BMA to establish the basis for a higher capacity and an energy-optimised operation
The requirements to be met by modern sugar factories are steadily increasing. Increased processing capacities must be brought in line with an efficient input of steam and energy, a higher plant availability, and economic operation. Especially in case of extensions of existing factories, it is therefore not sufficient to install additional equipment alone. The decisive factor is to combine new and existing plant components with each other in a technologically optimal way.
As long-standing technology partner of the international sugar industry, BMA supports factory owners not only with high-performance equipment, but also with comprehensive process know-how and engineering for the integration into existing plants. The extension of the evaporator station at Faiyum Sugar Works in Egypt is a current example.
Faiyum Sugar and BMA have been working together for many years. Confidence in each other and the precise knowledge of the existing plant form an important basis for the joint further development of the sugar factory. Already before 2010, BMA has been supporting Faiyum in a previous capacity extension with a countercurrent cossette mixer and a BMA extraction tower
Capacity increase to 12,000 tons of beet per day
Faiyum Sugar intends to increase the processing capacity of the sugar factory to 12,000 tons of beet per day. The key role for this extension is played by the evaporator station – for the necessary additional processing capacity as well as for the heat balance of the factory.
For the extension, BMA will supply an additional falling-film evaporator (BMA FFE) with a heating surface of 7.000 m², which will be integrated into the existing evaporator station at Faiyum.
As early as in 2022/2023, Faiyum Sugar and BMA started the technical discussions for this extension, which was steadily developed further in joint meetings and visits on site. Local BMA representatives as well as experienced BMA process specialists were involved in detail in the technical coordination.
At the beginning of 2025, the implementation of the joint project was started.
Concept study as basis for the extension
The concept study prepared by BMA was an essential part of the project for the integration of BMA’s FFE into the evaporator station at Faiyum.
Here, the new falling-film evaporator was not handled as a single apparatus, in fact, the BMA experts examined how the additional evaporation capacity could be optimally integrated into the existing station and the heat balance of the entire sugar factory.
For the future processing of 12,000 tons of beet per day, the focus of the study was laid on the energy balance of the evaporator station: The relevant flows of steam, condensate and product were analysed as well as the related operating conditions.
The existing pipelines, too, for steam, juice, and condensate as well as the necessary interfaces between new and existing equipment items were examined. In addition, the concept study considered all necessary ancillary units and the resulting adaptations within the evaporator station and the factory. The planning also included the integration of instrumentation and automation.
It is crucial for BMA that the extended evaporator station reaches not only the performance required; it is equally important that it is operated efficiently. Due to its central importance for the heat balance of the sugar factory, the integration of the new evaporator was systematically geared to an efficient utilisation of the available steam and heat flows.
Particularly in case of Brownfield projects like Faiyum, the benefit of a comprehensive engineering approach is demonstrated: It is not the single machine, but its optimal integration into the overall process, what decides on a later successful operation.
Engineering up to layout and plant integration
Apart from the process engineering part of the concept study, BMA examined jointly with Faiyum Sugar also the spatial integration of the new falling-film evaporator.
For this purpose, a plant layout was prepared which considers the installation of the new evaporator and associated equipment items within the existing factory infrastructure. The required space for pipelines as well as important interfaces to foundations and steel structures were equally covered by the study.
Especially for the modernisation of existing sugar factories, this interface competence is of vital importance. Existing structures, routings, and process conditions are to be considered, while the technical prerequisites for an increased production capacity must be ensured.
Modern falling-film evaporator technology for an efficient heat balance
The extended evaporator station is designed for an energetically optimised steam balance and a specific energy input that is as efficient as possible.
BMA’s falling-film evaporator technology offers essential benefits here: a high heat transfer coefficient, short juice residence times, and an even distribution of the juice over the heating surface. The multi-effect BMA juice distribution system ensures an even wetting of the heating tubes and supports stable heat transfer conditions. Thanks to the low juice volume and short residence times, the juice can be treated in a particularly gentle way.
For Faiyum, the interaction of the new falling-film evaporator with the existing evaporator station was of special importance. The technical design was therefore prepared with an eye to the overall process and the factory’s heat balance.
In this way, the project integrates additional processing capacity with the aim to operate existing and new plant components as efficiently as possible together.
The next steps of collaboration
BMA assists Faiyum Sugar in the installation and commissioning of the new falling-film evaporator, which ensures the successful integration into the existing plant.
At the same time, Faiyum Sugar and BMA are looking ahead to the next steps in the development of the factory. Further potential projects and technical extensions will be jointly assessed and agreed in the meetings to come.
The Faiyum project is an example showing how BMA assists existing sugar factories in the long-term further development: from the process analysis and integration study via engineering and equipment up to installation, commissioning, and continuous technological assistance.
In doing so, BMA focusses not only on a single project, but on a long-term collaboration with the customer. The partnership with Faiyum Sugar is a good example for this.