000 t/d. This combination of a countercurrent cossette mixer and an RT extractor fits into quite a number of plants, which have been built and employed worldwide since 1980 in different sizes. Since 1980, BMA has supplied and commissioned a total of 15 such countercurrent cossette mixers to Belgium, France, Ireland, Italy and Spain. The 16th plant for the Linares sugar factory of Azucareras Reunidas de Jaen S. A., Spain, is under construction and will be shipped in the second quarter of Apart from the fact that it substantially improves the overall energy balance by the production of cold raw juice, a countercurrent cossette mixer installed upstream of a horizontal extraction unit has the additional effect that the thermal preparation of the cossettes is much better at the time they enter the extraction drum. This extends the extraction length proper, which in turn means less raw juice draught at the same extraction losses or reduced losses at the same draught. BMA received the order for Coruche/ Portugal, in November The plant was shipped on schedule in April 2001 and, after smooth assembly and installation, went on stream in July 2001 in due time for the campaign. Günter Pohner Benefits Reduced energy consumption by cold raw juice Reduced extraction losses 6

9 Expansion of press station at Munzel sugar factory The presses of 1993 and 2001 Nordzucker AG, Germany, has awarded BMA another order for the supply of a vertical pulp press of type HP 4000 L for their Munzel sugar factory. The excellent experience they have gathered from the HP 4000 press installed in 1993 and operating since then without any trouble, has certainly contributed much to their decision to employ another BMA pulp press, which has persistently been improved over a period of almost 10 years. Now the prototype supplied in 1993 stands beside the latest model of this successful series. In the 2001 campaign, no short-time or even long-time press failures have been reported. In some respects, the design of the press, i.e. the spindle contour, the shape of the screen surface, the drive concept and some other components, have been decisively improved over the previous model, which means a great advance in terms of technological results. In addition, many details have been improved with a view to minimizing maintenance costs and requirements. When the campaign is over, nothing has to be done for many years than just clean the press. To date, this standard BMA has achieved is unequalled. The HP 4000 L pulp press installed at Munzel for the 2001 campaign is basically identical with the one that went into operation in 2000 at Südzucker AG s Ochsenfurt sugar factory (see BMA Information 39/2001), though the screen surfaces have again been improved. After on-schedule installation of the press for the 2001 campaign, it went through a successful performance test and has handled an average pressed pulp throughput of 31.5 t/h for a final dry substance content of some 32% (see diagram). The new BMA HP 4000 L pulp press installed at the Munzel factory is the final link in the pressing process chain; its throughput can be conformed to the wet pulp produced as and when required. This expansion of the pressing station now is a great thermal relief to the pulp drying plant, as the pressed pulp supplied to the dryer has a higher dry substance content. Rüdiger Hille / Timm Ibs Pressed pulp (t/h) Benefits High throughputs High dry substance content >32% Extremely reliable Minimum maintenance and repair costs Technical data of HP 4000 L pulp press Drive power installed 10 x 55 kw Overall height* approx. 19,400 mm Length of spindle 13,900 mm Outside diameter 5,000 mm Dia. of screen basket 4,000 mm Nominal torque 10,600,000 Nm Operating torque 8,600,000 Nm * incl. pressed pulp hopper HP 4000 L performance test 31,0 31,5 32,0 32,5 33,0 Pressed pulp (% DS) Meas. values Performance curve Avg. performance 7

10 Crystallization? Benefit from BMA s know-how! SUGAR-Division Automation of the crystallization process and of the other process steps involved Largely continuous operation of the crystallization process Reduction of primary energy consumption Minimization of maintenance and repair costs. Crystallization is the essential technological step in the production of crystal sugar to recover the sucrose dissolved in the thick juice. Over the past 20 years, BMA has intensively dealt with the technical and technological development and advancement of crystallization equipment and methods and set itself the following goals: Provision of equipment which can cope with today s demands on industrial-scale production of foodstuffs Flexible and modular design of components, allowing to offer individually and optimally composed crystallization equipment and plants on a fast and competitive basis Development of equipment for high sugar yields and for the production of high-quality sugar The core item of the crystallization equipment BMA has on offer is the vacuum pan equipped with a stirrer and designed for internal circulation (see drawing). This pan, which from a technological point of view is an ideal stirring vessel, has won through in the world s cane and beet sugar industry for the crystallization of sugar. The fact that many, even older, vacuum pans are now being retro-fitted with stirrers emphasizes the great importance of mechanically assisted circulation in sugar crystallization. The double-conical bottom, by its streamlined design, contributes to better circulation of the massecuite and at the same time provides a small starting volume. A special calandria manufacturing technique allows the provision of more heating surface per square meter of tube plate than conventional techniques. In addition, this goes along with a considerable reduction of incrustations in the continuous process. Optimized steam flow in the calandria and forced dissipation of non-condensible gases provide for constantly efficient operation of the pan. The vapour chest is equipped with an integrated entrainment separator, which stands out for its excellent efficiency. The calandria, i.e. tube plates, heating tubes, downtake and baffles, can be made in mild steel or stainless steel, subject to the product involved and the customer s requirements. The other components of the pan can be in mild steel, stainless-steel clad mild steel or solid stainless steel. 8

