INPUT DATA

Page - 1 / 33
355 tch

Defeco melt phosflotation process

INPUT DATA
1 Milling rate - To give value - tch 550.00
- Calculated - TCD 12100
2 Cane -pol % 14.50
-fibre% 18.00
3 First expressed juice -bx 21.44
-purity 89.50
4 Mixed juice -purity 88.00
5 Last mill juice -purity 75.00
Delta purity PJ to MJ 1.50
6 Imbibition -%fibre 240.00
Mud solids in mixed juice - % cane 0.42
7 Bagasse -pol% 1.80
-moisture% 50.00
8 Quick lime [80% purity] -%cane 0.10
- purity 90.00
9 Milk of lime -beaume 5.00
10 Commercial sulphur -purity 99.50
-%cane 0.00

11 Bagacillio mill wet(50% moist -kg/tch 10.00

Clarifier underflow % limed juice 0.15
12 Filter cake mud solids -%cane 0.42
13 Filter cake moisture -%cane 75.00
14 Pol % filter cake 1.70
15 Filter wash water
16 -Qty %dry matter 150.00
Clear juice - brix 14.00
- Purity 88.00
17 Syrup -brix 78.00
18 Purity product raw sugar 99.50
B + C Melt brix with water addition 70.00
Raw Melt brix with water addition 63.00
Concentrated Melt Brix 72.00
Final Scum Pol 1.50
Final Scum Moisturre 75.00
19 Massecuite Brix Purity
A-massecuite 90.00 91.71
B-massecuite 96.00 78.00
C-massecuite 100.00 58.30

20 Molasses Brix Purity

A-Heavy 82.00 78.00
A-Light 78.00 93.71
B-Heavy 85.00 57.00
B-Light
C-Light 80.00 63.00
Final Molasses 88.00 35.00
Brix Purity
21 C-Fore sugar 96.00 82.00
C- Fore magma 90.00 -
C- After sugar 96.00 94.00
C- After magma 90.00 -
Brix Purity
22 B- Fore sugar - 95.00
B- Fore magma 90.00 -
B- After sugar -
B- After magma 90.00 -

23 C- grain 63.00

24 A fore sugar - Reference purity 98.00

25 Is Clear juice used for melting Y/N 1/0 0.00

Raw Sugar Moisture 0.10

26 B+C sugar magma brix 90.00
27 Dust & rori sugar magma brix 90.00

28 A light boiled in B massecuite in % 100.00

C light boiled in B massecuite in % 0.00
29 Percentage of B seed for A fo - % Cane 100.00
30 Footing crystal size nm 350.00
31 Pan graining volume % 36.00
32 Required crystal size product sugar:
33 A. Small, nm (S grade) 600.00
34 , % of total A-sugar 100.00
35 B. Small, nm (M grade) 800.00

36 Unknown losses % cane 0.10

37 Percentage of sugar to be refined 100.00

CAS for B massecuite ( 1 / 0) 0.00

B sugar for A (1 / 0) 0.00

04/23/2024
DANGOTE SUGAR LTD.,
MATERIAL BALANCE Annexure - III
Nasarawa Sugar Project RECOVERY HOUSE Page-1 of 33

SUMMARY
Crushing rate -tch 550
-TCD ### 22.00 hrs

A Sugar Melted for refining 94.04 t/h

Sugar melted for refining 94.04 t/h = 2068.95 t/day
Refined sugar bagged 83.31 t/h = 1832.85 t/day

Material % cane t/h m3/h pol % Fibre % Moist. %

1 Cane 100.00 550.00 14.5018.00

2 Bagasse 37.82 207.98 1.8047.60 50.00
3 Imbibition 43.20 237.60 237.60 240.00
% on fibre
% cane t/h m3/h Pol % Brix % Purity
Primary Juice 19.19 21.44 89.50
4 Mixed Juice 104.96 577.31 544.63 13.17 14.96 88.00
5 Quick Lime 0.09 0.50
6 Milk of Lime 2.03 11.15 10.75
7 Sulphur 0.00 0.00
8 Sulphur Dioxide 0.00 0.00 0.00
9 Air for Sulphur Burning 0.00
10 Filter Cake 13.22 72.69
11 Filter Wash Water 4.96 27.26 27.26
12 Filtrate 10.34 56.86 55.75
13 Raw Juice 104.96 577.31 544.63
14 Limed Juice 117.33 645.32 620.50
15 Clear Juice to Evaporators 102.57 564.13 537.26 13.25 15.06 88.00
16 Syrup 26.06 143.31 108.57 78.00
17 Melt 5.14 28.25 21.40 70.00 94.54

Pan Floor Material: Solids %C Qty t/h Brix % Pol % Purity Qty % ca

18 A Massecuite 26.81 163.85 90.00 82.54 91.71 29.79

19 B Massecuite 9.68 55.43 96.00 74.88 78.00 10.08
20 C Massecuite 5.40 29.72 100.00 58.30 58.30 5.40
Total Massecuite % Cane 45.27

21 A Heavy Molasses 9.71 65.15 82.00 63.96 78.00 11.85

22 A Light Molasses 0.00 0.00 78.00 73.09 93.71 0.00
23 B Molasses 4.33 28.01 85.00 48.45 57.00 5.09
24 C Light Molasses 1.04 7.13 80.00 50.40 63.00 1.30
25 Final Molasses 2.72 17.03 88.00 30.80 35.00 3.10

Raw Sugar 17.0988 94.14 99.90 99.40 99.50 17.12

26 B Magma 5.35 32.68 90.00 85.50 95.00 5.94
27 C After Magma 1.64 10.03 90.00 84.60 94.00 1.82
28 C Fore magma 2.68 16.37 90.00 73.80 82.00 2.98

29 SUGAR BALANCE: % Cane 30 EXTRACTION: % Cane

Draft
DANGOTE SUGAR LTD.,
MATERIAL BALANCE Annexure - III
Nasarawa Sugar Project RECOVERY HOUSE Page-2 of 33

Sugar in Cane 14.50 Mill Extraction 95.31

Sugar in Mixed Juice 13.82 Reduced Mill Extraction 96.94
Sugar in Bagasse 0.68 Boiling House Recovery % C 90.03
Sugar in Filter Cake 0.22 Reduced Boiling House Recov 87.09
Sugar Added by R3 molasses 4.37 Reduced Boiling House Recov 87.90
Sugar in Final Molasses 0.95 Overall Extraction 85.80
Sugar Undetermined in raw sugar house 0.10 Reduced Overall Extraction 84.43
Total Losses in raw sugar house 1.96

Net Sugar recovery 12.54

Draft
DANGOTE SUGAR LTD.,
MATERIAL BALANCE Annexure - IV
Nasarawa Sugar Project REFINERY Page-3 of 33

SUMMARY Sugar colour after blending 44 IU

% Raw
Material t/day t/h Brix Colour
Sugar

Raw Sugar 100.00 2071.02 94.14 900

Hydrated Lime 0.04 0.77 34.84 Kg/h
Milk of Lime 0.35 7.23 328.68 Kg/h
Phosphoric acid 0.028 0.575 26.13 Kg/h
Talofloc 0.020 0.414 18.83 Kg/h
Taloflote 0.001 0.021 0.94 Kg/h

Total dilution water for scum dilution 13.82 286.12 13.01

Sweet Water 29.73 615.78 27.99 1200
Press Cake 0.66 13.63 0.62
Raw melt 175.57 3636.02 165.27 63.00 720
Fine liquor 159.74 3308.31 150.38 62.01 390
Concentrated Liquor 137.05 2838.31 129.01 72.00 150

Solids
Qty % Qty
Pan Floor Material: %Raw Qty t/day Brix Qty t/day Pty Colour
raw sugar %cane
Sugar

R-1 Massecuite 102.25 2117.70 88.00 2406.48 99.51 116.20 160 19.89
R-2 Massecuite 51.13 1058.85 88.00 1203.24 99.09 58.10 350 9.94
R-3 Massecuite 25.56 529.43 89.00 594.86 98.26 28.72 760 4.92
R-4 Massecuite 0.00 0.00 91.58 0.00 0.00 0.00 0.00
Total massecuite % Raw sugar 203.02 34.75

R-1 Run-off 51.13 1058.85 70.00 1512.64 99.09 73.04 310

R-2 Run-off 25.56 529.43 70.00 756.32 98.26 36.52 640
R-3 Run-off 12.78 264.71 70.00 378.16 96.59 18.26 1370
R-4 Run-off 0.00 0.00 70.00 0.00 0.00 0.00

R-1 Sugar 51.13 1058.85 99.97 1059.17 99.93 51.14 20.00

R-2 Sugar 25.56 529.43 99.97 529.58 99.93 25.57 50.00
R-3 Sugar 12.78 264.71 99.97 264.79 99.93 12.79 150.00
R-4 Sugar 0.00 0.00 99.97 0.00 99.00 0.00
Sugar recirculated 3.58 74.12 99.97 74.14 99.93 3.58
Unknown losses 1.00 20.71 99.97 20.72 99.93 1.00
Product refined Sugar 84.89 1758.16 1758.69 84.92
Sugar in R3 molasses sent to Recover 12.20 252.76
Scum going out 10.62 219.86 9.99

Draft
J.P.MUKHERJI & ASSOCIATES P. LTD.
Annexure - C
Renuka Sugars EVAPORATOR CALCULATIONS Page - 4 / 33
1.0 Basic Parameters As on 22 - 03 - 07
Factory crushing rate tch 550
Imbibition % fiber 240
t/h % cane
Raw juice 577.31 104.96
Sulphured juice 645.32 117.33
Clear juice 564.13 102.57
brix 15.06
Syrup brix required brix 78.00
Melt Brix brix 70.00
Condensate Flash Yes

2.0 Pan floor steam requirement at minimum demand t/h % cane

Vapour bleeding for A-pans 31.41 5.71 From Exhaust
Vapour bleeding for B1-pans 17.08 3.11 From Exhaust
Vapour bleeding for B2-pans 0.00 0.00 From Exhaust
Vapour bleeding for C-pans 11.14 2.03 From Exhaust
Vapour Bleeding for Refinery Pans 0.00 0.00
Variable Pan Demand met from exhaust 13.75 2.50
Pan Washing 0.00 0.00 From Exhaust
Superheated wash water 0.00 0.00

Total Pan floor steam demand 73.39 13.34

3.0 Exhaust Steam DEVC Quad

- Pressure kg/sq.cm (g) 1.31 1.31
- Temperature Deg C 124.67 124.67

4.0 Juice heaters bleeding Effect Heating (Deg C) Quantity

From To t/h % cane
Raw juice heating stage-1 Effect 4 30.00 50.00 19.05 3.46
Raw juice heating stage-2 Effect 3 50.00 65.00 14.29 2.60
Treated juice heating stage-1 Effect 2 65.00 82.00 19.01 3.46
Treated juice heating stage-2 Effect 1 82.00 103.00 23.82 4.33
Clear juice heating stage-1 Effect 1 95.00 103.00 7.93 1.44

