Scribd Logo
Upload

Welcome to Scribd!

  • Handbook of Sugar Refining Chung Chi Chou 1

    Uploaded by

    Roberto Rasgado Marroquin
    290 views744 pages

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    Report this Document

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    290 views744 pages

    Handbook of Sugar Refining Chung Chi Chou 1

    Uploaded by

    Roberto Rasgado Marroquin

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 744
    Handbook of Sugar Refining A Manual for the Design and Operation of Sugar Refining Facilities sited by Chung Chi Chou Sugar Processing Reseorc Insitut, Ine New Orleans, Louisiana ®) JOHN WILEY & SONS, INC. New York Chichester + Weinheim + Bnebane + Singazore + Toronto Tis book sprinted on aid ee paper. © Copyright © 2000 by John Wiley & Sons; ne. A igh resrved. Published sinltneouty in Canada No pact ofthis publenion may be reproduce, sored ina rel stem ot transmitted in any form o by aay mean, eletone mechanical Photocopying reording, sanning or aerse exept as permed unde Section 107 o 108 of the 1976 United Sates Copyeght Act witht ether the Prior writen permialon ofthe Publaber, or autorztion through payent of the appropriate pe-copy fe to the Copyright Clearance Cente, 222 Rovewood Drive, Davers, MA 01923, (973) 750-800, fax (978) 750-4744, Requests othe Puller for permision should be aesed to the Pemisions Depart, Taha Wiley & Sons nc, 608 This! Avenue New York NY 10158-0012, 212) 350-6011, x (22) 850-005, E-Mail PERMREQ@WILEY.COM. “This publiation ie designe to provide asurte and authoritative information in eg tothe subject mater covered It i od with the understanding hat the publisher snot engaged in rendering profesional serves. profeooal vice or eer expen astance i eguled the series af competent profesional perton should be sought Library of Cones Cataloging-in-Publiaton Date: ‘Chung, Chi Chow Handbcok of supa reining: a mane or dasign and operation of sat ‘efining facies / ote by Chang Chi Chou Inclades index |SBN 0-171-18357-1 (alle paper) 5 5 Contents Foreword vil Preface ix Acknowledgments x Contrisutors xi Part It Intraduetion to Sugae Refining 1 1 Glossary of Terms and Definitions, Chung Chi Chow 3 2 Sugar Refining Procescs and Equipment, Chung Chi Chow u 3 Automation in a Raw Cane Sugar Factory, Robert J Kwok and Eady H, Lame 1" 4 Raw Sugar Storage and Handling, Hsin Sui Chang and (Chung Chi Chow 8 Part li: Refining Process and Operations « 5 Afinaion, Thomas N, Pearson eo {6 Phosphataion for Turbidity and Color Removal, Richard Rifer 35 7 Carbonation for Tubilty and Color Removal, Petr Rein ” 8 Granular Carbon Decoloization System, Per J eld and HL Paul Benecke on 9. Pulsed-Bed Moving-Granular Activated Carbon Sytem, Juv Liang nt 10 Ton-Exchange Resin Proces for Color and Ash Removal, Denis Bowes and Franpie Rosset bs LL Biltation Processes, Chung Chi Chow 12. Evaporation Theory and Practices, Wiles H. Kampen 169 13. White Sugar Boling and Crystallization, Chung Chi Chow 189 14 Centiugation Operation, @. Clive Grimwood 20s 15. Refined Sugar Drying, Conditioning, and Storage, Dove Meadows 16 Pacakaging, Warehousing, and Shipping of Refined Product, Jean-Paul Mere 293 Pct Part Patt vs contents, 17 Remit and Recovery House Operations, Chung Chi Chow 18 Application of Membrane Technology ip Suger Manufacturing, Michael Sasta Refinery Design and Process Contol 19 Refining Design Criteria, Chung Chi Chow 20. Process Selection, Richard Rifer 21 Instoumentation for Process Control, Walter Simoneau, St 22. Operational Computers, Ray Burke 25 Automation of «Sugar Refinery, Naotugu Mera 24 Invgraton of Raw and Refined Sugar Operstions, Stephon J. Clarke 25 Of-Crop Sugar Refining for a Back-End Refinery, Raoul GRE Lonner 26 Energy Conservation for Sugar Refining, Joseph C. Tillman, J 27 Technical Control of Sucrose Los, fsephF. Dowling 28 Microbilogica Control in Sugar Manufacturing and Refining, Donal . Day 29. Refinery Maintenance Program, G, Faweet, updated by Chung Chi Chow 30 Eavizonmental Quality Assurance, Chung Chi Chow Specialty Sugar Products SI Brown oF Soft Sugar, John C. Thompson 32 Areado Soft Sugar Process, Las Sam Miguel Bento and Francisco Caras Bartolo 38 Liguid Sugar Production, Leon Anhaisr 34 Microcrstaline Sugar, Chung Chi Chou Chemisty af Sugar Refining 35. Refining Quality of Raw Sugar, Stephon J. Clarke 36 Nonsugars and Sugar Refining, Richard Rifer 57 Anayss of Sugar and Molasses, Wolter Altenburg Appendix: Reference Tables About the Editor! Author Index 358 355 363 39 5 a as “37 “sr 1 505, eed sa 65 67 379 37 397 60s or 61 637 va m3 Foreword Unt now the cane sugar industry has not had s handbook devoted ently tothe subject. of refining. More often than not, the technology of refining is included ina few chapters in handbooks on more general subjects. The Handbook of Sugar Refining isthe fst publi- cation dedicated 10 cane sugar refining. The detail and breadth of coverage required on this subject is possible only in a handbook suchas ths. ‘Cane sugar refining has undergone many changes inthis century, with changes acc crating in the last two decades. By 1930, bone char was the “standard” decoloizer in all large refineries, even though its mode of action vas not understood, Large quantities of char were used requiring lage ute of energy. The Bone Char Research Projet (1939) was the industry’s first cooperative reseatch effort, which succesfully defined what bone char id and how it did it. This resulted in satisfactory declornation win the use of less char land opened the way for other technologies, such at ion exchange resins, functionalized franular activated carbons, and new clarification procedures, Even these technologies bave been proven to be energy intensive, and with the competitive pressures ofthe later half of| the twentieth century ever more innovative processes, such as membrane technologies, waste, tueatment and reyeing, and higher quality rawsugar, have allowed ene portion ofthe traditional refning process to be eliminated, Today, the eefining industry isin a very early stage of reinventing ite procestes, and timing for & handbook on sugar refining covld not be beter. 