ADDIS ABABA UNIVERSITY

ADDIS ABABA INSTITUTE OF TECHNOLOGY

DEPARTMENT OF CHEMICAL ENGINEERING

INTERNSHIP REPORT

HOST COMPANY:ARJO DIDESSA SUGAR FACTORY

Title :Sugar production process

Prepared by:Tesfaye Bulti

ID.NO: UGR/4207/12

Name of Advisor:
Name of Supervisor:

Submission date:
Table of contents
 Acknowledgments

First and foremost I would like to acknowledge my God that helped me in

everything .In addition would like to thank my supervisor Dr.Abiy Tirfe at AAiT,
who gave me the chance to do my internship at Arjo Didessa sugar
factory .Moreover ,my heart felt gratitude goes to my mother , my dear two brothers
and my dear sister.
Last but not least ,I owe whole hearted gratitude to the whole Arjo Didessa sugar
factory workers specially my advisors and machine operators ,who told me
everything.
 1. Introduction
Sugar is a very important flavoured ingridient used in many food ,drink and
pharmeceutical purpose world wide.It is extracted from sugar cane and sugar
beet from which it can be obtained in economical way.Among the sugar factories
producing sugar in Ethiopia Arjo Didessa sugar factory is one that produce
refined sugar from raw sugar in integrated way .
The factory have 80,000 tone crushing capacity per day which is established by
an individual owner.
1.1. Factory Overview
Arjo Didessa Sugar Factory is 395km to the west far from Addis Ababa. For this
factory the main issue is the production of sugar. Area covered by this factory
for production of cane is 50,000hectar. But for now the area on which the cane is
produced is 40,000 hectar and the rest one is assigned for future plan. The main
purpose of this factory is to produce the sugar continuously with a good quality
and sell the sugar in international market. It also opened the chance of work for
non-employers.

Figure 1.1 Arjo Didessa Sugar Factory gate

 1.2.Factory Background

Arjo Didessa sugar factory first was established by an individual person who
called Hajji Margie paradise in 2001 E.C,who was in Pakistan. His main
objective was to increase the economic development by producing sugar, using
the modern technology. In 2003 the facory started producing some amount of
sugar, but fully not succeeded his work and then sell his factory to the Ethiopian
Democratic Government in 2005 E.C. Arjo Didessa sugar factory is located in
the western part of the country, Oromia National Regional state, bordered in
East Wollega, Buno Beddele zones and Jima zones within Didessa valley. It’s
located at 395kms distance from Addis Ababa

2.Methedologies Used
While doing my internship at the company I used the following methodogies

2.1.Teaching learning process with my advisor at factory

I used this methedology during my intern when my advisors told me every

process and procedures of sugar production.This method of acquiring
knowledge is preferred to know the production process theoretically

2.2.Observation

This methedology of getting knowledge is preferred after the theoretical

knowledge is acquired.This methology is used during my intern when my advisor
showed me every process and procedures practically after telling me
theoretically.This methology is most suited to my internship objective.
 2.3.Questionnairies

This methology is used to obtain specific information on a certain topic by asking

question.During my intern I asked many process operators and my advisors.

3.MATERIAL AND METHODS OF SUGAR PRODUCTION

3.1. Materials
3.1.1.Sugarcane
With its high fiber and carbohydrate content constitutes an important
renewable
source of energy. Sugarcane is planted in soil and the plant growth in the course
of its life cycle, during which it converts water and CO2 from atmosphere into
carbohydrates in the presence of sunshine, a phenomenon termed as
photosynthesis.
The reaction takes place as follows during the plant growth.
6CO2 + 6H2O + Light energy → C6H12O6 (sugar) + 6O2
The principal components of the cane stalks to be processed for commercial
sugar production are:-
Water ------------------------------70-75%
Sucrose ----------------------------10-17%
Reduced sugars ------------------ 0.4-2%
Organic non-sugar-------------- 0.5-1%
Mineral matters -------------------0.5-1%
Fiber-------------------------------10-16%
Besides these the composition of juice extracted from cane is marked by varying
amounts of mineral salts and organic compounds. The composition of sugarcane
is conditioned by the variety of cane, soils and agricultural factors in addition to
the climate during the different phases of growth of the plant.
Sugars in general are known as carbohydrates being formed of carbon, hydrogen
and oxygen.
Simple sugars like glucose, fructose etc. are monosaccharide’s which cannot be
further decomposed into simple carbohydrates by either acids or enzymes.
 ADDIS ABABA UNIVERSITY
ADDIS ABABA INSTITUTE OF TECHNOLOGY
DEPARTMENT OF CHEMICAL ENGINEERING

