Beruflich Dokumente
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TERM PAPER
To study the procedural methodology of production & control of the sugar industry
Submitted by: Ashish Suman Roll No. RS1904 A10 Reg. No. 10905868
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ACKNOWLEGMENT
It is our immense pleasure to present the Term Paper on To Study the Procedural Methodology of Production Planning & Central of The Sugar Industry
Here we would like to express our deep sense of gratitude to our Respected faculty
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CONTENTS
1. Introduction
Indian Sugar Industry Global Sugar Industry
2. 3. 4. 5. 6. 7. 8.
Yeilds Seasonal Nature Of Production Setting up Sugar Factory Operation & mangment Plant layout Industrial Process Based Classification of Sugar Manufactring Process of Raw Sugar
Manufactring Process Precaution to be taken during manufacturing of raw sugar
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9. Manufacturing Of refined Sugar 10. Sequence of steps in sugar production 11. Cleaner technologies 12. Significance of polluted Genreted 13. References
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INTRODUCTION
Indian Sugar Industry
India is the largest consumer and second largest producer of sugar in the world (Source: USDA Foreign Agricultural Service). The Indian sugar industry is the second largest agro-industry located in the rural India. The Indian sugar industry has a turnover of Rs. 500 billion per annum and it contributes almost Rs. 22.5 billion to the central and state ex-chequer as tax, and excise duty every year (Source: Ministry of Food, Government of India). It is the second largest agroprocessing industry in the country after cotton textiles. With 453 operating sugar mills in different parts of the country, Indian sugar industry has been a focal point for socio-economic development in the rural areas. The industry not only generates power for its own requirement but surplus power for export to the grid based on byproduct bagasse. It also produces ethanol, an ecology friendly and renewable energy for blending with petrol. The sugar industry in the country uses only sugarcane as input, hence sugar Companies have been established in large sugarcane growing states like Uttar Pradesh, Maharashtra, Karnataka, Gujarat, Tamil Nadu, and Andhra Pradesh. These six states contribute more than 85% of total sugar production in the country; Uttar Pradesh and Maharashtra together contribute more than 57% of total production. Indian sugar industry has grown horizontally with large number of small sized sugar plants set up throughout the country as opposed to the consolidation of capacity in the rest of the important sugar producing countries, where greater emphasis has been laid on larger capacity of sugar plants.
Yields
The yield of gur from sugar cane depends mostly on the quality of the cane and the efficiency of the extraction of juice. The table below gives some extreme values. High quality cane Juice per 100kg of cane % sugar in juice Gur per 100kg of cane 50kg 22 10kg Poor quality cane 40kg 17 7kg
High quality cane has a good juice content with high sugar levels (20%+). Poor quality cane or cane that has been harvested early may have similar juice content but the sugar levels will be reduced. The efficiency with which juice can be extracted from the cane is limited by the technology used. The simple three roller crushers used by most artisanal producers will never extract more than 50kg of juice from each 100kg of cane.Yields are also improved by careful control of the boiling process. Boiling should be completed as rapidly as possible and the conditions kept as clean as possible.
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Because the cane quality deteriorates quickly after harvest, it is important that the suppliers are contracted to supply cane at given times. This enables the factory to work continually while minimising the time harvested cane is allowed to stand.This type of factory is suitable for medium scale production of between 50 and 500 TCD where cane is available all year round or for a substantial part of the year. Sugar estatesThe sugar estate takes control of all aspects of sugar production from growing cane to processing and marketing. It is usual for the estate to provide the bulk of their requirements and occasionally to contract local growers to produce certain amounts of cane for them. The estates can be fully owned by the factory or leased from the farmers in the area. In both cases the factory farms the land in accordance with its needs, providing all equipment, fertiliser, pesticides and transport.Operating and managing an operation of this magnitude requires resources such as tractors, ploughs and harvesting equipment as well as a skilled workforce, all of which add to the cost of the process.
