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sugar factory capacity calculations

sugar factory capacity calculations

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13200 TCD (550 TCH)

Basis of Calculation: TCD (24 hr working)

TCD (22 hr working)

TCH (24Hr working)

= 13200

= 12100

= 550

= 105

TOTAL RAW JUICE % ON CANE

CLEAR JUICE % ON CANE

CLEAR JUICE BRIX

SYRUP BRIX

ADDED WATER % FIBRE

FIBRE % CANE

= 15

= 120

= 105

= 14

= 62.0

= 250

= 14

A MASSECUITE % ON CANE = 24

(ONLY M & S GRADE SUGAR PRODUCTION)

B MASSECUITE % ON CANE = 11

C1 MASSECUITE % ON CANE = 3

C MASSECUITE % ON CANE = 6

10 Ton / Tip

Maximum Tip / Hr

= 2 Nos.

= 24

= 2 X 10 X 24

= 480.0 X 24

= 11520 / 1.1

= 10472 Tons

= 156.0 X 24

= 3744 / 1.1

= 3403 Tons

6.5 Ton / Tip

Maximum Tip / Hr

= 1 Nos.

= 24

= 1 X 6.5 X 24

2. RAW JUICE PIPE LINE :Existing two Nos. parallel battery of 10" dia

Velocity of Juice

= 2 M / Sec

Flow rate

= 0.785 d2 V

= 364.6 M3 / Hr

One battery is suitable for crush / day

= 364.6 X 1.04 X 24 / 1.3

Two battery are suitable for cane crush /day = 7001 X 2

= 7001 Ton.

= 14002 Ton.

/var/www/apps/conversion/tmp/scratch_2/259945708.doc

Head

Existing capacity - 4 Nos.

Two Nos. in operation

= 2 M / Sec

= 60 M

= 360 M3 / Hr

= 360 X 2

= 720 M3 / Hr

= 720 X 24 / 1.3

= 13292 Ton

_________

K

T t0

Ln _________

Tt

H.S.

P

C

T

t0

t

K

K

= weight of juice in Kg . Hr

= Sp heat of juice (0.9)

= temp of heating vapour in OC

= Initial temp of juice in OC

= final temp of juice in OC

= coefficient of heat transfer in KCl / M2 / OC / hr

= 6T [ U / 1.8]0.8

C

T

t

U

= 0.9

= temp of heating vapour in OC

= Initial temp of juice in OC

= final temp of juice in OC

= Velocity of juice in M/ Sec

= 750 Kcl / M2 / OC / Hr

t0

H.S.

=

=

= 660000 Kg / Hr

= 56OC

= 30OC

= 44OC

= 1.8

P.C.

T t0

_________ Ln _________

K

Tt

660000 X 0.9

57 - 30

------------------- Ln ------------750

57 44

= 792 Ln 2.07

= 792 X 0.72

= 578 M2

Therefore, capacity of existing VLJH are sufficient.

b) Juice heaters for RJ2 heating :P

C

T

= 0.9

= temp of heating vapour in OC

= 660000 Kg / Hr

= 90OC

/var/www/apps/conversion/tmp/scratch_2/259945708.doc

= final temp of juice in OC

= Velocity of juice in M/ Sec

t0

t

U

K

= 550 Kcl / M2 / OC / Hr

H.S.

P.C.

_________

K

= 45OC

= 70OC

= 1.8

T t0

Ln _________

Tt

660000 X 0.9

------------------- Ln

550

90 - 45

------------90 70

= 1080 Ln 2.25

= 1080 X 0.811

= 875 M2

Therefore, 3 nos juice heaters of 350 m2 heating surface each are sufficient.

c) Juice heater for S J1 Heating :-

P

C

T

t0

t

U

2 O

= 575 Kcl / M / C / Hr

H.S.

P.C.

