TRAINING ON REFINE SUGAR

BOILING
FOR BELES SUGAR FACTORY
 Refining Qualities on Raw Sugar

• Refining :- Purification of sugar through re-

crystallizing and chemical and physical methods.
• For a refiner, raw sugar is the prime material, and
good refining quality of raw sugar is as important for
the refiner as good and fresh cane for the raw sugar
house.
• The purpose of affination is to remove as completely
as possible the impurities in the molasses film
surrounding the raw sugar crystal.
 CONT….
• There are two types of cane sugar refineries
1. Refineries operating in conjunction with a raw
sugar house, (Like Beles Sugar Factory)
2. Independent refineries which purchase raw
sugar from many raw sugar producers and from
different countries.
 CONT…

• Advantages of Factories with the back-end refineries

• Raw house can produce the type of raw sugar most
suitable for the refinery's requirements.
• All the material to be refined can be obtained from
“A” massecuites.
• The affination process, which is an expensive one,
can be eliminated as this step can be carried out in
the centrifugals.
• Al returns from the refinery can be sent back to the
raw house
 Process of refine sugar boiling
Refined sugar is produced from re-melted raw
sugar of good quality. The most popular
decolonization processes being:-
• Lime saccharate
• Phosphoric acid
• Talofloc
• Taloflote
• Sand Fileration
• Ion Exchange Resins
 Cont….
• Talofloc:
• Alternatively called color quest/ color precipitant/
surfactant, and the IUPAC name is dioctadecyl dimethyl
ammonium chloride.
• Color precipitants, which Talofloc is part of, must have
three properties for effective color removal.
• Strongly basic (cationic) centre that attach to anionic (-
ve) center of color molecule.
• Long chain or cyclic hydrocarbon which is hydrophobic.
• Readily dispensable in sugar solution.
• As most colloidal in sugar liquor carry –ve charges,
Talofloc reacts with and neutralizes these color body.
 Cont….
• Phosphoric Acid and Lime Saccharate: Lime as is so often
the case, corrects liquor PH and reacts with phosphate ion to
form an insoluble inorganic tricalcuim phosphate precipitate.
• This precipitate in turn bridges individual impurity particles
to form primary flocs.
• Taloflote:
• Is a high molecular weight anionic polyacrylamide used as
flotation aid.
• Due to its long chain and –ve charge in solution, this polymer
builds up large flocs which can be floated at much enhanced
velocity.
• The flocculant bridges between calcium ions in previously
formed precipitates, i.e. it provides secondary flocculation that
increases effective size and improve removal of precipitates.
• On top of that taloflote ensures air bubbles and flocs are
 Cont…
• Three stages in phosphoflotation process:
• The cationic surfactant (Talofloc) reacts with anionic
colorants to form insoluble precipitate.
• This precipitate is removed by calcium phosphate
forming ‘primary’ flocs.
• The anionic polyacrylamide flocculant (Taloflote) then
increases the effective size of the primary flocs by
concerning each other besides, to accelerate flotation
rate is it important to, after addition of polyacrylamide,
gently mix for a period of some few minutes.
 Cont….

• The raw sugar, after discharged from "A" centrifugal is

melted by steam and diluted by hot water to a Brix of 60-
65º in melter.
• Remelt liquor is sent to liquor storage tank, and then to
Direct contact heater where it is heated to 85ºc by exhaust
steam.
• From the heater the melt liquor goes to reaction tank.
• Talofloc and phosphoric acid are added prior to the
reaction tank, and lime saccharate at inside the reactor.
• After being agitated, it overflows to aerator tanks in which
air from compressor or rotating disk is injected to aid the
flotation process in the clarifier.
• At the very outlet of the aerator Taloflote is added.
 Cont…
• Up next, the content enters at the bottom of the
flocculation chamber which is a hollow cylindrical
part of the clarifier.
• Just inside the chamber an agitator provided to
enhance the flotation rate.
• After it is pretty well mixed, it overflows into the
flotation chamber.
• In Talo clarifier the separated impurities, called
scum floats on the top while the clear liquor called
fine liquor remains at the bottom of the clarifier.
 Cont….

