2020 International Conference for Emerging Technology (INCET)

Belgaum, India. Jun 5-7, 2020

Modeling and Optimization of Evaporation

Process in Sugar Industries
Sebastian George Kyatanavar D. N.
Professor, Director,
Sanjivani Engineering College, Sanjivani Engineering College,
Kopargaon Kopargaon
SPPU, Pune, India SPPU, Pune, India
seb.jessy@rediffmail.com

Abstract – Model preparation of evaporation process and Conventional control mechanisms like PID controllers do not
optimizing the same have been a challenging task for researchers. yield good result in controlling this process [12]. Hence,
Evaporation process in sugar industries is characterized by its controlling and optimizing the performance of evaporation
highly non-linear nature and conventional control strategies do process in sugar plants have become a hot topic for researchers
not yield good results for the control of the same. With the for many years.
evaporator being the most energy consuming unit in sugar
manufacturing process, it has direct impact on sugar quality as A control scheme using a real time simulator was designed
well as steam economy. In this paper, a simulation model of an and implemented by K. M. Nielsen et al [2] for an evaporator
evaporator having four effects has been developed in Simulink. having five effects. With little modifications, it was later
For optimizing this model, Taguchi technique combined with implemented in a Danish sugar plant. For a quintuple
Grey relational analysis has been employed. The level of evaporator, three different control strategies viz. Generalized
influence of variables like Temperature of the feed, Rate of flow Predictive Control, Linear Quadratic Gaussian and Internal
of the feed and Rate of steam flow, on the steam economy and Model Control were proposed by Lissane Elhaq et al [1]. For
sugarcane juice concentration has been determined using brix control, a Model Predictive Control scheme was proposed
ANOVA (Analysis of Variance). Minitab 17 software has been by P. D. Smith et al [3]. Arvin V. Pitteca et al conducted
used for this. Finally, the relative contribution of each process studies on how to model a quintuple effect evaporator and
parameter on the performance characteristics of the evaporator
optimized the model with genetic algorithm [4]. The same
has also been determined.
authors also designed a Fuzzy based control scheme in
Keywords— Analysis of Variance; Grey relational analysis; MATLAB for controlling the evaporator operation [5]. Raghul
Multiple effect evaporator; Optimization; Taguchi Technique R. et al [6] made a study of the behaviour of an evaporator
under auto-tuned PID controller and Fuzzy controller
I. INTRODUCTION A. MEE Operation
Evaporators are employed in many process industries for An evaporator chain having four effects, employed in the
concentrating a solute with non-volatile nature and a solvent sugar industry is selected here for analysis. Figure 1 shows the
like water which is volatile. With evaporation of the solvent, same pictorially.
the concentration of the solution increases. Usually, steam is
used as the heating medium for carrying out this operation. In
the evaporation process, no attempt is made for separation of
vapour components. Hence it is distinct from distillation. As
the residue is always a liquid, the process is not drying also. It
is different from crystallization even as the objective here is
concentrating a solution and not making crystals.
Among the various unit operations in a sugar plant,
evaporation process is the most energy consuming one. It
involves concentration of the sugarcane juice by addition of
heat energy. Economy of the sugar production is heavily
dependent on this process as large volume of steam is needed
in it [1]. The evaporator usually raises the concentration of
sugarcane juice (brix value) from a nominal value of 20% to a
Fig. 1. Evaporator Chains
high value of say, 65% [2].
II. MULTIPLE EFFECT EVAPORATORS (MEE) Different process parameters associated with this system
are listed below.
Evaporators are usually employed in multiple effects as
steam is removed only up to certain extent in each of these TF – Temperature of the feed (0C)
effects [14]. The brix value increases in a progressive manner CF – Feed specific heat (kcal/kg 0C)
as the sugarcane juice passes through each effect.
mF – Feed flow rate (kg/hr)
Modeling and control of MEE in sugar industries have been
a difficult task. The operation is highly complex and large TS – Temperature of steam (0C)
number of interactions exist between the process variables.
mS – Steam flow rate (kg/hr)

