Baghauli Balance-R

Double Sulphitation Process
A-A1 Masscuite boiling scheme

(Quintuple System)
INPUT DATA
1 Milling rate - To give value - tch
- Calculated - TCD
2 Cane -pol %
-fibre%
3 First expressed juice -bx
-purity
4 Mixed juice -purity
5 Last mill juice -purity
Delta purity PJ to MJ
6 Imbibition -%fibre
Mud solids in mixed juice - % cane
7 Bagasse -pol%
-moiosture%
8 Quick lime [80% purity] -%cane
- purity
9 Milk of lime -beaume
10 Commercial sulphur -purity
-%cane
11 Bagacillio mill wet(50% moisture) -kg/tch

Clarifier underflow % clear juice
12 Filter cake mud solids -%cane
13 Filter cake moisture -%cane
14 Pol % filter cake
15 Filter wash water
16 -Qty %dry matter
Clear juice - brix
- Purity
17 Syrup -brix
18 Purity product sugar
Melt brix with water addition
19 Massecuite Brix
A-massecuite 90.00
A1 massecuite 91.00
B-massecuite 95.00
C-massecuite 98.00
20 Molasses Brix
A-Heavy 82.00
A-Light 70.90
A1-Heavy 82.00
B-Heavy 85.00
C-Light 79.07
Final Molasses 88.00
Brix
21 C-Fore sugar 96.00
C- Fore magma 90.00
C- After sugar 96.00
C- After magma 90.00
Brix
22 B- Fore sugar -
B- Fore magma 90.00
B- After sugar -
B- After magma 90.00
Brix
23 A1- Fore sugar -
A1- Fore magma 90.00
A1- After sugar -
A1- After magma 90.00
23 C- grain
24 A fore sugar - Reference purity

24 A1 fore sugar - Reference purity
25 Is Clear juice used for melting Y/N 1/0
26 B+C sugar magma brix

27 Dust & rori sugar magma brix
28 A light boiled in B massecuite in %

C light boiled in B massecuite in %
29 Percentage of A1 seed for A footing - % Cane
30 Footing crystal size nm
31 Pan graining volume %
32 Required crystal size product sugar:
33 A. Small, nm (S grade)
34 , % of total A-sugar
35 B. Small, nm (M grade)
36 Unknown losses % cane

210 24.00 hrs 73.49
5040 8.60
15.10 15.10 117.68
14.00 21.83 139.08
21.83 120.94
86.00
84.50 97.39
76.00 82.59
1.50
330.00 46.20
0.42
1.65
48.00
0.18
80.00
5.00
99.50
0.05
10.00
0.15
0.72
70.00
1.80
250.00 3.00 117.68

12.00
85.00
74.00
99.84
70.00
Purity Input Output
90.00 91.71 91.71 67.95 34.46 13.71
85.00 46.90 4.70 13.00
77.00 66.32 13.96 24.00
55.00 65.76 7.17 25.50
Purity 60.29
78.00 75.00
93.71
72.00 0.007 65.00
53.00
63.40
29.50
Purity
82.00
-
94.00
-
Purity
95.00
-
Purity
99.00
-
69.00
99.30
99.00
0.00
90.00
90.00
0.00
0.00
0.00
800.00
38.00
800.00
5.00
1400.00
0.10
J. P. MUKHERJI & ASSOCIATES Pvt. Ltd., MATERIAL BALANCE Annexure - III
(PROPOSED)
DBSIL-Nigohi 300 TCH Page - 5/45
SUMMARY
Crushing rate - tch 210 24 hrs

- TCD 5,040
Material % cane t/h cu m/h pol % Fibre % Moist. %
1 Cane 100.00 210.00 15.10 14.00

2 Bagasse 28.10 59.00 1.65 49.83 48.00
3 Imbibition 46.20 97.02 97.02 330.00 % on fibre
% cane t/h cu m/h Pol % Brix % purity

4 Mixed Juice 117.68 247.14 233.15 12.44 14.72 84.50
5 Quick Lime 0.14 0.30
6 Milk of Lime 3.21 6.74 6.49
7 Sulphur 0.05 0.10
8 Sulphur Dioxide 0.10 0.21 557.90
9 Air for Sulphur Burning 1030.12
10 Filter Cake 4.00 8.40 1.80
11 Filter Wash Water 3.00 6.30 6.30
12 Filtrate 18.14 38.10 37.35
13 Raw Juice 117.68 247.14 237.63
14 Sulphured Juice 139.08 292.06 280.83
15 Clear Juice to Evaporators 120.94 253.97 241.88 12.04 14.17 85.00
16 Syrup 23.15 48.63 36.84 74.00
17 Melt 17.51 36.77 27.86 70.00 95.72
18 Melt (CAW Sugar) 0.00 0.00 0.00 70.00 82.76
Pan Floor Material: Solids %C Qty t/hr Brix Pol Pty Qty % cane
19 A Massecuite 31.01 72.36 90.00 82.54 91.71 34.46

20 A1 Massecuite 4.28 9.87 91.00 77.35 85.00 4.70
21 B Massecuite 13.26 29.31 95.00 73.15 77.00 13.96
22 C Massecuite 7.03 15.06 98.00 53.90 55.00 7.17
Total Massecuite % Cane 60.29
23 A Heavy Molasses 11.05 28.30 82.00 63.96 78.00 13.48

24 A Light Molasses 1.76 5.21 70.90 66.44 93.71 2.48
25 A1 Heavy Molasses 2.22 5.68 82.00 59.04 72.00 2.70
26 B Molasses 5.68 14.04 85.00 45.05 53.00 6.69
27 C Light Molasses 1.34 3.56 79.07 50.13 63.40 1.69
28 Final Molasses 3.61 8.63 88.00 25.96 29.50 4.11
29 A1 magma 2.06 4.80 90.00 89.10 99.00 2.29

30 B Magma 7.58 17.68 90.00 85.50 95.00 8.42
31 C After Magma 2.08 4.84 90.00 84.60 94.00 2.31
32 C Fore magma 3.41 7.97 90.00 73.80 82.00 3.79
33 SUGAR BALANCE: % Cane 34 EXTRACTION: % Cane

Sugar in Cane 15.10 Mill Extraction 96.93
Sugar in Mixed Juice 14.64 Reduced Mill Extraction 97.31
Sugar in Bagasse 0.46 Boiling house recovery % Cane 91.69
Sugar in Filter Cake 0.07 Reduced boiling house recovery 92.00
Sugar in Final Molasses 1.07 Overall Extraction 88.87
Sugar in Sugar 13.40 Reduced Overall Extraction 89.52
Sugar Undetermined 0.10
Total Losses (Bag., F.Cake, Mol., Undetermined) 1.70
Sugar Recovery % Cane - Expected 13.40

J. P. MUKHERJI & ASSOCIATES Pvt. Ltd., EVAPORATOR BALANCE
(PROPOSED) Annexure - V B
Dalmia Bharat Sugar Page - 6/45
Unit - Datta Sakhar Karkhana 340 TCH
1.0 Basic Parameters
Factory crushing rate tch 210 24 hrs
Imbibition % fiber 330
t/h % cane
Raw juice 247.14 117.68
Treated juice 297.98 141.90
Clear juice 274.21 130.58
Clear juice brix 13.12
Syrup brix required brix 74.00
Condensate flash YES
2.0 Pan floor Steam Requirement at Average Demand t/h % cane

