- Customer: UNICOL Limited

Commission in 2006, Unicol Limited is a joint venture distillery project of Faran Sugar Mills, Mehran Sugar Mills and Mirpurkhas Sugar mills. Unicol's plant is located at Mirpurkhas which is around 230 KM from Karachi.  Pakistan is presently the 5th largest country in the world in terms of areas under sugar cane cultivation and is consistently ranked in the top 10 sugar producing countries. In the last 2 decades Pakistan has consistently been ranked as one of the 3 largest molasses exporters in the world. However since the new millenium there has been consistent invenstment in ethanol distilling and now the country has become a major ethanol exporter. Ehanol exports have increased from 100,000 tons in 2004 to 225,000 tons in 2010. Record highest exports of 350,000 tons were seen in 2008. Today there are 15 distilleries operating in Pakistan with an installed capacity of 500 million liters (400,000 tons) and producing different grades of Ethanol. Pakistan has proven itself to produce world quality grades of ENA and ENA Anhydrous ethanol.

 - Flow Meter Type: MST Series Thermal Mass Flow Meter

  
- Specifications:

Model: MST100-300-I-IC-P2/EX   - Type: Insertion Sensor with Integral Converter   - Medium: Biogas (Density: 1.20 Kg/Nm3, Viscosity: 0.018 cP)   - Meter Size: 12" (300A)   - Flow Rate: 0 ~ 5000 NM3/H   - Connection: 1" NPT Compression Fitting   - Material:              Sensor - SUS 316              Wetted Part - SUS 304              Indicator - Aluminum   - Operating / Design Pressure: 200 mbarG / 16 barG   - Operating / Design Temperature: 20~50℃ / 100℃   - Flow Direction: Free   - Display: Graphic LCD with backlight (Flow Rate & Total)   - Input Key: 3 keys   - Power Supply: 24VDC   - Output: 4-20mA, Frequency, RS-485 (MODBUS-RTU)   - Enclosure: IP-65, Ex-Proof (Exd IIC T3)   - Accuracy: ±1.5% FS ±0.5% RD   - Repeatibilty: ±0.5% RD Quantity: 1 Set (This set is being purchased as a trial/evaluation set) Click to visit the website of this flowmeter.

1. Background

The end user, Unicol Limited had decided to replace the existing flow meters (KOBOLD DOG-3 Oscillation Flowmeter) installed in their 16 distilleries in Pakistan. Each distillery needs at least 5 sets. So, the total replacement quantity will be at least 80 sets.

The customer has a biogas production facility that uses spent wash from distillery to generate steam for their distillery process. And the meter will be used for measuring the flow of this biogas, whose typical composition is as below;

Typical composition of biogas
Compound	Formula	%
Methane	CH4	50~60
Carbon dioxide	CO2	40~50
Nitrogen	N2	0~10
Hydrogen	H2	0~1
Hydrogen sulfide	H2S	0~3
Oxygen	O2	0~0.5

The reason for that decision is unknown because we supplied this trial/evaluation set through our Pakistani distributor, Process Control Solutions. We don't know how the existing flow meters performed and how long either. They decided to make a big crossover from a by-pass oscillation meter to a thermal mass flow meter. Usually it's not very easy to make such a big changeover. One thing for sure is that they decided to replace them all.
2. Production and Delivery

Because the requirement is very small and didn't require very difficult specifications. But due to the fact that all the thermal mass flow meters have to be calibrated for quite a long time to ensure measurement accuracy. It usually takes 2-3 weeks, which was the case with this meter, too.

3. Installation and Commission
We expect that the customer will be very satisfied with the accuracy and the workmanship as should be authenticated by this trial unit. And we hope that it will lead to customer's satisfaction and purcase of their whole planned replacement meters, which, hopefully will take place in the year of 2017.

End..