Professional Documents
Culture Documents
Tiruppur District
Dindigul District
Coimbatore district
Cane Farm: total Extent =20.70 acres ; Irrigated area = 10.00 acres
3
The next important factor is the Sugarcane yield. India used to have a
proud record of highest yield of cane per hectare in the world .This
has declined in recent years due to various factors like selection of
varieties giving greater recovery, failure to combat pests and disease
effectively, lack of optimum irrigation, absence of drainage facilities,
absence of good seeding program, failure to select varieties suitable to
the area , lack of supervision over treatment of sugarcane sets for
distribution , rationing without any control , lack of suitable
application of organic manure and chemical fertilizers , untimely
harvesting ,lack of good weed management etc.
To produce quality cane and to get higher productivity per acre the
following should be adopted.
Cane Yard
Again automation has come to stay in this station and thus increase
the efficiency of uniform feeding leading to better mill extraction
Mill house
Minimum of four mills with three rollers each will function. Sets of
three rollers with feed and discharge and top roller for applying
hydraulic pressure are present .Prepared cane is fed to these mills
which are kept in sequence to accept the cane mat of the previous mill
and so on. Juice squeezed is collected in the tray below and the
residue mat proceeds to the next set of three rollers and the same
action is repeated and juice is collected separately. Except for the I set
and II set of mills , all the other mills’ juices are pumped back to spray
on the cane mat for imbibing action to effect better juice extraction.
For the last mill of tandem feed alone, hot condensate water is used
for imbibitions.
The juice from I and II set alone (the ultimate “outlet gate” for the
juice from the milling station) is screened to remove the coarse
suspended matter (fiber) and screened juice sent to the process house.
The mat that gets out of the last mill is called bagasse (first by
product) practically containing no sugar (though we can’t remove cent
percent). The milling efficiency is the ratio of sugar extracted to sugar
present in cane on percentage basis called mill extraction.
Sugar in mixed juice =sugar bagged + sugar lost in filter cake +sugar
lost in molasses + unknown loss of sugar.
Bagasse rich in carbon fit for use as fuel and with moisture less than
49% is sent to the furnace of the boilers for generation of steam. Sugar
loss via bagasse has to be the acceptable minimum and depends on the
8
Proper planning for the number of roller shafts with grooved rollers
that should be kept in readiness, not only for the incoming crushing
season and for the sub sequent seasons, is quite essential. Periodical
ultrasonic X-ray of the shafts and the rollers is a must. There should
be no inhibition on imbibitions. Maximum up to 300% on fiber should
be attempted. Tackling of resultant moisture is an important task of
engineers. There should be minimum reabsorption. Hydraulics should
function effectively.DSM screen or rotary screens will reduce mill
load, reduce power consumption, and improve juice heating efficiency
9
Boiler House
Bagasse that comes out of the mill station is fed into the furnaces
through carrier. Furnaces are of step-grate type, horse shoe type and
spreader striker type. Hot condensate water is sent to the drum and
ultimately through water tubes. Water inside the tubes is heated and
10
A portion of the steam is sent to the turbines which move the rollers in
mill stations. Another portion is sent to the turbo-alternator which
produces power. Many are not aware that a sugar factory produces its
own power, although dependent on power grid for local electricity
board. Another portion is sent to processing sections in a limited way.
“Steam flow meter is a must”. Extraction of steam and power
generation by various units is concomitant. In the absence of a steam
flow meter, the boiler efficiency cannot be determined.
All the boilers require thorough overhaul and should get certified by
the boiler inspectorate. Any breakdown due to tube failure of the
boilers should be intimated to boiler inspectorate and should be
rectified as per the instructions of the boiler inspectorate.
Power House
Many are not aware hat a sugar factory besides producing sugar also
produces its own power to run its units .It also draws power from the
11
There will be double bus-bar which regulates the power from the grid
and also distributes factory’s power to various units. There should be
a diesel power generator (say 250 kW) as a standby.
