MOHIT JOHRI

ANSI(SE)
Roll no. – SE/1415
In
M/S. Triveni Engg and Industries Ltd
Sugar Unit:Deoband

Duration of Training: 1 Dec. 2014 to 31 May 2015

Date of Submission:

Submitted to

Director
NATIONAL SUGAR INSTITUTE
MINISTRY OF CONSUMER AFFAIRS, FOOD &PUBLIC DISTRIBUTION
DEPARTMENT OF FOOD & PUBLIC DISTRIBUTION
Government of India
KALYANPUR
KANPUR-208017

1
 ACKNOWLEDGEMENT
It gives me immense pleasure to present the training report under taken during ANSI(SE) final
year.

I owe special debt of gratitude to Mr. IS.KALRA, DGM of TRIVENI ENGG AND INDUSTRIES
LTD. sugar unit Deoband For his perpetual inspiration and constant support and guidance
throughout the course of my training. His thoroughness and perseverance have been a source of
inspiration for me.

I also take the opportunity to acknowledge the real efforts of Mr.D.N.Mishra, hon. Vice
president (sugar) of TRIVENI ENGG AND INDUSTRIES LTD. sugar unit Deoband. to make me
a compatible sugar engineer.

I also don’t like to miss the opportunity to acknowledge the assistance and cooperation of all
engineers as well as chemists during the development of this training report.

July ’15

- MOHIT JOHRI

2
 INDEX

i. Certificate

ii. Acknowledgment

iii. List of tables

iv. List of annexure

v. Abbreviations

vi. Introduction and brief history

vii. Organizational setup

viii. Process flow diagram

ix. Process principles in detail

x. Plant machinery detail

xi. Calculations

xii. Analytical data

xiii. Bibliography

3
 CANE DEPARTMENT

Sr.no Name Designation

1. Mr.Sk Tyagi Gm(CANE)

2. Mr.T.S.Yadav Dy. Gm(CANE)

3. Mr. B.S.Tomar Sr.Manager

4. Mr.S.K.Tiwari Sr.Manager

5. Mr.Satendra Chauhan Manager

6. Mr.Ashok Kumar Manager

7. Mr.Amit Pundir Addl.Manager

8. Mr.Jagjeet Singh Addl.Manager

9. Mr.Vijay Kumar Sr.Manager

10. Mr.Sanjeev Rana Addl.Manager

11. Mr.Dharmpal Tyagi Dy.Manager

12. Mr.Rup Lal Addl Manager

13. Mr.Vineet Kumar Sr.Manager

14. Mr.Manoj Chauhan Sr.Manager

4
15. Mr.Virendra Tyagi sector incharge

16. Mr.Ishwar Pal Manager

17. Mr.Jaswant Singh Manager

18. Mr.Dinesh Kumar C.D.I.

19. Mr.Omkaran Singh C.D.I.

20. Mr.Manoj Bhyala sector in charge

5
 ORGANIZATIONAL SETUP
This group is governed by a body elected through shareholders of company. Chairman posses the
extreme powers followed by vice chairman.

There are twelve no. of Directors elected by shareholders, who along with Chairman, Vice
chairman and Managing Director forms the Board of Directors.

Chairman : Mr.Dhruv Shahani

Managing Director : Mr.Tarun Shahani

Engineering Dept. :

Dy. General Manager : Mr. I.S.Kalra

Manager (Mech.) : Mr. Ajab Singh

Addl. Chief Engineer (Mech.) : Mr.Jitendra Sharma

Dy. Chief Engineer (Instrument.) : Mr. Alok Balian

Manager(Boiler Operation) : Mr.I.P.Gupta

6
Sr.Engg (Mech) : Mr. Gopal Krishan

Manager(electrical operations) : Mr.P.Jain

There are 2 more mechanical engineers, 3 instrument engg. and 2 electrical engineer.

Manufacturing Dept. :

Chief Chemist(DGM) : Mr.R.K. Mittal

Addl. Chief Chemist : Mr. kapil Sharma

Manger(operations) :Mr.Anil Singh

Dy. Chief Chemist : Mr. Deepak singh

Lab incharge : Mr.Verma

There are four more chemist, works as shift chemist.

PROCESS FLOW DIAGRAM

Sugar cane

Cane carrier

Kicker

Leveler

Fibrizer

Milling Bagasse

7
 Mixed juice Boiler

Juice Steam
weighment

To Turbines
Juice heater
70 C

Juice sulphiter
Dorr clarifier Muddy juice

Clear
Juice juice
heater

102 C

Clear juice Rotary vacuum

heater 110 C filter

Evaporator
Filtered Press mud
juice

Syrup sulphiter
To raw juice
tank

Pan floor

Crystlizer

8
 A masscuite

AL molasses Centrifugal AH molasses

m/c

Sugar B masscuite

Hopper BH molasses B sugar

9
 C masscuite Melt
Elevator

Grader C Sugar A masscuite

Final
Bagged melt molasses

A masscuite

10
 PROCESS PRINCIPLES IN DETAIL

Manufacturing of white sugar from sugar cane takes place by following a no. of operations in a
row with a high level of supervision and controlled processes.

Cane Preparation is very first unit operation, which aims to open the maximum juice cells for
better extraction from it. To achieve this many devices are in market viz. cutter, leveler, fibrizer,
shredder, mincer etc. which is used solely or in combination with another as desired. Cane
preparation results in higher ‘preparatory index’ means improved extraction as well as capacity.

After cane preparation Milling Operation comes in line. Milling operation aims extraction of juice
by rupturing juice cells which is done by feeding cane blanket in mills. After milling two product
mixed juice and bagasse are met for further process.