• The scum is then removed intermittently by

scum rake/ scraper and sent to either mud
tank or defecation retention tank.
• The fine liquor, on the other hand, enters into
perforated (at the bottom most) down take-
shaped pipe lay inside the edge of clarifier.
• At one part, the pipe is extended up through
which fine liquor flows out of the clarifier to
storage tank below, after being adjusted by
the telescopic valve.
TALO Clarifier
 Refine boiling

• The fine liquor is transported to the supply tanks

of Refine pan station
• For boiling refine sugar here in Beles Sugar
Factory there are 6 Batch pans of having a
Capacity of 65ton each and the pans are
provided with mechanical stirrer .
 REFINE SUGAR BOILING SCHEME

SYRUP TANK FINE LIQUOR R1 RUN OFF TANK R2 RUN OFF TANK
TANK

R SEED CRYSTALLIZER

R1 Pan R2 Pan R3 Pan

Crystallizer Crystallizer
Crystallizer
ystalli

Batch Batch Batch

Centrifugal Centrifugal Centrifugal
R1 sugar R2 sugar

R3 Runoff to Raw
Fluidized Dryer
pan

R3 Sugar

3 Stage Sugar Grader

Dust sugar to seed Tank Sugar Bagging
 Cont…

Grain is made from fine liquor and refines seed.

•R1 Cuite is made from the prepared grain as
footing and by feeding Fine liquor
•R2 Cuite is made from the prepared grain as
footing and by feeding RO I (Run off 1)
•R3 Cuite is made from the prepared grain as
footing and by feeding RO II (Run off 2)
•Each strike is dropped to strike receiver and the
strike goes to centrifugal by gravity to separate
crystal from its mother liquor.
 Cont…

•The R1, R2, and R3 Cuites are single cured in

batch centrifugal where they are separated into R1
sugar & RO1, R2 sugar & RO2, R3 sugar & RO3
respectively. The refine sugar goes to drier for
drying while the R01, RO2 goes to refinery supply
tank to be used for R2 & R3 Cuite boiling and RO3
goes to raw sugar plant to be used for making A
grain.
•During centrifugation process, spray water is
applied to remove adhered molasses film from the
sugar crystal
 Overhead Storage Tanks
Fine Liquor overhead storage tank
 Fine Liquor inlet
 Fine Liquor outlet
 Vapour inlet
 Drain
 Level transmitte
Runoff 1, 2&3 overhead storage tank.
 Runoff 1, 2&3 inlet
 Runoff 1, 2&3 outlet
 Vapour inlet
 Drain
 Level transmitter(L.T
 Pan Supply Syrup ,Fine Liquor, Run Off (1,2,3)
Molasses & Wash Tanks.
Inlet

Syrup overhead
storage tank
Syrup inlet
Syrup outlet
Vapour inlet
Drain
Level transmitter

Out let
Batch pan for Refine R1,R2and R3 M/c Boiling

VAPOUR OUT

INLET :
Slurry/Seed
 Fine Liquor NON CONDENS GAS
Runoff -1,2
Hot water OUT :
Vapour R1,R2,R3 M/c
Wash steam (4 bar) Condensate
Cold water Vapour
Non Condense Gas
VAPOUR
CONDENSATE
FEED
R1,R2,R3 M/Cuite Out
•
REFINE-PAN

INLET
Fine liquor
Runoff-1 OUT :
Runoff-2 Refine Massecuite
Hot water Condensate Water
Steam wash(4 bar) Vapour
Refine seed
Non Condense
Slurry
Vapour Gas
 R1, R2 & R3 massecuite
In/out put materials Dropping& Feed brix Purity
R1 massecuite 86-88o 98±1
R2massecuite 87-89o 96±1
R3massecuite 88-91o 94±1
Refined undersize sugar magma 90±1 99.5±0.5
Feed syrup/melt brix 65-68o ≥84

Feed RO1, RO2&RO3 brix 70-75o 96,94,91 resp.

