UKA TARSADIA UNIVERSITY

By Guided by:
DESAI VIHANG KIRTIBHAI Mr. VINOD PATEL
201603100520006 Assistant Professor

Department of Mechanical Engineering

Chhotubhai Gopalbhai Patel Institute of Technology.
SAYAN SUGAR FACTORY
SHREE SAYAN VIBHAG SAHAKARI KHAND UDHYOG MANDLI LTD,SAYAN
BY VIHANG DESAI
SAYAN SUGAR FACTORY

 FOUNDED ON 20TH NOV 1972

 AREA : 200 Acres
 11406 SHAREHOLDERS
 TOTAL CAPITAL INVESTMENT OF FACTORY : 61Cr
 ANNUAL TURNOVER 150Cr
 SUGARCANES CRUSHED PER YEAR : 128397 TONS
 HOSPITAL OPENED BY FACTORY IN SAYAN
 ITI INSTITUTE & PRIMARY SCHOOL FREE OF CHARGE
PRODUCTS

 SUGAR CRYSTALS OF EXPORT QUALITY (A,B,C GRADES)

 BAGASSE (USED AS FUEL )
 MOLASSES (LIQUOR,FOOD FLAVOUR,ACETIC ACIDS etc)
 ABSOLUTE ALCOHOL (AZEOTROPIC DISTILLATION)
 RECTIFIED SPIRIT (FORMATION AND DISTILLATION)
VFD
VFD

 VARIABLE FREQUENCY DRIVE :

 variable-frequency drive is a type of adjustable-speed drive used in
electro-mechanical drive systems to control AC motor speed and torque
by varying motor input frequency and voltage.
 VFD is used in most industries To Reduce power using and increase
efficiency.
 Before vfd was available they used standalone drive which could not
change speed and was less efficient.
SAYAN SUGAR FACTORY

 Divisions :
9. Etp
1. Yard 10. Dissilary
2. Mill section 11. Cooling tower/pond
3. Juice sectiom 12. Molasis tank
13. Turbine section
4. Pan section 14. Boiler section
5. Storage
6. Workshop
7. Store room
8. Storage (godaon)
MILL SECTION
MILL SECTION

 Capacity : 7000 tons/day

 No of mills : 3
 Components : 3 types of rollers,chain drive,bucket conveyer
BOILER SECTION
BOILER SECTION

 WATER TUBE BOILER

 CapacIty :40 tons/hr
 Fuel type : baghas
 Final steam temp. : 390
 Insulation : lagging
 No of boiler : 4
 BOTTOM ASH CONVEYOR SYSTEM
TURBINE SECTION
Turbine specifications

 No of turbines : 5
 Types of turbine : backpressure turbine
 Inlet pressure of turbine : 32/25/21 kg/cm^2
 Outlet pressure : 0.5-1.5 kg/cm^2
 Rpm of turbine : 7200
 Alternator rpm : 1500
 MATERIAL : NICKLE BASED SUPER ALLOY(HIGH TEMP,CORROSIVE RESISTANT)
Mfg compnies of turbine :Triveni pvt ltd &APE Belish pvt ltd
Mfg compnies of alternator : Bhel pvt ltd,kirloskar pvt ltd & jyoti pvt ltd
JUICE SECTION
JUICE SECTION

 Flow chart of juice section

1. Primary juice (31°c)
2. Juice heater (70°c)
3. Juice sulphier (ph to 7.2)
4. Sulpher chimney
5. Juice heater (85°c)
6. Dore (waste seprator)
7. Press mud
8. Storage
JUICE SECTION

 Juice section main purpose is to convert the juice in liquid form to densed
liquid By using the heat of backsteam flow of turbines
 It does so by using convective heat transfer between pipes containing
juice and hot steam of turbines
 These section requires constant surveince of the process as mistakes can
result in stoppage Of plant for days
 And maintainance of these is a must after every 6-8 months as the nature
of juice is mostly acidic .
CENTRIFUGAL seprator

• This machine uses the pricipal of centrifugal force

to seprate the molasis and sugar crystals
• The top part of the machine contains a motor
driven stirer which keeps stiring the molasis in
container and doesnt let it become solid
• Then the mixture is dropped in to the drum which
rotates at around 4000 rpm and capacity of 1500
kg/ch
• It contains two filters to seprate the crstal and
molasis
STORAGE
STORAGE

 The storage is made of 3 Types of containers

 Type A ,type B ,type C
 Type A contains the small crystals
 Type B is for extra small sized crystals
 And type C for powdered sugar
 Then it is transferred to godaon
 There is total no of 10 godaons each with capacity of 7590 Bags atleast
PAN SECTION
PAN SECTION

 Its main purpose is to make diffrent diffrent sized crystals and then transfer
required size of crstal to storage tank A,B,or C
 It is done by using the saturated steam to boil the juice about 60°c so that
all the water content evaporates and juice turns into syrup which is then
converted to sugar crystals of brown color and the leftover molasis is then
used in pan B which makes B-Grade sugar crystls same for pan C and the
leftover molasis from there is sent to disillary to create pure alcohol
(ethanol) and rectified spirit.
 they boils the juice at 60c by creating vaccum .
WORKSHOP
Workshop

 The workshop consists of 5 lathes 2 grinding machines and a radial drill

machine
 Types of lathes in workshop
1. Turret lathe
2. Capstan lathe
3. Tool room lathe
4. Bench lathe
 Grinding wheel types : bench grinder
 Radial drill machine
 Hecksaw machine
Valves , FLV Unit and lubricator
Valves

 DCV : Direction control valves

 Butterfly valve
 Sweesh valve
 CG valve
 Blow valve
 Double bit valve
 Heavy valves
ETP & Biogas Plant
ETP

 This is the section whose main objective is to reduce as much pollution and
pollutants and recycle the waste in any way possible
 ETP is to comply with the various companies standards as well as national
standard of pollutions
 There is 2 floating drum biogas plants and the pressmud is used to make
producer gas as well as to make fertilizers To use in farms
 It is to control CO rankings (cardbon-oxygen) of water and reduce if need
be
 The sayan sugar factories etp is best in whole gujarat itS cor is well below
standard value of 1500 instead its almost half of standard value during
running seasons
DISSILARY

 Dissilary is the section of the sugar plant where the molasis which is
wastage product is used to create pure alcohol and rectified spirit which is
used in many industries .
 This department uses all pneumatic equipments and valves for precise
control.
 Its process is known as dissilation which means Distillation is to separate
components of a liquid mixture based on the relative volatility of the individual
components.We will get large quantity of highly volatile components in the vapor
phase than in the liquid phase.
Cooling ponds
Cooling ponds

 The sugar industry has 2 cooling ponds

1. Conventional Cooling pond(natural flow)
2. Spray pond
 The conventional pond is used to cool the liquid from sulpher chimney.
 And the spray pond cools the Exhaust steam of back pressure turbines.
THANK YOU.
By vihang desai