Mixed juice goes to Boiling House after weighment. It is heated upto 70 0C in first heating before
going to juice sulphiter where acidity of juices comes to neutral nature by use of milk of lime and
sulpher dioxide. After juice sulphitaion we does second heating of juice up to 102 0C and then send
it to dorr clarifier, where impurities of juice settle down and golden yellow color clear juice met.
Along with clear juice some amount of muddy juice also met which gets filtered in Rotary vacuum
filter. Clear juice of brix 14 then again heated up to 110 0C.

After that juice comes to Evaporator Section where evaporation of juice takes place through
heating action of steam. Here we are using quintuple effect evaporator and getting 60 brix syrup
from final body.

Syrup sulphitation process is done for making pH 4.9 to 5.4.

Sulphited syrup goes to pan floor where it converted into masscuite in vacuum environment at 65
0
C temperature. This masscuite goes to crystallizer for crystallization operation from where
through centrifugal action crystal sugar is separated from massecuite.

11
 Plant machinery detail

1. Cane supply
The harvested cane is transferred to factory from field by bullock carts, tractors
and lorries depending upon the distance. The management itself arranges
transport. The percentage contributed by each is given below
By carts – 40% to 50%
By tractors – 50%
By trucks –20 to 30%

2. Mechanical unloader
In our factory we are using sling type un-loaders there are six numbers. All are
two motion type unloader.

Numbers - six
Make -
Capacity - 5 MT
Height from the ground -
Length –
Width –
Hoisting speed –
Hoisting unit motor capacity(2 no.) –
Longitudinal speed-
Cane handled -

12
3. Cane carrier

Particulars Cane Rake elevator Belt conveyor

Carrier
no.1

Width 2286mm 2140mm 2300

Length 54m 26m 26m

inclination from horizontal -- 45 7

3.1. Variable speed drive

particulars Cane carrier Rake elevator Belt conveyor

drive Vfd(variable feed drive) Vfd Vfd

Motor H.P. 150hp 100hp 50hp

rpm 1440 1440 1440

4. Cane preparatory devices

Cane preparation is important in every sugar factory to increase the capacity and
to obtain good results of extraction. The cane gives considerable resistance to the
action of the rollers which squeeze out juice from cane, due to its bulky nature
and inherent resistance of the rind and nodes. The capacity and extraction of the
plant are mainly governed by the degree and quality of disintegration to which the
cane is subjected .

Following are the cane preparatory devices which have been used in the plant:-

particulars No of blades Motor hp on Motor hp on rpm Gear box

one side other side output

Cane kicker 28 100 -- 1480 56

Cane chopper 36 600 200 570 --

Cane cutter 52 750 500 742 --

Fibrizor specifications:-

13
 particulars Description

Installation year 1994

Make Uttam

Type Swivel hammer type

Hubs 44 nos

Rows 6 nos

Hammer 172

Weight of lugs 22 kgs

Swing diameter 1830 mm

Journal size 260 mm

Anvil type Pocketed

Hammer pin 6 nos 70mm dia

Fibrizor turbine:-

particulars description

Capacity 3000kw

Running speed 800rpm

Inlet pressure 32kg/cm2

Outlet pressure 1 kg/cm2

Enclosed gear box 1350/750 rpm

Fibrized cane equalizer:-

particulars Description

14
 Motor hp 15

Rpm 1440

Drum diameter 1700mm

Mill:- Purpose of milling is to extract juice from prepared sugar cane blanket by passing it
through a no. of mills. Here one no. of milling tandems are installed for 8000 TCD.

1.Specification of mills:
Number and size of mills ----------- 5 nos with GRPF having 26 rollers dia (o.d.)
1100 mmX2140 length(Ist IInd and Vth mill) preceded by GRPF with full size under feed rollers and
IIIrd mill IVth mill preceded by full size toothed under feed roller.
Make of plant ----------
Distance between two mills -----------
2. Head Stock
a) Type Straight
b) Material C.S Fabricated
3. Trashplate:
a) Type Rigid
b) Material C.S

4. Mill troughs:
a) Slope of troughs for continuous 'V' troughs
b) Slope towards outlet for individual troughs
(c) Material of troughs

Detailed specifications of each mill:-

Mill no.1 with GRPF (INDIVIDUAL DRIVE)

Particulars Description

mill motor ac VFD 1200 HPX 993 rpm

Gear box ratio 44.68:1

Open gearing 29TX36M and 136 TX36M

Mill speed 4.74 rpm

GRPF motor ac VFD 500 hp X991 rpm

Gear box ratio 35.5:1(HTN-560)

Open gearing 27TX25M and

124TX25M

15
 GRPF speed 6.07 rpm

Mill no. 2 and 5 with GRPF (INTEGRAL DRIVE)

Particulars Description

Steam turbine 1200 hpX6400 rpm

Input speed of gear box 800 rpm

Enclosed gear box SZ-560 ratio 11.2:1

Open gearing I motor 27TX30M and 124TX30M

Open gearing II motor 27TX36 M and 107TX 36M

Open gearing GRPF 106TX25M and 83TX25M

Mill speed 3.92 rpm

GRPF speed 5.01 rpm

Mill No.4
Particulars Description

Steam turbine 1200 hpX6400 rpm

Input speed of gear box 800 rpm

Enclosed gear box Szn 560:ratio 11.2:1

Open gearing I motion 21TX30M8 124TX30M

Open gearing II motion 27TX3M8 107TX36M

Mill speed 3.92 rpm

16
 Mill No.3

Particulars Description

Motor 900 kw

Rpm 993

Make ABB

Gear Box type Planetary made TRIVENI

Ratio 199.89 input

Rake Elevators
Particulars Description

Trough size 2600 wX23250 mm L

Sprocket 16TX9” pitch [forged]