_________

K

= 0.9

= temp of heating vapour in OC

= Initial temp of juice in OC

= final temp of juice in OC

= Velocity of juice in M/ Sec

= 660000 Kg / Hr

= 100OC

= 70OC

= 88OC

= 1.67

T t0

Ln _________

Tt

660000 X 0.9

------------------- Ln

575

100- 70

------------100 - 88

= 1033 Ln 2.5

= 1033 X 0.92

= 950 M2

Therefore, 3 Nos. JH of 350M2 HS each are sufficient.

d) Juice heater for S J2 Heating :P

C

T

t0

t

U

= 0.9

= temp of heating vapour in OC

= Initial temp of juice in OC

= final temp of juice in OC

= Velocity of juice in M/ Sec

= 660000 Kg / Hr

= 110OC

= 88OC

= 102OC

= 1.67

/var/www/apps/conversion/tmp/scratch_2/259945708.doc

K

K

H.S.

= 6T [ U / 1.8]0.8

= 6 X 110 [1.67 / 1.8]0.8

= 660 X 0.94

= 620 Kcl / M2 / OC / Hr

=

P.C.

_________

K

T t0

Ln _________

Tt

660000 X 0.9

=

------------------- Ln

620

= 958 Ln 2.75

= 958 X 1.01

= 967 M2

110- 88

------------110 - 102

Dia.

Working height

Density of juice 14 Bx.

At 13200 TCD

Retention time

No 1

= 435 HL

= 4.2 Meter

= 2.75 Meter

= 1.04

No 2

400 HL

4.2 Meter

2.50 Meter

= 3.75 Minutes

3.50 Minutes

Therefore, at 13200 TCD taking working height 2.5 meter and retention time 7 minutes. Capacity

of both juice sulphiter are sufficient.

Total no of furnace

Sulphur consumption

Consider as 3 Nos. S.F for juice clarification

Consider as 1 No S.F. for syrup clarification

Total sulphur brunt by 3 Nos. S.F.

At 65 % efficiency

Juice to be treated at 0.052 % on cane

Suitable for cane crush/ day

For syrup sulphitor

Syrup to be treated @ 0.028 % on cane

Suitable for cane crush/ day

= 200 Kg / Hr

= 5 Nos.

= 0.08 % on cane

= 200 X 3

= 600 Kg / Hr

= 390 Kg / Hr

= 750 Ton / Hr (juice)

= 13850

= 464 Ton / Hr

= 13200

At 80% efficient capacity

8 M3 / Hr air brunt

4000 M2 / Hr air brunt

= 5000 M2 / Hr

= 4000 M2 / Hr

= 1 Kg / Hr Sulphur

= 500 Kg / Hr

/var/www/apps/conversion/tmp/scratch_2/259945708.doc

OR

Suitable for cane crush/ day @ 0.08 % on cane

sulphur consumption

= 12 Ton / Day

= 15000

Existing dia

Velocity of air

Suitable for cane crush / day

= 10"

= 25 M / Sec.

= 15000

Total filtering area

Required filtering area per TCH

Filtering area required

= 4.27 X 6.1 M - 1 Nos.

= 371.5 M2

= 0.70 M2

= 550 X 0.65

= 357.5

No of plates

Area of 9 plates

= 17.82 M2

Old Mill

No of plates

Area of 4 plates

= 7.92 M2

No of plates

Area of 3 plates

Total screening area

Area required

Screening area required at 550 TCH

Screening area to be increased

= 3.15 M2

= 17.82 + 7.92 + 3.15

= 28.89 M2

= 0.06 M2 / TCH

= 550 X 0.055

= 30.25 M2

= 30.25 28.89

= 1.36 M2

Type

Capacity

RPM

Motor HP

Suitable for cane crush / day

=3

= PL 1250 A

= 3000 M3 / Hr

= 590 600

= 150

= 13500

/var/www/apps/conversion/tmp/scratch_2/259945708.doc

Capacity

= 3 Nos.

= 180 M3 / hr

Dia

Height

Holding capacity in HL

Retention time

= 2 Nos.