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Transportation :Transport may be required to bring cane from the fields to the factory and
also to take the product to market. If motor vehicles are used then capital, maintenance and operating costs must be added to the cost of the product. If animal powered transport is used then hire charges and feed costs are also applicable. There may also be costs associated with the loss of the draft animal to other duties. MaintenanceEquipment cannot be operated effectively without proper maintenance and repair. Engines, electric motors, crushers and permanently sited furnaces will all need routine maintenance if they are to operate efficiently. Crusher rollers will wear with time and require re-machining which necessitates access to a workshop with a lathe. Usually, rolls can only be re-machined once after which they will be too small for effective crushing. Therefore spare rolls or facilities for refacing old rolls will be required. Other spares such as bearings and gears may also be required. Therefore due consideration must be given to the provision of maintenance. Several options are available to the factory: provide its own spares buy spares from local suppliers import from outside the region or country. Sugar caneSuitable sugar cane must be available if a factory is to be efficiently operated. Because of local conditions and circumstances it may not be possible to grow the best type of cane and so a compromise will have to be made. Investigatory work can be undertaken with local agricultural research centres or, if possible, established sugar factories which will already have undertaken research into varieties suitable for processing. After selecting a suitable variety it will be necessary to test it to ensure that it will succeed under local conditions. However, introducing a new variety of cane into an area may have a number of problems including: Farming practises may have to change to enable the new cane type to be grown successfully and on a sufficient scale. Farmer may not wish to invest in a new variety of cane until a market is assured. Chemical fertiliser may be required Most medium-scale factories will require a set minimum amount of cane each day. Because of the rapid rate of deterioration of the harvested cane, it must be used with twenty four hours. In
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addition, the growing season may be shorter than the operational period of a factory and so farmers may have to grow cane over a longer period to meet demand. Therefore it may be necessary for farmers to change their farming practices to allow for a longer season and staggered harvests. In return the farmer will receive a guaranteed income per unit weight of cane from the factory and can often claim part of the payment in advance. However, the factory retains quality control and usually has the right to reduce payment if the condition of the cane falls below that required.
Plant Layout
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Raw sugar: It is brown sugar, which includes molasses and various impurities at the stage
before it is crystallized. Raw sugars are produced in the processing of cane juice but only as intermediates en route to white sugar.
Centrifugal sugar: This is raw sugar which has been crystallized and most of the molasses
spun off by the use of a centrifuge.
White sugar: In developed countries, most white sugar is sugar that has undergone one
further refining process. There are various degrees of refining and the consequent purity and consistency of sugar crystals. As in other developing countries, most of the mill sugar produced and consumed in India is plantation white, meaning sugar that has undergone a first stage of refining at the mill, but which is less refined than the refined white sugar consumed in developed countries.
It is produced by
primitive artisanal processes and mostly consumed in rural areas. In Northwestern India, mainly in UP, there is also very substantial production of khandsari , which is a type of sugar produced by small scale country mills with the use of a centrifuge. Gur is not a close substitute for sugar, and is mainly consumed by low income rural people as a food stuff rather than as a sweetening agent. Sugarcane contains 70% water, 14% fiber, 13.3% saccarose (about 10 to 15% sucrose), and 2.7% soluble impurities. Sugar beet has a water content of 75%, and the saccarose concentration is approximately 17 %.
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Manufacturing process
To avoid bacterial contamination and to control dextran, 10-17 parts per million (ppm) of quarternary ammonium compound base effective biocide is used, steam/hot water washing is carried twice in a shift. Screening of raw juice is carried with double stage DSM screen having 0.6/0.7 millimetre (mm) aperture. Mixed juice phosphate level is kept 300 to 325 milligrams per litre mg/L by addition of phosphoric acid of A Grade. Raw juice is heated to 76 to 78oC Simple detection process is followed only by adding milk of lime 60 to 80 brix to maintain the pH in the range of 7.2 to 7.6, juice is heated up to 102o C to 103oC and clarified. Addition of 1 to 3 ppm of mud setting and colourant is added to get brilliant colour. Juice or syrup sulphitation is not required. There massecuite boiling system is followed as that of white sugar. B m/c single cured seed taken for A m/c as a footing partially melted C m/c double cured melted B & C melt taken for A m/c boiling
Curing
A m/c is cured in steep cone machine of 38 x 49 machine Time cycle of A m/c is adjusted according to quality of dropping sugar without any lumps.
Conveying
Raw sugar conveyed in sugar hoppers blowing hot and cold air.
Grading
Mesh/screen fitted on top side for separation of rotary and for other deck that is, 6,8,10 mm mesh serves the purpose for bottom side with any type of plate having 2 mm thickness or tarpaulin/plastic paper no difficulty is experienced at grading.