Driven sprocket 63TX20TX3” pitch

Gear Box HTN 320: ratio 56:1

Motor [ac VFD ] 100 hp1440 rpm

Speed 26.38 m/min

No of rakes 74

Pitch of rake 27”

17
 Belt conveyor
Particulars Description

Belt 2300 widthX13.5 m long

Head drum diameter 625 mm

Gear Box HTN-200 ratio-40:1

Motor[AC VFD] 50 hpX1400 rpm

Speed 70.65 m/min

Inter Rake Carrier

Particulars Description

Trough size 2600 WX12500 mm lgth

Sprocket 14TX9”p[forged Block]

Driven sprocket 63 TX18TX3”

Gear box HTN 280 ratio 50:1

Motor 60 hpX1440 rpm

Speed 26.58 m/min

No of rakes 41

18
 Pitch of rakes 27”

Type and number Of Differential Angle grooving and Pitch with Depth and Mill Setting In
mm (P.C.D To P.C.D)

NO OF USE FOR PITCH ANGLE DEPTH MILL SETTING

MILLS MM MM
FEED DISCH TRASH UFR

GRPF With I TOP 60 35 73 226 385 -- 271

Mill
BOTTOM 60 35 73

UFR 60 60 43

TOP 50 50 43

FEED 50 35 63.8 68 34 126 --

DISCH 50 45 48

GRPF with TOP 60 35 73 217 372 -- 267

2nd mill
BOTTOM 60 35 73

UFR 60 60 43

TOP 50 50 43

FEED 50 35 63.8 58.8 28.8 116 --

DISCH 50 45 48

3rd mill TOP 50 50 43

FEED 50 35 63.8 48 23 100 292

DISCH 50 45 48

U.F.R 50 60

4th mill TOP 50 50 43

FEED 50 35 63.8

19
 DISCH 50 45 48 41 19 87.7 281

U.F.R 50 60

GRPF with TOP 50 35 60 180 335 -- 208

5th mill
BOTTOM 50 35 60

UFR 50 60 34

TOP 35 45 32

FEED 35 35 42 35 16.6 78 --

DISCH. 35 45 32

OTHER NECESSARY INFORMATION

Particulars Description

Speed of rollers in min/min 13.28 m/min at 4.00rpm at

6400 rpm of Turbine

Total hydraulic load on top 180

roller in tones

Length and dia of roller Length 660X dia 510

journal

IMBIBITIONS
State whether water used if hot or cool and hot water used of 72 ͦ c and to measure it

Arrangement provided for measure and/or electronic flow meter of capacity 0-

Weighing 200m3/hr used.

20
The Imbibition% fibre has significant role on extraction of sugar from sugar cane on
milling operation. The Mixed Juice% cane and solids extracted also increases with
Imbibition % Fibre.

Extraction increases rapidly at first, slowly latter on as the imbibition is

increased. Higher the added water, Higher will be milling efficiency.

Water
nd
st
I Mill II Mill rd
III Mill th
IV Mill Vth Mill
U.F T U.F T U.F T U.F T U.F T

F D F D F D F D F D

P.Jc S.Jc

M.Jc IMBIBITIONS water pumping set

Particulars Description

Pump type Kpd 125/32(kirlosker)

Size 125 X150 mm

Total head 30 m

Rate of flow 41.66 l/s

Pump input 17.95 kw

Speed 1470 rpm

Kw of motor 22

Bearing no. 309

STEAM GENERATING PLANT

A.Boiler Details

21
In most sugar mills bagasse fibre boilers are operated with little or no trouble; in
others slagging presents something of a problem and it has been observe that even
apparently identical bagasse may possess variable qualities, which are not
revealed in a chemical analysis, yet may affect combustion

Bagasse burns very well in a heap with air impinging on it, but the essential
factor in successfully burning it, or any wet fuel, is the maintenance of a
sufficient high local furnace temperature the dry the fuel and sustain ignition. For
this purpose it is advisable to have refractory brick work suitable arranged to
radiate heat on the incoming fuel and it is necessary to operate the furnace at a
reasonably high rate of combustion to maintain the furnace temperature, but of
course the furnace temperature should not be so high that trouble arises due to

the ash fusing.Ash from bagasse is friable normal furnace temperature but fuses
into a sticky mass at high temperatures, resulting in slagging of the furnace and
heating surfaces and damage to the furnace brickwork. But by adopting spreader
stoker particulars B. No. 10 B. No. 11 furnace we
are Make Taxmaco Walchandnagar avoiding
Year of 1992 1994
the above manufacture problems.
Reg. no. u.p.5132 u.p.5190
Note:- only Boiler no.10
Type Water tube Water tube
and 11 are running and
remaining Capacity 40 tph 65 tph Boiler are
not in use Drum pressure 34 34 due to not
requirement design(kg/cm2) of steam.

Super heater -- --
design kg/cm2
Actual pressure 32 32
Kg/cm2
Designed steam 400 deg 0C 400 deg 0C
temp. 0C
Boiler Heating 1465 1700
surface (m2)
Economizer 266 380
H.S. (m2)
Super heater 132 197
H.S. (m2)
Air preheater 945 2250
H.S. (m2)
Grate area (m2) 19.75 36.75
Type of furnace Dumping grate Dumping grate
Chimney dia 2.20m 2.70m
(m) 22
Chimney height 40m 14m
(m)
3. S A Fan Details

Particulars B. No. 10 B. No. 11

Capacity 225m3/min 225 m3/min

Rpm 1450 2959 1460

Motor hp 20 18.5 kw and 93 kw

Motor rpm 1440 2950 and 1487

4. Feed Water
tank details:
particulars B. No. 10 B. No. 11

23
5. De-aerator tank details

FD FAN details:-

particulars B. No. 10 B. No. 11

Drive
H.P. 90 180
RPM 1440 1500
Speed of 1440 1500
rotor RPM
Fan dia. (m)
Fan width
(m)
No. of vanes
Capacity 1250 1950
(m3/ hr)

Feed water treatment

Particulars Description

Particulars for arrangement if softening or Ro plant(reverse osmosis plant) flow rate at 75

otherwise treating the feed water entering the TPH
Bolers
Demineralized water treatment plant flow rate
25 m3/h.