Filtrate Heating 65.00 65.00

Melt Heating VC 2
Total 84.10 15.29
5.0 Evaporation
Total evaporation % cane 82.76
t/h 455.20
Evaporation by DEVC t/h 0.00 0.00%
Evaporation by Quadruple set t/h 455.20 ###
DEVC Quadruple
VC-1 VC-2 Eff-1 Eff-2 Eff-3 Eff-4
Evaporation from each body t/h 0.00 0.00 178.82 135.93 72.06 68.39
% cane 0.00 0.00 32.51 24.71 13.10 12.43
Condensate flow from each body t/h 0.00 0.00 176.95 134.71 71.60 67.96
Evap. condensate available for flash t/h 0.00 0.00 0.00 134.71 238.06 67.96
Juice heater condensate for flash t/h 0.00 0.00 0.00 31.75 19.01 0.00
Pan condensate for flash t/h 0.00 0.00 0.00 0.00 59.64 0.00
Total condensate for flash t/h 0.00 0.00 0.00 166.46 313.08 370.41

Juice flow from each body t/h 564.13 564.13 385.30 249.37 177.32 108.93
Outlet brix 15.06 15.06 22.05 34.07 47.92 78.00
Average brix 15.06 15.06 18.56 28.06 40.99 62.96

Quantity of heat loss, t/hr 0.00 0.00 0.00 0.00 0.00 0.00
n1 n2 n3 n4

Quantity of vapour lost with NCG 0.00 0.00 0.00 0.00 0.00 0.00

Quantity of Juice flash vapours, t/hr 0.00 0.00 0.00 0.00 0.00 0.00
f1 f2 f3 f4

Quantity of Condensate flash vapours ,t/hr 0.00 0.00 0.00 0.00 3.63 10.62
v2 v3 v4

Quantity of vapours for evaporation , t/hr 0.00 0.00 0.00 0.00 3.63 0.00

Evaporator Bodies
Set - A Sq. m 1600 2600 1200 1100 1100 1100

Standby body Sq. m 1400 2600 1100 1100 1100 1100

Sq. m
Heating surface for Calculation Sq. m 1600 2600 1200 1100 1100 1100

Specfic evaporation kg/sq.m/h 0.00 0.00 149.02 123.57 65.51 62.17

lb/sq.ft/h 0.00 0.00 30.52 25.31 13.42 12.73
Dessin coefficient kg/h sq.m. oC 5.47 4.92 4.72 2.01 -1.36 0.51
Overall H.T.Coeffecient Btu/h.sq ft. oF 0.00 0.00 488.33 213.67 -161.86 56.49

Apparent temp. drop Deg C 0.00 0.00 31.57 61.56 -48.30 122.53
True temp. drop Deg C 0.40 0.60 33.07 63.56 -45.30 127.03
Vapor temperature, oC 124.27 123.67 91.60 28.04 73.34 -53.69
Pressure in each body, bara 2.31 2.27 0.76 0.05 0.37 1.18
Vacuum in inch Hg 6.97 27.68 18.36

Total temperature drop calculated Deg C 1.00 178.36

Total temperature drop available Deg C 19.50 64.40

6.0 Steam consumption

t/hr % cane Alternative Representation
Exhaust steam for evaporators(Quad
evaporators(VC1 exhaust) 0.00 0.00 t/hr % cane
exhaust) 178.82 32.51 Juice Heating 84.10 15.29
Exhaust steam for juice heaters & other 0.00 0.00 Pans 73.39 13.34
Pan Steam demand met with Exhaust 13.75 2.50 Evaporator 49.34 8.97
Process Exhaust steam demand 192.57 35.01 Process 192.57 35.01
Deaerator 0.00 0.00 Deaerator 0.00 0.00
Losses @ 1 % on total demand 1.95 0.35 Losses 1.95 0.35
Total Exhaust steam demand 194.52 35.37 Total Exhaust 194.52 35.37

Live steam for process 11.00 2.00

Total Process steam demand 205.52 37.37
J.P.MUKHERJI & ASSOCIATES PVT. LTD
Evaporator Calculations with steam economy measures
Renuka Sugars System : DEVC + Quad Annexure - B2
Page - 5/33
#REF!
T.J. O/L

SJ - 2
103.00 #REF!
CJ O/L 82 0C
T.J. I/L T.J. O/L 65 0C
CJH - 1 st
#REF! RJ O/L
7.93 #REF! 19.01 t/h SJ - 1 19.01 t/h
103 0C RJH-1
CJ O/L CJ I/L
95 0C T.J. I/L 14.29
0.00 t/h C.J.H 2nd #REF! ### 65 0C RJ I/L
645.32 t/h 50 0C
CJ I/L C Pans 11.14 t/h
103 0C Pan Wash. 0.00 t/h Filtrate 0.00 t/h
B Pans 17.08 t/h
Ref. Pans 0.00 t/h A Pans 31.41 t/h
Raw Melt 0.00 t/h 135.93
68.43 57.77
0.00 t/h 0.00 t/h 178.82 t/h 135.93 t/h 72.06 t/h 68.39 t/h
115.67 0C 105.17 0C 115.56 0C 104.26 0C 88.94 0C 60.27 0C
VC1 VC2 Q1 ### Q2 Q3 10.62 Q4
Exhaust 0.00 t/h 1600 sqm 0.00 2600 sqm 1200 sqm 1100 sqm 72.06 1100 sqm ###
2.30 bara sp.evap.rate -kg/hr.m2 0.00 0.00 149.02 123.57 3.63 t/h 65.51 62.17
124.67 Deg.C H.T.C - kg /hr.m2.0C 0.00 0.00 1937.82 847.91 -642.29 224.16
Calandria pr. kg/cm2 (a) 2.30 1.73 2.30 1.72 1.17 0.67
0.00 176.95 71.60
0.00 134.71
V.P.demand 564.13 t/h 385.30 t/h 249.37 t/h 177.32 t/h Syrup
0.00 t/h J flash 15.06 bx 22.05 bx J.Flash 34.07 bx J.Flash 47.92 bx 108.93 t/h
Juice 564.13 t/h #REF! #REF! #REF! 78.00 bx
Clear Juice 15.06 bx To Q1
564.13 t/h 0.00 t/h 0.00 t/h ### ### ###
15.06 bx 121 0C 112 0C 122 0C 112 0C 99 0C
103 0C Pan cond. 0.00 t/h
JH cond 0.00 t/h Pan cond #REF! Pan cond 0.00 t/h Pan Cond 59.64 Recirc.Co
VC-2 cond 0.00 t/h JH cond #REF! JH cond 31.75 t/h JH cond 19.01
Condensate Heating Q3 cond #REF! VC2 cond 0.00 t/h Recirc. Con 162.83
Recirc cond 0.00 t/h Recirc cond0.00 t/h
Quint 2nd Condensate Condensate from CPU
0.00 t/h 30 0C
#REF! Exhaust ### Treated.J.I.L
2.30 bara #REF!
Condensate to hotwell To Polishing Unit 125 0C
#REF! #REF!
PHE #REF! #REF!

Overall Exhaust balance t/h % cane #REF!

Exhaust steam to VC1 + Quad 1st 178.82 32.51 Flue gas LPE Flue Gas PHE
Exhaust steam for clear juice heaters 0.00 0.00 #REF! #REF!
Exhaust steam directly for Pans 0.00 0.00 #REF! #REF!
Exhaust steam for variable pan steam deman 0.00 0.00 #REF! kg/kg Cond. Outlet
Process Exhaust steam demand 192.57 35.01 to Imbibition
CRUSH RATE ----------------------- 550.00 tch
Exhaust for Deaerator 0.00 0.00 IMBIBITION -------------------------- 240.00 % FIBRE Condensate Treated .J. O/L
Losses at 1% of total demand 1.95 0.35 RAW JUICE -------------------------- 104.96 % CANE #REF! #REF!
Total Exhaust demand 194.52 35.37 TREATED JUICE ------------------- 117.33 % CANE #REF! #REF!
J.P.MUKHERJI & ASSOCIATES P. LTD.
MATERIAL BALANCE - Raw Sugar
340 tch
Sai Krupa. Page - 1 /33

Crushing rate -tch 550

-TCD 12100 in 22 hrs
-TCD 13200 in 24 hrs

Raw Sugar Melted for refining 81.13

R4 Sugar recycled for melting 0.00
Sugar melted for refining 81.13 t/h = 1784.76 t/day
Sugar bagged from cane mill sugar plant 0.00 t/h = 0 t/day
Refined sugar bagged 68.87 t/h = 1515 t/day

Material % cane t/h cu m/h pol % Fibre % Moist. %

1 Cane 100.00 550.00 14.50 18.00

2 Bagasse 37.82 207.98 1.80 47.60 50.00
3 Imbibition 43.20 237.60 237.60 240.00
% on fibre
% cane t/h cu m/h Pol % Brix % purity
4 Mixed Juice 104.95 577.25 544.58 13.17 14.96 88.00
5 Quick Lime 0.08 0.44
6 Milk of Lime 1.13 6.21 5.95
10 Filter Cake 4.30 23.67
11 Filter Wash Water 1.61 8.88 8.88
12 Filtrate 13.81 75.97 74.48
13 Raw Juice 104.95 577.25 555.05
14 Treated Juice 119.90 659.44 634.07
15 Clear Juice to Evaporators 103.35 568.43 541.36 13.30 14.98 88.78
16 Syrup 22.53 123.94 93.90 78.00
17 Melt 5.43 29.87 22.63 70.00 94.63

Pan Floor Material: Solids %C Qty t/hr Brix Pol Pty Qty % cane exhaustion

18 A Massecuite 29.27 178.88 90.00 82.47 91.64 32.52 67.64

19 B Massecuite 9.28 53.14 96.00 74.88 78.00 9.66 62.61
20 C Massecuite 5.18 28.49 100.00 58.30 58.30 5.18 61.49
Total Massecuite % Cane 47.37

21 A Heavy Molasses 9.31 62.46 82.00 63.96 78.00 11.36

22 A Light Molasses 5.17 36.46 78.00 73.09 93.71 6.63
23 B Molasses 4.15 26.85 85.00 48.45 57.00 4.88
24 C Light Molasses 0.99 6.83 80.00 50.40 63.00 1.24
25 Final Molasses 2.61 16.33 88.00 30.80 35.00 2.97

26 B Magma 5.13 31.33 90.00 85.50 95.00 5.70

27 C After Magma 1.57 9.62 90.00 84.60 94.00 1.75
28 C Fore magma 2.57 15.69 90.00 73.80 82.00 2.85

29 SUGAR BALANCE: % Cane 30 EXTRACTION: % Cane

Sugar in Cane 14.50 Mill Extraction 95.31
Sugar in Mixed Juice 13.82 Reduced Mill Extraction 96.94
Sugar in Bagasse 0.68 Boiling house recovery % Cane 90.00
Sugar in Filter Cake 0.07 Reduced boiling house recovery 87.05
Sugar Added by R3 molasses 0.00 Overall Extraction 85.77
Sugar in Final Molasses 0.91 Reduced Overall Extraction 84.39
Sugar Undetermined in raw sugar hous 0.08 0.00
Total Losses in raw sugar house 1.75
Net Raw sugar recovery 12.75

