f 424 “Refresher course for Sugar Technologist & \ Sugar Engineers” 25" to 30" July 2005 Sr. ‘Name of article and author Page no. no. 7. | VSI three & half massecuite boiling scheme 1-5 Dr. M. B. Londhe & K.B. Kale 2. | Raw Sugar scenario in Indian Condition 6-13 R.V. Dani and Shekhar Pachpute 3. | Effective management to improve Mill Performance 14-29 K.B. Kale & Dr. M. B. Londhe 4, | Electrical Systems in the Sugar factory 30-34 U.A. Kulkarni — Electrical Engineer 5. | An overview on instrumentation in sugar industry 35-42 R.B. Chikhale 6. | Process Chemicals: Utility in Sugar Manufacturing Process: 43-53 Dr.(Mrs) A.D.Kulkarni & Mr. A.V. Yewale, 7. | CV and MA determination 54-60: V.P. Sidanale and Dr. M. B. Londhe 6. | Techniques for production of low coloured plantation white 61-75 sugar Dr. R.N. Bhosale @. | Sugar Factory Water & Waste water management 76-83 D.B. Sapkal 10.| Vapour bleeding and steam economy Fe 84-94 | DB Jambhale j TT, Different options in Cogeneration 95-124 Mr. V. G. Chikhalikar; Tech Advisor (Sugar Engg), VSI Pune 42| Milling - Repairs, maintenance, operation and trouble shooting 125-150 Mr. T. M. Karne, Consultant, Pune. 73. Design aspect of Cogen boiler & boiler trouble shooting Mr. Anand Mokashi, Director, M/S Gaurav Enterprises, Pune. 74| Improvement in Cogen cycle efficiency by providing HP heater Mr. K. R. Patil, Tech Advisor (Sugar Engg), VSI PuneiS bbbbud Bw om i 3 3 2 (= ‘Vasantdada Sugar Institute, VSI three & half massecuite boiling scheme ! Dr. M. B. Londhe & K.B. Kale Vasantdada Sugar Institute, Pune Key words: improved massecuite boiling scheme, Az massecuite, higher purity drop for ‘A boiling, Low purity AL molasses, Lower massecuite % cane Abstract: For desugarisation of high purity juices, normally factory adopts “three and half massecuite boiling scheme” with intermediate BI/B2 ot C1/C2 massecuite, The use of routine “three and half massecuite boiling scheme"is associates with number of disadvantages such as Increase in total massecuite % cane of the order of 3-5 % on cane, Decrease in plant capacity to the tune of 15 % cane due to need of additional pan boiling capacity for intermediate masseeuite, Increase in steam consumption as well as power consumption & Higher viscosity of low grade massecuite. ‘To overcome the disadvantages of three massecuite boiling scheme and three and half massecuite boiling Vasantdada Sugar Institute have developed “an improved three and half massecuite boiling scheme” comprising A, Az, B and C massecuite boiling. The intermediate A2 massecuite is prepared from low purity AL molasses. The improved boiling scheme was found helpful for reducing massecuite % cane as well as lower C ‘massecuite purity, which helps to reduce sugar loss in final molasses. Introduction: A Light molosses is generally used for high grade massecuite boiling. As a preliminary requirement for using AL molasses for high grade massecuite, the colour of ‘AL molasses shall be kept in the neighborhood of high grade massecuite, To achieve this fone has to keep syrup separator delay quite high i.e. 20 to 35 seconds. Due to this higher delay time, some portion of initial A Light molasses is diverted to A Heavy molasses stream. Due to this diversion of A Light molasses, the purity of A Heavy molasses increases by 2 to 4 unit depending on timing of syrup separator delay. At the same time, ‘A Light purity is also increases and the quantity of A Light molasses decreases considerably. As an overall effect of above leads to higher purity of A Heavy molasses, lowering purity drop from A massecuite to A Heavy molasses, increase in purity of B massecuite, increase in B massecuite quantity. At the end this results in higher C massecuite purity. In case of high purity juices and where A massecuite purity is 90.5 +, the A Heavy purity may also increase up to 80+. In such a situation, it becomes difficult to ‘control the C massecuite purity and sugar oss in final molasses to accepted level. Refresher course for ST & SE, July 2005‘Vasantdada Sugar Institute, Pune “To over come this, normally sugar mills adopt three and half massecuite boiling \ scheme. In three and half massecuite boiling, scheme, intermediate massecuite. in t between B and C massecuite is prepared. The massecuite % cane of intermediate ' errecuite is kept inthe range of 2 to 4 % on cane. The intermediate massecuite may be ae as BL/B2 or C1/C2 depending on the graining practice. This massecuite boiling “conventional three and half massecuite boiling” type is helpful for adent. However, it associates with number scheme of | controlling the final molasses purity to some © \ of disadvantages as follows, + Increase in total massecuite % cane of the order of 3-5 % on cane. 1 Decrease in plant capacity to the tune of 15 % cane due to need of additional pan | oiling capacity for intermediate massecuite. | 1 Tnorease in steam consumption as well as power consumption. Higher viscosity of low grade massecuite | ‘VSI three and half massecuite boiling scheme: | “To overcome these difficulties, the idea of A2 massecuite preparation from low | purity AL molasses is thought and the fied trials of the same were conducted of Mis ; Pay ghetkari &.8.K. Ltd, Shirol, Dist Kolhapur in 2004-05 crushing season. With this | patfihed boiling scheme, thee is deerease in massecuite % cane. The steam consumption \ falso remains on lower side, The basic changes / modification made in this boiling l scheme are as follows \ = The AL molasses purity is controlled to 85 in place of 90+ by controlling i centrifugal machine timers especially syrup separator delay from AH to AL, ! first water wash duration & second water wash delay or rpm. \ = Contol of AL putty to 85, helps to avoid mixing of Light molasses in | Heavy molasses. This lead to reduce heavy molasses purity by 2-4 units as | ‘compared to earlier system. \ «The separate boiling of AL molasses completely avoids the fear of decrease \ in sugar colour due to faulty operation of syrup separators. = Bamasseouite and C massecuite purty are controlled to satisfactory level “The object of VST massecuite boiling scheme is to overcome the disadvantages of conventional “Three massecuite boiling scheme” and “three and half massecuite boiling : SShome * for reducing final molasses purity with lower massecuite % cane. The VSI Three aad half massecuite boiling scheme comprising A, Az, B and C massecuite boiling Forcontrolling final molasses purity at desired level with lower massecuite % cane. The detail flow diagram of “VSI three and half massecuite boiling scheme” is given in figure Referring to figure 1, thick line blocks indicates the invention in comparison ‘> | conventional massecuite boiling scheme and describes the detailed improved masseouite Bolling process where an intermediate massecnite Az in between A and B massecults is prepared, A heavy purity is controlled below 76 (2-4 unit lower than normal purty) The Refiesher course for ST & SE, July 2005 zad PUBBHUHUESY ae ‘Vasantdada Sugar Institute, Pune maximum purity drop from A massecuite to A Heavy molasses is achieved by adjusting different centrifugal machine operational parameters such as Syrup separator from heavy to light, First water wash rpm, First water wash duration, Second water wash rpm, Chute wash delay and time etc. All A light and partial A heavy are used together for Az massecuite. Az massecuite is cured in continuous centrifugal and Az heavy having purity below 64 is used for boiling of B massecuite. ‘The special feature of the VSI massecuite boiling scheme is a special intermediate massecuite Az is prepared from A light molasses, the purity of which is controlled below 84 by using appropriate quantity of A Heavy molasses and the Az massecuite % cane is controlled to 3 to 3.5 % on cane by controlling the A Heavy molasses quantity used for Ac massecuite ‘The advantages of “VSI three and half massecuite boiling scheme” are as follows i) Decrease in total massecuite % cane as compared to conventional messecuite boiling scheme. if) Decrease in sugar loss in final- molasses iii) Increase in plant capacity without increasing the boiling house equipments as compared to conventional “three and half massecuite boiling scheme”. iv) "Decrease in steam requirement as well as power consumption. v) Decreases the viscosity of low grade massecuite. Table 1- Average comparative results of VSI three and half massecuite boiling scheme Sr Particulars Conventional three | VSI three and half 10. massecuite boiling | massecuite boiling scheme data scheme data T__| Massecuite % cane Total 33.55 49.84 A 31.79 30.27 Ag a 3.20 B 13.81 10.08 c 7.95 6.29 2_| Purity drop ‘A massecuite to AH 139 14.62 “Aa massecuite to AzH = 19.13 'B massecuite to BH 21.38 18.42 ‘Cmassecuite to Final 28.46 21.18 3_|% Exhaustion ‘A massecuite to AHL 60.60 68.10 ‘Az massecuite to AoHi = 63.96 B massecuite to BH 64.13 55.72 ‘C massecuite to Final 69.20 58.25 4 | Massecuite Purity A 90.56 91.04 Ag = 83.17 B 79.38 73.35 c 60.62 54.68 1 Refiesher course for ST & SE, July 2005 zField trials of VSI masseeuite boiling scheme: \ “The field trials of “VSI three and half massecuite boiling scheme” is conducted at ii Mis Datta Shetkati 8. S. K. Ltd, Shirol, Dist- Kolhapur during 2004-05 crushing season. \ ‘The details of the VSI masseeuite boiling scheme trials at factory are as follows, Aes 415 & 16" January 2005 -Modification in molasses pipe line work | 17" to 27" January 2005 -Implementation of VSI boiling scheme first tial \ 28° Jan to 7” Feb 05 — Factory faced problems & VSI massecuite boiling scheme | ‘was not adopted | 8" Feb to 28" Feb 05- Second trial of the VSI massecuite boiling scheme | “The second field ‘rials of the VSI boiling scheme were stated on 8 February \ 2005, The boiling scheme stabilized with in a day. The table no. 1 shows various \\ performance parameters for before and after implementation of the new boiling scheme. | Tipe factory had followed the same boiling scheme till the end of season. “The results of field trials of “VSI three and half massecuite boi \\ given in Table 1. The results confirmed the following | “Increase in purity drop from A massecuite to AH molasses from 11.39 to | 14.62 units | Decrease in B massecuite purity by 4-5 unit i | "Decrease in B massecuite % cane by 2-3 %. Control of C massecuite purity below 55. ig scheme” are Conclusion: | Vsti developed “VSI three and half massecuite boiling scheme” was found superior over conventional “three and half massecuite boiling scheme”. The new invented balling scheme is helpful for last massecuite purity control with desired level and lower || Sugar loss in final molasses with lower massecuite % cane. The totel low purity massecuites % cane also reduces considerably. Acknowledgement: 1 ‘Authors are thankful to Shri V. P. Rane, Director General & Mr. Shivajirao | Deshmukh, OSD, Vasantdada Sugar Institute, Manjari Bk, Dist-Pune, for their | encouragement during this work and permission to publish the same. Authors are also te thankful to Mr. M. V. Patil, Managing Director; Mr. Genge, Chief Chemist; Mr. M. R- Patil, works Manager and Mr. Tare, Dy. Chief Chemist of Mis Datia Shetkar S. S. K- | Tid Shirol, Dist- Kolhapur for their help during field tials. Authors are also thankful to fall chemists & Engineers of the factory for their cooperation during this work, I eee see rene eee eee Refresher course for ST & SE, July 2005an Fil Notas Py Below a9) ¢ (Cr Seer th 29 ‘BFW Sugar, Py-54r, 0010 CW mas AW, Py 935, 5000 (Conn barsee “Vasantdada Sugar Institute, Pune Raw Sugar scenario in Indian Condition R.V. Dani and Shekhar Pachpute Dept. of Sugar Technology, VSI Pune INTRODUCTION: Jone pars of our country such as Maharashtra, Kamataka, Tamilnady ot, Wee having shorlage of sugarcane during the years 2003 to 2005 which hax resulted into avin in production of sugar up to 125 Lakh MT in ast season 2004-05 Despite of an anticipated production of sugar in India in the coning Season 2005.06, domestic production i likely to remain about 15 min tons | (150 ‘Lakh tons) ane ten consumption, while surplus stocks are already exhausted. Thus India iy Iively remain a buyer of raw sugar from the world market for one more Year NOW and will have reprocess it into white sugar. vi tndia, Raw sugar is manufactured and exported when there was @ bumper Crop of sugareane eg, During 1995-96, 1999-00. But reprocessing of imported raw sugar or ag the year 2002 in India, Some Indian factories lke Sakthi Sugar, Renuka sugars fo. imported raw sugar and exported white sugar produced from it. Considering above facts, Indian sugar mills should develop flexibility to process Indian / imported raw sugar to produce best quality plantation white or refined sugar. PRODUCTION OF RAW SUGAR IN INDIAN SUGAR MILLS : "The cane juice is clarified by simple ‘Raw sugar is manufactured from cane juice. defeeation provess, In tis process lime & heat are two basic agents. This isthe oldest & heapest method of juice clarification, Phosphoric acd is added to increase 0s content Gf juice t9 300 ppm. Then ime is added to neutralize organic acs besides insoluble ieatctum phosphate: (Cas(PO)a}, is also formed which oecludes colloids & suspended impurities. In defecation process clarification of juice is done by following methods. Cold liming :- Juice is first limed to pH = 7.8 to 8.2 & then heated to 103 10 105°C & Ce seat to subsider. Disadvantages of this process is that there is growth of dextran gel ‘which causes choking of pipelines. Hot _ Juice is heated to 70°C & then lime is added upto 7.4 to 7.8 pH, depending. ton the plT of clear juice (it should be 6.8). This limed julce is heated tp © 103-105°C, ran ee Me subsider for seting. In the hot liming process, heating prior to liming bas aiastage of coagulating the colloids ike albumin, siliceous ete. Also there is constant difference in pH between limed juice & clear juice. Fractional li jouble Hi ‘A).__ Addition of lime to cold juice to pH = 6.210 6.4 B) Heating of limed juice to boiling temperature. ©) Then ation of lime in second stage upto pH = 74 to 7.6 & hewing of alkaline je to the temperature 103 to 105°C & then sending to subsides for settling, ‘Refresher course for ST & SE, July 2005 63 ee ye (mt) ew woe SUGAR IMPOR’ “Vasantdada Sugar Institute, Pune Tn order fo put the machinery of sugar factory, man power in operation rather than keeping idle and to reduce the overhead charges for a short crushing season2004-05, some sugar factories in Maharashtra have imported Raw sugar from Brazil and South ‘Africa and reprocessed it in the existing plants. Following Sugar factories in Maharashtra had successfully reprocessed imported the guidance of VSI Pune. raw sugar during the season 2004-05 under Factory namie "Total Raw sugar [ Cane crashed | Raw sugar | Yield of White FOB. price of raw sugar Reprocessed. | (MT/day) | Processed | sugar to Raw (MT) (MT Day) ‘sugar TK Warana SSK. Led 16953 Warananagar Season ~ 15655 3000 150 98.26 208 USS /M.T. (Off season - 1300 : 250 ‘Shri, Pandurang SSK. Lad 5000 Shreepur, Solapur Season ~ 4000 3450 100 95.50 260 USS MT. (Off season - 1000 : 200 PV. P.Pravara SSK Lid, AT TIL nagar. Season — 4275 2500 133 95.25 225.12 USS /M. Off season - 3696 : 100. Vishwas SSK. Lid. Shirala, Sangal 1368.06 2500 1 95.50 Job work from Warana, (season) ‘Mabankali S.SK. Lid. ‘Kavathemahankal, Sangli, unas _ 106.11 7830 | Job work from Warana (Off Season) i Kranti SK. Led. Kundal, Sangal 1403.165 2000 40 95.50 ‘ob work from Warana. season) ‘Sonhira SSK. Lid. Sengali 1770289 2000 0 95.50 Job work from Warana (eason) ‘Ch, Shabu SSK. Led, Kagal, 720000 Kolhapur. Season — 16351 4050 40 94.18 240 USS /M.T. Offseason - 3469 _ 240 Rajarambapu Patil SSKLG Walwe. 4355.30 4789 40 95.50 Job work from Renuka (Geason) Vaidyanath S.S.K. Ltd Parali,Beed. 5000.00 1200 210 93.00 (season) ‘Natural Sugars Lid, Kalam, T8I34T Osmanabad Season—7041.83 | 1200 0 1800 90 95.70 230 USS /M.T. Off Sea.— ‘i 180 0771.64 Senjivani SSK, Taka, "794040. 250 3000 ‘Ahmednagar Off: Season -8150 Kopargaon SSK Led 8020.89 3050 Kolpewadi, Ahmednagar Season - 800 to 1000 200 Offseason - 300 “Total Raw Sugar Processed 99070.894 (MD) Refiesher course for ST & SE, July 2005| ‘As mentioned in the above table about 99000 MT raw sugar has bess cS. processed by the sugar mills. The mills have processed imported raw sugar of only S | process south African source having low colour of 1100 to 1500 1U; Most of Pexriltar factories have processed raw sugar during the crushing sasoe CSG" R I 1 the Sua ie Ltd, Warananagar (for one week only ) and Sanjeevani SS. Lid a | Nramettpavar (for 40 days ) by using melt clarification system installed by factory oS Ahmedvagtrgson SSK. Ltd Abmednagat (for 15 days) using suiphiton & el | decoloursing chemicals. | \ By { PROCESSING OF RAW SUGAR: pany 1 Itis possible to process imported raw sugar by following methods, i i! Pe Raw sugar melt clarification by phosflostation method. & 2. Raw sugar melt sulphitation (Low TU raw sugar) Following specifications can be considered as guideline based on experience. & i + Specifications of _raw sugar: & i Sr.Now Parameter Units ‘Specification | 1__ | Polarisation % Min. 99.00 S |) 2 ‘Moisture % ‘Max. 0.10 a l 3 Conductivity ash % Max. 0.15 a I) 4 ‘Reducing sugar % ‘Max. 0.15 e | 3 Colour WwW. ‘Max. 1000 - 1500 aa it 6 Starch ppm ‘Max.150_ & I 7 Dextran ppm ‘Max. 150 e 8 ‘Sulphite ppm Nil. - | _ | ‘Melt clarification decolourisation by improved phosfloatation process in 2500 TCD a Sc | plant during season & Off season. \ i | ‘The factories in which syrup / melt clarification system is installed can reprocess raw i ugar by this process. The sugar produced by this process is of colour 70-90 TU, which can be easily exported. | Machinery & Equipments required for raw sugar melt clarification by pphosfloatation process are as follows. {. 1) Handling of Raw Sugar iar sugar bin of two hrsstorage capacity or feed hoppers Vr b) _Beltconveyor | ¢) Magma mixture _‘Afination centrifugals (for high colour raws- Optional) i 2) Melting of Raw Sugar a) Melter with Steam coil . — Refiesher course for ST & SE, July 2005 8c ne ‘Vasantdada Sugar Institute, Pune b) Screening arrangement 3) Clarification & decolourisation a) Receiving tank ») __ Lifting pump with flow control valve ©) Tubular/plate type heat exchanger 4) Reaction tank with cavitation aerator e) Flotation clarifier 2) _ Desweetening equipment h) Clarified and decolourised liquor receiving tank i) Chemical preparation & holding tank i) Lime suerate preparation tank ii) Lime suerate holding tank iii) Phosphoric acid preparation & holding tank iv) Colour precipitant preparation tank ¥) Colour precipitant holding tank vi) Flotation agent preparation tank vii) Flotation agent holding tank 4) Filtration a) Lifting pump to filter ) —_Leaftype / Multi bed filter ©) Filtered liquid receiving tank 5) Pan boiling (five massecuite boiling system) 6) Centrifugation, Drying & Cooling, Gradation & Bagging 3 9 D 6 oO 7 we Refresher course for ST & SE, July 2005 ||A) Scheme of boiling in Combined Processing of raw. SE with Sugar cane in 3200 TCD plant during season by using Phosfloatation ‘method or Sulphitation method. Sugarcane crushing Raw sugar melting at rate of 2500 tons / day 80 tons / day Clatificttion & Evaporation ‘Raw sugar conveying to Melter Voruged Syrup Mate iguor™ ——— 1» (Clarification or Sulph.) Reaction tank (ime, HsPOs, Flocculent, Colour preefpitant ) ‘Ac Masgecuite ¥ Clarified (Melt +Syrup) mixture 1 Mol Sugar A- HMol ‘Bagging B- Massect B- sugar B-H Mol For A- Mass. (C-Massecuite ce sugke for A-boiling > avy Molasses D- Massecuite. Y Fore Magma Final Molasses aoeeeeeeeen TY Deaftermagma _D-light Molasses. During off season, Raw sugar will be melted at the re of 350 Tons per day and five massecuite forward boiling scleme will be, followed as mentioned below. (Rear co TB SE ag 2005_— ae Refresher course for ST & SE, July 2005 10}fs ‘Vasantdada Sugar Institute, Pune B) Scheme of boiling in Independent Processing of raw sugar in 2500 TCD plant during off-season by using Phosfloatation method Raw sugar (Pol %- 99.0 min. ) ] Conveying of a to Melter | ! Melter Melted liquor heating to 80°C ~ 85°C. Phosphoric acid | (300 gm/ton solids ) Surfactant (500 gm / ton solids ) H Lime ( Cal. Sucrate) i (0.5 to 0.8 kg / ton Solids ) Reaction Tank | (15 gm /ton solids) Continuos float Floatation aid I + Micronised air mn clarifier —> Scum Removal Multi bed vende Clarified liquor for crystallisation (R-1 to R-5 Massecuite ~ Forward boiling scheme will be adopted. ) R-L sugar & Part of R-2 Sugar bagged. ©) Bleaching of raw melt: (During crushing season and off season ) | In this process the raw sugar melt isto be bleached by sulphur dioxide / hydrogen peroxide to produce white sugar of colour of about 120 to 130 TU depending upon input raw sugar colour: So far this process. is not followed in India. This process can be exclusively used in case of low colour raw sugar ( Raw sugar colour of less than 1000 TU) ‘Some medification in the existing machinery will be needed for this process that can be done at factory level with small expenditure. The equipments required will be as follows. Refresher course for ST & SE, July 2005 Saana aeaeeaauane i\Vasantdada Sugar Institute, Pune 1) Handling of Raw Sugar 8) Raw sugar bin of two hrs storage capacity / Feed hoppers b) Belt conveyor ©) Magma mixture 2) Melting of Raw Sugar a) Melter with steam coil b) Screening arrangement ©) Transfer pump to sulphitation tower Further the sulphited raw melt will be boiled in the conventional pans with five massecuite boiling system & the sugar produced will be of colour 120 to 130 IU. CHEMICAL USAGE AND Cost: Following tables shows the actual chemical cost involved in the raw sugar processing on per ton basis by using phosfloatation or simple sulphitation method of clarification of raw melt. Phosfloatation method : Sr. Material Cons. 7 ton of | Price 7 Kg of | Total cost in No. Raw sugar material Rs./ ton 1 |i) Lime 0.50 kg + 25 1.25 if) Phosphoric Acid 0.35 kg+ 35.0 12.25 iii) Colour Precipitant 035 kg+ 250.00 87.50 iv) Flocculent 0.015 kg 400.00 6.00 v) Ion Exchange resin 0.15 lit 200.00 30.00 Nal 5.00 Kg 2.00 10.00 NaOH 3.00 Kg 18.00 5.40 2 | Total Cost 152.40 Sulphitation.and Colour Precipitant: Sr. [Material Consumption Price per Kg of | Total eost_in No. Per tonne of raw| material Rs. Per ton sugar 1 |i) Sulphur 020 kgs 600 12.00 }) Colour Precipitant 0.25 kg 300.00 75.00 i) Flocculent 0.015 kg 400.00 6.00 2__ | Total Cost 93.00 STEAM, POWER AND WATER CONSUMPTION : With the recent experiences in the raw sugar processing, it was observed and calculated that One MT of Raw Sugar processing requires about 1.8 to 2.0 MT of Steam i.e. about 0.9 to 1.0 MT of Bagasse in case of Independent processing of raw sugar and in Combined processing of raw sugar with sugarcane the steam consumption is in the range of 1.35to 1.40 MT/ MT of Raw sugar.. During the season, it was noticed that power consumption per ton of raw sugar was in the range of 80 to 90 KW per MT of raw whereas in the off season, it Refresher course for ST & SE, July 2005ce acest gar nadine: Pane eis EE] was. increased to 120 -130 KW per MT. of raw depending on factory lay out and condensing and cooling system. ‘During Season, it is observed that total water requirement in Independent processing of raw sugar is about 1.16 to 1.20 MI/MT raw sugar, as condensate is equired for magma preperation, melting, washing at C/F machines, movement water in pans ete. hence same quantity is required as make up in boilers. While during Combined processing excess condensate from boiling house particularly evaporator Vapour condensate and Pan vapour condensate will be sufficient for raw sugar melting. ECONOMICAL VIEW OF RAW SUGAR BUSINESS: ‘With recent observations ffom the actual observations and calculations, following are the some of the typical expenses which take place in overall raw sugar business. 1) Raw sugar cost (C.LF.) was varying between 210 USS to 260USS per ton of raw sugar. 2) The Unloading, clearing , forwarding expenses are in the range of 25 to 30 USS per ton of raw sugar. 