SUGAR REFINERY by Crystal Amazons

1.) 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
 SUGAR REFINERY by Crystal Amazons

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
SUGAR REFINERY by Crystal Amazons

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

Decolorization 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
SUGAR REFINERY by Crystal Amazons

DESIRED LOCATION IN THE ECO-PARK

Near the following plants:
a. Distillery – The sugar manufacturing plant will be providing the molasses for this plant
b. Soft drinks manufacturing plant - The sugar manufacturing plant will be providing the sugar for this plant
c. CO2 purification plant - The sugar manufacturing plant will be utilizing the CO2 purifier in the plantation and other processes
such as clarification.
d. Fertilizer manufacturing plant - The sugar manufacturing plant will be using fertilizer from this plant.

Our industrial plant is in most suitable area for planting with a soil of Lugo Clay

PRODUCTION CAPACITY

Component Amount Destination

10,000 kg cane/(hour-farm)
Sugar cane entering mill Sugarcane yield per day: 400,000 kg -
Sugarcane required for refinery: 10,000 kg
Softdrinks, Packaging Department
Refined Dried Sugar 8000 kg/day
Distillery
Molasses 14,400 kg/day
Softdrinks, Packaging Department
Refined Sugar 18837.44 kg/d
SUGAR REFINERY by Crystal Amazons

2.) Energy

AMOUNT OF STEAM
PROCESS POWER REQUIREMENT (kWh/day) FUEL CONSUMPTION (KG/D)
SUGAR CANE PLANTATION 13741.67 DIESEL
MILLING 500 DIESEL
CANE JUICE MIXER 0.197 STEAM & DIESEL 9051.2
CLARIFIER 197 DIESEL
ROTARY VACUUM DRUM FILTER 1808.22 DIESEL
COOLING TOWER 314.4 DIESEL
EVAPORATOR 2433.28 STEAM & DIESEL 113,760
VACUUM BOILING PAN 2.72 STEAM & DIESEL
CRYSTALLIZER 32.14 STEAM & DIESEL 21,024
CENTRIFUGE 112.8 DIESEL
SUGAR DRYER 692 DIESEL 223,200
DECOLORIZER 173.48 DIESEL
TOTAL 20,007.91 kWh per day 367,035.2
SUGAR REFINERY by Crystal Amazons

*Energy Requirement for Office

Energy Required Energy Required (kWh per
Category Type (kW) day)
Lighting
60 W Light Bulb Incandescent x
50 3 72
Cooling
Convinience
Fan x 30 2.25 18
Air Conditioner x 15 60 480
Monitoring 0
Laptops x 10 1 8
Desktop with Printer x 50 22.5 180
Kitchen Appliances 0
Coffee Maker x 5 7 56
Food Blender x 5 2 16
Fridge/Freezer x 5 2 16
Microwave x 5 8.5 68
Rice Cooker & Stove x 5 6.25 50
Internet
Connection
Internet Router x 10 0.15 3.6
Charging Station 0
Smart Phone x 100 0.7 16.8
Tablets x 50 0.75 18
Total Power Required 1002.4 kWh per day
SUGAR REFINERY by Crystal Amazons

∴ Summary of Power Requirement for the Whole Manufacturing Plant

Areas Process
Requirement (kWh
per day)
Manufacturing Plant 20,007.91
With steam requirement of 367,035.2kg/day
Offices* 1002.4
MRF 1969.4306
Total 22,979.7406
kWh per day
SUGAR REFINERY by Crystal Amazons

3.) SOLID WASTES

Solid Process Type Pre- Disposal ( slf- Amount

Waste (hazardous or treatment(if mrf-other
from plant not) hazardous) industry)
To be treated
Silt HW for fertilizer MRF IN SUGAR 9744.248
Sugar Cane use REFINERY
Dry Leaves Plantation & SW - 48,870.6624
Green Tops Harvesting SW - MRF IN SUGAR 20,944.5696
REFINERY
To Biodiesel
Plant 45,211.9575
Bagasse Milling SW - To Steam
Generation 25,388.78
To Composting 49,399.2625

Mill Mud Filtration 1 HW To be treated To MRF IN 58,177.6

for fertilizer SUGAR
use REFINERY
To MRF IN
Filter Sludge Filtration 2 SW - SUGAR 6740.96
REFINERY
Bone Char Decolorization SW - To MRF IN
SUGAR 21,388.8
REFINERY
TOTAL 285,866.8
Solid waste Process Type Pre- Disposal ( slf- Amount
from offices (hazardous or treatment(if mrf-other
not) hazardous) industry)
Rice FW from the 5 NOT N/A SLF 14.544
major offices
Vegetables 4.848
SUGAR REFINERY by Crystal Amazons

