Equipment Papers

Forced Circulation Evaporator in the Sugar Industry
____________________
A Thesis
Presented to the Department of Chemical Engineering
Cebu Institute of Technology University
Cebu City, Philippines
____________________
In Partial Fulfillment
of the Requirements for the Degree
Bachelor of Science in Chemical Engineering
____________________
by
Cabarrubias, Jade G.
Cabili, Joseph Jay
Fernandez, Christine Maureen V.
Fernandez, Shaira Dale C.
Granados, Eric Francis T.
Largo, Cherry Ann L.
Tampus, Allan Jr. S.
June 2018
1
Abstract
This equipment is designed to be used in relation with concentrating sugar juice to a

syrup to produce crystallized sugar. This forced circulation evaporator is ideal for high
viscosity, high fouling and, shear thinning fluids. This applies to liquid-based feeds with high
solids content that must meet zero liquid discharge requirements. The two shells and four
passes heat exchanger systems are compact and easy to maintain. The design is configured to
adopt a broad range of operational requirements. A pump transfers diluted fluid into the
evaporator where it blends with a large volume of recirculating fluid. The fluid is heated
under pressure, so it does not boil in the evaporator heat exchanger. The entrance neck and
distribution area ensure even flow of fluid over the entire heat exchanger. Maintaining a
consistent flow and even temperature zones keep surfaces clean and safeguard product
quality. As the fluid moves through the channels, it is heated under pressure. High velocity
and high turbulence create a high heat transfer rate and high shear stress inside the surface of
the heat exchanger. The high shear stress prevents solids from accumulating on the sides. The
heated fluid flows from the heat exchanger towards the flash orifice. This creates a back
pressure of the tube and prevents boiling inside the heat exchanger. As the heated fluid passes
through the flash orifice, the pressure drops and a portion of the fluid flashes to steam. The
two-phase mixture enters the cyclone separator along a smooth tangential inlet. The
centrifugal forces improve vapor-liquid separation. And the low-density steam rises from the
circulating fluid into space above where mists and fine droplets are removed. The cyclone
reduces the risk of foaming and carry-over, resulting in a clean condensate. A vortex breaker
smooths the flow of the liquid to the circulation pump. The circulation pump transports the
fluid through the system and the low-pressure drop in the heat exchanger minimizes the
energy used by the circulation pump. The concentrated fluid is discharged from the
evaporator as a final product or further concentrated in additional effects. Finally, various
operational problems and difficulties are discussed.
2
Table of Contents
TITLE PAGE ……………………………………………………………………………….. 1

ABSTRACT ………………………………………………………………………………….
2
TABLE OF CONTENTS ……………………………………………………………….... 3-7
CHAPTER I
MARKET STUDY ………………………………………………………………………. 8-
11
A. Introduction ……………………………………………………………………….…..
8
B. Market Structure ……………………………………………………………………... 9
C. Future of the Sugar Industry ………………………………………………………....
11
CHAPTER II
PROCESS DESCRIPTION ………………………………………………………….... 12-
15
A. Process Diagram ……………………………………………………………………. 12
B. Process Description ……………………………………………………………….....
13
C. Process Stream Summary ……………………………………………………………
14
CHAPTER III
MATERIAL BALANCE …………………………………………………………….… 16-21
A. Mass Balance of Each Equipment ……………………………………………………
16
B. Overall Mass Balance of the Process ……………………………………………...…
20
C. Economic Margin ……………………………………………………………………
21
CHAPTER IV
EQUIPMENT DESCRIPTION ……………………………………………………….. 22-
26
A. Forced-Circulation Evaporator ……………………………………………………... 22
3
B. Main Body Design ………………………………………………………………..… 23
C. Circulating Pump Description ……………………………………………………….
26
CHAPTER V
FINAL RECOMMENDED DESIGN ……………………………………………...….. 27-
31
A. Heat Exchanger & Forced Circulation Evaporator Layout …………………….…….
27
B. Tube Sheet Layout ………………………………………………………….………. 28
C. Baffles Layout …………………………………………………………………...…..
29
D. Inside & Outside View of Heat Exchanger ……………………………………….….
30
E. Flash Vessel Separator ……………………………………………………………… 31
CHAPTER VI
CONCLUSION ……………………………………………………………………...…….. 32
A. Conclusion ……………………………………………………………………..…… 32
B. Recommendation …………………………………………………………………… 32
CHAPTER VII
APPENDICES ……………………………………………………………………...….. 33-46
CHAPTER VIII
REFERENCES ……………………………………………………………………………
4
LIST OF FIGURES
Figure 1: Sugarcane Milled

Figure 2: Raw Sugar Production
Figure 3: Retail (Peso per Kilo)
Figure 4: Sugar Industry on the year 2077
Figure 5: Process Diagram of Production of Raw Sugar
Figure 6: Heat Exchanger
Figure 7: Forced Circulation Evaporator
Figure 8: Tube Sheet Layout
Figure 9: Baffles Layout
Figure 10: Inside View of Heat Exchanger
Figure 11: Outside View of Heat Exchanger
Figure 12: Elevation of Heat Exchanger
Figure 13: Flash Vessel Separator
5
LIST OF TABLES
Table 1: Drying Process Stream

Table 2: Centrifuge Process Stream
Table 3: Crystallizer Process Stream
Table 4: Evaporator Process Stream
Table 5: Heat Exchanger Process Stream
Table 6: Clarifier Process Stream
Table 7: Heater Process Stream
Table 8: Roller Miller Extractor Process Stream
Table 9: Mass Balance of Dryer
Table 10: Mass Balance of Centrifuge
Table 11: Mass Balance of Crystallizer
Table 12: Mass Balance of Evaporator
Table 13: Mass Balance of Heat Exchanger
Table 14: Mass Balance of Clarifier
Table 15: Mass Balance of Heater
Table 16: Mass Balance of Roller Press
Table 17: Mass Balance of Dryer 1 in Activated Carbon
Table 18: Mass Balance of Furnace 1
Table 19: Mass Balance of Mixer
Table 21: Mass Balance of Cooler
Table 23: Overall Mass Balance of the Process
Table 24: Economic Margin of Production of Raw Sugar
Table 25: Abbreviations
Table 26: Compositions
Table 27: Thermodynamics properties of syrup (sucrose and water)
Table 28: Chemical properties of stainless-steel type 430
Table 29: Mechanical properties of stainless-steel type 430
Table 30: Physical properties of stainless-steel type 430
Table 31: Thermodynamics properties of evaporator
6
LIST OF APPENDICES
A.1Process Diagram of Production of Sugar