'A wide range of experts in vious fields of sugar refining have contributed to this handbook under the sbe editorship of Dr. Chung Ch Chou. It is hoped tht this handbook will ind wide use throughout the world, and follow in the footsteps of the Cane Sugar Handbook to become the Sug Bile I Frank Carpenter Formerly Director Cane Sugae Refining Research Projects ‘New Orleans, Lousiana ‘August 1599 Preface [As we enter the twenty-ftst century, the demand for high-quality white sugar around the ‘world has continued to increase. Consumers demand a high-quality product every bit as ‘uch as does the industrial user, for beverage, bakery, confectionery, and other applications. ‘At the same time, the competitive pressures on the sugar industry have also increase, leading the industry to sed innovative ways to produce refined sugar. With all of these changes ongoing, it was felt thar a handbook devoted entirely to the subject of sugar refining ‘vas needed In this first handbook of suger refining, Ihave attempted to give both a general over view ofthe many aspects involved in refining, s well a ogo into great detail inthe critical, areas. With the help of my very able co-authors, experts in many areas, [belive that we have come close to achieving our objective, which i to provide, in a single book, the most comprehensive teatment to dete on the refining of cane sugae, Since the refining of cane sugar begins with raw sugar, there are chapters devoted to rave sugat storage and handling, atomation in a rave sugat factory, and integration of raw and refined sugar operations. The traditional unit process in a vefinry are covered in ‘detailed chapters in Part Il. In this section are abo included some ofthe newer proceses ‘being introduced to refining, such as membrane technology. Refinery design ie very impor tant to achieve efficiencies, and an entre chapter is devoted to this subject. In Part Il we ‘cover subjects dealing with instrumentation and control, computer, automation, and the alvays dificult subject of loss control Thelieve that value-added products in the frm of specialy sugar products provide an cexcllent avenue for increasing profi margins and utilizing a refinety’s capacities 10 its ‘maximum. Thus, Part TV is devoted to that topic, with four chapers detailing various types of specialty products Tes hoped that this book will be useful to sugar technologists around the word (Chung Chi Chow, Ph.D. ‘Managing Director ‘Sugar Processing Reseach institute, Ine ‘New Orleans, Louisiana July 2000 Acknowledgments vany people to make possible a book of this magnitude. As editor, 1 wish to express re appreciation and thanks t9 the 29 contributors who, by giving freely oftheir hhave made this book possible, The collaboration was truly international, with ‘om many countries contributing, T would also like to thank my editor as wel as shers for seeing the need for such « handbook and agreeing to publish it, and for ence and forbearance with ws as we finalized the book. vald ike especially to thank Dr. James C. P. Chen, my co-author and chief editor "th edition of the Cane Sugar Handbook, the Sugar Bible I, for it support and erent during my long association with the word sugar industy ‘Chung Chi Chow Contributors Walter Altenburg New York Sugar Trade Laboratory 300 Teeminal avenue W" (Gack, 8] 07066 Leon Anbaiser (CR Sugse Company P.O, Box 308| ‘ies, HI 96701 Francisco Carle Bstolo Refinaias de Agicar Reunides, SA RUA Manuel Pinto De Azevedo 272/4100 Porte Portugal Paul Benecke (CSR Refined Sugars Group Level 5, 11 Help Steet Chatwood NSW 2067 Austria Lois San Migue! Bento Refinaras de Agicar Reus, SA RUA Manuel Pinto De Azevedo 272/4100 Porto Portugal Denis Bource Marelles Refinery 336 Rue de Lyon. 13348 Marseille Cedex 15 France Ray T Burke ‘Savannah Sugae Refinery PO. Box 710, Savannah, GA 31402 Hsin Sui Chang 7417 N, Peters St. Arabi, LA 70032 (Chung Chi Chow Sugar Processing Research Institut, Ine 1100 Robert E. Lee Boulevard New Orleans, LA 70124 Stephen J. Catke Flo-Sun Sugar Co. ‘Okeelanta Corporation PO. Box 86 Himion, OH 45102 Donal F. Day ‘Audubon Sugar Insite Louisiana State University ‘Sugar Station Building Baton Rouge, LA 70803 Joseph F. Dowling Refined Sugars, Inc (One Federal Street, Yonkers, NY 10702 G. Fawcett 487 Beauliew Ave Route 3 Savannab, GA 31406 Pater J. Field Feld Technology Consulting ‘Westeigh NSW 2120 Australia G. Clive Grimwood Broadbent Thomas & Sons Ld (Queens Steet South Huddersfield, Yorkshire England HDL 3EA Willem H. Kampen ‘Audubon Sugar Institute Louisiana State University Sugar Station Building Baton Rouge, LA 70803 xi CONTRIBUTORS: Robert I. Kwok Hawaiian Commercial & Sugar Company 1 Hanson Road Puunene, HI 9678 Eddy H. Lam Process Contol Engineer formenly of Hawaiian Commercial & Sugar Company Puunene, HI 96784 Ju-Hva Liang Taiwan Sugar Corporation No. 266 Chien-Kuo S, Rd: See 1 Taipe 106 Taiwan Republic of China G.R. . (Raoul) Lionnet University of Natal Private Bag X10 4014 Dalbridge Dave Meadows “Tongaat-Holett Sugar Led. Private Bag 3| Glenashley 4022 Kwa Zulu Netat South Africa ‘Naotsugu Mera 1-81-1106 Fotamata Ichikawa City Chiba Prefectore Japan 272-001 Jean-Paul Merle (Ca Sugar Company 830 Loring Avenue rocket, CA 94525 ‘Thomas N. Pearson 14 Epping Forest Way Sugat Land, TX 77479 Peter Rein ‘Audubon Sugar Institute Louisiana State University South Stadium Road Baton Rouge, LA 70803, Richard Rifer 1401 Walnut St, #18 Berkeley, CA 94702-1402 Michael Sasa Audubon Sugar Insitute Lousiana State University Sugar Station Building Baton Roage, LA 70803-7305 Walter Simoneaus, Sr Glenwood Cooperative, Ine 5069 Highway 1006 Napoleonvlle, LA 70372 John C. Thompsoa United States Sugar Corporation 