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Freeze concentration of sugarcane juice in a

jaggery making process


Milind V. Rane
*
, Siddharth K. Jabade
Mechanical Engineering Department, Heat Pump Laboratory, Indian Institute of Technology Bombay, Powai,
Mumbai 400 076, India
Abstract
A heat pump based Freeze Concentration System (FCS) is proposed to concentrate sugarcane juice from
20 to 40 Brix in a jaggery making process. Further concentration of the juice is carried out in a boiling pan.
Inclusion analysis is carried out to estimate sucrose loss in the ice formed in a layer freezing process. A
mathematical model is developed taking in to consideration eect of time varying ice thickness on evapo-
rator temperature, compressor capacity, Coecient of Performance (COP) of the heat pump. Data on
operating parameters for a jaggery unit located at Rahu Pimplgaon in Daund District, Maharashtra was
collected through eld visits. Using this data, energy consumption of this conventional jaggery making pro-
cess is calculated. Energy balance has been carried out and Sankey diagram is drawn. Energy consumption
of the FCS is calculated using results of the mathematical model. Total energy consumption of the FCS
integrated jaggery making process is calculated. Comparison of the conventional process and FCS inte-
grated process is presented. Bagasse saving of about 1338 kg per day can be achieved using heat pump
based FCS along with bagasse red pan boiling. Further, hot spots are eliminated thereby reducing cara-
melisation signicantly resulting in improved jaggery color.
Keywords: Freeze concentration; Heat pump; Jaggery
Nomenclature
Bx brix,
C
L
concentration of liquid phase, Bx
C
S
concentration of solid phase, Bx
D
L
diusion coecient in the liquid phase, m
2
/s
D
s
diusion coecient in the solid phase, m
2
/s
K distribution coecient, DC
S
/DC
L
r radial distance, m
t time, s
T temperature, C
e position of solidliquid interface, m
m mass of melted ice water, kg
q
ice
density of pure ice, kg/m
3
x
s,ice
solute mass fraction of ice, w/w
A area covered by ice on the plate surface, m
2
s run time, s
Bx
ice
sucrose concentration in ice, Bx
Bx
bulk
sucrose concentration in bulk solution, Bx
h
l
convective heat transfer coecient from juice to growing ice body, W/m
2
K
h
o
convective heat transfer coecient on the refrigerant side, W/m
2
K
t
l
juice temperature, C
t
o
refrigerant temperature, C
x ice thickness, m
k
i
thermal conductivity of ice, W/mK
t
fs
thickness of the freezing surface material, m
h
lat,ice
latent heat of fusion, kJ/kg
Dt
j
time step, s
l
juice
viscosity of sugarcane juice, kg/m s
m
water
mass ow rate of water to be separated, kg/h
m
juice
mass ow rate of sugarcane juice, kg/h
Bx
j
initial brix, Bx
Bx
f
nal brix, Bx
c specic heat, kJ/kg K
T
juice
temperature of sugarcane juice, C
P purity of sugarcane juice
d lm thickness, m
C mass ow rate per unit width of the surface, kg/m s
h
juice,20Bx, 1 C
enthalpy of juice at 1 C and 20 Brix, kJ/kg
h
Syrup,40Bx, 5 C
enthalpy of syrup at 5 C and 40 Brix, kJ/kg
h
fg
enthalpy of evaporation, kJ/kg
CV
bagasse
caloric value of bagasse, kJ/kg
2123
1. Introduction
Heat pump based FCS is proposed to concentrate sugarcane juice from 20 to 40 Bx in jaggery
making process. The juice concentration in FCS is carried out up to 40 Bx because juice viscosity
increases considerably beyond 40 Bx, which has an adverse eect on heat transfer and sucrose
inclusion as well. Further concentration of the juice can be carried out in a boiling pan.
A unit at Rahu Pimpalgaon, Daund District in Maharashtra is considered for case study. Data
collected through the eld visits is used as a basis for calculations in this paper. Following are the
details of the data:
COP
net
net coecient of performance
Q
R,ice
heat rejected for ice melting, kW
Q
R,sink
heat rejected to sink, kW
P
Total
total power input, kW
P
e,FCS
electrical energy consumption of the FCS, kW h
Q
L,heat
latent load for concentrated juice heating, kW
h
fg
latent heat of vaporization, kJ/kg
Q
s
, sensible load, kW
Q
T,heat
total heat load, kW
Q
in,con
energy input in conventional process, kW
s sucrose content per unit bagasse
w moisture in bagasse relative to unity
m
bagasse
rate of bagasse consumption, kg/s
m
baggase.jag
bagasse consumption per kg of jaggery, kg/kg of jaggery
m
jaggery
rate of jaggery production, kg/s
c CO
2
content per unit volume of ue gas
m ratio of excess air weight to weight theoretical air