Sugar loss in refinery 98.16%

Total Losses across refinery 0.24 1.98 0.24

Sugar in Sugar (Refinary) 12.52

 MATERIAL BALANCE
FOR INTEGRATED REFINERY Page - 2/33
Carbonation Process

SUMMARY

Material % Raw Sugar t/day t/h bx % purity

Raw Sugar 100.00 1784.76 81.13

Hydrated Lime 0.13 2.25 0.10
Milk of Lime 1.23 21.87 0.99
Carbon Dioxide 2.679 47.815 2.17
0.00
Total dilution water for cake slucing 12.63 225.33 10.24
Press Cake 0.41 7.28 0.33
Raw melt 154.48 2757.17 125.33
Fine liquor 153.60 2741.31 124.61

Pan Floor Material: Solids %Raw Qty t/day Brix Qty t/dayPty Qty % raw sugar

R-1 Massecuite 101.92 1819.10 90.00 2021.23 99.61 113.25

R-2 Massecuite 50.96 909.55 90.00 1010.61 99.28 56.62
R-3 Massecuite 25.48 454.78 90.00 505.31 98.62 28.31
R-4 Massecuite 0.00 0.00 90.00 0.00 97.30 0.00
Total massecuite % Raw sugar 198.19

R-1 Run-off 50.96 909.55 70.00 1299.36 99.28 72.80

R-2 Run-off 25.48 454.78 70.00 649.68 98.62 36.40
R-3 Run-off 12.74 227.39 70.00 324.84 97.30 18.20
R-4 Run-off 0.00 0.00 70.00 0.00 94.65 0.00

R-1 Sugar 50.96 909.55 909.55 99.94 50.96

R-2 Sugar 25.48 454.78 454.78 99.94 25.48
R-3 Sugar 12.74 227.39 227.39 99.94 12.74
R-4 Sugar 0.00 0.00 0.00 99.94 0.00

Sugar recirculated 3.32 59.33 59.33 99.94 3.32

Unknown losses 1.00 17.85 17.85 99.94 1.00
Product refined Sugar 84.86 1514.53 1514.53 84.86
Sugar in R3 molasses sent to raw plant 12.74 227.39

Refinery crystal yield % 84.86

Refinery yield % 97.60
DANGOTE SUGAR LTD., EVAPORATOR BALANCE Annexure - V

Nasarawa Sugar Project Page - 3/33

Basic Parameters
Factory crushing rate tch 550 22 hrs
Imbibition % fiber 240
t/h % cane
Raw juice 577.31 104.96
Treated juice 654.59 119.02
Clear juice 584.49 106.27
Clear juice brix 14.54
Syrup brix required brix 78.00
Condensate flash YES

Pan floor Steam Requirement at Average Demand t/h % cane

- A Batch Pans 20.42 3.71 From Effect - 3
- A Grain Pans 10.99 2.00 From Effect - 3
- Refinery Pans 45.68 8.31 From Effect - 3
- B Pans 11.10 2.02 From Effect - 3
- B Grain Pans 5.98 1.09 From Effect - 3
- C Pans 7.24 1.32 From Effect - 3
- C Grain Pans 3.90 0.71 From Effect - 3
- Total 105.32 19.15
Exhaust for varible pan stm. demand 0.00 0.00 From Exhaust
- Melt Evaporator 11.00 2.00 From Effect - 3
- Pan Washing 5.50 1.00 From Effect - 1
- Molasses Conditioning 1.98 0.36 From Effect - 3
- Run off Conditioning 0.00 0.00 From Exhaust
- Sugar Melting (B + C Sugar) 0.00 0.00 From Effect - 3
- SHHW System 0.00 0.00 From Effect - 1
- Sugar Drying 1.23 0.22 From Effect - 1

Total Pan Demand 125.02 22.73

Juice Heaters Bleeding Effect Heating ( 0C) Bleeding Quantity

From To t/h % cane
Raw Juice Heating Stage - 1 Effect - 5 Tubular 30.00 35.00 4.74 0.86
Raw Juice Heating Stage - 2 Condensate PHE 35.00 61.07 0.00 0.00
Raw Juice Heating Stage - 3 Effect - 4 DCH 61.07 72.00 9.27 1.69

Sulphited Juice Heating Stage - 1 Condensate PHE 70.00 81.02 0.00 0.00
Sulphited Juice Heating Stage - 2 Effect - 3 Tubular 81.02 91.37 11.66 2.12
Sulphited Juice Heating Stage - 3 Effect - 3 DCH 91.37 95.49 3.93 0.71
Limed Juice Heating Stage - 4 Effect - 2 DCH 95.49 103.00 7.15 1.30
Clear Juice Heating Stage - 1 Effect - 2 PHE 95.00 103.82 8.99 1.63
Clear Juice Heating Stage - 2 Effect - 1 PHE 103.82 112.52 8.96 1.63

Melt Heating Effect - 3 DCH 55.00 75.00 1.06 0.19

Syrup Heating Effect - 3 Tubular 61.63 61.63 0.00 0.00
Raw Sugar Melting Effect - 2 DCH 50.00 75.00 4.01 0.73
Raw Melt Heating Effect - 3 DCH 70.00 83.00 3.88 0.71
Clear Melt Heating Effect - 8 PHE 80.00 103.00 0.00 0.00
Sweet Water Heating Effect - 8 DCH 50.00 75.00 0.00 0.00

Total 63.65 11.57

DRAFT
DANGOTE SUGAR LTD., EVAPORATOR BALANCE Annexure - V

Nasarawa Sugar Project Page - 4/33

Evaporation
Total evaporation % Cane 86.46
t/h 475.56

Exhaust Quint - 1 Quint - 2 Quint - 3 Quint - 4 Quint - 5

Pressure Bara 2.30 1.83 1.38 0.95 0.54 0.16
Temperature 0
C 124.67 117.52 108.82 98.49 83.58 55.45

Evaporation from each body t/h 179.50 152.59 135.35 0.74 7.38
% Cane 32.64 27.74 24.61 0.14 1.34
Condensate from each body t/h 177.45 150.98 134.10 0.74 7.37
Juice heater condensate available for
t/h 0.00 8.96 8.99 11.66 9.27
flash
Pan condensate available for flash t/h 0.00 0.00 0.00 116.31 0.00
Condensate for flashing t/h 0.00 149.94 290.72 413.94 416.78
Condensate temperature in Cigar 0
C 121.98 108.82 98.49 83.58 83.43

Juice flow from each body t/h 584.49 404.99 252.40 117.05 116.31 108.93
Outlet brix 0
Brix 14.54 20.98 33.66 72.59 73.05 78.00
Average brix 0
Brix 17.76 27.32 53.13 72.82 75.53

Correction due to latent heat difference t/h 1.92 2.01 2.29 0.02 1.00
Quantity of heat loss due to radiation t/h 1.78 0.76 0.67 0.00 0.02
Qty of Heat loss due to non condensiblet/h 2.39 2.03 1.80 0.01 0.15
Quantity of Juice flash vapours t/h -5.11 5.41 3.50 2.14 4.77
Quantity of Condensate flash vapours t/h 0.00 2.31 5.49 13.80 13.90
Quantity of Flash vapours for evaporati t/h -11.21 2.91 4.22 15.91 0.00

Heating Surface (Working Set) m2 4500 4500 4500 1500 1500

4500 4500 4500 0 0
Heating Surface (Working Set) in Operam2 9000 9000 9000 1500 1500
Specific evaporation rate Kg/ m2/ h 19.94 16.95 15.04 0.50 4.92
lb/ ft2/ h 4.08 3.47 3.08 0.10 1.01

Specific Evaporation Rate (Targeted) lb/ ft2/ h 5.00 3.70 3.00 2.00 2.00
Specific Evaporation Rate (Targeted) Kg/ m2/ h 24.41 18.07 14.65 9.77 9.77
Required Heating Surface (As Targetedm2 7360 8450 9250 80 760

Dessin coefficient Kg/ m2/ h 0C 3.98 2.93 1.50 0.64 0.34

Overall H.T.Coefficient W/ m2 0K 2252 1610 769 52 158
BTU/ ft2 0F 396.56 283.52 135.51 9.11 27.88

Apparent temperature drop 0

C 5.01 5.78 10.02 0.77 14.29
True temperature drop 0
C 5.44 6.53 12.29 6.13 20.46

Vapour temperature 0
C 124.67 119.23 112.70 100.41 94.29 73.82
Pressure in each body bara 2.30 1.98 1.60 1.05 0.84 0.37
Pressure in body Bar (g) 1.27 0.94 0.57 0.02
Vacuum in body Inches of Hg 4.66 18.14
Flap valve to reduce the pressure ∆t 0.00 0.00 0.00 0.00 0.00

Total temperature drop calculated 0

C 50.85
Total temperature drop available 0
C 69.22

Exhaust Steam consumption t/h % cane t/h % cane

Exhaust steam to Effect - 1 181.26 32.96 JH 63.65 11.57

Exhaust steam for Raw Juice Heater 0.00 0.00 Pans 125.02 22.73
Exhaust steam for Sulphured Juice Heater 0.00 0.00 Evap 2.47 0.449
Exhaust steam for Clear Juice Heaters 0.00 0.00 Flash -11.66 (2.121)
Exhaust steam for Pans 0.00 0.00 lat.ht diff 1.77 0.321
Exhaust steam for SHHW System 0.00 0.00
Exhaust steam for Sugar drying 0.00 0.00
Process Exhaust Steam Demand 181.26 32.96 181.25 32.95

DRAFT
DANGOTE SUGAR LTD., EVAPORATOR BALANCE Annexure - V

Nasarawa Sugar Project Page - 5/33

Exhaust for evaporator soda boiling 2.00% 3.70 0.67 3.70 0.67
Losses & other uses @ ….on total de 0.00% 0.00 0.00 0.00 0.00
Total Exhaust Steam Demand 184.96 33.63 184.95 33.63

DRAFT
J.P.MUKHERJI & ASSOCIATES P. LTD
Annexure - V
EVAPORATOR CALCULATIONS Page - 6
Bhogpur - Punjab
Bhogpur
Basic Parameters
Factory crushing rate tch 550
Imbibition % fiber 240
t/h % cane
Raw juice 577.31 104.96
Sulphured juice 656.93 119.44
Clear juice 609.45 110.81
Clear juice brix 13.74
Syrup brix required brix 78.00
Condensate flash YES

Pan floor steam requirement at minimum demand t/h % cane

- A Pans 31.41 5.71 From Effect - 3
- B Pans 17.08 3.11 From Effect - 2
- C Pans 11.14 2.03 From Effect - 2
- Refinery Pans 45.68 8.31 From Effect - 2
- Total 105.32 19.15
Exhaust for variable pan stm. demand 0.00 0.00 From Exhaust
- Melt Concentrator 13.36 2.43 From Effect - 3
- Molasses Conditioning 0.84 0.15 From Effect - 2
- Pan Washing 5.50 1.00 From Effect - 1
- Superheated Wash Water System 1.81 0.33 From Exhaust
- Sugar Drying 0.84 0.15 From Exhaust