11 Stand-alone units of this BMA vacuum pan are employed for the production of seed and for batch crystallization of all massecuites in the beet and cane sugar industry. BMA s vertical continuous vacuum pan normally consists of four or five seriesconnected units or chambers of the aboveoutlined design. Chamber-wise composition of the continuous pan allows the layout to be conformed to local conditions. The chambers can be placed one on top of the other (VKT) or side by side (VKH). It is even possible to place two chambers on top of another two. Simple setpoint control systems allow individual adjustment of the crystallization conditions in each chamber. For cleaning purposes, one VKT or VKH chamber is disconnected from the process, while crystallization goes on in the other chambers. By raising the massecuite level and by increasing the heating steam pressure in the three or four remaining chambers it is possible to maintain the throughput at almost the same rate. Numerous measures have been taken to extend the intervals between chamber cleaning cycles. The biggest vertical continuous vacuum pan BMA built so far can produce 175 t/h of 2nd-white sugar massecuite. Every continuous vacuum pan is designed for retrofitting a fifth chamber, permitting easy increase in throughput at a later date. Benefits Energetically and technologically optimized designs Reduced energy requirements Largely continuous operation High sugar yield Large range The two upper chambers of a VKT Optimized vacuum pan 9

12 SUGAR-Division A low massecuite level and forced circulation of the massecuite by stirrers allows operation at very small temperature differences between heating steam and massecuite, which means reduction of primary energy consumption and production of massecuites with a high crystal or dry substance content. A particularly energy-saving technology is BMA s double-effect pan boiling process, where the pan vapours from B- and C-massecuite crystallization are used for heating purposes in whitesugar crystallization. (For details, see BMA Information 33/1995 and 34/1996.) BMA s continuous vacuum pans are successfully employed in all crystallization stages in the cane and beet sugar industry. In 2001, BMA supplied: One 5-chamber VKT for 2nd-white sugar to Union-Zucker Südhannover GmbH, Nordstemmen. (Apart from this VKT, Nordstemmen s crystallization station presently has a continuous VKH for rawsugar massecuite, a VKT for low-raw massecuite, and batch pans for 1st-white massecuite.) One 4-chamber VKH for raw-sugar massecuite and one pan for 2nd-seed magma for the Frauenfeld factory of Zuckerfabriken Aarberg / Frauenfeld, Switzerland (since 2000, Frauenfeld already has a low-raw massecuite VKT). One 2nd-white VKT and associated 2ndseed batch pan, for the Doukkala factory of Compagnie Sucrière Marocaine et de Raffinage S.A., Morocco. (These pans were supplied in connection with an order BMA received for conversion of the Doukkala factory from the production of raw sugar to the production of 2ndwhite sugar.) Besides batch pans and continuous pans, BMA s range also includes discontinuous cooling crystallizers for the production of low-aggregate 1st-seed magma, efficient cooling crystallizers for low-raw massecuite, and many other items of equipment for the crystallization of sugar. BMA s extensive and flexible supply line helps solve many crystallization problems. Heinrich Hartmann The new VKH cascade at Frauenfeld

13 Vertical cooling crystallizers Vertical cooling crystallizers equipped with oscillating cooling elements (VCC) are winning more and more recognition in the world. In the course of the past 18 months, BMA commissioned, or received orders for, the following VCCs: This great demand is another indication of the outstanding advantages of the VCC technology. The special design of the massecuite distributor and the optimized massecuite discharge provide for an excellent residence time spectrum. Together with uniform and gentle cooling, it is possible to obtain very high crystal contents and, consequently, to substantially reduce the molasses purity. At the San Nicolas sugar factory in Mexico, for example, the reduction in molasses purity was approx. 4% on a yearly average. Subject to the duration of the campaign and the molasses purity difference, the capital the factory invested will soon pay off by the higher sugar yield. As the VCC allows cooling of the low-raw massecuite down to 40 C, its viscosity must then be reduced again considerably for smooth conveyance and centrifuging. The ideal means to this end is the BMA molasses/massecuite mingler which is fed with almost saturated heated molasses; Benefits Distinctly reduced molasses purity Reduced incrustations due to moving cooling tubes /self-cleaning effect Controlled massecuite viscosity due to molasses/massecuite mingler Quick return on investment almost no damage of crystals and melting of sugar. The current of the molasses/massecuite mingler stirrer is used to control the quantity of molasses to be added, thus preparing the massecuite in an optimum manner for separation in the centrifugals. A molasses/massecuite mingler therefore dispenses with a heating zone in the VCC. A detailed description of the VCC system providing features and advantages can also be found in BMA Information 35/1997 and 37/1999 and especially in BMA s Crystallization plants brochure. By the way: You can download this brochure from our homepage at / Brochures. Jörg Schmidt / Steffen Kaufmann Vertical cooling crystallizer and molasses/ massecuite mingler in Japan Factory Country Volume Cane/beet San Nicolas Mexico 330 t cane Risaralda Colombia 330 t cane Olmedo Spain 981 t beet Nitten Memuro Japan 243 t beet Sidi Bennour Morocco 330 t beet Elsdorf Germany 612 t beet Konya Turkey 712 t beet Frauenfeld Switzerland 510 t beet Savannah USA 330 t cane Liepaja Latvia 330 t beet Marijampole Lithuania 330 t beet 11