- A Batch Pans 17.92 8.53 From Effect - 3
- A1 Pans 3.75 1.78 From Effect - 3
- B Pans 3.27 1.56 From Effect - 2
- B Grain Pans 1.76 0.84
- C Pans 2.25 1.07 From Effect - 2
- C Grain Pans 1.21 0.58
- Total 30.15 14.36
Exhaust for varible pan stm. demand 0.00 0.00 From Exhaust
- Pan Washing 2.10 1.00 From Effect - 1
- Molasses Conditioning 0.61 0.29 From Effect - 3
- Sugar Melting (B + C Sugar) 0.69 0.33 From Effect - 3
- SHHW System 0.24 0.12 From Exhaust
- Sugar Drying 0.50 0.24 From Exhaust
Total Pan Demand 34.30 16.33
3.0 Juice Heaters Bleeding Effect Heating ( 0C) Bleeding Quantity

From To t/h % cane
Raw Juice Heating Stage - 1 Effect - 5 Tubular 28.00 45.27 7.05 3.36
Raw Juice Heating Stage - 2 Condensate PHE 45.27 55.69 0.00 0.00
Raw Juice Heating Stage - 3 Effect - 4 DCH 55.69 72.00 5.92 2.82
Limed Juice Heating Stage - 1 Effect - 3 Tubular 68.00 85.00 8.71 4.15
Limed Juice Heating Stage - 2 Effect - 3 DCH 85.00 95.00 4.34 2.07
Clear Juice Heating Stage - 1 Effect - 2 DCH 95.00 103.01 3.11 1.48
Filtrate Heating Effect - 2 DCH 55.00 55.00 0.00 0.00

Syrup Heating Effect - 3 DCH 63.89 63.89 0.00 0.00
Total 36.01 17.15
4.0 Evaporation
Total evaporation % Cane 107.42
t/h 225.59
Exhaust Quint - 1 Quint - 2 Quint - 3 Quint - 4 Quint - 5

Pressure Bara 2.20 1.76 1.34 0.94 0.56 0.20
Temperature 0
C 123.35 116.29 108.01 98.17 84.26 60.27
Evaporation from each body t/h 73.93 63.82 53.44 17.28 17.12
% Cane 35.21 30.39 25.45 8.23 8.15
Condensate from each body t/h 73.08 63.13 52.94 17.16 17.05
Juice heater condensate available for flash t/h 0.00 0.00 0.00 0.00 5.92
Pan condensate available for flash t/h 0.00 0.00 5.51 21.67 0.00
Condensate for flashing t/h 0.00 63.13 120.61 157.12 175.52
Condensate temperature in Cigar 0
C 120.67 108.01 98.17 84.26 83.47
Juice flow from each body t/h 274.21 200.28 136.46 83.02 65.75 48.63
Outlet brix 0
Brix 13.12 17.97 26.37 43.34 54.73 74.00
Average brix 0
Brix 15.54 22.17 34.85 49.04 64.37
Quantity of heat loss due to radiation t/h 1.45 0.94 0.79 0.26 0.21
Qty of Heat loss due to non condensibles t/h 0.99 0.85 0.71 0.23 0.34
Quantity of Juice flash vapours t/h -2.20 2.57 2.01 1.68 2.21
Quantity of Condensate flash vapours t/h 0.00 0.97 2.32 4.57 5.11
Quantity of Flash vapours for evaporation t/h -4.64 1.75 2.82 5.76 0.00
Heating Surface (Working Set) m2 5000 5500 5600 1700 1500

Specific evaporation rate Kg/ m2/ h 14.79 11.60 9.54 10.16 11.41
lb/ ft2/ h 3.03 2.38 1.95 2.08 2.34
Specific Evaporation Rate (Targeted) Kg/ m2/ h 25.00 18.00 15.00 10.00 10.00
Required Heating Surface (As Targeted) m2 2960 3550 3570 1730 1720
Dessin coefficient Kg/ m2/ h 0C 3.73 2.83 1.87 1.06 0.43

J. P. MUKHERJI & ASSOCIATES Pvt. Ltd., EVAPORATOR BALANCE
(PROPOSED) Annexure - V B
Dalmia Bharat Sugar Page - 7/45
Unit - Datta Sakhar Karkhana 340 TCH
Overall H.T.Coefficient W/ m2 0K 2098 1545 970 565 247
BTU/ ft2 0F 369.43 272.11 170.91 99.48 43.46
Apparent temperature drop 0

C 3.97 4.09 5.11 9.57 26.70
True temperature drop 0
C 4.33 4.66 6.18 11.49 30.31
Vapour temperature 0
C 119.01 114.35 108.16 96.67 66.36
Pressure in each body bara 1.96 1.69 1.37 0.92 0.27
Pressure in body Bar (g) 0.93 0.66 0.34
Vacuum in body Inches of Hg 2.43 21.13
Flap valve to reduce the pressure ∆t 0.00 0.00 0.00 0.00 0.00
Total temperature drop calculated 0

C 56.99
Total temperature drop available 0
C 63.07
5.0 Exhaust Steam consumption t/h % cane t/h % cane
Exhaust steam to Effect - 1 73.93 35.21 JH 36.01 17.15

Exhaust steam for Raw Juice Heater 0.00 0.00 Pans 34.30 16.33
Exhaust steam for Sulphured Juice Heater 0.00 0.00 Evap 9.52 4.534
Exhaust steam for Clear Juice Heaters 0.00 0.00 Flash -5.14 (2.448)
Exhaust steam for Pans 0.00 0.00
Exhaust steam for SHHW System 0.24 0.12
Exhaust steam for Sugar drying 0.50 0.24
Process Exhaust Steam Demand 74.68 35.56 74.69 35.57 -0.007818
Exhaust for evaporator soda boiling 2.00% 1.59 0.76 1.59 0.76
Losses & other uses @ ….on total demand 4.00% 3.18 1.51 3.18 1.51
Total Exhaust Steam Demand 79.45 37.83 79.46 37.84 -0.007818
thyssenkrupp Industries India Pvt. Ltd., EVAPORATOR BALANCE Annexure - V
Indian Potash Limited Page - 8/45
Basic Parameters
t/h % cane
Raw juice 247.14 117.68
Pan floor Steam Requirement at Average Demand t/h % cane

- A Batch Pans 11.65 5.55 From Exhaust
- A Grain Pans 6.27 2.99 From Exhaust
- B Pans 3.27 1.56 From Exhaust
- B Grain Pans 1.76 0.84 From Exhaust
- C Pans 2.25 1.07 From Exhaust
- C Grain Pans 1.21 0.58 From Exhaust
- C1 Pans 3.75 1.78 From Exhaust
- Total 30.15 14.36
- Melt Evaporator 0.00 0.00 From Effect - 2
- Molasses Conditioning 0.80 0.38 From Exhaust
- Run off Conditioning 0.00 0.00 From Exhaust
- Sugar Melting (B + C Sugar) 1.39 0.66 From Exhaust
- SHHW System 0.00 0.00 From Effect - 1
- Sugar Drying 0.14 0.07 From Effect - 1
Juice Heaters Bleeding Effect Heating ( 0C) Bleeding Quantity

From To t/h % cane
0.00
Sulphited Juice Heating Stage - 1 Condensate PHE 70.00 85.00 0.00 0.00
Sulphited Juice Heating Stage - 2 Effect - 4 Tubular 85.00 90.00 2.47 1.18
Sulphited Juice Heating Stage - 3 Effect - 3 DCH 90.00 98.00 3.40 1.62
Clear Juice Heating Stage - 1 Effect - 2 PHE 95.00 110.00 6.79 3.23
Melt Heating Effect - 3 DCH 55.00 55.00 0.00 0.00

