MAPÚA UNIVERSITY

School of Chemical, Biological and

Materials Engineering and Sciences

Sugar Industry:
Amazona Corporation

Prepared by:

Submitted to:

Engr. Aileen D. Nieva

Professor

A Life Cycle Assessment Submitted in Partial Fulfillment of the Requirements for CHE 185-1
Industrial Waste Management and Control

March 2018
INTRODUCTION

Sugarcane is one of the thirstiest produce that retains in the soil for a year long. As one of

the world’s most water-demanding produce, it imposes a lot of negative environmental impacts

specially on sensitive domains. Despite these ill effects, the industry kept growing to the extent of

disregarding apparent negative effects due to business purposes. A massive global market for

sugarcane products makes the industry prosperous. One of these products is refined sugar.

Refined cane sugar is dominant in most modern diets and progressively a source of biofuels

and bioplastics. As the demand for petroleum hikes, the market for ethanol derived from sugarcane

expands. Management and control of social and environmental risks is a must for sugarcane

plantations, handlers and food factories due to supervisory pressures and consumer standards for

sustainable high-quality goods.

Refined cane sugar is one of the vital ingredients in most processed foods. It serves as a

component that elevates the tastes of the products for consumer satisfaction. Food industries that

manufacture sugar-based foods such as pastry, cakes, biscuits, preserved fruits and nuts, and

beverages have been flying their products off shelves due to this staple ingredient.

Amazona Corporation commits to its consumers to deliver top-quality refined cane sugar

and sugarcane derivatives. This corporation is composed of 2 divisions: Amazona Sugarcane

Plantation and Amazona Sugar Factory. The plantation will grow healthy sugarcanes and the latter

will process the raw materials to offer first-class products. Being part of the industrial eco-park

located in Toledo City, Central Visayas, our corporation takes part in the daily production of some

neighboring industries as we supply their raw materials fresh from the processes.
 Amazona Sugar Factory will be providing molasses to the distillery plant, refined sugar to

the soft drinks manufacturing plant and will be utilizing the fertilizer product of the fertilizer

manufacturing plant. By working hand in hand with other industries present in the eco-park, waste

minimization, environmental sustainability and maximum income returns will be expected.

MARKET STUDY

According to BCC Research 2013, the global market for sweetners is at approximately

$77.5 billion in 2012 with sugar comprising an almost 85% part. The sugar market is predicted to

upsurge at a compound growth rate of 4.6% with roughly 460 million tons per year. Globally, the

major sugar producers are Brazil (72%), India (15%) and the European Union (10%). Overall,

there are more than 123 sugar-producing countries, but only 30% of the produce is traded on the

international market.

In the Philippines, the sugarcane business adds in roughly 70 billion pesos to the economy.

With the estimated 30 million hectares land area suitable for plantations, sugarcane is developed

in coarsely 425,000 hectares in the Philippines, with about 65,000 growers. About 80% of total

domestic sugar production is locally expended. 50% of the local consumption is consumed by

industrial users, 32% by households and the remaining is by institutions (e.g., restaurants,

bakeshops, hospital etc.). The largest Philippine sugar export market is the United States, as prices

under the U.S. tariff rate quota system are normally higher than world market prices.

Sugar manufactured in the Philippines for the past years has been for the domestic market

and the US quota. Uplifted by high production – the Philippines started exporting sugar with an

average amount of 300,000 metric tons. This allowed the country to enter and thrive in the global
sugar trade map. With the increasing utilization of refined sugar in most food industries, demand

for sugar is expected to continue and sufficient production must be leveled with it.

PHILIPPINE SUGAR DEMAND

MILLION METRIC TONS

2010

2014

2018

Reference: Sugar Regulatory Admission of the Department of Agriculture

GOALS AND SCOPE

A Life Cycle Assessment (LCA) is one the vital tools for determining and managing the

activities of an industry. It contains a risk assessment, environmental performance evaluation,

environmental auditing and environmental impact assessment. This tool allows to evaluate how

human activity affects the environment on micro- and macro- perspective. For the Sugar Cane

Plantation and Factory, the primary goal is to quantify the environmental impacts of the sugarcane

production process starting from cane plantation, harvesting, transport to the sugarcane mill and

finally sugarcane milling to produce sugar and molasses. Once the environmental impacts are

identified, the researchers can determine which part of the sugarcane production would generate
the most harmful environmental impact. Then, mitigation measures will be implemented to combat

these ill effects.

SYSTEMS BOUNDARY

This study will use a cradle-to-gate life cycle assessment approach wherein the border

starts from the growing and harvesting of the sugarcane to the production of sugar and molasses.

All products or waste management activities transpiring outside the borders of the agriculture field

and factory is not considered in the LCA. The subsystems excluded, are:

a. Sugar and molasses transport to other consumers

b. Green tops, filter mud and ash transport to other consumers

c. Production of cuttings or setts used for sugar cane plantations

d. Road and rail transportation infrastructure

e. Production, maintenance of capital goods such as buildings and machinery

 PROCESS FLOW DIAGRAM

Power Plant

N2O
NO2
CO2
Cl2(g) Dust SO2(g)
NH3(g) Wash CO2 VOC WW: BOD, CO2
Water CO2
H2O(g) CO2 COD VOC
H2O(g)

Sugarcane Plantation Sugarcane Raw Can e Juice Clear To CO2

Cane Juice Clarification Evaporation
& Harvest Milling Juice Mixer Juice
Syrup
Purification
Muddy
Dust Plant
Carbon Dioxide

WW: BOD, Steam CO2

WW: Lime Sulfur Juice
COD Vapor VOC
Insecticide

Cane Buds
Herbicide

TSS, oil, BOD

Fertilizer

WW: Cooling
- COD
Water

SW: NO3 , P Rotary

Lime

Silt (HW) Filtrate To wer or

SW: Vacuum
Spray Pond
SW: Dry Bagasse Filtration
leaves Vapor
Steam
WW: BOD,
SW: Green Tops COD
PM10
CO2 SW: Mill
Lime Vacuum Pan
Mud (HW) CO2
CO2 VOC
CO2
Dust
Water CO2 CO2 CO2 H2O Materials
H2O(g) H2O(g) VOC
Dust
Recovery
Affined Rotary Massecuite Facility
Clarified Affination/ Raw Crystallizer & Water
Filter Press Clarification Sugar & Sugar Sugar
Liquor Centrifugation Sugar Centrifuge
Affined Syrup Drying

Molasses
SW: Filter
sludge (HW) WW: BOD, COD,
Bone WW: BOD, TDS, TSS
CO2
Char COD, TDS CO2
VOC
Dust
H2O CO2 To WWTP
Filtrate PM10
PM2.5
Fine Fine Sugar Refined H2O(g)
Deco lorizatio n Evaporation Crystallization Centrifugation Sugar Drying
Liquor Syrup Cube

WW: BOD,
Steam COD
WW: BOD, SW: Bone
COD Char (HW)
Fine Syrup/ Refinery Refined
Mother Liquor
Liquid Sugar Molasses Powder Sugar
Legend:
Main Process
Electricity
Air Emission
Wastewater
Solid Waste
LCA Boundary
 Capacity (BLUEPRINT: 170 m x 203 m; Area = 34,510 m2 or 3.451 ha)

Security
office
Canteen
0 sq m
Two Way Road
0 sq m Admin Building Parking Area Office Delivery and Shipping
Two Way Road
Gym and Spa
22 sq m

Two Way Road

Office

Two Way Road

Fire and
Research and Control Power 112 sq m
Emergency Utility Area
laboratory Room Management

Two Way Road

Facilities
Two Way Road
Two Way Road
Two Way Road Two Way Road

61.28 m
0 sq m Two Way RoadTwo Way Road

Two Way RoadTwo Way Road Two Way Road

Two Way RoadTwo Way Road
170 m

Two Way Road

AGRICULTURAL STAGE Space for Expansion
62.5 m
30.64 m
SPACE FOR EXPANSION
61.28 m