= 36'

= 20'

= 5900

= 2. Hrs

= 13200

Working Height

Retention time

= 250 HL.

- 1 No

= 2 Meter

= 15 Minutes

= 13500

Existing equipments capacity H.S. in M2

S. No

1.

2.

3.

S. K.

2050

1850

1400

V. C.

1950

1800

1390

1st body

1200

1390

790

2nd body

1400

790

510

3rd body

750

790

510

4th body

700

790

510

VL / Dy. J.H.

300

290

300

separate sheet. (Annexure 1)

16.

PAN STATION:-

a) A PANS

A massecuite % on cane

A massecuite produce / day

No. of A pans

Total capacity of A pans

= 24

= 13200 X 0.24

= 3168 Tons / day

= 4 nos. 120 Tons + 1 No. 60 ton

= 120 x 4 + 1 x 60

= 540 Ton

No. Of strike/ day/pan

= 4 hours

= 24/4

=6

/var/www/apps/conversion/tmp/scratch_2/259945708.doc

= 3168 / 6

= 528 Tons

b) B PANS

Taking B m/c % cane

Massecuite reduce / Hr

Capacity of B CVP

=11

= 550 X 0 .11

= 60.50 Ton / Hr

= 60 Ton/hr

Taking 25% graining volume, grain required / Hr

Taking 4 hours for graining pan

Capacity of B graining pan required

= 60 X 0.25

= 15.0 Ton / Hr

= 15 X 4

= 60 Tons

= 60 Tons (sufficient)

= 60 Tons

c) C1 PANS

C1 massecuite % cane

C1 massecuite produce / day

No. of C1 pans

Capacity of C1 pans

Taking C1 m/c boiling time

Total no. Of strike / day /pan

Pan capacity required

=3

= 13200 X 0.03

=1

= 120 Ton

= 6 hours

=24/6

= 396 /4

= 396 Tons

=4

= 99 Tons

d) C PANS

C massecuite % cane

C massecuite produce / day

No. of C pans

Capacity of C pans

Taking C m/c boiling time

Total no. Of strike / day /pan

Pan Capacity required

=6

= 13200 X 0.06

= 3 Nos.60 Tons

= 1 No. 80 Ton

= (3 X 60 ) + 80

= 7 hours

= 24/7

= 792 /3.5

= 792 Tons

= 260 Ton

= 3.5

= 226Tons

17.

A PANS

Assuming evaporation rate

Water required

H.S. of 120 ton pan

H.S. of 60 ton pan

= 40 kg/mt2/hr

= 45 kg/kg of vapour

= 565 mt2

= 238 mt2

/var/www/apps/conversion/tmp/scratch_2/259945708.doc

Water requirement

Total water requirement for A pans

= 4496 M3/hr

= 4496 m3/hr

B PANS

Assuming evaporation rate

Water required

H.S. of 56 Tons / Hr CV P

Water requirement = (1038X 25 X 45)/1000

Total no. of batch pan

=1

2

HS = 280 mt , ER

Water requirement = (280 X 30 X 45) / 1000

= 25 kg/mt2/hr

= 45 kg/kg of vapour

= 1038 mt2

= 1168 m3/hr

=1168+ 378

= 30 kg/mt2/hr

= 378 m3/hr

= 1546 m3 / hr

C1 PANS

Assuming evaporation rate

Water required

H.S. of pan

Water requirement

Total water requirement for C m/c pans

= 25 kg/mt2/hr

= 45 kg/kg of vapour

= 565 mt2

= (565 X 25 X 45)/1000

= 635 m3/hr

= 635 m3/hr

C PANS

Assuming evaporation rate

Water required

H.S. of 1 No 80 Tons pan

H.S. of 4 No 60 Ton pans

Total heating surface

Water requirement

Total water requirement for C m/c pans

= 25 kg/mt2/hr

= 45 kg/kg of vapour

= 418 m2

= 3 X 238 = 714 m2

= (714 + 418) X 25 X 45 /1000

= 1274 m3/hr

= 1274m3/hr

= 2000 m3 / hr

= 9951 m3 / hr

Hence, existing injection pumps capacity is sufficient to take crush upto 13200 TCD.