INTERNSHIP REPORT

HOST COMPANY:ARJO DIDESSA SUGAR FACTORY

Title :Sugar production process

Prepared by:Tesfaye Bulti

ID.NO: UGR/4207/12

Name of Advisor:
Name of Supervisor:

Submission date:

sugar. More than 60% of the world’s sugar production is from sugar cane and
the rest is from sugar beet, but in our country sugarcane is the only raw material
used for sugar production ,due to our country’s tropical climate.In addition
white sugar is produced from sugar cane.

3.1.2. Sugar beet

Sugar beet is the other raw material used for sugar production world wide.

The sugarbeet is a root crop that flourishes in temperate climates where the
growing season is about five months long. Farms can be found in California,
Colorado, Idaho, Michigan, Minnesota, Montana, Nebraska, North Dakota, Oregon,
Washington, and Wyoming.

Beets are planted in late March/early April and harvested in late September and
October. When fully grown, a sugarbeet is about a foot long, weighs two-to-five
pounds, and is about 18% sucrose. They are processed at 20 factories that are
Factories
located near the fields, because beets are a perishable vegetable.
generally operate around the clock, seven days a week, from October
through April. Beet sugar represents about 54% of domestically-produced
sugar. There is no difference between beet and cane sugar.

Some beet sugar brands you might recognize are: Crystal Sugar, Western
Sugar, Pioneer Sugar, White Satin, and Spreckels Sugar.

3.2. Methods of Sugar Production

Different sugar factories produces sugar differently by using different

methods of production.Some factories produce raw sugar only while
others produce refined sugar from raw sugar.
Arjo didessa sugar factory is one of the sugar factories in Ethiopia that produces both refined
and raw sugar in integrated manner as follows:

3.2.1. Cane Preparation unit operation

In sugar production the process from burning to milling is known as cane

preparation process,since it makes ready the cane for juice extraction.That
process includes the following activities.

3.2.1.1. Cane Burning

First and foremost the matured cane that is ready for harvesting is burned by fire to
remove leaves and a layer of wax for a short period of time after which only the stalk
remains.
Purpose of burning of cane:-

To remove impurities

To reduce transportation cost

To reduce the man power needed

 To reduce loading

To reduce sugar losses

3.2.1.2. Harvesting

At Arjo Didessa sugar factory harvesting is done by man power.During harvesting the stalk is
cut slightly above the ground which remains the root intact,that allow the cane to be
harvested many times without planting.

3.2.1.3 Transportation and balancing the cane

The harvested sugar cane is transported to the factory and balanced by a machine called
weight bridge before the cane is unloaded to be stored at the cane yard for a temporary
period of time.Sugar cane is balanced for the following reasons:

To compare the amount of sugar that can be obtained from a certain amount of sugar cane
with the world standard per tone of cane.

To estimate amount of chemicals that needs to be added to the sugar during production
process.

To accurately know the different cane varieties and calculate the yield of cane.

To determine input and output capacity.

To estimate the cost which is paid for the farmer whose the cane is belongs.

To know the chemical control and determination of factory performance

3.2.1.4. Storage at Cane Yard

Storing the balanced cane at the cane yard is not always advisable but, it is is stored during:
1) the production process is interrupted due to a certain problem in the factory.

2)When the amount of cane harvested is not enough to start crushing.

To avoids evaporation of water from the cane and inversion of sucrose the cane must
reach the production process at most within 24 hrs.

3.2.1.5. Cane Unloading

Is a process of dumping cane from cart, lorry and trailered bynmaterial called fixed
type crane which have high lifting capacity known as hello crane.

Figure 3.1 hello crane

Hello crane fed the cane to feeding table having crane is leveled by the

leveler without size reduction transported to main cane carrier. Then the cane is
transported to the first knife.

3.2.1.6 Crushing and shredding

Hello cane is used to feed sugar cane into cane table that in return inter the cane to the
machine calledMain cane Carrier( MCC).
MCC is a machine that transfer the cane to the the machine called Auxiliary cane
carrier( ACC).

