Sugar Technology notes.ppt

jyothi953281 841 views 159 slides Jul 07, 2023
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About This Presentation

Sugar Technology


Slide Content

Various terms
Cane
Primary juice
Secondary juice
Absolute juice
Mixed juice
Last mill juice
1

CANE
Raw material is delivered to the cane carrier
Raw material for Sugar Industry
Absolute juice + fibre = cane
2

SECONDARYJUICE
Diluted juice extracted from the mills in milling tandem
Addition of water to the juice
3

ABSOLUTE JUICE
Total juice extracted from the cane in milling
tandem
Absolute juice = Cane -fibre
4

Mixed juice
Total juice extracted from the mills
Mixer of primary juice and secondary juice
Juice sent out from the mill house.
5

Last mill juice
Diluted juice extracted by the last mill in milling tandem
Imbibition water added –extracted juice.
After extraction of the last mill juice the fiberous product
is called as Bagasse
6

RESIDUAL JUICE
 Juice left in the bagasse
 If juice left over is in bagasse is more pol in bagasse is more
7

CLEAR JUICE
After clarification juice getting from the clarifier
Removal of mud in clarifier –getting clear juice
Settling process taken place in clarifier.
Clear juice sent to evaporator.
8

Sulphured juice
Addition of so
2gas to the juice
So
2gas act as bleaching agent
9

Un diluted juice
With out addition of water in the juice
Generally primary juice is undiluted juice.
10

Muddy juice
Residue (mud along with juice) delivered from the clarifier
Muddy juice sent to rotary drum vaccum filter for getting
filtered juice and filter cake
11

Syrup
Concentrated juice coming out from the evaporator
60 to 80% water evaporated in evaporator
Addition of So
2gas in sulphitation tank to the syrup
then sent to pans
12

Various terms :
•Massecuite
•Molasses
•Filter cake
•Press cake
•Imbibition
•Maceration
•Bagasse
13

Massecuite
•Mixtureofsugarcrystals andmotherliquor
(Molasses)
•Differenttypesofmassecuitesnamed as
Am/c,Bm/c,Cm/c
14

Molasses
• Effluent obtained from the centrifugals
• Different types of molasses obtained
• A-heavy, B-heavy, C-heavy, A-light, B-light, and C-light
molasses
15

Filter cake
Residue delivered from the vacuum filter
It is used as a fertilizer
Used as cattle feed with the combination of
molasses
16

Press Cake
Residue delivered from the filter press
Used as manure and fertilizer
Used as cattle feed
17

Imbibition
“ Addition of water in the mills to the bagasse” bed
before last mill
Addition of hot water before the last mill
The process in which water or juice is applied to
bagasse to enhance the extraction of juice in the
next mill
Better extraction of juice
Hot water temperature should be below 70c
18

Advantages of hot water
Hot water ruptures some cells
Sanitary and enzymatic reactions
Efficient juice extraction
19

Advantages of cold water
imbibition
Reducing gums, waxes and pectin's
Good for clarification
20

Types of imbibition21
Two types of imbibition
1.simple
2.compound
Generally compound imbibition is followed in sugar factory
Imbibition water temperature should be around 65
0
c to 75
0
c.

22
Imbibition is the process which is generally adopted in all
the strength milling tandem in one form or other.
Simple Imbibition:The process of adding water alone to
the bagasse is known as simple imbibition.
Hot water addition between 3 and 4 mill
Juice withdrawal by individual mills
No recirculation of juice

Compound Imbibition:
Water is added to the bagasse going to the last mill. The juice from last mill
is added to the bagasse coming to the penultimate mill and the juice from
the penultimate mill is sent to the preceding mill and so on. Depending
upon the number of stages this is also known as double, triple, quadruple
compound imbibition and so on.
23

Maceration
Raw sugar is produced from juice in sugar cane crushed by a series of mills.
To improve the extraction a liquid bath is applied to the cane between mills.
This liquid bath, commonly called maceration, consists of water and some of
the produced juice. Although the extraction is improved with higher water
content in the maceration, the total juice output is restricted by the storage
capacity of the plant. The aim of maceration control is to manipulate the
added water within the process limits placed by the storage capacity whilst
optimisingsugar extraction Steeping of bagasse in excess water
Generally it is followed in diffusers
24