Syrup Heating Effect - 3 Tubular 59.63 59.63 0.00 0.00
Raw Sugar Melting Effect - 2 DCH 50.00 75.00 0.00 0.00
Raw Melt Heating Effect - 3 DCH 70.00 83.00 0.00 0.00
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
Process Water Reheating-1 Effect - 3 DCH 89.06 95.49 1.59 0.76
Process Water Reheating-2 Effect - 2 DCH 75.00 75.00 0.00 0.00
Total 29.73 14.15
Evaporation
t/h 210.88

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
% Cane 28.40 25.70 21.29 20.19 4.84
DRAFT
thyssenkrupp Industries India Pvt. Ltd., EVAPORATOR BALANCE Annexure - V
Indian Potash Limited Page - 9/45
C 121.96 108.82 98.49 83.58 83.03
Outlet brix 0
Brix 13.87 18.00 24.66 35.56 61.21 74.00
Average brix 0
Brix 15.93 21.33 30.11 48.39 67.61
Correction due to latent heat difference t/h 0.64 0.71 0.75 1.28 1.00

2000 2000 2000 0 0
Heating Surface (Working Set) in Operationm2 4200 4000 4000 4000 1500
lb/ ft2/ h 2.91 2.76 2.29 2.17 1.39
Specific Evaporation Rate (Targeted) lb/ ft2/ h 5.00 3.70 3.00 2.00 2.00

BTU/ ft2 0F 397.15 307.55 211.28 113.10 41.25

C 3.49 4.25 5.00 8.68 14.86
C 3.87 4.79 5.86 10.55 19.04
C 124.67 120.81 116.01 110.15 99.60 80.57
Pressure in each body bara 2.30 2.08 1.78 1.47 1.02 0.49
Pressure in body Bar (g) 1.27 1.04 0.75 0.44
Vacuum in body Inches of Hg 14.66

C 44.10
C 69.22
Exhaust Steam consumption t/h % cane t/h % cane

Exhaust steam for Pans 0.00 0.00 lat.ht diff 0.59 0.280
Process Exhaust Steam Demand 60.23 28.68 60.24 28.69
Total Exhaust Steam Demand 61.46 29.27 61.47 29.27
DRAFT
J. P. MUKHERJI & ASSOCIATES Pvt. Ltd., EVAPORATOR BALANCE Annexure - V
(PROPOSED)
Basic Parameters
t/h % cane
Raw juice 247.14 117.68
Pan floor Steam Requirement at Average Demand t/h % cane

- A Batch Pans 11.65 5.55 From Effect - 3
- A Grain Pans 6.27 2.99 From Effect - 3
- A1 Pans 3.75 1.78 From Effect - 3
- B Pans 3.27 1.56 From Effect - 3
- B Grain Pans 1.76 0.84 From Effect - 3
- C Pans 2.25 1.07 From Effect - 2
- C Grain Pans 1.21 0.58 From Effect - 1
- Total 30.15 14.36
- Sugar Melting 0.82 0.39 From Effect - 2
Juice Heaters Bleeding Effect Heating ( 0C) Bleeding Quantity

From To t/h % cane
Raw Juice Heating Stage - 2 Condensate PHE 45.34 57.09 0.00 0.00
Tubular
Sulphited Juice Heating Stage - 1 Effect - 3 Tubular 70.00 84.00 7.01 3.34
Melt Heating Effect - 2 Tubular 70.00 70.00 0.00 0.00

Total 34.79 16.56
Evaporation
t/h 217.54

Pressure Bara 2.00 1.61 1.23 0.87 0.52 0.20
Temperature 0
C 120.49 113.38 105.59 95.91 82.66 60.27
% Cane 34.39 28.67 24.79 8.10 7.64
C 117.80 105.59 95.91 82.66 81.96
Outlet brix 0
Brix 13.52 18.55 26.91 44.05 55.65 74.00
Average brix 0
Brix 16.04 22.73 35.48 49.85 64.82
(PROPOSED)

2000 2000 2000 0 0
Heating Surface (Working Set) in Operation m2 4000 4200 4000 900 600
lb/ ft2/ h 3.70 2.94 2.67 3.87 5.47
(PROPOSED)

BTU/ ft2 0F 357.77 263.77 169.67 95.27 26.88

C 5.10 5.38 7.42 20.38 111.06
C 5.48 5.96 8.52 22.37 114.75
C 120.49 115.01 109.04 100.53 76.16 -47.29
Pressure in each body bara 2.00 1.72 1.41 1.05 0.41 0.92

C 157.08
C 60.22
Exhaust Steam consumption t/h % cane t/h % cane

J. P. MUKHERJI & ASSOCIATES PVT. LTD., EVAPORATOR BALANCE Annexure - V B
Upper Doab Sugar Mills 333 tch Page - 13 / 45

1.0 Basic Parameters
Shamli
t/h % cane
Mixed juice 247.14 117.68

- A Batch Pans 11.65 5.55 From Quintuple - 2
- A Grain Pans 6.27 2.99 From Quintuple - 2
- A1 Pans 3.75 1.78 From Quintuple - 1
- B Pans 3.27 1.56 From Quintuple - 2
- B Grain Pans 1.76 0.84 From Quintuple - 1
- C Pans 2.25 1.07 From Quintuple - 2
- C Grain Pans 1.21 0.58 From Quintuple - 1
- Total 30.15 14.36
- Pan Washing 2.10 1.00 From Quintuple - 1
- Sugar Melting (B + C Sugar) 0.82 0.39 From Quintuple - 2
3.0 Juice Heaters Bleeding Quintuple Heating ( C)

0
Bleeding Quantity
From To t/h % cane
Mixed Juice Heating Stage - 1 Quintuple - 5 Tubular 28.00 45.34 7.04 3.35
Mixed Juice Heating Stage - 2 Quintuple - 4 Tubular 45.34 70.00 10.29 4.90
Mixed Juice Heating Stage - 3 Quintuple - 4 Tubular 0.00
Sulphited Juice Heating Stage - 1 Quintuple - 2 Tubular 68.00 94.63 13.50 6.43
Sulphited Juice Heating Stage - 2 Quintuple - 1 Tubular 94.63 105.89 5.77 2.75
Clear Juice Heating Stage - 1 Quintuple - 1 Tubular 95.00 106.00 4.90 2.33
Clear Juice Heating Stage - 2 Exhaust Tubular 106.00 113.63 3.43 1.63
Filtrate Heating Quintuple - 2 DCH 55.00 55.00 0.00 0.00

Syrup Heating Quintuple - 3 Tubular 58.97 58.97 0.00 0.00
Total 44.91 21.39
4.0 Evaporation
t/h 205.34

Pressure Bara 2.00 1.60 1.21 0.84 0.49 0.16
Temperature 0
C 120.49 113.21 105.20 95.09 81.09 55.45
% Cane 38.53 28.01 10.58 11.76 8.90
C 117.75 105.20 95.09 81.09 79.63
Outlet brix 0
Brix 14.17 20.79 31.50 39.11 53.45 74.00
Average brix 0
Brix 17.48 26.15 35.30 46.28 63.72
Quantity of Juice flash vapours t/h 0.00 2.12 1.74 1.90 2.41
Heating Surface (Working Set) 2000 2500 800 750 1300

2500 2000 400 750 0
lb/ ft2/ h 3.68 2.68 3.79 3.37 2.95
J. P. MUKHERJI & ASSOCIATES PVT. LTD., EVAPORATOR BALANCE Annexure - V B
Upper Doab Sugar Mills 333 tch Page - 14 / 45