AGRICULTURAL STAGE
INDUSTRIAL STAGE

31.5 m
Two Way Road
Two Way Road

Two Way Road

0 sq m 0 sq m
AGRICULTURAL STAGE
91.92 m
Two Way Road
Two Way RoadTwo Way Road 62.5 m

Materials
HOLDING TANKS
10 m

Recovery Facility Two Way Road Two Way Road Two Way Road
Two Way Road

203 m
 VISUALIZATION

Security
office
Canteen
Office
Parking Area Two Way Road
112 sq m

Two Way Road

Two Way Road
Admin Building Delivery and Shipping
Two Way Road
Gym and Spa

Office

Two Way Road

Two Way Road
Fire and
Utility Area/
22 sq m
Research and laboratory Emergency Control Room Power
Storage Management
Facilities

Two Way Road

Two Way Road Two Way Road Two Way Road Two Way Road

0 sq m
Two Way Road Two Way Road Two Way Road Two Way Road

Two Way Road

Two Way Road

AGRICULTURAL STAGE Space for Expansion

Two Way Road

Two Way Road

SPACE FOR EXPANSION
AGRICULTURAL STAGE
AGRICULTURAL STAGE AGRICULTURAL STAGE
INDUSTRIAL STAGE

Two Way Road

Two Way Road Two Way Road

0 sq m 0 sq m
AGRICULTURAL STAGE
Two Way Road

AGRICULTURAL STAGE

Two Way Road Two Way Road

Two Way Road
0 sq m
Materials Recovery
0 sq m Facility
HOLDING TANKS
Two Way Road Two Way Road Two Way Road Two Way Road
 Crystallizer and
Miller 3.5m Mixer 5m Clarifier 5m Evaporator 4.5 m Vacuum Pan 4.5m
Centrifuge

3m 4.5m

Rotary Vacuum
12m
Filtration
Cooling Tower
12m

5m
4.5m

Affination/ Rotary Sugar

Deco lorizatio n 4.5m Filter Press 5m Clarifier 5m 4.5m
Centrifugation Dryer

4.5 m

4.5m

Evaporator 6m Crystallizer 6.5m Centrifugation 6m Dryer

Holding tank 15 m Holding tank 15 m Holding tank 15 m Holding tank

1 2 3 4
 SCHEMATIC DIAGRAM OF CRYSTAL AMAZON’s SYSTEMS BOUNDARY

Emission:
Energy Raw Materials
Acquisition: Air Emission: CO2, PM,
SOx, VOC
Plantation and
Harvestation of Waste Water
Water Sugarcane
Solid Waste

Materials: Manufacturing:

Cane buds, CO2 , Lime, Milling Treatment and

Herbicide, Insecticide, Clarification Disposal
Fertilizer, Sulfur, Bone Filtration
Char Evaporation
Vacuum Boiling
Crystallization
Centrifugation
Affination Transportation
Decolorization
 WITHIN THE BOUNDARY

INPUT

Raw Materials : cane buds, water, and chemicals

Energy: steam, diesel, electricity

Raw Materials and Manufacturing and

Energy Acquisition Processing Distribution and Use, Reuse, Recover,
Cane buds, energy, water, Milling, Crystallization, Transportation Maintenance Recycle
chemicals Refining

OUTPUT
Treatment and
Disposal

USABLE PRODUCTS Environmental Impacts:

Refined powder sugar  Airborne Emissions: CO2, SO2, NOx
By products: liquid sugar,  Water effluent: BOD, COD, TDS, TSS
mother liquor, molasses  SW: bagasse, mill and filter mud, silt,
dry and green tops, contaminated bone
char

Functional Unit

The functional unit must be identified as it will be the basis of calculation and comparison of the

different systems fulfilling the same function. The functional unit must be measurable and when

two products with different life spans are compared, it is important that the period of use must be

considered.

Agricultural Stage includes cane cultivation, harvesting and transport of 10,000 kg of planted cane

for every farm. Cane cultivation includes irrigation and application of fertilizers. Harvesting of
sugar cane from the 5 operational farms is done manually, and the dry leaves and green tops are

separated from the cane.

Industrial Stage is based on a daily functional unit of 18,837. 44 kg refined sugar, 8,000 kg of

refined dried sugar and 14,400 kg molasses produced. The bagasse resulting from cane squeezing

activities will be used within the sugar mill for steam and electricity generation. The plant will

operate 16 hours a day with 8-hr shifts and rotating schedules, in 300 days a year.

Objectives of the company

-MICHELLE PALAGYAN NG OBJECTIVES NG COMPANY-
INVENTORY ANALYSIS
Life Cycle Inventory Analysis (LCIA) is a thorough procedure accounting for the
environmental loads during the product’s life cycle (Babu and Ramkrishna, 2003). Inventory
Analysis is a systematic, objective, stepwise procedure for quantifying energy and raw materials
requirement, atmospheric emissions, water borne emissions, solid wastes, and other releases for
the entire life cycle of a product, package process, material or activity. It is a process of data
collection and calculations intended to quantify the inputs and outputs of a product system. These
inputs and outputs may include resources used, as well as release to air, water, or land (SAIC,
2006). This data was made available by the sugar plantation and refinery in Toledo City, Cebu.
Some of the data was collected through databases.

Base Case Design & Assumptions:

 All units used in the calculation are in kg/h.
 Neglect the amount of air vent from the system and introduced to the system
 Calculation is based on the first day of plantation of sugar cane
 Milling and Diffusion efficiency = 25%
 Bagasse Moisture Content = 50%
 Assume efficiency of clarifier to remove impurities = 0.96
 Assume 92% recovery of sucrose as crystal with respect to its input during crystallization
 Assume 33% recovery of reducing sugar (RS) as crystals
 Assume moisture content associated with both sucrose and RS is 0.31
 Assume 0.1 of the feed is molasses adhering to crystal
 Solubility Coefficient = 0.97
 𝑘𝑔 𝑠𝑢𝑐𝑟𝑜𝑠𝑒
 Effective solubility = 0.97*2.71 = 2.6287 𝑘𝑔 𝑐𝑟𝑦𝑠𝑡𝑎𝑙
 Moisture of 0.2 to 0.5% is removed from final sugar crystal
 Temperature of 30℃ condition in the feed entering clarifier and mixer
 Temperature of 96℃ condition in the product leaving the evaporator
𝑘𝐽
 Heating fluid is steam at 1 atm, and its 𝐶𝑃 (𝑘𝑔−𝐾) = 4.19 − 2.35𝑋
; 𝑋 𝑏𝑒𝑖𝑛𝑔 𝑡ℎ𝑒 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑑𝑖𝑠𝑠𝑜𝑙𝑣𝑒𝑑 𝑠𝑜𝑙𝑖𝑑𝑠
 Assume the inlet steam is saturated

Standards Values per ton of cane

Fiber content in cane 13%

Sucrose content in cane 14%

Non-sucrose content in cane 0.5%

Water content in cane 70%

Ash and other impurities in cane 2.5%

Inhibition water content in cane 25-30%

Final bagasse moisture content 40-50%

Evaporator Load 80-90%

Design Evaporator Load 85%

Vacuum Pressure of Vacuum Plant 0.2666 bar

%(Sucrose +_RS) removed with filter cake 1%

% water removed with filter cake 10%

Syrup brix (degrees Brix) 60-65

Different Operating Point of the Plant Values

Mixed Juice Temperature to Clarifier 30℃

Clear Juice Temperature to Evaporator 96℃

Vacuum Boiling Pan Station Pressure 580 mmHg

Sugar to Dryer I temperature 60-80℃

Final Sugar to Storage Temperature 35-40℃

 Sugarcane is a tropical grass belonging to the same family as Sorghum, Johnson grass, and
corn (maize). Modern sugarcane is a complex hybrid of two or more of the five species of the
genus Saccharum. The production of refined sugar from sugarcane has three major steps: (1)
harvesting, (2) cane sugar production, and (3) refined sugar production.
Sugarcane should be planted at a row spacing of 90 cm to 1 m. Two budded double sets
should be placed end to end in the furrows covered with 2 to 3 cm soil layer. About 7650.3 kg of
cane buds is sufficient to plant with a (one farm only) land area of 938.75 m2 or 0.09386 ha. The
Amazona Sugar Plantation has a total of 5 farms.
Output Quantity