Total pan demand 127.67 23.21

Exhaust Steam
- Pressure Bara 2.30
- Temperature Deg C 124.67

Juice heaters bleeding Effect Heating (Deg C) Bleeding Quantity

From To t/h % cane
Raw juice stage - 1 Effect - 5 TUBULAR 30.00 45.00 14.29 2.60
Raw juice stage - 2 CONDENSAPHE 45.00 58.30 0.00 0.00
Raw juice stage - 3 Effect - 4 DCH 58.30 72.00 11.61 2.11
Raw juice stage - 4 72.00 72.00 0.00 0.00

Suphured juice stage - 1 Effect - 3 DCH 68.00 95.00 25.81 4.69

Suphured juice stage - 2 Effect - 2 DCH 95.00 103.00 7.90 1.44
Suphured juice stage - 3 103.00 103.00 0.00 0.00
Suphured juice stage - 4 103.00 103.00 0.00 0.00

Clear juice stage - 1 Effect - 1 PHE 95.00 110.00 16.11 2.93

Clear juice stage - 2 Exhaust PHE 110.00 118.20 8.80 1.60
Clear juice stage - 3 118.20 118.20 0.00 0.00

Filtrate Effect - 3 DCH 65.00 65.00 0.00 0.00

Syrup Heating Effect - 3 DCH 65.00 65.00 0.00 0.00
Melt Heating Effect - 3 DCH 50.00 75.00 0.66 0.12
Raw Melt Heating Effect - 3 DCH 50.00 75.00 11.64 2.12
Sweet Water Heating Effect - 3 DCH 50.00 75.00 1.02 0.19

Total 97.84 17.79

Evaporation
Total evaporation % Cane 92.60
t/h 509.32

Exhaust Quint - 1 Quint - 2 Quint - 3 Quint - 4 Quint - 5

Pressure Bar (a) 2.30 1.84 1.40 0.98 0.58 0.20
Temperature 0
C 124.67 117.68 109.17 99.23 85.04 60.27
114.24 103.47 90.53 76.41 48.39
1.68 1.17 0.73 0.42 0.12

Evaporation from each body t/h 203.68 173.26 92.89 17.64 21.85
% Cane 37.03 31.50 16.89 3.21 3.97
Condensate from each body, t/hr t/h 201.34 171.41 92.02 17.52 21.89
Juice heater condensate available for f t/h 0.00 16.11 0.00 0.00 0.00

Draft
J.P.MUKHERJI & ASSOCIATES P. LTD
Annexure - V
EVAPORATOR CALCULATIONS Page - 7
Bhogpur - Punjab
Bhogpur
Pan condensate available for flash t/h 0.00 0.00 73.90 31.41 0.00
Condensate for flashing, t/hr t/h 0.00 187.52 350.61 392.59 402.84
Condensate Temperature in Flash 0
C 122.08 109.17 99.23 85.04 84.67
Tank
Juice flow from each body t/h 618.25 414.57 241.31 148.42 130.78 108.93
Outlet brix 13.74 20.49 35.21 57.25 64.97 78.00
Average brix 17.12 27.85 46.23 61.11 71.48

Quantity of heat loss due to radiation t/h 3.99 2.56 1.37 0.26 0.27
Qty of Heat loss due to non condensiblt/h 4.07 3.47 1.86 0.35 0.44
Quantity of Juice flash vapours t/h 7.85 5.47 4.93 4.80 4.23
Quantity of Condensate flash vapours t/h 0.00 2.83 6.95 11.64 11.94
Quantity of flash vapours t/h 0.00 2.27 8.65 15.82 15.46

Heating surface Sq. m 5500 6500 4000 1700 1500

Specfic evaporation rate kg/h. sq.m/h 37.03 26.66 23.22 10.37 14.57
lb/h. sq.ft/h 7.58 5.46 4.76 2.12 2.98

25.00 18.00 15.00 10.00 8.00

8150 9630 6190 1760 2730

Dessin coefficient kg/h.sq.m. oC 3.74 2.75 2.26 1.00 0.70

Overall H.T.Coefficient Btu/h.sq ft. oF 383.85 270.21 198.46 82.59 60.02
Apparent temp. drop 0
C 9.91 9.69 10.26 10.41 20.92
True temp. drop 0
C 10.43 10.77 12.94 14.12 28.02

Vapor temperature 0
C 114.24 103.47 90.53 76.41 48.39
Pressure in each body, bara bara 1.68 1.17 0.73 0.42 0.12
Vacuum in inch Hg Inches Hg 7.85 16.90 25.63

Flap valve to reduce the pressure ∆t 0

C 0.00 0.00 0.00 0.00 0.00

Total temperature drop calculated 0

C 76.28
Total temperature drop available 0
C 64.40

Exhaust Steam consumption t/hr % cane

Exhaust steam to Effect - 1 203.68 37.03

Exhaust steam for Raw Juice Heater 0.00 0.00
Exhaust steam for Sulphured Juice Heater 0.00 0.00 t/hr % cane
Exhaust steam for Clear Juice Heaters 0.00 0.00 JH 97.84 17.79
Exhaust steam for variable Pan Steam Demand 0.00 0.00 Pans 127.67 23.21
Exhaust steam for Sugar Drying 2.65 0.48 Evap 7.56 1.375

Process Exhaust steam demand 206.33 37.51 206.32 37.51

Exhaust steam for Soda Boiling (Evap. 2.00% 4.25 0.77 4.25 0.77
Losses on total demand 1.00% 2.13 0.39 2.13 0.39
Total exhaust steam demand 212.71 38.67 212.70 38.67

Total Process Steam Demand t/hr % cane

Total Exhaust steam required 212.71 38.67
Live steam for process 1.00% 2.13 0.39
Total Process steam demand 214.84 39.06

Draft
J P MUKHERJI & ASSOCIATES PVT. LTD.
FLOW DIAGRAM OF EVAPORATOR Annexure - III A
SSC-GSF Page-8 of 33

To LJ4 Heating To 'B' Pan To Condenser

7.62 t/h To 'A' Pan 17.08 t/h To LJ2 heating 3.67 t/h
To CJ 1 31.41 t/h 0.00 t/h To LJ 1 Heating
13.69 t/h To LJ 3 Heating 14.29 t/h
To 'C' Pan 25.86 t/h Melt concentrator
11.14 t/h 10.74 t/h
Raw melt heating
To Refinery pans &
refinery other uses 5.17 t/h
51.18 t/h 164.90 t/h 81.72 t/h 25.19 t/h 17.96 t/h
198.91 t/h

Quint - I Quint - II Quint - III Quint - IV Quint - V

2000 2000 1200 400 400
m2 m2 m2 m2 m2
Exhaust
198.91 t/h 99.45 kg/sq.m/h 82.45 kg/sq.m/h ### 62.97 kg/sq.m/h 44.89 kg/sq.m/h
2.30 bar(a)
124.67 deg C
398.70 t/h 233.80 t/h 152.08 t/h 126.89 t/h
21.31 %Bx 36.34 %Bx 55.87 %Bx 66.96 %Bx
25.018 t/h

Clear Juice flow

597.60 t/h 17.90 t/h
14.22 %Bx 163.13 t/h 80.95 t/h
LJ2 heating Syrup
108.93 t/h
LJ3+ A' + B' Pan Condensate 78.00 %Bx
LJ4+CJ1+C + refinery Pan Condensate LJ1 condensate

196.62 t/h

Steam consumption t/h % cane

Juice flow 1 Cane crushing rate 550.00 100.00
Vapour flow 2 Exhaust steam to Quint I 198.91 36.16
Flash vapours 3 Exhaust steam to Juice heaters 10.75 1.96
Condensdate Flow Condensate Grade-1 4 Exhaust steam for pans 3.86 0.70 Condensate Grade-2
to Boiler 5 Exhaust steam Losses 2.20 0.40
6 Process exhaust steam demand 215.72 39.22
 1.0 BasicPVT
J P MUKHERJI & ASSOCIATES Parameters
LTD EVAPORATOR BALANCE Annexure-V-B
Factory crushing rate tch (PROPOSED) 550 Page-9/33
Dalmia Bharat Sugar Imbibition % fiber 340 TCH 240
Unit- Datta Sakhar Karkhana t/h % cane
Raw juice 577.31 104.96
Sulphured juice 654.68 119.03
Clear juice 584.57 106.29
Clear juice brix 14.53
Syrup brix required brix 78.00
Condensate flash YES

2.0 Pan floor Steam Requirement at Average Demand t/h % cane

- A Pans 20.42 3.71 From LTEM - 3
- A Graining 10.99 2.00
- A1 Pans 0.00 0.00 From LTEM - 3
- A1 Graining 0.00 0.00
- B Pans 11.10 2.02 From LTEM - 3
- B Graining 5.98 1.09
- C Pans 7.24 1.32 From LTEM - 3
- C Graining 3.90 0.71
- Refinery Pans 45.68 8.31
- Total 105.32 19.15
Exhaust for variable pan stm. demand 0.00 0.00 From Exhaust
- Molasses Conditioning 4.13 0.75 From Effect - 3
- Pan Washing 5.50 1.00 From Effect - 1
- Superheated Wash Water System 0.60 0.11 From Exhaust
- Sugar Drying 1.23 0.22 From Effect - 1

Total Pan Demand 116.77 21.23

3.0 Exhaust Steam

- Pressure Bara 2.20
- Temperature 0
C 123.35

3.0 Juice Heaters Bleeding Effect Heating (Deg C) Bleeding Quantity

From To t/h % cane
Raw juice stage - 1 Effect - 5 Tubular 30.00 50.05 19.10 3.47
Raw juice stage - 2 Condensate PHE 50.05 60.96 0.00 0.00
Raw juice stage - 3 DCH
Raw juice stage - 4 60.96 72.00

Suphured juice stage - 1 Effect - 3 Tubular 68.00 91.37 26.31 4.78

Suphured juice stage - 2 Effect - 3 DCH 91.37 95.17 3.62 0.66
Suphured juice stage - 3 Effect - 2 DCH 95.17 103.00 7.47 1.36
Suphured juice stage - 4 103.00 103.00 0.00 0.00

Clear juice stage - 1 Effect - 2 DCH 96.00 103.01 7.14 1.30

Clear juice stage - 2 Effect - 1 DCH 103.01 114.29 11.59 2.11
Clear juice stage - 3 Exhaust PHE 114.29 116.82 2.62 0.48

Raw Sugar Melting Effect - 3 50.00 75.00 2.21 0.40

Raw Melt Heating Effect - 3 Tubular 70.00 85.00 2.33 0.42
B C Melt Heating Effect - 3 DCH 55.00 75.00 0.53 0.10

