SUGAR MILLING RESEARCH INSTITUTE

(Incorporated Association Not For Gain)

UNIVERSITY O F N A T A L
KING GEORGE V AVENUE/FRANCOIS ROAD • P.O. BOX 1525 • DURBAN • TELEPHONE 359192

1071

ESTIMATE OF MAJOR EQUIPMENT RE OUIRED TO INCREASE

THE CAPACITY OF MALELANE FACTORY TO 350 T C H :

PREPARED FOR; The Manager, T,S,B,

PREPARED BY: G,N, Allan, P. Hoareau, J-P Larnusse,

DATE • 23rd June , 1975,

INTRODUCTION.

The SMRI was requested by T„S.B, to determine the maximum capacity to

which the Malelane factory could reasonably be expanded and to advise
on modifications and additions to major equipment which would be
required to achieve this capacity

After discussions with the factory management at Malelane, it was

agreed that the maximum capacity which could be considered was that
;
wh' ch was within the possibilities of the existing boiler plant An
additional boiler and auxiliary equipment would involve a very lar^e
capital outlay and lead to major changes in other equipment to meet
the increased throughput made possible by the enlarged boiler plant

It was initially thought that the existing boilers could provide steam
for a factory and refinery of 385 tons of cane per hour- A computer
programme was prepared to study the steam load under various conditions
and varying throughputs- It revealed that at 385 T-C-H- the steam
demand would be eouivalent to 240 tons per hour, with 70S steam on cane,
Since the boilers have a maximum continuous rating of 235 tons of stear.
per hour this would have resulted in an overload of 15% which was
corsKierec to be too high . A ; 350 TCH the overload factor is only &%
1

which is acceptable

The capacity of existing plant is reviewed and recommendations fcr

expansion of each section of the factory are made in this report - In
l
t e case of sense boiling house equipment two sets of recommendations
(istixiKiuni and mini mum) are made because of uncertainty as to the volure
of massecuites to be processed-

A list of additional major equipment required is given. It must be

stressed that this list does not inlcude auxiliary equipment such as
pumps» piping, va1ves electrical transmission, staging, building
s

extensions and civil wcrk.

2/
 TECHNICAL REPORT NO. 1071 2 23rd June, 1975.

ADDITIONAL EQUIPMENT.REQUIRED.

(Bracketed numbers after each item refer to relevant paragraph

in this report).

One Road off loader and feeder table 10 m x 18 m (1-2)

One Belt conveyor to feed main cane carrier.

Length 18 m x 2134 mm width (2,1)

One New drive for shredded cane carrier. Speed 130 m/mm (2,4)

Modifications to diffusers may be necessary. This may involve

lengthening the De Smit diffuser and/or modifying the
BMA diffuser to operate with a thicker bed of cane (4)

Four DSM juice screens 1829 mm wide (6).

One Lime slaker with a capacity of 800 Kgs/hr (S)

Two Juice heaters of 232 m each (11)

3
One Press water clarifier of 245 to 350 m capacity (12)
2
One Rotary vacuum filter of 37 m (13)
Modifications to the calandria of the second effect of«the evaporator
to increase its heating surface by 600 m (14)
3
One Vacuum pan of 42,3 m for A-massecuite (15,1)
3
One Vacuum pan of 42,3 m for refinery massecuite (15,4;3)
3
One Strike receiver of 42,3 m for refinery massecuites (16,4)
One Batch centrifugal for A massecuite (17,1)

Three Continuous centrifugals for B massecuite (maximum)

alternately, One continuous centrifugal (17,2)

Three Continuous centrifugals for C massecuite (maximum)

alternately, Two continuous centrifugals (17.3.1.)
See 'also"note '17.3.2. concerning possible use of C aftercurers
for B massecuite and C massecuite forecuring.

One One batch centrifugal for refined massecuites (17.4)

2
Two Rota filters of 117 m each for refinery liquor filtration
—
(20.3)
One New condenser for refinery evaporator (21)

One Additional sugar drier of 20 tons/hr capacity (22)

3/
TECHNICAL REPORT NO. 1071. 3. 23rd June, 1975.