11 Ponce de Leon Avenue Clewiston, FL 33440, Joseph C. Tillman, J Savannah Sugar Refinery PO. Box 710) Suvannah, GA 31498-4710 PART I Introduction to Sugar Refining CHAPTER 2 Glossary of Terms and Definitions* Affination Treatment of raw sugar crystals with 2 concentrated syrup to remove the fln fof adhering molasses. Tis is achieved by mixing sugar with syrup and then centrifuging the magm with or without water washing. Atfined sugar Sogar purited by affistion Agglomeration Sticking together of wo or more crystals daring the purging and drying ‘operations, Its usualy @ minor problem ‘Ash content Solid residue determines gravimetrically ater incineration in the presence of ‘oxygen. In analysis of sugar products, sulfur acid is added tothe sample, and this residue as sured ash heated 19 S00°C is taken to be a measure of the inorganic constituent Sometimes determined indiectly by messurement of electrical conductivity of the proguct in solution, Bagaclllo Fine fraction of bagase obtained by sieving Bagasse Cane fiber leaving extraction apparatus after exttaction of juce (eg tt mill Dagase). Batch From opening of the feed valve to discharge of the masiecite Blowup Holding tank or tank where darifcation is taking place Bolling point of sugar solution The boiling temperature of «sugar solution depends on (2) vacuum and (2) sugar concentration [ether % RDS (eefactometrc dry substance) or supersaturation]. Since the purpose of the pan operation isto grow suger erstal, we are ‘more interested in supersaturation than % RDS. Als, all sugar boiling is done under a ‘vacuum so that the operating temperatures are kept as low as possible Bolling polnt of water The boiling temperature of any pute gud, suchas water, depends fon the pressure at which itis boiled. If the pressure is greater than normal atmosphere pressure its Bolling temperature will be raised, Ifthe pressure is less than atmospheric (a "By Chang Chi Chou, 4 GLOSSARY OF TERMS AND DEFINITIONS. ‘acuum), its boiling temperature will be lowered, All sugar boing is done wnder reduced pressure Boling point rse (BPR) Difference between the boiling temperature of a sugar solution and the boiling temperature of pure wate, both measured at the same presure. The BPR ‘an be used to measure the supersturaton ofthe sugar solution and isthe bass for some pan supersaturation instruments. [Brix Measurement of total solids in ¢ sugae liquor or syrup using a Brix hydromete. For soletions containing only sugar and water, Brix = 4 sugar ‘Bulk density (volume welght) Weight of a specific volume of a solid. The volume is usually 1 cubic foot (a container | foot long, 1 foot wide, and 1 foot high). Granulated sugar weighs 50 to 52 Ib, Coarse sugars weigh 48 to $0 lb f Because the smal crystals pack very closely. Calandra Tubular heating clement situated in and constituting most of the bottom third ‘of ¢ vacoum ceystalizer known a5 calandvia pas {Candy crystal Large sugar crystals produced by «special crystallization process CCarbonation Introduction of carbon dioxide gas into limed juice oF syrup (eg. fist and second carbonstions) to emove nonsugar sold. The alternative term carbonatation is some times ured, Carbonation gas Gas vch in carbon dioxide for use in carbonation. Carbonation sludge Carbonation slurry afer concentration with vacuum fiers to 4540 5086 dry solids Carbonation slurry Tusbid liquid consisting of juice and carbonation precipitate (eg. frst carbonation srry, second carbonation slurry) ‘carbonation slurry concentrate Carbonstion sluery afer concentration with thickening Sikers or decanters. Clanitier Apparatus for the elimination by sedimentation or Hotation of suspended solids from 2 tue Liquid olor Attenuation index, determined under defined conditions Color type Rest of the visual assessment of white sugar agnnst standards, Condenser water Mixture of condensate and cooling water produced by a diectcontact condenser Conglomerate Two or more crystals grown together duting pan boiling. Conglomerates are undesirable because they ae dificult to wash inthe centrifugal and difiult to dry in the granulators. Conglomerstion i 2 major problem in sugar boing. Conglomeration Intergrowth caster of several crystal Cooling crystallization Crystalizaton by cooling ofthe magna. Cooling erystallzation effect Dilltence inthe purity ofthe mother liquor ofthe magms at the beginning and end of the crystallization by cling Glossary of Terms and Definitions Cooling erystalizer Vessel fr crystallization by seeding Cossette fines Porton of cosstes less than 1 cm Jong Crystal content Proportion by weight of crystals in magma (Crystal growth rate Crystal weight produced per time and sueace unit or cyst length per unit time. CCrystalzate Crystal fraction obtained by crystalzation. Crystallization Nucleation and growth of crystal. Ccrystalzation scheme Defines the numberof crystallization sags invelved in producing supa. CCrystalizer Cylindrical vessel equipped with cooling and agitating elements used for com: pleting the crystallization of a massecuite discharged from 1 paa, Curing Crystallization process that takes place in a erytlizr. (Cut @ pan Discharge 2 portion of the masscuite from 3 pan, retaining 3 footing upon which to feed more syrup for eryalization. Cycle time (2) In batch exaporatng crstalzaion time from start of drawing in 2 charge to the beginning of the next (b) ir centrifuging: time from start of loading th centrifuga to the beginning of the next charge. Deterlorated cane Cane of reduced suitability for prosesing due to external causes (eg. feos). Drop a pan Discharge all ofthe massecuite fom 2 pan Dropping. See Drop 2 pan Entrainment separator Apparatus for removing syrup oF magma from vapor. Evaporating crystallization Crysaliation by evaporation ofthe solvent (eg. wae. Evaporating erystalization effect Difference between the purty of the magma fillss and the purity of the mother liquor of the magma on