Bagasse
“ Insoluble matter (fibre) in the cane.
After extraction of juice the residue coming out from
the last mill
Generally used as a fuel in boilers
25

Sugar Industry can be divided into.
1)Mill House.
2)Boiling House.
26

Mill House
1)Cane Carriers
2)CaneKicker
3)Cane Leveler
4)Cane Cutter
5)Cane Shredder
6)Mills
27

Cane Carrier
Carries the cane
Distant location to mill house
Like a conveyor.
28

Cane Kicker
It kicks the cane
It eliminates choking
To maintain a uniform level
It increases crushing without effecting milling efficiency
29

Cane leveller
It levels the cane in cane carrier
It cuts the cane but levels the cane in cane carrier.
Leveller comprises a set of knives which cut the whole cane
The pitch between the two knives kept three inches apart
The clearance between leveller and cane carrier is 5” –10”
30

Cane cutter
It cuts the cane into pieces.
It comprises knives of similar design of cane
leveller
The pitch between the two knives is 1.5 in
The clearance between tip of the knife and
cane carrier surface is 3” –5”
31

Cane shredder
Ruptured the cane.
Improves the preparation of cane and preparatory index
Capacity increased without effecting extraction
It is generally driven by electric motor through flexible
coupling
32

Mills
Extraction of juice from the cane.
Getting mixed juice.
Milling tandem consists of 4to 5 mills
Three rollers present in each mill
Good preparation of cane results better
extraction
33

34 Sugar Industry can be divided
Mill House
(Cane carriers
Cane cutters etc.,)
Boiling House

Boiling House
1.Juice weighing scale.
2.Juice heaters
3.L & S Tank.
4.Clarifier.
5.Evaporator
6.Sulphitation Tank
35

7.Pans
8. Crystallizer
9. Centrifugal
10. Hopper
11. Grader
36

Juice weighing scale
Weighment of mixed juice.
Generally it is a 3 to 5 ton capacity
Mixed juice weighment and counting of weighing tank
37

Juice Heater
Heating of the juice.
It is a heat exchanger
Horizontal and vertical types of juice heaters
Mixed Juice heats upto 70
0
C
L & S juice heats upto 100
0
C –105
0
C
38

L & S Tank
Mixing tank
Mixing of lime, SO
2with mixed juice.
To maintain PH 6.8 to 7.2
SO2 gas for neutralizing and bleaching the juice
Lime used for PH and settling agent
39

Clarifier
Clarification of the juice
Removal of mud
Getting clear juice
40

Evaporator
Evaporates water in juice
Concentrated juice.
Brix will be raised from 15
0
to 60
0
brix
60 to 80 % of water in the juice will be evaporated
41

Sulphitation tank.
Addition of SO
2gas.
SO
2Gas for bleaching purpose
42

Pans
Crystals preparation
Massecuite preparation.
Preparation of A, B & C massecuites
Massecuite is a mixture of sugar crystals and mother liquor
43

Crystallizers
Growth of the crystals
Storage purpose.
Air cooled, water cooled, vacuum crystallizers
44

Centrifugals
Separation of crystals and molasses
Single curing and double curing
Heavy mollasses and light mollasses are obtained
B-seed ,C-seed, A-sugar are generated
45

Hopper
Getting dry sugar
Removal of slumps.
Removal of conglomerates
Removal of moisture
46

Grader
Sieves the sugar crystals
Uniform size of sugar crystals
Grading of Sugar
47

DOUBLE SULPHITATIONFLOW CHART
48
CANE CARRIER
CANE LEVELLER
CANE KICKER
CANE CUTTER
CANE SHREDDER
MILLS

49
MIXED JUICE WEIGHING SCALE
JUICE HEATERS
LIME AND SULPHITATION TANK
L & S JUICE HEATERS
CLARIFIER
FROM MILLS
LIME SO
2
FLOW CHART