Total 82.92 15.08

4.0 Evaporation
Total evaporation % Cane 86.48
t/h 475.64

Exhaust Quint - 1Evapplus-1Evapplus-2 Quint - 2 Quint - 3 Quint - 4Quint - 5

Pressure Bara 2.20 1.76 1.46 1.22 1.34 0.94 0.56 0.20
Temperature 0
C 123.35 116.29 110.57 105.48 108.01 98.17 84.26 60.27

Evaporation from each body t/h 177.39 103.19 104.55 48.85 33.48 1.00 7.18
% Cane 32.25 18.76 19.01 8.88 6.09 0.18 1.30

Condensate from each body t/h 175.35 101.94 103.28 48.33 33.16 0.99 7.18
Juice heater condensate available for f t/h 0.00 0.00 0.00 11.59 7.14 26.31 0.00
Pan condensate available for flash t/h 0.00 0.00 0.00 0.00 0.00 116.42 0.00
Condensate for flashing t/h 0.00 101.94 101.82 161.86 299.22 437.02 431.43
Condensate Temperature in Flash 0
C 120.73 114.31 109.13 108.01 98.17 84.26 84.15
Tank
Juice flow from each body t/h 584.57 407.18 303.99 199.43 150.59 117.11 116.10 108.93
Outlet brix 0
Brix 14.53 20.87 27.95 42.60 56.42 72.55 73.18 78.00
Average brix 0
Brix 17.70 24.41 35.28 49.51 64.49 72.87 75.59

Correction due to latent heat differencet/h 1.69 0.72 0.67 0.50 0.42 0.02 0.19
Quantity of heat loss due to radiation t/h 3.48 2.02 2.05 0.72 0.49 0.01 0.09
Qty of Heat loss due to non condensiblt/h 3.55 2.06 2.09 0.98 0.67 0.02 0.14
Quantity of Juice flash vapours t/h 0.00 3.99 2.37 -1.30 1.90 2.79 4.39
Quantity of Condensate flash vapours t/h 0.00 1.46 2.53 2.23 5.92 12.77 13.10
Quantity of flash vapours t/h -7.03 1.36 0.76 -0.76 6.65 15.53 17.26

Heating surface m2 7600 7600 7600 2500 2000 1500 1000

Specfic evaporation rate kg/h. m2/h 23.34 13.58 13.76 19.54 16.74 0.67 7.18
lb/h. ft2/h 4.78 2.78 2.82 4.00 3.43 0.14 1.47

kg/h. m2/h 25.00 15.00 15.00 18.00 15.00 10.00 10.00

m2 7100 6880 6970 2710 2230 100 720

Dessin coefficient kg/h. m2. 0C 3.63 2.97 2.30 1.98 1.54 0.68 0.40
Overall H.T.Coefficient Btu/h.ft2. 0F 363.57 276.8 202.2 171.78 114.93 11.68 33.15
W/m2. K 2064.42 1571.74 1148.26 975.40 652.60 66.3 188.24

Apparent temp. drop 0

C 6.42 4.57 5.98 9.85 10.84 0.98 17.89
DRAFT
J P MUKHERJI & ASSOCIATES PVT LTD EVAPORATOR BALANCE Annexure-V-B
(PROPOSED) Page-10/33
Dalmia Bharat Sugar 340 TCH
Unit- Datta Sakhar Karkhana

True temp. drop 0

C 6.95 5.35 7.46 12.44 16.13 6.43 24.98

Vapour temperature 0
C 116.39 111.05 103.58 103.95 87.82 81.39 56.41
Pressure in each body bara 1.80 1.51 1.17 1.19 0.66 0.51 0.17
Pressure in body Bar (g) 0.77 0.48 0.14 0.16
Vacuum Inches Hg 9.92 14.18 24.02

Flap valve to reduce the pressure ∆t 0

C 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Total temperature drop calculated 0

C 66.94
Total temperature drop available 0
C 63.07

5.0 Exhaust Steam consumption t/h % cane t/h % cane

Exhaust steam to Effect - 1 179.08 32.56 JH 82.92 15.08

Exhaust steam for raw juice heater 0.00 0.00 Pans 116.77 21.23
Exhaust steam for sulphured juice heater 0.00 0.00 Evap -11.93 (2.169)
Exhaust steam for clear juice heaters 2.62 0.48 Flash -16.52 (3.003)
Exhaust steam for variable pan steam demand 0.00 0.00 lat.ht diff 1.69 0.308
Exhaust steam for SHHW System 0.60 0.11
Exhaust steam for Sugar Drying 0.00 0.00
Process Exhaust steam demand 182.30 33.15 172.93 31.44 9.3713 1.7039
Exhaust steam for Soda Boiling (Evap. 1.00% 1.84 0.33 1.84 0.33
Losses on total demand 0.00% 0.00 0.00 0.00 0.00
Total exhaust steam demand 184.15 33.48 174.77 31.78 9.3713 1.7039

DRAFT
DANGOTE SUGAR LTD.,
Annexure – VI
JUICE HEATER CALCULATION Page-11 of 33
Nasarawa Sugar Project

DESCRIPTION Heater No. ---> #1

Heating Surface Area (HSA) - m2 392

Type of heater Tubular

Provision of heating for the juice RJ1
Dynamic
Working / Stand by (W/SB)
Calculated for RJ1

Crushing Rate - tch 550

Total Juice Flow - % Cane 104.96
Juice Flow per heater - % total flow 50%
Juice Flow per heater - t/h 288.65
Juice Flow per heater - m3/h 274.91

Calculated HAS - m2 392

No. of tubes per pass 30
Number of passes 16
Total No. of tubes 480
Tube material SS
Tube OD - mm 45.00
Tube Thickness - mm 1.20
Tube ID - mm 42.60
Tube Length - mm 6000

Bleeding Effect 5
Heating medium temperature - 0C 60.27
Dynamic / Conventional (1 / 0) 1
Juice Inlet Temperature - 0C 30.00
Juice Outlet Temperature (Attainable) - 0C 50.05

Juice Velocity - m/s 1.79

Pressure Drop -m 18.35

Draft
J.P.MUKHERJI & ASSOCIATES PVT. LTD.
Evaporator Calculations with steam economy measures
Renuka Sugars system : Quintuple Annexure - B3
Page - 12/33
103 0C
T.J. O/L

SJ - 2
118.11 7.62 t/h
CJ O/L 95 0C
T.J. I/L T.J. O/L Filtrate ht. 0.00 t/h 45 0C
CJH - 1st 95 0C RJ O/L
24.45 ### 25.86 t/h SJ - 1 25.86 t/h 57 0C 3.67 ###
118 0C RJ O/L RJH-1 Condenser
CJ O/L CJ I/L
95 0C T.J. I/L RJH-2 14.29
0.00 t/h C.J.H 2nd 0.00 t/h 597.60 t/h 68 0C 0.00 t/h RJ I/L
658.10 t/h 30 0C
CJ I/L C Pans 11.14 t/h RJ I/L 577.31 t/h
118 0C Pan Wash. 5.50 t/h Raw Melt 59.80 45 0C
B Pans 17.08 t/h ###
Ref. Pans 45.68 t/h A Pans 31.41 t/h
21.93
164.90 t/h 80.05 t/h 12.41
198.91 t/h 164.90 t/h 81.72 t/h 25.19 t/h 17.96 t/h
117.68 0C 0.00 t/h 109.17 0C 1.68 t/h 99.23 0C 3.26 t/h 85.04 0C 60.27 0C
Q1 Q2 Q3 25.19 t/h Q4 Q5
Exhaust 198.91 t/h 2000 sqm 164.90 2000 sqm 1200 sqm 400 sqm 400 sqm
2.30 bara sp.evap.rate -kg/hr.m2 99.45 82.45 68.10 62.97 5.55 t/h 44.89
124.67 Deg.C H.T.C - kg /hr.m2.0C 1443.62 748.90 81.72 -242.96 1613.82 1188.43
Calandria pr. kg/cm2 (a) 2.30 1.84 1.40 0.98 0.58
196.62 80.95 17.90
163.13 25.02
V.P.demand 233.80 t/h 152.08 t/h 126.89 t/h Syrup
0.00 t/h 36.34 bx 55.87 bx 66.96 bx 108.93 t/h
Juice 398.70 t/h 78.00 bx
Clear Juice 21.31 bx
597.60 t/h 196.62 t/h ### ### ### ###
14.22 bx 122 0C 115 0C 106 0C 95 0C 77 0C to OHT
118 0C Pan cond. 0.00 t/h
JH cond 12.53 t/h Pan cond 28.23 t/h Pan cond 31.41 t/h Q5 cond 17.90
Q2 cond ### JH cond 0.00 t/h JH cond 0.00 t/h Recirc. Con 330.79
Condensate Heating Q3 cond 80.95 t/h Q4 cond 25.02 t/h
### Recirc cond ### Recirc cond###
Quint 2nd Condensate Condensate from CPU ### To Hotwell
0.00 t/h 30 0C
112 0C Treated.J.I.L
71.00
Condensate to hotwell To Polishing Unit
100 0C 40 0C
PHE 89 0C 88.71

Overall Exhaust balance t/h % cane 76.00

Exhaust steam to Effect- 1 198.91 36.16 Flue gas LPE Flue Gas PHE
Exhaust steam for clear juice heaters 10.75 1.96 ### 110 0C
Exhaust steam directly for Pans 0.00 0.00 160 0C ###
Exhaust steam for variable pan steam deman 0.00 0.00 4.75 kg/kg Cond. Outlet
Process Exhaust steam demand 213.08 38.74 to Imbibition
CRUSH RATE ----------------------- 550.00 tch
Exhaust for Deaerator 4.39 0.80 IMBIBITION -------------------------- 240.00 % FIBRE Condensate Treated .J. O/L
Losses at 1% of total demand 2.20 0.40 RAW JUICE -------------------------- 104.96 % CANE 296.38 t/h 77 0C
Total Exhaust demand 219.67 39.94 TREATED JUICE ------------------- 119.65 % CANE 73 0C 658.10 t/h
 SUGAR FACTORY CONDENSATE BALANCE
Annexure–VIII
SSC-NHSF for 315 TCH Page - 13/33

Sr. No Description Condensate Condensate

Grade - I Grade - II
t/hr t/hr

1.00 Condensate Availability

1.01 Treated Juice heaters heating 47.77

1.06 Clear Juice heaters 1st stage 13.69
1.07 Clear Juice heaters 2nd stage 10.75
1.08 Raw liquor melt heating 5.17
1.09 Quint. 1st effect 196.62
1.10 Quint. 2nd effect 163.13
1.11 Quint. 3rd effect 80.95
1.12 Quint. 4th effect 25.02
1.13 Quint. 5th effect 17.90
1.15 Raw sugar factory pans 59.64
1.16 Refinery pans 45.68

Sub Total 196.62 469.69

Loss 1 % on total 1.97 4.70
Total condensate availability 194.65 465.00

Total (Grade I+ Grade II) condensate % Cane 119.94%

2.00 Condensate Requirement

2.01 Condensate for Steam Generation 194.65

2.02 Blow down loss @ avg 3 % on generation 5.84
2.03 Imbibition 237.60
2.04 MOL preparation 10.65
2.05 Filter cake washing 27.26
2.06 Molasses conditioning water 3.31
2.07 Pan Movement water 3.43
2.08 Centrifugals 11.00
2.09 Melting 7.54
2.11 Floor washings @ 2 % on cane 11.00

