Barata, J.C.F. et al. Proc. Int. Soc. Sugar Cane Technol., Vol.

26, 2007
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FROM BI-DRUM TO MONODRUM STEAM BOILERSA STEP

FORWARD INTO CO-GENERATION IN BRAZILIAN SUGAR MILLS

By

J.C.F. BARATA1, J.E. GOMES2, M.G. SANCHEZ1 and H. VERBANCK3

1
Caldema Equips. Inds.Ltda. engenharia@caldema.com.br
2
Thermocal, gomes.thermocal@boilers.com.br
3
Alstom John Thompson hansv@jtafrica@.co.za

KEYWORDS: Boiler, Bi-drum, Monodrum, Bagasse, Energy.

Abstract
THIS PAPER presents an assessment on the evolution of the bagasse-fired boilers to meet
the current cogeneration trends of Brazilian sugar and alcohol plants. For this purpose, a
single pass bi-drum Brazilian bagasse-fired boiler design is depicted through its
constructive and operational features to meet higher capacities and steam generation
parameters. The proposed comparative scenario contributes to illustrate the evolving
process, highlighting the recent introduction of the Monodrum boiler. The description
shows the progress and limitations of each development stage according to one key
aspect: the suitability of the boiler in the context of modern expanded high steam
generation parameters for cogeneration plants to match the ever growing tendencies of
the Brazilian sugar industry. The paper shows how the increased power generation trend
in Brazilian sugar and alcohol plants has successfully corroborated the use of
Monodrum boilers for this application, as the only boiler capable of efficiently
working at higher capacities and steam generation parameters.

Introduction
Sugar and alcohol plants in Brazil are increasing in size, and annual crushing capacities of
4.0 6.0 106 tonnes of cane are becoming more frequent. On the other hand, the government is
promoting cogeneration plants based on biomass, to help match electricity demands. Twenty-year
contracts for sales of electricity linked with more favourable finance are the elements to make
cogeneration feasible on a large scale at sugar mills.
The association of large crushing capacities with optimisation of cogeneration for electricity
sales purposes, together with the necessity to reduce operational costs, has pushed the demand for
boiler capacities up to 350 t/h and pressure/temperature range 92 bar/520C according to Caldema
Equips. Inds. Ltda (2006).
In parallel, the operation of traditional single pass two drum boilers, sizes 150175 t/h and
pressure 63 bar/480C, has shown problems related to tube leakages at the main tube bank, on
expanded area into drums, as discussed by Barata et al. (2005). These leakages are associated with
fast start-ups and shut downs, due to differential expansion between drum plate (~100 mm thick)
and tubes (~4 5 mm thick). On cogeneration plants for sugar mills, it must be taken into account
that rain periods force the mill to shut down at times due to the lack of sugarcane.
All the above factors expose the market to the Monodrum boiler technology, frequently
used in north Europe for utility boilers, as the predominant design for power plants all over the
world. The application of this technology started to be developed for sugar mill applications several
years ago, being successfully introduced into the Brazilian market by 2004.

