JUICE BOILING

The boiling section comprises of the pans (A, B, and C pans) and the centrifugals (A, B, C
centrifugals). In this section, the syrup from evaporator 4 is concentrated to form massecutes.
The optimum concentration of syrup at which to make the change from multiple effect to
vacuum pans is approximately 60-68% brix. Care is taken not to over-brix as it may lead to brix
that is too viscous to be pumped by the pumps.
Pans
Nzoia Sugar Company has three types of pans. A pans are used to boil A sugar, B pans boils B
sugar and C pans boil C sugar. Pans 4, 5, 6 and 7 are in the A station boiling A sugar. Pans 1,2
and 3 are in the B station and boils B and C sugar. Pan 1 is specifically meant for boiling C sugar
and for granulation purposes. Pan 2 is a multipurpose pan; that is, it can be used in boiling B and
C sugar depending on preference. However, pan 3 is specifically meant to boil B sugar.
A strike in pan 1 can discharge in C massecuite crystallizer 1, 2 and 3. Pan 2 can either discharge
in C4 massecuite crystallizer (if it is used to boil C sugar) or B1 massecuite crystallizer (if it is
used to boil B sugar). Pan 3 specifically discharges in B massecuite crystallizers 2 and 3.
Process flow in the Boiling section
The syrup leaves evaporator 4 with a brix of around 60-68%. The syrup is pumped into liquor I
tank in the A station. The syrup is boiled to in the A pans to obtain A massecuite for separation
in the A centrifugals to obtain wet sugar and A molasses. For effective and fast boiling sugar in
the A pans, B Magma from the B fugals is used as a seed. The seed acts as crystallization points
where sucrose from the syrup get attached to form large sugar crystals. The wet sugar from A
fugals is conveyed to the rotary drum drier for drying and packaging. The A molasses with a
purity of around 75% is pumped into liquor II and III tanks. The B pans receive the molasses
from liquor II and III tanks together with C magma from C magma receiver. The Magma acts as
the seed in the B pans while the A molasses is the source of sucrose. The sucrose in A molasses
attach themselves in C magma seed to form large crystals for separation in the B fugals. After
boiling, B massecuite is discharged into B massecuite crystallizer, from where the massecuite is
pumped into the pug mill in the B station for separation. The magma from the B fugals is
pumped into the magma receiver in the A station for use as a seed in the A pans. B molasses
from B fugals is pumped into liquor IV tank. B molasses is further boiled in C pans to obtain
more sucrose. The C pans are supplied with granulated sugar at 130HL. The granulated sugar is
built in the C pans. After boiling in the C pans, the C massecuite is released into the C
massecuite crystallizers. The massecuite is pumped to the pug mill in the C station for further
separation in the C fugals. The process flow in the boiling section is shown in the figure
belowEvaporator 4
This is the final evaporator where evaporation takes place. The syrup leaves the evaporator with
a brix of between 60-65%. The operator must ensure that the syrup does not over-brix as over-
brixing of the syrup will make it block pipes when it is being pumped to liquor 1 tank for
storage. Similarly, it becomes more difficult for the sugar boiler to obtain a regular grain.
Operation conditions in the last evaporator
  Exhaust steam pressure - 18 - 22psi (1.2 - 1.5 bar)
 Exhaust steam temperatures-125 - 130ºC.
 Vacuum on the last body 18 – 25 inches’ hg
Technical specifications of the evaporator 4
 Evaporation surface: 500 M2
Key performance indicators
 Raw syrup brix (60o – 68o brix)
 Condensate quality (sugar trace free, temperature ≥85oC)
 Condensate quantity – (≥40 m3/hr)
 All condensate from body No.1 and No.2 is supplied to the boilers at a minimum flow
rate of 40.0m3 per hour
Syrup storage
The syrup is pumped into liquor 1 tank. The tank stores/temporary hold the syrup before boiling
in the A pans. Care should be taken not to contaminate the syrup when in liquor 1 tank.
Similarly, inversion should be avoided. Inversion of sugar can be minimized by adding
chemicals like chlorine or biocide. It can also be minimized by ensuring that there is minimal
storage of syrup in the tank. The smaller the time taken in the liquor tank, the smaller the
inversion and vice versa.
Technical specifications
 Syrup tanks (Liquor 1): 100 M3
A-Boiling
A-boiling is done in A pans. Nzoia Sugar Company uses pans 4,5,6 and 7 for boiling A sugar.
The vessels are used to concentrate the syrup to the required brix and crystal size. When juice is
concentrated, its viscosity rises rapidly with brix and crystals begin to appear and the nature of
the material changes: it passes progressively from the liquid state to a part-solid, part-liquid
condition. It loses its fluidity more and more. It is then called massecuite