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- Brine recovery system Scum desweetening Crystallization Centrifugation Drying, storage and packaging Recovery house (Raw sugar house would be as recovery house)
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For the production of refined sugar, decolorization of the melt is required through ion exchange resins. Two stage decolorizing process for this particular application is recommended. In this process, the decolorization is effected by passing the clear melt through a styrene based resin. The resin, after completing the duty cycle, which is normally of 16-24 hrs, is desweetened by back flushing vigorously with hot, soft water to disperse the bed and to remove any suspended matter which may have collected during the duty cycle. Regeneration is carried out with 10% sodium chloride solution having 2% concentration of sodium hydroxide. Operation sequence: Sweeten on Service run Sweeten off Back wash Regeneration Displacement Descaling
i. Melt concentration The fine liquor is concentrated in the evaporator to brix 74-76 to save energy and to maintain the product quality by stabilizing the brix of the evaporated fine liquor. A thin-film falling filmtype double effect evaporator would be used for concentration of fine liquor. Typically the heating surface of each falling film would be around 500 m2. ii. Brine recovery system This recovery process is based on the concentration of COD and colouring material in the retentate, while smaller molecules such as sodium chloride, sodium hydroxide, and water can easily cross the membrane (permeate). In this recovery system, organic spiral - wound NF membranes are being used with high concentration factor of effluent. The spiral-wound membranes are much cheaper to tubular type. In this process each effluent from caustic brine regeneration is processed in a cross-flow filtration skid equipped with spiral nano-filtration membranes. Under a pressure of 20 bars, the spent brine would be highly purified to give a new load of recovered brine, which would be used for the next regeneration cycle.
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The membranes are easy to clean and the efficiency of resin regeneration with nano- filtration brine would be about 70-80% and it can be further increased by installing brine concentrator.
Process description
It is the process in which sugar is crystallized from concentrated fine liquor obtained by water evaporation under vacuum; the operation is carried out under vacuum to prevent the sugar from burning or decomposing by heat and to obtain the crystals of the adequate size.
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The most-effective decolorization is achieved by crystallization. Crystallization occurs in a saturated/supersaturated solution, which also means that crystals are always surrounded by a liquid phase. Color is removed by crystallization, assuming the syrup separation is executed well. For high quality massecuites like A and refined sugar, color removal is at least 90%, but can go as high as 97.5-98%. Lower purity massecuites like B & C exhibits less color removal of 95- 95.5% and up to 80% (75 - 80%) respectively. Back boiling or mixed boiling system will be followed for producing refined sugar of single quality. When the boiling is complete around 89 brix; pan is dropped into crystallizer and cured in batch centrifugal machine. This cured sugar is dried and cooled into drier before weighing & bagging.
F. Centrifugation
Centrifugation requires greatest attention as it ensures the effective crystallization. Inadequate mode of operation, badly cleaned screens, and mal-adjusted washing nozzles to mention a few of the key parameters of centrifugal work can destroy good results obtained in crystallization.
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Recovery house
The recovery house is the dirty end of the sugar refinery where, as the name implies, the refiner tries to recover as much as possible of the sugar in any residual liquors before rejecting them as the molasses. Maximum sugar must be recovered from runoffs to get the optimum yield of the refinery. Series of boiling and other processes are followed to get the maximum sugar out of those liquors, and producing at the end, a thick material called sugar syrup and used in cattle feed preparations. The yield performance of any sugar refinery depends upon the performance of the recovery house.
Advantage achieved in raw sugar production over to the white sugarto the process point of view
Rise in recovery percent cane by 0.63% Capacity utilization is increased by 6 to 8% Sulphur is not used in the process reduction in lime consumption by 58% Scale formation rate is very low and soft in nature Reduction in molasses % cane by 0.6-0.9 % Massecuite % cane is reduced by 5 to 6%
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Traditionally, cane has been burned in the field before transport to processing facilities to remove any leaves from the cane stalk. The current trend is to harvest green unburned cane, returning leaves to the field where the crop residue promotes soil conservation. Extraction of the sugar juice is achieved with roller mills which press out the juice. The remains of the cane stalk is called bagasse, which contains cellulose fiber. This is mostly used in the process facility as fuel for energy supply. Where fuel is available from another source, the bagasse may be used for further processing in the cellulose industry. Cane juice extraction may also be achieved by a diffusion leaching process, which can result in higher rates of extraction with 50% lesser energy consumption than a mechanical mill. C. Washing and extraction of beet Washing of sugar beet is water-intensive and washwater is typically recirculated. During washing, soil, stone and leaves are separated from the beet. Separated stone can be used, for example, as gravel for the construction industry. Disintegration of the beet is accomplished by cutting into slices (cossettes). The juice is extracted by a diffuser, where the slices are mixed with hot extraction water to form a sugar solution, known as diffusion juice . The spent beet cossettes in the beet pulp are then pressed and dried to produce animal feed. Sugar Manufacturing Process