(kg/h)

Input Quantity Cane 10,000

(kg/h) Solid Wastes: 1987.5

Cane Buds 7650.3  Silt (12.26%)

 Dry Leaves
Water 1000
(12.26%)
MAP 8.6
 Green Tops
NH4Cl 20.5 Sugarcane (75.48%)

Plantation & Waste Water 1000

Herbicide & 14.45
Insecticide Harvest
Nitrate (1.23 kg)

Organic 14.45 Phosphorus (0.0346

Fertilizer kg)

Lime 8.1 Air Emissions 217.635

CO2 4490 o N2O (0.485%)

o NO2 (0.0827%)
TOTAL 13206.4
o CO2 (98.8688%)
o Cl2(g) (0.564%)

TOTAL 13206.4

Figure 1. Material Inputs and Outputs of the Sugar Cane Plantation (For One Farm Only)
 For Cane Plantation, cane buds will be treated with hot running water of 1 m3 at 520 C for
1 hour, and with 14.45 kg of herbicide and 14.45 kg of organic fertilizer. This will help in better
germination and the control of many cane diseases. All phosphorus and potash(MAP) and one
fourth N (in terms of Ammonium chloride) from Global Ceres Corporation should be applied at
the time of planting. It is preferable that MAP may be applied in furrows where cane buds are to
be placed. Rest of the nitrogenous fertilizer (NH4Cl) may be applied in three equal splits (i.e.
during April, May and by mid-June). The best way to determine lime requirements is with a
reliable soil test. Liming (using 8.1 kg) is required if pH is greater than 5.0. It is recommended to
apply lime before fertilizing and after harvesting.
In Philippines, cane is manually cut in the field and the cane tops and dry leaves are
manually peeled as they contain little sucrose and high starch, thus reducing the sugar yield
required by the mills. The cane must be processed within a short time after cutting. The leaves also
have high silica content which causes mill role wear (EPA, 1997). The cane is loaded on animals
or small tractors to be then loaded on factory railcars or private trucks to be transported to the sugar
mills.
The cane train consists of 25 carts. Each cart is loaded with 10 tons of cane. The carts are
given numbers according to the cane owner. The carts are weighed in the factory and the weight
of the cart is subtracted. The amount of waste leaves is calculated and subtracted. The cane arriving
in the mills is weighed and is immediately processed as sugarcane undergoes deterioration of the
sucrose content if it is stored for later processing (EPA, 1997).
The residues of sugarcane consist of “green tops” (20% of the total harvest) and dry leaves
(5% of the total harvest). It is estimated that these residues amount to 3 million tons per five months
of harvest.
For Cane Milling, 10 tons of cane per hours are mechanically unloaded and placed in a
large pile. Prior to milling, the cane is cleaned, usually with high pressure water. The milling
process occurs in two steps: breaking the hard structure of the cane and grinding the cane. Breaking
the cane uses revolving knives, shredders, crushers, or a combination of these processes. For the
milling of the crushed cane, a three-roller mill is most commonly used. Multiple sets of mills are
used with combinations of 15 to 18 rollers being predominant. Conveyors transport the crushed
cane from one mill to the next. Imbibition is the process in which water (with 400 kg/h) is applied
to the crushed cane to enhance the extraction of the juice at the next mill. The common procedure
is to send the juice from the crusher and the first two mills for further processing, until 8967.94 kg
of juice is produced. In imbibition, water or juice from other processing areas is introduced into
the last mill and transferred from mill to mill towards the first two mills while the crushed cane
travels from the first to the last mill. The crushed cane exiting the last mill is called bagasse, one
of the most significant wastes in the sugar industry, which is about 1000 kg/h.

Output Quantity

(kg/h)

Raw Juice 8967.94

Solid Wastes: 1000

 Bagasse (100%)
Input Quantity
Waste Water 397.6
(kg/h)
Sugarcane TSS (0.12 kg)
Cane 10000 COD (0.0346 kg)
Milling
Water 400 BOD (0.12 kg)
Grease (1.2 kg)
TOTAL 10,400
Air Emissions 34.46

o CO2 (92.8%)
o H2O(g)(0.00195%)
o PM10 (7.1961%)
o PM2.5 (0.00195%)

TOTAL 10,400

Figure 2. Material Balance (based on the yield of cane produced at one farm)

Finally, the extracted juice from the mills is strained to remove large particles and then
clarified to remove non-sugar impurities.
 Output Quantity
Input Quantity
(kg/h)
(kg/h)
Juice 12,014.9091
Raw Juice 8967.94 Juice Mixer & Air Emissions 303.35
Lime 2500 Heater
o CO2 (45 %)
Sulfur 833.33 o H2O(g) (44.4%)
o SO2 (10.6%)
TOTAL 13206.4
TOTAL 13206.4

Figure 3. Material Inputs and Outputs of the Juice Mixer

In mixer having a similar function of heater, batches of raw juice (8967.94 kg/h) are treated
simultaneously with milk of lime (CaO) and sulfur dioxide (SO2), by air forced through a sulfur
furnace (833.33 kg of S), and quickly heated to 90ºC or above.
In Chemical clarification, based on modern cold lime sulphitation, it is carried out to
remove impurities which inhibit the formation of the crystals and can discolor the final product.
The addition of lime also has the advantage of reducing the natural acidity of the cane juice,
limiting the formation of invert sugars. This treatment formed a heavy precipitant that flocculates,
carrying with it most of the suspended impurities in the juice. About 400.65 kg of waste water,
which contains suspended solids, is separated from the treated juice. The muddy juice containing
mostly lime is then filtered in Rotary Vacuum Filtration, resulting in mill mud (useful solid
waste in sugar industry), and dried for use as a soil conditioning agent in agriculture. Filtrate will
be recycled back to clarifier, promoting zero waste in the said process. The resultant clear solution
of juice from clarifier is called “clear juice or thin juice”.
 Output Quantity

(kg/h)

Clear Juice 7823.16

Input Quantity Muddy Juice 7823.16

(kg/h) Waste Water 400.65

Juice 16019.88 Clarification TSS (0.19 kg)

COD (0.26 kg)
Water 400
BOD (0.1922 kg)
TOTAL 16419.88
Air Emissions 372.91386

o CO2 (91.13%)
o VOC (8.87%)

TOTAL 16419.88

Figure 4. Material Inputs and Outputs of the Clarifier

Output Quantity

(kg/h)

Filtrate 4004.97
Input Quantity
Solid Wastes: 3636.1
(kg/h) Rotary Vacuum
 Mill Mud (100%)
Muddy Juice 7823.16 Filtration
Air Emissions 182.0988
TOTAL 7823.16
o CO2 (98.13%)
o PM10 (1.87%)

TOTAL 7823.16

Figure 5. Material Inputs and Outputs of the Rotary Vacuum Filter

 After clarification, the thin juice has a sugar content of approximately 15 percent.
Concentrations greater than 68 percent are needed to allow sugar crystallization, and this is
achieved through evaporation. Water is removed from the thin juice in a series of evaporating
vessels until a syrup with a dry matter content of 68–72 percent is obtained.
Output Quantity

(kg/h)

Input Quantity Syrup 7640.84

(kg/h) Vapor 1000

Clear Juice 7823.16 Waste Water 400.22

Evaporation
Water 400 BOD (0.094 kg)
COD (0.13 kg)
Steam 1000
Air Emissions 182.1
TOTAL 9223.16
o CO2 (98.13%)
o VOC (1.87%)