24
 ID FAN DETAILS

particulars B. No. 10 B. No. 11

Drive
H.P. 280 280
RPM 1440 1500
Speed of 750 805
rotor RPM
Fan dia.
(mm)
Fan width
(mm)
No. of vanes
Capacity 2765 1950
(m3/hr)

POWER GENERATION PLANT

Particulars Description

Make alternator frequen Phase Supp Rpm Rpm Inlet Outlet

cy ly
Turbine Alternato Steam steam
r

Two no. Blohm 1500 kw 50HZ 3 AC 8500 1500 11.27 .8

multistage
back Vess 440V kg/cm2
pressure
turbine

One no. Sulzer 1250Kw 50HZ 3 AC 8015 1500 11.27 .8

multistage
back Make 440V kg/cm2
pressure
turbine

Two no. Triveni 3000Kw 50HZ 3 AC 8230 1500 30 1

multistage
back Make BHEL make kg/cm2
pressure

25
turbine

One no. Sakoda 22250KVA 50HZ 3 AC 5500 1500 87ata 3&9

multistage
back Make 11KV
pressure
turbine

Note:- power supply to sugar industry and balance supply to UPPCL.

JUICE WEIGHMENT:-

Particulars Description

Number type and weighing capacity per charge Two number load cell type weighing scale
of each tank and arrangement provided capable of handling 15 ton and 5 ton of juice
per tip with automatic counter.

Milk of Lime Preparation

Particulars Description

No of M.O.L. tank 3

I tank 3.66m dia 2.21m height

II tank 4.11m dia 1.50m height

III tank 4m dia 1.50m height

So2 generation

Particulars Description

No of furnace 4

Tray area Each of 1.4m2

26
 Continuous burner 3nos 0.6m2 tray area

Sulpher burner type Film type

Air drier 1 nos

Air drier capacity 1600 m3 per hour

Air compressors

Particulars Description

Vertical type compressor Four nos

Capacity 600m3 /h

Delivery pressure 1.5 kg/cm2

Horizontal type compressor 2nos

Capacity 2100 m3

Working pressure 1.5 kg/cm2

Syrup treatment plant

Particulars Description

Conical bottom dia Working height

I continuous syrup sulphitation tank 2.90 m 1.8m

II continuous syrup suphitation tank 4.0 m 1.75m

III continuous syrup suphitation tank 4.5m 1.75m

Clarifier

27
 Clarifier has task to settle down the impurities of sulphited juice. It works on principle of
gravitational force. Total two no. of clarifier are in working and one in standby for any
emergency. Retention time for all clarifiers is around four hour.

Particulars Description

Dia Height Holding

capacity

Two no dorr clairifier 32’ 20’ 455m3/h

1 no short retention type -- 200m3/h

Vacuum Filter

Here total five no. of vacuum filters are commissioned to filter the muddy juice which is

coming out from clarifier.

Particulars 1 2 3
Make
Dia. (m) 2.44 2.44 4.25
Length (m) 4.38 4.38 10.95
Filtering area (m2) 37.20 37.20 147
Time per revolution 4 min 4 min 6 min
Vacuum in light zone 10 inches of Hg 10 inches of Hg 10 inches of Hg
Vacuum in heavy zone 18 inches of Hg 18 inches of Hg 18 inches of Hg
Quantity of bagacillo 26 Kg (0.6 % on cane)
added per minute
Bagacillo Screen area

Vacuum pans

Particulars Capacity Boiling for

2 nos of pan 100 tons A m/c

8nos of pan 80 tons A m/c

2 nos of pan 54 tons A m/c

1 nos of pan 60 tons A m/c

1nos continuous vacuum pan 56 tons B m/c

1nos continuous vacuum pan 35 tons C m/c

28
 Note:- vacuum gauges are provided in each pan to record the vacuum.

Condensers
Particula Dia in Height Height Dia of No of No of Size of Size Jet spray
rs mm of flat of vapour jet spray jet of
portion conical pipe nozzles nozzles nozzles spra
portion y
mm nozz
les

Pan no.1 1400 850 1375 54 21 24 24 18 350 --

Pan no.2 1560 1060 870 48 41 24 24 18 350 --
Pan no.3 1400 850 1375 54 21 24 24 18 350 --
Pan no.4 1400 850 1375 54 21 24 24 18 350 --
Pan no.5 1560 1060 870 54 13 12 28 25 300 250

Pan no.6 1300 950 1450 48 24 21 28 25 350 --

Pan no.7 1300 950 1450 48 24 21 28 25 350 --
Pan no.8 1300 750 1375 54 21 16 24 20 350 --
Pan no.9 1300 1260 1550 48 17 35 24 16 350 --
Pan 1400 850 1375 54 21 24 24 20 350 --
no.10

Pan no.11 1300 1260 1550 54 17 35 24 16 350 --

Pan 1400 750 1500 56 33 24 24 16 350 --
no.12

Pan 1600 1400 1600 56 21 48 24 19 350 --

29
no.13

New set 1200 750 1350 48 24 21 28 25 350 --

Triveni 1200 750 1350 48 24 21 28 25 350 --
Fletcher 1540 1060 800 54 13 12 28 25 350 250