COOLING TOWER

No. of cells

Capacity of each cell

=5

= 2000 m3/hr

/var/www/apps/conversion/tmp/scratch_2/259945708.doc

18.CRYSTALLIZERS :A CRYSTALLIZER

A massecuite % cane

A M /C produced

A M/ C produced per hour

Total no. of A crystallizer

Capacity of each crystallizer

Total capacity of A crystallizers

Taking retention time of A M/C in crystallizer

Massecuite handled per hour

= 24

= 3168 Tons / day

= 3168 / 24

=7

= 65 Ton

= 455 Ton

= 3 Hour

= 455 / 3

=132 Ton

At the rate of 24 % A- M/C % cane this crystallizer capacity is sufficient for = 13500 TCD

B MASSECUITE VERTICAL COOLING CRYSTALLIZER (TWIN)

Capacity

Temperature of massecuite going in B vertical crystallizer

Out let massecuite temperature

Rate of cooling / hour

Total time required for cooling

= 650C

= 490C

= 20C/ hr

= (65-49)/ 2

= 8 hour

= 68 Ton / hour

= 60 Ton / Hr

Massecuite produced / Hr

Hence, @ 11% B m/c

Crystallizers capacity

Taking 6 hours minimum cooling time

Massecuite handled per hour

Hence, @ 3 % C1 M / C % cane C1 overhead

=120/6

=20 ton / hour

= (20 x 24 x100) / 3 = 16000 TCD

Crystallizer capacity is sufficient to take crush upto 16000 TCD, hence sufficient

C VERTICAL CRYSTALLIZER

C vertical crystallizer capacity

6 nos. horizontal C crystallizer capacity

Total capacity of C crystallizer for cooling

Total retention time required for cooling in C crystallizers

Massecuite handled / hour

Hence, @ 6% C m/c % cane C vertical crystallizer

=350 ton

=360 ton

=710 ton

=22 hours

=710 /22

= (32.30 x 24 x 100)/6

= 32.30 Ton/hr

=12920 TCD

Therefore, capacity of horizontal and vertical crystallisers for C massecuite cooling are sufficient.

/var/www/apps/conversion/tmp/scratch_2/259945708.doc

19.

CENTRIFUGALS

ACENTRIFUGALS

Total massecuite produce

No of Buckau Wolf machine 1 T / Charge machine

No of NHEC 1.25 T / Charge machines

Buakau Wolf Machine, No. of cycle / machine / hr

(After change in Dc drive)

NHEC machine, No. Of cycle / machine / hr

Total massecuite cured

= 8 Nos.

= 2 Nos.

= 13

= 18

= (2 X 1.25 X 18 X 22) + (8 X 1 X 13 X 22)

= 990 + 2288

= 3278 Ton / day

B CONTINUOUS MACHINES

4nos. NK 1500, capacity

Total massecuite handled

3 no. NK 1100, capacity

Total massecuite handled

Total massecuite handled from all machines

This is sufficient to take crush

(@ B massecuite%cane = 11)

Therefore, capacity of B continuous machines are sufficient.

= 12 ton/hr/machine

= 48 ton/hr

= 8 ton / hr / machine

=24 ton / hr

= 48 + 24 = 72 ton / hr

= (72 X 22 X 100) / 11 = 14400 TCD

C1 CURING

3 nos. NK - 1500, capacity

Total massecuite handled

This is sufficient to take crush

(@ C1 massecuite % cane = 3 )

= 9 ton / hr / machine

= 27 ton / hr

= (27 X 22 X 100) / 3 = 19800 TCD

C CURING

7 no. NK 1500, capacity

Total massecuite handled

This is sufficient to take crush

(@ C massecuite % cane = 6)

Therefore, capacity of C continuous machines are sufficient.

