Professional Documents
Culture Documents
Introduction
The target of sugar production and the installed capac ity needed to meet it for the 8th and 9th plan peri ods
are given in Table 2.
The energy requirement in various un its of a sugar
mill is given in Table 3.
Adoption of new systems and designs, as required for
better performance and higher efficiency for improving
the economics of sugar industry, is l}' 'must' , as suggested by Sood 6,7.
Major Processes involved in a Sugar Mill
S.No.
1250
Num bers
75
1250
140
125 i - 2000
80
200 1 - 2500
50
2501 - 3500
30
(j
Above 3500
50
77
Units
Installed capacity
required
(million tonnes)
3.2.
Energy Saving
Alternatives
8/h Plall
3.3.
Automation
1990-9 1
1147
1207
4.
Sugar Cr ystallization
1991-92
12. 07
12.70
4.1.
1992-93
12.17
12.8 1
Energy Requirements at
Vacuum Pans
1993-<:)4
12.78
!345
1994-95
1341
14. 12
1995-96
14.08
14.82
1996-97
14.79
15.57
1997-98
15.53
16.34
1998-99
16.30
17.17
1999-2000
17. 12
18.02
Plan/Period
Target of
production
(million tonnes)
Percentage
Energy Savings
At Vacuum System
At Cooling System
Continuou s Pans
Pan Automati on
Install at ion of
Mechanical Circulators
Molasses Conditioners
4.2.
Energy Requirement at
CrystalIizers
5.
5. 1.
Energy Saving at
Continuou s Centrifugals
5.2.
Selection of Process
5. 3.
Su gar Drying
54.
Choice Mag ma
Liquoring
5.5.
Schemes of sugar
conveying and grading
O.
Steam Generation
6.1.
Mill Speeds
Pressure Feedin g
42-45 kglcrn2g
Steam Temperature
4 15C
Power Requiremcnt
Tab le 3 -
S.No.
Unit s
Percentage
I.
40-45 %
1.1.
Cane Handling
5-10%
1.2.
Cane Preparation
1520%
13.
Milling
25%
0.
of Mills
Automat ion
Juice Purilication Plant
Furnace Design
10- 15 '1(
2.1.
Jui ce Heating
Bagasse Drying
2.2.
Treatment of Jui ce
6.2.
Boiler Operation
2.3.
Separation
6.3.
Boiler Automati on
3.
7.
Powel' Gene.-ation
:1 0% 01 tot al
steam required
for sligar pl allt
Arrangement Models
('OI/1d
10-15 %
0"
3. 1.
15-20 %
Design Selection
91h Plall
2.
COl/It!
7.1 .
7.2.
5-10 %
78
Power Saving
79
Automation
The automatic control sys tem of the evaporator
should be des igned in such way that the syrup, leavi ng
the evaporators has a predetermined consistency. This
design should also take care of the time-lag between the
admittance of steam and exist of sy rup . The control of
steam should also be linked with th e flow of va pours for
heating and boiling of juice.
The maintenance of consistent hi gher brix of syrup at
the evaporators is essential in view of the multipl e effect
advantage at this station compared to the other stati ons
like juice heating and pan boiling.
Sugar Crystallization
Energy requirement by Va cuum pans
Through proper controls, energy can be saved at this
stage which is estimated to be 15-18% of the total en ergy
required in a sugar plant. This could be reduced to about
10-12% by taking remedial measures. The automation
of vacuum pans can be of great advantage in reducing
both the mechanical/electrical energy as also the heat
energy requirement in this area of operation. Molasses
conditioners should be installed in line to feed from the
storage tank to the vacuum pans. The inline conditioning
of the molasses avoids the chances of molasses cooling
during the storage.
for reduction.
Evaporation
The variou s configurations of evaporators' arrangement are possible to evaporate juice from 14-16 Brix to
60-65 Brix, which accounts for about 30% of the total
heat requirement in the process. The evaporator arrangement should be such that it is possible to provide about
130-150 kg of vapours per tonne of juice for heating in
the juice heaters and about 230-270 kg of vapours/tonne
of juice for crystallization of sugar in the vacuum pans.
Therefore, a total of about 250-400 kg vapours/tonne of
juice additionally should be available from the evaporator station to meet the requirement of juice heaters and
vacuum pans .
80
Sugar CentriJugals
The energy consumption at centrifugals is also related to the selection of the process. The methods being
used for cooling, conveying and grading of sugar can be
modified to save energy. This primarily may require the
use of fluidized bed drier for cooling and conveying. The
design of the graders can also be modified so that a fewer
number of graders can handle the required through put.
Steam Generation
The factors responsible for efficient use and generation of steam are:
Steam pressure
Steam temperature
Design of boilers
Design of accessories
Design of furnaces
Use of heat recov,ery units, and
Bagasse drying.
The commonly used furnaces in the sugar factory
boilers are : (i) Step grate furnace, (ii) Horse shoe furnace, and (iii) Spreader Stroker furnace .
Boiler Operation
The automation in boilers can be of immense use in
achieving a higher boiler efficiency and hence reduced
energy costs. The automation in boilers can include
cont rol of C02 and/or 0 2 per cent, steam flow, feed
control, excess air control and excess 0 2 monitoring
system, etc .
Power Generation
Many sugar factorie in the world are producing or
co-generating additional power for tran sfer to the grid
or for use in the ancillary industry . Almost all factories
are equipped with turbo generators which are generally
of the back pressure type. Live steam from the boilers is
used for operating turbo generators set for producing
power. Exhaust steam is used for this process .
'\
81
Conclusions
Recent developments in the sugarcane processi ng in
the small scale sector have been reported by Gehlawat )4.
There are a number of other actions and precautions that
can help to minimize energy and heat losses in a sugar
plant. These include:
82
Acknowledgement
The author is thankfu l to Dr (Mrs) Abha Srivastava
for her help in preparing the manuscript.
Sood H C, A plea for redesigning sugar machinery to maximize production of sugar at low cost , Ma lwrashtra Sligar,
1987.
10
Mallritills SlIgarcan e /3.v-prodllcts Stlldv, United Nations Industrial Development Organi zation Report l' 81/24 Appendi x
4&5, Nov 1981.
II
12
13
14
Gehlawat J K, New developments in sugarcane processingA boon to mini sugar plants and kh andsari units, J Sci Ind Res,
57 (6) (1998) 299-305.
References
By-products of Sugar Industry, Mauritius Chamber of Agriculture, Memorandum to the Commission of Enquiry into the
Sugar Industry, 1983.