One Sugar conditioner of 20 tons/hour capacity (23)

One Servobalance scale with a capacity of 15 tons per hour for

refinery returns (24.3)

One Sugar silo with a storage capacity of 38 000 tons (25)

3
One Molasses storage tank with a capacity of about 2 000 m (26)
3
Two Cells of 460 m each to be added to the existing cooling
tower (28)

1. CANE UNLOADING.

1.1 Offloading time per road unit* 3,5 mins*

Time for cleaning offloading equipment* 4 mins/hour

Average weight of road unit* 20 tons

Capacity of road offloading equipment

6 0
•"• - x 20 = 320 T.C.H.
3,5

1.2 Offloading equipment for SAR railway trucks

is also available but it is improbab3e that
it will, at all times, be able to make up
the shortfall for 350 T.C.H. Moreover an
increasing proportion of the cane will be chopper
harvested and it is therefore recommended that
an additional road feed table be provided which
will handle mainly chopped cane.

A study made by Bosch and Associates shows that

the dimensions of this feeder tablje should be
10 m wide by 18 m travel.

REQUIRED: One 10 x m x 18 m feeder table with

road off loading equipment.

2. CANE CARRIERS.

2.1 An additional cane carrier will be required to

convey cane from the new feeder table to the end
of the existing cane carrier.

REQUIRED: One belt conveyed 18 x long x 2134 mm

wide with drive.

2.2 The existing main cane carrier (metal slots) is

2 438 mm wide. Its capacity is considered t6

* Data supplied by T.S.B.

A I
TECHNICAL REPORT NO. 1071. 4. 23rd June. 1975.

to be adequate for 350 TCH.

Capacity is estimated as follows:

In June, 1963 AK crushed 330 TCH at 14,1% Fibre on

a 2 100 mm carrier. Extrapolating to 2 438 mm and
15% fibre equivalent capacity would be:

330 x 2438 x 14,1 =

o c n
350
T r u
T C H
7MJ IT
2.3 Belt carrier for knifed cane. This carrier is
2134 mm wide and runs at 100 m/min. It should be
capable of handling 350 TCH.

2.4 Shredded cane carrier. Belt carrier 1 524 mm

wide and running at 100/m/min. designed for 275 TCH,
Side plates are to be fitted and this carrier will
have to be speeded to 130 m/min. to handle 350 TCH.
A new drive nut may be necessary.

REQUIRED: Speeding to 130 m/min. and possibly

new drive.

2.5 All the other carriers feeding and discharging

diffusers are considered to form part of the
equipment which they service.

3. CANE PREPARATION EQUIPMENT.

3.1 Power requirements.

Installed power:

Knives 1 788 Kw

Shredder 2 060 Kw

Total 3 848 Kw '

Power required for cane preparation is estimated at

60 Kw per ton of fibre.

Capacity of installed preparation equipment at 15%

Fibre = 3 8 4 0 x 1 Q 0 = 4 2 ? T C H

~5TT T5~

3.2 Knives:

Doubts have been expressed as to the ability of the

knives to process 350 TCH without choking. Enquiris
made at AK have revealed that similar equipment has
processed an equivalent tonnage without difficulty.

3.3 Shredder:

The 1778 x 2438 heavy duty Tongaat shredder is capable

of processing 350 TCH.
5/ •«• • •
TECHNICAL REPORT NO. 1071. 5. 23rd June, 1975.

4. DIFFUSION EQUIPMENT.

Experience of cane diffusion in South Africa is limited to one

season at AK with a diffuser operating below rated capacity.
It is therefore difficult to estimate maximum capacity of cane
diffusers and the estimate given below may have to be modified
in the light of experience at Malelane.

Fibre loading of bagasse diffusers = 0,18 tons fibre/m /nr.