Feed RO1, RO2&RO3 temperature 65±5oC

Feed fine liquor 60-67o 97±1

Feed fine liquor temperature 75±5oC

Refine sugar Polarization 99.80 R1=30-40, R2=41-50

and R3=50-75
Refined Sugar Colour < 45 ICUMSA@ 420 µm
 Raw Sugar Quality Desired By the Refiner

• A Sugar that will “Wash” Well, i.e. give a maximum

yield of washed sugar of high purity with the use
of a minimum quantity of wash water in the
centrifugal, there by assuring a relatively small
amount of raw sugar wash of affination syrup.

• A Sugar of Good Filterability that will filter rapidly

in pressure filters and work well in the clarification
process.

• A Sugar of Low Color and of such composition

that it will decolorize readily.
 Causes of Poor Refining Quality

• Cane Variety Cane varieties are selected on the basis of

their agronomic characteristics and sucrose levels. The
important agronomic characteristics include yield, vigor of
growth, ratooning ability, tolerance of local climatic
conditions, and resistance to pests and diseases.
• Soil
• Cultivation
• Climate: Cane can be damaged by frost, cyclone and
drought
• Pests and disease such as white bugs, gumming diseases
• Abnormal delay between cutting and crushing
• Burnt cane, if the cane is snot and crushed within 48 hours
 CONT….
However, manufacturing methods play a great part in the
refining quality of the resulting sugars, the most
important steps being.
• Good mill/Diffuser sanitation
• Good clarification which involves good flow, temperature
and pH control of mixed juice. Proper addition of
flocculants.
• Appropriate boiling scheme
• Good sugar boiling , good purging in the centrifugals
 Sugar Production From Cane

 Raw sugar Colour (800---1000 ICUMSA@ 420 µm)

 Plantation White Sugar Colour(200 – 3000
ICUMSA@ 420 µm)-the process uses
sulfitation/carbonation
 Semi-Refined White Sugars Colour (100 – 2000
ICUMSA@ 420 µm)-by phosphor-defecation process
on remelted raw
 Refined Sugar Colour < 45 ICUMSA@ 420 µm
 Operational Parameters

 Vacuum in pan 625-650 mm of Hg

 Boiling time for refined massecuite/or sugar
boiling in vacuum batch pans
R1, R2 & R3 massecuite 2 -3 hours
 Cont…

In/out put materials Dropping& Feed brix Purity

R1 massecuite 86-88o 98±1
R2massecuite 87-89o 96±1
R3massecuite 88-91o 94±1
Refined undersize sugar magma 90±1 99.5±0.5
Feed syrup/melt brix 65-68o ≥84
Feed RO1, RO2&RO3 brix 70-75o 96,94,91 resp.
Feed RO1, RO2&RO3 temperature 65±5oC
Feed fine liquor 60-67o 97±1
Feed fine liquor temperature 75±5oC
 Cont…
Utilities Optimum Values
Vapour pressure 0.4-0.6 bar
Vapour Temperature 108-111oC
Service steam pressure 1.0-1.5 bar
Service steam temperature 120-130oC
Live steam pressure 4kg/cm2
Live steam temperature 140-160oC
Injection water temperature 30-35oC

Injection water header pressure >0.4bar

Tail water temperature 42.5±2.5oC
Movement water temperature 75±5oC
Vacuum Batch Pan Cleaning & Testing Procedure