3) Processing cost of Raw sugar includes handling, fuel. Chemicals. Interest ‘on investments, Packing, Manpower, Maintenance etc is in the range of 55 to 60USS. 4) Based on above calculations the selling price of white sugar in the domestic. market on the basis of 95% yield_of white sugar from raw sugar will be in the range of 300 to 360USS ( Rs. 13000 to 16000/ ton) Reftesher course for ST & SE, July 2005“Vasantdada Sugar Institute, Pune Effective management to improve Mill Performance K;B. Kale & Dr. M. B. Londhe ‘Vasantdada Sugar Institute; Pune. ‘This article reviews the various techniques used to improve the mill performance as well as smiooth working of mill station. The authors implemented these techiiques to improve mill performance of few sugar rills.‘The case study of these sugar mills is also discussed in this note. Factor influc work: @ ‘The purpose of:milling is to extract as much sugar as possible from the cane, consistent with desired capacity. The mill extraction i. pol extracted percent pol in cane, is largely influenced by the pol and fibre percentage in cane. The work of ‘milling train is extraction of juice from fibre and performance can best be judged on removal of juice percent fibre. ‘The overall work of tandem depends on; DMD mH P (1) Crushing at the indivisual mills. @)__Imbibition between mills. ‘Therefore, to obtain maximum overall work, each mill must remove as much juice-as possible from the fibre and each stage of imbibition must dilute the residual juice in the corresponding bagasse. Good Extraction of Juice requires: a) Abigh degree of compression of the feed. b) Adequate preparation of feed. ©) Good drainage ofthe juice from the point where it is extracted. ‘The degree of compression is of prime importance to juice extraction. Since volume of juice removed is essentially equal to the reduction in volume from the feed. to that. of the compressed’ bagasse between the discharge rollers. = = Adequate preparation of feed is required to extract juice much more readily from finely prepared material than from whole cane. With coarse preparation, the pressure exerted by the roller is largly absorbed for breaking up the structure of cane instead of being available for ready expression of the juice. Ca Reffesher course for ST & SE, July 2005[ ‘Vasantdada Sugar Institute, Pune - Effective drainage of juice is necessary to enable juice to escape fully; otherwise, the juice released by the compression of feed will be re- absorbed in the bagasse instead of draining it. - The roller grips the feed at certain position and compresses it to a thickness, which is minimum opening between rollers. The position at which the rollers grip the feed depends on the friction between the feed and the roller surface. = When, external force tends to push feed into the opening between the feed rollers, such force assists the frictional grip and gives improved feeding and equipment that applying such external feeding force may be termed as a feeding device. Donnelly chute, underfeed roller, pressure feeders, thus classed are feeding devices. = They give a slight degree of compression to the feed and provide mill with higher bulk feed material and provide some positive pressure to push the feed into feed opening. Also, this devices remove some surplus imbibition fluid and feeding to some extend dry feed to the mill rollers. Such removal of juice alters nature of feed. Factors of mill construction and operation: Roller Surface: A rough surface will give a higher co-efficient of friction, where as a smootir surface/ polished surface will cause marked drop in friction. ‘The composition of the cost-iron used for roller surface is chosen to give a course grain structure and to maintain rough surface. The feed is liable to slip with certain conditions of operation; for example; use of hot maceration, and alkaline juices. Once slip occurs, it has polishing effect- siving boost to further slip. This may be further increased, with wearing roller grooving. ‘To prevent wearing the effect, and edging of roller grooving, it is now common practice to carryout arc welding the roller surfaces in order to-make roller surfaces rough, which gives substantial improvement in feeding qualities. Roller Grooving: ‘The circumferential V grooving of roller is designed to give better feeding by, ‘wedging action of the bagasse compressed in the grooves. For full of groove feed material- w= wCosec 0/2 ht = Co-efficient between feed material and roller surface. ‘Thus, smaller angle will give better frictional grip and groove angle less than 35° would give better feeding. ‘A larger diameter may be utilized to give a higher degree of compression at a given angle of nip, and hence, higher extraction. Larger diameters are utilized to give higher crushing rate at a comparable extraction. : SERENE Ta) Refresher course for ST & SE, July 2005 1‘Vasanidada Sugar Institute, Pune Speed of Rollers ‘The co-efficient of friction decreases with increase in roller speed and leads to interior feeding. It may be due to less efficient drainage at high speed, and thus juice has increased lubrication effect with decrease in co-efficient of friction, Economical mill speed to achieve desired capacity, extraction and optimizes power, is inthe range of 7-12 m/min. Cane Variety and Cane Preparation: ‘These two have to be considered for individual qualitative effect. Preparation produces felting tendency and particles become matted together and hence cane ‘compressed between rollers will have some pull of mat of cane into mill and this felting tendency will vary with degree of preparation and cane variety. It is useless to compress cane or bagasse to a high degree, unless it has proper juice drainage ie. removal of juice from the position from where it is actually extracted ‘rom fibre. ‘The principle factors concemed are as follows: Roller Speed: “The juice has to escape against the direction of roller movement, hence high roller speed give less effective drainage. The roller surface speed ~ 7-mv/min, - for achieving extraction. = 12-20 m/min.- for-achieving capacity. compromising extraction. However, it may be noted that with excessive decrease in speed, thickness of bagasse blanket increases, may suffer extraction for escaping the juice from the blanket, = Messchart grooves : Messchart grooves are often provided to facilitate juice drainage, as bagasse doesn’t penetrate to the bottom of grooves allowing clear space for juice escape. Trash plate setting : While trash setting adequate clearance in between ‘rash and delivery roller shall be provided for juice to enable freely drain, otherwise, the excess juice. will build up pressure, a causing trouble. = Density of compressed layer : The juice has to escape from the ‘compressed bagasse and it depends mainly on permebility of bagasse. ‘The permeability is influenced by degree of preparation and compression of bagasse. Hence, with high quantity of juice expressed at feed and less juice along with bagasse to discharge rollers has less serious restrictions to flow. ae Refresher course for ST & SE, July 2005 [Reffesher course for ST & SE, July 2005 00oeU ew Hydraulic pressure is a important factor in milling work and is a result of feeding quantities. Ifthe mill feeds well enough to lift the roller against a high hydraulic pressure Rat pressure is fly utilized and according to utilization of pressure upto certain limit, extraction is achieved. Imbibition: “The object of imbibition is to dilute the juice remaining in bagasse after each stage of milling, ‘The imbibition quantity is expressed on % of fibre and normally applied debre last mill, Last mill-expressed juice is used on imbibition before preceding mill and s0 on. Proportion of opening cells: “The juice in bagasse is available for dilution by imbibition fluid only if cane cells have been ruptured. Number of opened cells depends on the efficiency of milling work upto that point. This depends on preparation ‘of cane before I* mill, and with the anditional effect of various mills in braking up cane structure further as bagasse passes through mills. ‘The extraction at each stage of milling should be proportionate along the tandem, Otherwise, for poor working mill, concentration of juice in bagasse will be higher, even after dilution by imbibition, ‘Temperature of Imbibition: thas observed that temp. of imbibition above 60°C get definite improvement in imbibition effectivly. The reason may be destruction of cel tissue by heat, rendering cell alls becoming fully permisable, so that the water has direct access to the juice in the Walls, Besides this juice and water mixed more rapidly at high temperature. On the other trend, hot imbibition makes more difficult for feeding particularly soft variety of cane Satisfactory feeding can be obtained by use of are welding the roller surfaces and/or providing feeding devices. Uniformity of Mixin The imbibition fh juice in open eel. This in practice, don’t happens unless excessive quantity 9 vvaceration water are used. Hence, to improve imbibition affectvity, it should be even and uniformly distributed as for as possible throughout the bagasse layer. iS, a Refiesher course for ST & SE, July 2005 should mix completely with all the bagasse and dilute all eis (3 { wakany‘Vasantdada Sugar Institute, Pune Milling process is complex one. However, with simplified version, milling process said to be complete if crushing work at each pair of rollers and imbibition at each stage is satisfactory completed. This implies regarding operation and supervision Engineers or Technologist must watch at every stage with aid of frequent analysis as well as keen observations and see thatthe plant gives best results. ‘After careful study, international Society of Sugar Cane Technologists has recommended the following figures for judging the working mills: ({) Mill extraction ({i) Undiluted juice lost in bagasse per cent fibre, (fi) Moisture per cent final bagasse. These figures don't by themselves provide much idea as to the efficiency of any weak unit in the tandem. For assessment of any weak unit in milling tandem, a widely used method is calculating mill extraction of the milling tandem and also to draw the brix curves for individual mills. But the study conducted at number of sugar mills indicated that the use of brix curve and ME values are not sufficient for pointing out the faults in mill units. It is observed that, brix curves may indicate satisfactory performance of milling tandem but the extraction of milling tandem is very poor. We have used the individual mill extraction (pol, brix & juice) & Unit mill extraction of individual mill (pol, brix & juice) along with the brix curves for identifying the poor working mill unit in the milling tandem and this helped to asses the performance of each mill'in-milling tandem. With the use of study of individual mill extraction’ and technical study of various mill parameters related to individual mills, it-raises the level-of extraction of the milling tandem to maximum possible. ‘We have developed simplified method for the calculation of Individual mill pol, brix & juice extraction, which is also discussed in this article. Review of brix curve: The use of brix curve for assessment of individual mill performance is a normal practice in Indian Sugar Industry. However for achieving best possible results, the performance of all the mills in milling tandem shall be maximum. The results of brix curve.along with mill extraction, Feed discharge juice ratio, pol % bagasse are not useful or sufficient for judging individual mill performance, One has to find out either brix extraction or pol extraction of individual mill in milling tandem. Many research workers tried to their level best for various methods for estimating individual mill extraction and these are as follows: WEE. Smith discussed a study on “milling control by-juice density curve”. He advised that the practicability of this system of analysis depends largely on comparison ‘with curves obtained on a specific milling plant with a basic curve obtained when the mill Refresher course for ST & SE, July 2005 zunder examination was obtaining satisfactory results. To obtain this ideal curve was ‘become a problem. To overcome this Haldane (1934) used Noel Deer ideal extraction principles. Haldane (1934) utilized the brix values of total juice expressed by each ‘component unit instead of that atthe discharge opening only. He has solved the problem of obtaining the ideal curve by applying Noel Deer general formula for compound imbibition process, based on ideal cane. i.e. complete mixture of added water or returned juice with residual juice in bagasse and 50% fiber in bagasse in each mill. Using this formula the brixes of the juice extracted by the different units in train in relation to brix of primary juice are obtained. S.N. Gundurao (1969) have reviewed the various techniques of “ brix curve and milling control” and concluded as follows: * Various factors influencing the brix curve, the difficulty of individual assessing the influence, when all factors are simultaneously present, together with the opposite tendencies in which they work, indicate the necessity for extreme caution in interpreting brix curves, particularly when basic curve is obtained by Deer's formula, = The brix curves based on total juice appears to be more correct as compared to juice from discharge rollers. = Deers method for algebraic analysis is helpful in arriving at theoretical curve and to find the effect of different factors on curve. But for the purpose of comparison and operation control, the best thing to obtain actual curves when the particular mill has been adjusted to give good performance. * A smooth curve having the same slope as the basic curve and tending towards the brix of the last mill juice on the basic curve indicates performance at the different units corresponding to basic curve. Any disturbance of this smoothness by a kink in the curve indicates a defective unit, Gundurao (1969) further stated the limitations of Deer method for ideal brix curve as follows: ‘The conditions for obtaining ideal curve such as complete admixture of imbibition water / juice with residual juice, fiber % bagasse 50%, ideal cane do not obtain in actual practice. * Variation in composition of cane, distribution of various’ constituents in cane, concentration of sugar in pith cell and variation in ratio of sugar to brix (purity) are affecting the ideal brix curves. = Admixture between the added water or retumed dilute juice in bagasse can never be complete and various with conditions of bagasse, percentage of imbibition, method and place of imbibition. It is always less than 100. ‘©The assumption of uniform fibers % bagasse from first to last mill in imbibition train is not very correct. Gundurao further reported the various factors, which are influencing the nature of brix curve. These factors are as follows: Relfesher course for ST & SE, July 2005 9 ‘Vasantdada Sugar Institute, Pune‘Vasantdada Sugar Institute, Pune | | © Ratio of added water to fiber: When value of w/f ratio is less than unity, the basic | curve assumes a convex shape. When value of wif is greater than one, the curve is of concave shape and becomes more concave with increase in value of w/f. «Defective primary extraction: Defective primary extraction results in low fiber | | content primary bagasse and corresponding greater quantity of juice is presented to secondary train. The effect of this increased juice content is maximum on the unit following immediately, while this is not appreciable in the final bagasse. An increasing difference between the actual and ideal brix values from ‘the first to last mill in the imbibition train is not due to defective primary extraction alone, but also due to the defects in secondary units or other causes. * Defective secondary unit : A defective unit is to produce sharp kink in the brix curve, thus disturbing the smoothness. Further good working of succeeding units 44 will tend to bring back the’slope of the curve to correspond to basic. Thus the defective unit is disturbing the smoothness of the curve by kinks. = Efficiency of admixture: The influence of deficient admixture is therefore to render the curve more concave, thus leaving an impression of greater wif ratio than recorded. GSelvraj etal. (1982) have reported their work related to “liquid extraction | efficiency”. They have found that “liquid extraction efficiency” as an efficiency indicator for individual mills, They have also worked out complete mass balance of the milling process. ‘Toat Soemohandjo (1996) has also reported the material balance in the mill train. KN. Rustogi-(1995) also reported the relevance of brix curve in. ‘mill control. The major findings of his study are a follows: + The performance level of all the mills can never be same and so the performance | of a mill can not be directly related to the brix value of it’s juice. Due to this the comparison: between the ideal brix curve and actual brix curve can not provide | sufficient clue on performance of individual mill. | '* Tdeal-brix curve does give the theoretical best brix value of final bagasse and so efficiency of milling system can be established by comparing brix of final bagasse | with theoretical best fora particular imbibition loading. i «The poor performance of individual mill_may always not be identified with the | help of brix curve. HIN. Gupta (2001) states, “Only brix curvés of individual mill do not serve any | purpose to readjust the individual mill to achieve at definite conclusions, it is necessary t0 : | calculate other parameters, which are affecting mill extraction of individual mill. The final decision to readjust particular mill should be taken on the basis of the combined analysis of the various féctors". He have, furthet analysed a case study of milling | performance. He had: reported varius “parameters such as feed extraction, juice extraction, filling ratio, Re-absorption factor, fiber compression and from this study, he | pointed out as follows: Refresher course for ST & SE, July 2005 v‘Vasantdada Sugar Insitute, Pune + Feed extraction from individual mill does not give any definite clue to investigate behavior of individual mil. + Juice extraction reduces from first to last mill. (I* — 55-60%, 0" ~ 50-55%, II &IV"— 45-50%). + Reduction in juice extraction from particular mill is compensated from the subsequent mills if itis properly set. + Filling ratio & Re-absorption factor is increases from first mill to last mill. The higher values of filling ratio results in higher values of re-absorption ratio. Indivisual Mill extraction technique Methodology : "While assessing the individual mill performance, one has to consider all possible parameters. During the current study following procedure / methodology is used. ‘Sample Collection : ‘A due attention was paid for all sample collection. ‘The sample period was kept one hour. The sampling started from prepared cane and progressively ends with final ‘bagasse sample. Feed, discharge & composite juice samples and bagasse from one mill are collected almost in same period or simultaneously. ‘The frequency of sampling was kept 4 samples per hour. The collected four samples mixed together and used for analysis. A care has been taken to collect the-all juice and bagasse samples from individual mill unit at a same time and through out the length of roller. For collection of bagasse sample a special jaw is designed so as allow to collect bagasse just after emerging from top roller and before the addition of water / diluted juice on bagasse blanket. Sample Analysis t The collected sample of juices are analysed for Pol %, Brix % and purity while the bagasse sample for pol % and moisture % as per “systems of technical control for cane sugar factories in India by N. C. Varma. Data analysis and ca!culation of individual mill extraction 1) Brix Curve: Brix curve is calculated as per “K.S. Amolds”. We have used corrected brix % of juice for plotting brix curve. We feel that the observed brix % is not suitable a$ temperature of juice obtained from individual mill differs and may give misleading brix curves. We have drawn the brix curve forall juices ie. feed discharge and composite in place of only discharge juice. 2) Individual Mill Pol Extraction: For calculation of individual mill pol extraction following set of formulae are used: Brix % bagasse = ol % bagasse én nin X 100 cael Pty. of discharge juice giviual it) Fiber % bagasse (individual mit * = 100 - Moist % bagasse (individual mit ~ Brix % bagasse (ndividust mit) eye Refresher course for ST & SE, July 2005 st(esa Suga nate, Pane —__ Fibre % cane x 100 Fiber % bagasse (I* Mill) Pol % cane & fiber % cane figure are found out by direct method using cane and average of three samples is considered. Bagasse % cane ([I"* Mill)=__Fiber 2% cane x 100 Fiber % bagasse (iI Mill) Primary bagasse % cane = ol in Primary bagasse % cane= = Pol % bagasse (I* mill) x Primary bagasse % cane 100 Pol in bagasse % cane (1I™ Mill) = =Pol % bagasse (II mill) x Bagasse % cane co Mill) 100 (Similarly ealculated for other mills) PolinP.%cane = Pol % cane~ Pol in Primary bagasse % cane. Pol in $.J.%cane = Poli Primary bagasse % cane “= Pol in bagasse (II Mill) % cane. Fmill polextraction = PolinP.J.%ecane x 100 Pol % cane 11% mill pol extraction= = (Pol in primary bagasse % cane _- Pol in bagasse % cane 11% Mill) _x 100 ol in primary bagasse % cane TH Mill pol extraction = = (Pol in bagasse % cane II™ Mill - Pol in bagasse 26 cane mr Mill) x 100 Pol bagasse % cane [1% Mill IV" Mill pol extraction = = (Pol in bagasse % cane Il! Mill - Pol in bagasse 26 cane. Iv" Mill) x 100 % cane ID Mill Pol bagasse is calculated by dividing pol % cane figure to ‘The unit pol extraction of each mill ‘ll. The details formulae for the same are 2s the pol in extracted juice by individual mi follows, 1 mill unit polextraction = PolinP.%cane x 100 Pol % cane Ti mill unit pol extraction. = = (Pol in primary bagasse % cane_~Pol in bagasse % <1 1 Mil)_x 100 Pol % cane Refresher course for ST & SE, July 2005 zz‘Vasandada Sugar Instat, Pane zs 111" Mill unit pol extraction, = Hi = (Pol in bagasse % cane II" Mill - Pol in bagasse % cane III" Mill) x 100 Pol % cane TV" Mill unit pol extraction = 1 in bagasse % cane III" Mill - Pol in bagasse % cane IV* Mill) x 100 Pol % cane ‘The cumulative mill extraction is calculated as the sum of the individual rill unit extraction. On the similar basis individual mill brix extraction, unit brix extraction and cumulative brix extraction are calculated as follows. Brix % bagasse = Pol % bagasse _x 100 Pty. of discharge juice of individual mill Fiber % bagasse= 100 - Moist % of individual mill - Brix % bagasse (individual mill) | Primary bagasse % cane = Fibre % cane x 100 Fiber % bagasse (I* Mil) Bagasse % canc (i Mill)=_Fiber % cane x 100 | Fiber % bagasse (II°* Mill) | Brix in Primary bagasse % cane= i = Brix % bagasse ({"t mill) x Primary bagasse % cane ‘ 100 i Brix in bagasse % cane (II™ Mill) = =Brix % bagasse (II mill) x Bagasse % cane (1I™ Mill) {| 100 (Similarly calculated for other mills) i| Brix inP.J.% cane = (Pol % Cane — pol in primary bagasse % cane) * 100 Purity of primary juice 3 3 5 a 3 > > 7S ro 9 Brix % cane = Brix in P.J. % cane + Brix in primary bagasse % cane ww Brix inSJ.%cane = Brix in Primary bagasse % cane i ~ Brix in bagasse (II Mill) % cane. wo ¥'mill brix extraction= Brix in PJ. %cane x 100 | Brix % cane i ih ‘Refresher course for ST & SE, July 2005 a \‘Vasantdada Sugar Institute, Pune 1 mill brix extraction == = = (Brix in primary bagasse % cane- Brix in bagasse % cane II™ Mill) x 100 Brix in primary bagasse % cane IY" Mill brix extraction = (Brix in bagasse % cane II” Mill - Brix in bagasse % cane III Mill x 100 ‘Brix bagasse % cane II" Mill IV" Mill brix extraction = = (Brix in bagasse % cane III" Mill - Brix in bagasse % cane IV" Mill) x 100 Brix bagasse % cane III” Mill ‘The unit extraction of each mill is calculated by dividing brix % cane figure to the brix in extracted juice by individual mill. The details formulae for the same are as follows, 1 mill unit brix extraction = BrixinPJ.