T
f
temperature of ue gas, C
x
s,1
mass fraction of the solute in the bulk solution, w/w
m
ice
average ice growth rate in, lm/s
u
S,1
solution velocity, m/s
a. Capacity 1000 kg jaggery per day
b. Working hours per day 10
c. Batches per day 4
d. Batch Duration 2.5 h
e. Sugarcane juice concentration rate 400 kg/h
f. Jaggery production rate 100 kg/h
g. Sucrose content per unit sugarcane 0.120.15
h. Initial juice concentration 2022 Bx
i. Juice purity 84
j. Weight of juice per batch 1000 kg
2124
2. Working principle of Freeze Concentration System (FCS)
The heat pump based FCS uses layer freezing process. The juice ows over the refrigerated sur-
face, called as freezing surface. This surface alternately performs function of a condenser or evapo-
rator. Layer freezing of water from the sugarcane juice and subsequent melting of ice takes place
on the freezing surface. Ice is melted using condenser heat. The ice in contact with the freezing
surface will melt using the heat of condensation of part of the vapours and the rest of the ice will
slide down the vertical freezing surface. The ice collected in the lower collection bin will melt using
the rest of the condensing vapours. Incoming juice is pre-cooled to 1 C using melted water and
concentrated juice leaving the FCS. The use of heat pump facilitates rejection of a major part of
the condenser heat at about 10 C while melting the ice. The temperature lift in this case is of the
order of 20 C.
3. Inclusion analysis of layer freezing process
Average Distribution Coecient (ADC) for solute inclusion (solute mass fraction in ice), is de-
ned as ratio of the solute inclusion in ice to that in the bulk solution [1]. Experimental data on
the partitioning of solute between liquid phases is usually reported in terms of distribution coef-
cient K.
3.1. Experimental apparatus
Test section is in the form of a C shaped stainless steel channel. It acts as a freezing surface for
layer freezing of water from the sugar solution. Refrigerant passage is provided at the bottom of
the channel. The test section is insulated.
3.2. Experimental procedure
Sugar solution was prepared adding sucrose crystals in distilled water. Experiments were con-
ducted using 20 Bx concentration solution. It was conrmed that ice formation takes place over
the complete surface. The surface of the ice layer was washed with ice water immediately after the
solution ow was stopped. This helped in removing the thin dendritic layer of ice formed in which
sucrose is entrapped. Samples were collected for inclusion analysis.
k. Jaggery produced per batch 250 kg
l. Fuel Bagasse
m. Bagasse consumption per kg of jaggery 1.52 kg
n. Exhaust ue gas temperature 400 C
o. Striking temperature of the juice 118 C
p. Moisture in bagasse relative to unity 0.50
q. Foot print of the unit along with chimney 7.5 m 7.5 m
2125
3.3. Measurements
The sucrose inclusion in ice and concentration of sucrose in bulk solution was measured using a
temperature controlled bench type Abbe Refractometer with a refractive index in the range of
1.30001.7000 nD and accuracy of 0.0001 nD at room temperature. Temperature was measured
using thermocouples (K type) with accuracy 1 C and an indicator with accuracy 0.2 C, su-
crose and water weight was measured using weighing balance with accuracy 0.1 g.
3.4. Results and discussion
Figs. 1 and 2 indicate eect of operating parameters on ADC. It is a function of freezing surface
temperature, ice growth rate, solution velocity and bulk solution concentration. Chen has pro-
posed following correlation [2]
ADC 0:145 2:05x
s;1
0:139
m
ice
u
0:5
S;1
1
ADC, that is inclusion is more at a higher ice growth rate, because growth rate of the ice front can
become too high to overtake the solute outward movement. Increase in velocity increases mass
transfer coecient. This helps solute at ice solution interface to be transported in to bulk ow
and reduces inclusion. At a lower freezing surface temperature, the driving force for ice growth is
larger, which results in increased inclusion [3]. The experimental results are in good agreement with
the Chens correlation. Fig. 2 indicates ADCvalue of 0.20 at 1 m/s velocity. Sucrose included in ice is
ADC
Bx
ice
Bx
bulk
0:20
Bx
ice
20
2
From Eqs. (2), sucrose in ice formed is 4 Bx. That is 4% sucrose is included in the ice. Thus, ice
purity is 96%.
-14 -12 -8 -6 -4 -2
Surface Temperature
o
C
0. 0
0. 1
0. 2
0. 3
0. 4
0. 5
0. 6
A
v
e
r
a
g
e