discharge. Evaporating crystallization process Process of evaporating crystallization Evaporating erystallier Apparatus for crystallisation by evaporation. See aso Vacuum pan ‘vapor. Evaporator effect Evaporators operating in sves at 2 given steam pressre (eg fist effet, second effect), Condensates and vapors ae labeled corespondingly(e,fst con Senste or vapor: condensste of vapor from the Sst effect) False gran Undesirable smal crystal, formed when the concentation in the pan scared too high, Feed syrup Supply syrup for eryalzation Fulmass See Massecsite Filter cake Merial retained on the screens or cloth ofthe filters ‘trate Liquid pased through the screens or cloths of the fiers. Final oF final pan Last remeltsske boiled, which is dropped to « crystallize and then -fractofursnoide ‘Sugar Term for the disaccharide sucrose and products of the sugar industry, essentially composed of sucrore. ‘Sugar content (2) Sucrose content: a8 this tem is generally used, it refers to the fact that in adaltion to sucrose, other sugars are present (usualy determined by polaimety) (b) total sugar content: for technical products witha substantial amount of other sugars (e, liguid sugars, the term total sugar content should be used (c) recoverable sugar content: art ofthe sugar in cane, which can be obtained as white sugar ‘Suifitation Intzoduction of sulfur dioxide to juice or liquor ‘Supersaturated Sugar solution containing more sugar than its natural solubility Himit (Ley contains more sugar than would be expected}. Superaturation is defined as the ratio ofthe sugar concentration ofthe liquor to that of saturated liquor atthe same temperature, All pan operations, from Seeding to dropping, must be performed to maintain a supersaturated Tiquor so that crystal wl always continue to grow. However, the ratio must not be allowed to get t00 high since this would force new crystals to form (ie, false or smear grain), ‘Supersaturation coefficient Quotient formed by dividing the sugar] water ratio of a su persaturated solution by the sugar/water ratio ofa saturated solution under the same con- ditions (temperature and purity or nonsugar/ water ratio). Supersaturation, ertieal Supersaturation at which nucleation begins spontaneously ‘Sweetwater Wash water of wat containing sufficient sugar to warrant recovery Syrup Mother iquor obtained ftom 2 crystallization proces. Syrup is removed from the crystals in the centrifuga Glossary of Terms and Definitions = Target purty Reference purity offinl molasses, taking into account the eet of nonsuc rose on its exhaustion. Tighten the pan ‘The final step in boling a srike, wherein sup fed to the pan is discon tinued and boiling continued for a short period af time, to increase the massectite propin ‘uity toa point that will make its consistency and flowabily optimum for centrifuging Tight pan Opposite of Loose pan Treacle English term for mola, Undersaturated Sugar solution that i below its saturation point (ie, more crystals will dissolve) Vacuum Any pressure that is less than normal air pressure. There ate two seals: the ab- solute pressure scale and the vacuum prssute scale, both measured in inches of mercury and both used on pans. Absolute presture is shown by a mercury manometer and vacuums pressure is shown by a dal gauge. Their total wil always add to about 30 Vacuum pan vapor Vapor created in evaporating crystallization Washing Washing of sugar crystals during centefoging with syrup, water, or Wash syrup Syrup produced in washing sugar during centrifuging. CHAPTER 2 Sugar Refining Processes and Equipment* INTRODUCTION In this chapter we define briefly the technical terms in each process unit and the equipment used for twa standard suger cefineres, one with carbonation asthe primary desoloiation proces, the othe with phosphstation, Both refineries are rated for 1200 tonnes of rawsugar perday. Attempts have been made to indicate the number of units foreach type of apparatus and the ative sizeof equipment foreach process operation The criteria forthe design of 4 new sugar refinery ate alo presented 2.4 REFINING WITH CARBONATION ‘We describe next the equipment and operating condition requirements for a typical cr bbonation refinery handling 1200 tonnes of sugar per day, I Section 22 we da the same or 8 phosphatation refinery. 2.4.4 Raw Sugar Handling ‘When raw sugar i rectved itis weighed, sampled, and stored in a warehouse with carefal placement based on its origins, to minimize the need for Blending. A raw sugar hopper i ‘usually provided with a smaller surge hopper before the sugar is fed into the balance or scale. The hopper should be equipped with high and low indicators, Belt conveyors should be wide enough ro avoid spillage (eg, 061 m wide). The weighing scale generally has 2 maximum capacity of 700 kg per dump. A 600-kg dump with 2 45-s produce a melt rate of about 1200 tonnes! ay. 2.4.2 Affination Figute 2.1 shows a epical refinery discharged through a dry crush roller. The weighed raw sugar is then fed into a magma “By Chung Chi Chow, Retiring with Coboration a3 ringler, where it is mixed with affination syrup toa desired consistency. The magma tem= perature is maintsned at abou 40°C and mingling withthe affiation syrup is held at 72 Brix. The water temperature forthe afination heater should not exceed 85°C. The afination syrup can be added automatialy each time the raw sugar dicharge gates open. Alterna tively it canbe controlled through monitoring the motor load on the minglr drive motors. The motor load is correlated with the uidity ofthe magma in the mingler. ‘The magma from the minglers overflows t the mixers, which fed the seven Western States batch automatie centrifugal, with a basket sizeof 48 by 36 by 7 in, Each basket has a capacity of 05 m? with a loading speed of 250 rpm. The Alli-Chalmerssingl-winding ‘motors have two speeds and 250 A on acceleration with fll load. The waeh water temper- ature and pressure