3RD GLOBAL NETWORKING CONFRENCE ENERGY AND RECP CASE STUDY IN KAKIRA SUGAR IN UGANDA

1. 3RD GLOBAL NETWORKING CONFRENCEENERGY AND RECPCASE STUDY IN KAKIRA SUGAR IN UGANDA Presented By: Ludigo James Uganda Cleaner Production Centre 04.09.2013

3. Resources lost by poor practices in harvesting in farms!

4. Nexus of poor Loading Method to Energy use of Equipments

5. Practices at the yard in the plant

6. Looses along the Production Process

7. Nexus of water use with Energy Consumption

8. Energy Looses

9. Nexus of Procedures: use EE: 200 HP tractor to carry a 10 HP motor

10. Kakira Sugar Limited • Is the largest manufacture of sugar in Uganda. • The plant has a production capacity of 600MT of sugar per day and a production capacity of 150,000MT per year. • Has the largest co-generation capacity of 50MW of power of which 12MW is for domestic use and 30MW is for export to the national grid

11. Priority areas where RECP was applied The main areas addressed during the RECP assessment were: • Energy usage • Water usage • Raw materials Management • Process Efficiency • Altitudinal Transformation

12. Kakira Co-gen Project Previously excess bagasse was disposed off by open-field burning ! • At a cost US $ 470,000 per year for disposing of bagasse.

13. Currently all bagasse is used in the co-generation plant • 500Tonne of bagasse was being disposed of per day • 1 Tonne bagasse = 2T of steam • So 500Tonnes bagasse = 1000T steam/day • 12 Tonnes of steam = 1MW • So 1000T = 1000/12 =83MW • For a year (300 days) = 300x83 =24,900 MWH • A saving of 24,900 MWHof energy is being realised annually.

14. Currently: • Larger capacity boilers (160TPH, 67kg/ Cm2) have been installed where the excess bagasse is being utilised to generate 50MW of power for domestic use (12MW)and export to the national grid (30MW). • The 160TPH, 67kg/ Cm2 boilers are equipped with electrostatic precipitator that trap all the fly ash

15. New 160TPH, 67kg/Cm3 Boiler

16. Electrostatic precipitator

17. Replacement of Steam Mill drives with Electric Motor Drives • Improvement in the bagasse Pol that led to improved daily sugar production by 12% • Improved steam generation due to less moisture in bagasse • Increased tonnage in crushed cane • Reduced power consumption after mill electrification ( incorporated a VSD) • Increased revenue of 40,014USD per month at payback period of 37months for project cost of 1.5Millon USD

18. Other benefits Cont. • Speed of the mill can be accurately controlled depending on the amount of cane coming into the machine • Electronic type overload protection helps to protect motor as well as the mill and its accessories. • Minimum production loss due to possibility of reverse drive to remove excess/foreign material out of the machine and resume normal operation with. • Reduced noise levels (OHS)

19. Other benefits Cont. • Raw water consumption reduced by 40%. • Effluent discharge reduced from 59L/s to 22L/s . A reduction of 63% has been realised • On average, BOD and COD have reduced by approximately 78% and 77% • Improved productivity of power production to total of 30MW to the national grid • Reduced air emission to less than 50ppm • Annual savings of USD 943,680 for the options so far implementedand a reduction on carbon emissions 2,587,868kgCO2e

20. Thank You