14 Vacuum pans and centrifugals for Russia SUGAR-Division Licence for the manufacture of vacuum pans Benefits Pans complete in stainless steel Extremely short erection GOST certification Less energy consumption and higher sugar quality In late 1999, BMA received an order from the Wyselki sugar factory, Russia, for reconstruction of its white-sugar station. Wyselki is among the 16 most successful factories in the Krasnodar area, which essentially contributes to Russia s supply with sugar. BMA has excellent references in this area: Close by there is the Timaschewsk sugar factory which BMA built more than 30 years ago and which still is the biggest and most productive factory in the Krasnodar district. The essential items of the contract were four new vacuum pans for 60 tons each, the associated condenser, and four white-sugar centrifugals of type B At the customer s request, the vacuum pans are in stainless steel throughout, and for the very first time in this area, pans of this size have been equipped with forced-circulation systems. The white-sugar centrifugals are the first machines of the new B-series ever supplied to Russia In addition to technical and technological requirements, the reconstruction of the white sugar station meant considerable organizational and logistical challenges to the parties involved. Things were so difficult because the factory operates a 3-month beet campaign plus a 6 to 7-month cane raw sugar processing campaign. As a result, there were only about 6 weeks left for demolition of the old and installation of the new equipment. For this reason it had been agreed that BMA would manufacture the vacuum pans as complete units and deliver them to the site by sea; the centrifugals were simultaneously carried there by land. It should be emphasized that for manufacture of these pans and centrifugals in accordance with the import regulations of the Russian Federation and the regulations for pressure vessels, BMA had to be certified first in conformity with current GOST standards. The permit for operation of the pan, which had to be issued by the local inspection authorities, was obtained by close co-operation between the factory and BMA. The concerted efforts of all those involved made sure that installation was completed on schedule and the new equipment could be optimized for beet processing during a short raw sugar campaign. The customer completed the station with an automatic boiling process system and a new strike receiver manufactured according to BMA specifications. As early as after the first campaign it was proved that the new equipment has a great positive influence on both the factory s energy consumption and the sugar quality. Harald Veleta The vacuum pan under construction at BMA s shops

15 BMA batch centrifugals of the B-series Left: Centrifugals at Laredo/Peru; right: at Pongola/South Africa Benefits Stainless steel as standard Extremely short discharge time Integrated syrup separator Very high efficiency Progressive development Since the time they were successfully launched, more than 115 BMA centrifugals of the B-series went into operation at sugar factories worldwide, e.g. in Austria, China, Dominican Republic, France, Germany, Italy, Mexico, South Africa and the USA. These machines have proved a success under most different conditions and have operated for several years to the customers full satisfaction. Many customers placed follow-up orders for centrifugals of this series. The B-series, designed for 1,100 kg, 1,300 kg, 1,500 kg, 1,750 kg, 1,900 kg and 2,200 kg of massecuite, fulfills the customers each and every wish, from small to big machines. It incorporates quite a number of innovative solutions and designs. Previous issues of BMA Information (37/1999, 38/2000 and 39/2001) provided detailed reports and information of advanced components such as the basket, bearing system, screens used, discharger, syrup separator, control hardware and software, operator panel, and centrifugal drive. High-lights are: Product-contacted parts of the centrifugal housing in stainless steel as standard Novel discharger design, drastically reducing the discharging time and allowing more cycles per hour, without the need for a more powerful drive New syrup separator integrated in the centrifugal for optimum separation of the syrup and, consequently, reduced recirculation of colour and nonsugars in the wash syrup, and for adjustment of the required green syrup purity, which results in a distinctly reduced massecuite quantity in the following crystallization stage. In addition, BMA offers several options for both the mechanical and the electrical equipment, e.g. the innovative BMA drive system. A team of specialists is continuously occupied with the progressive development of these components, so that the customers can be served from one single source. For those customers who, due to their local markets and to electrical equipment already installed in their factories, give preference to a certain brand, BMA can offer appropriate customized solutions. Systematic standardization of most centrifugal assemblies to reduce the number of parts involved, use of more standard parts, and utilization of advanced production planning software (PPS) provide for smooth manufacturing sequences and shorter deliveries. The centrifugals are designed and constructed in compliance with the world s most stringent safety regulations so as to ensure utmost reliability in operation. All in all, this reliability, the high efficiency and the low maintenance requirements of BMA centrifugals mean that capital expenditure and operating costs result in an extraordinarily small sum. Enquiries for spare parts can now be made via the Internet: Just go to / Service / Spare parts. The services as outlined above clearly indicate BMA s position as the world s leading developers and manufacturers of batch and continuous centrifugals. Dr. Mohsen Makina 13