Before the cane started to be reduced in size by the first cutter leveler is used to level the
cane to make suitable condition for the first cutter.

ACC feeds the cane to the first Cutters,that cut the cane into pieces that make it suitable for
shredding the cane .

Arjo Didessa sugar factory have two cutters both of them are operated by the turbines that
convert mechanical energy to electrical energy which is operated by steam generated by
reboiler .

The first cutter cuts the cane into pieces.

The cane from the first cutter enter the second cutter where it cut into more smaller pieces
after which it enter the shredder .

Both cutters have knives that cut the cane into pieces,in which the first cutter have 60 knives
and rotates at 600 rpm and the second cutter have 80 knives.

In the shredder the cane cut into finest pieces that ,expose the inner part without juice
extraction which have 172 hammer on it that allow the cane to be reduced into pieces.

Figure 3.2 shredder

3.2.1.7.Magnetic separation

There is a magnetic separation between milling and shredding that help to avoid the
entrance of metals into the mills .

4. milling

The finest pieces of cane enter the mill where juice is separated from the bagasse
Milling is the process of extracting juice from prepared cane or the process where
bagasse is removed. Arjo Didessa sugar factory have five (5) mills one after another.

The shredded pieces of sugarcane travel on a conveyer belt through a series of heavy duty
rollers consisting of two rolled crushers .At every mill juice extacted .the that is not extacted
in first mill is extracted in the second mill,that not extracted in the second mill will be
extracted in the third mill and son.

The cane is made to pass through a succession of rollers that comprises the milling
tandem, and its juice is squeezed out as it goes through. To help to extract the
maximum juice, use of imbibitions’ water is made. The extracted juice is sent to
process and the fibrous material left after milling, known as final bagasse, is sent to
the boilers to be used as fuel for the generation of steam

4.1. Methods of Separation of Juice from Cane

The sugar content of cane is dissolved in juice contained in millions of plant cells.
There are two different systems of extracting the sugar containing juice from the cane.
Such methods of extraction are: -

By means of pressure in a number of mills provided with three rollers through
which the cane is forced.

By means of diffusion, extracting juice by applying heat, immersion in water

drum and squeezing of the bagasse. In this room there is about 80% of the juice are
extracted by adding imbibition water and lime. The lime used for settling material by
increasing density difference.

Mill is a combination of three rollers

Top roller: - is driven from prime mover through a redaction gearing.it is controlled
by hydraulic drum may rise or float with the variation in the feed cane. It is flexible
roller.

Delivery and feed roller: - are moved by the fraction of top roller .they are rigidly
fixed on their position.

The main objective of mill tandems;-

Is to extract a maximum amount of juice from the prepared cane.

To produce a bagasse with minimum amount of pol content.

A. First mill: - 65%of juice is extracted from the prepared cane in the first mill. The
juice extracted is called primary juice. To extract this juice the prepared cane is
delivered to top roller with the aid of under feeder when top roller rotates it produce
frictional force .with both feed roller where the first extraction takes place and
delivery

B. Trash plate: - The plate is which act as a bridge between the feed and delivery
roller. It maintains a part of compaction achieved at the feed roll while turning the
bagasse in to the nip between the top and discharge roll. Also it conducts the bagasse
from feed roller to the real mill opening have the teeth cut in the side of feed roller.

C. Roller scraper: - it is fitted on the top and delivery rollers. Their purpose is to
scratch of the bagasse caught.

D. Second mill-fourth mill:-the left 35% of juice is extracted by these mills. This
juice is called secondary juice.

Imbibition technique

It is not possible to remove all juice from the bagasse by pressure. In order to obtain a
satisfactory extraction of sugar, it is necessary to dilute the juice remaining in the
bagasse by adding water. Therefore; imbibitions’ is the process in which the water is
put on the bagasse to mix with and dilute the juice present in the bagasse. The water
so used is termed as imbibitions water.

The motor used in those milling 850 kW for each of them and the rpm 1200 for each.

The juice obtained from the mill is known as mixed juice.

Finally mixed juice is separated from bagasse at fifth mill that is used in the boiler for steam
generation and the mixed juice enter the first heater .

