Capacity expansion for Etihad Sugar Refinery, Iraq
Future-ready refinery design enables seamless capacity growth
BMA supplied key equipment for upgrade to 5,500–6,000 tpd
After more than ten years of successful collaboration, BMA once again supported the Etihad Sugar Refinery. Back in 2012, BMA was commissioned by Etihad Food Industries to design and build Iraq’s first sugar refinery. Under an EPCM contract, BMA provided comprehensive engineering and project management services as well as the supply of key process equipment.
Following the commissioning of the refinery in 2014, BMA and Etihad maintained regular cooperation to support the long-term reliable and efficient operation of the plant.
BMA once again assisted the company with a major capacity expansion project aimed at increasing the refinery’s production capacity to 5,500–6,000 tonnes of RSO per day.
Customer profile
- Company: Etihad Food Industries
- Location: Iraq
- Industry: Sugar refining (raw sugar to white sugar / RSO)
- Background: Iraq’s first and, to date, only sugar refinery; constructed in 2014 with BMA as EPCM partner
Initial situation & challenges
- The Etihad refinery was built more than a decade ago as a key project for strengthening Iraq’s sugar industry.
- BMA was responsible for the complete engineering and supplied all major process equipment, making the project a milestone for the country’s sugar sector.
- The refinery infrastructure was originally designed to accommodate future capacity expansions.
- Several years after start-up, Etihad had already increased production capacity to approximately 4,200 tpd without requiring major modifications to the existing process.
- Etihad subsequently targeted a further expansion to 5,500–6,000 tpd of RSO.
- The key challenge was to execute the upgrade with minimal disruption to ongoing operations while ensuring efficient integration of new equipment into the existing process.
Scope of delivery by BMA
Engineering & Collaboration (2023)
- On-site discussions between Etihad and the BMA team regarding the technical implementation of the capacity upgrade.
- Alignment of the expansion strategy based on the existing infrastructure and the original engineering concepts.
BMA Supply Scope for the Current Upgrade
BMA supplied key equipment for the capacity increase, including:
- 1 batch pan (DVK)
- 2 falling-film evaporators (FFE)
- 1 vertical cooler for the drying station
- 1 massecuite pump
Solution approach & implementation
- Strategic foresight: The original engineering design already included provisions for future capacity expansions.
- Efficient upgrade: The new BMA equipment was integrated seamlessly into the existing process chain.
- Continued close technical collaboration:
- On-site coordination and technical discussions
- Utilisation of the original engineering know-how
- Integration through existing process interfaces
Project Status
- All equipment was delivered.
- Installation was completed.
- Commissioning was successfully carried out in 2024.
Results & key figures
Target capacity:
5,500–6,000 tpd RSO following completion of the upgrade
Previous capacity after the first expansion:
approximately 4,200 tpd
Expected Benefits
- Improved production stability
- Minimal integration effort due to the infrastructure provisions incorporated during the original plant design
- Increased refining capacity through the addition of key process equipment
- Continued utilisation of the refinery’s proven process concept and operating philosophy