Relative length of bagasse and cane diffusers * 40 = 0,76

57
Equivalent fibre loading of cane diffuser = 0,18 x 0,75 = 0,135
2
Effective screen area: BMA 252,2 m
2
De Smet 160 m

Estimated capacity of BMA diffuser = 252,2 x 0,135 = 34 tons fibre/hr

at 15% fibre on cane = 227 tons.

Estimated capacity of De Smet diffuser = 160 x 0,135 = 21,6 tons/

fibre at 15% fibre on cane - 144 tons.

The estimates of fibre loading for bagasse diffusers was obtained

with diffusers operating with a bagasse bed depth of 1,5 to 2,0 m.
The BMA diffuser at ML has' been designed to operate at a bed
depth of 1,2 to 1,5 m. This will limit its capacity unless the
diffuser is speeded up which in trun may adversely affect
extraction. This diffuser may have to be modified by lifting
the juice distributors, and roof of the diffuser by about 500 mm.

The De Smet diffuser was not designed as a cane diffuser and its
performance is uncertain. To obtain a reasonable extraction,
the diffuser will probably have to be operated at maximum bed
height and low speed. It may be safer to downrate it to 120 TCH.

Estimated total diffuser capacity = 120 '+ 227 = 347 tons.

If a small increase in capacity is required, it can be obtained

most economically by lengthening the De Smet diffuser by one
washing stage.

REQUIRED: Possible modifications to De Smet and/or BMA diffuser

to increase capacity - Extent of modifications to be
established at a later stage. For budget purposes,
R100,000 to be provided for these modifications.

5. DEWATERING MILLS.

Available: Two 2100 mm 5 roller Walkers mills operating in

parallel.

6/
TECHNICAL REPORT NO. 1071. 6. 23rd June, 1975.

Estimated capacity based on previous performance of one

mill at Malelane = 450 TCH.

6. JUICE SCREENS.

Available: 12 DSM screens 1839 mm wide.

At 220 TCH, ML had 2 screens on diffuser juice

4 " " first mill juice

6 " " press water

At 220 TCH diffuser juice was about 50% of mixed juice. With
the cane diffuser it will be equal to mixed juice at 350 TCH,,

Extrapolating, No. of diffusers required for diffuser juice at

350 TCH = 2 x 2 x 350

* 6,3 day 6

No. of diffusers required for press water = 6 x 350 = 9,6 say 10.

REQUIRED: 4 DSM screens 1829 mm wide.

7. MIXED JUICE SCALE.

Available: One Servobalans mixed juice scale with a capacity

of 450 tons juice per hour,

8. WATER METER.

Available: One flow meter on imbibition water. No water scale

is used because of evaporation from the hot diffuser
bagasse.

9. LIME SLAKING PLANT.

Available: One drum slaker with a capacity of 544 Kg/hr.

Lime required/1000 tons cane = 2,30

For 350 tons of cane/hour slaking capacity required

= 350 x 2,30 = 800 Kgs/hour.
T000
REQUIRED: One slaker with a capacity of 800 Kgs. Lime/hr.

10. LIME AND JUICE MIXING PLANT.

3
Available: Mixing tank of 15,6 m
3
Tons juice/hr = approx. 360 m
TECHNICAL REPORT No, 1071. 7. 23rd June, 1975,

Retention time - 15,6 x 60 2,6 min.

With proper mixing retention time is sufficient and an additional

mixing tank is not tequ.r^d,

11. JUIC^JHEAJJERS_.
2
The f o r owing u n H s of 232 m each are available:

Diffusers Recirculation 4

Press water 3

Mixed Juice Primary 3

Secondary 3

Spare 1

An aaditional juice heater for recirculation heating is required

to enable only V2 to be used on these units. It is suggested
that the heater be a 4 pass x 98 tubes unit and placed in series
with the two parallel/series units.

The velocity distribution in the clear juice heating is not good

and to increase the temperature of juice into the first vessel
to 117 , it is recommended that the heating be done by two series/
parallel pairs of heaters.