D
i
s
t
r
i
b
u
t
i
o
n

C
o
e
f
f
i
c
i
e
n
t
0.0
0.1
0.2
0.3
0.4
0.5
0.6
Fig. 1. Eect of freezing surface temperature on average distribution coecient.
2126
4. Method to calculate FCS energy consumption
Since juice is a binary mixture, its properties change with the concentration as it ows over the
freezing surface. Freezing surface is assumed to be divided in number of segments. Mass of ice
formed and corresponding concentration of the juice is calculated in each segment. Based on this
concentration, properties of the juice such as freezing point, density, viscosity, velocity and spe-
cic heat are calculated for the subsequent segment and are used for heat transfer calculations.
Fig. 3 shows ow chart of the method.
Fig. 4 shows idealized thermal circuit [4]. Initially, freezing surface is bare, that is there is no ice
built up (Fig. 4a). The rate equation for this heat transfer q
r
is
q
r

t
l
t
o
1
h
l

t
fs
k

1
h
o
_ _ 3
Ice thickness in ith segment and corresponding properties of the solution at the entry of the i + 1th
segment are calculated as follows.
As shown in (Fig. 4b), equation for heat transfer q
2
is
q
2

t
l
1
h
l
_ _
4
The rate equation for heat transfer q
1
is
q
1

t
0
x
k
i

t
fs
k

1
h
o
_ _ 5
From energy balance consideration, q
1
is in excess of q
2
by the amount required for the rate of ice
formation dx/dt.
q
1
q
2
q
ice
h
lat;ice
dx=dt 6
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6
Ice Growth Rate x 10
-6
(m/s)
0.15
0.20
0.25
0.30
0.35
0.40
0.45
0.50
A
v
e
r
a
g
e

D
i
s
t
r
i
b
u
t
i
o
n

C
o
e
f
f
i
c
i
e
n
t
0.15
0.20
0.25
0.30
0.35
0.40
0.45
0.50
Velocity 0.75m/s
Velocity 0.5m/s
Velocity 1m/s
Fig. 2. Eect of sucrose solution velocity and ice growth rate on average distribution coecient.
2127
Start
Input initial juice and refrigerant temperature,
freezing surface dimensions, total run time,
time steps, number of segments, juice
properties
Assume refrigerant temperature for first
time step j
Calculate mass of ice formed in i
th
segment
Calculate overall heat transfer
coefficient in segment i
Calculate heat transfer in segment i
Summation of the individual heat transfers in
segments 1 to i to calculate total heat transfer Qr
Calculate juice viscosity, density, specific
heat, freezing temperature for the new
concentration of juice in i+1
th
segment
Calculate concentration of the juice
at the end of the i
th
segment
Calculate capacity of compressor Qc
corresponding to assumed refrigerant temperature
Next time step j+1 and repeat calculations
taking into account ice thickness in the
previous time step
Is Qc=Qr
Calculate COP and energy consumption of
the compressor corresponding to the
refrigerant temperature
No
Yes
Fig. 3. Flow chart of method of analysis for calculation of energy consumption of the Freeze Concentration System.
2128
Thermal energy abstraction in sub-cooling the ice is not considered. It is negligible relative to the
latent heat of freezing requirement [5].
Mass of ice is formed in the ith segment calculated as
Dm
ice;i

q
1
q
2
Dt
j
h
lat;ice
7
Concentration of the juice entering i + 1 segment in terms of brix is calculated as
Bx
i1
1
m
juice;i