• Cleaning Procedure
1) Discharge pan in crystallizer, wash it thoroughly with
vapour/live steam.
2) Close discharge valve, cut over valve, washing steam valve, air
breaker and washout valve.
3) Heat up pan with vapour up to 1000C+.
4) Open multi-jet condenser valve and establish vacuum in pan.
5) Open calanderia steam valve, and noxious Gas valves. Boil
pan for two hour.
6) Before vacuum breaking, clear wash out line, by back sucking
of air, now break the vacuum.
7) Send sweet water in raw juice tank slowly.
 Cont…
8) Cool pan and see scale intensity, if it is low clean pan by
brushing, though Turk head brush fitted on flexible shaft
connected to a 5 HP motor of 2900RPM. If scale intensity is
high, boil soda solution, drain it.
9)Wash pan thoroughly, cool it and brush it as described
earlier.
10) After brushing check cleaning of tubes, if some scale is
left re-clean it.
11) Wash pan with cold water thoroughly.
 Cont…

• Testing Procedure
1) Close condensate valve.
2) Fill up calanderia with water, till it comes out of vent.
3) Now check calanderia from inside and outside.
4) If any leakage is there, get it attended.
5) When calanderia becomes leak proof, close man holes, and
sight glasses.
6) Fill up water up to top glass level, check up body leaks if any,
attend it.
7) Drain body as well as calanderia water.
8) Close wash out and air vents. Now pan is ready for taking in
line.
 Cont…

Operating procedure
1) Ensure system is leak proof.
2)Wash/clean pan and cutover line with 4kg/cm2, /or
exhaust steam/1st vapor.
3) Close up cutover valve, wash out valve, and feed valves,
4) vacuum breaker valve and discharge valve.
5) Heat up pan with exhaust/vapour up to 1000C.
6) Open spray valve of condenser and then jet valve, in case
of multi -jet condenser.
 Cont…

7) Establish 625-650 mm of Hg vacuum in pan.

8) For grain preparation open main feed valve of pan.
9)Take medium i.e. syrup or molasses or mixture of both
as per requirement of medium purity up to tube plate level.
10) Open ammonia valves slightly, and condensate valve
fully.
11) Open steam /vapour valve 3-4 turns.
12) When boiling starts steam/vapour valve may be
increased suitably.
13) Concentrate the mass to a super saturation level
approaching Meta stable zone.
14) If mass level goes below top tube plate/below sampling
key level, make up dose of medium may be taken.
 Cont…

15) Open condensate valve, ammonia valve, and steam/vapor valve.

16) Concentrate footing below intermediate zone, this can be judged either by
experience or by proper instrumentation control.
17) Start taking feed, in small-small dose maintaining super saturation in above
zone, and fill up to desired level.
18) Finally, tighten the mass slowly up to dropping brix, in the mean-time keep
opened discharge gutter valve over crystallizer in which pan is to be
discharged.
19) After making ready to dropping brix or a little higher, close steam /vapour
valve, and then condenser as well as condensate valve.
20) Now open washing steam valve, and bring down vacuum in pan up to 300-
250 mm level. Then open discharge valve slowly when massecuite starts
coming out, and vacuum goes to zero level opening of discharge valve may be
increased desirably as per capacity of discharge gutter.
20) When complete massecuite is discharged, washing steam will forcibly
come out, weight for a while and close discharge valve for 2-3 minute, and then
open it, pressurized vapour will come out, as soon as thin liquor comes out
close the discharge valve and start pan for next cycle.
 TROUBLE SHOOTING
• If Vacuum of the Pan is not increasing?
• check for leakages at or else causes
 Joints between flanges on the pan/ on lines connected to
pan flanges.
 The discharge door seal on the pan and other valves via,
vacuum valves, vacuum breaker, and cutover valves.
 Shortage of injection water /hot injection
 Leakage on the multi-jet condenser system
 Leakage on the calanderia tubes
 The glands on the stirrer motor shafts
 Collapsed trays in condensers.
 Cont…

• How to check for leakage in the system:

 First option, the system must be filled with
steam or
 Second option, the system must be filled with
water and then see for the leaking portion/or
point(s).
 Precautions

 Steady vacuum should be maintained throughout the

course of boiling.
 Proper steam pressure & ammonia venting should be
maintained.
 Condensate removal should be efficient.
 During course of boiling massecuite should be neither too
thick nor it should be loose.
 Small -small drinks should be taken, long drink should be
avoided.
 If more than two feed material are to be taken in same
strike it should be taken in sequence from high to low purity
 Cont…

 Feed material should not have temperature less

than 650C, and its brix should be approaching to 70 o
 Whenever pan is dropped its cutover line and
discharge line should be washed properly.
 Arrangement should be made not to drop/stop more
than two pans at a time, one pan is preferable.
 Proper insulation of pan should be ensured.
 TROUBLE SHOOTING
SNO Problem(s) probable reason(s) Remedy
1 Fluctuation in  Nozzle chocking  Clean nozzle ,and strainers
Vacuum/unsteady  Fluctuation in header  check working of pumps, clean
vacuum pressure pressure suction strainers of pumps
 Leakage in system  Arrest leakages in the system
2 Brix of massecuite  Vacuum is low  Maintain consistent vacuum of
increment is  steam pressure is low 625-650 mm of Hg
slow/pan  scaling in tubes  Proper pressure should be
boiling is slow  leakage in tube/ inside maintained
ammonia pipe  clean tubes timely
 condensate release is poor  Check leakages and set right
 improper venting  Check extraction system, and set
 pan circulation is poor right if needed proper venting should
be ensured
 Check system and operation, and
improve circulation, it may be due to
design fault, obstruction in
bottom saucer, down take, poor
feed distribution’, low ΔT or high
PBR.
 Cont…
3 False grain/new  Vacuum fluctuation  already described
nuclei  slow boiling  already described
Formation  Heavy drink in pans  avoid excess drink/dilution
 Excessive tightening of  maintain proper consistency of pans
massecuite  maintain proper crystal population
 poor crystal population  Already described
 poor circulation  check system and set it right
 Poor feed distribution  Vacuum should not be very high
 low temperature boiling
4 Clustered/joint  Faulty boiling of high  Thorough care of high purity pan is
grain purity pan required, it should not be boiled
formation  Poor circulation in pan very thick
 Pocketing or channeling in  Already described
pan  check the system and set it right

5 Frequent  Thin boiling at high level  Restrict it

Entrainment  Pan filling beyond
capacity
 chocking in save- all
 low dia. vapor pipe
 Leakage in bottom portion
 Leakage in feed pipe
 Cold drink in pans
 It should be avoided
 It should be cleaned
 check and rectify
 It should be traced and ,arrested
 It should be traced and ,arrested
 it should not be less than 60OC
 Preferably it should be 70OC
 Cont…
3 False grain/new  Vacuum fluctuation  already described
nuclei  slow boiling  already described
Formation  Heavy drink in pans  avoid excess drink/dilution
 Excessive tightening of  maintain proper consistency of pans
massecuite  maintain proper crystal population
 poor crystal population  Already described
 poor circulation  check system and set it right
 Poor feed distribution  Vacuum should not be very high
 low temperature boiling
4 Clustered/joint  Faulty boiling of high  Thorough care of high purity pan is
grain purity pan required, it should not be boiled
formation  Poor circulation in pan very thick
 Pocketing or channeling in  Already described
pan  check the system and set it right
 Cont…
5 Frequent  Thin boiling at high level
Entrainment  Pan filling beyond
capacity
 chocking in save- all
 low dia. vapor pipe
 Leakage in bottom portion
 Leakage in feed pipe
 Cold drink in pans
 Restrict it
 It should be avoided
 It should be cleaned
 check and rectify
 It should be traced and ,arrested
 It should be traced and ,arrested
 it should not be less than 60OC
 Preferably it should be 70OC
THANK YOU!!!