B-CVP 1500 1060 1350 60 24 21 28 25 350 --

C-CVP 1200 1060 1350 48 24 21 28 25 350 --

Condenser Water Pump Injection Pumps:-9 C/F

Particulars Description

Motor capacity Capacity[hector lts/h]

One no c/f pump 200 hp 19000

Two no c/f pump 225 hp 22000

Three no c/f pump 150 hp 15000

Two no c/f pump 200 hp 16000

One no c/f pump 350 hp 30000

Air pumps

Particulars Connection Motor capacity

capacity

Three no vacuum pump Reduction gear 125 hp 1600m3/h

Two no vacuum pump Reduction gear 150 hp 3900 m3/h

One no vacuum pump Reduction gear 50 hp 600 m3/h

Water cooling system [spray pumps]

Particulars Make Motor capacity Capacity[hector lts/h]

30
One no c/f pump Kirloskar 150 hp 22737

Three nos c/f Kirloskar 215 hp 36368

pump

Three nos c/f Kirloskar 300 hp 54000

pump

Spray ponds: Total no of nozzles 1500 in 3 spray ponds.

Crystallizers

Particulars Type capacity for m/c

Two nos U shaped 55 tons For B

Four nos U shaped 55 tons For C

Two nos U shaped 55 tons& 35 tons For CAW magma

Two nos U shaped 55 tons& 65 tons For C1

Three nos U shaped 35 tons A

One no U shaped 85 tons A

Two nos U shaped 110 tons A

One no Vertical 240 tons B

One no Twin vertical 660 tons C

One no Vertical 160 tons B

One no vacuum 90 tons B-CVP

One no Vacuum 90 tons C-CVP

One no U shaped 90 tons B-CVP

One no U shaped 70 tons C-CVP

C/F MACHINES Total No Of Machine-31

Particulars Weight / Make Basket Basket Rpm

31
 charge Dia Height

4 nos A 1 ton/ charge 1244.6mm 1066.8mm --

Backau-
wolf(india)

4 nos A 750kg/charge Backau- 1244.6mm 762mm 1460

wolf(india)

3nos A 1750/charge NHEC- 1100mm 1600mm 1050

PUNE

8nos B -- Backau- -- -- --
wolf(india)&
NHEC-
PUNE

3 nos C -- Backau- -- -- --
wolf(india)

6 nos C -- NHEC- -- -- --
PUNE

3 nos C -- Backau- -- -- --
wolf(india)

Sugar driers

Hopper no Width length

1. 2.0 9.3

2. 2.0 11.8

3. 2.0 9.0

4. 1.5 8.5

5. 1.5 8.0

6. 1.5 8.7

7. 1.5 11.5

8. 2.0 13.0

9. 2.0 13.5

32
 10. 1.5 11.9

11. 1.2 11.5

12. 1.5 9.0

13. 1.2 9.0

14. 1.2 9.7

Evaporators:

Particulars New Big set H.S Old Big Set H.S. Small Set H.S. New Set H.S.

Semi kestner 2400 m2 1394 m2 1200m2 3500m2

V. C no.1 2300 m2 1022 m2 1500 m2 3500 m2

V. C no.2 -- 836 m2 -- --

Body no.1 1000m2 1115 m2 790 m2 --

Body no.2 1000 m2 1394 m2 836 m2 --

Body no.3A 1200 m2 1022 m2 232 m2 --

Body no 3 B -- 465 m2 511m2 --

Body no.4 511 m2 511 m2 372 m2 --

Total 8411m2 7759 m2 5441m2 7000m2

Apparatus for recording

Density of syrup Trough has Been provided for measuring the syrup density By
Beaume hydrometer.

Vacuum in last Body Vacuum gauge are provided in each vessels.

Juice heaters

Particulars Type Heating surface Purpose

5 nos Vertical juice heater at 300 m2 Raw juice

33
 small evaporator set

2 nos Dynamic juice heater 350 m2 Raw juice

1 nos Dynamic juice heater 250.83 m2 Raw juice

1 nos Dynamic juice heater 180 m2 Raw juice

1nos Dynamic juice heater 232 m2 Raw juice

5 nos Dynamic juice heater 450 m2 Sulphited juice

3 nos Heating surface 500 m2 Clear juice

CALCULATIONS

Calculation of plant capacity

A = 0.9 cn (1-0.06 nD) LD2 √N (ref. – E. Hugot)

f

where,
A – capacity in tch
c- cane preparation coefficient
n – rpm of mill roller
D – dia. Of roller
L – length of roller
N – no. of roller in tandem
f – fibre % on cane =0.13

G = n(1-0.06 nD) LD2

G1 = n1(1-0.06 n1 D1 ) L1 D1 2
= 4.1(1-0.06 x 4.1 x1.11) x 2.141 x 1.11x1.11
= 7.8622

G2 = n2 (1-0.06 n2 D2 ) L2 D22
= 4.11 (1-0.06 x 4.11 x 1.11)x 2.142 x 1.11 x 1.11
= 7.877

G3 = n3 (1-0.06 n3 D3 ) L3 D3 2
= 4.18 (1-0.06 x 4.18 x 1.12 x 2.20x 1.12 x 1.12
= 8.295

G4 = n4 (1-0.06 n4 D4 ) L4 D4 2

34
 = 5.10(1-0.06 x 5.10 x1.15) x 2.15 x1.15x1.15
= 9.39

G5 = n5 (1-0.06 n5 D5) L5 D5 2
= 3.9 (1-0.06x 3.9 x 1.13) x 2.13 x 1.13 x 1.13
= 7.802

Gm = (N1 - 1)G1 + G2 + G3 + G4 + G5
2(N1 - 1)