= 6 Ton / hr / machine

= 42 ton / hr

= (42 X 22 X 100) / 6 = 15400 TCD

CAW CURING

DC - 12 machine 1 no, capacity

SC 1350 - KT - 1 no, capacity

NK - 1100 1 no, Capacity

Total magma handled

Total (CFW + C1FW) magma

(C + C1) massecuite

So, these machines are sufficient to take crush

= 8 ton / hr

= 8 tons / hr

= 8 ton / hr

= 24 ton / hr

= 35 % of (C+ C1) massecuite

= 9 % cane

= (24X22 X 100 X100) / (9 X 35)

= 16760 TCD

Therefore, capacity of CAW continuous machines are sufficient.

/var/www/apps/conversion/tmp/scratch_2/259945708.doc

20.

Total capacity

Taking total melt quantity

Retention time in melter

This is sufficient to handle melt

Where (1.25 = specific gravity of melt)

This is sufficient to take crush

21.

= 32 m3

= 16 %

= 25 mins.

= (60 X 32) / 25

= 76.8 X 1.25

= 76.8 M3 / hr

= 96 tons / hr

GRADER

No. of graders

Taking utilization capacity of each grader

Capacity of all graders = (20 X 5) X 0.75

Taking 11.5 recovery

This is sufficient to handle sugar

This is sufficient to take crush = (1650 x100) / 11.5

= 75 %

= 75 ton / hr

= 750 bags / hour

= 75 x 22

= 14350 TCD

=1650 ton

22.

Bagging machine for M sugar

Bagging rate / machine (100 Kg bagging)

Total sugar handled

Taking M sugar % =85 and recovery % cane

This is sufficient to take crush

= 5 nos.

= 200 bags / hour

= 5 x 200 x 22

=17600 Qtls./day

= 11.50

= (17600 x 100 X 100) / (85 X 11.50)

= 18000 TCD

Bagging machine for M sugar

Bagging rate / machine (100 Kg bagging)

Total sugar handled

Taking S sugar % = 15 and recovery % cane

This is sufficient to take crush

= 1 nos.

= 200 bags / hour

= 1 x 200 x 22

= 4400 Qtls./day

= 11.50

= (4400 x 100 X 100) / (15 X 11.50)

= 25500 TCD

Therefore, capacity of power Build weighing machines with stitching machines are sufficient at

12500 TCD.

/var/www/apps/conversion/tmp/scratch_2/259945708.doc

Sugar Unit Khatauli

Summary of Existing Boiling House Equipments

BASIS OF CALCULATION

CANE CRUSH = 13200 TCD

OLIVER RETURN = 15%

TOTAL MJ % CANE = 120

S

Name of Equipments

NO.

1

R. J. Weighing Scale

R. J. Pipe Line

V. L. J. H. / Dy J.H.

5

6

7

8

9

R. J2. Heating

S. J1 Heating

S. J2 Heating

juice Sulphitor (2 NOS)

Sulphur furnace

10

Air Compressure

11

12

Vacuum Filter

13

14

15

Clarifier

clear juice pumps

Syp. Sulphitor

16

(for clear Jc. Heating)

17

Semi Kestner

18

Vapour cell

19

Quad Body

1st

2nd

3rd

4th

Velocity of vapours in:

SK header 30"(in 2 parts)