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 S– Latent heat of steam (kcal/kg 0C)
mP – Product flow rate (kg/hr)
mE – Water evaporated (kg/hr)
The specific heat of the products in the four effects of the
evaporator are denoted as CP1, CP2, CP3 and CP4. Similarly,
condensate specific heat in multiple effects 1 to 4 are CC1, CC2,
CC3 and CC4
The dynamics of the MEE is characterized by number of
variables at each effect. Correlation among these variables
exists through the mass balance and energy balance attributed
to Feed flow, Vapour flow and Product flow. The basic
equations describing the balance of mass and energy at the four
effects can be written as follows [8].
For first effect:
mF = mP1 + mE1
[mF*CF*ΔT] + [mS*λS] = [mC1*CC1*ΔT] +
[mP1*CP1*ΔT] + [mE1*λE1]
For second effect:
mP1 = mP2 + mE2
[mP1*CP1*ΔT] + [mE1*λE1] = [mC2*CC2*ΔT] +
[mP2*CP2*ΔT] + [mE2*λE2]
For third effect:
mP2 = mP3 + mE3
[mP2*CP2*ΔT] + [mE2*λE2] = [mC3*CC3*ΔT] +
[mP3*CP3*ΔT] + [mE3*λE3]
For fourth effect:
mP3 = mP4 + mE4
[mP3*CP3*ΔT] + [mE3*λE3] = [mC4*CC4*ΔT] +
[mP4*CP4*ΔT] + [mE4*λE4]
In these set of equations, ΔT represents the temperature
difference in each effect of the evaporator. The latent heat of
water evaporated in the four effects are denoted by E1, E2,
E3 and E4.
For determining the values of Steam Economy (SE) and
brix, the basic equations are:
mS = mE / SE
For calculating brix per each effect;
xnew = (rate of flow of feed to corresponding effect*xold) /
(rate of flow of product from corresponding effect) (10)
The brix value of the feed is usually 20%.
B. Modeling
As part of the data collection, a quadruple effect evaporator
installed in the sugar industry was studied extensively. A
Simulink model was then be developed based on these data and
above equations [7]. A summary of MEE parameter values at
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multiple effects is given in Table I. But it was found that there
is disagreement between the model predicted values of the
evaporator parameters with their actual values obtained from
the sugar industry. This is because of the fact that the steam
coming out from different effects are used not only for the
evaporation of the feed to the subsequent effect, but also for
various other purposes like pan washing, juice heating, vent
and radiation losses etc. Considering these additional
utilizations of the steam, the Simulink model has been
modified as shown in Figure 2.
Similar models were developed in the earlier works carried
out by the authors [12] on modeling of MEE and it was found
that the model predicted values of the evaporator parameters
agree with the values obtained from the sugar industry.
TABLE I. MEE PARAMETER VALUES
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Fig. 2. Simulink Model
(8) III. OPTIMIZATION
Proper tuning of model parameters becomes essential to
avoid disagreement between model anticipated steady state
values of the output parameters and that obtained from the
process plant [5]. In case of an evaporator, such a tuning is
very difficult as there are severe interactions of mass and
energy among the different effects. Hence, certain techniques
should be evolved for extracting the process parameters to get
the model optimized.
(9)
While conducting a run on any process, the first task is to
find out which process variables affect its response. The next
step is to find out the most favourable combination of such
variables to get the finest possible response [11]. As an
example, if the Steam economy of an evaporator is considered
as the response variable, we would seek a region of maximum
economy. The Taguchi technique proposed here is a powerful
statistical tool in such situations for determination of optimum
parameter combinations and relative contributions of the same.
A. Taguchi Approach
Taguchi method, basically an analytical means, has now
become a very popular optimization technique in many
engineering problems [10]. In this technique, the process then done through average of Grey relational coefficients
parameters are first identified and then bifurcated into control concerned with selected responses.
and noise factors. A set of trials are then conducted using
Orthogonal Arrays, the results of which are used for the In this study, the Grey relational analysis is applied to
optimization of the process. With the Orthogonal Arrays, the examine the influence of evaporator parameters on Steam
study of complete parameter space is facilitated with quite a economy and brix value. Experimental data have been
few numbers of experiments to be conducted. normalized to obtain Grey relational generation. While
selecting the normalization equations, larger-the-better
The Taguchi method recommends the use of loss functions criterion has been chosen for steam economy and specific
which are then transformed into signal-to-noise (S/N) ratio. target value criterion has been selected for brix. The
Three basic categories are prescribed for the analysis of S/N normalization equations are [15]:
ratio: Larger-the-better, Smaller-the-better and Nominal-the-
best. In the evaporation process under consideration here, the ୷౟ ሺ୩ሻି୫୧୬୷౟ ሺ୩ሻ
response parameters of concern are Steam economy and brix š୧ ሺሻ ൌ (11)
୫ୟ୶୷౟ ሺ୩ሻି୫୧୬୷౟ ሺ୩ሻ
value. The Taguchi method has been applied for improving
both these parameters. for larger – the – better criterion
B. Taguchi Trials
ȁ୷౟ ሺ୩ሻି
୓୆ȁ
The Simulink model developed earlier has been subjected š୧ ሺሻ ൌ (12)
୫ୟ୶ሼ୫ୟ୶୷౟ ሺ୩ሻି୓୆ǡ୓୆ି୫୧୬୷౟ ሺ୩ሻሽ
to the Taguchi trials based on L9 Orthogonal Arrays. The
experimental runs and results obtained from the trails are for specific target value criterion.
summarized in Table II.
xi(k) - Normalized value of experimental data.
TABLE II. RESULTS OF TAGUCHI TRIALS
min yi(k) and max yi(k) are the smallest and largest values
respectively of the kth response.
OB – Specific target value for the response. Here it is 0.65
for the brix.
The Grey relational coefficient is then determined by

