EQUIPMENT DESIGNS

Equipment designs and manufacturing drawings are offered for a range of sugar processing equipment as detailed below:

x Shredders / Cane Knives – Heavy Duty x Diffusers (Cane and Bagasse) x Juice Heaters x Vapour Heaters (Direct Contact type) x Evaporators x Kestner type x Robert type x Entrainment Separators (Vertical Chevron – Internal & External) x Condensers for Evaporators & Pans (Internal & External) x Batch Vacuum Pans & Stirrers x Continuous Vacuum Pans x Vertical Crystallisers x Massecuite Reheaters x Remelters x Sugar Driers x Sugar Refining Equipment x Direct White Sugar process x Rotary Distribution System x Fluegas Scrubbers x Miscellaneous Equipment Tongaat Hulett Sugar Equipment Designs

Shredders / Cane Knives (Heavy Duty)

The Tongaat Hulett heavy duty shredder is a robust swing hammer pulveriser. The design incorporates high operating efficiency, low maintenance costs and resistance to damage in service. The patented rotor design gives overlapping coverage of the full shredder width with reversible swing hammers. The shredders have been installed worldwide for the last 25 years and are reliable and proven. The rupturing of the cane cells by the shredder leads to high extractions being obtained in both milling trains and diffusers. Cane & Bagasse Diffusers

The Tongaat Hulett Diffuser is a variant of the moving bed diffuser. The basic design is a counter current contactor where juice is pumped (with a high percentage of recycle) onto a moving bed of prepared cane between 1.5 and 1.8 meters deep contained in a vessel approximately 60 meters long and divided into 10 to 14 stages. Typically the diffuser would have a working width between 6 and 12 meters. The prepared cane entering the diffuser is heated by juice which has been raised to a high temperature in juice heaters giving an average temperature in the diffuser of 85°C. The cane bed is moved across the top of a fixed screen by a series of chains with slats between them. The bed is prevented from blinding with fines and over-compaction by sets of patented lifting screws which break up the bed at two points in the diffuser. The bagasse is dewatered by one or two dewatering mills after exiting the diffuser.

The diffuser at Komati

Each diffuser is individually designed to suit the conditions and process specifications that the customer has supplied. Extraction can be as high as 98.5% if high imbibition rates are used with well prepared cane, but if a lower figure is all that is required then the diffuser size and imbibition rates can be reduced accordingly. Extensive use is made of 3CR12 in the construction of the diffuser to prevent corrosion and in addition a controlled liming system can be specified to control the juice pH to ±7. There are currently eight Tongaat Hulett diffusers in operation. Six in South Africa; at Felixton (2), Amatikulu, Maidstone and Komati (2), one in Kenya at Mumias and one in Louisiana, USA at Enterprise. Two more are under construction for commissioning in 2007, one at Savannah in Mauritius and the other at the new Skeldon factory in Guyana and a third is in the design phase for Bharat in India.

One of the major advantages of selecting diffusion is the ability to recycle mud from the clarifier, thereby removing the need for a filter station. Mud recycle is used at all Tongaat Hulett’s South African sugar mills that use diffusers.

A number of papers on the performances and advantages of the TH diffusers have been written and presented at various national and international conferences.

A list and details of the TH diffusers supplied to customers since 1984 is shown below:-

TH Designed Diffuser Installations

Capacity Width Number Date Country Mill TCH m of Stages Installed

South Africa Amatikulu 12 14 South Africa Felixton 600 x 2 12 12 1982/83 South Africa Komati 225 6,5 12 1993 South Africa Maidstone 300 9 12 1995 South Africa Komati 225 6,5 12 1998 Kenya Mumias 300 9 12 1997 USA Enterprise 300 9 12 1999 Mauritius Savannah 350 9 12 2007 * Guyana Skeldon 350 9 12 2007 * India Bharat 250 6.5 12 2008 *

* Planned commissioning year Juice Heaters

Tongaat Hulett offer the design of vertical shell and tube heat exchangers for heating raw and/or clarified juices to achieve the necessary process stream temperatures and for heat recovery throughout the factory, making use of low grade vapour, evaporator vapour and condensate streams.

The designs can be optimized in terms of pressure drop (pumping requirements), heat recovery and size to meet required heat balance targets.

Tongaat Hulett also have the capability and expertise to perform a pinch technology analysis to identify the optimal heat recovery layout as an additional process design service.

Hippo Valley Mixed Juice Heaters Vapour Heaters (Direct Contact Type)

Tongaat Hulett offer the design of direct contact vapour heaters which allow the possibility of using lower grade vapour for heating various liquid streams, thereby increasing the steam economy of the factory.

Press Water Heater (Malelane)

A list of TH design vapour heaters supplied to clients over recent years is given below:-

Tongaat Hulett Designed Vapour Heater Installations

Mill Service Diameter Date of mm Intallation

Amatikulu Press Water Heater 1454 1984 Malelane Press Water Heater 2100 1998 Pongola Primary Mixed Juice 2180 1998 Savola Heater 2005 Carbonatation Heater Evaporators

Tongaat Hulett TEG are experienced in designing both long tube climbing film (Kestner type) and Robert type evaporators complemented by the design of very efficient vertical chevron entrainment separators. Expertise in both steam chest design (in particular the removal of incondensable gases) and juice/syrup feeding and distribution, ensures optimal performance and maximum heat transfer coefficients. In addition, our multiple effect evaporator design procedure employs process models to distribute heating surface area between the effects most efficiently and can be used for the specification of the entire evaporator station, including all associated condensate receivers and flash vessels.

