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
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
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
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
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 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
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
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 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
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
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
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
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
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