Shamli Heating Surface (Standby) Sq.M. 2000 2000 1200 1500 1300
BTU/ ft2 0F 375.08 264.59 192.72 117.76 48.42

C 4.79 4.71 9.59 14.05 30.94
C 5.21 5.42 10.68 15.77 34.45
C 115.28 109.86 99.18 83.40 48.95
Pressure in each body bara 1.74 1.45 1.00 0.55 0.12
Pressure in body Bar (g) 0.71 0.42

C 71.54
C 65.04
5.0 Exhaust Steam consumption t/h % cane
Exhaust steam to Quintuple - 1 81.67 38.89 JH 44.91 21.39

Exhaust steam for Mixed Juice Heater 0.00 0.00 Pans 34.04 16.21
J P MUKHERJI & ASSOCIATES PVT LTD EVAPORATOR BALANCE Annexure-V-B
1.0 Basic Parameters Page-15/45
(PROPOSED)
Factory
Dalmia Bharat crushing rate
Sugar tch 340 TCH 210
Unit- DattaImbibition
Sakhar Karkhana % fiber 330
t/h % cane
Raw juice 247.14 117.68
Sulphured juice 292.06 139.08

- A Pans 11.65 5.55 From Exhaust
- A Graining 6.27 2.99
- A1 Pans 2.44 1.16 From Exhaust
- A1 Graining 1.31 0.62
- B Pans 3.27 1.56 From Exhaust
- B Graining 1.76 0.84
- C Pans 2.25 1.07 From Exhaust
- C Graining 1.21 0.58
- Total 30.15 14.36
Exhaust for variable pan stm. demand 0.00 0.00 From Exhaust
- Superheated Wash Water System 0.31 0.15 From Exhaust
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 40.00 72.00 13.05 6.21
Raw juice stage - 2 PHE 72.00 72.00 0.00 0.00
Raw juice stage - 3 DCH
Raw juice stage - 4 72.00 72.00
Suphured juice stage - 1 Effect - 8 Tubular 68.00 85.90 0.00 0.00

Suphured juice stage - 2 Effect - 3 DCH 85.90 90.00 2.06 0.98
Suphured juice stage - 3 Effect - 3 DCH 90.00 95.00 2.13 1.01
Suphured juice stage - 4 95.00 103.00 3.82 1.82
Clear juice stage - 1 Effect - 2 DCH 96.00 103.01 3.18 1.51

Clear juice stage - 2 Effect - 1 DCH 103.01 113.29 4.70 2.24
Clear juice stage - 3 Exhaust PHE 113.29 113.29 0.00 0.00
Filtrate Effect - 3 65.00 65.00 0.00 0.00

Melt Heating Effect - 4 DCH 55.00 75.00 0.70 0.33
Total 29.64 14.11
4.0 Evaporation
t/h 211.29
Exhaust Quint - 1 Evapplus-1 Evapplus-2 Quint - 2 Quint - 3 Quint - 4 Quint - 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 59.79 -4.02 -1.88 55.14 43.97 42.64 15.65
% Cane 28.47 -1.92 -0.89 26.26 20.94 20.31 7.45
Condensate from each body t/h 59.11 -3.97 -1.85 54.55 43.55 42.35 15.67
Juice heater condensate available for flash t/h 0.00 0.00 0.00 4.70 3.18 2.06 0.00
Pan condensate available for flash t/h 0.00 0.00 0.00 0.00 0.00 2.44 0.00
Condensate for flashing t/h 0.00 -3.97 -1.79 55.27 99.41 144.38 155.98
Condensate Temperature in Flash Tank 0
C 120.70 114.17 108.70 108.01 98.17 84.26 83.55
Juice flow from each body t/h 259.92 200.13 204.15 206.03 150.89 106.92 64.28 48.63
Outlet brix 0
Brix 13.84 17.98 17.63 17.47 23.85 33.65 55.98 74.00
Average brix 0
Brix 15.91 17.80 17.55 20.66 28.75 44.82 64.99
Correction due to latent heat difference t/h 0.57 -0.03 -0.01 0.56 0.55 0.67 0.41
Quantity of heat loss due to radiation t/h 1.17 -0.08 -0.04 0.81 0.65 0.63 0.19
Qty of Heat loss due to non condensibles t/h 1.20 -0.08 -0.04 1.10 0.88 0.85 0.31
Quantity of Juice flash vapours t/h -1.61 2.05 1.85 -1.01 2.52 2.30 2.27
Quantity of Condensate flash vapours t/h 0.00 -0.07 -0.05 0.85 1.87 4.07 4.58
Quantity of flash vapours t/h -3.98 2.14 1.88 -2.07 2.86 4.88 6.34
Heating surface m2 6000 3500 3500 1700 1500 1000 1000

Specfic evaporation rate kg/h. m2/h 9.97 -1.15 -0.54 32.43 29.31 42.64 15.65
lb/h. ft2/h 2.04 -0.24 -0.11 6.64 6.00 8.73 3.21
kg/h. m2/h 25.00 15.00 15.00 18.00 15.00 10.00 10.00

m2 2390 -270 -130 3060 2930 4260 1570
Dessin coefficient kg/h. m2. 0C 3.71 3.45 3.45 3.33 2.75 1.89 0.50
Overall H.T.Coefficient Btu/h.ft2. 0F 345.53 -1322.6 -219.7 342.18 278.45 191.21 48.49
W/m2. K 1962.00 -7510.18 -1247.72 1942.99 1581.11 1085.71 275.32
Apparent temp. drop 0

C 2.68 -0.33 -0.16 9.74 10.64 22.54 31.57
DRAFT
J P MUKHERJI & ASSOCIATES PVT LTD EVAPORATOR BALANCE Annexure-V-B
(PROPOSED) Page-16/45
Dalmia Bharat Sugar 340 TCH
Unit- Datta Sakhar Karkhana
True temp. drop 0

C 3.12 0.09 0.27 10.37 11.66 25.09 37.26
C 120.22 120.13 119.86 109.86 98.20 73.11 35.85
Pressure in each body bara 2.04 2.03 2.02 1.45 0.97 0.36 0.06
Vacuum Inches Hg 0.92 18.46 27.19
2.34
Flap valve to reduce the pressure ∆t 0
C 0.00 0.00 0.00 0.00 0.00 0.00 0.00

C 87.50
C 63.07
5.0 Exhaust Steam consumption t/h % cane t/h % cane

Exhaust steam for raw juice heater 0.00 0.00 Pans 34.09 16.23
Exhaust steam for sulphured juice heater 0.00 0.00 Evap 2.60 1.239
Exhaust steam for clear juice heaters 0.00 0.00 Flash -5.72 (2.722)
Exhaust steam for variable pan steam demand 0.00 0.00 lat.ht diff 0.57 0.272
Exhaust steam for Sugar Drying 0.50 0.24
Process Exhaust steam demand 61.18 29.13 61.19 29.14 -0.0078 -0.0037
Exhaust steam for Soda Boiling (Evap. Cleaning) 0.00% 0.00 0.00 0.00 0.00
Losses on total demand 1.24% 0.77 0.37 0.77 0.37
Total exhaust steam demand 61.95 29.50 61.96 29.50 -0.0078 -0.0037
DRAFT
J. P. MUKHERJI & ASSOCIATES Pvt. Ltd.,
JUICE HEATER BALANCE Annexure - IV A
Dalmia Bharat Sugar
(EXISTING) Page - 17/45
Unit - Datta Sakhar Karkhana
230 TCH
DESCRIPTION Heater No. ---> #1
Heating Surface Area (HSA) m2 210
Type of heater Tubular