Mixed juice tank

It is a tank which stores extracted juice for further processing in process house.
4.2.Bagasse Elevator

Bagasse elevator is a type of inclined carrier which transports the bagasse from last
mill outlet to all boiler’s inlet as well as towards the additional bagasse storage point.
Block Flow Diagram [Feed Section + Milling House]

Diagram 1.Block Flow Diagram [Feed Section + Milling House]

5.BOILER HOUSE
A steam generator or a boiler is defined as a closed vessel in which water is converted into
steam by burning of fuel in presence of air at desired temperature, pressure and at desired
mass flow rate.

Boiler is extremely dangerous equipment which should have to be treated with

ultimate care.
Function of a boiler:

 Used in steam turbines to develop electrical energy

 Used to run steam engines

 In the textile industries, sugar mills or in chemical industries as a cogeneration plant

 Heating the buildings in cold weather

 Producing hot water for hot water supplyProducing hot water for hot water supply

The battery of boilers and its connections form one of the most important parts of any
factory, and are of peculiar interest in a sugar works, in view of the evaporation
produced by the steam here generated, in addition to that required to supply motive
power for the engines.

Awater tube boiler is a type of boiler in which water circulates in tubes heated externally by
the fire.

Fuel is burned inside the furnace, creating hot gases which heats water in the steam-
generating tubes.

The boilers we use in sugar factories are almost water tube boiler type and entirely of the
multi tubular Class.
The water tube boilers have the advantage of being built in large units, of being adapted for
high pressure, and of being capable of raising steam quickly.
In water tube Boiler a number of water tubes are arranged in and around the furnace. This
type generally gives high steam production rates, but less storage capacity. water tube
boilers are also capable of high efficiencies and can generate saturated or superheated
steam.

In Arjo Didessa Sugar Mill (Factory) there are two water tube boilers are installed to
generate steam from water at the same conditions.
A steam super heater is integrated with boiler and in this saturated steam is converted to
superheated steam by exchanging heat with flue gases.
An air pre-heater is also integrated with boiler. Flue gases enter the air pre-heater at 250°C
and leave at 180°C. 2 tons of steam are produced per ton of bagasse combusted.
Steam from all two boilers combine in the steam header at 350°C temperature and 24
kgf/cm2 (bar) pressure, and then this steam is transferred to milling house, feed section, and
power house to run turbines.
When steam reaches the milling house and power house its temperature becomes 325 ~
330°C due to heat losses to environment. While the pressure of the steam reduces to 22
kgf/cm2 due to pressure drop in pipes and valves. After steam turbines its temperature
becomes near about 180°C and then it goes to steam desuperheater, where its temperature
is reduced to 125°C which is the requirement of process house.
Boiler Fans:

ID Fan (Induced Draught Fan):

Induced draught fan draw gases out of the boiler. The gas has already passed through the air
heaters and precipitators before it has reached these fans.

FD Fan (Forced Draught Fan):

It takes air from atmosphere and passes it through the air pre-heater tubes, which is then
blown into the furnace from its base through dumping gate. This warm air helps in
combustion and spreading bagasse. Each unit has forced draught fan. The fan draws warm
air from the top of the boiler house through large air heaters becoming the primary and
secondary air used for the boiler combustion process. The air heater warms the incoming air
by transferring heat energy from the outgoing flue gases.
SD Fan (Secondary Fan):

Secondary Fan is also admitted turbulently to complete the combustion. This fan supplies air
to the furnace from the bottom surface to ensure complete combustion. This fan is only
used when Bagasse is used as fuel otherwise it is kept off.

Super heater:
A super heater is a device in a boiler that heats the steam generated by the boiler again,
increasing its thermal energy and decreasing the likelihood that it will condense inside the
header.

Super heaters increase the efficiency of the boiler, and were widely adopted. Steam
which has been superheated is logically known as superheated steam.
Air Pre-heater:

This air pre-heater is used to heat the air inducted to the boiler by the hot flue gases.
Thus, raising the temperature of inlet air up to 110 C.
Economizer:

It is a device which heats the feed water on its way to boiler by deriving heat from the flue
gas. This results in raising boiler efficiency, saving in fuel and reduced stresses in the boiler
due to higher temperature of feed water. An economizer consists of a large number of
closely spaced parallel steel tubes connected by headers of drums. The feed water flows
through these tubes and the flue gases flow outside. A part of the heat of flue gases is
transferred to feed water, raising the temperature of the later.