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D. Sugar refining The refining of sugar involves affination (mingling and centrifugation), melting, clarification, decolorization, evaporation, crystallization, and finishing. Decolorization methods use granular activated carbon, powdered activated carbon, ion exchange resins, and other materials. E. Clarification, evaporation, and crystallization The juice resulting from the extraction process is clarified by mixing it with milk of lime, after which it is filtered to remove the mud. In beet-based sugar production, the lime is produced from limestone, which is combusted in a specially designed lime kiln. The main outputs are burnt limestone and carbon dioxide (CO2). The burnt limestone is used to generate milk of lime and the CO2 is also added to the liquid in a process called carbonation. Because large quantities of milk of lime and gas are needed, this is a continuous process. These substances are added to the juice and, in the process of carbonation, bind other components, such as protein, to the
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lime particles. The lime is then filtered, resulting in lime sludge, and dried for use as a soil conditioning agent in agriculture. The resultant clear solution of juice is called thin juice. Although the carbonation process gives good results, it is rarely used in the cane industry because of the investment required and a general lack of the main raw material, limestone. Cane processing facilities typically purchase ready-made burnt limestone powder and use this to generate milk of lime. After clarification, the thin juice has a sugar content of approximately 15%. Concentrations greater than 68% are needed to allow sugar crystallization, and this is achieved through evaporation. Water is removed from the thin juice in a series of evaporating vessels until syrup with a dry matter content of 68 72% is obtained. This thick juice is further evaporated until sugar crystals form, and the crystals and the accompanying syrup are then centrifuged to separate the two components. The final syrup, which contains 50% sugar, is called molasses. Sugar crystals are then dried and stored (e.g. in silos). Molasses is the most important by product of the sugar production. Molasses can be used as cattle fodder or as raw material in the fermentation industry. To facilitate the use of the molasses, which is generated in rela tively high volumes, sugar factories may be combined with distillation plants (see below). The basis for the distillery can be sugar juice, molasses, or a combination of these products.
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E. Distillery An associated distillery may employ batch or continuous fermentation, followed by distillation, to produce ethanol with a purity of 95%. This ethanol can be used in other industries or further processed and blended with gasoline. Waste from the distillation process is known as vinasse or spent wash. Anaerobic digestion of this waste is used to produce biogas, which can be utilized for the production of boiler fuel for the distillery or to fuel combined heat and power engines. Remaining waste can be returned to agricultural fields and / or used in the composting of organic solids emanating from processing. Cleaner technologies Based on the site visits and study; the following technologies may be classified as cleanertechnologies for sugar waste management. Segregation of concentrated and dilute waste streams and adopt Composting for concentrated wastes and Stabilization ponds for dilute wastes. Anaerobic Digestion/ Anaerobic lagoon/Anaerobic filter as primary treatment followed single stage aeration. Anaerobic pond + Facultative pond + aerobic pond Equalization tank + Monthly washing Holding Tank + Single/ two stage aeration + clarifier. (NOTE: In all the above cases oil & grease trap (preferably mechanical), Screen and V notch or continuous flow recorder is a must)
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Molasses
Final molasses is produced in the last steps of operation of separation of sugar from the mother liquor in centrifuges. It has been found that average production of molasses is 4.2% of the cane crushed. But there is quite a large fluctuation in this. Molasses has very high pollution characteristics.
biological treatment, typically anaerobic followed by aerobic treatment, for reductio of soluble organic matter (BOD) biological nutrient removal for reduction in nitrogen & phosphorus chlorination of effluent when disinfection is required dewatering and disposal of residuals; in some instances composting or land application of wastewater treatment residuals of acceptable quality may be possible
Solid waste and by-product management Sugar industry activities generate large quantities of organic solid waste and by-products (e.g., leaves from cane or beet, molasses from the final crystallization, press mud or cachaza, bagasse fiber from the cane, mud and soil arriving at the plant with the raw material, and lime solids from the juice clarification). The amount of waste generated depends on the quality of the raw materials themselves and on the initial cleaning in the field.
Emissions to air
Air emissions in sugar manufacturing are primarily related to particulate matter generated from bagasse-fired steam boilers, dust from unpaved access roads and areas, and sugar drying or packing activities. In addition, odour emissions are generated from beet processing activities and storage facilities. Air pollution from sugar industries The burning of bagasse produces particulate like unburnt fibers, carbon particles, and ash and gaseous pollutants like oxides of nitrogen, water vapour and other compounds of the particulate waste, the heavier particles slowly settle down in the surrounding area. Such dust fall leads to the problem of cleaning, reduction in property value, effect on vegetation, etc
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REFRENCES
Websites 1. http://www.sugarindustry.com/introduction.htm 2. http://www.trivenigroup.com/sugar-information/sugarcane-productioncenters.html 3. http://www.appropedia.org/Sugar_Production_from_Cane_Sugar_%28Prac tical_Action_Technical_Brief%29 4. http://164.100.194.13:8080/ssdn1/jspfiles/doc/Sugar.pdf 5. www.scribd.com 6. http://en.wikipedia.org/wiki/Sugar 7. http://www.cd3wd.com/cd3wd_40/vita/grapejuc/GIF/UGJX6.GIF
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