Kestner Evaporator & Robert Evaporator at Separator at Malelane Si A list of the TH designed Kestner and Robert evaporators which have been supplied to customers since 1993 is shown below

Kestner Type

Unit Size Mill Heat Transfer Area Date of m2 Installation Felixton 4 x 5800 1985 Komati 2 x 3800 1993 Triangle/Zimbabwe 2 x 3100 1996 Umfolozi 1 x 3500 1997 Malelane 1 x 1000 1998 Komati 2 x 3800 1998 Hippo Valley-Zimbabwe 1 x 5800 1999

Robert Type

Unit Size Mill Heat Transfer Area Date of Installation m2 Felixton 2 x 1430 1985 Felixton 4 x 1000 1985 Komati 2 x 1000 1993 Triangle/Zimbabwe 1 x 2000 1994 Felixton 1 x 1430 1996 Komati 1 x 2000 1998 Komati 1 x 1000 1998 Simunye 3 x 2200 1998 Xinavane/Mozambique 1 x 2000 2000 Mhlume 3 x 270 2002 Entrainment Separators

Tongaat Hulett provide a very successful design of entrainment separator that is suitable for installation in batch pans, continuous pans, evaporators and separator vessels. The design incorporates vertical chevron plates that disengage the liquid particles by repeated changes in vapour direction and impingement against the plates. The entrapped liquid is drained back into the vessel.

The design is in a modular form with easy access to the chevron plates by hinged sides. This allows rapid cleaning of the separator module if necessary. The number and configuration of the separator modules is defined by the evaporation rate, disengagement height and diameter of the vessel in which they are to be installed.

Under steady operating conditions which meet the design specifications an entrainment level below 20 ppm can be expected and pressure drops across the separators will be less than 5mm water gauge.

This design of separator is included in all the Tongaat Hulett designs of pans and evaporators and has also been very successful as a “retro-fit” to existing vessels with entrainment problems.

Vertical Chevron Plate (VCP) Entrainment Separator being installed Condensers (Internal & External) for Evaporators & Pans

Tongaat Hulett offer the design of efficient disc and doughnut “rain tray” type condensers for both internal fitment or external installation to a final effect evaporators, continuous vacuum pans or batch vacuum pans. The condensers are designed to operate on an approach temperature of ± 3°C.

TH Designed Internal Tongaat Hulett Raintray Condenser Condenser Installation (Komati)

A list of both internal and external Tongaat Hulett condenser designs which have been supplied to clients and installed since 1993 are shown below:-

External Condensers Size Diameter Duty Date of Mill mm Installation Maidstone 1840 C-Cont Pan 1994 Pongola 910 C-Cont Pan 1995 Felixton 2250 5th Effect 1996 Clewiston – USA 1500 W- Batch Pan 1996 Maidstone 1250 Batch Pan 1994 Pongola 1800 A-Cont Pan 1998 Simunye – Swaziland 1300 C-Cont Pan 1999 Entumeni 3 x 1100 Batch Pans 2000 Xinavane – Mozambique 3 x 3200 Batch Pans 2000 Xinavane – Mozambique 2 x 1820 Batch Pans 2000 Xinavane – Mozambique 1200 5th Effect 2000 Mhlume – Swaziland 590 Final Effect 2001

Internal Condensers

Size Diameter Duty Date of Mill mm Installation Simunye – Swaziland 1800 A-Batch Pan 1991 Maidstone 2 x 1700 Final Effect 1991 Triangle – Zimbabwe 1170 C-Cont Pan 1993 Komati 2 x 1026 B/C Cont Pan 1993 Komati 1520 A Cont Pan 1993 Komati 2 x 1472 A/B/C/ Seed 1993 Komati 1624 Final Effect 1993 Ubombo – Swaziland 1340 B-Cont Pan 1994 Triangle – Zimbabwe 2050 Final Effect 1994 Triangle – Zimbabwe 1250 B-Cont Pan 1994 Triangle – Zimbabwe 2000 A-Cont Pan 1995 Darnall 1130 B-Cont Pan 1995 Komati 1800 A-Cont Pan 1998 Komati 2280 A-Batch Pan 1998 Komati 1500 B-Cont Pan 1998 Komati 2000 Final Effect 1998 Batch Vacuum Pans & Stirrers

Tongaat Hulett designed batch pans are conventional vertical tube calandria pans with a central downtake, which have been designed for A,B and C massecuites and refined massecuites. They are low head designs with excellent circulation characteristics which are able to operate with high viscosity massecuites without the need for a stirrer. The pans are designed to accommodate both a stirrer and an internal chevron entrainment separator, for improved performance.

85m3 Stirred A Seed Batch Pan at Komati

Batch pans of the TH design, without stirrers, are used extensively in raw cane sugar factories owned and operated by TH. When fitted with a stirrer, these pans have been successfully used as seed pans in raw cane sugar factories and have proved successful in producing white sugar in cane sugar refineries and “back end” refineries attached to raw cane sugar factories.The TH stirrer design was originally developed for the TH central refinery and compares favourably in terms of performance with the design of other impellers used extensively in the raw sugar and beet industries. Later designs have been optimized for lower purity massecuites. A list of TH designed batch pans and stirrers supplied since 1985 is shown below:- Tongaat Hulett Designed Batch Pan Installations

Unit Size m3 Duty Date of Mill Massecuite Installation Felixton 1 x 85 A 1985 Felixton 1 x 85 B/C 1985 Komati 1 x 42,5 A 1993 Komati 1 x 42,5 B/C 1993 Clewiston – USA 3 x 60 Refined 1996 Komati 1 x 85 A 1998 Xinavane – Mozambique 1 x 42,5 A 2000 Mhlume – Swaziland 1 x 37,5 White 2000 Huletts Refinery – White Sugar 1 x 50 White 2002

Tongaat Hulett Designed Batch Pan Stirrer Installations

Unit Size Duty Date of Mill m3 Massecuite Installation Triangle – Zimbabwe 2 x 35 White Malelane 2 x 85 White Simunye 2 x 56,7 B/C Komati 1 x 42,5 A 1992 Komati 1 x 42,5 B/C 1993 Komati 1 x 85 A Seed 1998 Triangle 1 x 85 A 1998 Triangle 3 x 56,6 A 1998 Clewiston – USA 3 x 60 White 1996 Mhlume 3 x 37,5 White 1999 Huletts Refinery 1 x 50 White 2002 Continuous Vacuum Pans

The Tongaat Hulett design continuous vacuum pan is a world leader in cost effective and quality continuous pan boiling. The design incorporates a vertical tubed calandria for efficient heat transfer and massecuite flow, patented transfer ports for plug flow and flexibility in terms of throughput and product. The Tongaat Hulett CVP is a low head design with excellent natural circulation characteristics which saves power and construction costs relative to forced circulation systems and eliminates the need for a strike receiver. This feature allows it to operate efficiently with high viscosity massecuites and good heat transfer characteristics enabling it to be operated utilizing lower pressure steam than would be required for batch pans. The pan is simple in design and robust and can be equipped with controls ranging from sophisticated to basic depending on the customers requirements. When boiling low to medium purity massecuites, conductivity can be used for automatic control of individual compartments and for high purity massecuites, the Duotrac Digital Radio Frequency Probe is recommended. The massecuite capacities of CVP's installed to date have ranged from 40 m3 to 180 m3 .

A new continuous pan has been developed by Tongaat Hulett. This new design consists of two stacked calandrias stacked inside a cylindrical vessel. The 120m3 continuous A pan to be installed at Xinavane Mill in Mozambique has the same basic footprint as an 85m3 batch pan.

The first Tongaat Hulett CVP was installed in South Africa in 1981 and the first outside Southern Africa in Germany in 1986. To date, 166 units have been installed or are under construction worldwide in the beet and cane industries by Tongaat Hulett and Fletcher Smith Ltd. They can be found in the following countries: The Americas: USA, Mexico, Brazil, Colombia, Guadeloupe, Venezuela, Belize, Nicaragua, Guatemala, Guyana and Jamaica. Europe: England, Germany, France, Hungary, Finland, Sweden, Poland and Ireland. The Far East: Pakistan, Philippines, Indonesia, Iran, Thailand, Fiji and Vietnam. Africa: South Africa, Zimbabwe, Malawi, Nigeria, Senegal, Egypt, Reunion, Zambia, Swaziland, Mozambique, Mauritius and Kenya.

The Tongaat Hulett CVP design has been awarded the South African AS&TS National Award for Technology and the South African Institute of Chemical Engineers Innovation Award.

A number of papers on the operation and performance of the TH Continuous pans have been written and presented at various national and international conferences.

Installations by Region Africa 45 No. of CVPs on A-massecuite duty 46 27.5% Americas 64 No. of CVPs on B-massecuite duty 42 25.1% Europe 10 No. of CVPs on C-massecuite duty 79 47.3% Far East 31 Total No. of CVPs 167 Pakistan 22 Total 172

UNDER CONSTRUCTION – New design Round Pan No. FACTORY Country Duty m3 Year

1 Xinavane (vertical pan) Mocambique Cane A 120 2008 2 Mafambisse (vertical pan) Mocambique Cane A 100 2008 3 Xinavane (vertical pan) Mocambique Cane B 100 2009