Meat 4.848
Fruits 4.848
Powder 2.424
Watery 7.272
Particles
Food Remains 9.696
(Buto, tinik)
Plastics Bags Wastes from NOT N/A To MRF OF 2.424
the 5 major ADMIN
offices (recyclable)
Plastics Sheets Wastes from NOT N/A To MRF OF 3.636
the 5 major ADMIN
offices (recyclable)
Dry Papers Wastes from 6.402
the 5 major NOT N/A To MRF OF
Cartons 4.268
offices ADMIN
Paper Bags (recyclable) 1.067
Tin Cans Wastes from To MRF OF 2.968
the 5 major NOT N/A ADMIN
Aluminum 4.452
offices (recyclable)
Cans
R&D; To MRF OF
PPEs Manufacturing NOT N/A ADMIN 144.29
Plant; Control (recyclable)
Room;
Canteen
Batteries 13.6475
To MRF OF
Fluorescent 13.6475
Wastes from Sugar Refinery
Bulbs
the 5 major HW N/A (nearest HW
Broken Glass 13.6475
offices Treatment
Broken Facility) 13.6475
Ceramics
SUGAR REFINERY by Crystal Amazons

TOTAL 272.577
SUGAR REFINERY by Crystal Amazons

4.) Waste Water

Process @ Composition/Parameters Pretreatment Composition Final effluent Final effluent to

plant (kg/day) (if needed) after treatment amount (to be recycled
(kg/d)/(ppm) wwtp) Amount (Back to
your plant)
Manufacturing Nitrates-9.84 kg/d
Plant Phosphorus-0.276 kg/d
BOD-5.36 kg/d Physical &
COD-6.576 kg/d Biological N/A 114,892.2 N/A
TDS-47,912.176 kg/d Pretreatment
TSS-1.44 kg/d
Grease/Oil-9.6 kg/d
Water-66,946.9 kg/d
From Offices Composition/Parameters Pretreatment Composition Final effluent Final effluent to
(kg/day) (if needed) after treatment amount be recycled
(ppm) Amount (Back to
your plant)
Other Areas TDS-0.00642 kg/day N/A N/A 483.33 kg/d 483.33 kg/d
TSS-0.00257 kg/day (Class B) will go to
Nitrate-0.00051 kg/day plantation
Phosphorus-0.00015 kg/day
Chlorides-0.00077 kg/day
Alkalinity-0.00128 kg/day
Grease-0.001285 kg/day
BOD-0.00257 kg/day
Water-483.314 kg/day

*For more details about our waste water and air emissions leaving from manufacturing area, see the table below:
SUGAR REFINERY by Crystal Amazons

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 Amount (kg/h) Amount (kg/d) Concentration
Parameter (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
SUGAR REFINERY by Crystal Amazons

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

SUGAR REFINERY by Crystal Amazons

5.) Water

Process @ plant Class Source of water Amount (IN) Waste Water: OUT Composition Final effluent
(kg/d) after use amount (kg/d)
(kg/d)
Plantation B For Class B- 8000 Nitrates 9.84 OUT (WW):
Milling A Municipal Water 3200 Phosphorus 0.276 114,892.2
Clarification 1 A (recycled water) 3200 BOD 5.36
Evaporation A or rainwater 3200 COD 6.576
Cooling Tower A *For Class A- 3200 TDS 47,912.176 Class A Required:
Centrifugation A Municipal Water 39,802.4 TSS 1.44 52,602.4
Clarification 2 AA after WWTP 10,000 Grease/Oil 9.6 Class AA Required:
Decolorization AA (clean water) 3200 Water 66946.9 13,200
*For Class AA Class B Required:
-potable water 8000-483.33-3717 =
from purified 3799.67
drinking water
station

From offices Class Source of water Amount (IN) Amount(OUT) Composition Final effluent
after use: amount
Drinking AA For Class B- 202 Urine 202 None
Lavatories A Municipal Water 2515 Lavatories 2515
Cleaning/Watering A (recycled water) 1000 Cleaning/Watering 1000 Recycled Water:
or rainwater 3717 kg/d
*For Class A-
Municipal Water
after WWTP
(clean water)
*For Class AA
-potable water
from purified
drinking water
station
SUGAR REFINERY by Crystal Amazons

Number of Employees: 101

Number of vehicles (trucks): 12 trucks

To Distillery: 2 trucks
To Softdrinks: 2 trucks
To Biodiesel: 1 truck
Plantation: 2 trucks
To other consumers: 5

SCHEDULING

Harvesting months 5 months (December to April)

Working hours per day 8 hours per day (agricultural)
Working hours per day 24 hours per day (milling only)
Working hours per day 8 hours per day (refinery)
Working days per month 22 days
Working days per year 264 days
Maintenance days per year 12 days (Once a month)
Number of Employees 101
SUGAR REFINERY by Crystal Amazons
SUGAR REFINERY by Crystal Amazons