A.2 Computation of the Material Balance of Production of Sugar
A.3 Economic Margin
A.4 Thermodynamic Properties
A.5 Safety Precautions
7
Chapter I
Market Study
A. Introduction
Sugar is one of the oldest commodities in the world. Where it’s usually produced from
sugarcane, sugar beet and other crops containing sugar contents with large quantities of
sucrose. But sugarcane is far more affordable than sugar extracts from other sources. but
there are still factors to be considered in the sugarcane agriculture, such as the climate,
landform, soil composition and structure. And commercially sugarcane is usually grown in
the tropics and subtropics. Where its ideal environment is one in which rainfall is well
distributed during the growing season and the preharvest ripening period is relatively dry,
where the sunshine hours are plentiful throughout the whole season. Philippines was
considered as the second biggest producers of sugar in Southeast Asia and seventh in the
world because of its tropical conditions. (Glyn James, 2004).
Sugar made massive demand in the local and international market because of its wide
applications. One of the wastes from the sugar industry is the bagasse where it is either
utilized for steaming of the boiler or be made for another product such as activated carbon
and more (T. Silalertruksa et al., 2015). And some by-products of the sugar are reprocessing
for power and some pharmaceutical products. (A. Gupta et al., 2015). Sugarcane mill has a
significant contribution on government revenue and employment opportunities. It has other
goodness like the development of community system and administrative aspects of the
environmental management plan. (Omprakash Sahu, 2018).
The market is segmented on the basis of white, liquid, and brown sugar. High demand
for the product in confectionary and bakery products is expected to propel industry growth
over the projected period. It is subdivided on the basis of products as powdered, granulated,
and syrup. It is a consumed product amongst all, which finds high demand for food and
beverages, dairy, pharmaceutical, and bakery industry. Furthermore, increasing demand for
the product in the manufacturing of sweets, chocolates, chewing gum, and marmalade is
expected to have a positive impact on the industry trends. The increasing demand for sugar in
various application industries is embolden the new entrants in the market which in turn to
increase the competitive contention.
8
B. Market Structure
30000000
25000000
20000000
15000000
10000000
5000000
0
2013 - 2014 2014 - 2015 2015 - 2016 2016 - 2017 2017 - 2018 2018 - 2019
Sugarcane Milled (MT/year)
Figure 1: Sugarcane Milled
In the year of 2018, the sugarcane milled was higher compared to the year of 2019
due to the climate change that is affecting the agriculture products. Also, the result in 2015-
2016 started to change but it gave more impact in the year of 2016-2017. It happened that the
sugarcane milled was in demand and have begun gearing up to improve their efficiencies to
be competitive in the world
3000000
2500000
2000000
1500000
1000000
500000
0
2013 - 2014 2014 - 2015 2015 - 2016 2016 - 2017 2017 - 2018 2018 - 2019
Raw Sugar Production (MT/year)
Figure 2: Raw Sugar Production
9
In the year 2018 the target is lower than last year’s 25 million MTs due to the
expected unfavorable weather. Data from the Philippine Statistics Authority showed that the
lack of manpower in sugarcane fields, especially in Western Visayas, caused a drop-in
production in the first quarter by 11.56% due to delayed harvest. Also, one of the factors is
the decrease of operating sugar refineries which minimizes the supply and increase in
demand.
70
60 56.23 58.11
55.66
52.27 50.78 51.38 52.46
48.75 48.34 48.02 48.86 49.88
50 44.97
44.51
41.29
40
30
20
10
0
2013-2014 2014-2015 2015-2016 2016-2017 2017-2018
Raw Washed Refined
Figure 3: Retail (Peso per Kilo)
Wholesome prices for the three types of sugar (raw, washed, and refined) were
continuously increasing for the last 5 years notably 2013 – 2018. Retail prices for the 3 types
of sugar were increasing because of its high demand for consumers. And according to the
supply and demand theory, if there is an increase in demand the prices and quantity increases.
And if the supply decreases, the prices are raised while lowering the quantity. And base on
the graph on figure 3 the prices increased, meaning there is a demand of sugar but the supply
of sugarcane has decreased.
10
Raw Sugar Refined Sugar Molasses
1800000
1600000
1400000
1200000
1000000
800000
600000
400000
200000
0
2015 - 2016 2016 - 2017 2017 - 2018 2018 - 2019
Figure 4: Annual Total Demand in Metric Tons
Raw Sugar Refined Sugar Molasses

35.00%
30.00%
25.00%
20.00%
15.00%
10.00%
5.00%
0.00%
2015 - 2017 2 0 1 6 -2 0 1 8 2017 - 2019
Figure 5: Demand Percentage Per Year
According to the Sugar Regulatory Administration, the demand percentage of the raw
sugar has continuously increase from 2015 to 2019. One of the reasons for this high demand
are the number of food industries in the Philippines which require raw sugar as a main
ingredient in the production of their respective goods. But with the large amount of demand,
the Philippine market cannot supply the demand itself due to certain factors such as dry and
humid weather conditions resulting to droughts and such, low production and many more.
Thus, the food industries tend to opt for the importation of raw sugar from other countries.
This high demand and low supply raise the value of raw sugar, so innovations and
optimizations of the process in sugar production must be look over as to possibly boost the
country's own sugar production.
11
C. Future of the Sugar Industry
India has the world’s second largest production of sugar which is expected to expand
more as a result of recent sugar policy reforms. It is also expected to increase by 7 MT over
the next decade as it reached 31 MT in 2027. Also, in Thailand, it will maintain its market
position as the fourth largest producer but it is projected to experience a slower growth
compared to recent years due to elimination of price from January 2018. By 2027, Thailand is
expected to produce 13.5 MT which is similar to China’s production level. It is projected that
China will accelerate their growth in sugarcane and sugar beet production during the first
years of the projection period, supported by the 2015-2020 National Plan. By 2027,
production in China is expected to reach 13.4 MT, mainly through increases in yields and
area.
12
Chapter II
Process Description
A. Process Description
Different unit operations were selected in the process of raw sugar in this research.
The first unit operation that in which where the raw material was introduced is dryer. This
unit operation generally refers to removal of moisture from a substance, hence, this unit
operation is considered one of the oldest and power consuming unit operation being used in
the industry. In the processing of our raw sugar the type of dryer that the researchers used is
the solar drying. Solar drying is the type of dryer that uses solar energy for drying substances.
After the raw sugar cane was being cut, rolled, and washed, the raw material was introduced
to the dryer. The dryer was operated at 65 degrees Celsius with a pressure of 1 atm. The
advantage of this type of dryer is that it gives less spoilage of the dried product. The
materials that goes out of the dryer are the water evaporated and the dried sugar cane.
The dried sugar cane was then introduced to the crusher. Since ball mill crusher grinds
the substances efficiently it was decided that this will be the type of crusher that will be used.
The materials that will go out of this unit operation is the bagasse which is considered as a
byproduct and the raw juice which contains sucrose.
The raw juice will then go to the heater. Lime is also introduced in the heater to purify
the raw juice. Lime as a chemical. Lime and the heat introduced in the heater acts as a
clarifying agent so that the inlet of the next unit operation will give the desired result of the
mixture juice. Since lime will be introduced in this unit operation direct contact heater will be
the suitable type that will be used. Direct contact heater has many advantages especially in its
power consumption and provides a complete automation. Heated juice will be the product
that will come out the heater and then will be introduced to the clarifier or the settler.
Since the feed of the clarifier has already been prepared for the process of clarification
the unwanted solids will already settle down forming a sludge. The other product that the
clarifier will withdraw is the clarified juice. The clarified juice will then pass through a heat
exchanger to ready the syrup that will enter our double effect evaporator. The reason why a
13
heat exchanger was added in this process is because heat has a major relationship with the
surface area of the vessel to be used in the evaporator.
A double effect evaporator is needed in this process since we have a huge amount of
feed used. The amount of steam used in this double effect evaporator is 2026.24 MT/day
having a pressure of 200 kPa. The product that these two evaporators will produce will be
called syrup and will then undergo to the crystallizer to allow the formation of sugar crystals.
The type of crystallizer that was selected is freeze concentration crystallizer since it produces
crystals. The product that the crystallizer will give is a mixture of the mother liquor and
molasses. The other product that the crystallizer gives will be the amount of water
evaporated. Since we aim to produce sugar crystals in this unit operation a seed is introduced.
A seed is introduced in a crystallizer to control supersaturation; thus, it is also an effective
method in growing crystals inside this kind of unit operation.
Since the product of out crystallizer will be a mixture of sugar crystals and molasses,
in order to separate this mixture, a process of centrifugation will be done. The outlet of this
unit operation will be the wet sugar and the separated molasses. A small amount of water is
introduced in this unit operation to prevent coating of molasses in our wet sugar.
Lastly, since the given product will be a wet sugar, a dryer will be used in order to dry
this, so, we can get the desired product that we want which is the dry sugar. The kind of dryer
that would be used will be a solar dryer. The outlets of this unit operation will be the dry
sugar (wanted product) and the water evaporated from the wet sugar.
14
B. Process Diagram
Figure 6: Process Diagram of Production of Raw Sugar
15
Chapter III
Material Balance
A. Mass Balance of Each Equipment
Table 1: Mass Balance of Dryer