100Bx
i

100
m
ice;i
_ _
m
juice;i
m
ice;i
_
_
_
_
8
Mass ow rate of juice in the i + 1 segment is calculated as
m
juice;i1
m
juice;i
m
ice;i
9
The relation between concentration and freezing temperature is obtained from the sugarcane juice
phase diagram [6] using curve tting as
T
solution;i1
1 Bx
i1
15 0:18 10
Sugarcane juice
h
0
h
l
R
o
= 1/ h
o

q
r
t
o
t
l
R
h
= t/k
R
l
= 1/ h
l
t
o
q
r
t
l
Refrigerant
t
fs
Freezing
Surface
Sugarcane juice
Ice
h
0
t
fs
h
l
x
q
2
R
l
= 1/ h
l
t o
R
i
= x/k
t =0
R
o
= 1/ h
o

q
1
q
1
q
2
t o
t
l
t
l
R
h
= t/k
Refrigerant
Freezing
Surface
(a)
(b)
Fig. 4. Thermal circuit representations (a) bare freezing surface; (b) freezing surface with ice formation.
2129
The relation between viscosity and Bx in i + 1 segment is obtained from a graph of temperature,
concentration and viscosity [7] as
l
juice;i1

a
a b Bx
i1
c Bx
i1

2
_ _ 11
where a = 1.8214, b = 0.0337, c = 0.0002; Bx concentration of sugarcane juice (Bx).
Specic heat of sugarcane juice varies with its concentration (Bx) and temperature, it is calcu-
lated as [7]
c 1 0:6 0:0018T
juice
0:0008 100 P
_

Bx
100
4:19
_ _
12
Density of sugarcane juice in the i + 1 segment is
q
juice;i1
1:59
Bx
i1
100

100 Bx
i1

100
_ _
100 13
Velocity of the sugarcane juice in i + 1 segment is calculated by substituting the values from equa-
tions (11) and (13) in the following equations [8]:
V
gqd
2
3l
14
where
d
3Cl
q
2
g
_ _
1=3
15
This equation assumes that there is no drag force at the gas liquid interface.
Initially, evaporator temperature is assumed. For the rst time step, the heat transfer from juice
to refrigerant, that is q
r
is calculated for each of the segments taking in to consideration corre-
sponding properties of the juice in the respective segment. Compressor cooling capacity q
c
at
the assumed evaporator temperature and sum of the individual heat transfers in all the segments
are equated. If they do not converge, new evaporator temperature is assumed and above men-
tioned calculation is repeated to get evaporator temperature. Similar procedure is repeated for
the next time step. Resistance due to the ice formed in the previous time step in the corresponding
segments is taken in to consideration in the next time step. Compressor capacity and COP is cal-
culated for every time step using vapor compression cycle simulation program for R 22 refrigerant
with condenser temperature of 10 C and compressor isentropic eciency: 0.8.
5. Electrical energy consumption of the FCS
Compressor of the FCS is selected based on the nominal capacity and evaporator temperature.
Nominal cooling capacity is calculated for the specications of the unit at Rahu Pimpalgaon.
Water to be separated from the 400 kg/h juice to concentrate it from 20 to 40 Brix is
m
water
m
juice
1 Bx
j
=Bx
f
200 kg=h 16
2130
Thus, concentrated juice (syrup) ow rate at the exit of the FCS is 200 kg/h. In FCS, juice is
cooled from 1 C at 20 Bx to 5 C corresponding to 40 Bx is. Total load is
Q
tot
; Q
sensible;FCS
Q
latent;FCS
m
Juice;20 Bx
h
Juice;20 Bx;1