Clarification
Clarifier (used to be called as Dorr) will have a flash tank at the top
.Treated juice which comes out of juice heaters at 105°C output
reaches the flash tank and then enters the clarifier which will have
four compartments duly sealed with no inter connection. Juice enters
13
the compartments on the bottom side and the level goes up gradually
.Perceptible non-sugars get coagulated and form huge flocks. Heavier
flocks settle down slowly leaving a clear transparent juice at the top of
each compartment. Tempering the juice is an important step in
plantation white sugar. This clear juice goes to the evaporators.
Magnoflac can be used as an aid for better settling.
Evaporation
Clear juice coming out of the clarifier and which is relieved of the
suspended and perceptible non-sugars from the original mixed juice is
now ready for the next stage. Evaporator is a unit which contains
“calendria” through which exhaust (power house steam) enters and
after its function of heating outside the tube through which the clear
juice flows , condenses as hot water and comes down which is sent to
the boiler feed water tank.
14
There is adequate space on the top of the evaporator body. When juice
reaches the boiling point, water is naturally relived and goes above as
vapor in the available space on the top. This vapor is again sent to the
calendria of the second evaporator body. Also boiled juice from the
first to second is sent.
The vessels (evaporator bodies) are all lagged to avoid heat loss
through radiation. Each vessel should have provision for pressure
vacuum gauges, inter-connecting pipelines and control valves etc.
Juice level gauge should be there and the optimum level of juices
should be maintained to achieve maximum efficiency. Through view
glasses, we are able to see the boiling of juice and note any
abnormalities. They are not storage vessels. The main purpose of the
15
The tubes in the juice heaters and in the evaporator bodies (acting as
heat exchangers) accumulate scales inside on account of calcium,
silica etc. content of the juice. These scales shave to be removed
periodically. That is why factories have a shut down once in 25 days
to one month or so for cleaning tubes. Effective cleaning of the tubes
and efficient supervision there on during the shutdown is a must.
Instruments required for cleaning should be in a good shape and kept
ready even before shutdown.
Sulphited syrup reaches the next stage for further water removal to be
carried out in single effect pans. The body of the pan is similar to that
of the evaporator except that the diameter of the tubes will get bigger.
Solid sugar has to be separated from the mother liquor in the syrup.
Vapor (steam) flows from the evaporator bodies individually to the
pans. We concentrate the virgin syrup and at a specific viscosity,
sugar starts crystallizing .Normally there will be crystal bed already
existing and then with further deposits on these crystals, the crystals
gradually grow in size and become fit for bagging or reuse as seed. As
the evaporation proceeds, crystals are formed. Contents stay in the
vessels. As and when it concentrates, further feed is given. Thus the
16
material builds up in the volume to reach a full level. Then the vapor
is shut and the vacuum is released.
Product is discharged via the wider door provided at the bottom in the
conical portion. Product goes through wide gutters and falls in the
respective crystallizer. Product that comes out of pan is now called
massecuite. At one stroke, it is impossible to crystallize all sugar from
the syrup. It needs repeated boiling and concentration of the exhausted
mother liquor. this is the reason for “ three Boiling “ at least to extract
maximum possible sugar from the liquor until at the last stage ,
mother liquor separated is sent out as “ Final Molasses” , another
(third) by product. This product does contain some sugar and should
be kept at the minimum, a salutary duty of the process department.
Continuous Pans are also being tried in the place of batch pans. It has
been tried for “B” stage. People, who have reservations for “A” & “C”
stages earlier, have also started to operate conti-pans for “A” & “C”
stages. Good exhaustion is obtained. It may ensure optimal
exhaustion. Saving of power and sale of power to the grid thereby will
be worthy of the purpose. Steam consumption may be less and quality
of sugar may be better. A system will always have certain advantages
and disadvantages. If advantages far outweigh the disadvantages, the
system can be adopted with greater alacrity and devotion.