16 New 2nd-white sugar drying and cooling plant at Ochsenfurt SUGAR-Division The Ochsenfurt factory of Südzucker AG, Germany, had been faced with the necessity to replace its 2nd-white sugar drying and cooling plant and at the end of the 2000 campaign, BMA received an order to supply and erect a new plant. In view of the awkward layout inside the building, the customer decided in favour of a plant which consists of a drum dryer combined with a fluidized-bed dryer arranged underneath. BMA s supplies covered: Wet-sugar feeder screw conveyor Cocurrent drum dryer for a sugar throughput of 80 t/h Fluidized-bed cooler, including input-end and output-end rotary air locks Heat exchanger for ingoing air Filter of class F7/G7 for ingoing air Pipelines for ingoing air Fans with silencers for ingoing and outgoing air Setting up the equipment in the building in cramped conditions and with difficult accessibility was not an easy task and required special measures: No cranes could be used to move the dryer and the fluidizedbed cooler to their final location in the building. As ordered, the drying and cooling plant was commissioned in time for the 2001 campaign, and throughout the campaign the BMA components operated without any trouble. The figures guaranteed for the plant were successfully proved during a 2-day performance test. Lifting blades are the only internal components of the dryer drum. The dryer always produced a residual sugar moisture well below 0.03%. The drum is driven via a gearbox and a ring gear welded to the drum. Sturdy riding rings, together with a rigid support structure, make sure that the drum operates very smoothly. Exactly adjusted trunnions provide for a long service life and low wear. The cooler reliably fluidizes the sugar above the specifically designed screen bottom, and the intense contact of the cooling air with the sugar results in excellent cooling. The height of the fluidized-bed is determined by the discharge weir. Any lumps of sugar which might form during the drying process can be removed from time to time by opening it manually. The control system of the plant comprises five special matching control circuits for: ingoing-air temperature; aspirated air dried in a condensate-heated preheater exhaust-air temperature, dried in the cooling-air heaters sugar temperature at the cooler outlet by the cooling-air preheaters vacuum in the dryer drum generated by the axial ingoing-air fan bed fluidization pressure by the cooler exhaust air fan. The well-tried concept of a drum dryer and fluidized-bed cooler combination has again proved a great success - even in very cramped conditions. Dr. Andreas Lehnberger Benefits Smooth rotation of drum Minimized wear Proved drum-dryer / fluidized-bed cooler combination Transport and...

17 ... completion of the drum dryer 15

18 Fluidized-bed sugar cooler for Monitor Sugar Co. SUGAR-Division The old entrance building In 1989, BMA integrated the fluidized-bed drying technology in its product range. Since then, 43 units have been put into operation worldwide. Another four units are in the construction phase at present. In connection with an intended increase in capacity, maintaining the high product quality in their existing sugar drying and cooling plant, Monitor Sugar Co., Michigan, USA, has entrusted BMA with the overall planning and with modifying / supplying the following equipment: Modification of the existing drum dryer/ cooler (2.8 m dia x 16.5 m) to serve as a real drum dryer Supply of a fluidized-bed sugar cooler Dust separating system for the cooler exhaust air Fresh air filter and exhaust air fan Pipeline engineering. In connection with the new project, the existing BMA drum dryer/cooler (built 1985) was converted into a real drum dryer. Internal lifting facilities in the area of the former cooling zone were updated so as to ensure optimum drying at an increased throughput. When the capacity had been increased to a sugar throughput of 60 t/h, the residual moisture of the sugar leaving the modified drum dryer was still < 0.03% at a mean crystal size of MA = 0.4 mm. To provide for efficient cooling, a fluidized-bed cooler was installed downstream of the drum dryer. Via a specially designed distributor plate, air passes through the granular product to be cooled, the voids volume in the product bed being adjusted in such a way that the individual crystals are fluidized and move very turbulently. The high mixing efficiency is not achieved with additional mechanical drives, but only by the streaming air. When the air streams have passed through the sugar bed, they unite in the separating chamber of the cooler, where entrained sugar crystals are recovered from the exhaust air. A specific feature of fluidization, at a defined velocity, is the gentle treatment of the crystals retaining their brightness and avoiding abrasion, which in turn means only little dust. Details of the fluidized-bed cooler

19 The fluidized-bed cooler practises the suction technology, its great advantage being that the cooling air temperature does not rise by increasing the pressure of a fan, which in turn minimizes the differential temperature between ambient air and cooled sugar. Fluidization of the sugar crystals allows to utilize almost the full product surface as a contact surface for the cooling air. Hence results an intensive heat and mass transfer for highly efficient dissipation of the product heat. Subject to the cooling air temperature range, the sugar is cooled to the design temperature of C, related to an ingoing sugar temperature of 55 C. As an energy saving measure, the cooler exhaust air - separated from dust - is recirculated and is then used to preheat ambient air to the temperature allowed for entry into the fluidized-bed cooler. Despite ambient air temperatures as low as -12 C, it is thus possible to fully dispense with heat exchangers in the air suction route. The two drying zones in the drum dryer are also supplied with recirculated air from the cooler, which is another BMA contribution to minimization of energy requirements. No other dryer/cooler combination yields equally good results. The combination we selected, i.e. a rotary dryer and a downstream fluidizedbed cooler, is a mechanically simple solution which utilizes the specific technological advantages of both the rotary dryer and the fluidized-bed cooler. If the respective requirements can be met, such measures allow to increase the throughput of existing plants by up to 1.5 times. The plant was put into operation for the 2001 campaign under the supervision of BMA specialists and could immediately be integrated in the regular production process. Carsten Klemp Benefits Planning and realization from one single source High utilization of the sugar s intrinsic heat Reduced sugar cooling by countercurrent drying Less consumption of heating steam by using cooler exhaust air Low expenditure for maintenance and repairs Views into the modified drum dryer