(13)

ο୭୧ - ȁͳ െ š୧ ሺሻȁ (14)

ψ is the distinguishing coefficient the value of which is
taken as 0.5 throughout.
IV. INTEGRATED TAGUCHI GREY RELATIONAL
ο୫୧୬  and ο୫ୟ୶ are the smallest and largest values
APPROACH
respectively of ο୭୧
Though the Taguchi technique is a very powerful tool for
optimization, this method used alone is more or less confined The Grey relational grade gi is determined as:
to optimization problems having lone performance component ଵ
‰୧ ൌ σ୬୩ୀଵ Ɍ୧ ሺሻ (15)
[13]. For dealing with multiple performance attributes, ୬
integration of Taguchi method and Fuzzy set theory is a much where n is the number of responses.
powerful solution. The theory of Fuzzy logic introduced by Table III summarizes the Grey relational grades associated
Zadeh in the mid-1960s, furnishes a depiction blueprint to deal with different trials conducted based on the L9 orthogonal
with uncertainties in real time. In the optimization technique arrays [9].
proposed by the authors [14] by integrating Taguchi method
and Fuzzy logic, a multi-response performance index (MRPI) TABLE III. GREY RELATIONAL GRADES
was calculated. The trial run having larger MRPI gives
optimum performance characteristics. Here, an alternative
technique based on integrating Taguchi method with Grey
relational analysis has been proposed.
A. Grey Relational Analysis
The Grey relational analysis proposed by Deng [17] is very
much effective in handling uncertainties occurring in process
models. It also helps in analyzing relations between process
variables. In this method, the experimental data are first
normalized in the range 0-1. This is called Grey relational
generation. From the normalized data, the Grey relational
coefficient is calculated. The correlation between actual
experimental data and desired data is represented by this
coefficient. Calculation of the overall Grey relational grade is

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 The Grey relational analysis effectively converts a multiple
response optimization process into a single response
optimization problem [15]. The overall performance
characteristics of the process is dependent upon the calculated
value of Grey relational grade. The optimal parametric
combination corresponds to the highest value of the Grey
relational grade [16]. It can be observed that Trial No. 9 has the
largest value of Grey relational grade.
B. Connotation of ANOVA
Analysis of Variance (ANOVA) has been employed for
determining the response of response magnitudes obtained Fig. 5. Grey relational grade vs. Feed flow rate
from the experiments conducted as per the Orthogonal Arrays
[10]. This technique, originally developed by Fisher, is highly The relative contribution of each parameter is clear from
useful in the proper interpretation of experimental data. In this the ANOVA results shown in Table V.
context, ANOVA facilitates the investigation on how different
TABLE V. ANOVA RESULTS
parameters affect the evaporator performance. Here, the total
variability in Grey relational grade is separated into different
parameter contributions as well as error [18].
In fact, all the three process variables of the evaporator
considered here which are Temperature of the feed, Rate of
feed flow and Rate of steam flow, have three levels. These
levels are given in Table IV.

TABLE IV. GREY RELATIONAL RESPOSNSE TABLE

Here, the software Minitab 17 has been chosen for the

purpose of ANOVA and for drawing the Response table. A pie
chart has also been prepared as shown in Figure 6 on the
relative contribution of different parameters based on the
ANOVA results.
The same has been indicated graphically in Figure 3, 4 and
5.