are 2°C and 85 psi, respectively. The amount of wash waters contolled to give a washed raw sugar normally with 0.1% of invert and 0.196 of ash content. [After centrifugation, the washed raw sugat is melted in high-purity sweerwatee fom a carbonate cake sludge pres filter to 72 Brix at 75°C. Low: pressure steam and/or vapor from the evaporators can be used to mel the washed Yaw sugar. The afinaton syrup collected fom centrifugal is adjusted with lime slurey to give 2 pH of 7.2. Part of the syrup is cheated to 60°C for mingling raw suger, and the excess portion is directed to the vecovery side ofthe refinery for sucrose recovery. The recovered remeited sugar is then blended with washed raw sugar liquor fom the afination operation. The resulting liquor, commonly called melt liquors then pumped to the next stage of carbonation 2.1.3. Carbonation ‘Typically, «two-stage carbonation proces is wed. The melt Fiquor i blended with 20 Brix milk of lime ata ratio of 0.7 to 1% lime slid to total soluble sugar salds, depending on the quality of the raw sugar being processed. A typical lime saker might be a Wallace & ‘Tiernan model A-758 with a capacity of 900 kg/h. A sngle-deck No, 10 mes screen is ‘sed for grit handling. The frst stage consists of two paralel tanks, AA and AB (Fig. 2.1), Which are evenly spi forthe melt liguor flows, The second stage consists of singe ten, B, which receives the crmbined flow from AA and AB. Each tak has a volume of 40m ‘The retention time inthe AA/AB saturation is about 49 min individually, and 225 min in tank B Serubbed fue gs, recovered from natural gae-fired boilers, is pumped or dipersed through all thre tanks 25 «source of carbon dioxide, 10 reat withthe Lime inthe catbon- ation liquor to form calcio carbonate inthe tanks. About 75 10 99% ean dioxide gsing iscaried out in the frst sage (AA and AB). The resulkng pH is about 8 (when messuting cold) The B saturator is gassed to « pH of 8.2. The athonated liquor leaving the fst sage is tehested to 85°C, The clelum carbonate formed in the mel liquor inside the sturators centraps wax, gum, polysaccharides, colorants, and ash, mostly sulfate. Most inverts in the ‘melt liquor are also destroyed by carbonation. 2.4.4 Mud Filtration (Carbonate cake (mud) in the carbonated liquor is removed as shown in Fig. 2.1, by filtration through eight Sweetland presses using magnetic fowmeters to monitor and contol the liquor flow. Each press has 72 leaves, with a filtration area of $3m*. The polyester cloth carries 502/yd? multiflameat. Occasional in situ acid and caustic treatments are required te keep the cloth clean. Recirculation of liquor is needed atthe Begining of each press cele to minimize excessive turbulence while precosting. Sequencing ofthe pees cle ie handled automatically. A typical productive cycle length is about 45 t0 30 min. The color ofthe pressed liquor ranges from 600 to 800 ICUMSA. The pres lter liquor is pumped 44 SUGAR REFINING PROCESSES AND EQUIPMENT into a supply tank and the cathonate cake (mud) is sliced out of the primary filter for ‘sweetening in two automated presses. The filter employs compressed aie for final drying, of the mud 2.4.5 Bone Char Decolorization and De-ashing Bone char filtration can be used to farther reduce the processed liquor color to 100 to 150 ICUMSA with low ash content for the production of white sugar and soft sugar. Fifteen char cistern (Fes) are needed, of which 10 are in the productive eel. Nine are fr the filtered pressed liquor and one on jet 2. All are fe at a flaw rate af about 8 mh by gravity ata maximum Brit value of 675 snd a temperatare of 80°C. The total ligu cycling time ‘through chae cisterns ranges from 80 to 120 h, All citeras ate settled with filtered liquor at 60 Brix. After the capacity of the char cisterns to temove color and ash is exhausted, sswoctening-off is carved out with hot water ata low rate of 3 /h followed by hot-eater ‘washing at 80°C for about 25h. Following the washing, spent chat srvivifed ina Nichols Herreshoff kiln or conventional pipe kiln, fred on natural gas of oi. A Hereshoff ln has eight hearths witha static louver dryer and thee forced-ait coolers. Chat burning at hearth 1 proceads at about 45 tonnes/h witha temperature of 540°C, 2.4.6 Evaporation ‘The char-fitered A liquor at 65 Brix is evaporated to 76 Brix using 2 riple-fec fling fm evaporator. The Brix value ofthe liquor being discharged from the evaporator is mon- stored and controled bya density instrument that regulates the steam low to the evaporator. Sweetwater evaporation is accomplished by using the vapors fom the lke elect of the A liquor evaporator. The vapor from the fist body can be used to melt the raw sugae 2.4.7 White Sugar Bolling and Crystallization “Thick 4 liquor at 76 Brix is pumped into the vacuum pan supply tanks, Vacuum pans are of stainless steel construction equipped with (1) an agitator, using amperage output for ‘mobility contol; (2) a barometric condenser with water ring vacwum pumps: (3) 2 en tallocope and (5C refractometer for density contol and (4) steam at 26 pi with an Anubar flowmeter for flow control and the liquor feed controlled by a TigerMap flowmeter. ‘A ppical automated white pan boling eyce includes an initial charge of 18m seeded ‘with 700 ml. of fondant slurry at 115 supersaturation or 78.5 Brix at 157 mmnig absolute, land & pan to drop ata load of 50 A using mobility contrl with a stike volume of ap: proximately 40 m’. The total cycling time of one pan is about 85 mia, ‘Astraight hree-boling scneme is used to proce white sugar. The Fst strike is boiled fiom thick A liquor (fine liquor) with a small amount of jet | back-boiling, the second strike is boiled strictly from jet 1 syrup, and the third strike is holed fFor et 2 syrup. The jet 3 and 4 syrup, together with concentrated low-purity sweetwater arginsted in the chat {ecolorization proces, is wsed for sof stgar production. The resulting sft syrup