20 Components for the starch industry STARCOSA-Division Jet extractor for the wheat starch industry After it had tested a STARCOSA 3K10 jet extractor for one year, Manildra Group, Auburn, New South Wales, Australia, replaced its existing screening station by a new screening and washing station consisting of five jet extractors. These jet extractors were delivered at the end of 2001 and will be used in the separation of fine fibres. The particle size of these fibres separated from the wheat starch milk is >60 µm. These STARCOSA machines, which reckon among the slide-screen centrifuges, are available as jet extractors and jet refiners. The machines have an integrated washing system, which means screening, centrifuging and thorough washing with water under pressure can proceed in one go. This integrated washing system allows starch milk screening and fibre extraction at a substantially reduced water consumption. The machine housings have no dead corners where product can deposit and where germs and fungi can develop. This involves an essential advantage for the customer, as cleaning intervals can thus be much longer. Novel sintered stainless-steel screens ensure a long service life and reduce the percentage of coarse matter in the filtrate. The totally enclosed design meets the requirements of highly hygienic production and so makes hygiene management much easier for the starch producer. Benefits High level of hygiene Long screen service life Efficient separation of fine fibres Plant for the production of crystalline fructose In 2000, STARCOSA received an order from Turkey for a crystallization system and a centrifugal station for the production of crystalline fructose. The contract covered not only the key components, but also technological know-how for fructose crystallization, which of course is the core item of such a plant. The raw material used in the production of crystalline fructose is a 95% fructose syrup made from saccharified corn starch. The necessary peripheral equipment was locally fabricated by the customer himself, on the basis of BMA engineering and in close cooperation with BMA. Assembly and installation of the crystallization system and of the centrifugal station was completed in the summer of Commissioning of the two crystallizers and the two B 1750 centrifugals, which followed immediately thereafter, was largely accomplished by specialists of the Turkish customer and therefore only required short-time assignments of BMA experts. Commissioning went so successful that the customer, on his own accord, renounced the contractually agreed guarantee run. Since the middle of 2001, the customer continuously produces crystalline fructose, which he supplies also to his factories in West European countries for use in the refinement of various other products. Jet extractor for Australia Benefits Integration of equipment locally manufactured according to BMA basic engineering Commissioning largely accomplished by the customer Customer s quality expectations greatly exceeded 18

21 Basic design of a cooling crystallizer New dextrose monohydrate plant for Pure Chem, Thailand In 2000, Pure Chem Co., Ltd., Bangkok, Thailand, one of STARCOSA s good customers since the eighties, has ordered from STARCOSA a vertical continuously operating cooling crystallizer to double its production of dextrose monohydrate. The order also covers know-how, detail engineering for a horizontal pre-crystallizer, as well as basic engineering for the crystallizer periphery and measuring and control equipment. To date, Pure Chem has been using the previous version of the continuous STAR- COSA crystallizer, which was a disk type equipped with scrapers. However, the new vertical oscillating crystallizer has also been successfully employed in the production of dextrose monohydrate and crystalline fructose, and - regardless of the equipment already installed - the customer therefore decided in favour of the advanced version. It is an essential advantage of the STAR- COSA crystallizer that in spite of the absence of mechanical scrapers, it suffers hardly any malfunctions caused by product deposits. The multi-stage cooling system integrated in the crystallizer allows the operator to adjust a highly discriminating temperature profile precisely conformed to the product requirements - a feature no other crystallizer can offer. Assembly and erection of the crystallization plant was supervised by STARCOSA specialists and was professionally accomplished by Pure Chem s highly cooperative staff within a very short time. Commissioning, also accompanied by STARCOSA specialists, took place in December The customer is most delighted that the dextrose monohydrate crystallized in the new plant is much coarser than that produced in the old plant. This advantage of the STARCOSA crystallizer facilitates separation of the mother solution and provides for more efficient centrifugation. Wilfried Bartsch (3) Benefits Precise adjustment to the customer s requirements Fast assembly and erection Production of coarse crystals