%cane x 100 Brix % cane 1" mill unit brix extraction = = (Brix in primary bagasse % cane- Brix in bagasse % cane II% Mill) x 100 Brix % cane Ir" Mill unit brix extraction = = (Brix in bagasse % cane II Mill - Brix in bagasse % cane IIT" Mill) x 100 Brix % cane IV Mill unit brix extraction = = (Brix in bagasse % cane Ill" Mill - Brix in bagasse % cane IV Mill) x 100 Brix % cane ‘The following table No.1 to 6 gave on comparative data of these calculations for different mills during above study before as well as after adjustment in mill working parameters. ‘Case Study- Factory A: From. the brix curves of factory A, before mill adjustment, with the help of conventional performance analysis method, we may able to predict following points about total mill operations, = Klink observed for mill no. 2, for the both feed and discharge juice brix curves. But for the common juice, no Klink is observed and the graph is almost smooth indicating satisfactory performance. This indicates that the working of mill no. 2 may not be poor as indicated by feed & discharge curves. Refresher course for ST & SE, July 2005,(aes ‘Vasanidada Sugar Insitute, Pune + A wide gap / difference in between ideal and actual brix curves is observed in all three types of brix curves. From the use of only brix curves for all three types juices may conclude that, the link at mill no.2 is either due to defective working of mill no. 2 or poor extraction at primary mill or may be due to both. However, it is diffieult to conclude, as the primary extraction in this ease is 63.99 %, which is not poor. 1, we consider the figures of brix extraction & pol extraction data for factory A, before mill adjustment, we may able to predict following points about total mill operations, «The brix extraction and pol extraction of mill no.2 is 28.24 & 28.89 respectively. The individual mill extraction of this mill is very poor. = Primary extraction is also low & there is a scope for improving primary extraction. From the above study, there it is decided that there is need to. improve performance of mill no. 2. The detail reasons responsible for poor performance of mill no. 2 were identified with detailed study of various parameters and rectified. After these changes, the detail mill performance study is again conducted. From this study and with only brix curves, we may predict followings, = _Klink is still observed for mill no. 2, for the both feed and discharge juice ~ prix curves. = But for the common juice, no Klink is observed at any point in the brix curve & indicates good performance of all the individual mills + A wide gap / difference in between ideal and actual brix curves is also lowered as compared earlier study indicating excellent performance and almost matching with ideal curves. wy From above point, it is difficult to express views about the performance of mill no. 1 & rill no.2 only by using brix curves. If, we consider the figures of brix extraction & pol extraction data for factory A, after ‘mill adjustment, we may able to predict following points about total mill operations, "The brix extraction and pol extraction of mill no.2 is 40.05 & 43.89 respectively, The individual mill pol extraction of the second mill improved by 15 units, which is excellent one. ‘The individual mill pol extraction of the third & fourth mill also improved. vugda w Only by using, brix curve data, one may have to conclude that, first or second mill ‘working is defective. But use of individual brix and pol extraction analysis, indicates excellent performance of second, third and fourth mill in milling tandem. The excellent Refiesher course for ST & SE, July 2005 25C ~__Vasantdada Sugar Institute, Pune performance of these three mills overcome the poor performance of first mill and succeeded in achieving 95.95 total pol extractions and 95.45 total brix extractions. It is best practical example for necessity of analysis of individual mill extraction than brix curves to achieve better milling results. Also, quantification of increases or decrease in performance of any unit mill from the brix curve, in this-case mill no.2, is not possible. The initia individual pol extraction of mill no.2 was low (28.89 %), which after taking corrective action in the mill no.2, taken to a better level of performance (43.89 9%)... percentage increase in performance by 15 units which is not distinctly reflected in the before.and after mill adjustment brix curve. The conclusion of this study is that Brix curves and final bagasse analysis is not enough to evaluate factors affecting the mill performance. To arrive at definite conclusions for deciding corrective actions to improve the performance, it is necessary to have additional analysis like individual brix, pol and juice extraction of mills. This helps in taking the crucial decisions of mill adjustment for improving mill extraction. Case Study- Factory B: UGAR SUGAR MILLS The work conducted at Ugar helped substantially to improve mill extraction in their history. ‘The mills are assembled during off-season at rest position and this setting become more vulnerable during operation with floating of top roller under action of hydraulic load:and buoyancy force of bagasse. Therefore to have optimum performance of milling ‘tandem, every unit in the tandem should perform its best, for which assessment of each unit for individual’extraction and close:monitoring of working factors affecting individual mill extraction are essential. With-the help of laboratory analysis of expressed juice and ‘bagasse Individual extraction can be evaluatéd and combining it with working parameters itimprove mill performance. ‘M/s. Ugar Sugar is a very progressive factory. However their mill performance ‘was not upto mark: since: last. 10 to 12 years. So the factory requested to VSI give consultancy for the season2004-05 for obtaining RME 95+ at the crush rate of 10,000 TCD with existing coifiguration of evaporator with maximum possible imbibition % fibre with minor modifications. Mis, Ugar Sugar has 2 no. of milling tandem of size 42” x 84"- 4 mills with under feed roller and tandem ~2 of 6 mills having size 40” x 80” zero mill with under feeder and rest 5 mills of size 33” x 66” with short space TRPF. The comparative statement for performance of Ugar Sugar Works for last two years is enclosed table 1, it indicates the mill performance is below 94% . Accordingly during off-season study of both the tandems was conducted and care ‘was taken to improve cane preparation, feeding at each stage of mill, arrangement for the Juice drainage, adequate arching of roller surface, adopting low mill speed and optimum hydraulic pressure. However the factory had two / three problems in for poor cane preparation, mill setting and mill coupling and master gear bearing trouble of breakage. ‘These were main hurdels for achieving results. Detailed investigation and analysis of the problems in this regard were conducted and majors were suggested as under : Reffesher course for ST & SE, July 2005 6“Vasantdada Sugar Institute, Pune Cane Preparation: For an efficient milling, the combination of equipments viz.: cane equilizer, leveller, and fibrizer with sufficient power, has become common now a days to have Preparatory Index above 85% . To achieve this highest degree of preparation of cane , fibrizer plays major role in this regard. Therefore , to get desired level of preparatory index tip speed of the hammers ( 85 m/ sec +), anvil plate warp angle (120° — 160°) and setting (at centre average of inlet & outlet) , intact maintaining of working edge of all hammers are some of the parameters to be adopted. The clearance between tip of hammers and anvil plate should be maintained to the accurate level as stated above to achieve proper feedability and get desired Preparatory Index with less forming of powder. At Ugar, the clearance at the inlet & outlet of anvil plate was as per requirement but at centre it was more by about 120mm. This was due to deformation caused during fabrication period. So anvil plate was modified to have a correct circular {nside shape of required radius and installed it as per setting. Also, cane carrier at inlet of fibrizer modified to feed freely cane to the fibrizer without squeezing it. This helped to achieve desired level P.. with no jamming. ‘Mill Setting: Mill setting given to the Ugar was calculated by the VSI method considering the previous years performance and by adopting uniform & continuous flow throughout mill tandem with 200% + imbibition on fibre. However, Mis. Ugar had problem of accommodating trash plate cut as per profile during setting / assembling Zero Mill (40” x 80” size & Krupp make)of 33” x 66” size mill tandem since installation. Therefore during assembling of mill, there was practice to modify-trash plate machined as per trash profile by cutting it to 20-25 mm from back side resulting into depleting performance of zero mill. In depth study revealed that mill setting mechanism supplied by the Mill Manufacturer was faulty by 9.5mm. Taking corrective steps mill was assembled as per drawing without modifying the trash plate. Primary Extraction of the zero mill trough out season was above 70% +. Unequal lift of top rollers : . “This was one of the factor that factory was facing for breakage of mill roller coupling and poor performance. To sort out this problem , simple but rigid mechanical type, lift indicator were provided to all top rollers and lift of both ends of mill roller were asked to record hourly basis along with other data collection. Imbibition System : ‘The arrangement of addition of imbibition water after study alter for supplying 75% quantity from bottom of the bagasse blanket and 25% ori above bagasse emerging from penultimate mill. 100% quantity of added water was taken before last mill and ‘water temperature ensured for 85°C + through out season. With these above basics and by taking due care for maintenance during off- season, season-2004-05 was started on 1/10/2004 and after stabilization of crush rate, mill tandems were re-adjusted by conducting analysis and evaluating factors like individual mill extraction, (pol, brix & juice), proportionate extraction at feed and discharge roller for finding poor working unit if any. ‘The effect of assessment of performance and close continuous monitoring of this factors have a grate effect in achieving results. The effect can be seen from the actual data obtained before and after implementation of above during the visit period 27° to 30" er Reffesher course for ST & SE, July 2005 ]Vasantdada Sugar Institute, Pune Wi Sept. 2004. In depth study was conducted by carrying out analysis of prepared cane | bagasse and expressed juice of each mill, and individual extraction of each mill was j evaluated which is attached table no. . Accordingly the corrective action for re- adjustment of mills for improving was taken. ' ‘The result of this is there was improvement in Reduced Mill Extraction from 94 to 95.45 for the season04-05. The data is enclosed table no. Table 1: Combined mill Performance before readjustment of mills Particulars: DATE 24-10-05 25/10 26/10 27/10 __28/10__29/10 Crashing rate per (24 Hrs.) MT 9020 | 8730-| 10000 | 10030 | o160 | 9480 Including stoppages i Recovery % cane 0.16 | i018 | 1021 [1024 | 1027_| 1031 Fibre % cane $3.08 | 13.62 | 13.21 | 13.10 | 13.28” | 13.08, ‘Added water % fibre 212.08 | 202.7 | 213.40 | 216.18 | 223.57 | 226.91 Pol % cane 12.21 | 42.28 | 12.27 | 12.30 | 12.33 | 1236 | ‘Sugar loss in bagasse 0.724 [0.762 [0.732 | 0.716-| 0.735 | 0.589 | Total sugar loss (%) Mill Extraction 941 | 93.81 [9405 | 94.15 | 94.00 | 95.23 | RME. 94.40__| 94.39 | 9420 | 94.46 | 94.4 [95.47 ! I i | Refresher course for ST & SE, July 2005> ‘Vasantdada Sugar Institute, Pune © cable 2: Combined mill Performance after readjustment of mills DATE wu au 3M_ ants 6/7 “ap [Particulars “2 ‘Crushing, 9 | rate per | 9040) 9750 | 8870 | 9090 | 10070 9870 | 9680 | 9280 | 10040 f (24 Firs) H ~9 |MT Including stoppages Recsvery | 1040 | 10a0 | Tost | 1054 | 1037 | 10.60 | 10.66 | 10.71 | 10.77 Yeane —p bie 96] 1389 | 15.52 [13.73 | 13.84 [13.78 | 13.80 | 13-84 | 13.84 | 13.69 ~@ [sane . ‘Added | 228] 20854 | 186.74 | 184.75 [198.84 | 207.75 | 185.7 | 176.41 | 188.29 “D | water % Sugar toss | 0375 [0598 | 0580 | 0550 | 0.620 | 0595 | 0.643 | 0.652 | 0.617 il D | inbagasse | sp | Total | Y | sugar toss | 3 |e it sey [Mill 9537 | d5i2 | 9533 | 9557 | 95.04 | 95.20 | 94.94 | 94.80 | 95.13 ' 9 | Extraction i > [RME | 9550 | 95.69 | 95.80 [9606 [95.57 | 95.72 | 9550 | 95.52 | 95.71 9

‘To have highest possible mill performance emphasis is to be made for thorough i <> maintenance and further during season, essence of assessment of performance of every | nit in the milling tandem, so that it could point out low performing unit in totality and fl > make easy for taking corrective action to improve the mill performance. Combined mill Performance before readjustment of mills i) MW Gudud isomer STESE RIS CSC“‘“‘CSNS!TUC*d Refresher course for ST & SE, July 2005Nowa also hi 1) 2) “Vasantdada Sugar Institute, Pune Electrical Systems in the Sugar factory U.A. Kulkarni — Electrical Engineer Vasantdada Sugar Institute, Pune In earlier days, the sugar factory were operated on steam driven drives. days the electrical system in the sugar factory is incorporated. During this change the electrical systems were given less importance by no. of sugar factories due to which they have faced major faults in the electrical systems and jigher power consumption per TCH . To minimize the faults of electrical system in order to get better reliability of efficiency of electrical equipments, following points are to be kept in mind. Electrical Distribution System : In sugar factory, they are using L.T. power supply through LT. generators to fulfil in house consumption. Normally the system works on 3 phase, 4 wire/ 3 wire, 415 Volts, 50 Hz A.C. supply and having power factor 0.8 lag. ‘Application wise all the electrical equipments to be used having above specifications and only capacity/ rating differs. Earthing : This is a very important aspect of-electrical systems. In another words it is a basic! primary filter circuit. Good earthing will help to save human life as well as electrical equipments from hazardous electrical faults. The type of earthings are normally adopted are; a) Neutral earthing b) —_ Body earthing. ) Neutral earthing: Neutral earthing of generator will partially balances the current flow in phases and ultimately avoid neutral floating & effective protection for generator at fault condition. d) Body earthing for equipments/ machines : Body earthing ensures human safety and winding leakages due to poor insulation. All protections are related to fault current. If earthing is not provided then heavy fault current will flow through these equipments and can damage equipments. Now days most of the sugar factories are using D:C. drives and variable A.C. drives which will produces harmonics in system. To limit these harmonics to some extent earthing is necessary because all filter circuits contents resistance, capacitance & inductance. Refresher course for ST & SE, July 2005 304) ‘Vasantdada Sugar Institute, Pune ‘As per .S. Standard, the earthings to be done in two ways, 4) Pipe earthing and —(2) Plate earthing . ‘The pipe earthing to be used for smaller capacity loads and for hard strata plate earthing to be used for heavy capacity loads. But at higher capacity loads only plate earthing is recommended inrespective to conditions of strata. ‘The detail drawing for plate earthing and pipe earthing as per IS standard are enclosed herewith (Fig. 1 & 2). Motors: Most commonly Induction Motors ( |.M.) are used in the ‘sugar industry. The type of LM. are given below ; a) Squirrel cage Induction motor. b) Double squirrel cage Induction motor. c) Slip ring Induction motor. Squirell cage ILM. are used for constant loads where load is not varying at large scale. The Double cage motors are especially used for jerk & heavy loads. Siipring Induction motors are used for variable load at large scale e.g. leveller, fibrizer, etc. ‘These mentioned motors are used earlier. Now a days these motors performance has been up-graded by the manufacturers and they have introduced new motors called “energy efficient motors”. These energy efficient motors have higher efficiency due to lesser losses comparing to old conventional motors. Hence selection of motors is also one of the criteria. The comparison chart is given below : [" 4Pole Motors | Standard Motors | Energy Efficient Motors 0.75 KW 71% 71%. 1.5 KW. 76% 80% 3.7 KW 83% 86% 7.5 KW 85% 88.5% 41.0 KW 85.5% 89.5% 48.5 KW 87% 91.5% 37.0 KW 88.5% 9.2% Starters: All most commonly following starters are used i) Direct on line (DOL) starter below 10 KW. il) Star-Delta starter above 10 KW upto 100 KW. iil) Auto-transformer starter : Above 100 KW to 200 KW. iv) Rotor resistance starters for slipring motors. Refresher course for ST & SE, July 2005 3‘Vasantdada Sugar Institute, Pune But now a days new generation starters has been developed namely soft starters, variable voltage; variable frequency, and both variable voltage variable frequency (VVVF) starters. Introduction of these starter made revaluation in electrical ‘system. The features of these starters includes smooth start, power saving due to speed control as P a N°. Hence by adopting i these. starters power saving is possible and also life of motor is enhanced. | 5) LT. Switchgears : LT. ‘switchgears is main part of protection of electrical system which consist of ACB's/ MCCB's, SFU's/Fuses/ Air break contractors and relays. While selecting the switchgears we should consider voltage drop and full load current and type of duties i.e. continuous , inter-middent and periodical, For selection of switchgears capacity/ rating, the system voltage is to be considered and current carrying capacity ie. actual load current x 1.2 times. Accordingly all switchgears can be selected. 6) Cables Selection of cable size is mainly depend upon “group derating factor * which increased thermal resistivity of soil, ground temp. and air temp. The installation of cable is also depends on laying methods i.e. in air in duct, in ground, in group, in single. And also depends on site conditions. - derating factor = depth of laying x ground temp. x group factor & x | type of laying x Air temp. | Rating Factors Variations in Ground Temperature : Ground 15 |20 /25 [30 {35/40 [45 [50 [55 Temp. °C. Rating 4.17 | 1.12 | 1.06 | 1.00 | 0.94 | 0.87 | 0.79 | 0.71 | 0.67 | factor Rating Factor variations in Ambient temperature : AirTemp.°c [15 [20 [25 [30 [35 [40 [45 [50 |65 Rating 1.40 | 1.32 1.25] 1.16 | 1.09 | 7.00 | 0.90] 0.80| 0.68 factor Rating factors Laid in open racks. i No. of racks | No. of cables/ rack peaee 3 6 9 4.00 [0.88 [096 [0.93 | 0.94 7.00 [0.95 0.93 [0.90 | 0.89 7.00 [0.94 [0.92 [0.89 | 0.88 1.00 [0.93 [0.90 [0.87 [0.86 EXCore Refiesher course for ST & SE, Tuly 2005, 3‘Vasanidada Sugar Institute, Pune Arrangement - (2) [[No. of racks | No. of cables/ rack 1 (2 3 [e_ 1,00 [0.84 [0.80 [0.75 1.00 [0.60 [0.76 [0.71 1.00 |0.75 [0.74 [0.70 7.00 [0.76 [0.74 | 0.68 olen] For example : At ambient temp. 30°C & depth 9 cms. above 25 cms. Tk. rates factor = 1.16 x 0.99 x 0.87 x 1 0.99 Depth Rating Factor: VB Depth of laying] 75 [90 [105 | 120 [150 | 1804 Hage __| in cms. above 4.1 KV |Rating factor] 7.00 [0.99 [0.98 [097 [096/095 upto 2559mm RF. above 259{4.00 |0.98 [0.97 |0.96 |0.94 | 0.93 upto 399 sq.mm RF. above 300| 7.00 [0.97 [096 [0.95 [0.92 |0.97 sq.mm. COS 4. = active power es ‘apparent power cos¢ .=_KW KVA Dis Advance Power Factor : 4) Reduction in voltage. 2) _ KVA capacity of generator, transformer & motor will be required 3) Cable of higher capacity. 4) Effect of harmonics will be on higher side. 5) _ High power consumption . 7) Power Factor The Cosine angle (COS 4) between voltage and current in AC. circuit is knows power factor of the system. KW. KVAR Hence P.F. improvement is necessary as power consumption is totally depends on P-F. if power factor is unity then losses gets Refiesher course for ST & SE, July 2005 33C ‘Vasantdada Sugar Institute, Pune reduced & power consumption reduce if power factor is poor then losses increases & power consumption increases. Losses « 1/COS?$=FR ie. | «1/COS$ To improve the power factor. The selection of power capacitor is important by considering types of loading, system voltage, & actual P.F. The various types are available like M.P.P. (Mtalised polypropylene). M.D. (Mixed Dielectric )A.P.P. (All polypropylene). But for sugar factories use of M.D. type with self discharging capacitors are better as per their reliable performance. Maintenance :. is routine work. But while doing so the equipments duty & class of insulation is to be kept in mind so, that overhauling can be done according manufactures recommendations. These above points will help sugar factories for better performance: of electric system. Harmonics The Electrical loads can be classified as linear & non linear. "When any non sinusoidal current can mathematically resolved in to a series of sinusoidal. components (Fourier series). The first component is called fundamental: andthe remaining components whoes frequencies are integral. multiples of fundamental frequencies are known as Harmonics”. ‘The source of generations of harmonics are viable D.C. & A.C. drives, UPS; Furnaces; Welding machines etc. Due pressure of harmonic the power supply becomes “dirty” as they are distorated from pure sine-wave. These harmonic can be illiminated - with the help of Reactors. But before using reactor “Harmonic Analysis" is essential. After analysis data, we can design reactors with capacitors. As per IEEE 519 total % THD should not be less than 3%. Refiesher course for ST & SE, July 2005 Ei[ ‘Vasantdada Sugar Institute, Pune | An overview on instrumentation in sugar industry by Shri. R. B. Chikhale Head, Instrumentation Dept. | Vasantdada Sugar Institute, Pune | | INTRODUCTION: Instrumentation measurement and control in sugar industry has observed tremendous ups and down. This has perhaps due to the continuous developments in Instrumentation Science. During early 1980's the level of instrumentation in sugar industry was very poor and minimal, The implemented: instrumentation systems were either pneumatic or | electrical type. The electronic instrumentation systems were not prevalent. Most of the instrumentation systems, which were implemented for boilers were in non-working condition and purpose of their implementation could not be availed either for the correct boiler ing it case of mill section turbine section and boiling house the temperature, pressure and vacuum gauges, which are the basic minimum requirements Were generally found to be in working condition. But the sugar technocrats could not rely upon the indications provided by these gauges. This in our | © ‘on is due to the following reasons: i) The environment in the plant is very hostile having dust, high humidity and lack of proper ventilation resulting in high room temperature and hence instrumentation systems subjected to these conditions require high degree of maintenance... il) Unawareness of instrumentation measurement and control systems and the lack of interest to avail. of the knowledge, which is advantageous to | factor ii) Not-existence of the basic infrastrctual facilities for effecting the required instrumentation services. However, in the sugar industry the present trend in process instrumentation systems indicates that in near future, the industry will employ the combination of pneumatic and electronic instrumentation systems for process control. The technology of process instrumentation continues to grow in both application and sophistication. Now-a-days several new sugar factories are being commissioned and old units are being forced to modemize their plants under economic pressure. To maintain the profitability, these units will turn for advance instrumentation and automation. Widespread use of computers for process control is envisaged for improving the yield and quality. Advance monitoring and Refresher course for ST & SE, July 2005 |‘Vasanidada Sugar Ins control instrumentation systems will be widely accepted by the industry and hence, this is high time to discuss in detail about the following aspects of ‘Instrumentation in the sugar industry’ A) DOCUMENTATION: In the recent past, the advanced instrumentation measurement & control systems are being implemented in the sugar industry. However, for the successful implementation of these systems instrument vendor shall be insisted for the following