R^EQUIRED; One recirculation and one clear Juice heater of 232 m

each.

12. CLARIFIERS,
3
Available. One Graver clarifier 442 m
3
One Dorr clarifier 460 m
At present half of the D-^T clarifier is on mixed juice and half
on press water clarification.
3
At 220 T C H with
S a bagasse diffuser, ML had 1,97 m of clarifier
capacity/TCH. Clarifiers limited throughput during the rainy
season. With cane diffusion clarifier requirements should be
reduced out once again, because of lack of experience, it is
considered safer to have both available clarifiers on mixed juice.
3
This will be eauivalent to 902 = 2,6 m / T C H .
"33D*
Ar additional clarifier will therefore be needed for press water
clefification. Based on 70% press water on cane and one hour
retention time, it should have a capacity of:
3
350 x 0,7 = 245 m

8/..„...
TECHNICAL REPORT NO. 1071 8. 23rd June, 1975.

If clear press water is considered to be essential a longer

retention time would be required and a larger clarifier of 350
m which would give about 1J hour to 2 hours retention time is
recommended.

REQUIRED; One press water clarifier of 250 to 350 m capacity.

13. FILTERS.

Available: Two rotary vacuum filters of 3 7 2 m " each.

9

Experience acquired at AK with cane diffusers indicates that the

weight of filter cake, even during rainy months is only 2% OR
t

cane Instead of 5% in most mills.

Wt. of filter cake at 350 TCH - 350 x 2%= 7000 Kgs./hr. '
2
Assuming 60 Kgs. of cake per m of filtering area, filter area
required • 7000 * 116 m

Number of units required = 116 = 3 , 1

377?
REQU-lREel One additional filter of 37,2 m 2

14. EVAPORATORS.

Existing available heating surface and distribution is given below:

4st Effect 2nd 3rd 4th

2
2322 m 1022 745 745
1579 1022
1022
1022

5945 2044 745 745

From the steam balance the following heating surfaces will be

required at 350 TCH:

5483 2316 566 632

The only shortage appears in the second effect where some

additional 300 m of area are required. This area, „
together with a small surplus (say, an additional 300 m )
could be built intfco the existing two second stage vessels by
lengthening the existing tubes by 28%. The vessels' calandrias
would be lengthened by approximately 500 mm.

The total available heating surface per ton of cane would then
2
be = 10 079 = 28,8 m / T C H which is on the low side. However
"W*" 2
the first vessel area at 31,6 kg/m evaporation load will have
considerable reserve capacity.
 '3

TECHNICAL REPORT NO. 1071 9. 23rd June, 1975.

REQUIRED: 600 m heating area on second effect to be

obtained by lengthening calandrias.

15. VACUUM PANS.

The pan capacity will depend on the amount of massecuite per

ton of Brix in mixed juice. The Malelane ratio of massecuite
to Brix input is the highest in the industry and an appreciable
increase in capacity would be obtained if it was reduced to the
level of other mills. The vacuum pan capacities are therefore
worked out on two sets of figures:
3
(a) ML (1973) massecuite ratios (m /T.Bx in Mixed Juice)

(b) GH (1974)

(a) (b)

A-massecuite i 1,22 1,05

B-massecuite 0,46 0,34

C-massecuite 0,32 0,30

15.1 A-MASSECUITE PANS.

(a) at 1,22 m /T. Bx in M . J . . \ volume of massecuite

per 24 hours at 350 TCH = (350 x 1,09 x 0,14) x 24 x 1,22
3
= 1563 m
3 3
(b) at 1,05 m /T.Bx in M . J . vol. = 1345 m
3
Available pans: 5 units of 42,3 m each.
At 220 TCH pan cycle on A-massecuite was:

1563 x 220 x 1 = 5,8, per day

1 5 U 42,3 x 4

Assuming 6 strikes per pan per 24 hours, 5 pans of

42,3 m3 can do : 6 x 5 x 42,3 = 1269 m3

Additional pan capacity required:

3
(a) 1563 - 1269 = 294 m
3
(b) 1345 - 1269 = 76 m
3
REQUIRED: One pan of 42,3 m

15.2 B-MASSECUITE PANS.

3
(a) at 0,46 m / T . Bx in M . J . , vol. of massecuite
J
per 24 hours at 350 TCH = 590 m

10/
TECHNICAL REPORT NO, 1071. 10, 23rd June, 1975.