FLOW CHART cont’d
50
EVAPORATER
SULPHITATION TANK
PANS
CRYSTALIZERS
FROM CLARIFIER
SO
2

FLOW CHART cont’d
51
CENTRIFUGAL
HOPPER
ELEVATOR
GRADER
FROM CRYSTALIZERS
MOLASSES
BAGGIN
G

52
Preparatory devices
Mills
Classification
Manufacturing of Sugar
Sugar
Milling section
Cane
Lime
SO
2

53
Cane Carrier
Cane kicker
Cane leveller
Cane cutter
Cane shredder
Cane
MillsMixed juice Bagasse Boiler
Milling section

Cane Carrier
Carriesthecane
Itislongconveyerbeltaroundto20to30Mtslength
Itconstructedwithmildsteelframingwithtwoendschainsoftherollertype.
Dividedinto3portionshorizontal,inclined,andthehead.
54

Cane kicker
Kicksthecane
Uniformlevelinthecarrier
Eliminateschoking
Itisincreasescrushingwithouteffectingmillingefficiency.
55

Cane leveller
Levels the cane
It helps to maintained uniform level.
Leveller comprises a set of knives which cut the whole cane into small pieces
56

Cane cutter
Cutsthecaneintofinepieces.
Itcomprisesknivesofsimilardesignofleveller.
Thepitchbetweentwoknivesis1½’
57

Cane shredder
Ruptures the cane.
It improves preparation of cane and preparation into index.
Driven by electric motor through a flexible coupling
58

Mills
Milling tandem consists of 4 –5 mills
30 –40 % juice extracted in first mill.
Mill consists of a three rollers.
Good preparation cane results better extraction.
After extraction remaining cane named as bagasse
Bagasse used as fuel in boiler.
59

DOUBLE SULPHITATIONFLOW CHART
60
CANE CARRIER
CANE LEVELLER
CANE KICKER
CANE CUTTER
CANE SHREDDER
MILLS

61
MIXED JUICE WEIGHING SCALE
JUICE HEATERS
LIME AND SULPHITATION TANK
L & S JUICE HEATERS
CLARIFIER
FROM MILLS
LIME SO
2
FLOW CHART

FLOW CHART cont’d
62
EVAPORATER
SULPHITATION TANK
PANS
CRYSTALIZERS
FROM CLARIFIER
SO
2

FLOW CHART cont’d
63
CENTRIFUGAL
HOPPER
ELEVATOR
GRADER
FROM CRYSTALIZERS
MOLASSES
BAGGIN
G

64 Juice weighing scale
Juice Heater
L & S Tank
L & S Juice heater
Clarifier
Clarification section
Evaporater
Sulphitation tank
Syrup
V. FilterF.Cake
F. JuiceJ.W. Tank
Lime
SO
2
PH =6.8 –7.2
70
0
c
105
0
c
SO
2
Clear Juice

Juice weighing scale
Juice will be weighed
Weighing capacity of tank is 3 to 5tons
Weighment and counting of tanks will be taken place
65

Juice heater
•Heating of juice upto 70
0
c
•Heating for precipitation purpose
66

L & S Tank
Addition of lime upto PH 6.9 to 7.2
Addition of SO
2gas
Bleaches the juice.
67

L & S Juice heater
Heating of the juice upto 110
0
c
68

Clarifier
Getting clear juice
Withdrawal of mud
Mud sent to Rotary drum vacuum filter.
Getting filter cake, filtered juice
69

Evaporator
Syrup PH should be 3.8 to 4.2
Evaporates water
Getting syrup
70

DOUBLE SULPHITATIONFLOW CHART
71
CANE CARRIER
CANE LEVELLER
CANE KICKER
CANE CUTTER
CANE SHREDDER
MILLS Bagasse
Mixed juice

72
MIXED JUICE WEIGHING SCALE
JUICE HEATERS
LIME AND SULPHITATION TANK
L & S JUICE HEATERS
CLARIFIER
FROM MILLS
LIME SO
2
FLOW CHART

FLOW CHART cont’d
73
EVAPORATER
SULPHITATION TANK
PANS
CRYSTALIZERS
FROM CLARIFIER
SO
2

FLOW CHART cont’d74
CENTRIFUGAL
HOPPER
ELEVATOR
GRADER
FROM CRYSTALIZERS
MOLASSES
BAGGIN
G

Double sulphitation process
Milling section
Clarification section
Manufacture of sugar
75

Manufacture section
76
PANS
Crystallizers
Centrifugals
Elevator
Godown
Hopper
Grader
Molasses
Syrup