N1 = no. of mills in tandem

Gm = (5-1) x7.8622 + 7.877 + 8.295 + 9.39 + 7.802

2 x (5-1)
= 8.101

Now
A = 0.9 x C x G x √N
f

= 0.9 x 1.2 x 8.10 x √26

0.13

= 343.12 TCH
= 343.12 x 23.75
= 8149.21 TCD

Justification of cane carrier

Since one tandems are here so obviously one cane carrier is employed.
Capacity of one tandem (A) – 344 tch
Carrier width (w) – 2300 mm
Linear speed of carrier (u) – 12.6 m/min

A = uwh x 1000
60

344 = 12.6 x 2.3 x h x 1000

60

h = .712 m
= 712 mm

Cane Preparatory Devices

35
In this factory three cane preparatory devices are used –

I. Cane kicker

II. Cane leveler

III. Cane fibrizer

Combined effect of these devices results as preparatory index (PI) around 91.51

This value is admissible but not absolute; therefore some action should be taken to improve PI.
These include insertion of new preparatory device viz. cane cutter between leveler and fibrizer or
reduce the clearance at fibrizer.

Since clearance in leveler remain high as 200 mm so lower layer of cane passes without cut, while
in cutter after leveler we may keep clearance as low as 40 mm which results in better preparation
of cane stalk.

Calculation for preparatory index

1. Date – 15/12/2014

Method: we collect the sample of prepared cane and then take 500 gm sample and
dissolve it in 5 lt. water properly for about half hour this gives pol P 1 . again we take 1 kg
prepared cane and dissolve in 3 lt. water and puts in Rapi pol extractor for 40 min. this
gives pol P2.

P1 = 7.0

P2 = 21.6

r = p1/p2

= 7.0 / 21.6

= 0.324

PI = 1000 x r
III.88– 0.838r

36
= 1000 x 0.324
3.88 – 0.838 x 0.324

= 89.81

Same method is used for all reading of PI.

Date P1 P2 r PI

10/12/2014 7 21.6 0.324 89.81

21/12/2014 7.1 21 0.338 93.97

24/01/2015 7.2 21.7 0.331 91.87

25/02/2015 7.1 21.8 0.325 90.05

14/03/2015 7.3 22 0.331 91.87

Calculation of Primary extraction (PE)

1st discharge juice brix = 18.16

1st discharge juice pol = 14.57

1st discharge juice purity = 80.23 %

1st Bagasse pol = 7.00

1st Bagasse moisture = 56.00

x 100

x 100 =8.72 Fibre % Primary Baggase=[100-Moist.-Pol%P Baggase]

=[100-56-8.72]

=35.28

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Primary Baggase= X100 = X100 =39.40

Juice % Cane=100-P. Baggase=100-39.40=60.6

now primary extraction= x 100= x 100=70.38

Date 1st dis. 1st dis. 1st dis. 1st dis. Fibre % PE
Juice brix Juice pol Bagasse Bagasse cane
pol moisture
12/12/2014 18.16 14.57 7.0 56.0 13.90 70.38
21/12/2014 18.65 14.87 7.1 56.1 13.91 70.43
04/01/2015 18.45 14.89 7.0 56.0 13.23 70.23
05/03/2015 18.17 14.13 7.0 56.2 13.89 70.32

Mill extraction and Reduced mill extraction report

Date ME RME
11/12/2014 96.06 96.25
14/12/2014 96.07 96.55
21/12/2014 96.56 96.26
30/12/2014 95.12 96.21
02/01/2015 96.09 96.98
08/01/2015 96.34 96.78
12/01/2015 96.32 97.12
29/01/2015 95.78 97.09
01/02/2015 96.09 97.11
18/02/2015 96.00 96.37
22/02/2015 96.12 96.57
06/03/2015 96.32 96.29
20/03/2015 96.65 96.99
25/03/2015 95.89 97.04
10/04/2015 96.33 96.39

38
Steam consumption at mills

Since in this factory drive for mill is single stage turbine, make by triveni turbines. These turbines
use steam produced by boiler to give drive to mills.
Steam consumption of these turbines are 4 to 5 ton/hour.
As we know that steam consumption for mill turbine always exceeds the steam consumption by
power turbine to produce electricity sufficient to drive mills by using electric motor. This power
consumption may further reduced by employing AC motor with VFD systems on the place of DC
motor. Speed control in AC motor is also superior to DC motor.
Although power saving is necessary tool to make plant energy efficient and run in profit but no
one can exclude the capital cost of this replacement, when making decision for introduction of
new technology.
Now a day differential drive for mills getting popular due to its energy efficient operation as well
as best speed control. Above all commercial viability and economic feasibility of any type of
technology must be checked before finalizing it.

Bagasse analysis

Date Pol% Bagasse Moisture % Bagasse

10/12/2014 1.56 50.0
16/12/2014 1.57 50.00
22/12/2014 1.58 500.10
26/12/2014 1.56 50.10
01/01/2015 1.54 50.10
07/01/2015 1.56 50.00
18/01/2015 1.57 50.90
27/01/2015 1.58 50.00
01/02/2015 1.54 50.10
08/02/2015 1.56 50.00
22/02/2015 1.57 50.90
04/03/2015 1.58 50.92
12/03/2015 1.57 50.10
21/03/2015 1.56 50.15
26/03/2015 1.56 50.20
29/03/2015 1.57 50.23
30/03/2015 1.58 50.20
04/04/2015 1.56 50.10
08/04/2015 1.54 50.20
16/02/2015 1.56 50.50

Desuperheati ng process:

39
 For all process heat transfer equipments like juice heaters, evaporators,
vacuum pans, if is very essential to supply saturated steam because heat transfer
rate increases when equipment is supplied with saturated steam.