Mass In Mass Out
Ds = 300 MT/day
Ws = 646.667 MT/day
Wd = 346.67 MT/day
TOTAL
646.667 MT/ day 646.67 MT/day
Table 2: Mass Balance of Centrifuge

Mass In Mass Out
M = 837.46672 MT/ day Ws = 646.667 MT/day
Wce = 58 MT/ day Mo = 248.8002 MT/day
TOTAL
895.46672 MT/ day 895.4672 MT/day
Table 3: Mass Balance of Crystallizer

Mass In Mass Out
Sy = 1002.887904 MT/ day M = 837.46672 MT/day
Se = 27.64 MT/ day Wcr = 193.0611835 MT/day
TOTAL
1030.527904 MT/ day 1030.527904 MT/day
Table 4: Mass Balance of Evaporator

Mass In Mass Out
V1 = 1643.12792 MT/day
F = 4345.847584 MT/day V2 = 1698.262662 MT/day
L2 = 1002.887904 MT/day
TOTAL
4345.847584 MT/ day 4344.278486 MT/day
Table 5: Mass Balance of Heat Exchanger
Mass In Mass Out
CJ = 2716.15474 MT/ day HJ = 4345.847584 MT/ day
SI = 4149.597 MT/ day SO = 2519.898156 MT/ day
TOTAL
6865.75174.822 MT/ day 6865.74574 MT/day
16
Table 6: Mass Balance of Clarifier
Mass In Mass Out
CJ = 2716.15474 MT/day
MJ = 3969.76462 MT/day
SL = 1253.60988 MT/day
TOTAL
3969.76462 MT/ day 3969.76462 MT/day
Table 7: Mass Balance of Heater

Mass In Mass Out
RJ = 3854.76462 MT/day
MJ = 3969.76462 MT/day
L = 115 MT/day
TOTAL
4142.3288 MT/ day 4142.3288 MT/day
Table 8: Mass Balance of Roller Press

Mass In Mass Out
Ss = 4454.288971 MT/day RJ = 3854.76462 MT/day
Wr = 100 MT/day B = 699.5243514 MT/day
TOTAL
4554.288971 MT/ day 4554.288971 MT/day

MASS IN MASS OUT
WD2 = 205.7424563 MT/day
B =699.5243514 MT/day
DB = 493.7818951 MT/day
TOTAL
699.5243514 MT/day 699.5243514 MT/day
17
MASS IN MASS OUT
WF = 332.4578538 MT/day
F2 = 100 MT/day
PF = 466.3495676 MT/day
EA = 253.87 MT/day
FG = 43.055 MT/day
DB = 493.7818951 MT/day
R = 5.78947368 MT/day
TOTAL
847.6518951 MT/day 847.6518951 MT/day
Table 11: Mass Balance of Mixer

MASS IN MASS OUT
PF = 466.3495676 MT/day S = 41.8518843 MT/day
HP = 113.5979716 MT/day P = 538.0956549 MT/day
TOTAL
579.9475392 MT/day 579.9475392 MT/day

MASS IN MASS OUT
WF2 = 325.9752131 MT/day
F3 = 100 MT/day
PF2 = 471.5894504 MT/day
EA2 = 196.8058779 MT/day
FG2 = 34.17896935 MT/day
P = 538.0956549MT/day
R2 = 3.1579 MT/day
TOTAL
834.9015328 MT/day 834.9015329 MT/day
Table 13: Mass Balance of Cooler

MASS IN MASS OUT
PF2 = 471.5894504 MT/day
PC = 493.7818951 MT/day
WCO = 22.19244472 MT/day
TOTAL
493.7818951 MT/day 493.7818951 MT/day
18
MASS IN MASS OUT
AC = 428.2802151 MT/day
PC = 493.7818951 MT/day
WD3 = 65.50168 MT/day
TOTAL
493.7818951 MT/day 493.7818951 MT/day
19
B. Overall Mass Balance
Table 15: Overall Mass Balance of the Process

MASS IN MASS OUT
Ds = 300 MT/day
Wd = 346.67 MT/day
Ws = 646.667 MT/day
Ws = 646.667 MT/day Mo = 248.8002 MT/day
M = 837.46672 MT/ day M = 837.46672 MT/day
Wce = 58 MT/ day Wcr = 193.0611835 MT/day
Sy = 1002.887904 MT/ day V1 = 1643.12792 MT/day
Se = 27.64 MT/ day V2 = 1698.262662 MT/day
F = 4345.847584 MT/day L2 = 1002.887904 MT/day
CJ = 2716.15474 MT/ day HJ = 4345.847584 MT/ day
SI = 4149.597 MT/ day SO = 2519.898156 MT/ day
MJ = 3969.76462 MT/day CJ = 2716.15474 MT/day
RJ = 3854.76462 MT/day SL = 1253.60988 MT/day
L = 115 MT/day MJ = 3969.76462 MT/day
Ss = 4454.288971 MT/day RJ = 3854.76462 MT/day
Wr = 100 MT/day B = 699.5243514 MT/day
B =699.5243514 MT/day WD2 = 205.7424563 MT/day
F2 = 100 MT/day DB = 493.7818951 MT/day
EA = 253.87 MT/day WF = 332.4578538 MT/day
DB = 493.7818951 MT/day PF = 466.3495676 MT/day
PF = 466.3495676 MT/day FG = 43.055 MT/day
HP = 113.5979716 MT/day R = 5.78947368 MT/day
F3 = 100 MT/day S = 41.8518843 MT/day
EA2 = 196.8058779 MT/day P = 538.0956549 MT/day
P = 538.0956549MT/day WF2 = 325.9752131 MT/day
PF2 = 471.5894504 MT/day PF2 = 471.5894504 MT/day
WCO = 22.19244472 MT/day FG2 = 34.17896935 MT/day
PC = 493.7818951 MT/day R2 = 3.1579 MT/day
PC = 493.7818951 MT/day
AC = 428.2802151 MT/day
WD3 = 65.50168 MT/day
TOTAL
30227.67 MT/day 30226.1 MT/day
20
C. Economic Margin
Table 16: Economic Margin of Production of Raw Sugar