Sub Total 211.49 300.80

3.00 Net Condensate Availability

Condensate available 194.65 465.00

J P MUKHERRJI & ASSOCIATES PVT. LTD.
EVAPORATOR CALCULATION (355 tch) Annexure - III B
SSC-Tamboul
1.0 Basic Parameters Page-14 of 33
Factory crushing rate tch 550
Imbibition % fiber 240
t/ h % cane
Raw juice 577.31 104.96
Treated juice 658.10 119.65
Clear juice 597.60 108.66
Clear juice brix 14.22
Syrup brix required brix 78.00
Condensate flash YES

2.0 Pan floor steam requirement at minimum demand t/ h % cane

-A Pans 31.41 5.71 From Effect - 3
-B Pans 17.08 3.11 From Effect - 2
-C Pans 11.14 2.03 From Effect - 2
-Refinery Pans 45.68 8.31 From Effect - 2
-Total 105.32 19.15
Exhaust for varible pan stm. demand 0.00 0.00 From Exhaust
-Pan Washing 5.50 1.00 From Effect - 1
-Molasses Conditioning 3.33 0.61 From Effect - 2
-White Sugar Melting (B + C Sugar) 0.07 0.01 From Effect - 1
-Melt Concentrator 10.74 1.95 From Effect - 1
-Sugar Drying 3.86 0.70 From Exhaust

Total pan demand 128.81 23.42

3.0 Exhaust Steam

- Pressure kg/sq.cm (g) 1.31
- Temperature Deg C 124.67

4.0 Juice heaters bleeding Effect Heating (Deg C) Bleeding Quantity

From To t/ h % cane
Raw juice heating stage-1 Effect - 5 Tubular 30.00 45.00 14.29 2.60
Raw Juice Heating stage 2 CondensatePHE 45.00 56.92 0.00 0.00
Raw juice heating stage-3 Effect - 4 DCH 56.92 72.00 12.78 2.32

Limed juice heating stage-1 Effect - 3 DCH 68.00 95.00 25.86 4.70
Limed juice heating stage-2 Effect - 2 DCH 95.00 103.00 7.62 1.39
Limed juice heating stage-3 Effect - 1 Tubular 70.80 102.00 -1.16 -0.21
Limed juice heating stage-4 Effect - 1 Tubular 102.00 102.00 0.00 0.00

Clear juice heating stage-1 Effect - 1 PHE 95.00 108.00 13.69 2.49
Clear juice heating stage-2 Exhaust PHE 108.00 118.11 10.75 1.95
0.00

Filtrate Heating Effect - 2 DCH 55.00 55.00 0.00 0.00

Raw Sugar Melting Effect - 1 55.00 85.00 5.17 0.94
Raw Melt Heating Effect - 3 Tubular 70.00 85.00 2.52 0.46
Syrup Heating Effect - 3 Tubular 60.00 60.00 0.00 0.00

Total 91.52 16.64

5.0 Evaporation
Total evaporation % Cane 88.85
t/ h 488.67

Quint-1 Quint-2 Quint-3 Quint-4 Quint-5

Pressure Bara 2.30 1.84 1.40 0.98 0.58 0.20
Temperature 0
C 124.67 117.68 109.17 99.23 85.04 60.27

Evaporation from each body t/ h 198.91 164.90 81.72 25.19 17.96

% Cane 36.16 29.98 14.86 4.58 3.27
Condensate from each body t/ h 196.62 163.13 80.95 25.02 17.90
Juice heater condensate available for
t/ h 10.75 12.53 0.00 0.00 0.00
flash
Pan condensate available for flash t/ h 0.00 0.00 28.23 31.41 0.00
Recirculation condensate for flash t/ h 0.00 0.00 0.00 0.00
Condensate for flashing t/ h 10.75 175.66 283.17 336.33 348.68
Condensate temperature in Cigar 0
C 122.05 114.60 105.88 94.83 77.24

Juice flow from each body t/ h 398.70 233.80 152.08 126.89 108.93
Outlet brix 21.31 36.34 55.87 66.96 78.00
J P MUKHERRJI & ASSOCIATES PVT. LTD.
EVAPORATOR CALCULATION (355 tch) Annexure - III B
SSC-Tamboul
Average brix 17.76 28.83 46.11 61.42 Page-15
72.48 of 33

Quantity of heat loss due to radiation t/ h 0.00 0.00 0.00 0.00 0.00
Qty of Heat loss due to non condensibl t/ h 0.00 0.00 0.00 0.00 0.00
Quantity of Juice flash vapours t/ h 0.00 0.00 0.00 0.00 0.00
Quantity of Condensate flash vapours t/ h 0.00 1.68 3.26 5.55 0.00
Quantity of flash from recirculation condt/ h 0.00 0.00 0.00 0.00
Quantity of Flash vapours for evaporatit/ h 0.00 1.68 3.26 5.55 0.00
0.00 0.00

Heating Surface m2 2000 2000 1200 400 400

Specfic Evaporation Rate Kg/ m2/ h 99.45 82.45 68.10 62.97 44.89
lb/ ft2/ h 20.37 16.89 13.95 12.90 9.19

Dessin coefficient Kg/ m2/ h 0C 3.42 1.76 -0.55 4.43 3.73

Overall H.T.Coefficient W/ m2 0K 2066 1072 -348 2309 1701
BTU/ ft2 0F 363.79 188.72 -61.23 406.68 299.48

Apparent temperature drop 0

C 29.12 46.90 -124.74 14.22 12.03
True temperature drop 0
C 29.55 47.71 -123.03 17.40 17.30

Total temperature drop calculated 0

C -11.06
Total temperature drop available 0
C 64.40

6.0 Exhaust Steam consumption t/ hr % cane t/ hr % cane

Exhaust steam to Effect- 1 198.91 36.16 JH 91.52 16.64

Exhaust steam for raw juice heater 0.00 0.00 Pans 128.81 23.42
Exhaust steam for Limed juice heater 0.00 0.00 Evap 3.67 0.666
Exhaust steam for clear juice heaters 10.75 1.96 Flash -10.49 (1.907)
Exhaust steam directly for Pans 0.00 0.00
Exhaust steam for Sugar drying 3.86 0.70
Clear juice flash point -0.44 -0.08 -0.44 -0.08
Process Exhaust steam demand 213.08 38.74 213.07 38.74
Exhaust for evaporator soda boiling 2.00% 4.39 0.80 4.39 0.80
Losses & other uses @ ….on total de 1.00% 2.20 0.40 2.20 0.40
Total exhaust steam demand 219.67 39.94 219.66 39.94
 EQUIPMENT SIZE CALCULATIONS ( Boiling House)
Page - 16/33

Plant Capacity tch 550.00

Code Description Units Capacity

0500 Juice treatment

0501 Juice weighing scale Existing Proposed
-Juice quantity % cane 104.96
-Juice quantity t/h 577.31 577.31
-Mass flow meter capacity requir t/h 400.00 400.00

Available capacity OK --- ---

SHORT SHORT SHORT
1 # 400 t/h mass flow meter to be installed to splitup total
0507 Weighed Juice Pump
-Juice quantity % cane 115.30
t/h 634.17
m3/h 609.78
-Recirculation capacity required % 15.00%
-Pump capacity required m3/h 701.25

-Pump No. #1 #2
-Pump capacity available m3/h 430.00 430.00
-Working or standby W / SB W SB

Proposal Proposal
-Pump No. #1 #2
-Pump capacity available m3/h 430.00 430.00
-Working or standby W / SB W SB
-Total capacity available m3/h 430.00

Available capacity OK OK
SHORT ---

2#, 430 m3/h, 60 m head pumps to be installed with 2# 0-250 m3/hr capacity magnetic flow meters to splitup total juice fl
0510 Juice Liming tank
0510a Reaction tank New
-Raw Juice quantity % cane 129.06
Reaction tank Dia required m 7.54
Working height m 2.00
-Working volume m3
89.29
-Gross volume of sulphiter m3
-Quantity of juice to be treated m3/h 669.67
-Retention time available minutes 0.00
-Retention time required minutes 8.00
-Reaction tank volume required m3 89.29
Available capacity OK --- ---
SHORT SHORT ---
1 # new sulphiter of 22.87 cum working volume with 2.0 m working height to be installed

0512 Limed juice receiving tank Existing

-Limed Juice quantity % cane 117.33
Dia m
Height m
Volume m3 0.00
Total Volume m3 0.00

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Quantity of juice m3/h 620.50

-Retention time available minutes 0.00
-Retention time required minutes 5.00
-Receiving tank volume required m3 51.71
-Receiving tank volume proposedm3 55.00
Available capacity OK NA
SHORT NA
No Change

0513 Sulphiteded Juice Pump

-Juice quantity % cane 117.33
t/h 645.32
m3/h 620.50
-Recirculation capacity required % 15.00%
-Pump capacity required m3/h 713.57

-Pump No. #1 #2
-Pump capacity available m3/h 500.00 500.00
-Working or standby W / SB W SB

New New New

-Pump No. #1 #2 #3
-Pump capacity available m3/h 0.00 0.00 0.00
-Working or standby W / SB W W SB
-Total capacity available m3/h 0.00
-Pump capacity required m3/h 713.57

Available capacity OK ---

SHORT SHORT
2#, 500 m3/h, 60 m head pumps to be installed with 2# 0-300 m3/hr capacity magnetic flow meters to splitup total juice fl

0600 Clarification and filtration

0602 Clarifier Existing Proposed Alternative proposal Total
117.33 #1 #2
645.32 Existing Proposed
614.59 50.00%
-Quantity of juice to be treated m3/h 307.29 307.29 248.20 372.30 620.50
-Diameter of Clarifier mm 9754 9754 9144
ft 32 32 30
-Diameter of Clarifier mm 6096 6096
-Total volume m3 455.48 455.48 410.00
-Net volume m3 432.70 432.70 369.00
-Retention time possible (4 comp)h 1.41 1.41 1.49
-Retention time required h 2.10 2.10 2.10

Available capacity working with 4 OK --- --- ---

SHORT SHORT SHORT SHORT

Install 2 # New clarifier of 32' diameter or

OR Install 1# short retention clarifier suitable for capacity of 4

0607 Rotary Vacuum filters #1 #2

-Filter size , dia x length mm 4267 x 8534 67 x 8534 8534
-Filter size , dia x length ft 14x 28 14 x 28
-Filtering area m2 114.41 114.41

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-Total filtering area available m2 0.00 0.00

-Filtering area required per tch m2/tch 0.60 0.60
-Total filtering area required m2 330.00 330.00

Available capacity OK --- ---

SHORT SHORT SHORT

Install 2 # 14 x 28 vacuum filters

Vacuum pump for RVF
-Capacity available m3/h 0.00 0.00 0.00
-Drive Motor Motor Motor
-Working or standby W / SB 1W 1W SB
-Capacity required per filtering ar m3/m2/h 20.00 20.00 20.00
-Vacumm pump capacity required m3/h 2290.00 2290.00 0.00
-Vacumm pump capacity required( m3/h 2300.00 2300.00 0.00
Available capacity OK --- --- ---
SHORT SHORT SHORT ---