In pan boiling, there are three stages, viz. A, B and C stages. Products
produced by A Pan , B pan and C pan are called “A” massecuite, “B”
massecuite and “C” massecuite .The virgin sulphited syrup from the
tank is sucked into “A” pan . After boiling, the resultant “A”
massecuite goes down the gutter and then to crystallizer.(In
17
thus hot water gets cooled and comes back to the factory for being
pumped up to enter the individual condensers of the individual pans.
Cooling is necessary to condense the hot vapors. Vapors which go to
the condensers of the last evaporate body and condensers of each of
the three pans should contain no sugar. There should not be any
entrainment .Signs of foaming or hot water slightly brownish in color
is not good.
The next stage is “B “.Pan “B” receives the “A” heavy molasses from
the storage tank and boils it. Virgin syrup may be added to improve
the purity.”B” massecuite after drop in the crystallizer reaches the pug
mill over the “B” centrifugal. It is cured.”B” heavy molasses is stored
again and sucked into “C” pan.”B” sugar is melted and used as seed
and again sent to Pan “A”. Vapors as usual go to its condenser for
condensation as hot water.
“B” heavy molasses are further boiled in “c” pan. It is dropped in the
crystallizer and after cooling goes to the pug mill of “C” fore worker
(CFW) centrifugal machine for curing. Here the thick final molasses
are sent out as the “third” by product of the sugar factory. Loss of
sugar in this product should be reduced to the minimum. Separated
“C” sugar in this machine is sent to CAW (“C” after worker) machine
after storage in a pug mill.
sent to pan supply tank and then sucked into “A” pan for boiling along
with virgin syrup and “A” light molasses.
The above is the explanation of the process i.e. Pan boiling, vapor
condensation, spray pond, crystallizer cooling and centrifuging to
separate sugar from its mother liquor. Vertical crystallizers have also
come into operation. Continuous centrifugals are also in vogue for
“B” & “C” curing. Second vessel vapor drawn from evaporator bodies
helps in the boiling in the pans. People working in pan station should
be very vigilant. Gutters and crystallizers should be wide & slope.
Drawing of power by the centrifugals should be regulated. Baskets in
the centrifugals should be checked for dynamic balancing. Wear out
should be checked superheated water wash should be utilized in a
meticulous manner .Enough spares like screens, motors, shafts etc.
should be readily available. An efficient dust collector is must.
The final molasses are weighed, pumped and sent to the steel tanks.
The material with high viscosity requires special pumps for being sent
to the steel tanks. Proper maintenance of the steel tanks and the pumps
is a must. All the precautions are to be taken to avoid spontaneous
combustion in tanks. Temperature gauges should be there. Cool water
should be sprayed on the outer surface.
Sugar sent out by “A” centrifugals goes on the hopper. Solid sugar
material has to be conveyed and dried. The long wide tray like is
20
Sugar grades as per I.S.S are “S” (small) “M” (medium) and “L”
(large). Tamil Nadu bags mostly S30 (number indicates the color .
Color is 29, 30, 31 and “S” is size).For export purposes, the
recognized international method of procedure is to find ICUMSA
value.
Stores
Total 215000
Workshop
Laboratory
There are various norms and indices for different operations. Some of
those are indicated separately .All the sectors should take all sincere
efforts, and try to achieve those standards with devotion and mutual
co-operation.