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The main goal of this paper is to discuss how the shift towards increased power generation
in the Brazilian sugar mills has led to the development of a Monodrum boiler for this application
The bi-drum Brazilian bagasse-fired boiler in the sugar mill scenario
Two drum single pass bagasse fired boilers traditionally used in sugar mills, usually in the
range from 100 to 200 t/h steam, have basically a fixed geometry, where the evaporator is located
between the drums, and the superheater is located up stream to the flue gas flow, taking up some
space in the furnace. The superheater can be directly exposed to the furnace radiation or,
alternatively, can be protected by one or more rows of furnace tubes usually called screens. Either
the air heater or the economiser, or both, can be located down stream to the evaporator.
The single pass bi-drum boilers were specifically developed to overcome the tube erosion
problems and to eliminate structural refractory, a prevailing characteristic of many former boiler
designs, which led to higher maintenance costs (Alstom John Thompson, 2003). On the other hand,
as remarked by Snchez and Barata (2006), quite high furnace designs aimed at promoting the
stability of the heat released in the combustion chamber started to be considered in this type of
design used by boiler manufacturers, in order to reach higher combustion efficiency.
The first constructive single pass bi-drum design was the bottom supported boiler (no steel
structure), with finned water wall furnace, proposed for capacities up to 165 t/h and with steam
parameters around 65 bar and 490oC. Initial designs considered low height bagasse conveyor and,
therefore, lower height bagasse feeders. Partial suspension firing (up to forty percent) with positive
results started to be used in steam generation units, even without significant reductions in the
thermal load of the furnace and the consequent increase in the residence time.
The furnace volume increase, mainly due to its height, had more significant results in the top
supported bi-drum design, recommended for higher capacities (up to 200 t/h). Higher boiler heights
allowed suitable conditions for the reduction of air excess coefficients to reach efficient combustion
conditions, while very little change was experienced in the grate surface.
However, in such cases, the installation of supplementary burners for oil and/or gas is rather
difficult, as its design has to consider certain precautions to protect the grate and superheater tubes
from the direct radiation of these burners. Higher steam pressure results in much thicker drums (for
example around 150 mm for 200 t/h boiler/92 bar) and higher degree of superheating results in
rather large superheaters, using up furnace volume.
Figure 1 shows a diagram of a bi-drum top supported boiler.
The Monodrum bagasse-boiler
Opposite to the two-drum design, the Monodrum is a very flexible design as the boiler
modules, like superheaters and evaporators, can be located anywhere in accordance with the
convenience of the design engineer. As the main features of the Monodrum design, the following
points can be highlighted:
All risers and down comers are welded to drum No expanded tubes.
The drum is located out of the flue gas flow, which means no differential expansion
between plates and tubes welded to the drum. Thus, it is impossible to have tube
leakages and, therefore, consequential damages due to lack of water in the drum.
Water/Steam circulation circuits very well defined, resulting in very good level
stability
Possibility to have a cavity after the furnace, for further gas cooling before the
superheater.
Superheaters placed out of the furnace are of convective type and with secondary
superheater on parallel flow. Lower tube metal temperatures.

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The feature of convective superheater together with welded connections into the
drum allows very fast start up and shut downs, usually of conventional bi-drum
boilers, as shown in Figure 2.

Fig. 1Operational diagram of the bi-drum top supported design.

BI-DRUM COLD START-UP SINGLE-DRUM COLD START-UP

100

90

80
Steam pressure at drum (bar)

70

60

50

40

30

20

10

0
0 1 2 3 4 5 6
Time (hrs)

Fig. 2Cold start-up curves for Monodrum and bi-drum bagasse boilers.

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Fully drainable superheaters. Possibility to carry on chemical or acid cleaning. Wet

preservation during off-season.
Straight downward flow of gases at convection surfaces, with no hoppers and no
change of flue gas flow in superheaters and evaporators.
For boilers around and over 200 t/h, the suspension burning technology shows some
advantages when compared with combustion only on the grate. This technology
reduces the grate surface almost by half of the normal size due to suspension
burning. With this system, 50% or 60% of combustion air (secondary air) is injected
at high pressure and temperatures (~350oC) tangentially at the corners of furnace in
different rows, creating a swirling like movement in the flue gas. This results in
fantastic fuel/air combination with good residence time for the fuel. Primary air is
injected under the grate at temperatures around 250oC. Boiler load response for this
type of boiler is similar to oil and gas boilers.
Due to the location of superheater out of furnace, supplementary oil or gas burners
can be easily installed without any risks for either the grate or superheater, as shown
in Figure 3.

Fig. 3Functional diagram of the Monodrum boiler.

Pinhole grate has been the predominant combustion system in the Monodrum
boilers. For top supported projects, the grate is incorporated into the furnace,
resulting in no sealing problems.
Residence time at furnace is over 3 seconds and flue gas temperatures under 950oC
at superheater inlet.
Two levels of bagasse feeders for units over 200 t/h.