TOTAL 9223.16

Figure 6. Material Inputs and Outputs of the Evaporator

Evaporation is performed in two stages: initially in an evaporator station to concentrate the

juice and then in vacuum pans to crystallize the sugar. The clear juice is passed through heat
exchangers to preheat the juice and then to the evaporator stations. Evaporator stations consist of
a series of evaporators, termed multiple-effect evaporators. This process typically uses a series of
three evaporators. Steam from cooling tower is used to heat the first evaporator, and the steam
from the water evaporated in the first evaporator is used to heat the second evaporator. This heat
transfer process continues through the three evaporators and as the temperature decreases (due to
heat loss) from evaporator to evaporator, the pressure inside each evaporator also decreases which
allows the juice to boil at the lower temperatures in the subsequent evaporator. Some steam is
released from the first three evaporators, and this steam (about 1000 kg/h) is fed to cooling tower
and used in various process heaters in the plant. About 5 m3 cooling water/t raw material is required
to condense the steam from the last vessel of the evaporation plant and the evaporation
crystallizers. In the cooling water circuit, the mixed condensate (hot well water) produced from
the condensers (steam condensation) at 40 to 50°C must be recooled to 20°C maximum in cooling
towers so that it can be reused.
Output Quantity

(kg/h)
Input Quantity
Massecuite 7462.97
(kg/h)
Vacuum Boiler Vapor 1000
Syrup 7640.84
Pan Air Emissions 177.87
Steam 1000
o CO2 (98.13%)
TOTAL 8640.84
o VOC (1.87%)

TOTAL 8640.84

Figure 7. Material Inputs and Outputs of the Vacuum Boiling Pan

The evaporator station in raw sugar manufacture typically produces a syrup (7640.84 kg/h)
with about 65 % solids and 35 % water. This will proceed to vacuum boiling pan operation which
uses cascade type furnaces of various configurations. The main function of this equipment is to
produce sugar crystals from the syrup. In the pan boiling process, the syrup is evaporated until it
reaches the supersaturation stage. At this point, the crystallization process is initiated by "seeding"
or "shocking" the solution. When the volume of the mixture of liquor and crystals, known as
massecuite, reaches the capacity of the pan, the evaporation will proceed until the final massecuite
is formed. At this point, the contents of the vacuum pans (called "strike or final massecuite") of
about 7462.97 kg/h are discharged to the crystallizer.
Input Quantity Output Quantity

(kg/h) (kg/h)
Cooling
Vapor 2000 Steam 1997.28
Tower
Water 400 Waste Water 400.06

TOTAL 2400 BOD (0.024 kg)

 COD (0.0302 kg)

Air Emissions 2.66

o Dust (100%)

TOTAL 2400

Figure 8. Material Inputs and Outputs of the Cooling Tower

The massecuite is placed in U-shaped vessels where it is slowly rotated and allowed to cool
for up to 48 hours. This technique is often referred to as crystallization in motion. Rotation
promotes even cooling of the massecuite which helps to achieve uniform crystal growth. Seeding
will be carried out: that is granulated massecuite from a crystallizer in which grains have already
been developed, are placed into the crystallizer before it is filled with fresh massecuite. This helps
to promote uniform crystal growth. The massecuite, now consisting of crystals suspended in
molasses, is transferred to the centrifuge.
Meanwhile, the centrifuge, a scaled-down version of those used in large-scale factories,
consists of a perforated inner drum located inside a larger drum. The perforated drum is rotated
rapidly, forcing the molasses (1000 kg/h) to separate from the crystals (300 kg/h). Water (4975.3
kg/h) is sprayed into the spinning drum to assist in the removal of the molasses. Molasses contain
50% sugar; hence, it can be further processed or sent to distillery. The crystals of sugar are then
removed from the centrifuge and transferred for drying.
Output Quantity

(kg/h)
Input Quantity
Sugar 300
(kg/h)
Crystallizer- Molasses 1000
Massecuite 7462.97
Centrifuge Waste Water 10,964.52
Water 4975.3
BOD (0.06 kg)
TOTAL 12,438.27 COD (0.08 kg)
TDS (5989.022 kg)
TSS (0.06 kg)
 Air Emissions 173.75

o CO2 (98.13%)
o H2O(g) (1.87%)

TOTAL 12,438.27

Figure 9. Material Inputs and Outputs of the Crystallizer-Centrifuge

Output Quantity

(kg/h)

Raw Sugar 975.39

Input Quantity
Vapor 1000
(kg/h)
Air Emissions 24.61
Sugar 1000 Drying
o CO2 (92.8%)
Steam 1000
o VOC (1.78%)
TOTAL 2000 o PM (5.4%)
o PM2.5 (0.0041%)
o PM10 (0.02%)

TOTAL 2000

Figure 10. Material Inputs and Outputs of the Drum Dryer

The crystals can be dried in several ways: by placing them in the sun, or by using simple
solar driers, or rotary or hopper driers which require fuel to provide drying heat. For this company,
rotary drum dryer will be used. Sugar dust from sugar driers give rise to severe air pollution.
This is not only a health hazard but, at a grain size of < 0.03 mm, also highly explosive if the
dust/air mixture concentration is within the explosion limit (approx. 20 to 300 g/m 3). Aside from
the emissions obtained from the combustion of fuel, VOC and PM characterized by the release of
dust are significant.
Output Quantity

(kg/h)
Input Quantity
Affined Sugar 952.69
(kg/h)
Affination- Dissolved Molasses 501.995
Raw Sugar 975.39
Centrifugation Air Emissions 20.705
Saturated Syrup 500.00
o CO2 (98.13%)
TOTAL 1475.39
o H2O (1.87%)

TOTAL 1475.39

Figure 11. Material Inputs and Outputs of the Affinator-Centrifuge

In affination, the raw sugar (975.39 kg/h) is mixed with a saturated syrup (500 kg/h) and
then centrifuged to extract the crystals (952.69 kg/h). Surface impurities (molasses) dissolve in
this syrup and are removed and will be marketed. Air emissions are due to energy supplied to
centrifuge, during combustion of fuel.

For chemical clarification, carbonation will be used which requires the addition of lime,
about 2500 kg/h. Carbonation consists of adding lime to the raw affined syrup (952.69 kg/h) and
then bubbling carbon dioxide (CO2 ) through the liquor to produce a voluminous calcium carbonate
precipitate.
Although the carbonation process gives good results, it is rarely used in the cane industry
because of the investment required and a general lack of the main raw material, limestone. Cane
processing facilities typically purchase ready-made burnt limestone powder (from the nearest
Cement Company) and use this to generate milk of lime.
The source of CO2 is boiler flue gas, which contains about 12 percent CO2 by volume. For
oil or coal-fired boilers, the flue gas is scrubbed twice (water and Na2CO3 solution) to remove
sulfur compounds; for bagasse-fired boilers, only water scrubbing is used. A clear layer will be
seen, as the precipitate in the form of CaCO3, settle down in the tank, and will be removed in filter
press. The filter cake, a notable solid waste, consists of press cakes, muds, scums, suspended
solids, and colloidal matter.

Input Quantity Output Quantity

(kg/h) (kg/h)

Affined Sugar 952.69 Clarified Liquor 9097.97

Lime 2500 Clarification Air Emissions 104.72

CO2 4500 o CO2 (98.17%)

o VOC (0.00112%)
Water 1250 o H2O(g) (1.83%)

TOTAL 9202.69 TOTAL 9202.69

Figure 12. Material Inputs and Outputs of the Clarifier

Output Quantity

(kg/h)

Filtrate 8020.9002
Input Quantity
Solid Wastes: 842.62
(kg/h)
Filtration  Filter Sludge
Clarified Liquor 9097.97 (100%)

TOTAL 9097.97 Air Emissions 234.4498

o CO2 (98.12%)
o Dust (1.88%)

TOTAL 9097.97

Figure 13. Material Inputs and Outputs of the Filter Press

Decolorization removes soluble impurities by adsorption. Carbonaceous adsorbents made

from naturally occurring materials and synthetic resins are used as media for decolorization. Most
common adsorbent that will be used is bone char (about 2673.6 kg), manufactured from degreased
cattle bones. Bone char ix used in either fixed or moving bed systems. The latter will be moved
using electricity. A moving bed system operates continuously rather than cyclic, and the bone char
moves countercurrent to the flow of the sugar liquor (8020.9 kg). Spent adsorbent is removed from
the bed, regenerated (dried in kilns), and the regenerated adsorbent (classified as hazardous waste)
is transferred by conveyor to storage or to the decolorization beds.

Output Quantity

(kg/h)
Input Quantity
Fine Liquor 8020.68
(kg/h)
Solid Wastes: 2673.6
Filtrate 8020.9
Decolorization  Bone Char (100%)
Water 400
Waste Water 400.22
Bone Char 2673.6
COD (0.13 kg)
TOTAL 11,094.5
BOD (0.09 kg)

TOTAL 11,094.5

Figure 14. Material Inputs and Outputs of the Decolorizer

The decolorized sugar liquor is sent to multiple-effect evaporators, and then to the vacuum
pans; this is the same sequence used in cane sugar manufacture. An evaporator station consisting
of 3 evaporators is commonly used. The sugar liquor from the evaporators (thick juice) is
transferred to the vacuum pans to further reduce the liquor volume and form the massecuite.
In refined sugar production, the most common vacuum boiling system is the four-strike
system. When the liquor in the pans has reached the desired level of supersaturation, the liquor is
"seeded" to initiate formation of sugar crystals. The seed is usually sugar ground in a mill with a
saturated syrup. Crystallization proceeds to produce a massecuite with a sugar content as high as
the centrifugal can handle. At this point, the strike is discharged to the centrifugal. In
centrifugation, the white sugar is retained in the inner basket and the liquor centrifuged to the
outer shell. The sugar liquor is returned to a vacuum pan for further volume reduction and white
or brown sugar production. The white sugar is washed one time in the centrifugal; the separated
wash water, containing liquor and dissolved sugar, is returned to the vacuum pans. The moist sugar
(or refined sugar) of about 2354.68 kg/h from the centrifugals contains about 1% H2O by weight.

Output Quantity

(kg/h)

Fine Syrup (1) 2000

Input Quantity Fine Syrup (2) 5434.68

(kg/h) Vapor 1000

Fine Liquor 8020.68 Evaporation Waste Water 400

Steam 1000 BOD (0.09 kg)

COD (0.13 kg)
TOTAL 9020.68
Air Emissions 186.4419

o CO2 (98.15%)
o VOC (1.85%)

TOTAL 9020.68

Figure 15. Material Inputs and Outputs of the Evaporator

Output Quantity
Input Quantity
(kg/h)
(kg/h)
Crystallization Sugar Cube 3434.68
Fine Syrup (2) 5434.68
Mother Liquor 2000
TOTAL 5434.68
TOTAL 5434.68

Figure 16. Material Inputs and Outputs of the Crystallizer

 Output Quantity

(kg/h)

Input Quantity Refined Sugar 2354.68

(kg/h) Refined Molasses 1000.00

Centrifugation
Sugar Cube 3434.68 Air Emissions 80.00

TOTAL 3434.68 o CO2 (98.125%)

o Dust (1.88%)

TOTAL 3434.68

Figure 17. Material Inputs and Outputs of the Centrifuge

White sugar designed for dry, refined granulated sugar is transported by conveyors and
bucket elevators to the sugar dryers. The most common sugar dryer is the granulator, which
consists of two drums in series. One drum dries the sugar and the other cools the dried sugar
crystals. Dryer drums typically operate at a temperature of about 110℃ (230℉).
From the granulators, about 1000 kg/h dried white sugar crystals are mechanically screened
by particle size using a sloping, gyrating wire mesh screen or perforated plate. After screening, the
finished, refined granulated sugar is sent to conditioning bins, and then to storage bins prior to
packaging or bulk loadout.

Output Quantity
Input Quantity
(kg/h)
(kg/h)
Drying Refined Powdered Sugar 1000
Refined Sugar 2354.68
Water Vapor 1297.44
TOTAL 2354.68
Air Emissions 57.955
 o CO2 (92.8%)
o PM2.5 (7.183%)
o PM10 (0.017%)

TOTAL 2354.68

Figure 18. Material Inputs and Outputs of the Dryer

Table 1. Summary of Sugar Refinery Products

Name of Product to be Amount Source
Marketed
Unpurified Molasses 500 kg/h or 4000 kg/d Affinator-Centrifuge

Liquid Sugar 2000 kg/h or 16000 kg/d Evaporator 2

Saturated Syrup (for seeding) 2000 kg/h or 16000 kg/d Crystallizer 2

Edible Molasses 1300 kg/h or 10,400 kg/d Centrifuge 1 &2

Refined Sugar 2354.68 kg/h or 18,837.44 kg/d Centrifuge 2

Dried Powdered Sugar 1000 kg/h or 8000 kg/d Granulator

Table 2. Inventory Analysis on Solid & Hazardous Wastes

Solid Waste Amount (kg/h) Amount (kg/d) Source
Silt (HW) 243.75 1950

Dry Leaves 243.75 1950 Sugar Cane Plantation &

Harvest
Green Tops 1500 12,000

Bagasse 1000 8000 Sugar Cane Milling

Mill Mud (HW) 3636.1 29,088.8 Rotary Vacuum Filtration

Filter Cake 1818.05 14,544.4 Filter Press

Bone Char 2673.6 21,388.8 Decolorization

 Table 3. Inventory Analysis on Waste Water
Total amount of WW: 14,361.52 kg/h and/or 114,892.2 kg/d
Operational Schedule: 8 hours per day
Waste Water Parameter Amount (kg/h) Amount (kg/d) Concentration
(mg/L)
Nitrates 1.23 9.84 685
Phosphorus 0.0345 0.276 19.22

BOD 0.6702 5.36 373.3

COD 0.822 6.576 458

TDS 5989.022 47,912.176 3336490

TSS 0.18 1.44 100

Grease/Oil 1.2 9.6 668.5

Water 8368.4 66946.9 -

Table 4. Inventory Analysis on Air Emissions

Pollutants N2O NO2 CO2 Cl2 H2O PM10 PM2.5 SO2 VOC Total
Process Source kg/h
Plantation 1.056 0.18 215.173 1.227 217.636
Milling 31.98 0.000672 2.479 0.000672 34.46034
Mixing 136.51 134.69 32.155 303.355
Clarification 339.84 33.07 372.91
Filtration 1 178.7 3.41 182.11
Evaporation 1 178.69 3.4 182.09
Vacuum Boiling
Pan 174.54 3.33 177.87
Cooling Tower 2.66 2.66
Crystallization 1 170.5 3.25 173.75
Drying 1 22.84 1.34 0.0049 0.44 24.1849
Affination 20.3 0.387 20.687
Clarification 2 102.8 1.92 0.00117 104.7212
Filtration 2 230.04 4.408 234.448
Evaporation 2 182.9 3.45 186.35
Centrifugation 78.5 1.504 80.004
Drying 2 53.78 0.00985 4.163 57.95285
Total 1.056 0.18 2117.093 1.227 140.2477 15.81085 4.168572 32.155 43.69117 2355.629
Total (kg/d) 8.448 1.44 16936.74 9.816 1121.982 126.49 33.349 257.24 349.53
Total (kg/d) 18845.03
Total Amount of Emissions: 18,845.03 kg/d

 Basis: 1 day
 At Temperature = 20℃ & Pressure = 1 atm
 Assuming density and molecular weight of exhaust gases is the same as the molecular
weight of air:
𝑚𝑅𝑇
𝑃𝑉 =
𝑀𝑊
𝑚3 − 𝑘𝑃𝑎 1000 𝑚𝑜𝑙
(18,845.03 𝑘𝑔) ((8.314 𝑥 10−3 ) ( )(20 + 273.15)𝐾
𝐾 − 𝑚𝑜𝑙 ) 1 𝑘𝑚𝑜𝑙
(101.325 𝑘𝑃𝑎)(𝑉) =
𝑘𝑔
29
𝑘𝑚𝑜𝑙
𝑽 = 𝟏𝟓, 𝟔𝟑𝟎. 𝟖𝟑 𝒎𝟑

Table 5. Determination of Criteria Pollutants based on the standard values of RA 8749

𝝁𝒈 𝝁𝒈
Criteria Pollutant NAAQGV (𝑵𝑪𝑴) Amount (𝑵𝑪𝑴)) Remark

PM10 150 176.49 Fair

PM2.5 50 33.349 Approved

SO2 180 257.24 Not Approved

NO2 150 1.44 Good

*Averaging Time: 24-hour

 Comparison of Criteria Pollutants
180
160
140
Amount (kg/h)

120
100
80
60
40
20
0

Figure 19. Comparison of Air Emissions; Mixing in the refinery section has the highest amount
of Criteria Pollutants
 Waste Water Effluent Parameters
120.00

100.00

80.00
Percentage

60.00

40.00

20.00

0.00

Figure 20. Comparison of Quantities/Amount of Waste Water Parameters; Centrifugation 1 in

the raw sugar production section has the highest percentage of waste water

Energy Balance, Power Requirements, and Other Specifications

1.) Sugarcane Plantation
Power Consumption: 49, 470 MJ per day = 13741.67 kWh per day
2.) Sugar cane Milling
Number of Millers: 3 roller cane mills
Speed: 10-15 meter/minute
Supplier: Taxmaco Ltd, Calcutta
Power Requirement: 50 kWh per ton of cane (Hugot, 1986)
Power Consumed:
50 𝑘𝑊ℎ 1 𝑡𝑜𝑛
𝑥 10,000 𝑘𝑔 𝑐𝑎𝑛𝑒𝑠 𝑥 = 𝟓𝟎𝟎 𝒌𝑾𝒉 𝒑𝒆𝒓 𝒅𝒂𝒚
𝑡𝑜𝑛 𝑜𝑓 𝑐𝑎𝑛𝑒 1000 𝑘𝑔
3.) Cane Juice Mixer
Assuming the raw juice from milling and diffusion tandems is available at 30℃, before adding
lime to juice, the juice has to be heated. Thus, the final temperatures to which juices are heated in
clarification varies from extremes of 90 to 115℃, although by far the commonest practice is to
heat slightly above the boiling point. Superheating was advocated by some in earlier studies, but
it is generally believed today that superheating is not advantageous and temperatures just above
the boiling point say 103℃ are the maximum for good practice.
Assume it is heated to 102℃ and steam from the cooling tower is available at 1 atm for heating.
The heat capacity, from Hugot (1986) in his Handbook of Sugar Cane Refinery, for mixed juice is
calculated by:
𝑘𝐽
𝐶𝑃 ( ) = 4.19 − 2.35 ∗ 𝑋
𝑘𝑔 − 𝐾
Heat required to raise the temperature of raw juice from 30℃ to 102℃ is given by:
𝑄 = 𝑀𝐽 𝑥 𝐶𝑃 𝑥 ∆𝑇 = 𝑀𝑆 𝑥 𝐶𝑃 𝑥 ∆𝑇
where X is fraction of dissolved solids.
Feed to the mixer is 8967.94 kg/h and fraction of solids content from material balance is 0.1.
Therefore,
𝑘𝐽
𝐶𝑃 ( ) = 4.19 − 2.35 ∗ 0.1 = 3.955
𝑘𝑔 − 𝐾
𝑘𝑔 1ℎ 𝑘𝑔
𝑀𝐽 = 8967.94 𝑥 = 2.491
ℎ 3600 𝑠 𝑠
𝑘𝑔 𝑘𝐽
𝑄 = 2.491 𝑥 3.955 𝑥 (102 − 30)𝐾
𝑠 𝑘𝑔 − 𝐾
𝑘𝐽 0.001 𝑀𝐽 98.5 𝑘𝑊ℎ
𝑄 = 709.337 𝑥 𝑥 = 𝟎. 𝟏𝟗𝟕 𝒌𝑾𝒉 𝒑𝒆𝒓 𝒅𝒂𝒚
𝑠 1 𝑘𝐽 354.6 𝑀𝐽
𝑘𝐽
Assume the inlet steam is saturated steam, where ℎ𝑉 = 2257 𝑘𝑔

𝑄
Steam requirement: 𝑀𝑆 =
ℎ𝑉

709.337 3600 𝒌𝒈
𝑀𝑆 = ∗ = 𝟏𝟏𝟑𝟏. 𝟒
2257 1 𝒉
4.) Clarifier
Number of Equipment: 2
Type of Clarifier: Reactor Clarifier/Clari-flocculator
Power Requirement: 354.6 MJ or 98.5 kWh per day

Detention time 3 hours

 Target Industry Sugar Industry

Inlet Flow Rate 100 m3 per h

Installation Available

Installation Service Yes

Material of Construction MS

Number of Flocculators 2

Surface Area 3140 m2

Tank Diameter 20 m

Capacity 5000 m3
Type Horizontal Flow

Supplier Anuj Enterprises

5.) Rotary Vacuum Drum Filter

Specifications:

 Number of Equipment: 2
 Material: 304 Stainless steel
 Size: 5527*2080*2178 mm
 Weight: 670~4950 kg
 Capacity: up to 11000 kg/h
 Amount of Feed entering: (1) 7823.16 kg/h & (2) 10,073.4 kg/h
 Power Requirement: 3.33 GJ per day or 904.11 kWh per day

6.) Cooling Tower

Reference: Handbook of Cane Sugar Refinery by Hugo (1986)

550 kg of steam per ton of cane

0.03 kWh of energy per ton of cane

550 𝑘𝑔 𝑜𝑓 𝑠𝑡𝑒𝑎𝑚
𝑥 10,000 𝑡𝑜𝑛𝑠 𝑜𝑓 𝑐𝑎𝑛𝑒 = 5,500,000 𝑘𝑔 𝑜𝑓 𝑠𝑡𝑒𝑎𝑚 = 5500 𝑡𝑜𝑛𝑠 𝑜𝑓 𝑠𝑡𝑒𝑎𝑚
𝑡𝑜𝑛
 20 𝑘𝑊ℎ
𝑥 10,000 𝑡𝑜𝑛𝑠 𝑜𝑓 𝑐𝑎𝑛𝑒 = 𝟑𝟏𝟒. 𝟒 𝒌𝑾𝒉 𝒑𝒆𝒓 𝒅𝒂𝒚
𝑡𝑜𝑛

7.) Evaporator

Number of Equipment: 2
Number of Effects: 3

The energy balance around the evaporators is given by:

𝑀𝑠 ℎ𝑠𝑔 + 𝑀𝐽 ℎ𝐽 = 𝑀𝑠 ℎ𝑠𝑓 + 𝑀𝑉 ℎ𝑣,𝑇1 + 𝑀𝑃,𝑇1 ℎ𝑓

where 𝑀𝑠 = mass flow rate of the steam

ℎ𝑠𝑔 & ℎ𝑠𝑓 = latent heat of steam for the gas and liquid, respectively
𝑀𝐽 and ℎ𝐽 = mass flow rate and latent heat of the juice
𝑀𝑃 and ℎ𝑓 = mass flow rate and latent heat of the product at T1

T1 = operating temperature of the evaporators = 110℃ taken from the Handbook of Cane Sugar
Refinery
𝑀𝑉 & ℎ𝑣,𝑇1 = mass flow rate and latent heat of the vapors

To obtain its maximum power requirement, we will neglect the amount of vapor that escapes
from the evaporator and changed into condensate.
Analysis: From material balance, total dissolved solids is about 15% of the feed
 𝑘𝐽
𝐶𝑃 ( ) = 4.19 − 2.35 ∗ 0.15 = 3.85
𝑘𝑔 − 𝐾

𝑘𝐽
ℎ𝑠𝑔 − ℎ𝑠𝑓 = ℎ𝑔𝑓 = 2257
𝑘𝑔
𝑘𝐽 𝑘𝐽 𝑘𝐽
ℎ𝑉 = 2690 , ℎ𝐽 = 254 , ℎ𝑓 = 304
𝑘𝑔 𝑘𝑔 𝑘𝑔
𝑘𝑔 𝑘𝑔
𝑀𝐽 = 7823.16 = 2.1731
ℎ 𝑠
𝑘𝑔 𝑘𝑔
𝑀𝐶 = 3.63 , 𝑀𝑃 = 2.12
𝑠 𝑠
𝑘𝐽 𝑘𝑔 𝑘𝐽 𝑘𝐽 𝑘𝑔 𝑘𝐽
𝑀𝑠 (2257 ) + 2.1731 (254 ) = 𝑀𝑠 (2690 ) + 2.12 (304 )
𝑘𝑔 𝑠 𝑘𝑔 𝑘𝑔 𝑠 𝑘𝑔
8914.7
𝑀𝑠 = = 𝟑. 𝟗𝟓 𝒌𝒈/𝒔
2257
𝑘𝑔 𝑘𝐽
𝐻𝑒𝑎𝑡 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 (𝑄) = 𝑀𝑠 (𝐶𝑃 )(∆𝑇) = 3.95 (3.85 ) (110 − 100)𝐾 = 152.08𝑘𝑊
𝑠 𝑘𝑔 − 𝐾
𝑘𝐽 0.001 𝑀𝐽 98.5 𝑘𝑊ℎ 3600𝑠
𝑃𝑜𝑤𝑒𝑟 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 (1 ℎ 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛) = 152.08 𝑥 𝑥 𝑥
𝑠 1 𝑘𝐽 354.6 𝑀𝐽 1ℎ
= 𝟏𝟓𝟐. 𝟎𝟖 𝒌𝑾 − 𝒉
8.) Vacuum Boiling Pan
Equipment: Continuous Vacuum Pan
Voltage 380 V
Maximum Capacity 100 tons

Capacity based on material balance 8.64 tons

Power Consumption 0.340 kW-h

Other specifications:

 High heating surface volume ratio

 Uniform-plug flow through multiple compartments with no channeling and short circuiting
 Minimum hydrostatic head above top tube plate
 Entrainment prevention by multi baffle type entrainment catcher
 Uniform quality of massecuite and crystals
 Maximized exhaustion of mother liquor
 Better centrifugal separation
 Steady & uniform rate of boiling, requires no dilution
 Uniform load or power & vapor/ steam
 Low temperature
 Vapor boiling
 No encrustation on the heating surface - does not require frequent cleaning

9.) Crystallizer
Number of Equipment: 2
Type of Equipment: Continuous Vacuum Cooling Crystallizer
From material balance, crystallizer operates at 580 mmHg vacuum. At this pressure,
boiling point of water is 61.42℃. BPR is 4℃ from the Handbook of Cane Sugar Refinery. The
temperature in the equipment will be 65.42℃. Beyond on this temperature, conversion and
caramelization may occur.
(𝐹)(ℎ𝑓 ) + (𝑀𝑆 )(ℎ𝑠 ) = (𝐿)(ℎ𝐿 ) + (𝑉)(ℎ)

where F = feed flow rate to crystallizer = 2.07 kg/s

𝐶𝑃,𝐹 = 4.19 − (2.35)(𝑋); 𝑋 = 0.556
𝑘𝐽
𝐶𝑃,𝐹 = 2.883
𝑘𝑔 − 𝐾
𝐹𝑒𝑒𝑑 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 = 𝑇𝐹 = 54℃, 𝑤ℎ𝑒𝑟𝑒 𝑏𝑎𝑠𝑒 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑖𝑠 0℃
𝑘𝐽 𝑘𝐽
ℎ𝑓 = 𝐶𝑃,𝐹 ∗ (𝑇𝐹 − 0) = 2.883 ∗ (54 − 0)𝐾 = 155.704
𝑘𝑔 − 𝐾 𝑘𝑔
𝑀𝑆 = 𝑠𝑡𝑒𝑎𝑚 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑖𝑛 𝑘𝑔/𝑠
Assume steam is available at same pressure as that of evaporator:

ℎ𝑠 = 2257 𝑘𝐽/𝑘𝑔
𝐿 = 𝑜𝑢𝑡𝑝𝑢𝑡 𝑜𝑓 𝑐𝑟𝑦𝑠𝑡𝑎𝑙𝑙𝑖𝑧𝑒𝑟 = 1.3 𝑘𝑔/𝑠
𝐶𝑃,𝐿 = 4.19 − (2.35)(𝑋); 𝑋 = 0.97
𝑘𝐽
𝐶𝑃,𝐿 = 1.91
𝑘𝑔 − 𝐾
𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑜𝑓 𝑜𝑢𝑡𝑝𝑢𝑡 = 𝑇1 = 65.42℃
𝑘𝐽 𝑘𝐽
ℎ𝐿 = 𝐶𝑃,𝐿 ∗ (𝑇𝐹 − 0) = 1.91 ∗ (65.42 − 0)𝐾 = 125
𝑘𝑔 − 𝐾 𝑘𝑔
𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑊𝑎𝑡𝑒𝑟 𝐸𝑣𝑎𝑝𝑜𝑟𝑎𝑡𝑒𝑑 = 𝑉 = 0.77 𝑘𝑔/𝑠
 ℎ = ℎ𝑉 65.42℃ + (𝐵𝑃𝑅 ∗ 𝐶𝑃,𝑠𝑡𝑒𝑎𝑚 ),
𝑘𝐽 𝑘𝐽
𝑤ℎ𝑒𝑟𝑒 ℎ𝑉,65.42℃ = 2618 − 275.8 = 2342.2 𝑎𝑛𝑑 𝐶𝑃,𝑠𝑡𝑒𝑎𝑚@65.42℃ = 1.928
𝑘𝑔 𝑘𝑔 − 𝐾
𝑘𝐽
ℎ = 2342.2 + (4 ∗ 1.928) = 2350
𝑘𝑔
Substituting the values in heat balance:
(2.07)(155.704) + (𝑀𝑆 )(2257) = (1.3)(125) + (0.77)(2350)
𝑴𝑺 = 𝟎. 𝟕𝟑 𝒌𝒈/𝒔
𝐻𝑒𝑎𝑡 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑, 𝑄 = 𝑀𝑆 ∗ 𝐶𝑃,𝑠𝑡𝑒𝑎𝑚 ∗ ∆𝑇

𝑄 = 0.73 ∗ 1.928 ∗ (65.42 − 54)

𝑸 = 𝟏𝟔. 𝟎𝟕 𝒌𝑾𝒉 𝒑𝒆𝒓 𝒅𝒂𝒚
10.) Centrifuge
Number of Equipment: 3
Type of Equipment: Vertical Continuous centrifugals, where two centrifugal baskets are
mounted on a common shaft and driven by a common motor
Power Requirement: 37.6 kWh per day
SCP-C5, a stainless steel continuous centrifuge, with vertical axis concept is a premier quality
product with an AC electronic motor 110 kW-standard voltage 380/660 V+50 Hz, high power belt
drive, new transmission system and a mechanical brake. It showcases two different lubrication
systems (oil pressure and grease) for levels of roll and ball bearings and also displays the latest
design of bell distributor for better vibration damping. Also featured are devices to control
formation of magma or syrup at the required Bx, Qz. Customization of motor and outlets is also
possible as per the requirement. Sugar refining can be controlled by PLC as per the parameters set
according to process requirements.
 Figure 20. Vertical Continuous Centrifuge in Sugar Refinery
11.) Rotary Sugar Drying
Number of Equipment: 2

 The heat necessary to heat the weight of air (at air pre-heater) is given by:
𝑄1 = (𝑀) ∗ (𝐶) ∗ (𝑇1 − 𝑇𝑜 )
(1.5 ∗ 𝑃 ∗ ℎ)
𝑀= = 7.75 𝑘𝑔/𝑠
𝐻1 −𝐻0
where: 𝐻1 &𝐻0 , 𝑤𝑎𝑡𝑒𝑟 𝑐𝑜𝑛𝑡𝑎𝑖𝑛𝑒𝑑 𝑖𝑛 𝑠𝑎𝑡𝑢𝑟𝑎𝑡𝑒𝑑 𝑎𝑖𝑟 𝑎𝑡 𝑒𝑥𝑖𝑡 𝑎𝑛𝑑 𝑒𝑛𝑡𝑟𝑦, 𝑟𝑒𝑠𝑝𝑒𝑐𝑡𝑖𝑣𝑒𝑙𝑦
From Handbook of Hugo(1986), H1=0.082 & H2 =0.022
𝑃 = 𝑠𝑢𝑔𝑎𝑟 𝑡𝑜 𝑏𝑒 𝑑𝑟𝑖𝑒𝑑 = 1 𝑘𝑔/𝑠
ℎ = 𝑠𝑢𝑔𝑎𝑟 𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒 𝑐𝑜𝑛𝑡𝑒𝑛𝑡 = 0.31
𝑘𝐽
𝐶 = 𝑠𝑝. ℎ𝑒𝑎𝑡 𝑜𝑓 𝑎𝑖𝑟 = 1
𝑘𝑔 − 𝐾
 𝑘𝑔 𝑘𝐽
𝑄1 = 7.75 (1 ) (50 − 30)𝐾 = 155 𝑘𝑊
𝑠 𝑘𝑔 − 𝐾
 The heat necessary to remove moisture content contained in the sugar is given by:
𝑄2 = (𝑀) ∗ (𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒 𝑐𝑜𝑛𝑡𝑒𝑛𝑡) ∗ [607 + 0.3(𝑇1 − 𝑇𝑜 )]
𝑚 = 𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑠𝑢𝑔𝑎𝑟 𝑡𝑜 𝑏𝑒 𝑑𝑟𝑖𝑒𝑑 = 1 𝑘𝑔/𝑠
𝑀 = 𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒 𝑐𝑜𝑛𝑡𝑒𝑛𝑡 𝑜𝑓 𝑠𝑢𝑔𝑎𝑟 ∗ 𝑚 = 0.31 𝑘𝑔/𝑠

𝑄2 = (0.31) ∗ [607 + 0.3(50 − 30)]

𝑄2 = 191 𝑘𝑊

𝑇𝑜𝑡𝑎𝑙 𝑒𝑛𝑒𝑟𝑔𝑦 𝑜𝑛 𝑑𝑟𝑖𝑒𝑟 = 𝑄1 + 𝑄2 = 𝟑𝟒𝟔 𝒌𝑾𝒉 𝒑𝒆𝒓 𝒅𝒂𝒚

12.) Decolorizer

Tin = 25℃
Tout = 82℃
Operating Pressure = 1 atm

25 + 82
𝑇𝑎𝑣𝑒 = = 53.5℃
2
In the range of 0 to 100℃, the equation of Maczelka (1962) can be used to estimate the
specific heat capacity:

𝑘𝑐𝑎𝑙
𝑐𝑝 ( ) = 0.2712 + 0.00103 ∗ 𝑇𝑎𝑣𝑒
𝑘𝑔 − 𝐾
𝑘𝑐𝑎𝑙
𝑐𝑝 ( ) = 0.2712 + 0.00103 ∗ 53.5 = 0.3263
𝑘𝑔 − ℃
𝑘𝑐𝑎𝑙 4.1868 𝑘𝐽 𝑘𝐽
𝑐𝑝 = 0.3263 𝑥 = 1.366
𝑘𝑔 − ℃ 1 𝑘𝑐𝑎𝑙 𝑘𝑔 − ℃

𝑄 = 𝑚𝑓 ∗ 𝑐𝑝 ∗ ∆𝑇
𝑘𝑔 1.366 𝑘𝐽
𝑄 = 2.228 𝑥 𝑥 (82 − 25)℃ = 𝟏𝟕𝟑. 𝟒𝟖 𝒌𝑾 − 𝒉 𝒑𝒆𝒓 𝒅𝒂𝒚
𝑠 𝑘𝑔 − ℃

∴ Total electrical energy needed by the system is 217,562 kWh of energy and this is to be
supplied by the neighboring power plant in the ecopark.
 Table 5. Summary of Power Consumed of all the processes in Sugar Refinery in kW-h
per day
Process Unit Power Consumed (kWh per day) % Consumption %Consumption
(industrial)

Sugar Cane Plantation 13741.7 76.872 -

Sugar Cane Milling 500 2.797 12.093

Mixing 0.197 0.001 0.005

Clarification 1 98.5 0.551 2.382

Clarification 2 98.5 0.551 2.382

Filtration 1 904.11 5.058 21.866

Filtration 2 904.11 5.058 21.866

Cooling Tower 314.4 1.759 7.604

Evaporation 1 152.08 0.851 3.678

Evaporation 2 152.08 0.851 3.678

Vacuum Boiling 0.34 0.002 0.008

Crystallization 1 16.07 0.090 0.389

Crystallization 2 16.07 0.090 0.389

Centrifugation 1 37.6 0.210 0.909

Centrifugation 2 37.6 0.210 0.909

Centrifugation 3 37.6 0.210 0.909

Drying 1 346 1.936 8.368

Drying 2 346 1.936 8.368

Decolorization 173.48 0.970 4.196

Total 17876.437 100% 100 %

Table 6. Summary of Power Consumed of all the critical processes in the industrial stage
in kW-h per day
Critical Processes Power % Consumption
Consumed
(kWh/d)
Milling 500 12.09
Filtration 904.11 21.87
 Cooling Tower 314.4 7.6
Drying 346 8.37

Comparison of Energy Consumed

Sugar Cane Plantation
Milling
Mixing
Clarification 1
ClarIfication 2
Filtration 1
Filtration 2
Cooling Tower
Evaporation 1
Evaporation 2
Vacuum Boiling
Crystallization 1
Crystallization 2
Centrifugation 1

Figure 2. Breakdown of Energy Consumed of all the processes; More than three quarters are
occupied by sugarcane plantation

COMPARISON OF CRITICAL PROCESSES

Drying
17% Milling
24%
Cooling Tower
15%

Filtration
44%
 Figure 3. Breakdown of Energy Consumed of the critical processes in industrial stage; Rotary
Vacuum Filtration (44%) being the highest, followed by Milling (24%), Drying (17%), and lastly
Cooling Tower (15%).

COMPARISON OF POWER REQUIREMENT

25.000

20.000
% Consumption

15.000

10.000

5.000

0.000

Figure 4. Breakdown of Energy Consumed of all the industrial processes; Filtration (21.9%) and
Sugarcane Milling (12.09%) being the hotspots for the category of energy requirement
Determination of Hotspots
Summarized on Table 7 are the identified hotspots and the respective concerns as to why
they are determined to be hotspots.

Table 7. Hotspots of the Sugar Refinery Plant

Hotspots Concern

Rotary Vacuum Filtration (21.9%)  Highest Energy Consumption among

industrial processes

Sugarcane Plantation and Harvest  Highest Energy Consumption excluding

agricultural stage (76.87%)
 Highest rate of resource (Water) consumption
(2000 m3 for one year)

Mixing (with Preheating & Sulfur Combustion)  Highest Amount of Criteria Pollutants
(12.88%)

Crystallizer-Centrifuge  Highest Waste Water Effluent (99.93%)

Clarification 2  Highest amount of BOD & COD

(0.19 kg/h & 0.26 kg/h)
 Highest rate of resource (Water) consumption
in industrial stage
(1250 kg/h)
 Highest rate of resource (Lime) consumption
(2500 kg/h)

Rotary Vacuum Filtration  Highest rate of SW & HW generation

(3636.1 kg/h of mill mud containing Nitrogen
and Sulfur containing compounds)