Purchase Sales
Materials Price Materials Price
Sugarcane: ₱ 6 , 707 , 422.908 Raw Sugar: ₱ 15 , 678 , 000
Lime Juice: ₱ 1 ,725 , 000 Molasses: ₱ 2 , 570 , 404.626
Water: ₱ 3 , 173.75331 Activated Carbon: ₱ 85 , 656 , 043.02
Phosphoric Acid: ₱ 7 , 250 , 935.808
Seed Grain: ₱ 1 ,520 , 200
₱ ₱ 103,904,447.
TOTAL: TOTAL:
17,206,732.47 6
ECONOMIC MARGIN:
83.44 %
21
Chapter IV
Equipment Description
A. Forced-Circulation Evaporator
Evaporation is a unit operation that separates a liquid from solids by means of heat
transfer via vaporization or boiling. In general, steam is not the desired end product, and it
could be recovered (or not) based on its energetic value. Therefore, the evaporation process is
normally achieved by evaporating a portion of the solvent, resulting in a concentrated
solution. The unit is designed to concentrate liquid feed from the raw materials (sugarcane)
by means of evaporation of the solvent and separating it from the solute which is the product
to be attained to produce the final product of crystallize sugar. Evaporator used in
concentrating liquid-based mixtures which is widely used to concentrate liquid foods, such
sugar juice.
The equipment is a force circulation evaporator designed for concentrating the raw
juice of the sugarcane. Force circulation evaporator is the type of evaporator selected for it is
suitable for products with high levels of suspended solids or highly viscous products. It is the
most versatile of all evaporators, since it does not depend on a natural thermosyphon effect
that limits the heat transfer coefficient. Also, with the presence of pump, fouling can be
controlled well. It offers the highest operational flexibility, since heat transfer, vapor-liquid
separation and crystallization can take place in separate components by locating the pumps
outside the evaporator. It is compacted with high capacity circulating pumps, which extend
the production time causing to reduce the downtime for the cleaning operations. The
operation is not limited by the liquid/vapor ratio, and turn down can be as low as 5% of
capacity units. Forced circulation leads to high tube side velocities (6-18 ft/ s), and hence
higher heat-transfer coefficients and smaller heating surfaces. Positive circulation renders this
unit relatively insensitive to variations in physical properties or loads, making it suitable for
crystallizing solutions or slurries.
This type of evaporator is more expensive compared to the natural circulation

evaporator due to its operating cost and maintenance costs for the pump, however, the natural
circulation evaporator enlisted some limits under such condition: highly viscous solutions
due to low heat transfer coefficient, solution containing suspended particles, for heat sensitive
22
materials. All these problems may be overcome when the liquid is circulated at high velocity
through the heat exchanger tubes to enhance the heat transfer rate and inhibit particle
deposition.
The concentration is produced through a circulation that is continuous between the

tube bundles of the horizontal heat exchanger and the flash vessel (separator). A rising
circulation takes place when the products flows through the heat exchanger from the bottom
to the top and the product discharge vapor in the flash vessel. The rising forced circulation
permits a higher transfer coefficient that causes for vapor and liquid to be together “flow
boiling phenomena” and then the circulation goes through.
B. Main Body Design
The main body of the equipment, compromises the following components: tubular
shell and horizontal tube heat exchanger, a flash chamber (separator) mounted above the heat
exchanger and a circulating pump.
The feed that entered the equipment is composed of sugar composition that is related
to food industry and it is one of the main reasons in considering what type of material to be
used. The material used is a Ferritic Stainless-Steel Type 430 for it contains high chromium
and zero nickel. This type of stainless steel has low thermal expansion; has excellent high
temperature oxidation resistance, high thermal conductivity, have excellent creep resistance,
and not prone to stress corrosion cracking.
Force is used to convey the liquor through the tube of the heat exchanger that
produces adequate velocity to achieve good heat transfer. A circulating pump that has a high
efficiency is designed for large volume to supply the force, which is usually of the axial-flow;
single elbow design, well suited for high flow rates and low pressure drops. It is also
important that the pump and the system are matched. The required NPSH (net positive
suction head) is usually critical, thus the fluid that is pumped must be near to its boiling point.
The pump must be operating at this type of design level since the pump operates at low
speeds, which minimize erosion and reduce maintenance.
23
Heat exchangers can be located on the discharge or suction side of the circulating
pump. In some cases, both discharge and suction side heat exchangers have been provided in
the same circulating system to maximize heat transfer surface.
The type of heat exchanger used is the 2 shell 4 pass heat exchanger which is consists
of a number of tubes mounted inside a cylindrical shell. This exchanger consists of four
major parts: Front Header, Rear Header, Tube Bundle, and Shell.
Front header is where the fluid enters the tube-side of the exchanger. It is sometimes
referred to as the Stationary Header. Front header is made up of a valve bonnet that covers the
opening through which the internal parts are inserted. The bonnet serves as the mounting base
for the actuator. It includes the seal which prevents fluid leakage along the stem.
Rear header is where the tube-side fluid leaves the exchanger or where it is returned
to the front header in exchangers with multiple tube-side passes. It is a fixed tube sheet that is
most likely of stationary header. A fixed-tube sheet has straight tubes that are secured at both
ends to tube sheets welded to the shell. The construction may have removable channel covers
(e.g., AEL), bonnet-type channel covers (e.g., BEM), or integral tubesheets (e.g., NEN).
Tube bundle compromises the tubes, tube sheets, baffles, tie rods, etc. to hold the bundle
together.
a. Tubes - the usual outside diameter range for petroleum and petrochemical applications
is 15 to 32 mm, with 19 and 25 being the most common. The thickness tolerances for
minimum wall tubes are minus zero, plus 18% to 22% of the nominal thickness, while
those of average wall tubes are plus and minus 8% to 10% of the nominal wall
thickness. The most common tube length range is 3600 to 9000 mm for removable
bundles and 3600 to 15000 mm for the fixed tube type. Removable bundle weights
are often limited to 20 tons. TEMA specifies minimum tube pitch/ outside diameter
ratios and minimum gaps between tubes.
b. Channel Partition Plates - for exchangers with multiple tube passes, the channels are
fitted with flat metal plates which divide the head into separate compartments. The
24
thickness of these plates depends on channel diameter but is usually 9 to 16 mm for
carbon and low alloy steels and 6 to 13 mm for the more expensive alloys.
c. Shell baffles - have the dual purpose of supporting the tubes at intervals to prevent sag
and vibration, and also of forcing the shell side fluid back and forth across the bundle,
from one end of the exchanger to the other. Segmentally, single cut baffles are the
most common, however, thermal or pressure drop may dictate baffles of more
complicated shape. TEMA standards also specify that the minimum spacing between
segmental baffles need to be the larger of one-fifth of the shell inside diameter or 51
mm.
d. Baffle spacing - Baffle spacing is the centerline-to-centerline distance between