Provision of heating for the juice RJ-1
VLJH
Working / Standby Working
Crushing Rate tch 210

Total Juice Flow % Cane 117.68
Juice Flow per heater % total flow 100%
Juice Flow per heater - t/h 247.14
Juice Flow per heater - m3/h 235.37
Calculated HSA m2 210

No. of tubes per pass (Original) 25
Number of passes 12
Total No. of tubes 300
Tube material SS
Tube OD mm 45.00
Tube Thickness mm 1.20
Tube ID mm 42.60
Tube Length mm 5100
Bleeding Effect 5
Heating medium temp. oC 62.00
Dynamic / Conventional (1 / 0) 1
Juice Inlet Temperature oC 28.00
Juice Outlet Temp. (attainable) oC 45.34
Juice Velocity (Original) m/s 1.83
Pressure Drop m 12.39

Plant Capacity tch 210.00
Code Description Units Capacity
Juice treatment
Mixed Juice % cane 117.68
Quantity - m /h
3
235.37
Screened Juice tank

- Length - mm 3950.00
- Width - mm 2650.00
- Height - mm 3000.00
Holding Capacity - m3 45.00
- Retention time required - min 10.00
- Retention time Available - min 11.47
Available capacity OK OK
SHORT ---
Mixed Juice Pump
-Recirculation capacity required % 10.00%

-Pump capacity required m3/h 258.90
m3/h 260.00
-Existing Pump capacity m3/h 400.00
SHORT ---
Phosphoric Acid Preparation

210.00
Quantity of Mixed Juice % Cane 117.68
tons/hr 247.14
P2O5 in the juice ppm 150.00
Desired dose of P2O5 ppm 350.00
To be added ppm 200.00
phosphate quantity kgs/hr 49.43
Purity of Orthophosphoric acid % 85.00
P2O5 in H3PO4 by mass 72.45
P2O5 in above purity orthophosphoric acid % mass 61.58
Orthos phosphoric acid for above P2O5 dose kgs/hr 80.26
Specific Gravity of Ortho phosphoric acid wt/vol 1.71
Vol of Orthoric phosphoric acid required lts/hr 46.94
Dilution for phosphoric acid solution times 1.00
With 1:5 dilution, dosage of diluted phosphate solution lts/hr 46.94
Phosphoric acid Preparation Tank residence time hrs 10.00
Tank capacity lts 469.37
Storage Tank lts 469.37
Dosage Pump lts/hr 56.32
lts/min 0.94
Juice sulphiter
Reaction tank 210.00
Total juice retention time required minute 8.00
Sulphited Juice Quantity % cane 139.08

t/h 292.06
m3/h 278.16
Juice Sulphiter
Working height m 2.0
Diameter m 3.50
Working Volume (Available) m3 19.24
Working Volume (Required) m3 37.09
Retention time required min 8.00

Retention time Available min 4.15
Working Height m 2.00

Diameter m 4.86
Sulphiteded Juice Pump 210.00

-Juice quantity % cane 139.08
t/h 292.06
m3/h 278.16
-Nearest round up m3/h 320.00
-Pump No. #1
-Working or standby W / SB W
Existing
-Pump No. #1
-Pump capacity available m3/h 400.00
SHORT ---
-Recirculation capacity available % 143.80%
Sulphured Juice Pump After 1st heating 210.00

t/h 272.38
m3/h 259.41
m3/h 290.00
-Pump No. #1
Existing
-Pump No. #1
Available capacity OK
SHORT
Sulphured Juice Pump After 2nd heating 210.00

t/h 272.38
m3/h 259.41
m3/h 290.00
-Pump No. #1
Existing
-Pump No. #1
SHORT
Clear Juice Pump 210.00

t/h 266.16
m3/h 255.93
m3/h 290.00
-Pump No. #1
Existing
-Pump No. #1
SHORT ---
-Recirculation capacity available % 156.29%
Clear Juice Pump After 1st heating 210.00

t/h 249.85
m3/h 237.95
m3/h 300.00
-for 3500 m3/h 300.00
-Pump No. #1
Existing
-Pump No. #1
SHORT
Clear Juice Pump After 2nd heating 210.00

t/h 253.09
m3/h 241.04
m3/h 310.00
-for 3500 m3/h 310.00
-Pump No. #1
Existing
-Pump No. #1
SHORT
Clarification and filtration

Clarifier
210.00
-Quantity of sulphured juice to be treated % cane 142.95
-Quantity of juice to be treated m3/h 285.89
50%
142.95 142.95
ft 34 32
-Diameter of Clarifier mm 10363 9754
-No of compartments 4 4
-Height of Clarifier mm 6096 6096
-Total volume m3 514.19 455.48
-Total volume available including existing clarifier m3 503.91 446.37
-Retention time available h 3.53 3.12
-Retention time required h 2.25 2.25
Available capacity working with 4 comp OK OK OK

SHORT --- ---
Clear Juice Column

Clear Juice % cane 126.74
tons/hr 266.16
m3/h 255.93
-Retention time of column required min 5.00
-Required Column Capacity m3 21.33
-Column height m 12.00 12.00
-Column dia mm 2100 2100.00
-Actual Volume of column m3 41.54 41.54
-Retention time of each column min 19.48 19.48
Available capacity working with 4 comp OK OK OK
SHORT --- ---
Rotary Vacuum filters 210.00 Existing

- Filter Diameter 13 0
3962 0
- Filter Length 26 0
7925 0
- Filtering Area m2 99 0
- Total Filtering Area 99
-Filtering area required per tch m2/tch 0.65
-Total filtering area required m2 136.50
-Total filtering area required(additional) m2 37.85
Available capacity OK ---
SHORT SHORT
-Filter length mm 8536.59 8536.59

-Filter dia mm 4268.29 4268.29
-Filter size , dia ft 14.00 14.00
-x length 28.00 28.00
-Filtering area m2 114.48 114.48
-Total filtering area available/proposed m2 228.97
-Filtering area required per tch m2/tch 0.65
-Total filtering area required m2 136.50
-Total filtering area required(additional) m2 -92.47
SHORT ---
Vacuum pump for RVF 210.00

-Capacity available m /h 3
2500.00 2500.00
-Drive Motor
-Working or standby W / SB 1W 1W
-Capacity required per filtering area m3/m2/h 20.00
-Vacumm pump capacity required m3/h 4580.00
-Vacuum pump capacity avilable m3/h 5000.00
-Vacumm pump capacity required(additional) m3/h -500.00
SHORT ---
Bagacillo blower 210.00

-Blower capacity available m /min
3
365.00 365
m3/h 21900.00 21900.00
W SB
-Bagacillo qty. required kg/tch 8.00
-Air required per kg of bagacillo m3/kg 6.25
-Blower capacity required m3/h 10500.00
10500.00
m3/min 175.00
m3/min 200.00
SHORT ---
Bagacillo screens
Length mm 6000.00
Width mm 2500.00
Area m2 15.00
Screen area required m /tch
2 0.06 12.60
SHORT --
Bagacillo piping 210.00

-Bagacillo pipe diameter existing mm 400.00
-Design velocity m/s 25.00
-Bagacillo duct diameter required mm 310.00
SHORT ---
MOL and SO2 preparation

Lime slaker 210.00
-Capacity Existing kg/h 2500.00
-Lime consumption (max.) % cane 0.20
-Capacity suitable for working hours hours 12.00
-Lime slaker capacity required kg/h 840.00
SHORT ---
MOL storage tanks 210.00