is sent to the recovery house for further sucrose recovery. These vacuum pans with a 40m strike volume are needed for white sugar production ‘Two pans with an average strike capacity of 38 m? are used on the recovery (remelt) side to boll three stikes for sucrose recovery: highs, mediums, and finals. Melted highs nd rediams constitute the remeltiquor, which is combine with the washed sugar liquor for the carbonation, The meltes final are uted to boi high or seeds stekes. The Rest to (frst and second crops) boiling are machined immediately, while the finals (tied erop) are cured for approximately 80 h before being machined, Refiing with Cartonation 45 For firs-crop boiling (highs), the inital charge is 20 m? of syrup. The pan is seeded with 150 mL of fondant. The gaining purity is controlled at 78 Brix. The target purities for the first and second masies ae 88 and 78, witha strike volume of 40m’, respectively ‘The third crop (finals) is seeded with 500 ml of fondant slumy. The gaining leceding) charge and third masses party ate contrlled at 76 and 64 Bri, respectively. All inl charged syrup shosld const of abovt 80% affination syrup, to falitte the inl stage of ena growth, 2.1.8 Centrifugal Operation For white sugar centrifugation, eight machines, identical in size to the affnation machines, axe used, Those machines have @ nine-nozale wash tree witha highspeed spin cle of 90 In addition, wo BMA G1S00 batch centrifgils are used, These machines have a basket ‘ylume of 0.87 mand 0.1m cape and a wah tre with five lly retectable nozzles, The machines are also equipped with a variable-speed induction drive with a high-speed spin of 70 5 The moisture content of white sugar discharged from the centeifugal should be about 19 or les "Two BMA K1100 continuous centrifugal with a maximum of 2000 rpm and a 30° basket angle is used forthe frst+ and second-crop boiled masse. For the thirdcrop (na) masses, two Western Sttes C5 continuous centrifgals with « maximum of 2200 pm and 30" basket angles ae use. 2.1.9 Sugar Drying and Conditioning, ‘Major drying of sugar discharged fiom white centrifuga is achieved in thre rotary gran- slators, Wet sugar with about 19% moisture enters 2 granulator countercurrent t0 aloe and exis at about 50°C with a moisture content of about 0.08%. Air enters and exits the {granulators at about 85 and 42°C, rexpecively Sugar discharge from the granulatars is fist coarse screened in Rotex screeners, which allow the sugar to cool down further and dissipate the additional moisture. The sugar is then stored in bins for about 2h to “repose” for further conditioning in two sos. In the silo, conditioned ait s percolated through the sugar from the bottom. Aer about 24h of resident time, the sugar leaves the sos witha moisture content of about 0.02%, For railar bulk shipment, farther coling of the sugar in Muidzed bends immediatly prior to loading ito the ca is helpfl. Following conditioning in the sos, the granulated sugar is screened ‘gain to produce sugar mestng the site requirements of various customers 24.40 Packaging ‘Typically, granulated sugar i packaged in -,2- and 4-kg bags with one ply of natura raft and one ply of printed bleached kraft and closed with a rol-top seal and in 10-, 20+ and 40-Kg in mulivalled bags. Icing sugae, produced by & esicropulverize hammer mil, is usually packed in 0.5 and 1-kg bags and 20- and 40-kg packs. In conjunction with the production of white sugar, natural brown or sof sugar i also produce in rv grades, ight snd dack, Soft sugae is packed in 1- and 2-kg bags and in 20- and 40-kg open-mounted slhwalled bags with a vapor barit. 2.4.44 Liquid Sugar Production In Nosh America, quid sugar consists primarily of either 67.5 Bex sucrose syrup or invert syrup with 50% sucrose at 76 Brix. Sucrose syrup is produced by meling the granulated 16 SUGAR REFINING PROCESSES AND EQUIPMENT sugar collected atthe point of discharge from centrifugation and before entering the gren- ulators. The melted sugar is treated with activated carbon and a filter aide and then press fered. The finished product is shipped to customers via railcar or truck. Invert syrup is produced by acid hydrolysis of sucrose syrup using 31% hydrochloric acd. The inverted Syrup is then neutralized by 20% sodium hydroxide and fash evaporated to 76 Brix for shipment. 2.2 REFINING WITH PHOSPHATION ‘The equipment aceded for a phosphatation refinery with a 1200-tonne/day capacity is de- scribed inthis scion, The information is based on material puesented a the Suge Industry ‘Technology Inc. Séth Annual Meeting in Montreal Canada by Lantic Sugar Ld. 2.2.4 Sugar Recelving and Storage ‘The receiving wharf 183 m long, There are two cranes, each rated at 300 tonnes/h. The ‘belt conveyors are 1.2 m wide and have » maximum rate of 800 tonnes/h. Two weighing bins have a capacity of 2 tonnes each per weighing, The rw sugar shed has a ttal storage “apacity of 44,000 tonnes, 2.2.2 Affination ‘The caw sugar elevator has a maximum rate of 55 tonnes/h. The minglr is 06 m in iameter ane 9 m long, the magma header i 0. m wide and 10 m ong with a capacity of 285 rm The affiation centrifugal have » total rate of $0 tonnes/h with four Batch ma- ‘chines 1219 mm in diameter and 762 mm in height and rwo batch machines 1219 mm in tliamter and 914 mm in height, The wathed raw sogarselscrew conveyor is 508 mim in slameters and 8839 mm long, and the washed rave sugar meter stscrew conveyer is 508 rm in diameter and 4724 mmm long. The washed raw sugar melter has a capacity of 136 sn? with a diameter of 2667 mm and a height of 2515 mam. Three units of 1524-mm-diameter screens with 2 foal capacity of €D tannes/h are required to seen ra sugat 2.2.3. Clarification “The coagulant tank has 2 200-L capacity: the Nocculant solution tank is 1.8 m in diameter and 19 m high with a capacity of §.1 mr. There are two lime sucrate tanks, cach 17 m in ameter and 2.1 m high with a volume of 4 m* each. The