documentation. i) Process flow sheets. ii) Process and Instrumentation (P & I) diagrams. Instrument index sheets. iv) Instrument specification sheets. v) Sizing calculations of the transducers and end devices wherever applicable. vi) Loop wiring diagrams / hookup diagrams. vii) Panel drawings and specifications. vill) Cable schedules. ix) Installation details. x) Bill of materials. B) PRACTICAL APPROACH IN INSTRUMENTATION ENGINEERIN It isnot, only essential fo have. instrumentation in an. operating condition but‘it is equally important to ensure that it is working correctly and indicating the correct readings and: gives the true picture of the conditions. existing at various points. To achieve the correctness of the measurement and control it is imperative to pay attention towards the following points to ensure continued availability of the correct indication and / of control action. }) Selection: The selection of the instruments is done by correlating the designed process parameters and their ranges, process equipment details and the comparative study of technical specifications of the available instrument under consideration, i) Inspection: The. verification of the various technical specifications of the ordered instruments at manufacturer's workshop is utmost important. This will avoid the incorrect supply.and hence delay in the system commissioning. ii) Expert supervision for erection, installation, pre-commissioning and commissioning: Refiesher course for ST & SE, July 2005 Peetfa ‘Vasanidada Sugar Institute, Pune This will improve the reliability in instrumentation systems operation by eliminating the errors/ faults in installation & erection, which results in better monitoring and control on process parameters. iv) Maintenance: Unless and until instruments are maintained properly and give correct informations, installing instruments and leaving them to their own faith is as bad not installing them, therefore for the smooth and proper maintenance following points should be considered seriously. a) The employment of instrumentation staff. b) Provision of instrumentation laboratory consisting of advanced 1 calibrators, simulators, multimeter, oscilloscope, frequency meter, required tools and tackles is essential. °c) Stock of spares, which are not readily available in market. (©) PROCESS AUTOMATION: “Though latest advanced technology of the process control through instrumentation has came to stay in the foreign countries, their total adaptation to Indian Sugar Industry conditions may not be entirely justified and rational. Only those aspects, which are intentionally suitable for Indian ‘Sugar Industry conditions, need careful considerations from the viewpoint of incorporating them in the industry. So taking into consideration these facts, it is advisable to proceed with station wise automation through the advanced process control instrumentation. In view of this | have explained some of the proven instrumentation measurement and control systems. | 1) Auto Caine Feed Control System: The speed of the cane carriers is synchronized as per the load variations on cane preparatory devices and 1* mill turbine. The various predetermined settings of load and speed ensure uniform desired crushing rates. The salient features of this system are as under: i) The level sensing of prepared cane at the carriers and Donnelley | chutes is totally eliminated. ii) Load Vs speed settings are provided at the operator's consoles. | This ensures the appropriate tuning of the system as and when req The following advantages are gained by installation of this system: | |) 10 to 15% increase in crushing rate. {i) Complete elimination of choking at mills, cutter and fibrizer. i ii)Reduction in bagasse pol iv) Increase in reduced mill extraction. v) The fluctuating demand of the cane preparatory devices gets eliminated and there is uniform drawl of current, which ultimately Refresher course for ST & SE, July 2005 Es(Vesna Sia nite, Pane} leads, in better performance of cane preparatory devices. Because of uniform loading the power demand in the mill remains same. vi) Due to uniform loading the rate of wear and tear in general is minimized. vii) The uniform demand of the power & bagasse feeding minimizes the pressure fluctuations of the boilers. ‘Steam consumption is reduced because of uniform loading. ix) Juice flow becomes stable. Due to the stable juice flow the amount of lime and SO2 gas can be optimized which results i better clarification and which ultimately. contribute for better ICUMSA, x) The overall efficiency of the whole plant increases due to the constant feeding and optimizing the electrical and steams consumption. 2) Imbibition Water Flow Control System: Automatic control of imbibition water flow rate based on brix of last expressed juice or chest pressure of the penultimate mill turbine with temperature contro! will result into following benefits. 1) Better milling efficiency. ‘Optimum imbibition during lower crushing rates ill) Decrease in boiling house load & hence energy saving, iv) The variations in bagasse pol & bagasse moisture are considerably minimized. 3) On-Line Mass Flowmeter: The recent trend in sugar industry is to go for on-line mass flow ‘measurement of juice and water due to its advantages over the traditional tank weighment system. A flow metering system is comprised of a sensor, signal processing transmitter and digital flow indicating totalizer. The juice flows into the sensor tubes and forced to take on the vertical momentum of the vibrating tube. The amount of. sensor tube twist is directly proportional to the mass flow rate of the juice flowing through the tube. Electromagnetic sensors are located on each side of the flow tube to measure the respective velocity of the vibrating tube at these two points. Any time.difference between these two velocity signals is caused by the twisting of the tube. The electromagnetic sensors send the information to the transmitter where it is processed and connected to an output signal directly proportional to the mass flow rate. The various advantages of this flow meter are given below: |) Fluctuations in juice flow are minimized. Errors in daily report will be eliminated. Elimination of raw juice pumps effects additional power saving and that of space also. Refiesher course for ST & SE, July 2005‘Vasantdada Sugar Institute, Pune iv) The chances of bacterial formation in existing system will be i eliminated. I} ‘v) Steam utilization at the juice section will be uniform which avoids | fluctuating steam demand. 4) Juice Flow Stabilization System: The very first object of process control instrumentation systems employed for juice flow stabilization is to ensure the continuous constant flow of mixed juice per unit time. This results in most efficient use of installed equipments. In this control system the juice flow rate is measured by the magnetic flowmeter. Depending upon the deviation between actual flow rate and set value the pneumatically actuated control valve installed | in the bypass line is operated which controls the re-circulation of the mixed | juice from the discharge line to the juice receiving tank. The level switches are installed to the juice-receiving tank for override control. In case of high | level of the mixed juice in the receiving tank the output signal of the controller closes the control valve while the low level of mixed juice stops the raw juice pump operation. However, the need of the override control signal is almost nullified with synchronizing output signal of magnetic flow meter with the Auto Cane Feed Control System. This ultimately achieves the effective juice flow stabilization, which is the basis of starting point of efficient operations ‘in the boiling: house. The advantages of the system are: es ’) The fluctuations in steam and power demand are reduced. il) Improvement in juice clarification. iiiSmooth operations of pH control system. 5) Auto pH Control System for Juice Clarification: The mixed juice from the mills contains soluble & insoluble _ suspended non-sugars. The primary purpose of juice clarification stage is, to remove these impurities. These impurities are precipitated by judicious | controlled addition of milk of lime & sulphur dioxide gas. The various control philosophies implemented for juice sulphitor automation in various | sugar factories are:- i) Three loop pH control system il) Two loop pH control system ii) Single Loop pH Control System iv) Proposed pH contro! systems using V.S.D. with conventional & film type sulphur bumer. The advantages of this system are briefed below: ') Higher settling rate leading to increase in capacity utilization. ii) Less CaO rise from mixed juice to clear juice. Refresher course for ST & SE, July 2005 {Vasantdada Sugar Institute, Pune = lil) Improved boiling at pan station with better molasses exhaustion resulting in high recovery. iv) Better clarity of juice and improvement in purity and colour (ICUMSA) of clear juice v) Reduction in scaiing of evaporators and pans. 6) Semi-Automation for Batch Pan: Automatic pan boiling for low/high grade massecuite based on measurement of conductivity/ viscosity/consistency and level of massecuite at predetermined points to control the feed continuously results into the following advantages: j) Uniform boiling reducing vapor fluctuations on pan floor. il) Water consumption for ‘A’ boiling is stopped. ill) Consistency in boiling operation with required massecuite brix throughout the strike. This avoids false grain formation or twin grain formation, thus more purity drop in boiling operations. iv) Increase in pan capacity due to the reduction in strike time. vv) Reduction in steam consumption. 7) Brix and Temperature Control of Molasses Conditioner: This system consists of two separate control loops for brix and the temperature of the molasses. These controls are always better to maintain the brix and temperature of the molasses for effective pan boiling. For the brix control the brix values: of. the- molasses is sensed either by conductivity / consistency / viscosity sensor. Depending upon the specific relation between the above sensor signal and brix, the brix transmitter is calibrated.and: proportionally 4-20mA DC signal is obtained. This signal is compared-with-the-set value of the brix in the brix indicating controller and the differenceof two signals operates the proportional control valve controlling the flow of water and results in the desired brix. Similarly, temperature is sensed by the RTD & the output signal of RTD is converted into 4-20mA DC with the temperature transmitter and given to the temperature-indicating controller in which actual value is compared with the set value. The differential signal in terms of 4-20mA DC operates the temperature control valve’ and regulates the steam entering into the molasses conditioner and maintains the temperature of the molasses. 8) Centrifugal automation: Automatic control of massecuite supply for high and low grade centrifugal machine eliminates. manual operation, controls the molasses purities, improves sugar quality and saves the down time. 9) Steam pressure reducing and de-superheating station: ‘Automatic control on steam pressure and temperature reduction will ‘smoothen the work of heating, evaporating and boiling equipments. Refresher course for ST & SE, July 2005 aeee é Geddes ddHobbdbunuEdd Refresher course for ST & SE, July 2005 z 7 Vasantdada Sugar institute, Pune 10) Boiler Automation: Boiler automation is one of the important subject from the viewpoint of energy saving, smooth and safe boiler operation. It mainly includes the following control systems: a) Combustion control. b) Three element drum level control ¢) Furnace draft control. d) SH. steam temperature control. e) Deaerator level and pressure control. The control configurations of these control systems are highlighted below: a) Combustion control: ‘The S.H.O. steam pressure is the master signal being maintained by the combustion control. This pressure signal is fed to the pressure controller and output signal of the controller will regulate the bagasse feeders and F.D. fan power cylinder through Auto! Manual station to maintain constant steam pressure. Airflow control, which uses the master pressure controlled signal through ratio relay, also has automatic airflow correction through oxygen trim control. b) Three Element Drum Level Control: The purpose of this system is to maintain the drum level at a manually-set value with minimum-fluctuations. The system continuously matches feed water flow to steam fiow. The relationship between the two flows is trimmed by the drum level controller to maintain the drum level at desired value over load range. The control system is a three element ‘cascade system in which the primary or drum level controller functions to trim the drum level and the secondary or feed water controller functions to maintain the balance between feed water and steam flow. Feed water flow demand is set by steam flow with the corrections added for the changes in drum level. The three-element control helps in minimizing the occurrence of dangerous conditions of boiler drum level. i.e. i) Too high level (swelling) ii) Too low level (shrinking) c) Furnace Draft Control: This is one of the simple controls, which keeps the pressure inside the furnace at desired value. In this system the master pressure indicating controller senses the difference between actual furnace pressure and the desired furnace pressure and produces the control signal, which throttles the |.D. fan damper through power cylinder. @) SH, Steam Temperature Control: This control system maintains the temperature of final superheated steam at the desired value. The temperature of steam is measured by K-controller. The output of the controller adjusts the water control valve for type thermocouple and this signal is fed to the steam temperature : mixing the water in attemperator header. €) Deaerator Level and Pressure Control: Deaerator is equipped with 2Nos. of single element controls. One is Pressure control and the other is level control. The pressure control maintains the desired pressure at deaerator. The pressure is measured by the pressure transmitter and its signal is fed to the microprocessor-based controller. The output of the controller regulates inlet steam control valve so as to maintain the set pressure of deaerator. Similarly, the level is sensed by the level transmitter and its signal goes to microprocessor based level controller. The output of this controller controls the water control valve which regulates the inlet water to deaerator to maintain its level. Refresher course for ST & SE, July 2005 ie‘Vasantdada Sugar Institute, Pune | 3 Process Chemicals: Utility in Sugar Manufacturing Process Dr.(Mrs) A.D.Kulkarni & Mr. A.V.Yewale, Chemistry Dept. Vasantdada Sugar Institute ‘The use of process chemicals in the manufacture of sugar has evolved rapidly over the past thirty years and an integrated programme of utilisation of proper process Chemicals in optimum quantities during sugar manufacturing process has become one of the assured ways to bring improvement in recovery and quality of sucrose as Indian Sugar Industry has entered into this era of global competitiveness and total quality management. Proper process chemicals means to use chemicals conforming to specifications. Optimum dose of chemicals has to be adjusted according tothe conditions jn each factory. Another advantage of this integrated programme is prevention in excess ! scale formation at evaporator station. The required specifications and optimum dose of il process chemicals are discussed in this paper. ‘Table 1a and 1b show the list of process chemicals used at various stations in sugar | ‘manufacturing process and cleaning chemicals respectively. The specifications required for process chemicals and cleaning chemicals are given in the table 2a to 2r. 1Mill Sanitation Chemical (MSC) Utility := Target of Mill Sanitation Chemical is to inerease sucrose recovery, reduce troublesome dextran, slime, fructose degradation products, organic acids as well as bad odour during the manufacture of cane sugar by providing control over growth of various micro-organism especially Leuconostoc “mesenteroids. Generally, mill sanitation chemicals act as bacteriostatic rather than bacetriocidic. Benefits of Mill Sanitation Chemical ‘« Increase in sucrose recovery by reducing loss of sucrose to 0.2 to 0.4 kg per tonne | of cane as against loss of sucrose 1.2 to 2 kg per tonne of cane if mill sanitation ‘chemical is not used. (Quantitative benefit) © Reduction in formation of dextran on'mills leading to less dextran content in sugar crystals. (Quality benefit) + Reduction in slime so as to control sucrose loss on mills which cannot be quantified. «Reduction in colour forming precursors such as fructose degradation product. Evaluation of Mill Sanitation Chemical: Evaluation of MSC can be carried out in terms of % reduction in increase of sugar loss from primary juice to mixed juice based on % reduction in increase of invert sugar from primary juice to mixed juice and further information can be gained by % reduction in increase of dextran from PJ to MJ. ee Refresher course for ST & SE, July 2005, iie "Vasantdada Sugar I Chemical Nature :- Generally MSCs used in India are as follows - ‘a. Dithiocarbamate (Na/K dimethyl dithiocarbamate, disodium ethylene bis dithiocarbamate). . Quaternary Ammonium Compound (Benzalkonium chloride) c. Halogen based : Sodium hypochlorite, Chlorine dioxide Specifications : Table 2a Optimum Dose : Optimum dose of MSC is dependent upon RS and dextran content in primary juice. Tentative optimum dosage of MSC per tonne fresh sugarcane is given in Table-3. ‘Suggestions for better mill sanitation Active content of MSC should, be determined and at least optimum dose based on active content should be applied during manufacturing process. Quality of primary juice and mixed juice in terms of RS and dextran should be checked daily. Good house keeping practices should be followed for better mill sanitation viz. regular thorough washing and steaming should be carried out to dislodge the accumulated slime matter around the pockets, comers, chains, troughs, strainers etc, with high pressure hot water (70 - 85°C) at an interval of 4-8 hours. Bleaching powder should be spread over surroundings of the mills. If there is sudden spurt in slime, dose of MSC should be increased to its MIC (Minimum inhibitory concentration) level. + More than one MSC should be used in a system because it is always possible for a bacteria's to become’ iminune (resistant) to any one MSC. Generally, the MSC programme should be designed such that one particular MSC is dosed for three consecutive weeks and then in the fourth week; an alternative MSC is added. The addition of MSC may be manual or via a dosing pump. To reduce sucrose loss in processing, it is important to ensure a continuous and uniform addition of mill sanitation chemical at mills 2 Phosphoric Acid Utility :- Phosphate content of the juice is the most important factor in efficient clarification: as colloids are adsorbed on calcium phosphate precipitate. In sugarcane, phosphates are organic as well as organic, ‘The organic phosphate exist in the form. of phospholipids, phosphoproteins, nucleotide phosphates and hexose phosphates. Only free phosphate ions take part in juice clarification and as adequate quantity of phosphate ions is not present in juice, inorganic phosphate ions in the form of phosphoric acid have to be added. ‘Chemical Nature : Orthophosphoric acid, HsPOs Specifications : Table 2b Optimum Dose : It is well documented that before addition of lime, mixed juice should have phosphate content as 300 ppm. Refresher course for ST & SE, July 2005 bid q‘Vasantdada Sugar Institute, Pune ‘Suggestions : Food grade phosphoric acid must be used. Fertilizer grade phosphoric acid contains sulphate Hence if phosphoric acid gives white, thick precipitate with barium chloride solution, it should be rejected. If turbidity is | observed, the sample should be analysed for its phosphate and sulphate content before use in the process. 3. Lime : Use of lime in clarification of juice is at least 300 years old. t Chemical Nature : Lime / Quick lime (calcium oxide ) : CaO Hydrated lime (calcium hydroxide ): Ca(OH): | ‘The convenience, cleanliness and purity of hydrated limehas led to its use ; jn many sugar factories abroad. Pulverized quick lime is separated by air | flotation and the better grades show 99% and more through @ 300 meshscreen. Specifications : Table 2¢ Optimum Dose :- Ideally determination of optimum lime dose to obtain better quality of clear juice should be carried out weekly in the laboratory. Optimization i) of lime dose can be carried out online with the help of pH electrodes. ‘Suggestions :- It is important to store the lime out of contact with air until itis ‘used in process. Optimum dose of lime results in improvement in quality of ‘sugars in terms of reduction in colour, starch, dextran, turbidity. Also due to less CaO rise from MJ to CJ, scale formation is reduced at evaporators. Hence, | optimization of lime dose should be done. 4 Sulphur Utility :- Clarification of juice by employing lime and sulphur dioxide is termed as sulphitation. In sulphitation, the lime-reacts with sulphurous acid forming calcium sulphite. For good filterability course aggregates of CaSOs should be formed which is achieved by maintaining low concentration of CaO and SOs ions. Chemical Nature :- Sulphur dioxide SO. is a colourless gas 2.264 times heavier than air and 45 volumes being soluble in one volume of water. Sulphurdioxide reduces the coloured ferric salts. Ferrous salt 2Fe;"+2e > 3Fe* Specifications : Table 2d 5 Color Coagulant : Utility :- This is relatively new process aid, colour coagulant, coagulants colloids and does not reduce the concentration of color forming constituents such as amino acid and polyphenols. As the precipitate formed by colour coagulant has to be removed it should be added either before lime addition of flocculant addition. Refresher course for ST & SE, July 2005 =Vasantdada Sugar Institute, Pune Chemical Nature :- Colour coagulant is characterized by a strong basic centre coupled with a long chain hydrocarbon or sometimes a polymer chain, Specifications : Table 2e Optimum Dose :- Optimum dose hes to be determined in the laboratory by determining colour of MJ, SJ, CI and sugar itself, ‘Suggestions :- Colour coagulant should be used only after a proper factory tral 6 Flocculant Utility :~ The functions of a good floceulent are (a) to increase the setting rate of insoluble solids (b) to decrease mud volumes (¢) to produce good clarity for clarified juice (4) to produce good filterability of mud. Chemical Nature :- By and large, flocculant are the high molecular weight co- polymers of acrylamide and sodium acrylate.These are mainly anionics which camry the same charge-as the suspended particles in the juice. Flocculants are supplied as white, granular powder. Specifications : Table 2f Optimum Dose :- Settling test should be carried out at various ppm concentration of flocculant on sulphited juice in the laboratory. Generally, about I to 2 ppm dose of flocculant per tonne cane should be given in the process ‘Suggestions :- If very high m.w. flocculants are used, settling time will be reduced ‘but it may cause problems during filtration, 7 Antiscalant Utility :- Antiscalant fights against scale deposition on evaporation bodies 3 ways ‘+ Threshold effect Crystal distortion *. Dispersion One can expect the following improvements from a properly applied antiscalant programme, ‘% Fewer slow downs in milling caused by slow downs in the boiling house, Longer evaporator runs between cleanings . % Formation of soft, less adherent sludge rather than hard scale, ‘® Conditioned deposits which.are more easily removed with less concentrated boil out solutions and/or reduced boil out times. ‘% Less corrosion of equipment from exposure to cleaning chemical solutions. & Fewer cleanings affording less downtime and less labour requirements, Reduced steam sugar requirement for heat transfer surfaces. ‘Chemical Nature :- Chemical nature of most of the antiscalants is that they are polymers of acrylic acid and acrylic acid derivatives like methacrylic acid ester, Sulphonated acrylate etc, Antiscalant is supllied as water solution, Solution Reffesher course for ST & SE, July 3005 LidCc ~Vasantdada Sugar Institute, Pune contains above mentioned polymers as well as stabilizers, antioxidants and sometimes organo phosphonates. Specifications : Qptimum Dose antiscalant. Table 2g Optimum dose should be based on value of % Ca inhibition of 8 Hydrogen Peroxide Utility :- Hydrogen peroxide is an efficient bleaching agent and offers promise as a bleaching agent to sugar industry because of its low cost. Also being indigenously manufactured, it has an edge over SO2 which is imported in India. Decomposition of H;02 affords only water and nascent oxygen which ‘brings about oxidation of colourants and thus ensures a very clean and environment friendly bleaching operations. Effect of H2O2 treatment was that sugar produced had reduction in colour in the range of 10 to 35% and further also showed better keeping quality when studied after a period of one year. Chemical Nature :- It is the most simple peroxide having formula H20z, It is, generally available as 50% solution. Specifications : Table 2h Optimum Dose :- Dosing points for H,0; should be unsulphured syrup, sulphured syrup and A massecuite. The total dose should be 20 ppm per tonne cane crushed of 5% H02 solution. @ 9 Hydros Dv = Utility :- Hiydros is added to 'A' massecuite to improve colour and during low Gaal grade boilings to reduce massecuite viscosity. This compound releases SO: into > the massecuite, acting on colouring matter, lime salts and iron salts. Specifications are given in Table 2i. ° 3 10 Viscosity Reducers :- <> Target of viscosity reducers is wo increase fludity of mother liquor by lowering viscosity of massecuites, reducing surface tension 9B leading to improvement in boiling efficiency, crystallisation, centrifugation and exhaustion of molasses. Benefits Reduces time for C-boilings. + Better purging, less washing. * Reduced ash content in sugar. * Better molasses exhaustibility in quality and quantity. Higher sucrose recovery. Chemical Nature: These are surface active chemicals.These compound are Zenerally organic compounds with high molecular weight. Reffesher course for ST & SE, Fuly 2005‘Vasantdada Sugar Institute, Pune =| Optimum dose : Optimum dose has to be determined by carrying out efficiency test the laboratory. Specifications are given in Table 2j 11 Turkey Red Oil Utility :- It is used to avoid delay in boiling time of C' massecuite and to reduce the viscosity of molecule. Chemical Nature :- It isa sulphonated castor oil Specifications : Table 2k Alll the process chemicals and cleaning chemicals must conform to above specifications. VSI has prepared a manual entitled "Manual for Analysis of Process Chemicals’ where analytical methods for each parameter of | specifications for process chemicals are systematically described. The test ‘methods are simple, accurate and adoptable in the laboratory of sugar factory. It is extremely important to recognize that process chemicals should be used i continuously, without interruption in order to achieve additional sucrose recovery. f Optimum doses have to be adjusted to correspond the changes in factory conditions, as determined by proper analytical methods. The process parameters that need to be analysed for optimum dose as wellas-contrl of the manufacturing | process are, RS, dextran, silica, phosphate, sulphite, calcium, calcium + ‘magnetism, conductivity ash ete. If testing, evaluation and data gathering has to become a routine activity in the daily operations of the factory, itis must that no. of samples should be analysed in cost effective and time saving manner. Hence, j ‘VSI has developed. the chemical kit; VSI, Fastest kit, Sugar House Product { Test Kit. i Sugar House Product Test Kit :- This kit has been designed for testing the following parameters : (a) Ca + Mg (b) Ca (c) Sulphite (d) Phosphate (e) Silica.The testing of parameters just need about 15 minute time. Conelusion : In conclusin it can be said that there will be definitely improvement in quality and quantity of sucrose if proper process chemicals with optimum dose are applied continuously at appropriate dosing points with constant monitoring of process parameters. Refresher course for ST & SE, July 2005 ]ow Low ji we ess ‘Vasantdada Sugar Institute, Pune | ‘Table 1a Process Chemicals [Sr.No. [Process Chemicals Station fh. ‘Mill sanitation chemical Mills 2. Phosphoric Acid Mixed Juice Tank 3. Lime Clarification 4 ‘Sulphur Clarification 5. Colour Coagulant Clarification 6 Flocculant Dor, 7. ‘Antiscalant Evaporator 8. Hydrogen peroxide Pan 9. Hydros Pan| 10. Viscosity Reducer ‘C massecuite i. TRO Cmassecuite ‘Table 1 b Cleaning Chemicals ‘Commercial hydrochloric Acid Sulphamic acid ‘Acid inhibitor Caustic soda Scale softner Bleaching powder pH Booster Formalin Specifications of Process chemicals Table2a Mill sanitation Chemicals Dithiocarbamate Sr.No_| Parameters Requirements. 1. Physical appearance ‘Yellow liquid 2. pH 9t0 10 3. ‘Active content, min, 3510 40 Quaternary Ammonium Compound SrNo. | Parameters Requirements a Physical apperance Colourless liquid 2. pH 8109 3. ‘Active content, min. 30 t0 35, Refresher course for ST & SE, July 2005 &~Vasantdada Sugar Institute, Pune Chlorine Based SrNo. [Parameters Requirements. 1 ‘Physical apperance Colourless liquid 2. pH 10to 1 3. ‘Available chlorine contentmin. [15 to 20 ‘Table-2b Phosphoric acid ‘Sr.No__| Parameters ‘Requirements 1 Physical appearance Colourless viscous Fiquid 2. Purity (as HsPO.).min. 85.00 3. POs content, min. 61.50 4. Ton (ppm),max. 300.00 5 ‘Sulphate (as SO,)¥%,max. 125 6. Specific gravity at 25°C,min._| 1.69 ‘Table-2ci Lime ‘SrNo._| Parameters ‘Requirements it ‘Avalible lime, Cao,min. 90.00 2 ‘Acid insoluble matter as Silica (S103), max. | 1.50 3. Tron, as Fe,Os,max. 2.50 4 ‘Magnesium, as Mgo, max, 2.0 | 3. ‘Alumina, as AlLOs, max. 10. 6 [Dead burnt lime, max. 2.0 Table-2eii_ Hydrated Lime Sr.No. [Parameters Requirements a ‘Avalible-lime, Ca(OF )min. 90.00 2: ‘Acid insoluble matter as Silica (SiOz, max. | 1.00 3. Tron, as Fe,0,,max. = 4, Magnesium, as Mgo, max. 13 3. ‘Alumina, as AlnOs, max. = 6 ‘Dead burt lime, max. = I Table-2d__ Sulphur ‘Sr.No._| Parameters ‘Requirements I Physical appearance | Yellow granular material 2. Elemental sulphur, min. | 99.50 3. ‘Moisture, max. 0.5 4 ‘Ash, max. 0.20 Table2e Colour Coagulant Performance evaluation test on limed and sulphited juice to ‘measure the % reduction of colour of juice at various doses of sample. Refiesher course for ST & SE, July 2005‘Vasantdada Sugar Institute, Pune Table-2f _Flocculant i Sr.No_| Parameters Requirements 1 Physical appearance White gramular material 2. | pH (0.1% soln in water) 7t08 3. ‘Nitrogen content 10 to 12 4 Charge density 401042 | 3 Inttsic viscosity (100 ml/gm) 3108 ‘Time required for’0.1 % soln in 2% NaCi,sec__| 30 to 35 Table-2g_Antiscalant Sr.No. _| Parameters 1 Physical apperance Colourless liquid 2. pH Sto7 3. Solid content 251030 4. Sequestral value :Miligrams of CaCOs | 225.00 Sequestrat per ml of antiscalant, min. 5. ‘Ca % inhibition 15ppm,min 40 10 45 20pm 50 to 55 Table-2h Hydrogen Peroxide Sr.No. _| Parameters ‘Requirements = 1 Physical appearance = Colourless liquid = 2. Purity (as H202),min. 50.00 3. Acidity (as H2S04), max. 15 to 0.03 Table-2i_Hydros : jodium hydrosulphite Sr.No. _| Parameters ‘Requirements 5 Physical apperance ‘White granular powder 2. Purity (as NagS,0.),min. 90.00 3. ‘Sulphur dioxide (as SOs) 66.00 Table-2j Viscosity Reducer || Sr.No. | Parameters Requirements 1 Physical appearance Colourless or yellow’ brown liquid 2. pH 7.0 10 8.0 3. ‘Active content, min.% 35-40, Refresher course for ST & SE, July2005__ 5 |Table- 2k Turkey Red Oil Sunedsemauseeeseetace ‘Requirments | Sr.No. _| Parameters Grade I | Grade IL i ‘Degive of sulphonation % by mass, min 6 6 [2 “Total alkali (as KOH) % by mass, max 3 3 3. “Total fatty matters % by mass, min. 70 50 4 pH value 65-75 [65-75 5. ‘Total ash % by mass, max 8 8 | ‘ 4 Table-21__Commercial Hydrochloric acid Sr.No. _| Parameters ‘Requirements 1 Physical apperance Faint yellow liquid | 2. Total acidity (as HCI), min. 30.00 3. Specifie gravity at 25°C 1152 zl ‘Table-2m _ Sulfamic acid (Descalant) ‘SrNo._| Parameters ‘Requirements 1. Physical appearance ‘White granular powder | ze Parity (as sulfamic acid), min. 84.00 ' 3 “Matter insoluble in water.max. 0.10 0.15, q Table-2n__Acid inhibitor SrNo. | Parameters ‘Requirements 1. Physical appearance reddish brown liquid 2. pH 7.0 to 8.0 3. Performance test: % corrosion inhibition test Table-on_Commereial Caustic Soda SrNo.__| Parameters Requirements 1. Physical appearance ‘White sticks or pellets 2. arity (as NaOH), min. 95.00 } \ 3. ‘Carbonate (as NajCO3), max. 2.00 4 Chloride (as NaCl ), max. 3.50 } ‘Table-2p_Formaline | ‘Requirements , % by Wt. Sr.No. | Parameters 1 Physical appearance Colourless liquid 2. pH at 25°C 3.0 t0 5.0 \ 3. Purity (es formaline) min 3010 35 } 4. ‘Acidity (as HCOOH).max. 0.03 Sree cesses eee ses reese Refresher course for ST & SE, July 2005 32APH HUHHUB a Vasantdada Sugar Institute, Pune Table 2q Bleaching Powder Sr.No. _| Parameters Requirements Grade I | Grade TT ai ‘Available chlorine by % by mass, min 34.0 (32.0 zi ‘Stability loss in chlorine, max wis [qr 3. ‘Moisture % by mass 03 05 4. Particle size through 1.7 mmlIS sieve % by mass, |99.3 [99 min Table-2r pH Booster ‘Sr.No. | Parameters ‘Requirements 1 ‘Physical appearance ‘Colourless or yellow's brown liquid 2. pH 1210 125 Table-3 Tentative Optimum Dosage of MSC/ tonne of sugareane Sr.No. | Parameters ‘Active Content % | Dose ppm L Dithiocarbamate 35-40 12-15 2. ‘Quatemary Ammonium Compound | 50 45 3. Chlorine Based 25 10-15 Refiesher course for ST & SE, July 2005,i ‘Vasantdada Sugar Institute, Pune J CV and MA determination | V. P. Sidanale and Dr. M. B, Londhe | Vasantdada Sugar Institute, Pune. | SE ae uercsee ICUMSA method no GS 2-37(1994) describes determination of particle size of white suger. This method is also found suitable for calculating CV and MA \ of Indian Plantation white sugar. After successful application of this method for ' Plantation White sugar, authors further developed new VS! method to calculate ! CV and MA of massecuites. The developed method with further calculation / assessment is found useful for judging the performance of centrifugal operation. j ‘The principle of this method is ,an appropriate set of woven wire cloth 1: sieves is assembled. A weighed sample is transferred to the uppermost sieve. ‘The sample is segregated into size fractions by shaking the set of sieves. The | weight of each size fraction determined and expressed as @ percentage of the sample. l | The particle size analysis of sample of sugar obtained by test sieving can | be mathematically treated to evaluate grain size distribution. The most commonly used parameters-are Mean aperture (MA) and Coefficient of Variation (CV). The | I | | MA is that aperture that would retain 50 % by weight of the sample and CVis the f standard deviation of the-distribution-expressed as a percentage-of the MA. VSI developed new method-for CV and MA calculation for massecuites: Sampling ' “The sample.for grain size must be a truly representative sample and must ! be the whole of the final sub sample. The sample shall be well mixed with stainless steel rod. Washing Only required for .cuites for separati | for sugar washing is not required) i Itis necessary to separate the film of molasses of the massecuite crystals prior to the soreening and care shall be taken to avoid dissolution of sugar crystal. | | iH | Procedure: iH | | crystal from molasses 4. Weigh 500 g + 1g sample of massecuite in Erlenmeyer flask. Before weighing mix the sample slowly for five minutes with siow stirring preferably 1 | Refresher course for ST & SE, July 2005 Ea‘Vasantdada Sugar Institute, Pune with stainless steel rod to avoid settling of crystals at the bottom of massecuite layer due to gravity difference. The care shall be taken to avoid crystal breakage during stirring operation. 2. Add 100-150 cm® 90% methanol to the massecuite (500g) in the Erlenmeyer flask and stopper. 3. Shake for 2 minutes. Allow soaking for 1-hour but shake for 2 minutes after ‘every 15 minutes. 4. Centrifuge all the material through lab basket centrifugal machine (Remi B 4L. or similar basket centrifuge with appropriate working screen aperture generally 0.06 X 1.7 mm aperture size) at about 2000 -3000 rpm so that the entire methanol plus molasses layer and diffused water can be washed out. 5. Remove the centrifuged sugar with scrapper carefully avoiding crystal breakage. To achieve this the rpm of centrifugal machine is to be kept as low as possible and the centrifuged sugar layer in basket should not be very ‘compact. This is to be done by trial and error and depending on mother liquor brix and viscosity as well as crystal size and crystal % in massecuite. 6. Repeat steps 1 to 4 till the molasses layer on the surface of crystal is thoroughly washed. 7. Remove sugar from the centrifugal basket and spread all the sugar crystals in plastic tray fo dry it with cold air. Use air pressure pump during this period for crystal drying and shake gently. To avoid lump formation, sugar may be mixed intermittently with hand, until crystals are free flowing and dry. Use these crystals for sieve testing. Screening Select a set of test sieves so that between 10 and 20% of sample is retained on the top sieve, between 10 and 20% passes through the bottom sieve and not more than 30% is retained on any intermediate sieve. Ensure that the sieves are clean and dry. They may be washed in warm water and dried at a temperature not more than 75°C if required. Sieving Weigh each sieve and the base pan to the nearest 0.1 g on the top pan balance. Assemble the sieves in descending order of aperture size and include the base pan and lid. Weigh the test portion obtained to the nearest 0.1 g and transfer to the uppermost sieve. Place the slack of sieves on to the mechanical shaker and shake for 10 minutes. Remove the stack of sieves from the shaker ‘Refresher course for ST & SE, July 2005seal | | is ‘Vasanidada Sugar Institute, Pune | i | and care fully reweigh each sieve with its retained sugar.. Similarly reweigh the H base pan to the nearest 0.19. Calculation Determine the amount of sugar.retained by each sieve and the amount of sugar in the base pan, from their différences in weight before and after shaking, Hy ‘Sum the amounts retained by each sieve and base pan. This sum must be equal tt to the weight of test portion taken initially within + 0.6 g. If the sum of the weights \ is out side this limit the test should be repeated. | For calculation of CV and MA, the “Powers method” as described in | ICUMSA method GS 2-37(1994) is followed and given in annexure |: | EXPERIMENTAL TRIALS / RESULT AND DISCUSSIONS ‘The experimental trials were conducted at M/s Datta Shetkari S. S. 1 | K. Ltd. Shirol Dist- Kolhapur, and M/s Vighnahar S. S. K. Ltd. Dist- Pune. The method was tried for A massecuite and B massecuite with respective sugar for particle size and calculation of CV and MA was done. The results were as follows. Tablé Not — CV & MA data.at M/s Datta Shetkari S. S. K. Ltd. ‘Sr.No | Particulars of CF 410772005 16/07/2005 t Machine Hy \} MAin] 1 MAin Make _|Capacity| cv %| mm |Colour| cv % | mm 7 _|AMass. = (35.256 7.550] - a = H |) 2 WiL__| 1750 [35.354 | 1.324 | 49.31 [38.67 | 1.434 | 3 Wit. 750 | 35.55 | 1.312 | 51.58 | 37.778 | 1.523 4 ‘Wit. 750__ [35.372 | 1.324 | 63.21 | 36.205 |" 1.39 5 ‘Wit 760 _ [37.098 | 1.303 | 54.45, | 39.434 | 1.443 6 WIL | 1750__|36.445| 1.325 | 56.94 [39.306 | 1.595 7_| Kruup | 1250__| 34.403 | 1.386 | 62.18 = : | Kruup_| 1250 | 35.041 | 1.407 [67.11 | 36.331 [1.54 | 9-_| Kruup | 1750 | 35.204 | 1.465 | 66.59 | 39.352 | 1.600 | 7o[_Kruup | _750__|35.816| 1.521 | 70.44 | 32.767 | 1.421 44 [_Kruup | 750 | 36.856 | 1.535 | 76.74 | 38.453 | 1.541 ; After calculating the MA and CV of total A centrifugal battery, we noticed | that there was decrease in MA of centrifuged sugar as compared to MA of the | relative massecuite. The decrease in crystal size was of the order of 15 to 247 | micron. The possible reasons for decrease in crystal size may be as follows, Refresher course for ST & SE, July 2005 6Sa (ee ‘Vasantdada Sugar Institute, Pune = Unsatisfactory / defective washing in centrifugal operation, 8 - Crystal breakage due to high gravity factor as well as due to ploughing = operation in flat bottom centrifugals. 2 Table No 2- CV & MA data at M/s Vighnahar S. S. K. Ltd. 3 Sr. No. Particular 03/02/2005 > wv% | wi i Amie 39.098 1.410 =) 2 ‘Sugar, machine 7 41.55 1.341 3 3 ‘Sugar, machine 2 42.962 1.439 4___[Amle (set 1) 43.540 1.603 3 ‘Amlc (set2) 44.768. 1.343 Ms 3 ‘Sugar, machine 1 47.020 7.499) 6 ‘Sugar, machine 2 42.962 1271 > 7 Sugar, machine 3 44,050 1.339 8 B mic 37.03 0.470 ° 9 B seed 37.021 0.450 > 10 | Dry Seed + Dust 35.71 0.653 e 11___| Dry Seed 21.61 0819 SS 12 [Dust 49.82 0.398 3 13___| Dry Seed + Dust 37.677 0.782 The crystal breakage due to ploughing operation may be judged from the powder or fine sugar passing through 25-mesh sieve. However the wash water dissolves the upper layer of sugar and decreases MA. The values of MA can be used as one of the tools for judging the efficiency of wash water application in centrifugals. The table no. 3 indicates the quantity of sugar washed out during centrifugal operation. The figure no. 1 indicates the relation between sugar colour Refiesher course for ST & SE, July 2005“Vasantdada Sugar Institute, & decrease in crystal size in mm. From this data, following observations were noted, Lower the sugar colour, higher is the crystal dissolution. This is mainly due to heavy washing of crystals during centrifugation. _ The washed sugar quantity from crystal layer is on account 8 to 21 % of the crystals present in massecuite. This washing was helpful to decrease sugar colour by 20-25 IU but at the cost of heavy re- dissolution of crystals, which increases sugar recycling in the process. ~ The figure no. 1 indicates the relation between sugar colour & decrease in crystal size in mm. Higher the crystal dissolution, better is the sugar colour. However higher crystal dissolution increases process, load and the dissolution of crystals shall be reduced as far as possible ~The CV values of centrifuged sugar are observed higher as compared to the CV values of relative massecuite samples. ‘Thus the determination of Mean aperture (MA) and Coefficient of Variation (CV) is one of the useful tools for judging the efficiency of washing operation at centrifugal machine. The heavy ‘water wash at centrifugals may help to improve ‘sugar quality with respect to sugar colour, however it increases heavy sugar recycling in process. Refresher course for ST & SE, July 2005,Vasantdada Sugar Insitute, Pune J Table no. 3: Details of MA and crystal dissolution in centrifugal machine during centrifugation Paniculars Ame | Machine | Machine 2+ | machine 3+ | Machinea* | achineS | Machine 6 | Machine? | Machine 8 | Machine 9+ | Machine 10° ‘Quantity oF Masseculte, MT. L Ls 075 07 075 178 Las Las Ls 075 075 Crystal Sarassecuite 3s ss 55 55 55 38 3s 38 33 3s 55 ‘Weight of ental inmascecute,g | 50000_| _962s00_| _12s00_| _a12s00_| _s12s00_| _962500_| _e87so0o_| os7soo_| 962500 | 412500 | 412500 [Number of crystals inmaswooite | 211x10* | 39x10" | 1sexto* | isexiot | tsexiot | 360x108 | 26x08 | 26rxi0! | sooxro! | issxiot | 1sexiot ‘Average Crystal SizeinA Massciteinmm | isso | 1324 1312 132 1.303 agas_| i386 | taor | aes | sa 1.535 Volume of single sta em? ooo41ss | o.o0rs762 | o.0025068 | ooorsre2 | oor4sss | o.oo2se2i | o.ona9sss | o.ons0s18 | 0.003490 | oo0390ss | o,ooso1s7 0.002604 | o.0016230 | 0.0015793. | o.016230 | aooisa7o | 0016267 | aoorssis | ooor9e7s | oocrisss | o.o024so7 | o,002s290 crystal weight due tovsthings + | oooaps11 | ooorozss | oooossi1 | aooiosr1 |-oon09774 | cooorax2 | o.oo0sses | o.coos0se | oovo14s4 | o.oo007s9 ‘Toual weight of washed sugar, Ke ‘ 302.6 1623 1354 er saz_| is60 | 13 | os | m7 us Washed ari Tefal male © | tom | aves | rom | ass | ono | isos | rossi | ass | smo | sti we pa | » [toa ot [Se om | 256 ras] av| oe] ns| sn] st s|_ ao] ss Ser ascarge ential Refresher course for ST & SE, July 2005 RAB(aaeeaaneaaae ‘Vasanidada Sugar Institute, Pune "ANNEXURE I Powers Method “The powers method for calculating MA and CV assumes a Gaussian distribution of crystal sizes for granular sugars. To show the method of calculation the data given in following table are Used as an example. % Retained on sieve ‘Cumulative % retained 113) 13 19:3 30.6. 146 452 148, 08 176. TTA 63 83.7 5.9) 896 Base Pan 40.4 100 J ‘A graph is constructed on arithmetical probability paper by plotting cumulative weights % retained on the probability axis against sieve aperture size on the linear axis. The best straight line js drawn through the plotted points. ‘The graph is shown in folowing Figure. Powe Mood Graph ———— |, 3 Te is 8 $5 & ° 10 eo arcuate tae SS By reading from the graph the aperture retaining 50% die is obtained. Similarly the apertures corresponding to 16 % dhe and 84%, dy, are noted. Then MA = deo = go. = 048mm. “The difference between the apertures, djs and dyes equal to tivice the standard deviation of the distribution, Consequently: ow 068-030 X 490. = 30% 2 04s Refresher course for ST & SE, July 2005 0_ Vasanidada Sugar fi ‘Techniques for production of low coloured plantation white sugar Dr.R.N.Bhosale Vasantdada Sugar Institure, Manjari Bk., Pune ABSTRACT- Present era is about the quality concept, it this regard quality has got the vital importance. For export-import market the sugar color is one of the most important parameters. In last decade the sugar production below 100 ICUMSA in most of the cases was very difficult. A production of 120 to 150 TU plantation white sugar was remarkable achievement, But through continuous efforts and up gradation of technical knowledge, Indian sugar industry is able to produce 60- 70 TU colour plantation white sugar consistently with the efficient follow up of the conventional liming and sulphitation ‘method. In this endeavor, Vasantdada Sugar Institute has done lot of work on suger quality improvement and still it is engaged in this work. VSI Succeeded in sugar quality improvement and is able to produce plantation white sugar of 40 to 70 TU (Average 60 TU) consistently with conventional clarification system. The some of the case studies where the sugar seeeeee ‘Vasantdada Sugar Institute, Pune Part-II: Case studies of production of low colour plantation white sugar _ with conventional method ~ Some The sugar colour improvement project work is implemented atthe following > factories in the Maharashtra during the season-2001-02 Vighnahar S.S.K. Ltd, Dist~Pune Ghodganga S.S.K. Ltd, Dist - Pune Kumbhi-Kasari §.S.K. Ltd, Dist Kolhapur Mahankali S.S.K. Ltd, Dist Sangli Bhaurao Chavan $.S.K. Ltd, Dist Nanded > With joint efforts of VSI and the factories we are succeeded to produce sugar of 60 _ + 10 IU consistently after rectification by implementing judicious steps for process control. ‘@ The details about the above work are as under. Experimental Methods I "Measurement of colour of all boiling house product at 560 nm as well as 420 me spectrophotometer. : + “sntification of stations where the improvement in process needed. +s, of various operations and variations in colour value atthe particular stations * Implementation of suggestions with the help of factory staff under guidance of VSI staff * Lower level staff training if necessary + Analysis of results obtained for further improvement in process. * Guidelines to factory staff for further improvement Case I - Vighnahar S.S.K Ltd; Dist.-Pune From the colour audit of boiling house product following observations/action points are considered for improvement. ‘+ Even though the colour of clear juice was uptol800 IU, the visual appearance was very dull. ‘There was no brightness or sparkling nature to clear juice. The % transmittance of unfiltered juice was in the range of 25-30 only while % transmittance of filtered juice was in the range of 37-40. This indicates very high turbidity in clear juice ie. above 100 %. Observations "The shock liming time was just 2 seconds before SOs bubbling starts * No arrangement for checking of shock limed juice p"* + Low consumption of lime & sulphur equivalent to 8.2 0.3 * Lower addition of phosphoric acid Steps taken: * The milk of lime consumption was increased to the tune of 9.0 + 0.3 shock p" by increasing SO, ges production. "Addition of phosphoric acid at the rate of 30 ppm dose * Clear juice withdrawal operation started by overflow Refresher course for ST & SE, July 2005 & ddd / @ JdOIPOGOGHUES = M“Vasanidada Sugar Institutes Pune «The delivery valve of weighed raw juice Pt ‘that the current load shall not show the emp! the kick load shall not pump. Achievements: “The above steps helped to improve clear juice time the % transmittance at 560 nm 33.95 %. In due course the factory modified t pH sampling pol fransmittance of unfiltered clear juice was © The %-colour increase at within acceptable limits. «The colour of the boiling house produet such are found with in the range and does not needs Gf lower color of massecuite and molasses in + Use of continuous pans for all grades 0 ‘= Stabilized conditions of vacuum jump was o% ty load more than 10 sec as well as icra per the suggestion. After completion of nis improved up to 38-40 %. evaporator station is found 5.78 % rontrolled in such a fashion te higher than 10 A than average current load of the color below 1800 IU at the same ‘of unfiltered clear juice was improved to the shock pH connection & shock job the % at 420 nm. This is as miassecuite, molasses and magma any change. The some of the reasons this factory were as follows. sf massecuite Adoption of B massecuite double curing “Table no.1- Colour data of boiling house products Sr. | Partiewlars Colour at 7.0| Colour at 7.0] Colour at Colour at 7.0) 0 Cais atam | pH.& S6onm —|7.0 pH & | pH Soon 200m TT Chose ioe Tai, T0554 T64h 38 3 Unsuipbured syrup _[ 2377 15320, 1677 10777 3 [Sul Syrup 29 11107 1628 7998 [A Massecutess [2286 aid 1670, 6155 B Massecuite 5957 =| 325 294i 12631 ‘C Massecuite 3068. 26271 6172 "24805 AHL 3575 13865 2550. 11267 ‘AL 1690 3500 2020 9571 BHT 331 1712 3854, 1 Ch oy 27291 5638, 26526, FM, 8630 56526 3930 47058. ‘cw 3974 18168 2454 11220 CAW, 1623 6317 1329, 3172 B seed = 2796 #70 4036 Dry seed zi 1988 226.8 BAW. 52.43 ‘BFW 486.54 CAW 1792.0 Fable no. 2 Sugar colour data before and after modification Parieulas Sugar colour by GS2B-10, Before changes “Hii changes | ecolour reduction SavOWst (85.80 36.46 3432 80.50 58.33 2734 298 640 1176 71.89 59.14 1174sédd a6 bb oo dé (Wasa Suga Tats, Pang Case Il- Ghodganga 8.S.K Ltd; Dist- Pune Observations: From colour audit of boiling house product the colour values of the same before and after audit are given in the following tables. Table no.3 - Comparative statement of colour values of various boiling house products, Sh] Sample panealas [TORO at | TOAD0 at Sample | TOSGO ak TO pH | TUDO ar TO pT Sample pH | pH 1 Ciara 130 Toe ise TOTS 2] Gnu. Sp 1365 5703 138 3668 5 [Sul Symp. 1473 eit 6a S19) TA massecut 165 6053 iat “798 S| B masse 3776 19268 3 2025 6} Cmasseouite 6555 30077 684 57620 7 [AHen 2 T1065 2500 13457 aati 136 ous 1577 8195 [Bie Tiss 33318 80 36764 10 —[ Chight 233 31088 786 35156. | Final masses | 10857, 52760 10386 S013 12 CrW. 056 is7i6 197 21496 13 CAW 10z2 S621 31 4709. [Bed 206 Ta 24 i576 15 [Dry seed S38 189, 8.6 240 His — [ches ise OL 2008 1207 5008 T7—| Wasa. Syrup 1512 8872 1s 7810 1s Sul Sy 1m #413 19 [A massecute [1361 ST a3 5 20'S massecute [3588 16525 SR 17965 zi [afew 239 11301 2682 1428 Taian 1328 6280 1658 TB ‘Table no. 4—Details of undiluted clear juice % transmittance at 560 nm SN J Particulars of ial ‘Range of % tans. At 560 nm undiluted clear juice sing 1.18 Cm cell length 1 | Factory practice before change 2710 42% 2 | After controlling raw juice pump suction valve _| 3610 44% to 9.5 pls and manual control of juice flow 3125 ppm phosphoric acid, increase in Shock pH [500 56% to 9.5 plus and manual control of juice flow & film type sulphure burner in operation F]25 ppm phosphoric acid, inorease in Shock pit | 58 t 62 % ‘Table no. 5 — Details of Sugar colour & centrifugal timer changes SN_| Pariiealars setting Modified setting 1] High speed spinning time——_| 10 see 35 sec 2 First wash rpm 450 450 3 | First wash duration Bee See 4 | Second wash rpm 750 1050. 3 | Second wash duration 10 see 12 ses 6 | Charging time 12sec. 15 see sugar colour by GSB-TO [83 t0 110 20s 530 M30 wow 0 ee Refresher course for ST & SE, July 2005 6 [Refresher course for ST & SE, July 20050= The average Following are the observations. 4560 nm, The variation in clear jul transmittance of unfiltered clear juice was +» For reducing purity 0 B massecuite. Hence col molasses. «The sugar colour was found varying iar of A masseeute was found 7204 TU at ‘sugar colour was improve ‘steps taken for colour improvement She raw juice pump delivery valve control Toad. This step help to achieve constant juice + Sulphur bumer is oper as secondary air. « Better attention was paid to meet 1 The phosphoric acid adition at the rate of 40 quality. «Baz of CL and BH molasses for topping of B Lire get better sugar quality, the centrifugal © ‘changed as shown in the table. « For removal of final fine molasses layer “uring time need is. maintained above 30 consistent sugar quality. Result: o “The colour vallie-of therclear juice was ‘at 420 nm and 1200 IU at 60 nm. juice was improved to 52% and stabil [ese Vi ‘Sugar institut jui observed above 10: FB massecuite, factory is using CL & four of B massecuite increases Very from 70-80 TU by GS: 1d to 50-55 IU by method GS: 1 to almost 50% to get constant current flow to the tune of + 10%. ‘ated by avoiding air venting to atm« 1180p gas demand for 9.5 shock pH. ‘kgshift started to get better clear juice The % transmittar Pune 1500 TU at 420 nm & 1600 TU ‘pserved very high. The % ‘observed varying from 33 to 47%. 'BH molasses for topping of ‘high as compared to AH 2/3-10 method. But the ‘and 1200 TU at 560 nm. The 23-10. josphere but using excess ait -massecuite is stopped. mers of 1750 kg/charge centrifugals from sugar crystal, the high speed duration i. ‘seconds continuously: This ensures and is reduced to 8000 1U improved snce at 560 nm of clear ised better at 58-60% with in-a one was reduced to 50-5 after the day. = The. sugar colour at the centrifugal rectification. is reduced in the range 40-70 1U «The overall sugar colour ‘Suggestions for further improver ment in sugar colour «Film type sulphur bumer to be put in operation continuously. an and cut to 60 MT A pans. Follow 3A footing in 80 MT Tow head e i i 4 Follow cleaning of hopper & pug mill 2 instead of reboppering of old suger, fl Fofiesher course for ST & SE, July 2005 hoppers at safe distance. ‘vacuum P regularly. low melting of old suger.Vasantdada Sugar Institute, Pune tdada Sugar Institute, Pune Case IHl- Kumbhi-Kasari S.8.K Ltd; Dist- Kolhapur ‘The colour audit of the factory was done and the average colour value of various boiling house products are as follows. ‘Table no. 6- Comparative statement of colour values of various boiling house products Particulars Sai Sa 360 nm 20am $60.am, Bam Clear jue Rapidorr uss 7513 1401 9870 4s 1435, 6780. 1421 9850, ‘Ussynp 238. 9269 2900. 9925, Sulsyrup 1287 7130, Tie 7192. ‘A masseciile 1308, 7138 1297 6675 ‘Bmasseculte 2701 13761 2573 11826 ‘Cmassecuite 6359 24059 6400. 28681 ‘Abeavy 2163 2173 2297 11669 ‘Light TE 3596 837 “4574 Bheavy 6567 25026 602, 26174 ‘Clight ‘81 18618 3985 19503 cEW 2016 8166 2130. 10589) CAW, 377 1732, 366 2572 EM, 1998 40521 10077 52007 a B sood 66. 197, 232 1192 Cseed 60 22 8 34 ‘Table no.7- Details of Sugar colour before & after of centrifugal timer changes Ceniriingal no, | Before tar adjusiment | After timer adjustment i 6 2 z 71 39, 3 a al 4 80 37 3 8 o 6 ca a 7 90) a ‘Sugar colour variation by GS23-10 Beiore changes in Aer changes in process process 330 30 10 140 wT M30 100 10 145 321070 Observations: ‘The clear juice colour is found in the range 1400-1500 IU at 560 and 7500-10000 LU. at 420 nm and was within the acceptable limit. The variation in clear juice quality was “observed very high. The % transmittance of unfiltered clear juice was observed varying from 33 to 47%. ‘The colour of boiling house products such as massecuite, molasses and magma are as per the recommendations. The colour of A massecuite was found in the order of 6600- 7100 TU at 420 nm and 1300-1500 IU at 560 nm. But the sugar obtained from this Refresher course for ST & SE, July 2005 8——Vesanidada Sugar inst ‘The colour of sugar obtained from these quality massecuite is of higher colour qetrifugals was 71 to 90 IU by method GS2/3-10. Steps taken for colour improvement Fees juce the very high variation in juice colour following steps were followed. Tt-was observed that due to higher raw juice pump capacity, large fluctuations are noticed in jue flows. For maintaining minimum variation in color of the clear juice note ald be minimum variation in juice flow. Controlling te suction as well as tlelivery valve to maximum possible extent the juice flow was stabilized. The juice tank empty time reduced from 30-50 sec to 5-8 see. oe shock pH, Point of lime application and phosphate dosing were ¢5 PSF the ‘need, No change is made at other points. s Beouthough the colour of the A-massecuite the colour of the suas? WEL To higher veya This shows the problem at centrifugal working, After changing: setting of rash, water 1% wash water, spinning time ‘and steam wash duration as well as vetiagof wash nozzles, the sugar colour improved to 50-70 TU as given in the table. RRevaleThe sugar colour before the audit was in the range of 90-140 TU. After Retifcation at respective stations the sugar colour was reduced 10 18 the range 40-70 TUlt is general observation that the colour increase from centrifuged sugar to graded sugar is 15-20 units, Suggestions for further improvement in sugar colo¥r » «Tr ivsnggested to pay better attention on centrifugal maintentncs, In future it was suggested to replace present steep cone centrifugals with modem high gravity factor flat bottom centrifugals. . ‘To clean A Crystalliser pug mill and hopper regularly. Refresher course for ST & SE, July 2005 saaueaC Vasantdada Sugar Insti itute, Pune, Case IV- Bhaurao Chavan S.S.K Ltd; Dist- Nanded ‘The colour audit of the factory was done and the average colour value of various boiling house products is given in the following tables . ‘Table no.8 - Colour values of various boiling house products Se | Name of sample Colour oF sample at 7.00 pH | Colour of sample at 7.00 pH & m0 & at 560 nm 3 420 om ‘earoir2002 | 0570172002 | 04/01/2003 | 0570172002 1] Clear juice comp no.1 | 1473 1599 TO1s2. 10348. 2 | Clear juice comp no.4 | 1485 iis 10237 10460 3 Unsulpbured syrup 1508 1852, 10478, 10696 | Sulphured syrup Bad 1366, 9020 ‘9889 3 | A Massecuite 143 1762. "7610 9147 ‘6—_[B Massecuite 3897 3233 17038 15726 T__[C Massecuite 252 6553, 26547 32717 8 | A Heavy Molasses 2602. 3038, BOL 14959 9 [A Light Molasses 2198, 2135. 10932, 13846 10__[ B Heavy Molasses 6203 6302. 23807 25779 T/C Light Molasses 4964 6053. 20806 24400. 12 | Final Molasses 12687 12080 $4329 ‘6089. 13] CFW sugar 3388, 2749 12764, To044 14] CAW sugar 1201 1201 4673 6208 15__| Dry Seed 8. 30 280 380 16 | B Seed 104, 638 398 1250 (7 TMett 1817 1643 ‘8012 10074 ‘Table no. 9— Details of undiluted clear juice % transmittance at 560 nm Sr.) Particulars of tial Range of % tras. At 560 am no. undiluted clear juice using 1.18 Cms cell length 7__| Factory practice before change 30 1045 % 2] After controlling raw juice pump suction [381047 % valve 3 [After addition of 25 ppm phosphoric acid, | 42 t0 54% increase in Shock pH to 9.5 by running two compressors for fulfilling air demond and manual control of juice flow [After addition of 25 ppm phosphoric acid, | 48 to 54% increase in Shock pH to 9.5 by running two compressors for fulfilling air demand, ‘manual control of juice flow& clarifier operation by overflow Refresher course for ST & SE, July 2005 aut Hes. Nal uaaey J) et ee‘Vasantdada Sugar institute, Pune santdada Sugar Institute, Pune __ [cesses ‘Table no-10 - Details of Sugar colour before & after of centrifugal timer changes - Details of Sugar co on ee aang | Modi na (Sener Tiners pails acinar sting_| Mosiod ime seting | i Tigh pend spin cred 130 see | ater wash dl 3580 15sec Fer ash dation Teo Saco Pater wah Seo Tee 4 i rater wash dion iasee Osco | Sem wash de 250 1dr 7 Sugar colour vrision A010 san 10 ‘Observations and steps taken: Sosy colour of clear juice was observed from 1400 to 180010 at 560 nf and 10000 to T1000 TU at 420 nm. The direct % trans of clear juice at 560 nm is also found varying from 30% to 54% "This very bigh Variation was the combine effect of following . ‘Very high crush rate . ‘Variation in raw juice temperature . ‘Variation in juice flow . Clarifier operation by liquidation and only up to 1" compartment. . Poor quality of quick lime «To reduce variation in clear juice quality and alsg to improve the clear juice colour, ait quantity to sulphur bumer is ‘increased to 900 m’/hr by running spare compressor and Nip burner VPC temp maintained to 470+ 5°C at 3 tank crush rate. The bagacllo in sugar was observed very high. This might be combined effect of bagacillo in clea: juice as well as bagacillo in atmosphere. To reduce this following points are suggested: “Operate clarifier always by overflow ‘Adopt ‘Vibro sereens? for lime and filtrate | Closing of ventilations from the bagasse yard side, The variation in sugar colour obtained from various cenrifugals was found higher. At ‘the same time the variation in sugar colour at the time Sf bagging and sugar discharged from centrifugal is also found very high about 60 TU. To reduce this difference following steps are suggested. = Follow hopper cleaning regularly. Cleon bottom side of centrifugal machine carefully in every shift * Avoid molasses leakages at centrifugals, RuRlove tori at end of the hopper carefully. Pick up brownish ror SAgEE jumps on hopper before mixing with normal sugar. = amps maseccuite charge regulator foreach A grade centrifugal. eThe'grain size of A massecuite is observed very small. ‘This small grain size affect sugar colour. To overcome this, atypical timer seting reeds to be implemented for stesining good quality sugar. The timers suggested for seting_ are given 19 the table Sihich will yields in further improvement in the sugar colour. Eee eee eee ee Refresher course for ST & SE, July 2005; > Dv duvdw GOW Cc Vasantdada Sugar Institute, Pune Case V- Mahankali S.S.K Ltd; Dist- Sangh ‘The colour audit of the factory was done and the average colour value of various boiling house products is as follows. Table no.11 - Colour values of various boiling house products {O7560, samplefUTA20, — Samp [Sample Particulars pH ty \ruvs60, 7.0 pH1_|fW/420, 7.0 pH ‘A_[Before changes Tear fice 2098 12601 25, 73403 2 Unsul. Syrup 2261 13138 2393, 13814 3. Bulphured Sup 1918, 6942 1998 10560 4 [A massecuite 5762 10016 5710) 13030 [A Hea 4204 14700 4140) 19826 6 [aight 1794 6780 1899 9338 7 BHeaw 3175 28879 10857 36949 hight 7649, 27933 3863 36786 97 Final Molases 13962 49873 16390 4082 10 Masseaute 412 14891 4011 17482 11_[eMasseouite 8580 30683 9051 37525 12 CF aia = 3192 = 13 FAW 1082 3808 363 3691 4B Seed 616 7359 742 3085 15 Dry Seed 127 447 127 422 16 Meft 632 2346 730 2936 17 B Manat = 651 2408 688 2598 B ‘ter Changes 1 lear fice 38a 5140 394, 326 2 [Unsul. Syrup 14a 3523 1215 3759 3. Bulphued Syrup 789 6498 351 6614 4 massecuite 1389 7885, 1661 7383 ‘Table no. 12-Compartment wise’ variation in undiluted clear juice % transmittance at ‘Refresher course for ST & SE, July 2005 560 nm ‘Se Paricuars of ad “KE SG oe wnaated clear Joes wi Comp. No.3 _[ Comp. No.3 [ Comp. Naa T | Fasion practice Before ange [404 308 384 362 392 388 338 402 2 Raion 25 pois Onto [51.8 S24 318 a8 ‘phosphoric dose & modifications [39.4 316 306 ane or shock liming fr 5 sec 308 504 28, 30 3 ]25 ppm Onho phosphoric dow ‘addition & modifications for ‘hock liming for 5 se all maddy juice withdrswal by overflow | $56 312. 564 556 TB—~Tasantdada Sugar Insti details - before & after of cent Observations and steps taken: «The colour of clear juice was observed above 2250 TU at 560 nm and above 13400 TO at 420 nm. The direct % trans of ear juice at 560 nm is also found vary oe i igh colour of clear juice was the combine effect of following = Hiigher erush rate = Yation in raw juice & sulphured juice temperature ~ Variation in juice flow Chartier muddy juice withdrawal operation by liquidation 1 Use of total milk of lime dose as preliming (PH 8.5) and retention time for preliming was above one minute «To iinprove clear juice colour and f improve % transmittance 10 above 50 %, following stepshave-been taken. ee ytixed juice flow Tate is controlled manually by appropriate opening of weighed Juice pump suction and delivery valve (0 ive minimum variation in pressure of ‘ramped weighed juice delivery ine. «stared addition of phosphoric acid 40 Ke Shift ie. about 25 ppm of PxOs with ‘constant dosing pump. «5 Milk of line addition Hine 18 made to suit shock pH timing of 5 second before 0, bubbling starts. 4s preliming followed only up to 68 10 7.0 pit Gpreviously up to 8.5 pH and farther shook limed to 9.5 pH. Siar juice withdrawal from clarifier Py overflow but disturbs the fon lines. These practices im conditions in clarifier and many 106% the bagacillo particles observed in ‘lear juice.-To restrict this both muddy juice and:clear juice withdrawal st by overflow from all compartments, nag a result of tis clear juice colour valve We improved to 1000-1200 TU st am Ay at 420 num. The Mo ransmitance of clea juice was also’ fo improved to 57 % (This % transmitane™ may be considered as one of the best clear ity. being achieved in various Teter). This will help to further wase for ST & SE, July 2005 on~_Vasantdada Sugar Institute, Pune He = The variation in sugar colour obtained from various centrifugals was found higher. At | the same time the variation in sugar colour at the time of bagging and sugar discharged from centrifugal is also found very high about 30 IU. To reduce this difference following steps are suggested. - Follow hopper cleaning regularly. = Clean botiom side of centrifugal machine carefully in every shift. - Avoid molasses leakages at centrifugal. - Remove rori at end of the hopper carefully. Pick up brownish rori sugar, lumps on hopper before mixing with normal sugar. = Provide massecuite charge regulator for each A grade centrifugal. 3 Result: As a result of this the sugar colour variation in centrifugals is reduced to considerable level. Similarly as a combined effect of excellent juice clarification and ' [D> optimized timers setting at centrfugals, the sugar colour is improved up to 60 IU. If further \ attentions is paid for cleaning the colour of sugar will be stabilized at 50 to 70 IU by method GS2/3-10. For long term, it was suggested to replace the present high grade | centrifugal machine with 1500 ke/charge fully automatic flat bottom centrifugal machine. Refresher course for ST & SE, July 2005 8 |“Vasantdada Sugar Institute, Pune Sugar Factory Water & Waste water management D.B. Sapkal V.S.L, Pune INTRODUCTION “The conventional “End of pipe” approach to waste managerers which provides for required treatment of wastes generated at various Sage ‘of process operations does not lead required solutions in the long run. It is so because, rs, ‘waste treatment in many 1 ssovzes leads to mere transformations of pollutants fom ome ‘phase to another. Secondly, estates substantial investment and budget to mest te ‘operating costs. Thirdly, wastes are ouree utilization and loss in production opportunity. In contrast, modem approach to waste management aims at optimizing production and at minimizing generation of wastes and then ‘managing the unavoidable wastes rreme environmentally acceptable and economical manner. Sugarcane is the raw material forthe produetion.oF ‘white sugar. While producing ugar, it's mandatory to keep our environment ciean- “The sugar industry generates waste sa ould be very valuable by-products i. molasses, bagns® ‘and press mud cake which have provided an attractive source to revenue fo SEAT “factories. It is necessary to remove extraneous matters from ‘sugarcane to minimize wastes and increase in sugar production. Tiguid wastes can-be minimised considerably by ‘plant control techniques and proper segregation of waste streams. SOURCES OF WATER 1. Water comes along with sugarcane 2. Wate cotyes fiom outside such as rive, canal, canal, well dam, bore-well etc USE-OF WATER: “The water utilized in the sugar factories can be classified into two categories jue. internat Water and external water. e INTERNAL WATER Clean cane contains shout 70% water; therefore, the water coming from the cane itself is primary source for sugar manufacturing proces: The Wate ‘from cane itself in the Foam of condensate is more than sufiient forthe intemal process of sugar manufacturing, te ot Condensate water used for imbibitons, boiler, filter cake washing, milk of lime preperation, movement water at pans, molasses dilution, centrifugals, melting etc. Refresher course for ST & SE, July 2005 6° ° ° o 3 ° > > J} s 3 ° 8 3° oo 3 2 ‘Vasantdada Sugar Institute, Pune HOT WATER BALANCE (Base- 100 TCH) A. CONDENSATE GENERATION Se No._| Particulars ‘Quantity, MT a. ‘Exhaust Condensate i) Vapour cell condensate 24.80 Quad 1* body condensate 20.56 S.J. 2" heating J.H. condensate. 01.88 Sub- Total 4724 b ‘Vapour Condensate. DiHCondensate —RTheating and S..1" 11.08 heating ii) 2" body Quad. condensate. 15.51 4ii)3" body Quad condensate. 09.48 iva" body Quad condensate 09.48 vy) Pan Condensate 24.80 Sub-Total 70.35 Total 117.59 B. CONDENSATE CONSUMPTION in Excess condensate = Source of condensate ~ Consumption of condensates 3.85 M.T. = 11759~ 103.74 For 2500 TCD sugar factory excess condensate Generation = 346.25 M*/day. EXTERNAL WATER (COLD WATER) The extemal water does not generally come in contact with the sugar manufacturing process directly. The external water such as cooling water used for Reffesher course for ST & SE, July 2005 Sr.No. | Particulars ‘Quantity, MT a For Boilers. i) Exhaust Condensate 4724 ii) Vapour condensate 10.00 b Imbibition water 30.00 c. MOLL. Preparation 1:50) a. Oliver filter 6.00 € Movement water at pans 5.00 £ Centrifugal Washing & Melting 2.00 & Miscellaneous and Floor washing ete. 2.00 Total 103.74 EXCESS CONDENSATE 77til [Eases ; condensing and cooling, power turbines, mill turbines, ‘bumers, air compressors, vacuum PUMPS, rill bearings, crystallizes, sulfur | hhot liquor pumps etc. and water used for floor | | | ‘washing, vessel washing and domestic use. | COLD WATER BALANCE FOR 2500 TCD SUGAR FACTORY \ ‘Cold water requirement atthe following stations. ; H He Maa) A Cooling Water T._] Water which is recycled : a. Mill Turbines 675.00 { b. Mill Bearings 450.00 | c. Power Turbines 800.00 ' | Water which is warm reused after cooling a. Crystallisers 260.00 Sulphur Bumers 200.00 i j ¢. Air Compressor 100.00 \ ,_ Vacuum Pump. 30.00 | 3.7] Water which is let out as waste water a. Mills Bearings (External cooling) 75.00 | 'b._Hot liquor pumps gland. 25.00 B._ Cleaning and Miscellaneous 7. Daily cleaning and washing 30.00 | 2. Laboratory use 006.00 3. Domestic use (300 persons/shift, 100 liviead) 090.00 ‘C.” Make up water | 1. Cooling. water.(2% less) for recycled wate 050.00 D7 Water for periodical cleaning (2000 M'eleaning) 75.00 | AGB+C+D_ Total 37 WASTE WATER GENERATION FROM 2500 TCD PLANT {|| Hh | ‘SENo._| Source. Milday_| | ‘| a “Mill bearing ( External cooling) 75 j 2. Fiot liquor pumps gland cooling 25 a 3. ‘Daily cleaning and washing, 50 } 4. Laboratory Use 006 ‘| 3. Domestic 0907 | 6 ‘Spray pond overflow 50 ‘| 7. ‘Excess condensate 346 | 8. ‘Boiler blow-down 075 \ 9. Periodical cleanin; O75 } TO. | Leakages and steam trap. 100 | | Total 392 8] | Reliesher course for ST & SE, Tuly 2005Cc ‘Vasantdada Sugar Institute, Pune 2 ® WASTE WATER SUB-STREAMS cs) ‘The wastewater is generated from different sub-streams. These streams can be ~D described as follows. . = Mill House: : 2 The effluent consists of water used for cleaning the mill house floor, which is liable to converted by spilled and plashed sugar juice. (This cleaning-up operation will, incidental prevent growth of bacteria on the juice covered floor). Water used for cooling of mills bearings also forms part of the wastewater from this 3 source. Basically, this water contains organic matter like sucrose, bagacillo, oil and grease from =) the bearings fitted into the mills. It’s BOD amounts to 900 to 1200 mg/L, oil and ‘grease amount to 150 to 200 mg/L, and COD around 2500 mg/L. + Waste water from boiling house: ‘The wastewater from boiling house results from leakages through pumps, pipelines and the washings of various sections such as evaporators, juice heaters, clarification, pans, crystallisation and centrifugation etc. The cooling water from various pumps also forms part of the waste water. The BOD of this stream is about 800 to 1500 mg/L and COD is about 2000 to 3000 mg/L. + Waste water from boiler blow down: = ‘The water used in boiler contains suspended solids, dissolved solids like Ca-salts, Mg- salts, Na-salts, Fe-salts ete. ‘These salts get concentrated after generation steam from the original water volume. These solids have to be expelled from time to time to save the boiler being covered up by scales. ‘This water has following charactetistics. BOD = 6010 70mg/L. cop = 100to 1200 mg/L ss = 800t0 1500 mg/L ‘TDS = 150010 3500 mg/L Temperature - 90 t0 100°C + Excess Condensate: ‘The excess condensate does riot normally contain any pollutant and is used as boiler > feed water and the washing operations. Sometimes, it gets contaminated with juice due to entrainment of carry over of solids with the vapours being condensed in which case > it goes into the waste water drain. The treatment requirement in this case is almost 3 negligible and can fresh water or it can be let out directly as irrigation water after cooling it to ambient temperature, Refiesher course for ST & SE, July 2005 7(ened Sogerinatons Pe + Condenser Cooling water: Condenser cooling water is recirculated again unless it gets contaminated with juice which is possible due to defective entrainment separators, faulty operation beyond the design rate of evaporation etc. If it gets contaminated, the water should go into the Grain invariably. This volume of water is also increased by addition condensing of ‘vapours obtained from the boiling juice in the pan. ‘This water has following characteristics. BOD - 100-150 mg/L COD - 150-300 mg/L pH - 7.0t07.2 + Soda and Acid Wastes : ‘The heat exchangers and evaporators are cleaned with caustic soda and hydrachlorie acid in order to remove the formation of the deposits of scales on the surface of the tubings. In India, most of the sugar factories let this valuable chemical go into drains. The rinsing of soda and acid wash contribute to considerable amount of organic and inorganic pollutants and may cause shock loads to waste water treatment plants. Characteristics of combined Sugar Factory Wastewater SiNo._| Parameter Range ae ete pH 4.2-6.0 2 ‘Total Solids, mg/L 1200-2000 3. Suspended Solids, mg/L. 200-300 4 COD mg/L 2000-2500 5. BODS at 20°C. mg/L 1000-1500 6 Oil & Grease mg/L 60-100 7. Sulphates mg/L. 200-250 8 Chlorides mg/L 50-100 General Standards for Discharge Sr.No. | Parameter Tnland Surface [Land for water. Irrigation. T_| pH 55-90 55-9.0 2. BOD; mg. 30 100 3. | COD mg/L. 250 = 4.___| Suspended Solids, mg/L._| 100 200 5.____| Dissolved Solids, mg/L | 2100 2100 6. | Oil & Grease, mg/L 10 10 7. Chlorides (as Ci), mg/L_[ 1000 600 8. [Sulphates (as SO.) mg/L | 1000 1000 9. [Suiphite (as S) mg/L [2.8 : Refiesher course for ST & SE, July 2005 309 a > 3S s > Reffesher course for ST & SE, July 2005 Cc ‘Vasantdada Sugar Institute, Pune MEASURES TO MINIMISE WASTE WATER. Floor cleaning with dry bagasse instead of water washing. Recycling of all Machinery cooling water. Recycling of mills bearing cooling water (external). Installation of Mechanical pumps. Regular check of all glands, flanges, pumps etc. for leakages and effect immediate repair. Do not allow juice, syrup, molasses or sugar to trickle from pipes, valves or flanges. 6. Strict in using water after evaporation stage, Hot water must be used instead of cold water in the latter stage to reduce the quantity of steam requirement. 7. Using nozzles and spay for washing and rinsing operations would reduce the water consumption. 8. The number of water taps in the factory shall be minimum with minimum leakages from them. 9. Provision of collection pits at each pump especially in mill and centrifugal section. 10. Provision of overflow line to storage tanks of syrup, melt and other molasses tanks. 11. It is an usual practice to use caustic soda for cleaning the evaporators, which can be stored, settled and the supernatant can be reused for spray pond and ETP to maintain pH. 12. Use of spray pond water for cleaning, washing and juice-heater brushing. 13, Reuse of excess condensate after cooling. veers EFFLUENT TREATMENT PLANT ‘After segregation of cooling water and condensate water, the quantity of sugar factory effluent to be treated during the sugar factory season is about 500-800 M’/day. Considering large quantity of effluent with variation, it is advised to treat it by anaerobic followed by aerobic treatment. The treated effluent will be useful for irrigation purpose. Brief Flow Sheet Details: Screen chamber Oil & Grease Skimmer Notch Equalization Tank Primary Clarifier Anaerobic digester Aeration Tank Secondary Clarifier Sludge Drying Beds Pen ansene Brief Description of the scheme 1. Screening: Coarse screen or rack is used for removal of large pieces of gunny bags, plastics, branches, rubbers, packing materials, gaskets, cotton waste and other floatable. It is used as ®‘Vasantdada Sugar Institute, Pune protecting devices so that large suspended solids and floating material do not damage pumps, agitators, mixers and aerators. Coarse screens have qpenings ranging from 75mm fo 130 mm and racks are usually set at an angle of 45° — 60°. The cleaning of screens is done either manually or mechanically. 2. Oil & Grease Skimmer: (Oil being is lighter than water, floats. This property is used to separate it out However if there is more turbulence or if the travel distance is high, gradient slop is more, ‘or if boiler blow down, excess condensate, stream trap, cooling purging co-enters, the oil gets emulsified and then does not float out easily. It has to avoid such situations to the maximum extent possible by either providing the traps very near to the source, or by segregating the sub-streams, If the oil does not float and a thick film does not develop, the physical removal by big spoon becomes difficult. In such case, the oil & grease escapes ut to further downstream units of the ETP to spoil the situation. In aeration tank the Contents are further chumed and the oil may cover the bacterial cell wall, stopping their ‘work of adsorbing and absorbing the food (BOD) and utilizing the same in tum for their life and growth cycle, The BOD will not get utilized for removal, and the shining oil will escape out from the secondary clarifier to the disposal site. Removal of oil and grease is necessary to increase treat ability. In an industry oil and grease traps are situated close to the source of oil and grease. Various pattems are vailable for oil end grease trap. The most common is the one in which inlet is below the Surface and outlet is at the bottom with sufficient retention period (10-30min). The floating ‘material rises and remains on the surface of the wastewater. The oil & grease will be collected in a separate sump, by manually or mechanically, from where it can be removed ‘with the help of a hand-pump. Considering floating matter and oil & grease in the effluent. It is advised to provide-oil &-grease-trap-near mills-as-major oil & grease come from milling section. 3. V-Notch: ‘The triangular or V-notch sharp-crested consist of an angular notch cut into a bulkhead in the flow channel. The apex of the notch is at the bottom, and the sides are set equally on cither side of a vertical line from the apex. The angle of the notch most commonly used is 90° The discharge equation ofa fre flowing triangular weir takes the form. Q (mS) = 815 x (2g) Cob"? Where -h (m) is the head referred to the vortex of the notch -g= 9.81 m/S* = Gp is the discharge coefficient, which is given by following table. Heady 10.030 [0.075 [0.100 [0.125 [0.150 [0.200 _] 0.300 Value of Cp [0.608 | 0.598 [0.588 [0.588 [0.586 [0.585 | 0.585 4. Equalization Tank: Equalization is often. used for smoothening out individual wastewater stream flow -vaviations so that a composite stream of relatively constant flow rate is fed to the treatment plant and, also to even out variations in effluent feed BOD to the treatment facility. Refresher course for ST & SE, July 2005, 2egies ‘Vasantdada Sugar Institute, Pune ae ‘The equalization tank should not work as settling tank, The solids should be kept is suspension. For this, the water must be in motion. A stirrer, mixer, agitator, or diffused ait is employed. 5. Primary Clarifier: Purpose of this process is to reduce: settlable suspended solids content of the wastewaters. When a liquid containing such solids is detained without disturbances for a time, particles of higher specific gravity will settle and those with lower specific gravity will float. About 50-65 % removal of suspended solids and 20-40 % of the BOD removal can be achieved in a properly designed and operated primary clarifier. Common retention time is 90-150 minutes based on average rate of flow. If these precede a biological treatment unit, 30-60 minutes retention time is sufficient. Sugar factory effluent contains bagacillo particles as a suspended particle, These should to be separated out before the biological treatment. 6. Anaerobic Digester: ‘The supernatant from primary clarifier is further subjected to anaerobic digester. It is submerged digester with plastic media, The microbial growth is retained on the plastic media making possible higher loading rates and efficient digestion, The BOD removal is about 80%. Advantages: 1) Higher degree of stabilization. 2) Little sludge production. 3) Low capital and operating cost. 7. Aeration Tank: The effluent from anaerobic digester is further subjected to aeration tank. The biological treatment of effluent by aeration process with sludge culture is very sensitive. ‘The efficiency depends on pH, temperature, air contact, suspended solids, culture growth, concentration of floc i.e. optimum mixed liquor suspended solids concentration (MLSS). ‘The microbial culture concentration is to be maintained in the range of 1500 to 4000 mg/l. Hence initial culture development and maintaining of activated sludge rate by re- circulation of sludge and addition of cow dung, urea, DAP and their mixing are essential. ‘The nutrients are to be in liquid form. The ratio of BOD: N: P is 100:5:1 will be maintained. Care is to be taken not to destabilize the microbial culture, 8 Secondary Clarifier: itis a cylindrical concrete tank with conical bottom. There is a central well to which water is fed to avoid short-circuiting of water into the overflows. The central stirrer is rotated at 2 RPH. Sludge will be collected at the bottom from where it re-circulated to aeration tank and excess sludge is taken on sludge drying beds by pumping. There is circumferential overflow from which treated effluent is collected and sent for agricultural use. 9 Sludge Drying Beds: ‘Sludge drying beds will be provided for the disposal of sludge from clarifier. The dried cakes will be scrapped off periodically and can be utilized for as manure, Refresher course for ST & SE, July 2005 Lu——esanidade Sugar ote, Pune VAPOUR BLEEDING AND STEAM ECONOMY DB Jambhale 4 General: Originally all the vessels from multiple effect evaporator wert made of equal size, Each suppling vapours to the folowing vessel witout withdrawal of any sesoure. No much steam economy was considered. possible to take a certain Juantity of vapours from either of the bodies of ‘evaporator set for juice heating and from the first or ‘second effect for pans boiling. We have seen in Rillieux’s the ara id principle there is more steam economy when vapour® we withdrawn from further effect of evaporator set. ‘Vapours from the last effect going to condenser that otherwise lost when used for heating raw juice, there jis complete savi exhaust. ing of “The exhaust steam production by the prime movers should be less (about 2% on cane) than optimum steam requirement of the factory so that frequently no ‘exhaust steam blown to atmosphere. “To raw sugar factory a total steam consumption of less than 40% on cane is achieved. The plantation white sugar by double sulphitation may need some 45- ‘48% on cane. ‘The"stéam requirement at juice heaters dépends on initial mixed juice temperature- and: mixed: juice % cane as. wel as filteration retumed % cane. Trowover the inital juice temperature’ and fiterate percoriage does not vary much set or calculation purposes raw juice intial temperature generally taken as 25/30°C where as filterate return is taken as 42-45% on cane. The mixed juice % 2ne Sa measured quality and even though in most of the factories it remains in Tar eange of £2-979%. In some factories it may be as high os 440% on cane and in ore frcases the steam consumption for juice heating increases. For calculation purposes itis taken as, 100% on cane and the steam consumption at juice heater remains more or less constant.” steam consumption at pan station can be reduced as close 38 to ideal ‘igure-by proper control at the pan station for €.. PY Keeping control over dilution ture oy Pe ovement water, iming for grain hardening and higher syrup brix. ‘The main unit where the steam consumption can be reduced is the evaporator station. The evaporator steam consumpto nothing but vapours going from the last effect to the condenser. Thus ‘main principal in governing the Seer economy measures is to reduce the quality of vapours going to condenser Ste oeiast body of the evaporator. This is possible with maximum vapour bleeding from the preceding bi Refresher course for ST & SE,, July 2005, 4 |asant stitute, Pune _Vasantdada Sugar Institute, Pune DEVC with all vapours to pans in conjunction with quadruple with conventional vapour bleeding to juice heaters or can conventional quintuple system exhaust steam consumption at evaporator below 3.0% on cane. This can further be brought down upto 1.5% by the use of mechanical vapour compression (MVR). However MVR needs better maintenance because of high speed and also is not cost effective. Higher capacity utilization with minimum mill stoppages gives frmaximum steam economy. If there are frequent mill stoppages the steam consumption increases, the vapour bleeding is affected; the pans and juice heaters have to change on exhaust heating. Every one-hour stoppage during working results in extra steam consumption of approximately 20 Tones for a 2500 TCD pian In addition to this steam consumption is increased by about 0.5-1.0% because of general cleaning depending upon no. of cleanings. The lower MJ.% cane decreases the steam consumption at evaporator. However reducing the imbibition% at mill is not recommended as it directly affects the mill extraction. Clear juice heating above the bolling point of the juice in the first effect of the evaporator is very much essential to achieve good performance at evaporator. In standard specifications plate type heat exchanger is recommended for clear juice heating, but tubular juice heaters are better. In India some 25 years back the bagasse saving was not economical for most of the factories because use of bagasse was limited and bagasse was fetching very low price. Even bagasse handling and transportation cost was not being recovered. Therefore much emphasis was not given on bagasse saving and ‘consequently efficient use of steam in sugar factories. Bagasse was generally saved only to run the boilers in mill stoppages, general cleaning, finishing the end process and starting the next season. Now bagasse prices are going up and factories can eam crores of rupees only on sale of saved bagasse. Therefore, efficient utilisation of steam has become essential to save the bagasse for factories without cogeneration or cogeneration with backpressure route. In case of factories with cogeneration by condensing route the steam saving in boiling house can produce more electricity for export Low-pressure steam coming out from power turbines and mill turbines generally called as exhaust steam or simply exhaust is used to heat, boil and concentrate the juice and massecuites in the boiling house. The exhaust steam production by the prime movers should be less (about 3 % on cane) than optimum exhaust steam requirement of the factory so that frequently no exhaust steam blown to atmosphere. [Refiesher course for ST & SE,, July 2005 85c ‘The steam used in boiling house for — 4, Juice heating 2. Evaporation 3. Panboiling 4, — Miscellaneous use 2 Steam required for Juice Heating: — 7 Vasantdada Sugar Institute, Pune _ ar factories where sulphitation process the steam requirement In Indian sug: is calculated hereunder assuming Crush rate 400 teh, Raw juice % cane 700% Raw juice heating From 30° to 75°C ‘Sulphited juice % cane 115 % ‘Sulphited juice heating From 70° to 105°C Clear juice % cane. 100 % Clear juice heating From 95° to 110°C Specific heat of juice (0.91 Keal/kg eet heat of sleam at 0.76 kalom2 9 pressure _| $30 K callkg 24 Steamrequired:for.raw juice heating: quantity of heat required to heat the raw juice fom 30°¢ 10 75° Latent heat ofthe heating steam K callks ouantity of juice ha) Xp heat of ulce Xie In temperature (28) ‘atont heat of the hating steam K callkg +400 X 1000 X 0.91 X (75-30) ‘T126 kg or say. 530 2.3. Steam required for sulphited juice heating: 445 X 1000 X 0.94 X (105~70) = e9tt kg orsay 69¢ 30 d for clear juice heating: 400 x 1000 X0.91 X (110-88) = 2576 Kg or 28t 6 Reliesher course for ST & SE,, July 2005~ Vasantdada Sugar Institute, Pune 2.5 Total Steam required for juice heating: ‘Steam required for raw julco heating ‘Steam required for sulphited juice heating ‘Steam required for clear juice heating 2E “Tofal steam requirement a73t =| ‘Thus, we.can say the total steam consumption cane for juice heating is about 17.3%, However the steam consumption at juice heater may vary with variation in mixed juice % cane. The mixed juice % cane varies as imbibition % cane is varied. The imbibition % cane varies considerably (from 92 % to 115 %). The steam requirement for juice heating also changes with narrow range on initial temperature mixed juice as well as percentage of fitrates returned in the process. 4 Steam requirement at pan station: With conventional three massecuite boiling system the steam consumption can be calculated hereunder assuming ‘ArmassocuTe cane 255 i masseculle % cane 11.50 C massecuite% cane. 2.00 ‘Total masseculte % cane 45.00 = “Sugar recovery % cane 71.50 J Considering the material feed to A masecuites (syrup/ melt/AL) of 60 brix and all molasses feed to B and C massecuite (AH, BH, CL) of 70 brix (after conditioning) ‘The water to be evaporated for one tonne of each massecuite is as under Wassecuie | Fe ‘Average | Tonnes of | Massocuto | Massocute —] Water quantity | brxofteed | soldsin feed | Brix | production | Evaporated Tonnes, x Teme | 60.00, a0 B00, O85, 035 ‘| tonne | 70.00 0.70 95.001 ‘0.76. ‘O24 ‘CT tonne [70.00 0.70 "100.00 070, 0.30 ‘Therefore, water to be evaporated at pan station can be as under Wiassscute | Massecile % | Water be Theoriical [Ratio ‘Aetual starr cane ‘evaporated per | Steam ‘Actualideal | required % tonne of requled % on fon cane (neluding massoculte cane. heat oss) ‘Rimasseoulie | 25.50 0.54 877 70, 16.15 Bmassocule | 11.50 0.33 3.80 115; 437 Cmassecute 8.00 0.42 3.36 120. 408 otal 45.00 0.488) 2182 124 23.55) Refresher course for ST & SE,, July 2005 7‘Vasanidada Sugar Institute, Pune ‘Thus, the total steam consumption at the pan station with normal figures can be around 23.55 % on cane. ‘A massecuite boiling dry seed or B seed is taken which save steam. The actual steam consumption at pan station can be reduced by proper control at the pan station for e.g. by keeping control over dilution of molasses, movement water, timing for grain hardening and higher syrup brix. Proper exhaustion of massecuite at each ‘stage, ‘The massecuite % cane assumed is 45 %, however massecuite % cane considerably varies from 41 to 53% depending upon recovery % cane, massecuite boiling scheme followed, exhaustion of masseouites at each stage and the care taken at the time of boiling. In some Caribbean countries and South American countries two massecuite boiling scheme is followed for raw sugar manufacture. In such factories, the total massecuite percent cane and hence the steam consumption at pan station is considerably low. However, in some factories in India three and haif or four massecuite bolling ‘scheme is followed to. mainly to produce high quality bolder grain sugar of low ICUMSA colour. in high recovery area such as Kolhapur and Satara districts with high purity juies, the A masseouite purity is.above:90-91. It becomes impossible to bring down C massecuite:purity.at-a desired level say. 57-58. Therefore some of the factories in: these:-areas. follow~three.-and: half massecuite boiling scheme. Consequently steam consumption of these factories is increased. 4 Steam consumption at evaporator station: ce ‘The steam consumption at evaporator is the quantity of vapours going to condenser. The main’ principle governing the. steam economy is to reduce the quantity of vapours going to condenser. This is possible with extensive vapour bleeding from the preceding bodies. Originally, all the. vessels from multiple effect evaporator were made of equal size. Each supplying vapours to the following vessel without withdrawal of any vapours:-Nomuch steam economy was considered. Itis possible to take a certain quantity of vapours from either of the bodies of evaporator set for juice heating and from the first or second effect for pans boiling, We have seen in Rillieux’s the second principle there is more steam economy when vapours are withdrawn from further effect of evaporator set Vapours from the last effect going to condenser that otherwise lost when used for heating raw juice, there is complete saving of exhaust. [Refresher course for ST & SE,, July 2005 888 8 wubde dow fz ‘Vasantdada Sugar Institute, Pune ferent vapour bleeding configurations: Considering water evaporation 75 % for the 1st and 2" case and 80 % for the 3°, and 85 % 4" and 5" case on cane in multiple effect evaporator are given hereunder 44 Vapour Bleeding Case | - Quadruple ‘* Raw juice first heating in vapour line juice heater from 30 to 42°C. «Raw juice second heating by vapours from the second effect from 40 to 75°C. ‘* Sulphited juice first heating by vapours from first effect, from 70 to 90°C. Wator to be evaporated in the last body X TAB Vapours consumed at VLJH 24 \Vapours going to condensor 4275 ‘Steam consumption ofthe factory 1 ‘Steam used for juice heating 473 2 ‘Steam used at pan station 2355 3 ‘Steam required for evaporation 1276 4 Miscellaneous use 30 Total 56.60 Refresher course for ST & SE., July 2005 89Vapour Bleeding Case I! V C plus Quadruple jour line juice heater from 30 to 42°C. + Raw juice first heating in vap © Raw juice second heating by vapours t0 75°C. © Sulphited juice first 90°C. « Panbolling by vapours from VC heating by vapours from first effect, from 70 to from the second effect from 40 ‘Water to be evaporated in the Tast body X ‘Vapoure consumed at VLIH going to condenser ‘Sieam consumption ofthe factory ‘Steam used for juice heating Steam used at pan station ‘Steam required for evaporation Miscellaneous ust Total Retiesher course for ST & SE,, uly 2005 “Tonnes water evaporation per hr 90 30 48 188 5145, 0][ssa eee vemoti 4.3 Vapour Bleeding Case Ill - DEVC plus Quadruple Raw juice first heating in vapour line juice heater from 30 to 42°C. Raw juice second heating by vapours from the second effect from 40 to 75°C. + Sulphited juice first heating by vapours from second effect of DEVC from 70 to 90°C. | ‘+ Sulphited juice second heating by vapours from the first effect of DEVC. + A&B massecuite boiling by vapours from the second effect of DEVC ‘+ Cmassecuite boiling by vapours from the first effect of DEVC. To pane ] 7 Rut i I Are wt | "eons | > JH hi ve i] | a a2] || as ||] a ! > +4 | : ro ‘a =y Exhaust = eee a us | f ° st] [Ruz } Water evaporated in DEVC I 3 DEVE second afoct | > —_| Vapours used for $3 heating from 70 to 90°C 40 Vapoure used for AsB mascecute bol 1882 > _| Total vapours generated aa DEVE fiat effect = __| Vapoure used fr $2 heating from 90 o 105°C 3.00 } Vapoure used for massecuteboting, rs | <> _| Yaboure supplied tothe second effect, Be Total vapours generated ios i > ‘Total vapours generated in DEVC 54.07 i Water to be evaporated in quadruple 25.93 | i = [Beat apr iosaing Toi wat vapor pari] ji 3 R22 St q a x 3 sx Po Xs se ee H yori Ix Hs Reftesher course for ST & SE,, Tuly 2005 3“Siem consumption of the factory ‘steam used for Juice heating Steam used at pan station “Steam required for evaporation Miseellancous use Total 44 Vapour Bleeding Case IV - Quintuple . Raw juice first heating in vapour line juice heater from 30 to 42°C. Raw juice second heating by vapours from the third.effect from 40 to 75°C. ‘Sulphited juice first heating by vapours from,gegond effect from 70 to 90°C. Sulphited juice second heating by vapours: from the first effect from 90 to 105°C A&B massecuite boiling by vapours from the second effect Oe Besocuite boling by vapours from the frst effect ‘Vapour bleeding Ruz sia Siz © x x x +58 X + 58 +40 +2017 Xo Se +40 +2047 43.0 + 403 Bas tra +60 440.94 +30 + 608 2.‘Vasantdada Sugar Institute, Pune Walor to be evaporated in the last body X aH Vapours consumed at VLJH. 24 Vapours going to condenser ost ‘Sisam Consumption of te factory 1 ‘Steam used for juice heating 173 2 ‘Steam used at pan station 23.355 3 ‘Steam required for evaporation 061 4 Miscellaneous use 3.0 Total 4446 4.5 Vapour Bleeding Case V- Quadruple * Raw juice first heating in vapour line juice heater from 30 to 42°C. Raw juice second heating by vapours from the third effect from 40 to 75°C, Sulphited juice first heating by vapours from second effect from 70 to 90°C, Sulphited juice second heating by vapours from the first effect from 90 to 105°C A&B massecuite boiling by vapours from the second effect C massecuite boiling by vapours from the first effect ax 338 so x + 58 218 2 X + 58+ 4042017 3270 tet X + 68+ 4042017430 + 403 39.73 Total _SX+ 174+ 80+40.34+3.0+ 403 35.00 | Water to be evaporated inthe last body X33. \Vapours consumed at VLJH 2A \Vapours going to condenser 1.28 Refresher course for ST & SE, July 2005 93‘steam used for ju Steam used at pan “Steam required for evaporation 4.28 Miscellaneous use Total VLiH is provided to all 1250 TCD plants installed according to 1972 specification. However some factories do not use it, There is a net raise of 10 to 45°C in raw juice by use of VLJH ‘affecting steam saving of about 2%. This also Teduces load on condenser and helps to keep vacuum steady. 5 Other Aspects: 4 Capacity utilisation and stoppages: Higher capacity utlization with minimum mil oped gives maximum steam Higher If there are frequent mill stoppages the sfear consumption increases, fio vapour bleeding is affected; the pans and juice eaters have to change on ‘exhaust heating. Every one-hour stoppage dune ‘working results in extra steam exhatstption of approximately 20 tonnes for @ 2500 TCD plan 2. Mixed juice % cane “The lower M.J.% cane decreases the steam consumption at evaporator. However reducing the imbibition’ at mill is not recommended as it directly affects the mill extraction. 3. Heat lossvacross the evaporator: ‘At evaporator, some heat is lost by convection, Conduction and radiation. WE Kerr estimates the loss of heat in welllagged ‘quadruple 2.7 % of stem applied to Tact effect (A L Webre p 235). Thus we can safely Say the lossof heat at evaporator fist San be around 2.5 to 3.5 % of the steam applied to the first effect. 4 Falling Film Evaporator: Now in many factories FFE has been installed. In this ‘equipment care has to be taken that the full heating surface remains wet every ‘moment for which sufficient juice should be passed through each tube ‘continuously. For which juice circulation ‘with proper distribution of juice is very much ‘essential. Failure of this results into ghoking of many tubes. The efficiency of the ‘equipment and consequently of evaporator set is’ drastically reduced. Many factories have faced this problem. Buring factory operation because of mill stoppages or Poor turbine tripping, the juice flow may stop but steam may continue. in these conditions to avoid Juice teation oF choking of the tubes because of starvation: water has to be Greulated in the equipment immediately, for which an ‘automatic arrangement is needed. neede‘tion to this steam consumption is increased by about 0.5-1.0% because of general cleaning depending upon number of leanings ‘Refresher course for ST & SE,, July 2005 aebawsodddsdsod BAGASSE BASED COGENERATION IN SUGAR INDUSTRY “ STEAM AND POWER CYCLE FOR B.P. AND CONDENSING ROUTE " V.G.Chikhalikar Vasantdada Sugar Institute, Pune 95ASPECTS COVERED Cogeneration Cogeneration (BP route) Cogeneration (Cond.route) ‘Steam to Bagasse ratio ASR of TG set at ext. & cond.stage | Desup. water requirement Steam for De-aerator Thermal cycle efficiency (BP route) Thermal cycle efficiency (Cond.reute) . Boiler pressure and temp.for cogen.eeedbsus aeosod Jdduwwt ded s ow we we 11. 12. 13. 14, 15. Captive energy consumption Typical case study (2500 TCD plant) - Steam & Power cycle (BP route) - Steam & Power cycle (Cond. route) Qualifying Criteria ( MERC) - Cogen ( BP route) - Cogen ( BP & Cond. route) Total Power gen. & Surplus power to grid per T cane or bagasse. Cogen. potential in Maharashtra Sugar Industry. oF~ COGENERATION 1 © By DEFINATION— SIMULTANEOUS GENERATION OF ELEC: POWER & Low PRESSURE PROCESS STEAM. © IN PRESENT CONTEXT - surpLus ELEC. GENERATION FED TO séB. 2 e ACCEPTED MERITS — RENEWABLE SOURCE TO REDUCE on Fossit FUELS. € DEPENDENCE o LOWER CAPITAL COST \-S- .5 CRORES/MW . (Cw RS.5 CRORES may FOR THERMAL) © LOWER GESTATION PERIOD - 1 70.2: YEARS. “=(ST06 YEARS FOR THERMAL) ee © REDUCED TRANSMISSION LOSSES . @ ENVIRONMENTAL FRIENDLY GENERATION. e@ TECKNO - ECONOMIC VIABLE PROJECT. © Economical & TIMELY SOLUTION TO ENERGY CRISIS.BASE CASE? COGEN.- NIL westeam SF CACTINE CONSOM bodes. -EX.GEN < EX-COSUM. ‘MAKE UP? THRO’ PRO-2 -ELE. POWER GEN = CAPTIVE CON SUM MODIFIEO BASE CASE TOGEN GP.) = Ve Steg -EK GEN Cogen(cond) a ol9 voles yo aolhn Tosa SPAM Zar-B oh Se-B wenh MN PEP Y D] oa MAS AM, + BAeye wordy Con 20%) BDB- WW -t~ Vyok oket = eHnvewg|s -- Tencge sey CREAN 3a MAN) O97 Bs 50\- £08) ® Ett = See = oyerds - DSO) 1 APH W] WY) wr Na — (row £o%) 23847! (HI27QBD So M*VIG —— P.bo Wrage - ) WZ Gog - FASE CAMPANIA IH FORM) OR B/S ops we bey ma Garssyre Ag: 34 Mae IVER 78 HO PTL) Wows % Goa yeas = 2 eqn Soq 03 WeaASv we ‘ wd oF eS pales SPS; CONSUM OF TG SET (ASR) 66 ata 805 kealikg 1 tc }-o Sa’ shin 0.1 R, 582 Keal /kg SEO Formula Q = 860 = a= a2) mAs. CASI 2) VrGovev alt Q=ASR*(kg/kwh) j4= Total heat of stearv at nozzle -chest (kcal/kg) a= Theo total heat of steam at outlet (kcal/kg) n= Thermodynamic eff.of turbine mm = Mechanical eff. of turbine } ne = Eff. of reduction gear box } 95% ng = Eff. of generator } “ro dver al = Ae Ay Ng, = Nreoverall. = Ovevalle ff of TE en“ Mg Mech. eff- of TOHe ba] yo) ( o TOwaN See APNWOW Prem mg DROKRAK ARORA PPPLRERAP OP PROPOR RP MP* ASR. eee 805 kcalkg Assume overall eff: of T-G. 180% n= 623 KAI B60 = CAA 2) #76 Overall = 5.9 kghkwh Q= wena )x0.8 Considered losses thro" Q= 6 kghkwh " Ar 60ve Thermodynamic eff.of turbine = 8 = 84! nol iy n a> Vion ‘ho = 182 kcal/kg condensation & leaks @ 3% Theo.heat drop = A1- drop = theo. heat drop x 1 =-182.x 0.84 = 153 kcal/kg @25ata: Actual heat Actual temp: & total heat 435°C ,652 kcal/kg. [centre eC etkeae Chinen cd pe Thermedyn am! Kean bed bro aburbet geneva yal by a peed Gabeb) ASR @ 8 ata | A, = 805 Kcal/ Kg. \ N2 = 700 Kcal/ Kg. Qs 860 = 860 Actual heat drop x 0.95 (805-700) x 0.95 ! = 8.6 Kg/Kwh. Considering losses thro’ condensation & leaks @ 3%. Q = 8.8 Ka/ KWH c) ASR @ Cond. Stage (0.1 ata & x = 0.94) Ai = 805 Keal/ Kg. N2 = 582 Kcal/ Kg. | ole 860 = 860 | Actual heat drop x 0.95 (805-582) x 0.95 } 4.06 Kg/Kwh. | | Considering losses thro’ condensation & leaks @ 3%. Q = 4.2 Ka/ KWH |Let.a=desup. water required. Fotatheat-before= Fotatheatafter (a. x.105)-+t (3.92 a)7001 3.9 x 665 + 3.9700 « 700 a= 3.9 x 665 4058" 96 a= 3.9 (700 - 666) = 3.9.x 35 9X35 = 0.23T 595 =. Steam ext. @ Bata=3.9-0.23= 3.67TSerre eeerieeeee adddadobs bee dds } edd Bouugs dudvudodse ddd STEAM @ 2.5 ata read. for Deaerator ( Ex-BP route): Let x = Steam @ 2.5 ata reqd. for Deaerator. “ Steam @ 8 ata = 3.67 T. Steam ext. @ 2.5 ata = 54.6 +x Total mass flow before Deaerator : = SF return cond. + Make up + Deaerator steam. = 54.6 + Make up +x. Total mass flow after Déaerator : = Desuper water + Actual boiler water + Blow down. = 0.23% 1.028 387 +546) +x. Equating mass flow before & after Deaerator : 54.6 + Make up'+ x = 0.23 + 1.025 (3.67 + 54.6) + x. Make up = 5.36 T Equating total heat before & after Dearator : 54.6 (95) + 5.36 (32) + x (652) = (64.6 + 5.36 + x) (105) eeaeeacies i lap-tiel -/. 1.71 T steam @ 2.5 ata is reqd. for Deaerator to increase BFW temp. to 105°C. 107STEAM @ 2.5 ata read. for Deaerator ( DECT route): Let x = Steam @ 2.5 ata reqd. for Deaerator . Steam @TSV = 83.2 T. Steam ext. @ 8 ata = 3.67 T. Steam ext @ 2.5 ata = 54.6 +x. te = 83.2 — (3.67 + 54.6 +x) _ , Steam @ cond. rou = 24.93-x. Total mass flow after Deaerator = 85.43 T. a SE Cond. return = 54.6T. \ Dane Teturn-front cond:-stage= (24.93 -*) T Steam to Deaerator= X- Make up ? Equating mass flow after & before Deaerator : 85.43 = 54.6 + (24. 93-x)-+ x + Make up. "Make up = 5.9T Equating total heat after. & before Deaerator (652) + 5.9 (32) 85.43 (105) = 54.6 (95) + (24.93-x) (46) + x ( 4.04T 4.04T steam @ 2.5 ata is reqd. for Deaerator to increasy BFW temp. to 405°C.Fhevcaal egele: eff. et BP your opulent +4) = OF KO-4S = 0-665 = 66°52 HEAT IN EX- STEAM \S CSEFOL 09THERMAL CYCLE EFFICIENCY (COND ROUTE) Steam to Deaerator (a) Total heat-be fore. = Total heat after a (652) + (2.23-a) (46)= 2.23 (105) a = 0.22T. Steam to-cond. stage = 2.23-0.22 = 2.01T Steam to.Bag ratio = 2270. x 0.69=2.23 a. 807-105 Useful power generation: Power gen. @ 2.5 ata = 220 =37KW 6 Power gen. @ cond. stage = 2010 = 479 KW : 42 Total = 516 KW.T.G.Thermal eff. = Useful Power & Heat O/P ‘Heat /P = Gl6x 360) + (220 x'652) + 2010x 46) x 100 (2230'x 805:) = 37.9% Say 38%. Thermal cycle eff. of cond. rout [ 1 cycle (I) ] Moycle (T) = = MBoiler (1) x9 TG(T) 07038 0.266- ; 26.6% Say 27%. aud 2010 537 X100= 60% | Hy, @ 0.1 ata } 537 Keal/ &x=0.94 }Kg. atCO-GENERATION SYSTEMS: BACK PRESSURE ROUTE (BP)- — COGENERATION WHILE MEETING PROCESS STEAM DEMAND - SAVING OF BAGASSE © CONDENSING Cum EXTRATION ROUTE CCEST). _ STEAM IN EXCESS OF PROCESS DEMAND PASSED THROUGH cond. STAGE — SAVING OF BAGASSE — NIL BOILER PRESSURE & TEMP. MORE ENTHALPY oF STEAM O% MORE COLEN HP BOILERS CRUCIAL (IN COGEN. © 45 ATG BOILERS STABILIZED SUGAR FACTORY ENVIRONMENT OPTimum PARAMETERS — G6FATG , 485°C ABOVE THESE, METALLURGY OF Come (BoHTG) CHANGES RESULTING HIGH I ESTMENT, 21 ATG —e 32 ATG —> 45 ATG—rG EATG-WBTATGCAPTIVE ENERGY CONSUM. IV SUGAR FACTORY : © LOWER ConsumPTION K MORE COGENERATION © AT PRESENT (\N MASORITY FACTORIES) STEAM CONSUMPTION — 5ZTOSO%. CANE ELEC. k MECH ENERGY — 34 To 32 KWH/T CANE © STEAM CONSUM, REDUCED TO AE 4 CANE BY? —-MAK- CAP. UTIAZATION —_HOT ImRipition WATER — CONTINVOUS PANS — BACK PR.OF STEAM - PROCESS AVTOMAT= 10 To 12 Psig (ON Ete. — DEVE /QUINTUPLE/QUAD Wits EFFECTIVE _ VAPOUR BLEEDING © ELEcT. RMEcH. ENERGY ConsumM. REDUCED To 7 30-28 KkwH/T CANE 8; Ie MAX CAP uUTibt. facet ELec./ HyDRAULIC miLL _ EFFICLENT PUMP SETS DRVE — VARIABLE SPEED THY RISTER CONTROLLED _ AC/DC DRWES FOR COOLING SYSTEM, MODIFIED COND. AND wduwtae TYPICAL CASE STUDY 1 Assumed Tech. Data of SF Assumed Tech. Data of SF Registered cap. Actual crush cap. (25% more) : Bag. Production Bag. for Vacuum filter 2500 TCD 3120 TCD (130 TCH) 30% cane ( 39 TPH) 0.9 % cane. Bag. reserved for start up / stopp./ cleaning : 0.4% cane Net bag. available Steam Consumption - Process @ 2.5 ata - Misc. @8ata ~ Total Power Consumption. - SF - For cond. route Mill wet bagasse Boiler thermal efficiency BFW temp. after Deaerator Steam to bagasse ratio 28.7% cane ( 37.31 TPH) 42% cane fe aalis 6 PH) 3% cane (3.9 TRE ——— 45% cane (58.5 TPH) 28 KWH/T cane. 10% power gen. of cond. route. 50% moisture & 2270 Keal/ Kg GCV. 69% on GCV. 105°C. 2.23j9dCbbGHHSS 6162 KW. paoasse_, |®! 26.90 TPH (oat eae) SAVED BAG. (FOR SALE) ([censaen [EW FRED PUMP BEW TRANSFER PUMP STEAM AND POWER CYCLE FOR EX-BP ROUTE (IN SEASON -130 TCH) :"~~ Pawer generation’ power. consumption = - Power Balance (Ex-BP route) - Power Generation *Thro' | ext @ 8 ata: 3670 = 417 kw * Thro'BP @2.5 ata : sesi0 = 9385 kw Total : 9802 kw - Power consuption * SF @ 28 kwh /T cane : 28 x 130 = 3640 kw Y - Power Export 9802 = 3640 = 6162 kw.‘BEW Fata PUN? EW TRANSFER PUMP ce STEAM AND POWER CYCLE FOR DECT ROUTE (IN SEASON -130 TCH) oF -UE<POWER BALANCE (DECT ROUTE - Power Generation * Thro'lext@8ata : 3670 =417KW 8.8 © Thro’ llext@25 ata: 58640 = 9773 KW 6 « Thro’ cond. stage @ 0.1 ata: 20890 = 4974 KW 4.2 Total: 15164 KW - Power consumption © SF @ 28 Kwh/T cane : 28 x 130 = 3640 KW © Cond. route : 10% of 4974 KW = 497 KW. Total : 4137 KW. = cee : Power Export Total_géneration - Total consumption. 15164 - 4137 = 11027 KW.~ “GY. of bag : 2250 Keal/ Ke. Boiler thermal eff: 69% onGCV Fuel (Bag.) consumption: 26.90 TPH ‘Net energy input (A): 26.9-x 10° x 2250 Kcal/hr. + 60,525 x 10° Keal/hr, Useful elect. output(B): _ 9802 KWH. 9802 x 860 Keal/hr. 8.42972 x 10° Keal/hr. inthalpy of steam reqd. for process : “3 : i)" 700 Keal/Kg (Misc process) ii)" 652 Keal/Kg. (Process) Useful thermal output (C) : i) _3.67x 10° x 700 Keal/hr. = 2.569 x 10° Keal/hr. ii) 54.6 x 10° x 652 Keal/hr. = 35.5992 x 10° Keal /hr. Total (i + ii): 38.1682 x 10° Keal/hr. 9Total Eneréy O/P 8.42972 x 10° + ¥4 (38.1682) 10° 60.525 x 10° =~ 45:4586%> 45%: Qualifying Criterion (j) fulfilled. ‘ ‘ ‘ “38.1682 x 10° “One 8.42972 x 10° + 38.1682 x 10° = 81.91% > 20% Qualifying Criterion (ji) fulfilled. Cogen scheme on B P route fulfills both Qualification criteria. The scheme is ELIGIBLE eeJeod - CV. of bag - Boiler thermal eff. - Net energy input (A): QUALIFICATION CRITERIA ( AS PER MERC} 2250 Keal/ Kg. 69% on GCV - Fuel (Bag;) consumption: 37.31 TPH 3731 x 10? x 2250 Keal/nr, - Useful elect. output(B): 15164 KWH. - Enthalpy of steam reqd. for process : i) 700 Keal/Kg (Misc process) ii) 652 Kcal/Kg. (Process) - Useful thermal output (C): i) 3.67 x 10° x.700 Kcal/hr- = 2.569 x 10° Keal/hr. ii) 54.6 x 10° x 652 Kealfir. = 35,5992 x 10° Keal /nr. Total (i+ ii): 38.1682 x 10° Keal/hr. an 83.9475 x 10° KeaW/hr: 2:3:Ht 83.9475 x 10° j iF : = 3827% < 45%. a | “43.04 0a'x 108 + % 8.1682) 10° | _-. Qualifyinig Criterion (i) not fulfilled: 38.1682 x 10% 13.04104 x.10° + 38.1682 x 10 = 74.53% > 20% Qualifying Criterion (ji) fulfilled. Cogen schemic on BP & cond. route does not fulfill Qualification Criteri on (i) The sctieme is NOT ELIGIBLE« COGEN ON BP ROUTE - Total Power gen. - Total Power gen/T cane : : 7SKWH 2 9802 / 26.9. : 365 KWH - Total Power gen/T bag ~ Surplus power to grid. ~ Surplus Power /T cane - Surplus power/T bag : 6162 KWH : 9802 KWH 9802/ 130 : 6162/ 130 : 472KWH : 6162/269 : 229 KWH...(Bag.saved=8% cane)y 15164/37.31 : 409. KWH » 1NOQ7 KWH: :11027/ 37.31 : 8S KWH 110271 37:31 COGEN POTENTIAL IN MAHARASHTRA SUGAR INDUSTRY - Total cane crushing + $50 lac T. 2 - Season duration + 170 days ( 22 hrs.) - Total cane crushing /hr 14706 TCH = Surplus power/ T cane»: 85 KWH ee ~ Surplus power/'14706 TCH: 1250 MWH6u3 JB SNS HL JORVNSINIVE Be e = by at SHNIT GRY SivIS SHivHd 30 SLIOS-LAN @ SHid VILLI 40 SNITTIN ASU 1 vt AQHIQUA] SHNGE HOI WOd ROUIEIEMT IALLO213 'E2 SOHUHNG ALISHIG @ HIZ7THEYLS MOT IRYS Isandl ‘SOAVOUGT 10 SHIAUIS THA 40 SHOLLVOEIT HOIWSIOMI LIN E3716 01 TOINWHOIE Tides NO SS 1GNVSE GIATOS GN SALON ‘SNOLINESG, so0z ‘9% Aine | | sigauibug ueidoiyya i Jo4 | Bunseuibuz sens ul euweiBoig uORe CHC LOE ZLP -Uld VICNI ‘eres eyysezeyeyy, aNNd 39uISIC H9aey ]eL (4p) weluey JUALISH! THORS WEUEIRESUA so0z ‘92 Aine £0-3E-L3 YIAOD-LOSTISA-SIU) Tow hedar XK repueacugi dd neKARNE SUCROTECH PVT. LTO. REF: VSL-LECT-ML-STNGS-1 VASANTDADA SUGAR INSTITUTE, MANJARI, PUNE Sneaker: 1. M.Karne, Sugar Consultant, Pune: 411039 Subject: Mill Settings Every mill engineer has his own method of mill setting, but Farrel Corporation has a practical suggestion which can be followed advantageously. It is tecommended that brix test can be made and mills adjusted accordingly. After the most efficient operation has been achieved by this method, samples of bagasse leaving each mill should be taken and moisture content determined. This procedure should be followed at least four or five times during the crop to obtain the average moisture content of the bagasse leaving each mil Once the average moisture of bagasse leaving each mill has been determined, the basic bagasse roller opening ‘O' is obtained for each mil from chart-table no.1.'0' is total bagasse roller opening, per short ton of cane per 24 hours, per inch of roller face, per foot per minute of roller speed for cane with 10% fibre. Table no.2 shows the relation of basic delivery opening relative to the bagasse moisture. For particular mill conditions, actual opening = ‘0’ x factor. In the original foltowing formulae of Farrel, [have added the factor of arcing of mill rollers, which is a vital parameter in the modern days. Short tons of cane per 24h x fibre / cane Factor = - Roller length in inches x speed in ftlmin x 0.1 x factor of arcing Openings are calculated from pitch line to pitch line of grooving, or when the top and side rollers have the same grooving from the point to root. Roller settings at rest are less than the roller openings while working on load, due to the roller float. Farrel mill engineers | recommend a cane roller opening from 2 times the bagasse opening on the fist mil, increasing proportionately to three times on the last mill, But we can assume this ratio 2.4[ 2 to 3], for all mills in the following example, having grooved under feeder roller of @ f 90% diameter wr.t. mill roller size, for each mill. The trash plate openings should be about 1.50 times the cane openings. But we can assume this ratio 1.56 for the first mill increasing to 1.70 for the last mill. The opening can be calculated for the under feed roller dand Donnelly chutes assuming the ratios w.rt operating feed opening @ 2.5 to.4 and || 8.0 to 12 respectively | Table no.1: MOISTURE % BAGASSE[BYFARREL] | NUMBEROFMILLS MILLNO, 1 2 3 4 5S 6 7 SEVEN 67 61 56 58 4947 Six 67 60 55 52 4a FIVE 67 58 53 50 FOUR 67 58 53 50 THREE 67 56 50A ARNE, INTERNATIONAL PUNE - 411 009 (rece 2 These are theoretical figures of moisture % bagasse leaving each mil and are oniy for reference, Actual values are to be established by mill engineers on observation of miling performance for several years, Table no.2: BASIC DELIVERY OPENING RELATED TO H THE BAGASSE MOISTURES [ BY FARREL ] | Bagasse moisture % Biss Gle COssesoiee og tegg tec i | Basic delivery Opening 084 064 060 055 050 047 o42 | | | | Bagasse moisture % joes Sane O01 ag trap ite ayitege | Basic delivery Opening 0.39 0.38 0.36 034 033 032 031 | | | eee J PRACTICAL EXAMPLE FOR A PARTICULAR FOUR MILL ING ‘TANDEM OF 33” x66" Let us take one practical example for your reference: BASIC DATA: Mill crushing capacity: 3,300 tedi/24 hrs, -Fibretcane: = = 011526 {per unittane] Speed: : 4.0 rpm average, but variable suitable for dia. of roller. Roller dia. PCD: 802mm = 2.96 feet Roller length: 1700mm = 66.93 inch Factor for average arcing: 1.21 for capacity enhancement MILL NO: 1 2 3 4 | Turbine rpm 2730 2770 2635 2635 Mill ppm 4.0 4.063 3.861 3.861 l Roller dia. PCD mm: 87067 857.60 ©9020 gong [ Roller dia. PCD ft 288 62812-2989 agg Dia. Yowiet itt 100.00 9850 = 10360-10340 Roller float mm feed & det: 10 10 8 8 | Roller float mm trash plate: 12 12 10 10 | Ratiot: feed work to dwo. 2.4 24 24 24 | Ratio2: tpwo to fwo: 1.55 162 168 170 ; Ratio’: UFR to fwo: 2.80 2.68 370 3.98 H Ratio4: Donnelly to fwo: 8.00 8.45 10.85 11.75 Moisture % bagasse: 58 56 49 46 Basic del. Opening inch: 0.55 0.50 04 0.31 : | ~ 12 F-CALCULATIONS:- Basic factor of mill capacity = Roller length inch x roller speed FPM x 0.1 x arcing factor | 3,300 x 0.1525 19.78 GO93x31416XDXNXO1X121 DN (OxN #2856 xA0= 11.426, 28124069 = 11425 12.959 « 3.061 = 11.4247, 2.959 x3.061 = 11.4247 19.78 19.78 19.78 19.78 4.73144 = 1,73129, 73134, = 1.73134 14.424 14,425 11.4247 41.4247 asic total mil cop. factors = 1.73144, 1.73128, 1.73134 4.73134, Average = 1.731 Operating delivery openings in mm = B.D ©. X basic factor of mill capacity x 25.40 : = BD.O.X 1.731 x 25.4 mm = BDO x 43.9674 mm dwo = BDO x 43.9674 wo fwo tpwo UFR op _ Donnelly op. smo x Ratio’ fo x Ratio? fwo x Ratios fwo x Ratiod dwo- 24,18" 58.04 89.96 145.0 464.32 dwo2 = 0. 21.00.5040 81.64 135.0 410.76 dwo3 = 0.34 x = 18,00°36.00 60.48 133.2 380.60 dwod = 0.31 x =. 13.62 32.69 $5.59 130.10 384.14 itl setting at rest = work opening — float Mill no. 1 2 3 4 feed 48 40 28 25 podto ped delivery 44 4 7 4 podto ped trashplate 78 70 st 45 ped to top surfa UFR 445 135 133 130 od tood Donnelly Bottom. 464 415 390 385 Donnelly Top 428 375 350 345 yo OOO XX4 Mill settings at rest ped to ped for KV SATARA SF! Season OS05 all bb JE unl BASIC DATA Crashing rate: 4560 tod/24hr, 199 tch;fiber%écane: 13.50%: speed of rollers: 8.25 rpm: arcing and fourth roller pressure feeding factor: 1.15; dia of roller: 2.87° length of rollr shel 68.93"; imbibition % fiber: 225 to 250%. Mill seting’s Farrell Method, is modified by me, which is as under: Mill No. 1 2 3 4 Moisture % bagasse 58 54 50 48 Basic delivery setting” 9,55 0.45 0.36 0.33, Liftassumedmm Feed 16 14 12 12 || Tresh-plate 12 10 8 8 Discharge 8 6 4 4 Operating Ratios id €- All 2.00 tplf 4.65 1.65 1.15 4.75 Ted/24hr x fibericane | Capacity factor = Roller face" x surface speed fpm x 0.10 x arcing factor 4560 x 0.135 = 169 66.93" x 3.1416 x 2.87' x 4.25 x 0.10 x 1.15 operating settings: delivery = basic capacity factor x basic delivery opening” x 25.40 mm MiILNo. = te 2 eerie teaeae@ ee = : delivery 23.60 49.31 15.45 14.16 | feed 47.20 38.62 30.90 28.32 | trashplate 77.88 63.72 54.08 49.56 -By deducting lft’ Mill settings at rest: feed, discharge pcd-ped and trachplate top surface: ped of top roller: Feed mm 31.20 24.62 18.90 16.30 Discharge mm 156 13.31 14.45 1916 Trash plate mm 6588 53.72 4808 41.58 Therefore, on the observations of various parameters in actual working and for b efficiency the settings at rest will be re-adjusted as under: Feed {pcd-ped mm} 32 28 419 16 Discharge (ped-ped mm} 18 18 10 7 | Trash plate 86 54 46 42 | {pcd-top surface mm} TM KARNE, Consulting Sugar Engineer Date: January 10, 2005 | -128- :5 July 24, 2005 REF.NO.KSTPL-PSML-R-006-MS HILL SETTINGS SEASON 2005-06 {PSM ial senings are calculated during vist in presence of SN Bhorkade CE and Shi. Balaji Mi se vdokar ME, which are stated again and confimes unider: ‘pt 1.60 1.65 165 1.70 1.70 UFR 3.00 3.25 3.50 375 4.00 Donneliy top/f 80 90 100 110 120 : Todi24h x fverican Capacity factor: — a : Faller Longitt x x x Roller die! x RPM x 0.10 x urcin 10 for Mt 1.27M2-M5 Wy fwetor operating ratio {id x delivery openin Operating feed opening in-mm. 37.086; Mid = 23.224; NIB = 24.29 att = 30.73, M2 = 30.32; MIS = peratina irash plate opening in mm = operating (2° pif x feed opening = 39.48; MipS = 36.19 Mipt = 49.17, Mp2 = 50.00, Nips = 44.71; Mp4 peraiing ratio UPR x feed openings 4287, MUFRS=85 Gpenings of UFR od to od wil be UPR’ +92; MUFR2=98.5; MUFR3=94.8; MUFR’ iil sotings at est are calculated by deducting it rom operating openings. Therefore the are the adjusted mil settings at rest WILL SETTINGS AT REST 1 2 3 4 5 MILL NO. | Pedped Feed 23 24 20 v7 | pecpea Dish. 6.5 60 56 50 4.omm | Pea-top surt Trash-piate 41 38 36 (Od-od UFR 100 98 j Donnelly top: 280 275, Botiom __3 320 318 IWKARNE Consuliing Sugar Engineer Reto PSHL RSENS io ase delivery opening {BLO} s detined as inute of roller speed for following