0618 Bagacillo blower

-Blower capacity m3/min 0.00
m3/h 0.00
-Bagacillo qty. required kg/tch 10.00
-Air required per kg of bagacillo m3/kg 6.25
-Blower capacity required m3/h 34400.00
-Blower capacity required m3/min 573.33
Available capacity OK ---
SHORT SHORT
Install 1 # bagacillo blower of 400 cu.m/min capacity each.
0619 Bagacillo piping
-Bagacillo pipe diameter existing mm 0.00
-Design velocity m/s 25.00
-Bagacillo duct diameter mm 550.00

Available capacity OK ---

SHORT SHORT
Install 1 # bagacillo line of dia 500 mm.
0700 MOL and SO2 preparation
0702 Lime slaker
-Capacity Existing kg/h 800.00
-Lime consumption (max.) % cane 0.15
-Capacity suitable for working ho hours 12.00
-Lime slaker capacity required kg/h 1650.00

Available capacity OK ---

SHORT SHORT
Install 1 # new slaker of 1200 kg/h capacity
0705 MOL storage tanks #1 #2 #2
-size of storage tanks, diameter m 3.00 3.00 3.00
- height m 3.60 3.60 3.60
-Capacity of storage tank, each m3 0.00 0.00 0.00
-Total capacity of storage availab m3 0.00 0.00
-MOL quantity, @ 6 Be' % cane 2.03 2.03
m3/h 10.75 10.75
-Storage time available h 0.00 0.00
-Storage time required - minimumh 8.00 8.00
-Total capacity of storage - requir m3 86.01

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Available capacity OK ---

SHORT SHORT
Install 3 # new 25 cu.m holding tanks for MOL storage
Sulphur burners
0707 Sulphur burners - for juice #1 #2 #5
-Sulphur burners Type Cont. Cont. Cont.
-Tray area m2 -- -- --
-Capacity, each kg/h 200.00 45.00 200.00
-Working / Standby W / SB W W SB
-Total capacity of continuous bur kg/h 200.00 245.000
-Sulphur consumption for juice % cane 0.000
-for capacity calculation % cane 0.070 0.070
kg/h 385.00 385.00

Available capacity OK --- ---

SHORT SHORT SHORT
Addition
0708 Sulphur burners - for syrup #3 #4 #5
-Sulphur burners Type Cont. Cont. Cont.
-Tray area m2 -- -- --
-Capacity, each kg/h 25.00 25.00 70.00
-Working / Standby W / SB W SB W
-Capacity Available in working kg/h 95.00
-Sulphur consumption for syrup % cane 0.000
-for capacity calculation % cane 0.030
kg/h 165.00

Available capacity OK ---

SHORT SHORT No addition

0710 Air compressors for sulphur burners

Air compressor (for juice) #1 #2 #3
-Capacity available m3/h 2000.00 500.00 1200.00
-Working / Standby W / SB W W SB
-Delivery pressure required kg/cm2(g) 1.00 1.00 1.00
-Total working capacity available m3/h 2000.00 2500.00
-Air required per kg of sulphur m3/kg 8.75 8.75
-Total air required m3/h 3370.00 3370.00

Available capacity OK --- ---

SHORT SHORT SHORT

Air compressor (forsyrup) #3 #4 Not applicable

-Capacity available m3/h 0.00 0.00
-Working / Standby W / SB W SB
-Delivery pressure required kg/cm2(g) 1.00 1.00
-Total working capacity available m3/h 0.00
-Air required per kg of sulphur kg/kg 8.75
-Total air required m3/h 1440.00

Available capacity OK ---

SHORT SHORT

0821 Syrup sulphiter #1 #2 #1 + # 2

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-Working / Standby W / SB W SB
-Quantity of syrup to be treated m3/h 108.57 108.57 108.57
-Diameter m 0.00 2.45
-Parellel Height m 0.00 4.60
-Working height m 1.50 1.50
-Gross volume of sulphiter m3 0.00 21.69
-Working volume of sulphiter m3 15.00 5.00 20.00
-Retention time available minutes 8.29 2.76 11.05
-Retention time required minutes 20.00 20.00 20.00

Available capacity OK --- --- ---

SHORT SHORT SHORT SHORT
To work both together
0900 Crystallisation
0901 Syrup & molasses storage tanks Tank size Capacity No. of Total
Length Diameter Height Each tank tanks cap.
m m m m3 m3
- Unsulphured syrup 35.00 4 140.00
- Sulphured syrup 35.00 0 0.00
- Melt 35.00 2 70.00
- AL 35.00 1 35.00
- AH 35.00 4 140.00
- BH 35.00 2 70.00
- CL 35.00 1 35.00

Syrup & molasses storage tanks Quantity Tank cap. Retention time Available capacity Required
available Available Required OK SHORT capacity
m3 / h m3 Hrs Hrs
-Unsulphured syrup 112.00 140.00 1.25 2.00 --- SHORT 224
-Sulphured syrup 109.00 0.00 0.00 0.00 --- --- 0
-Melt 22.00 70.00 3.18 3.00 OK --- 66
-AL 0.00 35.00 #DIV/0! 2.00 #DIV/0! #DIV/0! 0
-Total Sy + Melt + AL #DIV/0! 7.00 #DIV/0! #DIV/0! 0
-AH 50.00 140.00 2.80 3.00 --- SHORT 150
- BH 22.00 70.00 3.18 3.00 OK --- 66
-CL 6.00 35.00 5.83 3.00 OK --- 18
-Total #DIV/0! 16.00 #DIV/0! #DIV/0! 0
-Storage Tank capacity cu.m 35.00
Add one nest of three tanks for storing sy + AL+ melt. Reshuffle existing tanks
0902 Molasses conditioners AH BH CL AL
-Capacity available t 0.00 0.00 0.00 0.00
m3 0.00 0.00 0.00 0.00
-Quantity m3/h 50.00 22.00 6.00 0.00
-Retention time available min 0.00 0.00 0.00 #DIV/0!
-Retention time required min 20.00 20.00 20.00 20.00
-Capacity required m3 16.67 7.33 2.00 0.00
Available capacity OK --- --- --- #DIV/0!
SHORT SHORT SHORT SHORT #DIV/0!

Vacuum pans 341.00 EstimstedEstimstedEstimstedEstimstedEstimsted Estimsted

Massecuite A B B2 C Grain A-seed
Massecuite Quantity Average % cane 29.79 10.08 0.00 5.40 ---
t/h 163.85 55.43 0.00 29.72 ---
Massecuite Quantity Maximum % cane 32.77 11.09 0.00 5.94 ---
Massecuite Quantity Maximum t/h 180.24 60.98 0.00 32.69 ---
t/day 4325.76 1463.43 0.00 784.63 749.35 1441.92
Massecuite boiling time hrs 3.00 5.00 6.00 8.00 4 2

04/23/2024
 EQUIPMENT SIZE CALCULATIONS ( Boiling House)
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No. of strikes per day 8.0 4.8 4.0 3.0 6.0 12.0
Grain capacity required t/day 1441.9 487.8 0.0 261.5
Grain/Seed boiling time hrs 2.0 4.0 4.0 4.0
No. of grain/seed strikes per day 12.0 6.0 6.0 6.0
Grain boiling pan Capacity required
- Batch pans t/strike 120.2 81.3 0.0 43.6
- Total grain + massecuite p t/strike 660.9 386.2 0.0 305.1
Capacity required ---
- Batch pans t/strike 540.72 304.88 0.00 261.54 124.89 120.16
- Batch pans m3/strike 380.79 214.71 0.00 184.18 87.95 84.62
- Batch pans HL/strike 3807.89 2147.05 0.00 1841.85 879.52 846.20
- Continuous pans t/h 185.00 65.00 --- 35.00 ---
Let batch pan capacity is t 100 80 50 80 50 50
Therefore no of pans required Nos. 5.41 3.81 0.00 3.27 2.50 2.40
Nos. 6.00 4.00 0.00 4.00 3.00
Existing 2.00 1.00 1.00 1.00
cont.pan cont.pan

Install 2 # 55 t/h capacity cont. pans & 1# 80 t pan for A massecuite boiling.
Install 1 # 45 t/h capacity cont. pan & 1# 60 t pan for B massecuite boiling.
Install 1 # 25 t/h capacity cont. pans & 1# 50 t pan for C massecuite boiling.

0907 Seed crystallisers Dry seed B seed

-Capacity available t 0.00 0.00
-Capacity required t 60.00 60.00

Available capacity OK --- ---

SHORT SHORT SHORT

0908 Vacuum crystallisers

Massecuite A B C
-Capacity available t 0.00 0.00 0.00
-Capacity required t 90.00 65.00 55.00

Available capacity OK --- --- ---

SHORT SHORT SHORT SHORT
No addition

Receiving crystallisers (112 tch)

- Receiving crystallisers (112 tch 180.00 A B B2 C
EstimstedEstimstedEstimstedEstimsted
-Massecuite quantity estimated % cane 29.79 10.08 0.00 5.40
-Massecuite quantity for cap calcu % cane 32.77 11.09 0.00 5.94
t/h 180.24 60.98 0.00 32.69
Let massecuite boiling cycle time r hrs 3.00 6.00 0.00 8.00 261.54
Let massecuite cooling time require hrs 0.00 4.00 4.00 16.00 523.09
Therefore total massecuite retentio hrs 3.00 10.00 4.00 24.00
Therefore total massecuite prod.in r t 540.72 625.00 0.00 785.00
Let Pan capacity t 110.00 0.00 0.00 0.00
Let crystalliser capacity t 110.00 65.00 5.00 65.00
Therefore no.of crystallisers requir Nos. 4.92 9.62 0.00 12.08
Nos. 5.00 10.00 0.00 13.00 28.00
Existing 3.00 2.00 1.00 2.00 8.00
vert.crystallizer vert.crystallizer
Cont.pan Receiving crystallisers
0910 A - Cont.pan Receiving crystallisers
Existing Required c
-Capacity, each t 0.00 50.00

04/23/2024
 EQUIPMENT SIZE CALCULATIONS ( Boiling House)
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-No. of crystallisers 2 2
-Total t 0.00 100.00 100.00
Install 2# of 50 t crystallisers
0911 B - Cont.pan Receiving crystallisers
Existing Required
-Capacity, each t 0.00 50.00
-No. of crystallisers 2 1
-Total t 0.00 50.00
Install 1# of 50 t crystallisers
0913 C - Cont.pan Receiving crystallisers
Existing Required
-Capacity, each t 0.00 50.00
-No. of crystallisers 2 1
-Total t 0.00 50.00
Install 1# of 50 t crystallisers

0911 Cooling crystallisers

0914 Massecuite B C
Type - Horizontal / Vertical Vertical Vertical
- Twin / Mono Mono Twin
Capacity available ---
-Capacity, each t 0.00 0.00
-No. of crystallisers 1 1
-Total t 0.00 0.00

-Massecuite quantity estimated % cane 10.08 5.40

-Massecuite quantity for cap calcu% cane 11.09 5.94
t/h 60.98 32.69
-Retention time available h 0.00 0.00
-Retention time required h 10.00 24.00

Available capacity OK --- ---

SHORT SHORT SHORT

Short by 609.76 784.63 Install new vertical crystallisers of capacity 425

Add t 250 400 Install new vertical crystallisers of capacity 580
Nos 1 1

1000 Centrifugals

1001 Batch Centrifugals A

Make and/or type Krupp

Massecuite quantity - % cane 32.77
- t/h 180.24
- t/day 4325.76
Hours working per day - hrs 21
Massecuite quantity for capacity ca - t/h 205.99
Type Batch / Continuous Batch
Capacity per charge -t 1.75
Number of charges per hour - Nos 16
Capacity of each machine - t/h 28.00
Total capacity available - t/h 0.00
Capacity per day - t/day 0.00
No. of machines available - Nos 0 (5 + 1)
No. of machines required - Nos 7.36
No. of machine for standby duty - Nos 1.00
Total No. of machines required - Nos 8.36

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Available capacity OK ---

SHORT SHORT
say - Nos 9
To add - Nos 9 Addition

1005 Continuous Centrifugals B CAW Standby Total

(B and CAW)
Make and/or type Nk-1100 NK-1100
Massecuite quantity - Average - % cane 11.09 3.27
- t/h 60.98 18.01
- t/day 1463.43 432.19
Hours working per day - hrs 21 21
Massecuite quantity for capacity ca - t/h 69.69 20.58 90.27

Capacity of each machine (0.06 mm - t/h 14.00 14.00

Total capacity available - t/h 0.00 0.00
No. of machines available - Nos 0 0 0 0
Number of machines required - Nos 4.98 1.47 1.00 7.45
Available capacity OK --- --- --- ---
SHORT SHORT SHORT SHORT SHORT
say - Nos 4 1 1 6
To add - Nos 4 1 1 6
(Addition)

9 Continuous Centrifugals (CFW) CFW Standby Total

Make and/or type NK1503

Massecuite quantity - Average - % cane 5.94
Massecuite quantity - Average - t/h 32.69
- t/day 784.63
Hours working per day - hrs 21
Massecuite quantity for capacity ca - t/h 37.36

Capacity of each machine (0.05 mm - t/h 8.00

Total capacity available - t/h 0.00
No. of machines available - Nos 0 0 0
Number of machines required - Nos 4.67 1.00 5.67
Available capacity OK --- --- ---
SHORT SHORT SHORT SHORT
say - Nos 5 1 6
To add - Nos 5 1 6
(Addition)

1038 FM storage tanks #1 #2 #3 #4

-Capacity each tank cu.m 4000.00 4000.00 5000.00 5000.00
t 0.00 0.00 6500.00 5500.00
-Total capacity available t 0.00 6500.00 12000.00
-Final molassess production t/h 18.73 18.73 18.73
-tank capacity required ton ### ### 35968.42
(at 50 % production in 160 days)

Available capacity OK --- --- ---

SHORT SHORT SHORT SHORT
Short by ### ### ###
Tanks required 5.53 1 1 Addition
Tanks required 6.00
1100 Sugar handling

1101 Single tray grass hopper*****

04/23/2024
 EQUIPMENT SIZE CALCULATIONS ( Boiling House)
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1102 Sugar elevators #1 #2

-Capacity - each t/h 20.00 20.00
-Total Capacity Available t/h 40.00
-Actual sugaar quantity t/h 86.87
-Capacity required t/h 84.00
(equivalent for 3 new m/cs)
Available capacity OK --- No addition
SHORT SHORT

1104 Sugar grader #1 #2

-Capacity - each t/h 20.00 20.00
-Actual sugaar quantity t/h 79.98
-Capacity required t/h 84.00
(equivalent for 3 new m/cs)

Available capacity OK --- Addition

SHORT SHORT

1106 Sugar Bin

Recovery - Maximum % cane 12.00

Total sugar produced t/h 66.00
t/day 1584
Grades M-30 S-30
Distribution % 85.00% 15.00%
Quantity of sugar t/day 1346.40 237.60
Bins capacity - No. 1 t 0 -
- No. 2 t 0 -
- No. 3 t - 0
Total t 0 0
Retention time Available hours 0.00 0.00
Retention time preferable hours 16 16

Available capacity OK --- ---

SHORT SHORT SHORT
Short by t/day 1346.40 237.60
Bin capacity required @ 16 hrs ret. t 897.60 158.40
Add No additionNo addition
to accept 15 hrs ret. Time

1200 Condensing Station

1205 Injection Pump

a) Water for condensation:
Vapour from evaporator t/h 12.00
Vapour from pans t/h 90.00
Total t/h 102.00
% cane 18.55
Vapour load - Maximum % cane 35.00
t/h 192.50
Temperature difference of hot & colDeg C 9.00
Water required for condensation kg/kg of va 63.56
Total water required for condensati t/h 12234.44

b) Water for ejectors: Total

No. of ejector Nos. 4 2 6
Size of ejector mm 300 400
Water consumption per ejector cu.m/h 300.00 400.00
Water required for all ejectors cu.m/h 1200.00 800.00 2000.00

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Total water consumption cu.m/h 14234.44

Pump capacity, each cu.m/h 2500.00
No. of pumps required Nos. 5.69
Rounded to Nos. 6
Spare Nos. 1
Total No. of pumps required Nos. 7
No. of pumps available Nos. 0

Available capacity OK ---

SHORT SHORT
Short by Nos. 7
Add Nos. 7 Addition

1206 Cooling Tower

Water used for condensation cu.m/h 12234.44

Vapour condensed cu.m/h 192.50
Total water to be cooled cu.m/h 12426.94

Capacity of each cell cu.m/h 1000.00

No. of cells required Nos. 12.43
Rounded to Nos. 13
No. of cells available Nos. 0

Available capacity OK ---

SHORT SHORT
Short by Nos. 13
Add Nos. 13 Addition

1207 Cooling water pump

Total water to be cooled cu.m/h 12426.94
Pump capacity, each cu.m/h 2250.00
No. of pumps required Nos. 5.52
Rounded to Nos. 6
Spare Nos. 1
Total No. of pumps required Nos. 7
No. of pumps available Nos. 2

Available capacity OK ---

SHORT SHORT
Short by Nos. 5
Add Nos. 5 Addition

04/23/2024
 EQUIPMENT SIZE CALCULATIONS ( Boiling House)
Ramgarh Page - 26/33
200 tch

Plant Capacity tch 550.00

Code Description Units Capacity

Fine Liquor tanks

0900 Crystallisation
0901 Molasses storage tanks Tank size Capacity No. of Total
Length Diameter Height Each tank tanks cap.
m m m m3 m3
- Melt 40.00 3 120.00
- R1-Run-off 40.00 2 80.00
- R2-Run-off 40.00 2 80.00
- R3-Run-off 40.00 1 40.00

Molasses storage tanks Quantity Tank cap. Retention time Available capacity
available Available Required OK SHORT
m /h
3
m3 Hrs Hrs
- Melt 126.00 120.00 0.95 2.00 --- SHORT
- R1-Run-off 53.00 80.00 1.51 2.20 --- SHORT
- R2-Run-off 27.00 80.00 2.96 4.00 --- SHORT
- R3-Run-off 14.00 40.00 2.86 2.50 OK ---
-Total 8.28 10.70 --- SHORT

0903 Vacuum pans

Massecuite R1 R2 R3 Total
Type Batch Batch Batch Batch
Capacity Available
-Pan Capacity each, ( i ) 50 50 50
-Pan Capacity each, ( ii ) 60
-Pan Capacity each, ( iii ) -- -- --
-Pan Capacity each, ( iv ) -- -- --
-Pan Capacity each, ( v ) -- -- --
- Batch pans t 110 50 50 0 210
- Continuous pans t/h --- --- --- --- ---
Massecuite Quantity Average % cane 19.89 9.94 4.92 --- 34.75
t/h 109.39 54.69 27.04 --- 191.12
Massecuite Quantity Maximum % cane 21.88 10.94 5.41 --- 38.22
t/h 120.32 60.16 29.74 --- 210.23
No. of strikes per day 12.00 12.00 12.00 --- ---
Capacity required ---
- Batch pans t 240.65 120.32 59.49 420.46
- Continuous pans t/h --- --- --- --- ---
Available capacity OK --- --- --- --- ---
SHORT SHORT SHORT SHORT --- SHORT
Short by t -130.65 -70.32 -9.49 0.00 -210.46

0910 R1,R2,R3 - Receiving crystallisers

Existing Required
-Capacity, each t 65.00 65.00
-No. of crystallisers 1 4
-Total t 65.00 260.00

1000 Centrifugals

1001 Batch Centrifugals Refinery

Make and/or type

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 EQUIPMENT SIZE CALCULATIONS ( Boiling House)
Ramgarh Page - 27/33
200 tch

Massecuite quantity - % cane 34.75

- t/h 191.12
- t/day 4586.81
Hours working per day - hrs 21
Massecuite quantity for capacity ca - t/h 218.42
Type Batch / Continuous Batch
Capacity per charge -t 1.50
Number of charges per hour - Nos 18
Capacity of each machine - t/h 27.00
Total capacity available - t/h 27.00
Capacity per day - t/day 567.00
No. of machines available - Nos 1
No. of machines required - Nos 8.09
No. of machine for standby duty - Nos 1.00
Total No. of machines required - Nos 9.09
Available capacity OK ---
SHORT SHORT
say - Nos 10
To add - Nos 9 Addition

1100 Sugar handling

1101 Single tray grass hopper*****

1102 Sugar elevators #1

-Capacity - each t/h 20.00
-Total Capacity Available t/h 20.00
-Actual sugar quantity t/h 92.67
-Capacity required t/h 27.00
(equivalent for 1 new m/c)
Available capacity OK --- No addition
SHORT SHORT

1104 Sugar grader #1

-Capacity - each t/h 20.00
-Actual sugaar quantity t/h 92.67
-Capacity required t/h 27.00
(equivalent for 1 new m/c)

Available capacity OK OK Addition

SHORT ---

1106 Sugar Bin

Recovery - Maximum % cane 16.85

Total sugar produced t/h 92.67
t/day 2224
Grades R1 R2 R3
Distribution % 57.00% 29.00% 14.00%
Quantity of sugar t/day 1267.68 644.96 311.36
Bins capacity - No. 1 t - - -
- No. 2 t - - -
- No. 3 t 60 60 60
Total t 60 60 60 180
Retention time Available hours 1.14 2.23 4.62
Retention time preferable hours 16 16 16

Available capacity OK --- --- ---

SHORT SHORT SHORT SHORT
Short by t/day 1207.68 584.96 251.36
Bin capacity required @ 16 hrs ret. t 805.12 389.97 167.57
Add

04/23/2024