REFINERY CONTROL

Definitions
 Liquor – sugar solution which the material are
used in the refinery.
 Refinery syrup – combination of affination
syrup and last run-off.
 Run-off – syrup removed by centrifuging white
massecuite. It is classified as first, second,
third, fourth depending upon the grade of
massecuite it was obtained.
 Raw Sugar Quality
Polarization, % 97.5 min
Moisture. % 0.5 – 0.7
Safety Factor 0.25 max
Color, i.u. 3000 – 6000 max
Reducing sugar, % 0.6 – 0.7
Ash, % 0.3 – 0.5
Filterability (ml) 80 – 140
Mean aperture, mm 0.9 min
Coefficient of variation, % 25 max
 Affination Station
Affination syrup brix, deg 70 -75
Affination syrup, % AP 85 – 86
Affination syrup temp, oC 71.1 – 73.9
Magma brix, deg 89 – 91
Magma % AP 82 – 83
Magma pH 6.6 – 7.0
Magma temp, oC 43.3-48.9
Affined sugar color, iu 800 – 1500
Affination % color removal 70 – 75
 Carbonatation Station
Raw liquor, obrix 60 – 65
Raw liquor, pH 6.8 – 7.2
Raw liquor, temp. oC 71.1 – 76.7
Raw liquor, color, i.u. 1000 – 1700
Milk of lime, oBe 12 – 15
Lime liquor ratio, % CaO on solids 0.6 – 0.7
Lime liquor pH 10.5 – 12
1’st carbonation liquor pH 9.3 – 9.5
1’st carbonation liquor temp. oC 76.7 – 82.2
 Carbonatation Station
2’nd carbonation liquor pH 8.3 – 8.5
2’nd carbonation liquor temp. oC 79.44 – 85
Filtered Liquor brix 60 – 63
Filtered Liquor Temp 79.44
Filtered liquor 500 - 1000
Carbonatation % color removal 50 – 60
Filter cake, % Pol 1.0 – 1.5
Filter cake, % moisture 45 - 47
Flue gas, % CO2 9 - 12
 Centrifugal Station
Crystal yields, %:
1’st massecuite 56 – 58
2’nd massecuite 52 – 54
3’rd massecuite 48 – 52
4’th massecuite 48 – 52
Recovery House high remelt mass 45 – 50
Recovery House low remelt mass 40 – 45
AP reject syrup, % 40 – 45
Recovery house final molasses 30 - 42
Wash water temp 100 – 105 oC
Wet refined sugar % moisture 0.9 – 1.1
 Drier/Cooler Station
Discharged sugar temp 37.89 – 40.56oC
Discharged sugar drier temp 40.56oC
Discharged sugar cooler temp close to ambient
Discharged sugar moisture 0.02 – 0.04
Refinery Control Calculations
Theoretical Refining yield , Y
2P – 100
Y= --------------- x F
100
where:
 F = a constant factor to correct for the effect of
sugar attributes other than pol. Generally the value
taken is 0.9735
 P = Pol of the sugar
Actual Refining yield
Lkg refined sugar produced
Refining ratio = -------------------------------------------------------
Lkg equivalent raw sugar processed
Tonnes production
% Refining yield = --------------------------------
Tons processed
where:
 Tonnes production = actual refined sugar produced
= (refined sugar &/or refined sugar
equivalent of liquid sugar)
 Tonnes processed = (Tonnes raw melt + Tonnes raw
equivalent of previous stock) -
(Tonnes raw sugar equi. pesent stock +
Tonnes available raw sugar in
Refinery syrup)
 Basic Principles:
Refinery Pol balance:
Tons Pol in Raw Sugar processed = Tons Pol in refined
sugar produced + Tons Pol lossesl

where: Tons Pol Losses are losses in Filter Mud, Molasses,

Sewer/sludge etc, and Undetermined