3 3
(b) at 0,34 m / T , Bx in M . J . , vol. = 436 m
3

Available pans: One of 42,3 m

3
One of 85 m

At 220 TCH,pan cycle on B-massecuite was:

590 x 220 x 1 = 4 , 4 per day

Assuming 4 strikes per pan per 24 hours>
o ,
one 42,3 m ^ pan can do 1 x 4 x 42,3 = 169 m

one 85 m 3
" " 1 x 4 x 85 - 340 m 3

3
Total 509 m

Pan capacity is sufficient to cover massecuite 3

production under conditions (b) but short by 81 m

for conditions under (a). At 4,4 strikes per day
however total pan capacity would be 560 m per day,
only 30 m short for (a)

No additional pan required.

15.3 C ^ASSECjnT E_PANS.

(a) at 0,32 nT/T. Bx in M . J . , Vol of-massecuite

J
per 24 hours at 350 TCH = 410 m
3 3
(b) at 0,30 m /T.Bx n M . J . , vol. = 384 m
3
Available pans: One of 42,3 m
3
One of 85 m

At 220 TCH pan cycle on C-massecuite was:

410 x 220 x 1 =3

Assuming 3 strikes per pan per 24 hours:

UIIC
AD
t i
O
j j
m 3 ,f « ' .„- l l „„„
III
,|„
I d 11 U U
T
I
„A oO ^A AO O
t t j J
_
-
1 0 7
ICI

3
One 85 m " " 1 x 3 x 85 = 255
3
382 m

Pan capacity is suffiicent under conditions (b)

but short by 28 m for conditions (a)

No additional pan required,

15.4 REFINER Y_P ANS.

Volume of refined massecuite assumed to be:

11/ o « • • e •
TECHNICAL REPORT NO. 1071. 11. 23rd June, 1975.

3 3
m /Ton Sx in M.J. m per_ 24 hours

1st Massecuite 0,88 1128

2nd, 3rd, 4th

Massecuite 0,72 923

Total 1,60 ,(51

15.4.1. 1st Refi ned_Mas_secui te

3
Avallable. 3 pans of 42,3 m
n i. i o n T f i i _.. _ . , 1 v i Hirpwniin ,..-.r>
tti. CC\J lL>n, [JCiii ic vji! I O Un o o b e t . u 1 W C 3

1128 x 220 x 1 = 8,4

•35TJ 4'2TJT2
Assuming 8 5 strikes per 24 hours the available pans
4

can bei1
3
3 x 8,5 x 42,3 = 1079 m
3
Total volume to be boiled --- 1128 m
3
,\ Pan capacity is short by 49 m

15.4.2,, 2nd,_ 3rd, 4th Refined J^ass^cuites. L

3
Available 2 pans of 42,3 m

At 220 TCH, pan cycle >„n other refinery massecuites was;

923 x 220 x 1 = 6,9
350* 42,3 x 2
Assuming 7 strikes per 24 hours ^he available pans
w
can boil: 2 x 7 x 42,3 = 592 m ,
3
Total volume to be boiled = 923 m
3
Additional pan capacity required = 923-592 = 331 m"

15.4.3, Total additional nan capacity required for all refinery

massequires - 231 + 49 = 380 m

One additional 42,3 nan at an average of 8 strikes per

day would boil 338 m . Additional marginal capacity
could be obtained by boiling more stirkes per day. Nine
strikes per pan for 1st massecuite and 8 for other
massecuites should be achievable.
3
REQUIRED: One 42,3 m pan for refined massecuites.
6
15°4.4. NOTE; An additional two 42,3 m pans will have to be
installed on the pan floor, Because of the cost
involved in building extensions to house these pans

12/.
TECHNICAL REPORT N 0 o 1071. 12. 23rd June, 1975.

consideration should be given to obtaining increased

pan capacity by replacing existing 42,3 m pans by
85 m units.