-Storage time required - minimum h 8.00
-MOL quantity, @ 6 Be' % cane 3.21
-MOL quantity, @ 6 Be' t/h 6.74
-MOL density, @ 6 Be' 1.045
-MOL quantity, @ 6 Be' m3/h 6.45
-Total capacity of storage - required m3 51.56
m3 52.00
- existing storage tanks capacity m3 30.17
- size of storage tanks height m 4.90
-size of storage tanks, diameter m 2.80
-Storage time available h 8.07
-No of Tanks W / SB 1W
MOL Pumps 210.00
-MOL quantity, @ 6 Be' % cane 3.21
-MOL quantity required m3/h 6.45
-MOL pump capacity required m3/h 12.89
m3/h 13.00
-MOL pump available m3/h 10.00 10.00
-Working or standby W / SB 1W 1 SB
-Available capacity OK ---
SHORT SHORT
Sulphur burners
Sulphur burners - for juice
210.00
-Sulphur burners Type Film Type Cont.
-Tray area m2 --
-Capacity, each kg/h 200.00 200.00
-Working / Standby W / SB W SB
-capacity of continuous burner availabe kg/h 200.000 200.000
-Sulphur consumption for juice % cane 0.054
-for capacity calculation % cane 0.050
kg/h 110.00
SHORT ---
Sulphur burners - for syrup

210.00
-Sulphur burners Type Film Type Cont.
-Tray area m2 --
-Capacity, each kg/h 200.00 200.00
-Capacity Available in working kg/h 200.00
-Sulphur consumption for syrup % cane 0.027
-for capacity calculation % cane 0.030
kg/h 70.00
SHORT ---
Air compressors for sulphur burners

Air compressor (for juice) 210.00 0.00
-Capacity available m /h
3
2000.00 2000.00
-Delivery pressure required kg/cm2(g) 1.00 1.00
-Total working capacity available m3/h 2000.00 2000.00
-Air required per kg of sulphur m3/kg 8.60 8.60
-Total air required m3/h 946.00 0.00
-Total air required for 200 kg m3/h 1720.00 1720.00
m3/h 1800.00 1800.00
SHORT ---
Air compressor (forsyrup) 210.00
-Capacity available m3/h 800.00 800.00
-Working / Standby W / SB W
-Delivery pressure required kg/cm2(g) 1.00
-Total working capacity available m3/h 800.00
-Air required per kg of sulphur kg/kg 8.60
-Total air required m3/h 602.00
-Total air required for existing burner capacity m3/h 1720.00
m3/h 1720.00
SHORT ---
Syrup sulphiter 210.00

Total syrup retention time require min 15.00
working height m 1.5
Diameter m 4.00
Working Volume cu.m 18.85
Syrup Quantity % cane 23.15
110% 25.47
Syrup Quantity t/h 53.49
Let density of juice 1.32
Syrup quantity m3 40.52
Volume required 10.13
Syrup sulphiter 210.00

Total syrup retention time require min 15.00
working height m 1.5
Syrup Quantity % cane 26.16
Melt Quantity % cane 0.00
Total Syrup & Melt Quantity % cane 26.16
Syrup & Melt Quantity t/h 54.93
Syrup & Melt quantity for 15 min t 13.73
Let density of juice 1.32
Syrup quantity for 15 min m3 10.40
Required Diameter of the sulphiter m 2.97
Syrup sulphiter capacity required m3 10.40
Syrup sulphiter capacity available m3 18.84
Height above syrup column should be 2.0 x w.h. m 3.0
Available retention time min 27.2
SHORT ---
Crystallisation
Syrup & molasses storage tanks
70 TCH Estimsted Estimsted Estimsted

210.00 Quantity Quantity Retention time
Required
% cane m /h
3
Hrs
-Sulphured syrup 23.15 36.84 2.50
-Melt 17.51 27.86 2.50
-Melt CAW 0.00 0.00 2.50
-AL 2.48 3.95 2.50
-Total Sy + Melt + AL 43.15 68.64 10.00
-AH 13.48 21.44 4.00
-A1H 2.70 4.30 6.00
- BH 6.69 10.64 6.00
-CL 1.69 2.69 6.00
-Total 24.56 39.07 32.00
-Each Tank Capacity m3 40.00
Molasses conditioners AH B1
330.00 Estimsted Estimsted
-Quantity m3/h 21.44 4.30
-Retention time required min 20.00 20.00
-Capacity require m3 7.15 1.43
Vacuum pans 210.00 Estimsted Estimsted

Massecuite A A1
Massecuite Quantity Average % cane 34.46 4.70
t/h 72.36 9.87
Massecuite Quantity Maximum % cane 38.46 5.17
Massecuite Quantity Maximum t/h 80.76 10.85
t/day 1938.24 260.51
Massecuite boiling time hrs 3.00 5.00
No. of strikes per day 8.0 4.8
Grain capacity required t/day 678.4 86.8
Grain/Seed boiling time hrs 2.0 4.0
No. of grain/seed strikes per day 12.0 6.0
Grain boiling pan Capacity required
- Batch pans t/strike 56.5 14.5
- Total grain + massecuite pan capacity required t/strike 298.8 68.7
Pan Capacity required
- Batch pans m3/strike 170.62 38.22
- Batch pans HL/strike 1706.19 382.20
- Continuous pans t/h --- 15.00
Existing Grain pan capacity tons 60 80
- Grain pans required 0.94 0.46
1 1
- Existing Grain pans 1 1
- Balance required 0 0
Existing m/c pan capacity 120 35
- m/c pans required 2.02 15.00
3 cont.pan
- Existing m/c pans 3 1.00
- Balance required 0
One 30 t/hr continuous pan for B1 massecuite &
Vacuum pans (330 tch) Estimsted Estimsted
Massecuite A B1
Massecuite Quantity Average % cane 34.46 4.70
t/h 0.00 0.00
Massecuite Quantity Maximum % cane 37.90 5.17
Massecuite Quantity Maximum t/h 0.00 0.00
t/day 0.00 0.00
Massecuite boiling time hrs 3.00 5.00
No. of strikes per day 8 5
Capacity required
- Batch pans m3/strike 0.00 0.00
- Batch pans HL/strike 0.00 0.00
- Continuous pans t/h --- 0.00
cont.pan
No. of 60 t pans required Nos. 0.00 0.00
No. of 60 t pans available Nos. 0.00 0.00
Balance required Nos. 0.00 0.00
0.00 0.00
Let batch pan capacity is t 120 50

Therefore no of pans required Nos. 0.00 0.00
Nos. 0.00 0.00
Seed crystallisers(330 tch) Dry seed B seed

Estimsted Estimsted
-Capacity available t 60.00 60.00
-Capacity required t 40.00 53.33
t 40.00 60.00
Available capacity OK OK OK
SHORT --- ---
Vacuum crystallisers (70 tch) Estimsted Estimsted
Massecuite A B1
-Capacity available t 70.00 90.00
-Capacity required t 66.00 36.00
Massecuite Production Quantity Maximum % cane 37.90 5.17
Massecuite Production Quantity Maximum t/day 1910.30 260.51
Seeding / Grain quantity required t/day 636.77 86.84
t/8hrs 212.26 28.95
Available capacity OK OK OK
SHORT --- ---
Receiving crystallisers (330 tch)