23
Total 11000
4.PERFORMANCE STANDARDS
1. Preparatory Index
6. Total Losses
7. Time Lost
Mechanical 2.0
25
Electrical 0.5
Process 0.5
No Cane 1.0
Miscellaneous 0.5
8. Power Consumption
9 Steam Consumption
10 Chemicals
11 Final Molasses 28 to 30 %
5.DISTILLERY UNIT
• Capacity
Rectified Spirit
Extra-Neutral Alcohol
Total 12000 MT
Total 41.8
29
• Fermentation
• Distillation
6.1.Fermentation
6.2.Distillation
Analyser Column
Rectifier column
Vapors from the Analyzer column are fed to the bottom of the rectifier
column. The vapor are condensed and the spirit is obtained .The
rectified spirit has 94.68% of alcohol. It is used as alcohol beverage
and applied in paints , drugs ,oils, perfumes ,varnish, gums etc. In
pharmaceutical it is used as preservative for biological specimens and
used as fuel in spirit lamp.
The effluent left after distillation is used fro the production of Bio-Gas
.The Biogas is used for boilers. The secondary effluent is used as
manure.
31
7.1.Biomethanization Technology
The bacteria responsible for this conversion are strict anaerobes and
are called the methanogenesis. The figure in appendix shows the main
reaction performed by these bacteria. The most important bacteria of
this group are those which are degrading acetic acid and propionic
acid. They have very slow growth rate and as a result their
metabolism is usually considered as rate limiting in the anaerobic
treatment of organic wastes. In the second step the actual waste
stabilization is accomplished by the conversion of the organic acids
into methane and carbon dioxide. Methane gas is highly insoluble and
its departure from solution represents actual waste stabilization.
7.3.Process Description
Effluent Line
Digestor
The digestor is a fixed bed reactor with flocor “R” plastic media
having a large surface area upto 230 sq.m/m3.The recirculation pumps
collect the treated effluent at the bottom of the reactor through a pipe
works of assembly which permits uniform draw of the whole area.
34
Operation Methodology
Gas Line
De-sludging System
Description Detail
COD reduction 45 MT
For running the 55kL rectified spirit plant there is no additional fuel
requirement . If we operate with 80% efficiency, the plant requires
1500-2000 litre for running the entire plant for providing entire
requirement of steam and to run the turbo-alternator.
37
The existing digester was commissioned in the year 1994 and the
plant is under operation since the inception. This plant was provided
with all control units for maintaining the feed rate, pH control, and
recirculation effluent and biogas booster. During the normal operation
the entire effluent generated from the distillery is stored in lagoons.
After cooling it is pumped for feeding the digester at required level to
meet the gas requirements and plant conditions.
7.6.Performances
Pollutant removal
In stillage, soluble COD removal efficiency will not be less than sixty
percent and soluble BOD removal will not be less than 90.If higher
COD and BOD is in inlet effluent then dilution shall be practiced.
Biogas Production
Energy Production
8.1.Steam Generation
The above details will emphasize the need for maintaining optimum
operational conditions required for efficient performance of mills and
boilers. The factory was quite old but with modern facilities in a
number of areas. The boilers (4 nos.) were also old and of low
pressure designs but retrofitted with system for efficiency
improvement. Because of poor state of maintenance the boiler
efficiencies recorded with the high moisture % in bagasse was ranging
from 50% to 56%. The bagasse steam ratio was 1.85 only against the
optimum of 2%.
It is seen that the bagasse steam ratio which used to be of the order of
1:2.0 with old low pressure, low efficiency systems have improved to
1:2.45 in the modern cogeneration systems which is a clear
improvement in the productivity of bagasse and a positive step
in energy conservation through improved boiler designs for higher
efficiency.
Thus this promises to be the key area in sugar industry for future
indexation of the statutory energy regulatory authority that has been
formed to monitor energy conservation
43
9. CONCLUSION
The potential for saving cost per annum will be different in different
places and there are bound to be concern areas in all places if honestly
looked into, since no one could claim to have reached the state of
perfection. Therefore it will be prudent for all organizations to set
up energy committees within the organization, identify lacuna
dispassionately and rectify them immediately. Total commitment,
involvement and guidance of top managements are essential for this
and if implemented effectively, it will usher in prosperity not only to
the organization but also to the Industry and the Nation at large.
45
10.APPENDICES
4. Biomethanisation Plant
46