Pans
Preparation of massecuite
Massecuite is a mixture of crystals and molasses
Preparation of A, B, C massecuite
77

Crystallizers
Growth of crystal
Storage of massecuite
Air cooled , water cooled , vacuum cooled and
monovertical crystallizers
78

Centrifugals
Separation of crystals and molasses
Single curing and double curing operations
A, B , C massecuites cured by batch and
continuous machines
79

Hopper
Hot air blower , cold air blower are attached
to the hopper
It is a vibrating screen
Wet sugar converted into dry sugar
80

Elevator
Conveying equipment
Lifts sugar into some distant height for easy
passage of bagging
81

Grader
Sieving will be taken place
Consists of 5 chutes
Bold sugar and powdered sugars are recirculated
82

Godown
Bag consists of 100 kgs
Sugar bags are stored in place called
godown
83

DOUBLE CARBONATATION
FLOW CHART
84
CANE CARRIER
CANE LEVELLER
CANE KICKER
CANE CUTTER
CANE SHREDDER
MILLS

85
MIXED JUICE WEIGHING SCALE
JUICE HEATERS
LIME AND CARBONATATION TANK
L & C JUICE HEATERS
CLARIFIER
FROM MILLS
LIME CO
2
FLOW CHART

FLOW CHART cont’d
86
EVAPORATER
CARBONATATION TANK
PANS
CRYSTALIZERS
FROM CLARIFIER
CO
2

FLOW CHART cont’d87
CENTRIFUGAL
HOPPER
ELEVATOR
GRADER
FROM CRYSTALIZERS
MOLASSES
BAGGIN
G

88
Preparatory devices
Mills
Classification
Manufacturing of Sugar
Sugar
Milling section
Cane
Lime
CO
2

89
Cane Carrier
Cane kicker
Cane leveller
Cane cutter
Cane shredder
Cane
MillsMixed juice Bagasse Boiler
Milling section

Double carbonation process
Milling section
Clarification section
Manufacture of sugar
90

Cane carrier
Carries the cane
Long conveyor belt
Carrier divided into three portions,
horizontal , inclined and the head
91

Cane kicker
All steel construction mounting on the cane carrier and fixing
upon the shaft 48 no. of blades welded on it
It eliminates chocking
Does not cut the cane but helps to maintain uniform level
92

Cane leveler
Levels the cane in cane carrier
Leveler comprises of a set of knives which
cut the whole cane into small pieces
93

Cane cutter
Cut the cane into fine pieces
Comprise knives of similar design of leveller
94

Cane shredder
Cuts the cane into very fine pieces
It improves the preparation of cane and
preparatory index
95

Mills
Milling tandem consists of 4 or 5 mills
60 to 70% juice extracted in first mill
Good preparation of cane results better
extraction of the juice
96

DOUBLE CARBONATATION
FLOW CHART97
CANE CARRIER
CANE LEVELLER
CANE KICKER
CANE CUTTER
CANE SHREDDER
MILLS

98
MIXED JUICE WEIGHING SCALE
JUICE HEATERS
LIME AND CARBONATATION TANK
L & C JUICE HEATERS
CLARIFIER
FROM MILLS
LIME CO
2
FLOW CHART

FLOW CHART cont’d
99
EVAPORATER
CARBONATATION TANK
PANS
CRYSTALIZERS
FROM CLARIFIER
CO
2

FLOW CHART cont’d100
CENTRIFUGAL
HOPPER
ELEVATOR
GRADER
FROM CRYSTALIZERS
MOLASSES
BAGGIN
G

Double carbonatation process can be divided into
Milling section
Clarification section
Manufacture of sugar
101

102 Juice weighing scale
Juice Heater
L & C Tank
L & C Juice heater
Clarifier
Clarification section
Evaporater
Carbonatation tank
Syrup
V. FilterF.Cake
F. JuiceJ.W. Tank
Lime
CO
2
PH =6.8 –7.2
70
0
c
105
0
c
CO
2
Clear Juice

Juice weighing scale
Weighment tank
Generally 3 to 5tons capacity
Mixed juice weighed
103