22 Spray-belt dryer in Meppel TAG DRYER-Division The city of Meppel, in the South West of the Drenthe province, The Netherlands, is the domicile of Zuivelfabriek De Kievit bv, which was founded in 1984 and, since 1999, belongs to Friesland Coberco. Initially, the company was in the milk drying field, but in the past 20 years Kievit has changed into one of the biggest suppliers of dried ingredients for the food industry. The cornerstone of the company s positive development always has been and still is the conversion of innovative ideas into new products. Among these are basic materials for instant drinks, coffee whiteners, new recipes for soups and sauces, various fat powders for bakeries, flavourings for chocolates and ice creams, as well as functional food additives. New products always call for extra development work. The long way from the first idea to production is characterized by a huge number of laboratory and research unit tests. The production of representative samples at an industrial-scale plant such as Kievit s requires at least 5,000 kg of wet matter, and the outcome of test productions is always afflicted with uncertainty. For the production process Kievit has three spray-belt drying plants for water evaporation rates between 1,500 and 2,800 kg/h. Consequently, the percentage of non-usable dry matter can be relatively high. The TAG pilot spray-belt drying plant Kievit now purchased, and successfully commissioned, is a research-unit dryer which requires only very small quantities of test material and thus speeds up the development of new products. A wet product quantity of 150 to 200 kg is sufficient for this pilot plant to produce representative samples, as its temperature/time behaviour compares to the conditions prevailing in an industrial-scale drying plant of this type. This was one of the weightiest arguments for Kievit to purchase the plant from TAG DRYER-Division. Another argument was the dryer s high flexibility. As BMA s own research centre in Braunschweig has a dryer of the same type and capacity which is available for tests and experiments, the customer could be convinced of the plant s performance on the spot. The TAG spray-belt system combines the advantages of a spray dryer with those of a belt dryer. The fact that the drying process proper is divided into several separate drying zones allows optimum adjustment and individual control of the drying parameters by separate air streams and separate air conditioning. Primary drying / spraying zone A high-pressure nozzle atomizes the product to be dried in the primary drying zone, where most of the water is removed from the wet product and the particle structure begins to form. The product, which at this point has a relatively high residual moisture content, drops down on a special airpermeable conveyor belt. This belt then conveys the product layer into downstream drying and cooling zones. The drying air required for the primary drying zone is supplied by two separate systems, i.e. their air streams only merge in the drying zone itself. It is possible in this way to conform both the quantity and the temperature of the air in the product atomization area to the requirements of the wet product. In the spray-belt system, the total drying air is sucked through the product layer and the belt and is then dissipated underneath the belt. The product cake on the belt acts as a filter, producing agglomerated low-dust material and minimizing product losses. Due to the small quantities of dust produced, the total exhaust air can be passed through a cyclone separator into the atmosphere. Secondary drying / cooling Downstream of the primary zone follow several secondary-drying and cooling zones, which can be utilized variably, i.e. according to requirements. The air entering these zones is dehumidified, and its temperature is controlled in separate heat exchangers for each zone. Thus, the drying conditions for each zone can be individually conformed to the product concerned. The residence time is adjusted by the linear speed of the conveyor belt. When it has passed through the cooling zone, the belt returns to the primary drying zone. At the point where the belt turns back, the product comes off the belt and drops into a screw conveyor which discharges it from the dryer. A scraper blade and an air blast tube serve to remove product particles still clinging to the belt. In addition, a washing system integrated in the system can be activated to wet-clean the belt during the drying process. Hoisting the dryer in place 20

23 Delivery and installation The pilot plant as supplied is a complete system and was designed and pre-assembled in such a way that the time for installation at site could be reduced to a minimum. The dryer proper was shipped and hoisted in place in the building in one piece. Subject to the time and work required to incorporate the dryer in upstream or downstream treatment systems, installation can be completed within approx. 3 weeks. Scope of supplies: SBS dryer SBS plant control system Display and operator panel Powder dosing and feeding system CO 2 dosing system Steel structures Assembly and installation Since it is an experimental plant, the dryer can be modified in many ways. For example, a cooling/heating system allows to set a defined wall temperature for the doublewalled primary drying zone. Certain process steps can be deliberately influenced via the control system. The spray and belt zones can be separately controlled in terms of both time and energy. All these features make the system a highly flexible one. TAG s CO 2 dosing system is designed for kg/h liquid CO 2. The injection of liquid CO 2 into the high-pressure zone can directly influence the properties of the finished product. Combining the two systems (SBS and CO 2 ) allows addition of a defined quantity of CO 2 into the wet product stream. Variations in wet product feed during start-up and shut-down phases are minimized by the CO 2 flow control. Such a CO 2 dosing system can easily be retrofitted in existing dryers. Tests and experiments are indispensable in the development of new products, and this involves frequent changes of the product to be tested. An integrated CIP (Clean In Place) system largely automates general cleaning, and a change to another formula can be made - even after wet cleaning - within a very short time. The plant was designed and constructed in conformity with GMP (Good Manufacturing Practise) standards and ensures a high standard of hygiene, which permits the dryer to be employed even in the pharmaceutical industry. Dryer capacity and applications The TAG pilot plant is suited not only for drying tests and experiments in the development of new products. At a water evaporation of kg/h, the spray-belt system reaches a level which is sufficient for the production of small market test charges or which would justify its employment as a production-scale dryer for high-priced products. An identical system is available for tests at BMA s research centre in Braunschweig, where one can convince himself of the possibilities and capabilities of this dryer and where tests and experiments are made on behalf of international customers. Dr. Mirko Löhn The research-unit dryer speeds up the development of new products Benefits High plant flexibility Practical tests with the customer s product at BMA s research centre Low-cost production of samples and small charges Shorter development periods for new products CO 2 dosing system can easily be retrofitted in existing dryers 21

24 Components from the TAG DRYER-Division TAG DRYER-Division Installation of the prilling tower Photo: Ciba Prilling tower for plastic additives In the spring of 2001, TAG supplied a prilling plant to Ciba Spezialitätenchemie GmbH, Lampertheim, Germany. This plant is employed to give plastic additives a defined commercial shape. For this purpose, the product melt is atomized in the prilling tower and crystallized with chilling gas. Appropriate systems then discharge the resultant prills (beads produced by spray crystallization) from the tower and convey them to a packaging plant. TAG did all the planning and supplied the prilling tower, cooling system, discharging system, air supply and exhaust system (except the filter), and all pipelines and air conduits. All plant components have been designed for an operating pressure of -100 to +100 mbar. The plant was successfully commissioned in the summer of A preserving sugar production technology is winning through The third plant for the production of preserving sugar, which practises the technology developed together with Nordzucker AG (see BMA Information 39/2001) will be set up in Scandinavia. The plant in Kantvik, Finland, will supply the demand of DANISCO/Suomen Sokeri Oy for preserving sugar. DANISCO decided on this relatively new technology, as they want to offer their customers a higher quality product. The final coating of the agglomerate produced in the first zone of the fluidized-bed system provides a higher resistance to abrasion and almost completely excludes de-mixing of its constituents. As compared to other processes, this new technology requires much less gelling agent. Another great advantage is the product s stability, even if it should be a very long way to its end user. Hartmut Stolte (3) Every 3rd potato flake made in Germany is produced on TAG drum dryers Besides other potato products MKV, Mecklenburger Kartoffelveredelung, Hagenow, Germany, produces potato flakes for various purposes. The major part, in the form of purée, goes to end users and large-scale caterers. Over the past few years, sales have continuously increased at high growth rates, and in the meantime MKV s market share in Germany has reached 35% - not least due to the high and constant quality of the potato flakes produced on TAG drum dryers. Now, this customer s factory has been up for an expansion, and as if it was a matter of course the decision was taken in favour of the world s biggest drum dryer (see also BMA Information 37/1999), and with that MKV now has a total of six TAG drum dryers. Benefits Higher product quality Distinctly reduced use of gelling agent 22