One 85 m pan on A and one on first refined massecuite

would provide all the additional capacity required
and the two 42,3 m pans which they replace could be
sold.

16, CRYSTALLIZERS.

16,1 A-Massecuite crystaHilars,

Available; 8 crystallizers of 42,3 m"" arranged for

series flow.

Based on 6 hours retention time in crystallizers, the

capacity of air-cooled series flow crystal 1izers required;
3
(a) 1563 x 6 = 390 m
IT
3
(b) 1345 x 6 = 336 m
TT
3
Available: 340 m

No additional equipment required.

16,2 B-Massecuite crystallizers.

3
Available : 1 strike receiver 85 m
3 3
4 crystallizers of 45 m each= J_70 m
J
Total 255 m

Retention time in crystallizers:

<») 255^1 = ,0,4 hours

0) 155^24 . 1 4 h o u r s

10 hours retention is considered sufficient and no

additional equipment is required.

16.3 C-Massecuite crystallizers.

3
Available^ One strike receiver 85 m"
12 water cooled crystallizers ,
3
of 42,5 m = 510 nT

Retention time in crystallizers:

13/.
TECHNICAL REPORT NO, 1071, 13 23rd June, 1975

(a) Air cooled (strike receiver) - 85 x 24 5 hours

Water cooled 510 x 24 - 30 hours

Total 35 hours

(b) Air cooled 85 x 24 5 hours

Water cooled 510 x 24 32 hours

Total 37 hours

No additional equipment required,

15,4 Refined Massecuite strike Receivers.

Available 5 crystallizers

Required; One per pan = 6

REQUIRED; One additional strike receiver,

17, CENTRIFUGALS,

17,1 A-Massecui te _Centri fugcUs.

Available 5 Western States 1372 x 1016 x 1500 RPM

2 BMA 1340 x 1000 x 1500 RPM

3
Capacity of one W..S. Machine (19 cycle/hr) - 12,600 m /hr,
3
" BMA " (20 cycles/hr)-- 17,000 m / h r .

Total ,>ail able capacity = 5 x 12,600 + 2 x 17,000

3
= 97 m / h r .
3
Assuming 22 hours operation, capacity/day 2134 m
3
Required capacity/day a) 1563 m
J
b) 1345 m

Existing equipment is sufficient but exper U M ' X L C+ Mi-

has shown that very often a machine has to be removed
, m service for repairs. It is therefore recommended
to have a spare i e-r-'irifugal,

REQUIRED; One batch centrifugal for A - M a s s e c i t r e

17,2 B-Massecuite Centrifugals.

Avaiiable: 4 Western States 34" continuous

2 BMA K850 Continuous
14/.
TECHNICAL REPORT NO. 1071, 14, 23rd June. 1975.

Capacity of both types of machine taken to be 2,83 m /hr

per unit.

Total available capacity assuming 22 hours operation per

3
day - 6 x 2832 x 22 = 37 m
3
Volume of massecuite to be processed a) b90 m
3
b) 436 m
3
Capacity shortage. a) 216 m
3
b) 62 m

REQUIRED 3 continuous centrifugals (type WS 34

or BMA K850) for condition (a) or one
centrifugal for condition (b)

17,3 C^Massecuite centrifugals,.

:: 1
\ ..., F'orecun ng.