Fig. 3. Grey relational grade vs. Feed temperature

Fig. 6. Relative Parameter Contribution

V. RESULTS AND INFERENCES

The Grey relational grade is a clear representation of the
correlation between the reference and comparability sequences.
The stronger the correlation between the comparability
sequence and reference sequence, the larger the value of the
Grey relational grade. Thus, this study helps in the selection of
the combination of levels which provides the highest average
response. It can be found from Table III that Trial No. 9
accounts for the maximum value of the Grey relational grade,
which is 0.5. the brix value for this trial is found to be 64.47%.
This is highly appropriate as far as the working of the MEE is
Fig. 4. Grey relational grade vs. Steam flow rate
concerned. The Steam economy found as 2.67 is also highly
reasonable in this case. Hence, the parameter settings of Trial
No. 9 can be considered as the optimized values for attaining
better performance characteristics of larger Steam economy
and nominal brix value.

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 Once the optimum settings are found, the remaining task is
to investigate into the relative influence of each parameter on
the evaporator performance. This information can be found out
from the ANOVA results shown in Table V. As indicated in
the pie chart, the most influential variable is the Feed
temperature (73.79%) followed by steam flow rate having a
low contribution level of 13.36 %. The least influential
parameter among the three is the Feed flow rate with a
contribution level of only 6.25%.
VI. TEST FOR CONFIRMATION
Like any other optimization technique, the final step in the
Taguchi method is also to conduct the confirmation test. This
will verify the improvement in the performance of the process
under the optimum settings identified. In fact, most of the
applications of Taguchi technique are in the manufacturing
processes like machining, welding, milling etc. where
conduction of such a test is very much feasible. But that is not
the case in this process. Considering the specific nature of
sugar industries, it is not possible to go for a confirmation test
on the evaporator system with the determined optimum
parameter settings when the plant is running. As an alternative
method, the accuracy of the results obtained has been examined
by experts from different sugar industries. These experts have
tremendous experience on the evaporation systems and their
opinion can be treated as confirmation of the optimum settings.
There will be certain degree of uncertainty as no practical tests
have been conducted for confirmation.
VII. CONCLUSION
In this paper, a mathematical model based on mass and
energy balance has been attempted for multiple effect
evaporator employed in sugar plants. An analytical model has
been prepared in MATLAB and a Simulink file has been
prepared in accordance with the data obtained from the sugar
mills. The model has then been later optimized using integrated
Taguchi Grey relational method. The overall Grey relational
grade has been taken as the performance feature. Effectively,
this approach has converted a multi-response optimization
issue of an evaporator into a specific performance optimization
case. Through ANOVA, the relative influence of different
parameters of the evaporator viz. Temperature of the feed, Rate
of feed flow and Rate of steam flow on the performance
characteristics of the evaporator system has also been analyzed.
Minitab 17 software has been employed for the same.
While going for the integrated Taguchi Grey relational
approach, equal weight was assigned to both the brix and
Steam economy which are the quality indicating parameters.
But it is not necessary that all such quality indicating
parameters will have the same weight. It may vary from case to
case and there are no standard guidelines for assigning such
weights. More or less, it is left to the judgement and
understanding of the decision maker while designing the
experiments. This can sometimes cause uncertainties on the
optimum solutions. Another problem may arise because of the
existence of correlation between the different quality indicating
parameters. If there is any change in one of such parameters,
other parameters also may change significantly. To tackle such
issues, Fuzzy integrated Grey Taguchi method will be highly
useful [19]. Though this is beyond the scope of this paper,
further research can be undertaken on this area for optimization
of the MEE.
Many techniques developed for controlling and optimizing
the performance of evaporators are closely related. New
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control strategies have evolved to minimize consumption of
energy as well as to improve sugar quality. Soft computing
tools like Artificial neural networks, Fuzzy set theory and
Genetic algorithms are very powerful tools in designing
advance control systems for MEE operations. The optimized
models may be tested under such environments which is
another promising area of research.
ACKNOWLEDGMENTS
The authors place on record their deep sense of
appreciation to the support extended to this work by Sanjivani
(Takli) Sahakari Sakhar Karkhana Ltd., Sahajanandnagar,
Kopargaon, MS, India. Frequent visits were carried out to this
industry for understanding various processes involved in
manufacturing sugar. The evaporator station at the sugar
industry was also studied.
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