To obtain high efficiency at power turbines, steam is usually generated at high

pressure and temperature, thus enabling the maximum release of kinetic energy
per unit mass flow. These high pressure and temperature conflict with the
requirement of heat transfer, where the steam is required to be at reduced
temperatures and pressures to obtain maximum efficiency. This is due to the large
amount of heat available in saturated steam when pressure and temperature levels
are low.

So, when saturated steam enters the heat exchanger, it starts condensing and
the latent heat, which is major portion of the local heat content of steam, becomes
immediately available for heat transfer, if the steam is de-superheated.

So de-superheating close to saturation temperature at the lowest possible

pressure level is essential for obtaining maximum utilization efficiency.

BOILER TEMPERATURES

Date Temp. in 0C
Furnace dry steam S.H steam economizer air heater flue gas

27.01.2015 1177 250 351 166.43 176 147

01.02.2015 1178 249 350 167 177 149
08.02.2015 1150 245 354 168.32 178 148
21.02.2015 1145 244 351 166 179 150
04.03.2015 1160 251 352 165 176 151

JUICE SECTION ANALYSIS

Juice Heater :
Raw juice is heated to a temperature of 65 o – 70 o C in raw juice heaters. Heating
of juice is generally accompanied by exhaust steam or bled vapour. The latent
heat of the steam or vapour is transferred to the juice and sensible heat leaving

40
with hot condensate. However there is small heat loss due to radiation depending
upon the insulation of juice heater. The reasons for maintaining this temperature
of raw juice are
a. To deactivate Mesophyllic bacteria from the cane juice. If these bacteria
are not deactivated they will produce bacterial inversion in raw juice.

b. This temperature is conductive for getting proper rate precipitation

reactions in the juice sulphitor, when the juice is treated with MOL and
SO 2 gas. If the temperature of raw juice is exceeded beyond 70 o C then
the inversion rate of sucrose will increase as the p H of the raw juice is in
the range of 5.0 to 5.5

Sulphited juice is heated up to 102 o C to have an effective flocculation i.e.,

formation of Calcium Sulphites and Calcium Sulphates. Normally it requires in
two stages i.e. 1 s t and 2 n d heating. So clarification will be good at this particular
temperature.
Clear juice is heated up to 108 o C to get effective evaporation process.
Juice heater consists of an assembly of tubes fitted to top and bottom tube
plates. The juice circulates through the tubes and vapour/steam outside the tube.
Baffles provided in the juice heater force the juice to pass a certain number of
times from bottom to top and from top to bottom of the heater by restricting the
juice each time to a few of the tubes.
The circulating velocity of juice inside the juice heater must be in between
1.5 to 2 m/sec, if it falls below 1.5 m/sec, the heat transfer coefficient will be
lower and if exceeds 2.2 m/sec the heater causes a marked pressure drop which
rapidly becomes prohibitive.
Factors affecting heat transfer from steam to juice
1. Film of the condensate around the tubes.
2. Film of the oil particles outside of the tubes.
3. Non condensable gasses or presence of insulation of air in the steam
space.
4. Material of the tube.

41
 5. Diameter and thickness of the tube.
6. Philosophy of juice flow within the tubes.
7. Philosophy of steam around the tubes.
8. Mean temperature diff erence between steam and juice.

Head loss in juice heaters:

There is a pressure drop suffered by the juice in its passage through heaters. The
loss of head due to the 180° change of direction at the end of each pass may be
considered as equivalent to a length of 1.5 times the diameter of the tube. The
loss of head in juice heater is given by the following formula.

h = 0.0025 nv 2 [(L/D)+3]
Where
h = Loss of head caused by the passage through heater in meter of
the water column
n = No. of passes in the heater
v = Velocity of juice in tube in m/sec
L = Length of the tube in m
D = Inside diameter of the tube in m

Calculation for Juice Velocity:

Crushing Rate : 8149TCD
Mixed juice % Cane : 100 %
Filtrate Juice % Cane : 15 %
Total Raw Juice % Cane : 115 %
8149 115
Tonnes of juice /hr : -------- x ------ = 390.47
24 100
Tonnes of juice /sec : 390.47/3600 = 0.1084

42
 Density of juice : 1.06
Volume of juice per sec : 0.1084 /1.06 = 0.1023 m 3 /sec
3.14
Cross secti on of Jc.H : ------ x D 2 x N
4
Where D : Dia. of the tubes
= 0.042 m
N : No. of tubes = 36
3.14
Cross secti on of Juice Heater : ------ x (0.042) 2 x 36 xv
4

= 0.0498v m 2
Velocity of Juice : 0.1023 / 0.0498
= 2.05m/se c

Pan floor data

Sugar Boiling:
The whole process of boiling, principles involved can be explained very
reasonably, Starting with syrup, continuous removal of water by evaporation
allows a point to be reached, at which the water is insufficient to keep all the
sugar in solution, then which begin to crystallize out. If the syrup consisted of
sugar and water only the complete removal of water could afford a complete
recovery of the former in a dry and pure state. Some water must be left in the
magma or Massecuite sufficient to keep the non-sugar in solution, where by a
means is afforded for separating the solid crystals from the mother liquor or
molasses.

Aim of Crystallization:

43
 The aim of crystallization of sucrose have two basics; Primarily the sugar in
solution must be transformed into a crystalline state that in the following steps of
sugar manufactures, the centrifugation, the highest possible yield of the
commercial sugar be obtained as commercial product. Second, it is necessary that
the amount of sucrose present in the raw material is transformed into the highest
possible crystallization process, the last mother liquor or black strap is well
exhausted.