2.2.6.3 Boiler Water treatment plant

Boiler requires clean and soft water for longer life and better efficiency. However, the source
of boiler feed water is generally a river or lake which may contain suspended and dissolved
impurities, dissolved gases etc. Therefore, it is very important that water is first purified and
softened by chemical treatment and then delivered to the boiler.

There are two plants for treatment of water that is fed to the boiler.

Physical treatment plant

Chemical (Demineralization) plant

Physical treatment plant

It’s a mechanism that treating or softening the water that comes from lake or river.

First water is treated physically by storing the fresh water comes from river and the mud and
undissolved material is settled down.

Then this water is pumped through overhead tanker to water softening plant. In this plant
there is a tank called multi grade filter and the tank is full of sand. When this water is passed
through the suspended material in the tank the mud is further trapped in and the filtered
water is going to chemical treatment for further treatment.

Chemical (Demineralization plant):

We use Nacl (table salt) in chemical treatment to remove Ma, Ca, K and sulphates from
water.

A Demineralization Plant consists of two pressure vessels containing cation and

anion resins.

Why we need Water Treatment…?

Impure water may cause many problems in the boiler so it must be poured some way to
avoid problems in the boiler. The most common problems caused by the impure water are
as followed:

 Scaling:

Total hardness in the water if not properly removed will cause in scale formation.
A layer of scale on the metal surface of the boiler will acts as an insulator and
reduce the rate of heat transfer from hot zone to water.
Scaling results in more fuel will be used to maintain boiler output at acceptable
level.
Since heat transfer is retarded the metal become hotter to a point where it deforms and
even rapture with disastrous results.

Corrosion:

The most common source of corrosion in boiler systems is dissolved gas: oxygen, carbon
dioxide and ammonia. Of these, oxygen is the most aggressive.

The importance of eliminating oxygen as a source of pitting and iron deposition cannot be
over-emphasized. Even small concentrations of this gas can cause serious corrosion
problems.

 Sludge formation:

The impurities which are floating on the surface in the form of light fluffy mass are
called sludges.
These are insoluble impurities that float at the surface of water at high temperature.
Treatment is as follows:
The impurities of Na, Ca, Mg, react with ant scaling agent and form their sulphates and
phosphates which are easily removed. However due to sludge formation the rate of water
evaporation is decreased. The sludge formation starts at 40oc and maximum sludge is
produced at 80oc, at this temperature it is automatically drained off.
Deaerator:

Purposes of deaeration are:

 To remove oxygen, carbon dioxide and other non-condensable Gases from
feed water.
 To heat the incoming makeup water and return condensate to an optimum
temperature for:
 Minimizing solubility of the undesirable gases
 Providing the highest temperature water for injection to
the boiler
 To heat the incoming makeup water and return condensate to an optimum
temperature for:
 Minimizing solubility of the undesirable gases
 Providing the highest temperature water for injection to
the boiler

Cooling Tower
In order to improve the efficiency of the plant, the steam exhausted from the turbine is
condensedby means of a condenser. Water is drawn from a natural source of supply such as
a river, canal or lake and is circulated through the condenser. The circulating water takes up
the heat of the exhausted steam and it becomes hot. This hot water coming out from the
condenser is discharged at a suitable location down the river. Hot water from the condenser
is passed on to the cooling towers where it is cooled. The cold water from the cooling tower
is reused in the condenser and transported through the injection pipe.

the flow of water from lake to boiler isdescribed as blow.

Didessa river Main Pond Overhead Tank Softening plant

Reservoir tankDeaerator Water feed pump Boiler.

Figure 1 the flow of water from lake to boiler

2.2.6.3 BOILER COMPONENTS

1. Combustion Chamber (Burner)
It’s a place where a combustion takes place and used to gain a heat that used in turns
evaporate the steam from water. Without combustion chamber we can’t get a desired
stream.

There are three types of combustion. Those are incomplete, perfect and complete
combustion. To get a complete combustion the stoichiometry of air, heat and fire must be
equal.

Furnace material is cast iron. Furnace inside layer is made of refractory bricks, grate
and middle is of insulating bricks and outer is of cast iron. Furnace tube material is
Mild Steel (M.S.). Tubes are of M.S. No. A192/A520 ASME (American Standard for
Mechanical Engineers).
Bagasse is used as a fuel for boiler furnaces. Bagasse having 52% moisture is burned.
Bagasse is the final solid product of mill section. Bagasse from the last mill is sent to the
boilers by bagasse elevator.
Air is supplied to furnace by Forced Draft Fan, Secondary Fan, and Induced Draft Fan. The
furnace is operated under negative draft. To produce negative draft Speed Ratio of (F.D. Fan)
: (I.D. Fan) is kept to 1:1.2 ~ 1.5.