Juice heater
Juice heats up to 70c
Horizontal ,vertical types used
Vertical type juice heater preferred
Heating for precipitation purpose
104

Lime and carbonatation tank
Addition of lime and carbon dioxide
Maintain ph of 6.8 to 7.2
Mixed tank
Carbon dioxide is used for bleaching and
nuteralising purpose
105

L & C juice heater
Juice heats up to 110c
Generally two juice heaters used
106

Clarifier
Called rapi Dorr
Four compartments consists of 200 to 300 tons capacity
Separate juice with drawl and mud with drawls are provided
Settling process takes place
Mud is sent to vaccum filter for getting filtered juice and filter
cake
107

Evaporator
60 to 80% of water evaporated
Concentrated juice called syrup
108

Carbonatation tank
Carbon dioxide gas added in second time
For bleaching purpose
109

DOUBLE CARBONATATION
FLOW CHART110
CANE CARRIER
CANE LEVELLER
CANE KICKER
CANE CUTTER
CANE SHREDDER
MILLS

111
MIXED JUICE WEIGHING SCALE
JUICE HEATERS
LIME AND CARBONATATION TANK
L & C JUICE HEATERS
CLARIFIER
FROM MILLS
LIME CO
2
FLOW CHART

FLOW CHART cont’d
112
EVAPORATER
CARBONATATION TANK
PANS
CRYSTALIZERS
FROM CLARIFIER
CO
2

FLOW CHART cont’d113
CENTRIFUGAL
HOPPER
ELEVATOR
GRADER
FROM CRYSTALIZERS
MOLASSES
BAGGIN
G

Double carbonatation process can be divided into
Milling section
Clarification section
Manufacture section
114

Manufacture section
115
PANS
Crystallizers
Centrifugals
Elevator
Godown
Hopper
Grader
Molasses
Syrup

Pans
Preparation of massecuite
Mixture of crystals and mother liquor is called massecuite
Preparation of A, B and C massecuite.
116

Crystallizers
Growth of crystals
Acts as a storage tank
Different types of crystallizers like air-cooled, water
cooled, vaccum cooled and monovertical crystallizers.
117

Centrifugals
Separation of crystals and molasses
Single curing and double curing operations
Batch type and continuous type centrifugals.
Batch type used for A –massecuite curing
Continuous type is used for B & C –massecuite curing
118

Hopper
Vibrating screen
Hot air blowers and cold air blowers are attached
Removing of conglomerates sugar
119

Grader
Sieving taken place
4 or 5 chutes are used
Bold grain and powdered sugar is recirculated
120

Preparatory devices
Cane kicker
Cane leveler
Cane cutter
Cane shredder
121

CANE KICKER
All steel construction suitable for mounting on the cane
carrier and fixing upon the shaft the required no. of
blades welded on it.
Total no.of blades around 48
Speed of the kicker about 70r.p.m
122

CANE LEVELLER
It comprises a set of knives which cut the
whole cane into small pieces
Knives worked with high clearance 4 to 10
inches
Pitch between two adjacent knife blades is
3inches
123

CANE CUTTER
It comprises a set of knives which cut the whole cane
into fine pieces
Clearance of about1” to1.5”
Pitch between two sets of knives is 2inches
124

CANE SHREDDER
It driven by an electric motor through a flexible coupling
Hammers are fixed to shaft they are mild steel about 8’long
2.5” wide each weighing 1.75to 3.5lb.
Fitted at head of the tandem between crusher and cutter
125

PREPARATORY DEVICES
Cane kicker
Cane leveler
Cane cutter
Cane shredder
126

Function of Cane Kicker
It cut the cane and helps to maintain a uniform level
It eliminates chocking
Increases crushing
127

Function of Cane Leveler
It levels the cane in cane carrier
It cuts the whole cane into small pieces
128

Function of Cane Cutter
Depending on TCD of plant cane cutters should be 1 to 3
It cuts the whole cane into fine pices
129

Function of Cane Shredder
It cuts the whole cane into very fine pieces
It gives almost the same extraction as a
three roller mill
It adds both to capacity and extraction
130

FUNCTIONS OF CANE CRUSHER
Assist intensive preparation of cane
Extract more juice
131