C
m
Syrup;40 Bx
h
Syrup;40 Bx;5

C
_ _ _ _
m
water
h
lat;ice

3 18:6 21:6 kW
Heat gain from ambient into the ice separated is, assumed to be 10% of the latent heat load, which
is 1.8 kW. Thus, nominal cooling capacity of the FCS is 23.4 kW. Assuming minimum approach
of 3 C, initial evaporator temperature is xed at 8 C. Results were computed using the above
discussed model.
5.1. Results and discussion
Results are shown in Fig. 5, the evaporator temperature decreases through out the ice building
process. As ice thickness on the freezing surface increases, overall heat transfer coecient de-
creases because of increased ice resistance. This results in reduction of the evaporator temperature
and pressure leading to reduced cooling eect and power consumption. However, reduction in
cooling eect is much more than the reduction in power consumption leading to reduction in
the COP.
It can be seen that at 7 mm ice thickness, COP of the system is around 8. This COP value does
not take into account eect of mismatch of condenser and evaporator duties. The COP is based on
the assumption that the total heat in the condenser is rejected for melting ice only. In practice,
condenser can reject a part of the total heat (equivalent to the latent load) at 10 C for ice melting.
0 15 30 45 60 75 90 105 125 135
Time (minutes)
-15
-14
-13
-12
-11
-10
-9
-8
-7
E
v
a
p
o
r
a
t
o
r

T
e
m
p
e
r
a
t
u
r
e

o
C
7.
.
5
8.
.
0
8.
.
5
9.
.
0
9.
.
5
10.
.
0
10.
.
5
C
o
e
f
f
i
c
i
e
n
t

o
f

P
e
r
f
o
r
m
a
n
c
e
0
1
2
3
4
5
6
7
8
I
c
e

T
h
i
c
k
n
e
s
s

(
m
m
)
20
21
22
23
24
25
26
27
28
C
o
m
p
r
e
s
s
o
r

C
a
p
a
c
i
t
y

(
k
W
)
Evaporator Temperature
Coefficient of Performance
Compressor Capacity
Ice Thickness
Fig. 5. Eect of time varying ice thickness on the compressor performance.
2131
Excess heat, contributed by compressor power input and leakages has to be rejected to heat sink
at ambient temperature. Eect of this heat rejection on the COP is analyzed in the following
section.
Fig. 6 illustrates the cooling loads and eect of delivery of excess heat to the sink at ambient
temperature on net COP. Thus, 23.4 kW heat has to be pumped to a higher temperature. Out
of this, part of the heat (16.5 kW) is pumped at 10 C for ice melting. Since cooling COP of
the FCS is 8, power input for pumping 16.5 kW heat is 16.5/8 = 2.1 kWe. Thus, total heat deliv-
ered for ice melting is 16.5 + 2.1 = 18.6 kW which is equal to the latent load.
Excess heat (6.9 kW) is pumped to 36 C in the water cooled condenser. Cooling COP of 3.7 is
calculated for this condensing temperature using vapor cycle simulation program. Power input for
pumping 6.9 kW heat to 36 C sink is 6.9/3.7 = 1.9 kWe. Thus, total heat delivered at 36 C is
6.9 + 1.9 = 8.8 kW.
The net COP is calculated as
COP
net

Q
R;ice
Q
R;sink
P
Total

18:6 8:8
1:9 2:1
6:8 17
Electrical energy consumption is
P
e;FCS

Q
cooling
COP
net

23:4
6:8
3:44 kW h 18
Since unit works for 10 h in a day, total electrical energy consumption of the FCS to concentrate
juice from 20 to 40 Bx for the day is 34.4 kW h.
Sensible heat load
3 kW
c
Latent heat load
18.6 kW
c
at -10
o
C
Total cooling load
23.4 kW
Freeze Concentration System
Heat rejection to heat sink
Heat leakage
1.8 kW
Heat rejection for ice melting
COPc = 8
Power Input
2.1 kWe
18.6 kW
at 10
o
C
16.5 kW
8.8 kW
at 36
o
C
COPc = 3.7
6.9 kW
Power Input
1.9 kWe
Net COP = (8.8 + 18.6)/(1.9 + 2.1)
= 6.85
Fig. 6. Eect of excess heat rejection on COP.
2132
6. Bagasse consumption for the concentrated juice boiling
It is required to evaporate 100 kg/h water at a striking temperature of 118 C from (200 kg/h)
concentrated juice coming from the FCS. Vapor generated in the boiling pan at 118 C is used to
heat the concentrated juice at the exit of the FCS. With an approach of 6 C, the concentrated
juice is heated from 112 C before entering the boiling pan.The juice is heated from 112 to
118 C in the boiling pan. Total heat load in the boiling pan is
Q
T;heat
m
w
h
fg
m
Syrup
c T
f
T
i