Inside the burner there are certain ways or holes used to intake different ingredients such as
air, furnace oil(sprayer.) and bagasse.

There a lot of tubes (bank tubes) mounted on the wall of burner which transport a hotted
water hots in burner.

There are four types of headers available in this section. Those are Front header, two Side
header and Back header.

Front header is the most vulnerable section if the water is low in the boiler b/c it gains a
water from upper drum only.

The rest two headers’ gains water from mud drum.

3.Mud drum

It used to feed a water for lower and back header.

It’s a place where a mud in water is removed.
It has a drainage tube to discharge unwanted water.
4.Feed Water Pump
It’s a type of pump which is used to pump a water from reservoir tank to boiler.
It has four stage b/c if it’s single stage it can’t pump that much pressurized water (r. 24 bar).
So, to pump this water we have to use a four-stage feed pump.
In this plant there is a turbine that operated (run) by steam and its used only during the
emergency time if the water is stopped to transported to boiler during operation time.
Water is the life of boiler. If the boiler can’t get water, it will cause great damage on the plat.
E.g., the tube may be burst.
The speed of this turbine is controlled by the machine called governor. There are two types
of governors those are hydraulic and piston.
Now we are using hydraulic type of governor.

Furnace Oil
Furnace Oil
It used to initiate and ignite the combustion and stored in reservoir tank.
It pumps by gear pump.
There is a dust filter in this plant to trap the dust from oil.
The viscosity of oil is decreased by heat exchanger and its convenient to transport this oil by
gear pump to combustion chamber.
There is a coil in tubes and heat exchanger and which’s used to lowering the viscosity of oil.
Bagasse

Bagasse is the fibrous residue of sugar cane remaining after the extraction of juice. It is well
suited for use as a fuel, having adequate calorific value, is low in ash and virtually free of
environmental contaminants such as sulfur.
The energy content per one-ton bagasse (50% moisture content) is 2.85 GJ.
Bagasse is burnt in suitable boilers to produce steam which in turn is transformed via prime
movers, for example turbines, to mechanical or electrical energy.
2.2.7 PROCESS HOUSE
2.2.7.1 Vapor Line Juice Heaters
After juice accumulator tank, juice comes to the tubes of vapor line juice heater and where it
is heated. Vapor line juice heater is the shell and tube heat exchanger in which heating
media is vapors which are generated by multiple effect evaporators.

Vapor flows in shell side. There are two vapor line juice heaters are installed in the industry.
Only one of them is operated in season.

There are three heaters in this factory and all are differ in each other with their working
temperature

Primary heater…...55oC
Secondary heater…...70oC
Tertiary heater……...115oC

Primary Heaters

After passing through the vapor line juice heater, the juice goes to the primary heaters.

Primary heaters are actually shell and tube heat exchangers. Vapors from the multiple effect

evaporator are the heating media used in the shell side. Juice from vapor line juice heater is

fed to the tube side of the primary heaters. There are five primary heaters are installed in
the

industry. Only three heaters operate during production.

Defecation

Lime (CaO) has remained the universal basic defecant from the beginning. The treatment of
juice with lime is called defecation.

Defecation is carried out in order to raise the Ph value of the juice. It is necessary to

raise the Ph value because at low Ph and high temperature juice decomposes which causes

sucrose losses and it is not feasible for industry. Inversion losses can also take place.

In the industry there are two tanks.

There are three chemicals which are used in FSF for purification of juice in general.
This are:

Lime (Cao); the treatment with lime is called ―defecation‖.

Sulphurous acid; from SO2; treatment with SO2 is called ―Sulphitation‖.

Phosphorous acid; from P2O5; treatment with P2O5 is called ―phosphatation‖

Advantage of lime on juice clarification

Eliminate (neutralize) the organic acid (oxalic acid and tartaric acid).

(i.e.3ca (OH) 2+p2O5 ca3 (p2O5)2+3H2O)

Easily separating of juice from mud.

Advantage of Sulphitation on clarification

Neutralize excess quantity of lime added

(i.e.Ca (OH) 2 + H2SO3 CaSO3 + H2O)

Fast crystallization of sucrose

For whitening of sugar

The mud settles more rapidly (hence improved capacity of clarifiers).