For quad Ist body 30"dia

R.J./S.J.1 heating 32" dia

S.J2 heating 24'dia

FIBRE % CANE = 14

CLEAR JUICE % CANE =105

CLEAR JUICE BRIX = 14

CAPACITY AT

13200 TCD

Existing Capacity

10 Ton / Tip, 2 Nos.

6.5 Ton / Tip, 1 Nos.at 25 Tip / Hr max.

12" dia , 2 Battery, 'at velocity 2.0 m/s

14" dia header, 'at velocity 2 m/s

300 M2 X 2 Nos. Valocity 2 M / Sec.

290 M2 X 1 Nos.

360 M3 / Hr X 4 Nos. Head 60 M two remain

in operation

2

350 M2 X 3 Nos. Velocity 2 M / sec.

350 M2 X 3 Nos. Velocity 2 M / sec.

435 HL retention time 7 Minutes

200 Kg /Hr X 4 for juice

200 Kg /Hr X 1 for syrup

at total 0.08 % Sulphur on Cane

2000 M3 / Hr X 1No.

1000 M3 / Hr X 3 Nos.

10" dia

10' X 20' : X 5 Nos.

14'X 20' : X 1 No.

36' dia X 2 Nos.at Retn time 2 hr

245 m3/hr X 3 nos., head=30 mt

250 H.L. - 2 No.

Retention time 15 minutes

3Nos.,90M2 each

2 Nos., 45M2 each

1 No., 110 M2

H.S. 3900 M2 (SK no 1+2)

evp. Rate 50 Kg/M2/Hr or 10 lb

H.S. 3750 M2 (VC no 1+2)

evp. Rate 30 Kg/M2/Hr or 6 lb

O.K.

O.K.

O.K.

O.K.

O.K.

O.K.

O.K.

O.K.

O.K.

O.K.

O.K.

O.K.

O.K.

O.K.

O.K.

O.K.

O.K.

O.K.

O.K.

O.K.

HS 2190 M2 Evp rate 18.0 kg or 4.25 lb

HS 1540 M2 Evp.rate 10.0 Kg or 2.5 lb

HS 1540 M2 Evp.rate 10.0 Kg or 2.5lb

Approx 35 m/sec

Approx 26.5 m/sec

Approx 20 m/sec

Approx 30.5 m/sec(3 nos. J.H.)

Approx 17 m/sec (2 NOS .J.H.)

O.K.

O.K.

O.K.

O.K.

O.K.

O.K.

O.K.

O.K.

O.K.

/var/www/apps/conversion/tmp/scratch_2/259945708.doc

BASIS:

A MASSECUITE % CANE

B MASSECUITE % CANE

C1 MASSECUITE % CANE

C MASSECUITE % CANE

= 24

= 11

=3

=6

S.

NO

1

EQUIPMENT

A PANS

B PAN (CVP)

DETAIL OF EQUIPMENTS

4 NOS. X 120 TONS EACH

1 No X 60 Ton

60 TONS/HR

C1 PANS

O.K.

C PANS

O.K.

O.K.

O.K.

COOLING TOWER

1 NO. 80 TONS

2000 m3/hr X 5 NOS.

A CRYSTALLIZERS

B VERTICAL

CRYSTALLIZER

C VERTICAL AND

HORIZONTAL

CRYSTALLIZERS

C1 CRYSTALLIZER

A C-F MACHINES

550 TONS

8

9

10

11

12

13

14

15

16

17

CAPACITY

AT 13200 TCD

O.K.

O.K.

O.K.

8 NOS.- 1 TON/CHARGE

2 NOS.- 1.25 TON / CH

4 NOS.- NK 1503

3 NOS.- NK 1100

3 NOS. NK 1503

O.K.

7 NOS. NK 1503

O.K.

1 NO. DC 12

1 NO. SC1350 KT

1 NO.- NK 1100

O.K.

B/C SUGAR

MELTER

GRADERS

2 NOS 16 M3 / HR EACH

O.K.

5 NOS X 20 TON / HR

O.K.

POWER BUILD

AUTO WEIGHING

MACHINES

1 NO. FOR S SUGAR

O.K.

B CONTINUOUS

MACHINES

C1 CONTINUOUS

MACHINES

C CONTINUOUS

MACHINES

CAW MACHINES

O.K.

O.K.

/var/www/apps/conversion/tmp/scratch_2/259945708.doc

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