Aims of Pan Boiling:

In evaporator our aim is only to evaporate the water and concentrate the juice up
to desired brix. But pan boiling have various aims as follows-

1. Evaporation of water as per need to increase super saturation.

2. Separation of sucrose molecules from it’s associated impurities either

by forming grain or by development of grain. Thus transfer of sucrose
molecule from liquid phase to solid phase.

3. Separations of granular crystallizing particles by centrifugation and

get maximum sugar recovery by maximum exhaustion of mother
liquor.

Effect of purity on boiling:

The rate at which the sugar deposits on the crystals is a function of purity. As the
purity increases deposition rate also increase. The grain growth, crystal
development, final Massecuite formation will take place in the pans only.

Vacuum:

The adoption of vacuum in sugar boiling is due to

a) Boiling will take place at low temperature, so that we can avoid destruction
of sucrose.
b) Boiling will take place at low temperature, so that we can avoid inversion.
Mr. E.C. Howard invents vacuum pans in 1893. We are using batch pans for
A massecuite.

44
 In modern sugar factories for crystallization only vacuum pans used. The
vacuum pans are having number of advantages over open pan boiling (Still in
some khandasari units open pan boiling procedure being adopted). These
advantages are listed below
1. Temperature of boiling massecuite is very low as compared to
open pans. This avoids color formation and caramelisation of sugar.
This helps to produce a superior quality sugar.
2. Heating medium used is steam and could be controlled as per
wish. In direct fire open pans this is not possible.
3. Various methods could be adopted in vacuum pans to improve
exhaustion while in open pans it is not possible.
4. Time and energy saving.
Vacuum Pans:
Vacuum pan is a single effect evaporator. It can be rightly called as
evaporator crystallizer, since evaporation as well as crystallization is taking place
in pans. In pans mainly following three function are carried out.
a. Concentration of feed
b. Nucleation
c. Finishing the strike with a thick tight “massecuite”

Heating Surface to working volume i.e. S/V ratio:

A very important factor in the design and performance of vacuum pan is the ratio
of their heating surface to their working volumetric capacity. This ratio is not
only sufficient to characterize evaporation rate in the pan but also for the majority
of pans with tube diameter as used at present, it continues to be dominating
factor.
Heating surface is expressed in square meter and working volume expressed
in cubic meter. So the unit of S/V ratio becomes m 2 /m 3 . For bleded vapors
generally the S/V ratio kept 6 – 7.5 m 2 /m 3 . However S/V ratio is mainly
depending on steam pressure and massecuite type.

45
 However it is desirable to take in to account since the massecuite becomes
more viscous as its purity decreases. Generally it is preferred to decrease the S/V
ratio for low grade massecuite to avoid risk of caramelisation and formation of
false grain due to viscous and badly circulating massecuite.
The terms used in pan boiling
1. Saturation:
The solubility of pure sucrose in water varies with temperature and
increases rapidly with increase of temperature. When a solution contains the
total quantity of sucrose which it can dissolve, then the solution is said to be
saturated.
2. Super Saturation:
If a solution of sugar is concentrated by evaporation or cooled beyond the
saturation point, the crystals do not appear immediately, but the sugar still
remains in solutions. This is known as “Super Saturation”.
3. Super Saturation Co-efficient (SSC):
It is the ratio of the weight of sucrose percent water contained in a super
saturated solution to the weight of sucrose percent water which would be
present in a saturated solution having the same temperature and the same
purity.

Sucrose % Water in super saturated solution

S = -----------------------------------------------------------
Sucrose % Water in saturated solution

4. Metastable Zone:
Between a super saturation co-efficient of 1.0 to 1.25 the zone is known as
“Metastable Zone”. In the zone existing sugar crystals grow further in size by
the constant deposition of sugar, as evaporation proceeds but no new crystals
are formed.

5. Intermediate Zone:

46
 Between the super saturation co-efficient of 1.25 to 1.40, the zone is known
as “Intermediate Zone”. In this zone, existing crystals grow, as well as new
crystals may also form, but only in the presence of existing crystals.
6. Labile Zone:
Beyond the super saturation co – efficient of 1.4, the zone is known as
“Labile Zone”. In this zone, sugar crystals spontaneously grow and new
crystals can form even in the absence of existing crystals.

Final molasses analysis

Date Ash % Brix Purity TRS RS

14.12.2014 11.90 86.54 27.55 46.20 17.10
27.12.2014 10.66 85 28 48.00 15.54
04.01.2015 11.70 86.34 27.12 48.78 15.40
18.01.2015 11.90 86.12 27.54 49.67 15.34
02.02.2015 11.35 86.43 27.87 48.90 15.60
09.02.2015 11.80 86.32 27.34 48.67 16.20
25.02.2015 11.10 87 27.12 48.70 15.90

Analysis of Sugar (ICUMSA)

Date L M S
27.12.2014 107 102 105
03.01.2014 106 102.1 105.2
18.01.2015 107 102.2 106
22.02.2015 Syrup
107.2 102.2 105.2
10.03.2015 107.3 102.1 105.1
03.04.2015 107.1 102.2 105.3 C M/C
A M/C B M/C

Final
A.L. A.H. B.H.
Molasses
Molasse Molasse Molasse
s A Sugar s B Sugar s C.F.W. Sugar
MASSECUITE BOILING SCHEM

Grader C.L.

Molasses
Dry Seed Rori Sugar
C.A.W Sugar
47
SUGAR
Melter
 Bibliography
The following books and journals were referred for preparing this in-plant
training report
1. Hand book of sugar cane engineering - E. Hugot

2. Hand book of cane sugar technology - R.B.L. Mathur

3. System of technical control for cane sugar factories in INDIA- - N.C.Varma

4. SISTA & DSTA journals

5. Various websites related to sugar engineering and sugar process control.

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SNAPSHOTS FROM THE PLANT

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