Aval lab It; 8 Western states 34" continuous

4 BMA K850 continuous

Assuming 22 hours operation pen day;

3
Capacity of W-,Sc Machines ••• S x 1 ,133 x .2 = 199 m day
3
Capacity of BMA " = * x 1,41b x 22 * ]25 m day
J
Total 324 m /day
3
Volume of massecuite to be processed a) 410 m
3
b) 384 m
J
Capacity shortage; a) 410-324 = 86 m
3
b) 384-324 = 60 m
REQUIRED; 3 continuous centrifugals for condition (a)
and 2 for condition (b)
17,3,2,, A. tercuring

Assuming an aftercurer to forecurer ratio of 1 to 3

Number of aftercurers needed - 15 5
3
Available; 5 BMA K850 centrifugals

No additional equipment required,

NOTE, The use of aftercurers may not be necessary if
sufficient forecurers are available and steps

15/.
TECHNICAL REPORT NO. 1071. 15. 23rd June, 1975.

are taken to ensure that a magma purity of 85

is obtained at all times. Several mills operate
successfully without aftercurers.

The 5 aftercurer centrifugals could then be used

for B and C massecuite and no additional continuous
centrifugals would be required.

17.4. Refinery Centrifugals.

Available: 4 Western States 1312 x 1016 x 1500 RPM

Assuming 22 hours operation and 20 eye. ; per hour.

Capacity of the 4 W.S. machines = 13,200 x 4 x 22

3
= 1160 m

Capacity of the 2 BMA machines - 17,500 x 2 x 22

3
• 770 m

Total capacity = 1930 m *

Total massecuite to be processed _• o2051 —3

ne i m

3
Capacity shortage = 2051-1930 « 121 m

REQUIRED: One additional centrifugal.

18. REFINERY SATURATION TANKS.

At 350 TCH and a 9,0 cane to sugar ratio, w t . of raw sugar

produced = 38,9 tons/hr + 4 tons of 4th sugar. Wt. of melt
at 62 Brix = 42,9 x 100 = 69,2 tons/hr. -

3
Volume of melt at 62 Bx «= 69,2 = 53,3 m /hr.

Volume of melt and 4th. sugar remelt at 80°C = 53^3 = 54,8 m /hr
972
3
Available; A saturation tank 71 m

B saturation tank 41,2 m 3

Retention time assuming tanks 70% full

A saturator 56 minutes

B saturator 32 minutes

16/
TECHNICAL REPORT NO. 1071. 16. 23rd June, 1975.

No additional equipment required,

19. C 0 GAS PRODUCTION.

2

19.1 Scrubber.
3
Capacity required - 3,5 nT/sec.
3
Available 3,8 m /sec,

No additional equipment required,

19.2 CO^ Compressors,

Capacity of pumps which were sufficient at 220 TCH has been
doubled. No additional equipment required for 350 TCH.

20. REFINERY^ FJ.ITERS.

20.1 .• • jcnatation fi Iters.

2
Available: / rota filters of 117 m each.

At 220 TCH, ML used 5 rota filters.

Number of filters needed at 350 TCH - 350 x 5 = 8

Additional filters required - 8 - 7 = 1

20.2 SuljJhitation filters.

2
Available; 3 rota filters of 117 m each

Number of filters at 220 TCH - 2

At 350 TCH number of filers needed = 350 x 2 = 3

7213"
Additional filters required = 1
2
20.3 REQUIRED; 2 additional Rota filters of 117 m each
for liquor filtration.
2 0 a t e e
^ ^ £l lg„^lJJ,..flj E _fjJi I^°
Available: 3

At 220 TCH 2 filters were sufficient to handle refinery

sludge. Scaling up to 350 TCH, number of filters
required = 3

No additional equipment required,

2 1
• REFINERY EVAPORATOR.

In order to cope with an expected increase in evaporation capacity

and simultaneously maintain good steam economy, the triple effect

1 7 / c o o o o o o o o o
TECHNICAL REPORT NO. 1071. 17. 23rd June, 1975.

evaporator could be rearranged to run with calandrias on V2 and

all body spaces connected to a new enlarged condenser. This
1
rearrangement would increase the temperature differentia in all
three vessels to(101~56) 45 C and thereby more than double its
existing capacity. Steam piping would have to be modified.