phosphoric acid tank has a capacity of 02 nr (610 mm in diameter and 838 mm high). The raw sugar tank has 2 ‘apacity of 35 my? and is 43 m in diameter and 2.7 m in height. The main aeration and. reaction tanks have capacity of 0.3 and 3.8m, respectively, The main clarifier has volume ‘of 246 with arate of 50 tonnes/h at 65 Bri, and the reel ior tank has capacity of 17.8 m® and is 3048 mm in diameter by 2667 mm high. The remel liquor aeration and ‘reaction tanks have capacity of 0.3 and 0.5m, respectively. The remel liquor eaifier has 4 volume of 4.6 m? at rate of 10 tonnes hat 65 Brix. The scum feed tank has a eapacty (of 93 mand is 3048 mm in diameter and 1422 men in height, The three-nits three-stage scum clarifier has a total volume of 7.5 m? at arate of 60 tonnes. The thre seum mixing tanks, ane preceding each scum clair, each has taal capacity of 07 mm. The final tank for the scum ftom the last stage of the scurn clarifier has = capacity of 8.6 m and is 2591, som in diameter and 1829 eam in height. The scum centrifugal decanter can produce 2 tonncs/h of heavy scum from 10.8 tonas/h of diluted scum at 3000 rpm. In pale with Refring with Prosphation 47 the centrifugal decanter, « Parkaon twin-belt press with various speeds would also produce 2 tonnes/h of heavy scum from 108 tonnes/h of diluted scum, 2.2.4 Filtration ‘The clarified liquor tank has 2 capacity of 328 m! with diameter of 3658 mm and a height of 3023 mm. The precoat liquor tank, 1219 mm in diameter and 1118 me high, has 2 ‘capacity of Lm. Four Sparkler filter preses for clrifiod liquor esc have a filtration ‘surface of 92.9 m* The fer liquor tanser tank, 3048 mm in diameter and 2438 in height, hase capacity of 16.1 m 2.2.5 Decolorization and Regeneration ‘Two filtered liquor tanks, each 3. by 3.0 by 181 m have a total capacity of 42.5 m’. Thirty bone char filter, each with a volume of 29.5 m? have total rate of 55 tonnes/h. Each zefiterng B liquor transfer tank and B liquor feed tank has a expacity of 42.5 mv and is 3.6 by 30 by 1.8 m. Five bone char blow filters, cach with a volume of 386 m? have a total wot char rate of 8.75 tonnes/h, One Nichols-Herresof kil furnace with a predryerre- generates 875 tonnes of car per hour. Thee are 950 tonnes of stock chat inthe dec! ovation char system, 2.2.6 White Sugar Boiling and Centrifugal Operation There is one No. 1 liquor tank with 2 volume of 18 m? (3 x ja diameter and 2.1 m ia height) and two No. | liquor polished presses, each with a capacity of 6.2m of filtration surface, The fine liguor preheater has @ maximum rate 685 tonnes! with 83 m of heat surface, Two single-ffect& liguor evaporators 1.8 m in diameter each hs 2 heating sutace area of 148.1 m’. The concentrated A liguor is discharged into two concentrated No. 1 Tiguor tanks each, with a capacity of 73.1 m" (38 m in diameter and 64 m in height). The ‘#0 white sugar pans, equipped with an agitator and tube calendriacach has heating suesce (of 287.1 m! and a capacity of 48.2 mP. There are to magia enor, each with 2 capacity of $1 m? (32 m in diameter and 6.3 m in height). The bouder drum for the eight batch centrifugal 0.9 m in diameter and 1.6.m in height with a capacity of 10.7 m’. The eight white sogar ceatefugals have «total cate of 686 tonnes/b; each is L2 m in diametee by 0.76 m in height. The distributing screw conveyor for granulators is 0.5 min diameter and 27.7 m long. The five granulators for sugar drying, each 1.8 m in diameter and 7.8m in length, have tora ate of 69 tonnes/h The (tsm-wide bet conveyor used to convey sugar to the slo, has a capacity of 17.2 2.2.7 Conditioning Silo All screw conveyors to and from the conditioning silos are 0.4 m in diameter. The lower and upper sales for weighing sugar going into and out of sila, espectively, have» capacity ‘of S00 tonnes/h, with 544.3 kg per weighing. The two silos (each 15m in diameter and 33, 1m in height) have a total capacity of 9400 tonnes. ‘The belt conveyor used to carry sugar ‘beyond the upper sae is 0.5 m wide, 2.2.8 Screening, Storage, and Shipping ‘The distributing screw conveyor for Screening hs a diameter of 5 m, There are LO screens, cach with four levels, I'm by 1.8 m, with 7.41 of screening surface for each seen. The 18 SUGAR REFIKING PROCESSES AND EQUIPMENT ‘maximum total rate for screening is $0 tonnes/h. There ate 10 storage bins each with a capacity of 5 tonnes. In addition, there are 10 storage sls 3.6 m in diameter and 9.4 m in eight, each with a total capacity of 639 tonnes. The ralar bulk rte i 83 tonnes/h and the truck bul rate i 30 tonnes 2.2.9 Soft (Brown) Sugar Boiling and Centrifugal Operation In this particular refinery raw sugar/affnaion syrup is tested, presed, and char filtered ‘before boiling into soft/brown products. These are high-proft items that any refinery should tay to develop and market. The following equipment is used in this operation, ‘The raw syrup teating tank, 3.8 m in diameter and 1.3 m in height, has a capacity of 224 m?, The raw syrup filter pres has a filtsation surface of $1.7 ms the tered rave syrup tank (18 m in diameter and 2.2 m high) has a volume of 3.8m’. Seven bone char filters teach 29.5 m’, are needed, with a total rate of 11 tonnes/, The chartered igor, termed ‘oft gun, is subjected to farther treatment. The sof liquor teeting tank, 3.8 m in diameter bby L6 min height, has a volume of 18.2 in The soft liquor filter press hat filtration area fof 38,7 mt the filtered soft liquor tank (15 m in diameter and 2.2 m in height) has a ‘capacity of 38 m?. The single-effect soft Hiquor evaporator (1.8m in diameter) has heating surface of 8.5m? ‘The concentrated soft liquor tank (3.8 m in diameter and 6.4 m in height) has a volume ‘of 73:1 m®. The Soft sugar is boiled in a vacuum pan with 158 m? of heating surface and 37.7 m of maximum capacity. The sot sugar magma miner, whichis 29m in diameter and 64 m in height, hae s capacity of 41.8 m The soft sugar is