330.00 A B1
Estimsted Estimsted
-Massecuite quantity estimated % cane 34.46 4.70
-Massecuite quantity for cap calculation % cane 38.46 5.17
t/h 80.76 10.85
Let massecuite boiling cycle time requred hrs 3.00 5.00
Let massecuite cooling time required hrs 0.00 2.00
Therefore total massecuite retention time hrs 3.00 7.00
Therefore total massecuite prod.in retention time t 242.28 100.00
Let Pan capacity t 120.00 #REF!
Let crystalliser capacity t 130.00 #REF!
Therefore no.of crystallisers required Nos. 1.86 #REF!
Nos. 2.00 #REF!
Existing 3.00 2.00
vert.crystallizer
Centrifugals
Batch Centrifugals A
330
Make and/or type 271.00
Massecuite quantity - % cane 38.46
- t/h 126.91
- t/day 3045.80
Hours working per day - hrs 21
Massecuite quantity for capacity calculation - t/h 145.04
Type Batch / Continuous Batch
Capacity per charge -t 1.75
Number of charges per hour - Nos 20
Capacity of each machine - t/h 35.00
Total capacity available - t/h 105.00
Capacity per day - t/day 2205.00
No. of machines available - Nos 3
No. of machines required - Nos 4.14
No. of machine for standby duty - Nos 1.00
Total No. of machines required - Nos 5.14
SHORT SHORT
Total No. of machines required - Nos 6
To add - Nos 1
Continuous Centrifugals ( 70 tch) A1 B
(B and CAW)
Make and/or type NK-1100 NK-1100
Massecuite quantity - Average - % cane 5.17 15.35
- t/h 10.85 32.24
- t/day 260.51 773.87
Hours working per day - hrs 21 21
Massecuite quantity for capacity calculation - t/h 12.41 36.85
Capacity of each machine (0.09 mm screen) - t/h 10.00 16.00

Total capacity available - t/h 20.00 64.00
No. of machines available - Nos 2 4
Number of machines required - Nos 1.24 2.30
Available capacity OK --- OK
SHORT SHORT ---
say - Nos 2 3
To add - Nos 0 -1
110%
A1 B CAW
4.70 13.96 3.79
5.17 15.35 4.17
10.85 32.24 8.76

12.41 36.85 10.01
Type 1400 1500 1400

# of Machines 2 3 3
Capacity t/h 10 16 8
total capacity available 20 48 24
1.24 2.30 1.25

2 3 2
Proposal 1
Continuous Centrifugals (CFW) CFW

210.00
Make and/or type NK1503
Massecuite quantity - Average - % cane 7.89
Massecuite quantity - Average - t/h 16.57
- t/day 397.65
Hours working per day - hrs 21
Massecuite quantity for capacity calculation - t/h 18.94
Capacity of each machine (0.05 mm screen) - t/h 4.00

Total capacity available - t/h 8.00
No. of machines available - Nos 2
Number of machines required - Nos 4.73
SHORT SHORT
say - Nos 5
Spare - Nos 1
To add (total) - Nos 4
FM storage tanks 210.00

-Capacity each tank cu.m 12500.00
cu.m 5400.00
-Total capacity available cu.m 17900.00
-Estimated Final molassess production % cane 4.11
-Final molassess production for cap calculation % cane 4.52
-Final molassess production t/h 9.49
-tank capacity required ton 12525.90
(at 50 % production in 120 days)
-tank capacity required cu.m 9076.74
-tank capacity required considering 20 % exra cu.m 10892.09
-tank capacity required cu.m 10900.00
SHORT ---
Short by cu.m 7000.00
Tank required nos. 3 x 5400 cu.m.
Sugar Melter 210.00

- Quantity of melt % cane 14.47
t/h 30.39
m3/hr 23.02
m3/min 0.38
- melter number #1
- Dia m
- height m
- capacity m3
- Retention time available min
- Retention time required min 30.00
- capacity required m3 11.51
- capacity required T 15.20
- capacity available m3 11.40
- retention time avaialble min 29.72
Sugar handling
Single tray grass hopper*****
Sugar elevators 210.00

-Capacity - each t/h 15.00
-Total Capacity Available t/h 0.00
-Sugar recovery - % cane 10.21
-Sugar recovery for cap calculation - % cane 12.21
-Actual sugar quantity t/h 25.64
-Capacity required t/h 30.00

SHORT SHORT
Sugar grader 145 tch

-Capacity - each t/h 15.00
-Actual sugar quantity t/h 25.64
-Capacity required t/h 30.00

SHORT SHORT
Sugar Bin
Recovery - Maximum % cane 12.00

Total sugar produced t/h 25.20
t/day 605
Grades M-30
Distribution % 85.00%
Quantity of sugar t/day 514.25
Bins capacity - No. 1 t 150
- No. 2 t 150
- No. 3 t -
Total t 300
Retention time Available hours 14.00
Retention time preferable hours 16

SHORT SHORT
Short by t/day 214.25
Bin capacity required @ 16 hrs ret. Time t 142.83
Add 1
SUGAR GODOWN
Existing Godown capacity Qtls 20,000
Season days days 120

Recovery 11.23
Required capacity (50% of total) 311250.00
Condensing Station
Injection Pump
a) Water for condensation:
Vapour from evaporator t/h 2.00
Vapour from pans t/h 55.00
Total t/h 60.00
% cane 28.57Theoritical requirement
Vapour load - Maximum @ 35 % on cane % cane 35.00 28.57
t/h 73.50 60.00
Temperature difference of hot & cold water Deg C 9.00 8.00
Water required for condensation kg/kg of vap 63.56 71.50
Total water required for condensation t/h 4671.33 4290.00
b) Water for ejectors:

No. of ejector Nos. 1
Size of ejector mm 200
Water consumption per ejector cu.m/h 133.00
Water required for all ejectors cu.m/h 133.00
Total water consumption cu.m/h 4804.33

Pump capacity, each cu.m/h 4900.00
Existing pump capacity cu.m/h 6300.00
Existing number of pumps Nos. 1.00
Existing pump available capacity cu.m/h 6300.00
Additional pump capacity required cu.m/h -1400.00
No. of pumps required Nos. -0.22
Rounded to Nos. -1
Spare Nos. 1
Total No. of pumps required Nos. 0
No. of pumps available Nos. 0

SHORT ---
Short by Nos. 0
Add Nos. 0
Cooling Tower
Water used for condensation cu.m/h 4671.33

Vapour condensed cu.m/h 73.50
Total water to be cooled cu.m/h 4744.83
Capacity of each cell cu.m/h 1000.00

No. of cells required Nos. 4.74
Rounded to Nos. 5
No. of cells available Nos. 2

SHORT SHORT
Short by Nos. 3
Add Nos. 3 Addition
Cooling water pump

Total water to be cooled cu.m/h 4744.83
Pump capacity, each cu.m/h 2250.00
No. of pumps required Nos. 2.11
Rounded to Nos. 3
Spare Nos. 1
Total No. of pumps required Nos. 4
No. of pumps available Nos. 2

SHORT SHORT
Short by Nos. 2
Add Nos. 2 Addition
2500.00
SB
Existing
27.16
1.5
W Vol
18.84
4.00
Estimsted Existng
Storage cap. eah tank No of Total
Required 10 % extra capacity tanks capacity
m3 m 3
Dia Length cu.m
92.09 101.30 3.50 8.40 80.01 2 160.02 58.72
69.65 76.61 3.50 8.40 80.01 1 80.01 3.40
0.00 0.00 3.50 8.40 80.01 1 80.01 80.01
9.86 10.85 3.50 4.20 40.00 1 40.00 29.15
171.60 188.76 5
85.76 94.33 3.50 8.40 80.01 2 160.02 65.68
25.81 28.39 3.50 8.40 80.01 1 80.01 51.62
63.82 70.20 3.50 8.40 80.01 1 80.01 9.81
16.16 17.78 3.50 4.20 40.00 1 40.00 22.23
363.16 399.47 9.99 29.40 2279.96 5 ###
B2 CL
Estimsted Estimsted
10.64 2.69
20.00 20.00
3.55 0.90
Estimsted Estimsted Estimsted Estimsted