adjacent baffles. The TEMA standards specify the minimum baffle spacing as one-
fifth of the shell inside diameter or 2 in., whichever is greater.
e. Tie rods - Tie rods and spacers are used to hold the tube bundle together and to locate
the shell baffles in the correct position. Tie rods are circular metal rods screwed into
the stationary tube sheet and secured at the farthest baffle by lock nuts. The number of
tie rods depends on shell diameter and is specified, by TEMA.
Upon evaluation of the said part, Type B for stationary header (bonnet), Type F for the
shell tube, and Type M for Fixed tube sheet rear end are used.
The vapor/liquor flash chamber (separator) is connected at the bottom, or the top of
the heat exchanger, as per the geometrical arrangement based on the number of passes and it
is connected to each other through a recirculation loop. The flash chamber provides sample
liquor retention time to allow relieving supersaturation via crystal growth. This separator
compromises an inlet device: a demister, vortex breaker, and a control valve.
The separator includes internal parts, to promote separation of the process, such as:
a. A stationary elongated vessel having an upper section containing a vapor phase outlet.
25
b. Primary separation section (entrance): for separating the bulk of the liquid from the
gas. It is desirable to remove the liquid slugs and large droplets of liquid quickly from
the gas stream, and to remove gas from the liquid.
c. Secondary separation section: for removing smaller particles of liquid by gravity

settling depends to a large extent on the decreased gas velocity and reducing the
turbulence of gas.
d. Liquid separation section (or the liquid accumulation section): for removing gas
bubbles which may be occluded with the liquid, and for sufficient storage of the liquid
to handle the slugs of liquid anticipated in routine operation.
e. Mist extractor or eliminator section: for removing from the gas entrained drops of
liquid, this did not separate in the secondary separation section. Mist extractor might
be used to decrease the amount of entrained liquid in the gas and to reduce diameter
of the vessel.
f. Vortex breaker (in the bottom of the vessel): prevents potential pump suction
problems if a pump is used to remove collected liquids.
Circulation evaporation incorporates the use of both heat exchangers and flash
separation units in conjunction with circulation of the solvent in order to remove liquid
mixtures without conventional boiling.
26
C. Circulating Pump Description
The type of pump that used in the equipment design is an axial flow pump, or AFP
consists of a propeller in a pipe. The pressure in an axial flow pump is developed by the flow
of liquid over the blades of impeller. In an axial flow pump, blades have an airfoil section
over which the fluid flows and pressure is developed. Also, the power requirements and
pump head increase with an increase in pitch, thus allowing the pump to adjust according to
the system conditions to provide the most efficient operation.
Axial type can pump up to 3 times more water and other fluids at lifts of less than 4
meters as compared to the more common radial-flow or centrifugal pump. Axial Pump can
easily be adjusted to run at peak efficiency at low-flow/high-pressure and high-flow/low-
pressure by changing the pitch on the propeller.
27
Chapter V
Final Recommended Design
A. Layout
28
29
30
31
32
33
Chapter VI
Conclusion
A. Conclusion
Sugar has been a part of our lives for over centuries now, even though too much of it
can cause an imbalance lifestyle, this product can also help in improving the taste of many
foods that has an integral part in cultural activities. In processing raw sugar variety of unit
operations will be considered, one of which is the evaporator. Due to increase in temperature
and/or pressure the liquid state of a substance changes to gaseous state, and this is called the
process of evaporation. Evaporation is included in the production of raw sugar since the
product that this unit operation will produce is a mixture between molasses and the sugar
crystals.
Forced-circulation evaporator is selected in this design due to the high viscosity that
the raw sugar have. Different parameters were considered in designing this equipment such
as, the dimensions of the inside and outside of the flash vessel together with the dimensions
of heat exchanger that will help in reducing the area of the evaporator. Forced-circulation
evaporator, though it is more expensive compared to natural circulation evaporator, its
performance when it comes to evaporating high viscous substances is very efficient unlike the
natural convection which is only limited to not to high viscous substances.
The type of material in which the evaporator will be made of is also related to the type
of material that the design will going to process. Since sugar is related to food industry, the
type of material that will be used is a Ferritic Stainless Steel Type 430 for it contains high
chromium and zero nickel which will not give harm in processing food and also contains a lot
of advantages when it comes to the production of sugar.
B. Recommendation
Other considerations that may help minimize fouling include allocating the more
fouling fluid to the tube side (if possible); keeping the fluid velocity constant; easy access for
cleaning is allowable; and tube wall temperatures are not too high for salt deposits to
accumulate.
34
Chapter VII
APPENDICES
A.1 Process Stream Summary
Table 1: Drying Process Stream

S/N 29 IN 30 31 PRODUCTS
Name Wet Sugar Water Out Discharge
MT/day MT/day MT/day
Components
646.667 346.67 300
Phase S L S
Pressure 1 1 1
Temperature 60 60 60
Table 2: Centrifuge Process Stream

S/N 25 IN 26 27 28 OUT
Name Mixture Water In Molasses Discharge
MT/day MT/day MT/day MT/day
Components
837.46672 58 248.8002 646.667
Phase L L L S
Pressure 1 1 1 1
Temperature
Table 3: Crystallizer Process Stream

S/N 21 IN 22 23 24 OUT
Name Syrup Seed In Water Out Discharge
Components
1002.887904 1643.12792 53 837.46672
Phase L S L L
Pressure 1 1 1 1
Temperature 65 65 45 65
Table 4: Evaporator Process Stream

S/N 17 IN 18 19 20 OUT
Name Heated Juice Vapour 1 Vapour 2 Discharge
Components
4345.847584 1643.12792 1698.262662 1002.88790
Phase L V V L
Pressure 1 1 1 1
35
Temperature 96 91 58.20 56.4
Table 5: Heat Exchanger Process Stream

S/N 13 IN 14 15 16 OUT
Name Clarified Juice Steam In Steam Out Discharge
Components
2716.15474 4149.597 2519.898156 4345.847584
Phase L G G L
Pressure 1 1 1 1
Table 6: Clarifier Process Stream

S/N 9 IN 10 11 12 OUT
Name Mixed Juice Lime In Sludge Discharge
Components MT/day MT/day MT/day MT/day
3969.76462 115 1253.60988 2716.15474
Phase L G G L
Pressure 1 1 1 1
Table 7: Heater Process Stream

S/N 5 IN 6 7 8 OUT
Name Raw Juice Lime In Lime Out (sludge) Discharge
Components
3854.76462 115 3969.76462
Phase L L L L
Pressure 1 1 1 1
Table 8: Roller Miller Extractor Process Stream

S/N 1 IN 2 3 4 OUT
Name Raw Juice Water In Bagasse Discharge
Components
4454.288971 100 699.5243514 3854.76462
Phase L G G L
Pressure 1 1 1 1
36
A.2 Abbreviations of the Production of Raw Sugar