100=3600 kg=s 2300 kJ=kg 200=3600 kg=s 3 kJ=kg K118 112


64:8 kW 19
Caloric value of bagasse with 50% moisture and 12% sucrose content is calculated as [7]:
Gross Calorific Value 4600 1 w 1200 s 4:187 9027 kJ=kg 20
Bagasse consumption is
m
bagasse

Q
T;heat
CV
bagasse
25:8 kg=h 21
Assuming combustion eciency to be 60%, actual bagasse consumption is 41.2 kg/h. Thus, total
bagasse consumption for producing 1000 kg jaggery in 10 h using FCS is 412 kg.
The total energy consumption for producing 1000 kg jaggery in 10 h constitutes the following:
a. Electrical energy consumption for concentration of the juice from 20 to 40 Bx using FCS is
34.4 kW h.
b. Bagasse consumption in the boiling pan for further concentration is 412 kg.
7. Case study: Energy consumption of the conventional jaggery making process
Details of the energy consumption are:
Energy supplied by combustion of bagasse is calculated as
Q
in;con
m
bagasse
CV
bagasse
22
The bagasse consumption per kg of jaggery produced is in the range of 1.52 kg. An average value
of 1.75 kg is considered for the analysis. The jaggery production rate is 100 kg/h, that is 0.03 kg/s.
Bagasse consumption rate is
m
bagasse;con
m
baggase;jag
m
jaggery
1:75 0:03 0:05 kg=s 23
From Eqs. (20), (22) and (23)
Q
in;con
415:3 kW
2133
As indicated by Tiwari [9], natural convection boiling of sugarcane juice is up to 90 C and pool/
nucleate boiling starts at 9095 C. Fig. 7 shows the temperature ranges with corresponding sen-
sible and latent heat loads. It may be noted that in practice, sugarcane juice is heated in pan from
about 27 to 118 C in a single stage. Three stages and corresponding temperature ranges consid-
ered in Fig. 7 are assumed for calculation of sensible and latent loads.
Total heat load is summation of latent and sensible heats in three stages. Thus
Q
tot
Q
s;I
Q
s;II
Q
s;III
Q
L;II
Q
L;III
m
juice
c
avg
90 27 m
juice
c
avg
109 90 m
juice
c
avg
118 109
m
w;e
h
fg

