Kakira Expansion Project
Planning for Success through Innovation
With a population of over 30 million, Uganda's current per capita sugar consumption is 10.7 kg pa – with about 325,000 tonnes (MT) of sugar being consumed each year.
The total quantity of sugar produced in Uganda in 2009 was 287,000 MT – the balance is made up through imports of sugar.
From 2004 to 2008, Kakira undertook a comprehensive expansion program at a cost of over US$ 50 million. The project was funded by:
In addition, the biomass based cogeneration component was awarded a Global Environment Facility grant under Uganda’s ERT Programme for 6MW electricity supply to the grid during the peak-period (6h/d). Moreover, Kakira applied to UNFCCC for the Carbon Emission Reductions for the incremental electricity supply which was increased to 12MW 24/d.
There was a complete overhaul of certain operations and installation of more equipment to achieve a crushing rate of 280 tonnes cane per hour (TCH) - over 6,000 TCD. In addition new equipment was installed for additional electric power co-generation.
The Cane Yard
The Milling House
And in the Processing Plant…
A new Turbo-Alternator
A new Powerhouse
Strengthening the Power Distribution System
Increased Steam Power
The new Electric Power Co-generation Plant
Planned Further Expansion 2010-2012
Based on Kakira’s experience so far, we envisage that there is adequate potential to expand total cane supply to 2 million tonnes per year (2,000,000 TCY) by the year 2012.
The Madhvani Group has therefore decided to expand the Kakira plant to a capacity of around 315 TCH (say 7,200 TCD) and expand its cogeneration plant to utilise all the additional bagasse (fibrous residual of cane) from the expanded project considering the continuing power shortage in Uganda.
Kakira Sugar appointed J. P. Mukherji & Associates Pvt Ltd [JPMA] of India in June 2009 to prepare a Techno Commercial Evaluation of this Expansion Proposal. The Consultants’ report has confirmed the technical feasibility of:
The expansion project includes implementing steam efficiency measures in the existing factory to make more steam available for electricity generation.
According to the JPMA Report, the total expansion project cost is estimated at US$ 65 million.
Project implementation has commenced with the ordering of a 3 MW turbine and 60 ton batch pan to ensure that the Kakira capacity is increased to 1,800,000 TCY in the financial year 2010/11. Kakira has also replaced the steam turbine drives on one of its two milling trains with high HP electric motors.
The other factory project components include:
All of these will be procured shortly and the expanded project is expected to be commissioned by July 2012. After the completion of the expansion project, KSW will produce 180,000 tonnes of sugar each year.
Simulataneously, Kakira’s cogeneration capacity will also be expanded.