Definition Abbreviation
Dry Sugar Ds
Wet Sugar Ws
Water Evaporated @ Dryer Wd
Mixture M
Molasses Mo
Water @ Centrifuge Wce
Syrup Sy , L2
Seed Grain Se
Water Evaporated @ Crystallizer Wcr
Feed (Heated Juice) F , HJ
Steam S
Mother Liquor @ 1st Effect L1
Vapor @ 1st Effect V1
Vapor @ 2nd Effect V2
Clarified Juice CJ
Steam In SI
Steam Out SO
Mixed Juice MJ
Sludge SL
Raw Juice RJ
Lime Juice L
Shredded Sugarcane SS
Water Extracted @ Roller Press Wr
Bagasse B
Water Evaporated @ Dryer 2 WD2
Dried Bagasse DB
Coal Feed 1 , 2 F2 , F3
Excess Air 1 , 2 EA, EA2
Water Evaporated @ Furnace 1, 2 WF, WF2
Product @ Furnace 1, 2 PF, PF2
Flue Gas 1, 2 FG, FG2
Refuse 1, 2 R, R2
Paste P
Steam S
Phosphoric Acid HP
Water @ Cooler WCO
Wet Carbon PC
Water Evaporated @ Dryer 3 WD3
Activated Carbon AC
37
A.3 Compositions of the Production of Raw Sugar
Definition Composition
Dry Sugar 300 MT/day
97% Sugar
3% Water
Wet Sugar 55% Sugar
45% Water
Mixture 20% Sugar Crystals
80% Mother Liquor
(50 – 50% Sugar Crystals, Water)
Molasses 80% Molasses
15% Water
5% Sugar Crystal
Water @ Centrifuge 58 MT/day
Syrup 65% Sugar
35% Water
Seed Grain 27.64 MT/day
Water Evaporated @ Crystallizer 8.3% Water Evaporated
Clarified Juice 80% Raw Juice
20% Water
Mixed Juice 30% Lime
70% Raw Juice
Sludge 95% Lime
5% Water
Lime Juice 115 MT/day
Shredded Sugarcane 25% Sugarcane
75% Water
Water Extracted @ Roller Press 100MT/day
Bagasse 60% Solids
40% Water
Dried Bagasse 85% Solids
15% Water
Coal Feed 1 , 2 7% C, 60% C
5% H, 10% H
10% O2, 7% O2
1.5% N, 5% N
3% S, 10% S
5.5% Ash, 3% Ash
Flue Gas 1, 2 5% CO2
33.7% CO
15.7% H2
45.6% N2
Refuse 1 & 2 95% Ash
5% Others
Paste 78% Solid
38
7% H3PO4
15% H2O
Phosphoric Acid 70% H3PO4
30% H2O
Product Furnace 2 89% Solid
7% H2O
4% H3PO4
Wet Carbon 85% Solid
13% H2O
2% H3PO4
Activated Carbon 98% Solid
2% H2O
Table 26: Compositions
A.2 Material Balance Computation of the Production of Raw Sugar
Solution {1}
Sugar Crystal Balance: @Ds = 300 MT/day

0.97 Ds = 0.45 Ws
0.97 Ds = 0.45 Ws (300 MT/day)
Ws = 646.667 MT/day
Overall Material Balance:

Wd + Ds = Ws
Wd = 646.667 – 300
Wd = 346.667 MT/day
Solution {2}
Overall Material Balance: @ Ws = 646.667 MT/day

M + Wce = Ws + Mo
M + 58 = 646.667 + Mo
M – Mo = 588.667 {1}
Water Balance:
(0.8)(0.5)(M) + Wce = 0.55 Ws + 0.15 Mo
(0.8)(0.5)(M) + 58 = (0.55)(646.667) + 0.15 Mo
0.4 M – 0.15 Mo = 297.66685 {2}
M = 837.46672 MT/day Mo = 248.8002 MT/day
Solution {3}
Overall Material Balance: @ M = 837.46672 MT/day

Sy + Se = M + Wcr
Sy – Wcr = 837.46672 – 27.64
Sy – Wcr = 809.82672 {1}
39
Water Balance:
0.35 Sy = 0.083 Wcr + (0.5)(0.8)(M)
0.35 Sy = 0.083 Wcr + (0.5)(0.8)(837.46672)
0.35 Sy – 0.083 Wcr = 334.986688 {2}
Sy = 1002.887904 MT/day Wcr = 193.0611835 MT/day
Solution {4}
BP R2 = 1.78x + 6.22x²
BP R2 = 1.78(0.15) + 6.22(0.15)²
BP R2 =0.40695
T s 3 = T 2 + BP R 2
T s 3=56+ 0.40695
T s 3=56.40695 °C
F = L2 + ( V 1+ V 2 )
0
0.15 F = 0.65 L2+ ( V 1+ V 2 )
0.15 F = (0.65) (1002.887904) + 0
F = 4345.84784 MT/day
¿
F = ¿ V1 + V2
L2+ ¿
4345.847584 = 1002.887904 + ( V 1+ V 2
( V 1+V 2=3342.95968
3342.95968
V 1=V 2= =1671.47984
2
F = V 1 + L1
L1=¿ 4345.84784 - 1671.47984
L1=2674.367744
L2=L1 − V 2
L2 = 2674.367744 – 1671.47984
L2=1002.887904
F (0.15) = L1 X 1
4345.847584 (0.15) = 2674.367744 X1
X 1=0.24375
L1 X 1=L2 X 2
2674367744 (0.24375) = 1002.887904 X 2
X 2=0.65
BP R1=1.78 X 1 + 6.22 X² = 1.78 (0.24375) + 6.22 (0.24375)²

BPR 1=0.80343
2
BPR 2=1.78 X 2+6.22 X =1.78 ( 0.65 )+ 6.22 ( 0.65 ) ²
40
BP R2 = 3.78495
∑ ∆Tavailable = T S −T 2 − ( BP R1 + BPR2 )

1
∑ ∆Tavailable = 120 - 56 – 4.58838

∑ ∆Tavailable = 59.41162 °C
∑ ∆ T U1 59.41162 ( 2270 1
)
1
∆ T 1= =
1 1 1 1
+ +
U1 U2 2270 1705
∆ T 1=¿ 25.48 ℃
∑ ∆ T U1 59.41162
1
( 1705 )
2
∆ T 2= =
1 1 1 1
+ +
U1 U2 2270 1705
∆ T 2=¿ 33.928 ℃
∆ T 1=29 ℃ ∆ T 2=32 ℃
T 1 =T S − ∆ T 1 T 2 =T 1 − BPR1 − ∆ T 2
T 1 =¿ 120 – 29 T 2 =¿ 91 – 0.80343 - 32
T 1 =91℃ T 2 =¿ 58.19657
T S =T 1 − BPR 1
2
T S =¿ 91 – 0.80343
2
T S =¿ 90.19657 ℃
2
Effect 1: Effect 2: Condenser:

T S =120 ℃
1
T S =90.19657 ℃
2
T S =56.40695 ℃
3
T 1 =91℃ T 2 =58.19657℃
Cp = 4.19 – 2.35 x
F: 4.19 – 2.35 (0.15) = 3.8375
L1 : 4.19 – 2.35 (0.24375) = 3.6171875
L2 : 4.19 – 2.35 (0.65) = 2.6625
T 1 =91℃ T S =90.19657 ℃
2
BPR 1=0.80343℃ T S =120℃ 1
Saturation Enthalpy @ 90.19657 ℃

90 2660.1
90.19657 2660.4136
95 2668.1
H 1=H S +1.884 ( 0.80343 )

2
H 1=2660.4136+1.884 ( 0.80343 )
H 1=2661.927262
41
Saturation Enthalpy @ 120 ℃
Vapor Liquid
H S =2706.3 1
hS =503.71
1
λ S =H S − hS
1 1 1
λ S =2706.3 −503.71
1
λ S =2202.59
1
Effect 2: T 2 =58.19657 T S =56.40695