They are less viscous and boil faster (better crystallization in cons

Secondary Heaters

Before defecation process the juice goes to the secondary heaters.

Secondary heaters are shell and tube heat exchangers. Juice from retention tanks is fed to
the

tube side of the secondary heaters. Vapors from the multiple effect evaporators are the
heating

media used in the shell side. There are two secondary heaters are installed in the industry.

2.2.7.2 SRI (Short Return Interval)

It’s a tank where clear juice is separated from the mud juice. The mud is settled down and
the clear juice is gone through the prepared channel.
In this tank there is a device called agitator used to mixed the juice and there is a scrapper
used to clean and guides the clean juices.

The clear juice is goes to clear juice tank and the mud is gone to the mud boot tank.
There are three chemicals which are used in FSF for purification of juice in general.
This are:

Lime (Cao); the treatment with lime is called ―defecation‖.

Sulphurous acid; from SO2; treatment with SO2 is called ―Sulphitation‖.

Phosphorous acid; from P2O5; treatment with P2O5 is called ―phosphatation‖

Advantage of lime on juice clarification

Eliminate (neutralize) the organic acid (oxalic acid and tartaric acid).

(i.e.3ca (OH) 2+p2O5 ca3 (p2O5)2+3H2O)

Easily separating of juice from mud.

AdvaNeutralize excess quantity of lime added

(i.e.Ca (OH) 2 + H2SO3 CaSO3 + H2O)

Fast crystallization of sucrose

For whitening of sugar

The mud settles more rapidly (hence improved capacity of clarifiers).

They are less viscous and boil faster (better crystallization in cons

Mud from the clarifier goes into the Mud Mixer. The main purpose of mud mixer is to

form the thick (viscous) mud, by adding the milk of lime, polyelectrolyte, and bagacillo into
it.

Addition of bagacillo to the mud, is necessary, otherwise vacuum filter will not furnish a
Satisfactory filtration.

2.2.6.1.3. Roll of Phosphate

The phosphate content of the juice is the most important factor in efficient
clarification. In sugar
cane the phosphates are found as inorganic as well as organic forms. It is obvious that
only the

free phosphate ions (inorganic form) take part in juice clarification.

Therefore, the juice with adequate quantity of inorganic phosphate is most desirable.
During

cane growing, if fertilizers are not properly applied, there may be more organic
phosphate in the

juice than inorganic phosphate. Then the juice may not respond well to clarification.

It is demonstrated that the inorganic phosphate level in raw juice is less than 300 ppm,
the juice

can’t be properly clarified and addition of phosphate is required.

The advantages of phosphate adding are:-

Greater colloid elimination

Fewer lime salts in clarified juice

More rapid settling

Faster mud filtration

The disadvantages of phosphate addition

The precipitate tri-calcium phosphate is difficult to filter

Increased mud volume

Higher lime consumption and extra cost

2.2.7.5 OC-Filter
2.2.7.10 Evaporators
Evaporator is an equipment that is used to concentrate the solution by evaporating the

solvent (water).

There are two types of evaporators are used in the industry. Which are following:

1- Falling Film Evaporator (FFE)

2- Multiple Effect Evaporators (MEE)

For our case we I’ll deal (discuss) with the second one.

1.Multiple Effect Evaporator

It is also a type of shell and tube heat exchanger. In this evaporator vapors or steam which is
used for first effect as a heating media will condense and the vapors produced by
evaporation of solution will be used in next effect as heating media, while the same solution
is evaporated in multiple effects. This Process repeats in the remaining effects. Such type of
ten effects is installed in the industry while five of them work for the produced capacity.

Juice enters from the bottom of calandria and after heat exchange it comes back from
central well. Water present in the juice is evaporated and collected from the top and is
further utilized as heating media to the next evaporator. Concentrated juice is collected
from the bottom and it is sent to the next body.

There are four types of evaporator in ADSF and all are differ in temp. Those are;

 First effect
 Second effect
 Third effect
 Fourth effect

Juice discharges as concentrated juice termed as syrup is collected from last body
(evaporator).

2.2.7.11 Pans

Batch Pans
It’s a pan in where the grain is prepared.

Batch pan is an equipment in which syrup concentration is increased by heating it under

vacuum. By increasing temperature vacuum decreases, while by decreasing temperature

vacuum increases.