TYPES OF CRUSHER
Krajewski crusher
Splitter or fultron crusher
132

Krawjewski crusher
It has double helical teeth on the
circumference of the rollers
Improves extraction
It has three roll crusher
Speed 25% greater than the mills
133

SPLITTER or FULTRON CRUSHER
It has deep circular grooves with spiral
horizontal grooves on the roller
Improves crushing rate
Spiral grooves assist feeding
It has three roll crusher
134

Pitch of the splitter is in conventional design 1 to 1.5inch
Increase rate of crushing pitch is usually 3inches
It runs at a greater speed
40 to 50% greater speed than the mill
Provided sometimes messchaert grooving
135

FUNCTIONS OF MILLS
Three rollers consists a mill
4 to 6 mills consists of a milling tandem
Circumferential grooving, messchaert grooving are used
for grooving on mill rollers
136

Grooves is generally used for increasing juice handling
capacity
First mill at high pressure –for better extraction
Last mill is for lowest speed
Applying for maximum loads for first and last mill
137

Hydraulic pressure provided to all mill rollers
Handling and conveying between the mill rollers is
intercane carrier
Imbibition-hot water provided between 3 and 4 mills
60 to 70% extraction taken place at first mill itself
138

Top halves of roller journal brasses should
not rest on the bottom halves while mill is
working
Mills having higher pressure and lower
speed achieve highest performance
139

CANE CRUSHER
Crusher have helical teeth on the circumference
Assist intensive preparation
Generally it is two roller crusher nowadays it has
three roller crusher
It assist feeding
140

It runs at a greater speed
40 to 50% greater speed than mills
Sometimes circular grooves and spiral horizontal
grooves are used
141

MILLS
Generally it has three rollers
Three rollers consists a mill
Circumferential grooving,messchaert grooving
are generally used
Imbibition water used between 3 and 4 mill
142

Used for crushing and extraction of juice
Hydraulic pressure is required for rapid extraction
purpose
Runs slowly
143

Grooving
Mill rollers were smooth it exists in some countries
Advantage with smooth rollers wear and tear in them
is much less
Moisture content of the bagasse is lowered
Mill rollers with fine, medium or coarse grooving
adopted in most of the sugar industries
144

Advantages of grooving
Crushing rate is very high
Facilitate drainage
Break up the bagasse completely
Facilitate the extraction of juice
145

Types of grooving
Circumferential grooving
Messchaert grooving
146

Circumferential grooving
These are made along the length of the rollers on
circumference
Groove forms isosceles triangle with an apical angle
of 55
0
-60
0
Pitch of the groove separates the axes of two
successive teeth
Depth of the groove is slightly less than the pitch
147

Specifications
Angle is-60
0
Height is 0.85”
Pitch is 0.80”
Angle of the groove at the top and bottom
rollers is identical
148

Specifications
Fine grooves is 5-20mm pitch
Medium grooves is 25-50mm pitch
Coarse grooves is above 50mm pitch
149

Advantages of circumferential grooving
They increase gripping effect
Facilitates drainage of juice
Cause better rupturing of the pitch of cane cells
150

Messchaert grooving
Improve gripping effect
Provided free drainage
Messchaert grooving rendered 2% higher extraction
10 to 15% greater mill capacity
151

Lesser power consumption
Deep circumferential grooves spaced about
4 inches apart
Provided on all mill rollers
152

Specifications
Width is1/2 “to 3/16” on the feed rollers
Depth 1” and should not deeper than 1.5”
Pitch is 3” to 4” on the discharge roller
153

Good results
Apply maximum load on the first and last mill
Lesser loads on the intermediate mills
154

Factors
Mills
Mill rollers
Imbibitions
Preparation of cane
155

Good milling
Feed should enter to avoid choking
All hydraulics should float freely
Top halves of roller journal brasses should not rest on
the bottom halves while the mill is working
Max. lift of crusher top roller is 1.5 inch to 2 inch
156

Juice should be free flowly down the entire length of the
feed roller in full quantity
Juice being discharged with considerable force
Proper imbibition
Proper maintance
157

Regrooving according to life of the roller
Proper lubrication of cane carrier and inter
cane carrier
No vibration or undue noise from mills
158

Causes of vibration
Insufficiently strong foundation
Fault alignment
Defective lubrication system
159
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