3
BPR 2=3.78495
Saturation Enthalpy @ 56.40695 ℃

55 2600.9
56.40695 2603.34846
60 2609.6
H 2=H S + 1.884 ( 3.78495 )

3
H 2=2603.34846+1.884 ( 3.78495 )
H 2=; 2610.479306
H S @90.19657
2
90 355.90
90.19657 356.7408
95 376.92
λ S =H 2 −356.7408
2
λ S =2610.479306 −356.7408
2
λ S =2253.738506 kJ /kg
2
V 1=F − L1
V 1=4345.847584− L1
V 2=L1 − L2
Equations:
{1} F Cp ( T F −0 ) +¿ S λ S =L1 Cp ( T 1 − 0 ) +V 1 H 1
1
4345.847584(3.8375)(48) + S (2202.59) = L1 (3.617)(91) + (4345.847584 - L1 )

(2661.927262)
800505.125 – 11568330.16 = -S (2202.59) – 2332.780262 L1
-10767825.04 = -2202.59 S – 2332.780262 L1
{2} L1 Cp ( T 1 −0 ) +V 1 λ S =L2 Cp ( T 2 − 0 ) +V 2 H 2
2
L1 (3.617)(91) + (4345.847584 - L1 )(2253.738586) = L2 (2.6625)(58.19657) + (

L1 − L2 (2610.479306)
9794403 = 4535.070892 L1 - 2455.530938
L2
Since L2=1002.887904
42
Using Eq.2: 9794403 = 4535.070892 L1 - 2455.530938 (1002.887904)
L1=2702.719664
Using Eq.1: -10767825.04 = -2202.59 S – 2332.780262 (2702.719664)

S = 2026.239086
V 2=L1 − L2=2702.719664 −1002.887904

V 2=¿ 1698.262662 MT/day
V 1=4345.847584− 2702.719664
V 1=¿ 1643.12792 MT/day
V 1 + V2 1643.128+1698.26
Steam Economy = = = 1.65
S 2026.24
Solution {5}
Q = (2.66)( 109 )(4345.847584)(66) ( 241 dayhrs )( 36001 hrsec )

Q = 8830520855 KW
∆H = 2257 – 419 = 1838

C
m=
∆H
m = 4149.597 MT/day (SI)
Sucrose Balance:
0.15 HJ = (0.30)(0.80)(CJ)
0.15(4345.847584) = (0.30)(0.80)(CJ)
CJ = 2716.15474 MT/day

CJ + SI = HJ + SO
2716.15474 + 4149.597 = 4345.847584 + SO
SO = 2519.898156
Solution {6}

S L +CJ=MJ
S L – MJ = -2716.15474 {1}
Lime Balance:
-0.95 S L + 0.30 MJ = 0 {2}
MJ = 3969.76462 MT/day
S L = 1253.60988 MT/day
43
Solution {7}

RJ + L = MJ
RJ = 3969.76462 - 115
RJ = 3854.76462 MT/day
Solution {8}
Overall Material Balance: @Wr = 100

S S + Wr = B + RJ
SS – B = 3854.76462 – 100
SS – B = 3754.76462 {1}
Water Balance:
0.75 S S + Wr = 0.4 B + 0.842 RJ
0.75 SS – 0.4 B = (0.82)(3854.76462) – 100
0.75 SS – 0.4 B = 3060.906988 {2}
S S = 4454.288971 MT/day
B = 699.5243514 MT/day
44
A.3 Material Balance Computation of the Production of Activated Carbon
Solution {1}:
Solid Balance:
0.60 B = 0.85 DB
(0.60)(699.5243514) = (0.85)(DB)
DB = 493.7818951 MT/day

B = WD2 + DB
WD2 = 699.5243514 – 493.7818951
WD2 = 205.7424563 MT/day
Solution {2}:
Basis: 100 kg Feed
Carbon Balance:
( 0.75 ) ( 100 kg C) (1 mol C
12.01 kg C )
= (0.05 + 0.337) X
X = 16.13642378 kmol dry flue gas
PV = nRT
(16.13642)(1000)(8.314)(273.15)
V =
101325
V = 361.6611872 m3
nair = [ ( 0.456 ) (16.13642378 ) -

14.01 2 )] ( 79 )
( 1.5 )( 1 1
x 100
nair = 9.246425384 kmol Air
PV = nRT
(9.246425384)(1000)(8.314)(273.15)
V=
101325
V = 207.2375656 m3 air
kg
Excess Air (EA) = (207.2375656 m3) ( 1.225
m3 ) = 253.87 MT/day
Theoretical flue gas ( F G )= ( 361.661872

8.4 )=43.055 MT /day
Solid Mass Balance:
0.80 DB = 0.90 PF
(0.85)(493.7818951) = 0.90 PF
PF = 466.3495676 MT/day
45
Ash Balance:
(0.055)(100) = 0.95 R
R = 5.78947368 MT/day

F + EA + DB = WF + PF + FG + R
100 + 253.87 + 493.7818951= WF + 466.3495676 + 43.055 + 5.78947368
WF = 332.4578538 MT/day
Solution {3}:
Solid Balance:
0.90 PF = 0.78 P
(0.90)(466.3495676) = (0.78)(P)
P = 538.0956549 MT/day
Water Balance:
0.10 PF + 0.30 HP = 0.15 P
(0.10)(466.3495676) + (0.30)(HP) = (0.15)(538.0956549)
HP = 113.5979716 MT/day

PF + H P = S + P
S = 466.3495676 +113.5979716 – 538.0956549
S = 41.8518843 MT/day
Solution {4}:
Basis: 100 kg Feed
Carbon Balance:
( 0.60 ) ( 100 kg C ) ( 1 mol C
12.01 kg C )
=( 0.09+ 0.30 ) X
X = 12.80983796 kmol dry flue gas 2
PV = nRT
(12.80983796)(1000)(8.314)(273.15)
V=
101325
V = 287.1033425 m3
nair = [ ( 0.456 ) (12.80983796 ) - (514.01 )( 12 ) ](179 ) x 100
nair = 7.168154607 kmol Air
PV = nRT
46
(7.168154607 )(1000)(8.314)(273.15)
V=
101325
V = 160.6578595 m3 air
Excess Air (EA) = (160.6578595 m3) (1.225 kgm )

3 = 196.8058779 MT/day
(8.4287.1033425 )=34.17896935 MT /day

Theoretical flue gas ( F G 2 ) =
Solid Mass Balance:

0.78 P = 0.89 PF2
(0.78)(538.0956549) = 0.89 PF2
PF2 = 471.5894504 MT/day
Ash Balance:
(0.03)(100) = 0.95 R
R = 3.1579 MT/day

F3 + EA2 + P = WF2 + PF2 + FG2 + R2
100 + 196.8058779 + 538.0956549= WF2 + 471.5894504 + 34.17896935 + 3.1579
WF2 = 325.9752131 MT/day
Solution {5}:
Solid Balance:
0.89 PF2 = 0.85 PC
(0.89)(471.5894504) = 0.85 PC
PC = 493.7818951 MT/day