The syrup is sent to A-Batch Pan A1-Molasses and B-Sugar is added into

it which improves the rate of nucleation. In the pan the mixture is boiled through vapors
under
vacuum. In the similar way A-Heavy after dilution is sent to the B-Batch pan where it is
mixed

with c-seed and the mixture is heated with vapors under vacuum. B-Heavy after dilution is
sent

to the C-Batch pan where it is mixed with c-light and the mixture is heated with vapors
under

vacuum. Vapors from 2nd effect are used for heating purposes.

Continuous Pans
It’s a pan in where the prepared grain is growth.

Continuous pans are used in which further syrup vaporization is achieved by heating with
vapors under vacuum.

Syrups after batch pans are sent to their corresponding continuous pans for further
vaporization.

2.2.7.12 Crystallizers
There are two main types of crystallizers:

1- Horizontal crystallizer

2- Vertical crystallizer

1.Horizontal Crystallizer

The crystallizer, horizontal in shape with open top side is called horizontal crystallizer.

The crystallization process consists of two major events, nucleation and crystal growth.

Nucleation is the step where the solute molecules dispersed in the solvent start to gather
into clusters that become stable under the current operating conditions.

The crystal growth is the subsequent growth of the nuclei that succeed in achieving the
critical cluster size. Nucleation and growth continue to occur simultaneously while the
supersaturation exists. Supersaturation is the driving force of the crystallization hence the
rate of nucleation and growth is driven by the existing supersaturation in the solution.

2.Vertical Crystallizer
Vertical crystallizer is used in cane sugar industry for efficient sugar crystallization from low-
purity crystal suspensions. In this factory the vertical crystallizer is out function.

2.2.7.13 Pug Mills

After crystallizers their respective massecuites are sent to the respective pug mills.

The main purpose of pug mill is to prevent the massecuite from solidifying by the mixing
process, through rotating shaft on which the rods are fixed.

2.2.7.14 Remelter
After A-centrifuge, A-sugar is sent to the remelter and wasted sugar is also added in the
remelter. This remelter melts both sugars and makes a homogeneous mixture. This mixture
is sent to the buffer tank.

2.2.7.15 Buffer Tank

The main purpose of the buffer tank is to give the residence time to make the mixture
homogeneous. The entering temperature to the buffer tank is 70°C.

2.2.7.16 Baby Heater

After buffer tank the mixture goes to the baby heater. The main purpose of the heater is to
heat up the mixture. The entering temperature of the mixture is 68°C and the outer
temperature is approximately 80 to 85°C.

2.2.7.17 CENTRIFUGAL MACHINE

It’s a rotating machine used forseparation of sugar crystal from mother liquor (crystal from
molasses). They separate the phases by filtration using centrifugation process. The walls of
the centrifuge basket are porous, and the liquid filters through the deposited cake of solids
and is removed. After pug mill massecuites are sent to centrifugal machines for separation of
crystals from mother liquor.

There are two types of centrifugal machine used in ADSF. Those are;

1. Batch Centrifugal
2. Continuous Centrifugal

1. Batch centrifugal machine

Batch Centrifuges are filtration machines used to separate sugar mesquite into its
constituent crystals and mother liquor under the action of centrifugal force. The product is
processed in a cylindrical perforated basket fitted with filtering screens which is hung on the
bottom end of a long spindle

2. continuous centrifugal machine

As this name implies this type of centrifugal machines are used to cure continuously low
grade massecuite of high viscosity at constant speed of 1500 – 2000 rpm. The centrifugal is
fed continuously by the massecuite and the cured sugar is discharged continuously at high
speed.

2.2.7.18 Sugar Grader

Sugar grader is used to separate the different sizes sugar crystals for market and industrial
operation demands.

2.2.7.19Dryer
Drier is used to dry the final product sugar crystals with the help of steam.

2.2.7.20 Hopper
Hopper is used to supply the final sugar to packaging section.

2.2.7.21Bucket Elevator
It’s a type of conveyor which is used to transport the produced sugar from hopper to sugar
bin.

2.2.7.22Packaging
After hopper sugar is packed into 50 kg bags. Manual packaging is used and it is closed by
sewing machine.

2.2.7.23 Store
It’s a place where the final product (Refine or White sugar) is stored and transported by belt
conveyor.