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Conclusions
With some units already in operation, it can be concluded that Monodrum boiler
technology is a very competitive and reliable technology available for bagasse boilers, with real
advantages for units over 200 t/h capacity associated with high steam pressure and temperature.
Only as an example of how this technology has successfully struck the market, a 300 t/h, 92 bar and
520oC unit is under construction at the moment with its start up scheduled for 2nd half 2008, which
will be, as per available references, (Subramaniam 2005; Natu 2005), one of the highest associated
steam pressure and temperature bagasse-fired boilers installed at a sugar mill worldwide.
REFERENCES
Alstom John Thompson (2005). Cogeneration in the Sugar Cane Industry. Reference Boiler
Manual, AJT.
Barata, J.C.F., Lopes, A.L.R. and Gomes, J.E. (2005). The evolution of the Brazilian bagasse
boiler: From the furnace to the single-drum boiler, SINATUB, Ribeiro Preto, So Paulo,
Brazil, Dec. 2005. (In Portuguese).
Caldema Equips. Inds.Ltda. (2006). Manufacturer Data, Sertozinho, So Paulo, Brazil.
Natu, S.C. (2005). Bagasse based cogeneration, India marching ahead. International Sugar Journal,
107(1279): 416424.
Snchez, P.M.G. and Barata, J.C.F. (2006). The evolution through the single-drum steam boiler
inside the expansion of cogeneration in the Brazilian sugar mill context, ENCIT 2006, 11th
Brazilian Congress of Thermal Sciences and Engineering, Curitiba, Brazil, Dec 58.
Subramanian, A.K. (2005). High pressure multi-fuel co-generation grate boilers for the sugar
industry. International Sugar Journal, 107(1279): 431434.

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CHAUDIERES MONODRUMPROGRES VERS LA COGENERATION AU BRESIL

Par
J.C.F. BARATA , J.E. GOMES , M.G. SANCHEZ1 et H. VERBANCK3
1 2
1
Caldema Equips. Inds.Ltda. engenharia@caldema.com.br
2
Thermocal, gomes.thermocal@boilers.com.br
3
Alstom John Thompson hansv@jtafrica@.co.za
MOTS CLS: Chaudires, Bi-Drum, Tambour, Bagasse, nergie.
Rsume
CE PAPIER prsente lvolution des chaudires a bagasse, particulirement vers la cognration, dans
les sucreries et distilleries brsiliennes. On donne des dtails de construction et dopration dune
chaudire a bagasse pour atteindre des capacits plus hautes. On prsente des scnarios et on discute
la chaudire Monodrum. On dcrit le progrs et les limitations du dveloppement stage par stage, a
partir dun point central: une chaudire approprie a lindustrie brsilienne en pleine expansion et
avec des demandes de cognration. Les chaudires Monodrum sont un facteur important pour la
gnration dnergie au Brsil; elles sont les seules chaudires capables de produire les capacits
ncessaires.

DE CALDERAS CON DOS DOMOS A UN SOLO DOMOUN PASO ADELANTE EN LA

COGENERACIN EN INGENIOS AZUCAREROS DEL BRASIL
Por
J.C.F. BARATA , J.E. GOMES , M.G. SANCHEZ1 y H. VERBANCK3
1 2
1
Caldema Equips. Inds.Ltda. engenharia@caldema.com.br
2
Thermocal, gomes.thermocal@boilers.com.br
3
Alstom John Thompson hansv@jtafrica@.co.za
PALABRAS CLAVE: Caldera, Bi-drum, Monodrum, Bagazo, Energa.
Resumen
ESTE ARTCULO presenta un seguimiento a la evolucin de las calderas bagaceras para cumplir con
las tendencias actuales de cogeneracin de las plantas brasileas de azcar y alcohol. Para este
propsito se describe una caldera bagacera brasilea de un solo paso y dos domos desde los puntos
de vista de sus atributos constructivos y operacionales tratando de satisfacer mayores capacidades y
mayores parmetros de generacin de vapor. El escenario comparativo propuesto contribuye a
ilustrar el proceso evolutivo, sealando la reciente introduccin de la caldera Monodrum. La
descripcin muestra el progreso y las limitaciones de cada etapa de desarrollo de acuerdo a un
aspecto clave: la idoneidad de la caldera en el contexto de los parmetros modernos de generacin
de vapor para plantas de cogeneracin dentro de las tendencias cada vez crecientes de la industria
azucarera brasilea. Este artculo muestra cmo la tendencia hacia mayor generacin en las plantas
brasileas de azcar y alcohol ha corroborado exitosamente el uso de calderas Monodrum para
esta aplicacin, como la nica caldera capaz de trabajar eficientemente a las mayores capacidades y
parmetros de generacin de vapor.

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