B C Grain A-seed Total
13.96 7.17 --- 60.29
29.31 15.06 --- 126.60
15.35 7.89 --- 66.87
32.24 16.57 --- 140.43
773.87 397.65 477.34 646.08 4493.68
6.00 8.00 4 2
4.0 3.0 6.0 12.0 ---
258.0 132.5
4.0 4.0
6.0 6.0
43.0 22.1
236.5 154.6 758.66
--- 260 500.00
193.47 132.55 79.56 53.84 755.97
136.25 93.34 56.03 37.92
1362.45 933.44 560.26 379.15
--- 17.00 --- ---
60
0.72
1
1
0
25
17.00
cont.pan
1
uous pan for B1 massecuite & rearrange the pans

Estimsted Estimsted Estimsted Estimsted
B2 C Grain Total
13.96 7.17 --- 60.29
0.00 0.00 --- 0.00
15.35 7.89 --- 66.32
0.00 0.00 --- 0.00
0.00 0.00
6.00 8.00
4 3 --- ---
---
0.00 0.00 40 40.00
0.00 0.00
0.00 0.00
--- 0.00 --- ---
0.00 0.00 1.00 1.00

0.00 0.00 0.00 0.00
0.00 0.00 1.00 1.00
0.00 1.00 1.00
60 50 25
0.00 0.00 1.60
0.00 2.00 2.00
Estimsted Estimsted
B2 C
90.00 70.00
40.00 40.80
15.35 7.89
773.87 397.65
257.96 132.55
85.99 44.18
OK OK
--- ---
B2 C
Estimsted Estimsted
13.96 7.17
15.35 7.89
32.24 16.57
6.00 8.00 132.55
4.00 16.00 265.10
10.00 24.00
322.45 398.00
60.00 #REF!
65.00 #REF!
4.96 398.00
5.00 398.00 #REF!
1.00 2.00 8.00
t.crystallizer vert.crystallizer
CAW Total Manufactu

rer
recommen
Screen dation (t/h)
slot size
Spare Spare (mm)
For B1 B2/CAW
NK-1100 NK-1100 NK-1100 NK-1100
3.79 B & C after curing 0.09 10 - 12
7.97 0.06
191.19 C fore curing 0.06 6 - 8
21 0.05
9.10 21.51 NK-1350
B & C after curing 0.09 12 - 14
10.00 0.06
10.00 C fore curing 0.06 8 - 10
1 0 0 7 0.05
0.91 1.00 1.00 5.45
OK --- OK NK-1503
--- SHORT --- B & C after curing 0.09 16 - 18
1 1 1 8 0.06
0 1 1 1 C fore curing 0.06 10 - 12
0.05
CFW
7.17
7.89
16.57
18.94
1500
4
10
40
1.89
2
1
Available Required
dia 2200 2.71
ht 3000 2.00
vol 11.40 11.51
tical requirement
Okay
Okay
Okay
Okay
Okay
Okay
Okay
Okay
Capacity
consider
ed for
calculati
on (t/h)
10
8
6
4
14
10
8
6
16
14
10
8
Data for equipment size calculations
S.No Description Units Quantity
1 Plant Capacity tch 210.00 210.00

Mixed Juice %cane 117.68 117.68
Raw Juice %cane 117.68 117.68
Sulphured Juice %cane 139.08 139.08 142.94635
Filrate %cane 18.14 18.14
Clear Juice %cane 120.94 120.94
Syrup %cane 23.15 23.15
Quick lime cosumption %cane 0.14 0.14
Milk of Lime %cane 3.21 3.21
m3/h 6.49 6.49
Sulphur consumption %cane 0.05 0.05
Massecuite quantities
-A %cane 34.46 34.46
- A1 %cane 4.70 4.70
-B %cane 13.96 13.96
-C %cane 7.17 7.17
Molassess quantities
- Melt %cane 17.51 17.51
- AH %cane 13.48 13.48
- AL %cane 2.48 2.48
- A1H %cane 2.70 2.70
-B %cane 6.69 6.69
- CL %cane 1.69 1.69
- FM %cane 4.11 4.11
Magma
A1 Magma %cane 2.29 2.29
B Magma %cane 8.42 8.42
C After Magma %cane 2.31 2.31
C Fore Magma %cane 3.79 3.79
Sugar recovery %cane 13.40 13.40

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Baghauli Balance-R

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Baghauli Balance-R

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Double Sulphitation Process

A-A1 Masscuite boiling scheme

11 Bagacillio mill wet(50% moisture) -kg/tch

24 A fore sugar - Reference purity

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

26 B+C sugar magma brix

28 A light boiled in B massecuite in %

36 Unknown losses % cane

250.00 3.00 117.68

Crushing rate - tch 210 24 hrs

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

1 Cane 100.00 210.00 15.10 14.00

% cane t/h cu m/h Pol % Brix % purity

19 A Massecuite 31.01 72.36 90.00 82.54 91.71 34.46

23 A Heavy Molasses 11.05 28.30 82.00 63.96 78.00 13.48

29 A1 magma 2.06 4.80 90.00 89.10 99.00 2.29

33 SUGAR BALANCE: % Cane 34 EXTRACTION: % Cane

Sugar Recovery % Cane - Expected 13.40

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

Total Pan Demand 34.30 16.33

3.0 Juice Heaters Bleeding Effect Heating ( 0C) Bleeding Quantity

Filtrate Heating Effect - 2 DCH 55.00 55.00 0.00 0.00

Total 36.01 17.15

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

Heating Surface (Working Set) m2 5000 5500 5600 1700 1500

Dessin coefficient Kg/ m2/ h 0C 3.73 2.83 1.87 1.06 0.43

Apparent temperature drop 0

Total temperature drop calculated 0

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

Exhaust steam to Effect - 1 73.93 35.21 JH 36.01 17.15

Indian Potash Limited Page - 8/45

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

Total Pan Demand 34.59 16.47

Juice Heaters Bleeding Effect Heating ( 0C) Bleeding Quantity

Melt Heating Effect - 3 DCH 55.00 55.00 0.00 0.00

Total 29.73 14.15

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

Indian Potash Limited Page - 9/45

Heating Surface (Working Set) m2 2200 2000 2000 4000 1500

Dessin coefficient Kg/ m2/ h 0C 4.07 3.17 2.24 1.22 0.46

Apparent temperature drop 0

Total temperature drop calculated 0

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

Exhaust steam to Effect - 1 60.23 28.68 JH 29.73 14.16

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

Total Pan Demand 34.70 16.52

Juice Heaters Bleeding Effect Heating ( 0C) Bleeding Quantity

Melt Heating Effect - 2 Tubular 70.00 70.00 0.00 0.00

Total 34.79 16.56

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

Heating Surface (Working Set) m2 2000 2200 2000 900 600

Dessin coefficient Kg/ m2/ h 0C 3.54 2.67 1.75 0.93 0.24

Apparent temperature drop 0

Total temperature drop calculated 0

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

Exhaust steam to Effect - 1 72.87 34.70 JH 34.79 16.56

Upper Doab Sugar Mills 333 tch Page - 13 / 45

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

Total Pan Demand 34.04 16.21

3.0 Juice Heaters Bleeding Quintuple Heating ( C)

Filtrate Heating Quintuple - 2 DCH 55.00 55.00 0.00 0.00

Total 44.91 21.39

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