REQUIRED: One new conuenser for refinery evaporator.

2 2
• SUGAR DRIER.

Available One rotary drier with a capacity of 23 tons sugar

per hour.

Weight of refined sugar to bt p o u t e d at 350 TCH

REQUIRED;: One additional drier of about 20 tons/hr capacity,

23. SUGAR CONDITIONER.

Available. One f l u i d u e d bed cooler, capacity = 23 tons/hr.

REQUIRED One additional cooler of about 20 tons/hr cepacity.

24, SCALES.

24.1 Sugar Scale.

Available; One Servobalans with a capacity of over 40 tons

of sugar/hr,

24.2 Contaminated SugarSeale.

Existing scale sufficient to handle increased capacity.

This scale has been transferred to weighing of molasses.

REQUIRED; One Servobalans scale with a capacity of 15

tons per hour.
25
• SUGAR STORAGE.

Storage must be provided for the off-season and in addition ML

is required by the S.A, Sugar Association to carry a buffer stock
equivalent to one month's sales.

At 350 TCH and 9 tons of cane per ton of sugar, production during
the 40 weeks season

= 350 x 40 x 168 x 0,75 x 1 = 196,000 tons

+ Initial stock equivalent to one month's sale

196,000 x 4 = 15,000 tons

211,000 tons
TECHNICAL REPORT NO. 1071. 18. 23rd June, 1975.

c/fwd 211,000 tons

Less sales during season = 40 x 196,000 = 150,800 tons

Storage capacity required = 60,200 tons

Available: Silo 15,000 tons

Store

(palletised)7,000 "

Total available 22,000 tons

REQUIRED: An additional silo with a storage capacity of 38 000 tons, 9

26. MOLASSES STORAGE.

3
Available: One tank of 3410 m
Scaling up for 350 TCH molasses storage capacity required =
3

3410 x 350 = 5 500 m

3
REQUIRED: One molasses tank of about 2 000 m

27. ELECTRICITY GENERATION.

Available generating capacity 19,2 Mw

Electrical load for: Irrigation 7,2 Mw

Refi nery 1,0 Mw

Cane 1,0 Mw
diffusion 9,2 Mv

Available for raw sugar factory 10,0 Mw

At 350 TCH raw sugar factory load is equivalent to 28,6 Kw/TCH.

This compares favourably with the electrical load of several mills
in the industry (e.g. UK: 19,5, SZ: 27,7, AK: 26,1. EM: 23,4,
UF: 25,9, PG: 28,3)

No additional equipment required.

28. WATER COOLING TOWER.

Additional cooling water will be required for the condensers of

two pans (one A pan and one refinery pan) and for the condensers
of two additional single effect refinery evaporators.

Water requirement of pans calculated on basis of 40 Kgs. water per

Kg evaporation.
2
Evaporation rate per m heating surface: Refinery pan 50
A massecuite
pan 40

19/
TECHNICAL REPORT NO. 1071. 19. 23rd June s 1975.

2
Both pans have 237 m heating surface.
J
One refinery pan will require : 237 x 50 x 40 = 474 m
3
One A massecuite pan will require 237 x 40 x 40 - 379 m

3
Total 853 m

Existing c c o h n g tower has three cells with a capacity of

-360 m-V hr. each,
2
REQUIRED; Two additional cells of 460 m each to be added
if*. G v i c t i iiri rnislinn fnuiovc f n /~nr\l iA/a + ctv f vAm
WW w r\ i -j w i i i v j v w w i i 1 1 3 b W f l W I J ww w w w i n v . 1 • • win

additional pans and refinery evaporator,

ACKNOWLEDGEMENTS;

The assistance received from Messrs Laaper and Tijl of T.S.B. and
Mr, Boustread of Bosch and Associates in the preparation of this
report is gratefully acknowledged.

SMRI
JPL/WH,