25 Uticon Dynatherm: Process optimization by problem analysis Nederland The highly reputed multidisciplinary engineering company Uticon Dynatherm B.V. (Netherlands), an affiliate of BMA AG and part of the BMA Groep Nederland B.V., is making great progress in its Energy and Process division. In this division the company, which has four branches with a total staff of 160, closely cooperates with Solutherm B.V. (Solutions in Thermodynamics). Quite frequently, traditional energy saving technologies do not suit a particular production process. However, the projects handled by Uticon Dynatherm and Solutherm often disclose why energy saving measures are so important and why this is the way to achieve extraordinary results the customer would not have thought possible before. This singular technique can be applied to both new and existing plants and in almost every case yields outstanding results. The key to success in this course of action is a profound knowledge of production processes, thermal processes and product characteristics. Uticon Dynatherm and Solutherm have combined their powers and capacities in the Energy and Process division in an effort to give their customers optimum support and assistance. As at Uticon Dynatherm every project is internally discussed with specialists of all disciplines, all possible ways and means which could lead to process improvements are considered - even if these should not be covered by the original order. A project we handled for a renowned producer of foodstuffs shall serve as an example to show the potencies and strong points of Uticon Dynatherm s Energy and Process division: Due to the fact that the packing of a product had to be altered, this firm found itself compelled to subject the production process to radical modifications. The consequences were highly momentous. In order to maintain the product output at the same level, the capacity of a pasteurizer belt conveyor had to be increased by about 24%. The customer believed the only way out was to install a second production line. Uticon Dynatherm therefore got the order to work out a new design meeting the following requirements: Increase the belt capacity by 24% Keep within the budget of 1,800,000 EUR Basically, this was an order many engineering offices can execute in a way that it meets its requirements and all those concerned are satisfied in the end. However, there are only a few who would execute this order as Uticon Dynatherm did. For Uticon Dynatherm thinks one step further. During a project meeting the Energy and Process specialists soon found out that the pasteurizer was the bottleneck in the process, and they were convinced that there were certain possibilities. So, this pasteurizer was subjected to a thorough functional check. And this check gave a clear picture of how this situation was to be optimized. Now, what was the outcome of all this? The original order covered the installation of a second production line for 1,800,000 EUR. However, this order could be optimized, as the new pasteurizer design, which worked out at a mere 135,000 EUR, did not only come up to, but even exceeded the customer s expectations. In addition, this solution reduced energy costs by 54,000 EUR per year and increased the original production capacity by 20%. This example clearly shows the important role Uticon Dynatherm s Energy and Process division can play for a customer. We call that Looking beyond the tip of one s nose. What we do is think with and for the benefit of our customers. Simon Bruijnooge 23

26 news & personalities A group from DANISCO Sweetener, Xyrofin Oy, Kotka, Finland, on a visit to Braunschweig A delegation of Sudanese Sugar Company pays a visit to BMA Modification of alcohol rectification plant In late 2000, STARCOSA received an order from VLSF, Berlin, Germany, for the supply of engineering, machinery and equipment to modify an existing mash distillation and rectification plant. A new concentration column system connected to the existing mash column, plus peripheral facilities, was to produce 20,000 l/d alcohol with a strength of 95% by volume from fermented molasses mash with 8% alcohol by volume. Efficient separation of aldehyde and fusel oil and extended automation were further parts of the order and entailed additional supplies of measuring and control equipment, a fusel oil separator and peripheral equipment. The machinery and equipment was manufactured at BMA s shops in Braunschweig and could be delivered long before the contract deadline. Early delivery was of great importance to the customer, as the civil work to be carried out before installation of the equipment in the process building took quite a long time. Thanks to the very close cooperation between VLSF and STARCOSA, installation of the equipment could be completed still in 2001, and so the plant is in operation since January Rüdiger Fischer / Eckard Maedebach Benefits Engineering and equipment from one single source Optimum adaptation to existing plants and buildings Short construction time Short commissioning phase Automation for reduced labour force Customer s quality expectations greatly exceeded 24