No. FACTORY Country Duty m3 Year No. FACTORY Country Duty m3 Year 1 Maidstone R.S.A. Cane A 110 1981 81 San Antonio Nicaragua Cane A 120 1998 2 Felixton R.S.A. Cane A 120 1984 82 Pichichi Colombia Cane C 65 1998 3 Felixton R.S.A. Cane A 120 1984 83 Gniezno* Poland Beet C 44 1998 4 Felixton R.S.A. Cane B 76 1984 84 Umfolozi R.S.A. Cane C 100 1998 5 Felixton R.S.A. Cane B 76 1984 85 Ubombo Ranches Swaziland Cane A 129 1998 6 Felixton R.S.A. Cane C 76 1984 86 Indolampung 2 Indonesia Cane B 140 1998 7 Felixton R.S.A. Cane C 76 1984 87 Indolampung 2 Indonesia Cane C/D 140 1998 8 Hippo Valley Zimbabwe Cane C 120 1986 88 Nakambala Zambia Cane C 120 1998 9 Zeil Germany* Beet C 115 1986 89 Moses Lake** U.S.A. Beet B 120 1998 10 Darnall R.S.A. Cane C 86 1987 90 Kopingebro Sweden Beet C 110 1998 11 Mirpurkhas Pakistan Cane C 68 1987 91 Gora Slaska* Poland Beet C 88 1998 12 Shahtaj Pakistan Cane C 68 1987 92 East Grand Forks U.S.A Beet B 50 1999 13 Leopoldsdorf Austria* Beet C 90 1988 93 Abou Kourkas Egypt Cane C 80 1999 14 Brothers Pakistan Cane A 55 1989 94 Komati R.S.A. Cane A 130 1999 15 Brothers Pakistan Cane A 55 1989 95 Komati R.S.A. Cane B 130 1999 16 Gunung Madu Indonesia Cane C/D 120 1990 96 Sucoma Malawi Cane B 120 1999 17 St. James U.S.A. Cane C 50 1990 97 Dwangwa Malawi Cane A 105 1999 18 Malelane R.S.A. Cane C 120 1990 98 Enterprise U.S.A. Cane B 180 1999 19 Turenki (moved to Sakyla) Finland* Beet C 65 1989 99 Enterprise U.S.A. Cane C 180 1999 20 York England Beet C 55 1990 100 Sterling U.S.A. Cane C 100 1999 21 Usine du Gol Reunion Cane A 145 1991 101 Carlow** Ireland Beet B 150 1999 22 Richard Toll Senegal Cane A 120 1991 102 El Palmar Venezuela Cane C 100 1999 23 Don Pedro Philippines Cane A 105 1991 103 La Gloria Mexico Cane B 140 1999 24 Brothers Pakistan Cane B 102 1991 104 Puunene Hawaii/USA Cane C 100 2000 25 Brothers Pakistan Cane C 97 1991 105 Simunye Swaziland Cane C 120 2000 26 East Grand Forks U.S.A. Beet B 120 1992 106 Maidstone R.S.A. Cane B 58 2000 27 Bunga Mayang Indonesia Cane C/D 150 1992 . . 107 Belle Vue Mauritius Cane A 105 2000 28 Ramzan Pakistan Cane A 55 1992 108 Puunene Hawaii/USA Cane A 100 2000 29 Ramzan Pakistan Cane B 102 1992 109 Raceland USA Cane A 150 2000 30 Ramzan Pakistan Cane C 97 1992 110 Tarlac Phillipines Cane A 110 2000 31 Ramzan Pakistan Cane A 55 1992 111 San Antonio Nicaragua Cane B 120 2000 32 Usine du Gol Reunion Cane C 97 1992 112 San Antonio Nicaragua Cane C 120 2000 33 El Modelo Mexico Cane C 97 1992 113 Appleton Jamaica Cane A 40 2000 34 Shakjarganj Pakistan Cane C 97 1992 114 Constancia Mexico Cane C 89 2001 35 Shakjarganj Pakistan Cane A 102 1992 115 San Francisco Mexico Cane C 89 2001 36 Choudhary Pakistan Cane A 55 1993 116 Queseria Mexico Cane C 89 2001 37 Choudhary Pakistan Cane A 55 1993 117 Cam Ranh Vietnam Cane A 95 2001 38 Choudhary Pakistan Cane B 102 1993 118 Cam Ranh Vietnam Cane A 95 2001 39 Choudhary Pakistan Cane C 97 1993 119 Cam Ranh Vietnam Cane B 120 2001 40 Mataram Indonesia Cane C/D 150 1993 120 Cam Ranh Vietnam Cane C 120 2001 41 Batangas Philippines Cane C 100 1993 121 Khuzestan 1 Iran Cane C 120 2001 42 Petoehaza Hungary* Beet B 105 1993 122 Xinavane Mozambique Cane A 43 2001 43 Sucoma Malawi Cane C 70 1993 123 Bukidnon Philippines Cane B 135 2001 44 El Palmar Venezuela Cane A 100 1993 124 Khuzestan 2# Iran Cane C 120 2001 45 Haseeb Waqas Pakistan Cane A 55 1992 125 Khuzestan 3# Iran Cane C 120 2001 46 Haseeb Waqas Pakistan Cane A 55 1992 126 South Minnesota USA Beet B 150 2001 47 Haseeb Waqas Pakistan Cane B 102 1992 127 South Minnesota USA Beet C 120 2002 48 Haseeb Waqas Pakistan Cane C 97 1992 128 Colonial USA Refin B 57 2002 49 Komati R.S.A. Cane A 105 1994 129 Bukidnon Philippines Cane C 180 2002 50 Komati R.S.A. Cane B 75 1994 130 St. James USA Cane A 140 2002 51 Komati R.S.A. Cane C 75 1994 131 San Rafael Mexico Cane C 115 2002 52 Sheikhu Pakistan Cane C 97 1994 132 Bukidnon Philippines Cane A 180 2003 53 Mendota** U.S.A. Beet B 120 1994 133 Santa Teresa Brazil Cane C 120 2003 54 Mitr Phol Thailand Cane A 170 1994 134 Ameca Mexico Cane B 100 2004 55 Triangle Zimbabwe Cane C 86 1994 135 Constancia Mexico Cane B 100 2004 56 Trangkil Indonesia Cane C/D 79 1994 136 Queseria Mexico Cane B 100 2004 57 Bacita# Nigeria Cane C 68 1994 137 Brawley (ex-Sidney) USA Beet B 100 2004 58 Maidstone R.S.A. Cane C 120 1995 138 Xinivane Mozambique Cane A 75 2004 59 Ubombo Ranches Swaziland Cane B 110 1995 139 Victorias Philippines Cane C 200 2004 60 Scottsbluff U.S.A. Beet B 75 1995 140 Enterprise U.S.A. Cane A 160 2004 61 Hillsboro** U.S.A. Beet B 120 1995 141 San Rafael Mexico Cane B 120 2004 62 Indolampung (PT Sweet) Indonesia Cane A 140 1995 142 San Miguel Mexico Cane C 120 2004 63 Indolampung (PT Sweet) Indonesia Cane B 140 1995 143 Tamazula Mexico Cane C 100 2005 64 Indolampung (PT Sweet) Indonesia Cane C/D 140 1995 144 Tala/IJM Mexico Cane C 180 2005 65 Triangle Zimbabwe Cane B 120 1995 145 Korach Thailand Cane C 250 2005 66 Abbeville France Beet B 68 1995 146 Magdalena Guatemala Cane A 200 2005 67 Manuelita Colombia Cane C 120 1996 147 Magdalena Guatemala Cane C 130 2005 68 Richard Toll Senegal Cane A 145 1996 148 Magdalena Guatemala Cane C 130 2005 69 La Gloria Mexico Cane C 60 1996 149 Tala Mexico Cane B 250 2006 70 Victorias Philippines Cane A 130 1996 150 Benito Juarez Mexico Cane C 120 2006 71 Eston R.S.A. Cane A 86 1996 151 Savannah Mauritius Cane A 170 2006 72 Pongola R.S.A. Cane C 65 1996 152 Savannah Mauritius Cane C 80 2006 73 Darnall R.S.A. Cane B 86 1996 153 Magdalena Guatemala Cane A 200 2006 74 Gardel Guadeloupe Cane A 90 1996 154 Hawaiin & Philippines Co. Philippines Cane C 120 2006 75 Wahpeton** U.S.A. Beet B 150 1996 155 Surin Thailand Cane C 250 2007 76 Twin Falls** U.S.A. Beet B 160 1996 77 Triangle Zimbabwe Cane A 160 1997 156 Sonedco Philippines Cane C 120 2007 78 Labasa Fiji Cane C 125 1997 # Purchased, built and delivered but not commissioned 79 Trapiche Brazil Cane C 120 1997 * in conjunction with Wiedeman KG, FS licencees. 80 Tower Hill Belize Cane C 73 1997 ** Stacked configuration of multiple sections Vertical Crystallisers

Tongaat Hulett vertical crystalliser design incorporates finned static cooling elements which are scraped by rotating arms. This promotes heat transfer and the rotor and stator geometry allows heating surface to volume ratios in excess of 2:1 without crystal settling out on the elements. The crystallisers are designed to handle high viscosity C massecuites and can be fitted with either hydraulic drives or electrical variable speed drives. These vertical crystallisers have been installed in most of the latest mill expansions in Southern Africa.

Vertical Crystallisers at Komati Tongaat Hulett Vertical Crystalliser

A list of TH designed Vertical Crystallisers installed for customers since 1993 is shown below: - Tongaat Hulett Designed Vertical Crystalliser Installations

Mill Capacity Duty Date m3 Komati 2 x 110 A 1993 Komati 4 x 110 C 1993 Triangle 110 B 1994 Triangle 110 C 1994 Bois Rouge – Mauritius 160 C 1995 Ubombo 120 C 1998 Pongola 160 C 1998 Komati 110 A 1998 Komati 2 x 110 C 1998 Xinavane – Mozambique 2 x 120 C 2000 Xinavane – Mozambique 1 x 160 A 2000 Eston 160 B 2001 Cameroon 2 x 90 C 2001 Komati 2 x 110 C 2005 Massecuite Reheaters

The Tongaat Hulett design provides efficient reaheating of low grade massecuite after cooling crystallisers, and prior to centrifugation. The unit employs finned tubes carrying warm water to heat the massecuite and achieves a low resistance (pressure drop) to massecuite flow whilst requiring only a small temperature difference for heating. The result is a unit that requires a low head (gravity feed) to drive the massecuite flow whilst ensuring a minimum of re-dissolution of crystal. The design is backed by many years of production experience on some of the most viscous massecuites in the cane sugar industry.

C Massecuite Reheater at Komati

A list of the TH designed reheaters which have been supplied to customers since 1992 is shown below:- Tongaat Hulett Designed Reheater Installations

Mill Size m2 Date -Year Felixton 1858 1992 Komati 1240 1993 Bois Rouge – Mauritius 1858 1995 Komati 1240 1998 Xinavane - Mozambique 1240 2000 Remelters

The TH remelter design is a multi compartment system comprising an optimum number of tanks fitted with vortex tubes and stirrers and direct steam heating spargers, where appropriate, for complete dissolution to take place.

A list of TH designed remelters which have been supplied to customers since 1993 is shown below:-

Tongaat Hulett Designed Remelter Installations

Mill Size (m3 ) Duty -Grade Date -Year Komati A 1993 Triangle – Zimbabwe 15 A 1993 Triangle – Zimbabwe 6 A 1995 Triangle – Zimbabwe 3 White 1995 Maidstone 6 B/C 1996 Clewiston – USA 30 White 1997 Triangle – Zimbabwe 3 White 1998 Xinavane – Mozambique 6 C 2000 Triangle A 2005 Sugar Driers

The Tongaat Hulett Rotary Cascade Sugar Drier design draws on well established conventional technology, but has a number of attractive features of its own. A unique seal design provides maximum integrity against air/sugar leakage, ensuring high levels of energy efficiency and plant hygiene. The drier internals provide positive sugar transport and high air-sugar contacting efficiency. Finally, the wheel-driven (rather than chain-driven) drum is a clean and quiet installation.

10 t/h White Sugar Dryer at Bois Rouge Reunion

A list of the TH designed sugar driers which have been supplied to customers since 1995 is given below:- TH Designed Rotary Cascade Sugar Drier Installations

Mill Capacity (t/h) Duty Date Triangle- Zimbabwe 60 VHP 1995 Bois Rouge 10 VHP 1998 Darnall 60 VHP 2001 Sugar Refining Equipment

Tongaat Hulett designs for sugar refining equipment have been developed and perfected in our large sugar refinery in Durban. We can offer designs for sugar melters, carbonatation systems, ion exchange decolourisation, ion exchange vessels and distributors, filtration, evaporators, white batch vacuum pans, condensers, pan stirrers and continuous recovery pan boiling.

Tongaat Hulett Refinery - Durban White sugar Mill (WSM ) Technology and the Rotary Distribution System (RDS)

A process to produce white sugar directly from cane juice has been developed by TH in partnership with SA Bioproducts. The process uses ultra filtration and ion exchange to remove impurities prior to crystallisation. In 2006 a plant designed to produce 36 000 tons of white sugar per annum was commissioned.

To accommodate large scale ion exchange, TEG developed the Rotary Distribution System (RDS). This is a mechanical device that allows a batch process to be configured in a way that approaches continuous operation. On the WSM plant, stationary ion exchange vessels are connected using the RDS to achieve simulated moving bed operation. The RDS has a much wider application and can be used for industrial chromatographic separations for example.

The Rotary Distribution System

LINK to WSM Process – See document Fluegas Scrubbers

The Tongaat Hulett boiler fluegas scrubber is based upon the irrigated sieve plate concept which has a number of advantages over spray scrubbers. It is very resistant to fouling with smuts or fibres and operates with a low pressure drop of ± 100mm water gauge. Particulate emission levels are typically less than 100mg/Nm3 . The scrubber can be designed to operate on bagasse or coal fire boilers and have good turn down capability. Apart from the scrubbers fitted at the Tongaat Hulett Sugar mills, seven have been designed and installed in Mauritius, one at Simunye in Swaziland and one a Komati, the capabilities ranging from 25 to 125 MCR t/h.

Water Circuit Clarifiers at Felixton Fluegas Scrubber at Beau Champ

Tongaat Hulett Designed Boiler Fluegas Installations

Boiler MCR Capacity t/h Diameter m Date of Installation Mill Mon Desert Alma Mauritius 50 4.2 1995 70 4.7 1995 Rose Belle – Mauritius 25 x 2 3.1 1996 Beau Champ – Mauritius 140 x 1 6.4 1996 FUEL - Mauritius 100 x 1 5.3 1997 Simunye – Swaziland 125 x 1 8.6 1998 Riche-en Eau – Mauritius 43 x 1 4.7 1998 Amatikulu 80 x 2 4.2 2002 Komati 150 6.2 2006 Miscellaneous Equipment

Other equipment designs are available for sugar processing and sugar factory services, including :

Entrainment Separators (Internal and External) Strike Receivers Seed Receivers (with Continuous Pans) Syrup Clarifiers Sugar / Bagasse Cyclones Flash Tanks Hilo unloaders Static (in-line) mixer for juice liming and syrup clarifiers Molasses conditioning (blow-up) tanks Technology & Engineering Group

SUGAR ENGINEERING AND PROCESSING CONSULTANTS REFERENCE LIST

Major projects, design and consulting work carried out since 1981 is summarised below :-

1981 Integration of a new ethanol plant at Triangle Sugar Mill in Zimbabwe.

1982 Installation of a 110 m3 continuous A pan at Maidstone Sugar Mill.

1982 Expansion of Triangle Sugar Mill from 270 to 375 tons cane per hour. This included the installation of a new cane diffuser, a boiler, a turbo-alternator, extensions to evaporators and centrifugal modifications.

1983 Design, construction and project management of a new sugar mill at Felixton to crush 600 tons per hour (current value U$ 250 million). Most process equipment, including A, B and C continuous pans, diffusers, batch pans, evaporators, vertical crystallisers and syrup clarifiers were designed in-house.

1984 Modernisation and expansion of the Mount Edgecombe Sugar Mill evaporator system, including a 3 200 m2 Kestner evaporator.

1985 Installation of new 110 TPH melt station at Tongaat Hulett Sugar Refinery.

1986 Installation of 120 m3 continuous C pan at Hippo Valley Sugar Mill in Zimbabwe.

1987 Installation of a syrup flotation clarifier at Triangle Sugar Mill, Zimbabwe.

1987 Expansion of Tongaat Hulett Sugar Refinery to 600 000 ton p.a. output, incorporating the installation of additional filters, stirred white sugar pan and additional second stage ion exchange decolourisation system.

1987 Design and installation of a 2500 ton white sugar conditioning plant at Tongaat Hulett Sugar Refinery in consultation with Bosch & Associates. Capital value $5.5 million.

1988 Expansion of Darnall Sugar Mill from 270 to 310 tons cane per hour - major plant changes included the installation of evaporators and a continuous C pan.

1989 Modernisation of Maidstone pan floor including the installation of 2 x 51 m3 batch pans.

1990 Installation of a 110 m3 continuous C pan at Malelane Sugar Mill.

1990 Installation of new 85 m3 white refined batch pan with stirrer at Malelane Sugar Mill and the installation of a pan stirrer in existing an 85 m3 pan.

1991 Design of a phosphatation clarifier for Zuenoula, Ivory Coast.

1991 Design and installation of a Hilo unloader and cane conveyor system at Mt Edgecombe sugar Mill.

1992 Installation of pan stirrers in B and C massecuite pans at Royal Swazi Sugar Corporation’s Simunye Sugar Mill.

Installation of 2 x 45 tons/hour coal-fired boilers at Tongaat Hulett Sugar Refinery. 1992 Design of a 70 m3 continuous C pan at Sucoma Sugar Mill in Malawi.

1993 Installation of 8 MW turbo-alternator at Tongaat Hulett Sugar Refinery.

1992-94 Partial design and project management of three irrigation schemes in Northern Kwa-Zulu Natal. Total area irrigated 5300 Ha with a capital value of $28 million

1993 Design of diffuser, evaporators, pans, crystallisers and reheater for the new Komati Sugar Mill in Mpumalanga, South Africa.

1993 Design and installation of a syrup clarifier at the Mount Edgecombe Sugar Mill.

1994 Installation of bagasse depithing station at Darnall Sugar Mill, for supply of fibre to a paper mill.

1994 Design of a new C station for Triangle Sugar Mill, Zimbabwe, including an 86 m3 continuous C pan and 110 m3 continuous vertical C crystallisers.

1994/95 Expansion of Maidstone Sugar Mill from 360 to 440 TCH. TMD managed the project involving U$ 15 million capital expenditure. New equipment included a 300 TCH cane diffuser, 120 m3 continuous C pan and a brown sugar packing station.

1995 Design of a 110 m3 continuous B pan at Ubombo Ranches Sugar Mill - Swaziland.

1995 Design of an expansion at Triangle Sugar Mill in Zimbabwe, to expand capacity to 430 TCH. New equipment installed included a 120 m3 continuous B pan.

1995 Design of an 86 m3 continuous A pan at Eston Sugar Mill.

1995 Relocation of a 60 tons steam/hour boiler ex Empangeni Sugar Mill to Darnall Sugar Mill.

1995 Design of a 65 m3 continuous C pan for Pongola Sugar Mill.

1995 Design of two boiler scrubbers for Mon Desert Alma Sugar Mill in Mauritius. One for a 50t/h MCR bagasse boiler and one for a 70t/h MCR bagasse boiler including the design of the ash sluicing systemns.

1995 Design of a 160 m3 vertical C crystalliser and 1858 m2 C massecuite reheater for Bois Rouge Sugar Mill in Reunion.

1996 Design of two boiler scrubbers for 25t/h MCR bagasse boilers at Rose Belle Sugar Mill in Mauritius.

1996 Design and installation of a 86 m3 continuous B pan and boiler smuts handling plant at Darnall sugar Mill.

1996 Design of a boiler scrubber for a 140t/h MCR bagasse/coal fired boiler at Beau Champ Sugar Mill in Mauritius.

1996 Design and installation of a 1430 m2 Robert evaporator at Felixton Sugar Mill.

1996 Design of three 60 m3 stirred stainless steel refined sugar batch pans with welded calandrias together with condensers for U S Sugar Clewiston Mill in Florida USA

1996/97 Consulting on energy efficiency and steam control for Al Khaleej Sugar Refinery in the UAR in conjunction with Pinchtech SA. Design of a vapour melter for Al Khaleej Sugar Refinery.

1997 Design of a refined sugar melter for U S Sugar Clewiston Mill in Florida USA

1997 Design and installation of a 160 m3 continuous A pan at Triangle Sugar Mill in Zimbabwe

1997 Design of a 600 m2 C massecuite reheater for Mon Tresor Sugar Mill in Mauritius.

1997 Design of a 100 m3 continuous C pan and a 3500 m2 2nd effect Kestner evaporator and separator vessel for the Umfolosi Sugar Mill expansion. 1997 Design and installation of plate heaters, plate evaporator and a thermo-compressor at Tongaat Hulett Sugar Refinery as part of energy economy consultations in conjunction with Pinchtech S.A.

1997 Design of a boiler scrubber for a 100t/h bagasse/coal fired boiler at Flaq United Estates Limited Sugar Mill in Mauritius.

1997 Design of a 120 m3 continuous A pan for Ubombo Ranches Sugar Mill in Swaziland.

1997 Design of a direct contact presswater heater for Malelane Sugar Mill.

1997/98 Design and installation of 25kg and 50 kg packing lines at Tongaat Hulett Sugar Refinery.

1997/98 Conceptual process design, equipment specification and design for the expansion of the Komati Sugar Mill from 225 TCH to 500 TCH with an intermediate phase of 375 TCH. Equipment designed included a 225 TCH diffuser, 130 m3 continuous A pan, 130 m3 continuous B pan, 85 m3 stirred A batch pan, two 3800 m2 Kestner evaporators and separators, 2000 m2 Robert evaporator, 1000 m2 Robert evaporator, 110 m3 A crystalliser, two 110 m3 C crystallisers, 1240 m2 C massecuite reheater, seed receivers, blowup tanks and condensate tanks.

1998 Design of a boiler scrubber for a 125 t/h MCR bagasse boiler at Simunye Sugar Mill in Swaziland.

1998 De-bottlenecking Entumeni Sugar Mill with modifications to the diffuser drive, evaporators and cooling towers.

1998 Design of a 10 t/h refined sugar rotary cascade dryer/cooler for Bois Rouge Sugar Mill in Reunion.

1998 Design of a 160 m3 continuous A pan, a 160 m3 vertical C crystalliser and two direct contact juice heaters for Pongola Sugar Mill.

1998 Design of a 1000 m2 1st effect Kestner evaporator and separator for Malelane Sugar Mill.

1998 Design of a 120 m3 vertical C crystalliser for Ubombo Ranches Sugar Mill in Swaziland.

1998 Designs for the Phase 1 expansion of the Simunye Sugar Mill including a new cane knife rotor and an expanded evaporator station including three 2200 m2 Robert evaporators, two louvre entrainment separators for existing evaporators and a new condenser.

1998 Design of 120 m3 continuous B pan for Sucoma Sugar Mill in Malawi.

1998 Design of 105 m3 continuous A pan for Dwangwa Sugar Mill in Malawi.

1999 Design of a boiler scrubber for 43t/h MCR bagasse boiler at Riche en Eau Sugar Mill in Mauritius.

1999 Independent assessment, audit and report on the Plate Evaporators at Hippo Valley Sugar Mill in Zimbabwe with regard to performance, operation, suitability, design and meeting supply warranties.

1999 Designs for the Phase 2 expansion of the Simunye Sugar Mill including a 120 m3 continuous C pan with external condenser, Hilo offloader, feeder table and cane carrier.

1999 Investigation and recommendations for improvements to the Hippo Valley Sugar Mill juice heaters, evaporator configurations and evaporator operations. Designs were supplied for four 349 m2 mixed juice heaters and vertical louvre entrainment separators for the 1st effect Kestner evaporators and the 4th effect Robert evaporators.

2000 Conceptual process design, equipment specification and design for the rehabilitation and expansion of Xinavane sugar mill to 120 TCH. Equipment designed included 43m3 continuous C pan, 30 t/h sugar dryer, two 120 m3 vertical crystallisers, 43m3 batch pan, 2000m2 1st effect Robert evaporator, remelter, reheater, entrainment separators and condensers. Designs for cane preparation included a Hilo offloader, cane knife and shredder.

2000 Assessment of the constraints to optimal crushing capacity and identification of bottlenecks in processing for the Hippo Valley Sugar Mill in Zimbabwe. Recommendations included modifications to the diffusers, changes in the boiling schemes and optimisation of existing equipment in the boiling and crystallisation sections.

2001 Design of a 90m3 vertical C crystalliser and a 920m2 massecuite reheater for STE Engineering to be installed in a sugar mill in the Congo owned by SOMDIAA.

2001 Design of 3 vacuum pan stirrers and entrainment separators for retro-fitting into existing white sugar pans at Mhlume Sugar Mill in Swaziland.

2001 Design of a 160m3 vertical B crystalliser for Eston Sugar Mill

2002 Design of a triple effect Robert evaporator set (3 x 270m2 ) for the refinery at Mhlume Sugar Mill.

2002 Design of three entrainment separators for new kestner and semi-kestner evaporators at Ubombo Ranches Sugar Mill.

2002 Process design specification for the expansion of Malelane Sugar Mill to a crush of 2.2 million tons of cane in 38 weeks. High level studies for the requirements for a further increase to 2.4 million tons and for a refinery expansion to 400 000 TPA were also carried out.

2002 Capacity increase design for the SASA Sugar Export Terminal.

2003 Design of two entrainment separators to replace existing Poly-baffle separators in 1st and 2nd effect Kestner evaporators at Komati Sugar Mill.

2003 Design of a stainless steel boiler scrubber for a boiler burning grape pomace for Vin-O-Kem (Pty) Ltd.

2003 Energy survey and proposals to reduce the quantity of coal consumed for Simunye Sugar Mill in Swaziland.

2003 Investigation of energy saving measures that could be implemented at Komati Sugar Mill to allow an increase in crushing capacity without requiring an expansion of boiler capacity.

2003 Desktop design for a 40 000 TCD raw sugar mill in the Sudan. 2003 Investigation and reporting on the factory requirements to enable Komati Sugar Mill to crush 2.6 million tons of cane in a 38 week season.

2003 Design for the expansion of Xinavane Sugar Mill to a throughput capability of 150 TCH.

2004 Design of two phosphotation clarifiers for STE Engineering to be installed in sugar mills in the Cameroon and Chad.

2004/5 Design, procurement and project management of a R50 million WSM slipstream plant at Felixton Sugar Mill to produce white sugar directly at a rate of 8 tons /hour.

2004/5 Design procurement and project management of 3 RDS units for the WSM slipstream plant at the FX sugar mill.

2005 Technology and engineering input to the Feasibility Study for Metahara Sugar Factory in Ethiopia to provide capacity to produce 26t/h of EEC2 refined sugar with integration into the existing factory to provide maximum energy efficiency.

2005 Design of two 110m3 C massecuite vertical crystallisers for Komati Sugar Mill.

2005 Design of irrigated sieve tray boiler scrubber for a new 150 t/hour boiler at Komati

2005 Design of improved 350 TCH cane diffusers for the Fives Cail Group to be installed under licence in Savannah Mill Mauritius and Skeldon Mill in Guyana.

2005 Design of a direct contact vapour heater for carbonatation in the Savola Refinery, Saudi Arabia.

2006 Technology and engineering input to the Feasibility Study to expand Metahara Sugar Factory, Ethiopia, to 700 TCD with allowance for an ethanol production capability and co-generation. 2007 Design Of the XN Expansion to 380 tch (from 150 tch)

2007 Design of the proposed Mafambise expansion to 200 tch