boiled from a pan with a Capacity of 38 mand a heating surface of 158 mi The two sot sugar centrifal, ach 1200 mm in diameter and 760 mas in height, have a toa rate of 1? tonnes/h The soft sugar is cared toa packaging machine using 2 oscilaing conveyor at arate of 7 tonnes 2.2.40 Recovery (Remelt Operation) Both high- and low-purity swestwater are pressed filtered through two filter presses with a filtration aces of B1 m per press. The combined pres-itered sweetwater i concentrated lasing #tripleefect evaporator each effect has a heating surface of 85 m*. Two pans are needed for remelt boiling: one has a capacity of 354 m? and 163 m* of heating surface and the other has a capacity of 21 m? and a heating surface of 126 m?. Two batch eentrifogals swith a total capacity of 17 tonnes/ ate used for remelt sugar recovery, and two continuous ‘centrfugle with a total sate of 13 tonnes/h are used for final strike Sugar recovery. 2.2.44 Liquid Sugar Production Both liquid invert and liquid suerose are produced. The equipment requirement depends fn the volume of the market 2.2.42 Steam and Power Plant “Three natural gas or oilfired boilers, havea tota) output of 82 vonnes/. Each boiler has 4 heating surface of 710m Steam is produced at 145 psig and 172°C, The turboralternator has 2 375-kVA output with exhaust steam at 15 psig The deserator (1980 mm in diameter and 3660 mam in height) i rated at 112 m'/h. The bloworf tank i rated at 4.6 m?/b. Five Comprescrs, cach with » separate desccent deyer, produce & total of 1840 f/min com- rested ai at 100 psig for plant use. CHAPTER 3 Automation in a Raw Cane Sugar Factory* INTRODUCTION Factory automation inthe raw cane factory ranges fom fully automated facilities to faites without any automation, [i evident tat for countries where labor cot i expensive sugar factories ae highly automated, On the other hand, in some countries where the need is 0 employ as many people as posible, the level of automation is sometimes nonexistent. ‘Today, factory managers and owners ate geating up to implement automation in thet factories. The push toward automation isthe result of inereasing complexity in equipment and processes. In some cass the rising cost of labor and lack of qualified workers are forcing manages to move into automation and computerization. In others, the benefits of auto: mation to optimize process and sugar quality are the driving force in moving into auto 3.4. BRIEF HISTORY OF PROCESS AUTOMATION Automation in raw sugar factories started shortly afer World Wat I with what was sate of the art at that time, the pneumatic systems. Pneumatic systems were primarily single-loop controllers, and in some instances, cased loops were implemented, Later, the advent of some electrical functionality in controllers enabled signal characterization such a8 consis: tency controls. The advent of powerful electronic controllers in the 19608 and 1970s helped ‘revolutionize control systems inthe factory. With the new electronic controllers, complex «control strategies ate posse, Alo, electrically carrying contcal signal allowed for enended distances between conteol elements, Isand-type conteo strategies were the primary method ‘of control unt the emergence of the data highway and distributed conto ystems (DCS). DCSs took advantage of advanced communication protocols to stretch the control system beyond the geographic limit imposed in earlier systems. Siqnals could now be tansmitted thousands of feet avay on 2 wire. Devices were equipped with smart fentres to report health and diagnostic information about itself, Proceses could now be monitored from By Robert. Kwok and Bay H, Lam, a9 20, AUTOMATION IN A RAW CANE SUGAR FACTORY several stations. Sharing of information among the various pats ofthe fctory became an integral part ofthe overall operation. Further advances in communication yielded increas ingly sophisticated devices and controllers. The move from analog systems to digital ystems marks the arrival ofa new era in the control industry 3.2. CONTROL SYSTEM IN A RAW SUGAR FACTORY The general layout of the control system consists of regulatory controllers, programmable Iogle controllers (PLCs), operstor workstations, contol input/output (1/0), and configu: ration workstations. In addition, several stations on office personal computers (PCS) may bbe part of the general network. The system is distributed throughout the plat and the ‘operator consoles end man-machine imerface (MMI) are divided among several contol rooms. The contollers are centrally located in different areas with thie 1/0 distributed in the field. The configuration sation is located at a remote location easly accesible by the engineering staf and technical staff. The PLCs are locted in the motor conteol centers (MCCS) and interfce with the rst ofthe contol system. PLCS use man-machine interface for operator accessibility. The main purpose of using PLCS is to handle most of the discrete logic in the sytem. The cane yard and milling area presents 2 wide aray of process and ‘auipment, It important fo protect and properly contol these equipment. An intiate combination of interlock and regulatory control scheme i therefore requited. ‘Control sytem in a raw cane sugar factory features a wide variety of contel sategies. ‘The system ranges ftom material handling to crystallization, evaporation, drying, and baller controls. The basic aystens in 2 sugar factory may be divided into four distin unit opers- tions, the cane yacd/ milling oF difosion are, the clarification, filtration, evaporation, and vacuurn pan crysalization area, the crystlizer and centrifugal area, and the boiler and tarbogenerstor area ach aca mentioned viously can be considered in ite own entity, However ina modern automated sugar factory where efficiency is important, sharing information between the various unit operations is necessary. The control system makes use of state-of the-art

    You might also like