@ 99:5

C
m
w;e
h
fg

@ 113:5

C
216:6 kW 24
7.1. Sensible heat loss in ue gas
Ratio excess air weight to weight of air theoretically necessary is calculated as [7]:
c
0:871 w
4:451 wm 0:0561 w
25
Assuming CO
2
content per unit volume of ue gas to be 0.13, from Eq. (25)
m 1:52
Suarcane Juice at 20Bx,
400 kg/h, 30
o
C
Vapor
100
o
C,150kg/h
Syrup
90
o
C,400kg/h , 20 Bx
Syrup
109
o
C,250kg/h , 32 Bx
Vapor
113.5
o
C,150kg/h
Jaggery paste
118
o
C,100kg/h , 80 Bx
Stage I
Stage II
Stage III
Sensible heat
Sensible heat + Latent Heat
Sensible heat + Latent Heat
Fig. 7. Temperature ranges for heat load calculations.
2134
Heat loss is
Q
f
1 w 1:4m 0:13 0:5 T 4:18 m
bagasse;con
125:5 kW 26
Other losses include unburnt and radiation loss. Unburnt loss is assumed to be 10% of the total
heat input. The result of the energy balance is indicated in Fig. 8(a).
8. Comparison of the FCS integrated jaggery making with the conventional process
Fig. 8 shows that, bagasse consumption in FCS integrated process is 41.2 kg/h as against
175 kg/h in conventional process. Saving in bagasse is
175 41:2 133:8 kg=h
Energy Input 415.3 kW
h
Bagasse Consumption 175 kg/h
Loss in Flue Gas
125.5 kW
Juice Evaporation
216.6 kW
Other Loss
73.2 kW
(a)
Freeze Concentration
System (FCS)
Sugarcane Juice
400 kg/h
27
o
C
20 Bx
Ice Water
200 kg/h
0
o
C
Electrical Energy Input 34.4 kWe
Loss in Flue Gas
28.7 kW
Other Loss
9.5 kW
Energy Input 103 kW
h
Bagasse Consumption 41.2 kg/h
Boiling Pan
112
o
C
Concentrated Juice
200 kg/h
1
o
C
40 Bx
64.8 kW
Jaggery Paste
100 kg/h
Water Vapor
100 kg/h
118
o
C
Condensate
100 kg/h
118
o
C,
(b)
Fig. 8. Comparison of energy consumption of the Freeze Concentration System integrated jaggery making and
conventional process.
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Thus, bagasse saving for 1000 kg jaggery production in 10 h is 1338 kg.
8.1. Initial cost
The FCS consists of two latent heat exchangers, a sensible heat exchanger, multi way valve and
controls. A boiling pan of juice holding capacity 500 kg is used to further concentrate the juice
from the FCS. The initial cost of FCS and boiling pan is about Rs. 2 Lakh. Conventional jaggery
making unit essentially consists of a furnace, chimney and a boiling pan of juice holding capacity
1000 kg. Cost of the complete unit including construction of the chimney and furnace is about 2
Lakh.
8.2. Jaggery quality
The boiling pan in the proposed unit is half the capacity of the conventional jaggery making
unit. Reduced size of the boiling pan facilitates proper stirring of the juice. This reduces localized
hot spots. Further, time for which juice is exposed to high temperature reduces because 50% of the
concentration is carried out in the FCS. This reduces caramelisation and improves jaggery color
and quality.
9. Techno economics
As indicated in the results of the experiments, loss of sucrose is 4%. During 10 h working,
2000 kg ice is separated. Loss of sucrose in this ice is (2000 0.04) 80 kg. It is assumed that
80 kg jaggery forms out of 80 kg sucrose loss in ice. Considering rate of jaggery as Rs. 3 per
kg realized by the farmer [10], Rs. 240 is the loss due to sucrose inclusion.
9.1. Net savings
Saved bagasse can be sold to various industries like sugar factory, paper and pulp industry at
the rate in the range of Rs. 0.60 to Rs. 1.2 per kg [10]. Considering an average value of Rs. 0.9 per
kg, revenue generated per day by sell of the 1338 kg saved bagasse is Rs. 1204.2.
Electrical energy consumption of the FCS for 1000 kg jaggery production is 34.4 kW h. Con-
sidering electricity rate of Rs. 5/kW h (in Maharashtra), electricity cost is Rs. 172.
Net saving per day is Revenue generated by the sell of bagasse
Electricity cost of the FCS
cost of the sucrose lost in inclusion
Rs: 1204 Rs: 172 Rs: 240 Rs: 792 per day
Simple pay back period of the system is about 252 days.
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10. Conclusion
A heat pump based Freeze Concentration System is proposed to concentrate sugarcane juice
from 20 to 40 Brix in a jaggery making process to save bagasse and enhance jaggery quality. Eect
of operating parameters on ADC is studied through experiments. Use of heat pump facilitates
rejection of a major part of the condenser heat at about 10 C while melting the ice. COP of
the FCS is estimated as 6.8 using mathematical model and considering heat losses and mismatch
of evaporator and condenser duty. Comparison of the conventional and FCS integrated jaggery
making process is presented. FCS integrated process results in better quality jaggery by reducing
hot spots and caramelisation due to reduced size of the boiling pan. Bagasse saving of 1338 kg per
day or for 1000 kg jaggery can be achieved.
Acknowledgements
The authors would like to acknowledge the help and support oered by Dr. J.P. Patil, Director,
Regional Sugarcane and Jaggery Research Station, Kolhapur, Dr. B.S. Patil (Kolhapur) and Mr.
Hanumant Shinde from Rahu Pimpalgaon.
References
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