27 Continuous centrifugals of the 2000 series In the previous business year, BMA increased worldwide sales of its continuous centrifugals by 15%, which underlines our good relations with the sugar industry. Several innovations of the 2000 series machines have been successfully tested during last year s campaign and will now be included as standard. Stainless-steel screens were fitted into a K 2400 basket. The advantage of these screens is that they have a longer service life than chromium-nickel screens. At the end of the campaign, the screen segments had no visible signs of wear; deposits could be wiped off easily. Massecuite feed has been improved in the sight glass area. A programmable control system for fully automatic operation of continuous centrifugals has been developed and tested. The inherent advantage is the optimally controlled feed of auxiliary media, even during the starting phase. Outstanding features of this control system are operator convenience and clear display of process parameters. In practical operation with low-raw beet sugar massecuite the K 2400 centrifugal processed 16 t/h, at an excellent sugar quality and with minimum use of water and steam. Eckhard Bartsch / Hans-Heinrich Westendarp Cooperation of BMA and Walkers It has always been BMA s philosophy to intensify its presence near its customers so as to be able provide them with most advanced products and first-class service in a better, quicker and more efficient way. This goal can be achieved, for example, by establishing strategic partnerships. In view of that, BMA and Walkers Pty. Limited, Mayborough, Australia, made in May 2001 a marketing and engineering agreement for the Australian market and neighbouring territories. The agreement refers to cane and bagasse diffusers, vertical cooling crystallizers and falling-film evaporators, supplementing BMA s supply line for the cane sugar industry and allowing to offer and process complete diffuser projects - from the cane receiving station through to the dewatering mill - from one single source. This cooperation between Walkers as mill manufacturers and BMA as diffuser manufacturers provides a huge potential for the diffusion technologies in these markets, increases the benefits for the customers by well-matched solutions, and pushes continuous progressive development of all components involved. Dr. Mohsen Makina K 2300 at Monitor Sugar, USA

28 During centrifugal installation at the Jangji, Tunhe Group, P.R. of China Batch centrifugals for Chevrières A master contract BMA concluded with the French sugar producers Eridania Béghin- Say covers the supply of approx. 30 batch centrifugals till the year 2006 (see BMA Information 39/2001). The first three batch centrifugals for 1,750 kg massecuite per charge supplied under this contract were put into operation at the Chevriéres factory for the 2001 campaign. These machines are equipped with BMA s new syrup separator (see BMA Information 38/2000) and with a housing washing system which is integrated in the centrifugal cycle control. BMA batch centrifugals already operate at the EBS factories in Connantre (one machine since 1990), Chalons-sur-Marne (six since 1991), Villenoy (two since 1994) and Sillery (seven since 1996). Heinrich Hartmann BMA massecuite pumps BMA s supply line also includes massecuite pumps of the proved FF series, which we manufacture and sell in large numbers. Last year, such pumps have been supplied to Australia, El Salvador, Hungary, Sweden, Spain, U.A.E. and the USA. The various pump sizes that are available allow delivery rates of m³/h. Especially for high-viscosity media such as lowraw massecuite after cooling crystallization, BMA pumps are the optimum choice. Their technological advantages are, in the first line, high delivery rates at low rotor speeds and absence of leakage due to the use of mechanical seals. In addition, FF pumps excel in high reliability and low maintenance. Harald Veleta Falling-film evaporator for Groß Gerau A new BMA falling-film evaporator of the Epsilon type went into operation at the Groß Gerau factory of Südzucker AG, Germany, at the beginning of the 2001 campaign. In this type of evaporator, separation of entrained juice takes place in a cyclone installed in parallel to the calandria. The guarantees for evaporation and vapour purity were fully met. In conjunction with the new condensate system, steam consumption was reduced by approx. 2 kg per 100 kg beets. In addition, thick juice colours were distinctly lower than before. Erwin Farwick 26

29 Fayoum sugar factory in Egypt goes into operation After a short test campaign in 2001, the new beet sugar factory of Fayoum Sugar Works Company, Egypt, designed for a slice rate of 7,000 t/d, now goes into full operation. As reported before, BMA received large orders covering the supply of equipment, engineering services, supervision of erection and commissioning of the major part of the main process. During the 2002 beet campaign, a BMA team of experts successfully commissioned and optimized the plants supplied and handed them over to the customer. Two things to be emphasized are the employment of vertical pulp presses of type HP 4000 and that, for the very first time in the Egyptian sugar industry, all three boilings in the sugar house take place in vertical continuous vacuum pans (VKTs). Reinhold Hempelmann View of the factory premises and The pulp drying plant housing estate (top left) Here comes the bread for the lunch break 27

30 Talking in Braunschweig: Kenji Nakamura and Isamu Hori of Nitten Hokuren, Japan, with Dr. Rolf Mayer and Uwe Schwanke of BMA (from left) Visit us on our homepage! Besides latest news, you will also find More information about our products Questionnaire for direct enquiries for spare parts (Service/Spare parts/enquiry for spare parts) Questionnaires for different products (Sugar/Delivery program, ) Questionnaire concerning our customers satisfaction Are we doing a good job? (Service/Claims management) Various brochures you can download (Brochures/Brochures and symposia papers) You can also download this issue of BMA Information and the previous one (39/2001). New management and continued close connection with BMA s majority shareholder At the beginning of 2002, after many years of operational responsibility and of dedicated engagement for our company, Carl-Gerrit Deilmann has entered the management of our majority shareholder, Deilmann-Montan GmbH. From this position and by his work in our supervisory bodies, he will continue to exert influence on the strategies and targets of BMA and thus assist us even in the future. In November 2001, BMA s management was already reinforced by Frank Lohrer who, together with Dr. Rolf Mayer, will now bear the operational responsibility for our company. 28