PF2 + WCO = PC
WCO = 493.7818951 – 471.5894504
WCO = 22.19244472 MT/day
Solution {6}:
Solid Balance:
0.91 PC = 0.98 AC
(0.85)(493.7818951) = 0.98 AC
AC = 428.2802151 MT/day

PC = AC + WD3
WD3 = 493.7818951- 428.2802151
WD3 = 65.50168 MT/day
47
A.4 Computation of the Economic Margin
BOUGHT:
Sugarcane:
( PMT
1500 4471.615272 MT
)( day )=P6707422.908
Lime Juice:
( Pkg15 )( 1000MTkg )( 115dayMT )=P 1725000

Water:
( P 30517.70
m
3 )( 1
3
1000 m ) ( 1000 kg 183.914621 MT
MT )( day )=P 3173.75331
Phosphoric Acid:
1.88 g 100 c m 3 1 m 3
( cm 3 )(1m )( 1 kg
)(1 MT
)(=
1
1000 L 1000 g 1000 kg 1.88 )
x 10− 3
120 L 113.5979716 MT
( P
L )(531.915
MT )( day )
=P 7250935.808
Seed Grain:
( Pkg55 )( 1000MTkg )( 27.64dayMT )=P 1520200

TOTAL = 6707422.908 + 1725000 + 3173.75331 + 7250935.808+1520200
= P 17206732.47
SALES
Raw Sugar:
( P 52.26 1000 kg 300 MT

kg )( MT )( day )
=P 15678000
Molasses:
( P 10331.20
MT )( 248.8002 MT
day )=P 2570404.626
Activated Carbon:
( Pkg200 )( 1000MTkg )( 428.2802151

day
MT
)=P 85656043.02
48
TOTAL: 15678000 + 2570404.626 + 85656043.02 = P 103904447.6
Economic Margin:
Total Sales −Total Bought

x 100
Total Sales
103904447.6 −17206732.47
x 100=83.44 %
103904447.6
A.5 Thermodynamic Properties
Thermodynamics properties of process materials are needed at all stages of design.

This chapter covers the estimation of physical property data.
Sucrose Water
Molecular formula C12H22O11 H2O
Molecular weight 342.3 g/mol 18.02 g/mol
Boiling point 397.76°C @ 1 atm 100°C @ 1 atm
Melting point 185-187 °C 0 °C
Critical Pressure (atm) 45.67 atm 217.7 atm
Specific gravity 1.040 1
Latent heat of vaporation 184.54 kJ/mol 40.657 kJ/mol
Latent heat of fusion 63. 65 kJ/mol 79.7 cal/g
Specific heat (Cp) 2.66 kJ/kgK 4.187 kJ/kgK
Table 27: Thermodynamics properties of syrup (sucrose and water)
Element in %
Carbon 0.12
Chromium 16.0-18.0
Manganese 1.00
Nickel 0.75
Phosphorus 0.040
Silicon 1.00
Sulfur 0.030
Table 28: Chemical properties of stainless-steel type 430
Property
Elongation, min. (%) 22
Hardness, max. (Rb) 89
Tensile Strength, min. (ksi) 65
Yield Strength, min. (ksi) 30
Table 29: Mechanical properties of stainless-steel type 430
49
Property
Coefficient of Thermal Expansion, 68- 5.7 x 10-6
212˚F, (/˚F)
Density, (lb/in3) 0.276
Electrical Resistivity, (µΩ-in) 23.6
Modulus of Elasticity, (psi) 29.0 x 106
Specific Heat, Btu/lb-˚F 0.11
Thermal Conductivity, Btu/ft-hr-˚F 13.8
Table 30: Physical properties of stainless-steel type 430
Steam in 2026. 239086 MT/day

Steam out 1698.262662 Mt/day
Enthalpy steam 259.2786259.2786 Kj/ kg
Specific volume 1.67 ml/g
Internal energy 428.49135 Kj/kg
Table 31: Thermodynamics properties of evaporator
50

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Forced Circulation Evaporator in the Sugar Industry

This equipment is designed to be used in relation with concentrating sugar juice to a

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Figure 1: Sugarcane Milled

Table 1: Drying Process Stream

A.1Process Diagram of Production of Sugar

Figure 1: Sugarcane Milled

Figure 2: Raw Sugar Production

Figure 3: Retail (Peso per Kilo)

Figure 4: Annual Total Demand in Metric Tons

Raw Sugar Refined Sugar Molasses

Figure 5: Demand Percentage Per Year

Figure 6: Process Diagram of Production of Raw Sugar

A. Mass Balance of Each Equipment

Table 1: Mass Balance of Dryer

Table 2: Mass Balance of Centrifuge

Table 3: Mass Balance of Crystallizer

Table 4: Mass Balance of Evaporator

Table 7: Mass Balance of Heater

Table 8: Mass Balance of Roller Press

Table 9: Mass Balance of Dryer 1 in Activated Carbon

Table 11: Mass Balance of Mixer

Table 12: Mass Balance of Furnace 2

Table 13: Mass Balance of Cooler

Table 15: Overall Mass Balance of the Process

Table 16: Economic Margin of Production of Raw Sugar

This type of evaporator is more expensive compared to the natural circulation

The concentration is produced through a circulation that is continuous between the

B. Main Body Design

d. Baffle spacing - Baffle spacing is the centerline-to-centerline distance between

c. Secondary separation section: for removing smaller particles of liquid by gravity

A.1 Process Stream Summary

Table 1: Drying Process Stream

Table 2: Centrifuge Process Stream

Table 3: Crystallizer Process Stream

Table 4: Evaporator Process Stream

Table 5: Heat Exchanger Process Stream

Table 6: Clarifier Process Stream

Table 7: Heater Process Stream

Table 8: Roller Miller Extractor Process Stream

Table 25: Abbreviations

A.2 Material Balance Computation of the Production of Raw Sugar

Sugar Crystal Balance: @Ds = 300 MT/day

Overall Material Balance:

Overall Material Balance: @ Ws = 646.667 MT/day

Overall Material Balance: @ M = 837.46672 MT/day

BP R1=1.78 X 1 + 6.22 X² = 1.78 (0.24375) + 6.22 (0.24375)²

∑ ∆Tavailable = T S −T 2 − ( BP R1 + BPR2 )

∑ ∆Tavailable = 120 - 56 – 4.58838

Effect 1: Effect 2: Condenser:

BPR 1=0.80343℃ T S =120℃ 1

Saturation Enthalpy @ 90.19657 ℃

H 1=H S +1.884 ( 0.80343 )

Effect 2: T 2 =58.19657 T S =56.40695

Saturation Enthalpy @ 56.40695 ℃

H 2=H S + 1.884 ( 3.78495 )

4345.847584(3.8375)(48) + S (2202.59) = L1 (3.617)(91) + (4345.847584 - L1 )

L1 (3.617)(91) + (4345.847584 - L1 )(2253.738586) = L2 (2.6625)(58.19657) + (

Using Eq.1: -10767825.04 = -2202.59 S – 2332.780262 (2702.719664)

V 2=L1 − L2=2702.719664 −1002.887904

Q = (2.66)( 109 )(4345.847584)(66) ( 241 dayhrs )( 36001 hrsec )

∆H = 2257 – 419 = 1838

Overall Material Balance: