An ideal approach for the

determination of Primary Extraction

(Presented in the Google Meet Webinar held on 25-08-2020 from 17:00 to 18:30 hrs)

K. JAGADEESH
jagdishnsi@gmail.com
7757019011 1

8/25/2020 PUNE
Milling Control Significance of
Parameters Primary Extraction

OVERVIEW
What is Primary Methods used for
Extraction determination of PE

Comparison & Limitations Proposed

of different Methods Method for PE
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2
Tools for Monitoring of Milling Operations

➢ By Physical Observation
➢ Field Instruments
➢ Sampling & Analysis

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Milling Control Analytical
Brix%
Pol %
Purity
Moisture
Calculated
Pol in Bagasse % Cane
Pol In MJ % Cane
Pol % Cane
Mill Extraction
Fibre % Cane
Measured RME
Temperatures Java Ratio
Preparation Index
Flows of Juice, Imb Water
Primary Extraction
Weight of Cane.
Brix Curves etc
 PRESCRIBED METHODS FOR FEW PARAMETERS

Pol % Bagasse N C Verma

Moisture % Bagasse N C Verma/ ICUMSA

Mill Extraction By Calculation

Reduced Mill Extraction N. Deerr

Degree of Preparation ICUMSA (PI)/ Australian (PPOC)

Pol Basis
Primary Extraction Bx Basis
Juice basis

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MILL HOUSE PERFORMANCE PARAMETERS
- NORMALLY ACHIEVED VALUES

Pol % Bagasse 1.50 – 2.00

Moisture % Bagasse 47.50 – 50.00
Mill Extraction 94.00 – 96.00
Reduced Mill Extraction 96.00 – 97.00
Preparation Index 85.00 – 90.00
Primary Extraction 70.00 – 75.00

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 Primary Extraction
Its Significance in milling Control

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 PRIMARY EXTRACTION
• The efficiency of a milling tandem is directly related to its PE values. A C Chaterjee
and S S Thakur had observed that first mill is the principal contributor to maximize
overall tandem extraction
• Hugot refers that an increase of 1 % PE may lead to a gain of 0.12 - 0.20 % and 0.10 -
0.15 % of total extraction in 4 and 5 milling tandems respectively.
• D K Goel et. al. had pointed out that degree of cane preparation, type of pressure
feeding devices for primary mill, mill speed, juice drainage etc are some of the factors
that affect primary extraction.
• Pritam Singh et, al. had even proposed Factorial Design Analysis method for setting
the first mill to achieve optimum value of primary extraction.
• For obtaining higher PE, measures such as Donnelly chute under feed roller and lotus
roller in the first mill, mill setting, Low speed milling, higher PI, moisture reduction
units etc are considered • E Hugot, Handbook of Cane Sugar Engineering, 3 Edition, 1986, pg 328.
rd

• A C Chatterjee and S S Thakur, “Studies in Primary Extraction”, STAI Proceedings, 1975, pg M31 – M34.
• D K Goel and B M Patel, “Influence of Primary Extraction on Overall Mill Efficiency- A case study”, STAI Proceedings, 1993, pg E31-36.
• Pitam Singh, J P Srivastava and G K Shukla, “Tuning of mill for Optimum Primary Extraction”, STAI Proceedings, 2005, pg E75 -E79.
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 Mill House Juice & Bagasse Samples

Imb. Water
PB

Bagasse
LMJ
Sec
Pri. J (Comp)
Juice
Mixed Juice

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• Thus, PE determination is important for regular controlling
of milling operations
• Whenever any improvements or additions are made in the
1st mill, PE analysis before and after the modifications is
mandatory to assess the effect those changes
• Any false assessment of PE will lead to wrong
interpretations and incorrect actions in the mill
• Thus accurate assessment of PE values is very essential for
proper milling control
 Primary, Secondary & Mill Extractions

Primary Bagasse
Imbibition Water

Bagasse 4 %

PJ Sec J 24 % LMJ
PRIMARY PART of ME SECONDARY PART of ME
MILL EXTRACTION
72 % Mixed Juice 96 %

Almost 75% of pol extraction is taking place in the first mill itself 11
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 Primary Extraction
How it is determined ?

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 Primary Extraction
1. Juice Basis Output
Efficiency = X 100
2. Brix Basis Input
3. Pol Basis
Primary Juice % Cane X 100
PE Juice =
Absolute Juice % Cane
Brix in Primary Juice % Cane
PE Brix = X 100
Brix % Cane

PE Pol = Pol in Primary Juice % Cane X 100

Pol % Cane
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 Primary Extraction (Juice)

1 2

Primary Juice % Cane

55
1 (55/(100-F)) X 100 PE - Juice basis

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Primary Extraction (Pol Basis) – by 3 methods

PE
Juice Bx Pol

Pol Basis = Pol in Primary Juice % Cane

X 100
Pol % Cane
F-1 NC Verma &
Hugot

F-2
F-3
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 Different approaches for Primary Extraction (Pol)

1 2

B 8.5
Pol in Primary Juice % Cane
PE = (B/A) %
A DMR Determine C F-1 ((A-C)/A) X 100 70.83
A DMR Determine B F-2 B/A X 100 70.83
A B+C Determine C & B F-3 (B / (B+C) )X 100 70.83
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 F -1 F-2 F -3
Pol in Pri Juice % Cane (B)=
Pol in Pri Juice % Cane (B)

Pol in Pri Bagasse % Cane (C) =

PJ % Cane =
Pol in Pri Bagasse % Cane (C)
100 – Pri Bag % Cane

Pri Bag % Cane = Pri Bag % Cane =

Fibre % Pri Bagasse = Fibre % Pri Bagasse = Pol % Cane (B+C)

100 – Moist % Bag – Bx % Pri Bag 100 – Moist % Bag – Bx % Pri Bag

Bx % Pri Bag = Bx % Pri Bag =

8/25/2020 Formulae used in the three approaches of PE (Pol basis) 17

Comparison & Limitations of Different Formulae
used for Primary Extraction (Pol basis)

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S. No Material Analytical value F-1 F-2 F-3
1 Primary Juice (Composite) Pol % Х √ √
2 1st Mill Discharge juice Purity √ √ √
3 Primary Bagasse Pol % √ √ √
4 Primary Bagasse Moisture % √ √ √

Values not measured but taken from different period’s reported data
S. No Reported Value Depends on accuracy of
1 Pol % cane Wt of Cane
2 Pol % Mixed Juice
3 Pol % Bagasse √ √ Х
4 Mixed Juice % cane
5 Bagasse % Cane
6 Imbibition % Cane
7 Fibre % cane Bagasse % Cane
8 Moisture % Bagasse
√ √ √
9 LMJ Purity
10 Pol % Bagasse
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 1 2 3 4 5 6 7 8 9 Average
1st Mill Discharge juice
Brix 16.24 16.06 17.16 16.64 17.71 17.44 16.60 18.65 18.56
Pol 12.62 12.52 13.26 12.93 14.22 14.02 13.13 14.56 14.51
Pty 77.71 77.96 77.27 77.70 80.29 80.39 79.10 78.07 78.18
Pri Bagasse Pol 7.00 7.26 6.30 6.82 8.06 7.28 6.74 6.20 6.72
Moisture 58.20 57.10 54.80 56.30 54.80 54.80 58.00 54.50 54.5
1st Mill Comp Juice
Brix 16.46 16.26 17.24 16.80 17.66 17.48 16.55 18.70 18.56
Pol 12.88 12.74 13.41 13.09 14.13 13.94 13.03 14.52 14.51
Pty 78.25 78.35 77.78 77.92 80.01 79.75 78.73 77.65 78.18
DMR
Fibre % Cane 14.68 15.11 14.52 14.64 15.60 15.45 17.20 15.69 15.68
Pol % Cane 10.68 10.62 10.80 10.74 11.42 11.11 11.25 11.82 12.20
Calculations
Bx % PB 9.01 9.31 8.15 8.78 10.04 9.06 8.52 7.94 8.60
Fibre%PB 32.79 33.59 37.05 34.92 35.16 36.14 33.48 37.56 36.90
PB%Cane 44.77 44.99 39.19 41.92 44.37 42.75 51.38 41.78 42.49
PJ % Cane 55.23 55.01 60.81 58.08 55.63 57.25 48.62 58.22 57.51
Abs Juice % Cane 85.32 84.89 85.48 85.36 84.40 84.55 82.80 84.31 84.32
Pol in PB % Cane (B) 3.13 3.27 2.47 2.86 3.58 3.11 3.46 2.59 2.86
Pol in PJ % Cane (C) 7.11 7.01 8.15 7.60 7.86 7.98 6.34 8.45 8.34
PE Juice Basis 64.74 64.80 71.14 68.04 65.92 67.72 58.72 69.06 68.21 66.48
F-1 : Hugot & NC Verma 70.66 69.25 77.14 73.38 68.69 71.99 69.22 78.09 76.60 72.78
F-2 : Pol in PJ basis 66.61 65.99 75.50 70.79 68.84 71.84 56.32 71.52 68.40 68.42
F-3 : Pol in PB and Pol in PJ 69.42 68.21 76.76 72.67 68.73 71.95 64.66 76.55 74.51 71.50
Variation
Diff 12 4.05 3.25 1.64 2.59 -0.15 0.15 12.90 6.56 8.20 4.35
Diff 13 1.24 1.03 0.38 0.71 -0.05 0.04 4.56 1.54 2.09 1.28
Diff 23 -2.81 -2.22 -1.26 -1.88 0.10 -0.11 -8.34 -5.02 -6.11 -3.07
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Analytical Comparison of different formulae of PE (pol basis)
82

78

74

70

66

62

58

54
1 2 3 4 5 6 7 8 9
PE Juice Basis F-1 : Hugot & NCV F-2 : Pol in PJ basis F-3 : Pol in PB and Pol in PJ
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 Even though all the formulae are theoretically almost
identical, the chances of errors can not ruled out due to;
OBSERVATIONS

• Sampling errors
• Primary bagasse sampling is momentary
• Absence of larger sample size/more samples
• Difficulties for proper sampling at site
• Not comparable with each other
• Analytical mistakes – Disch PJ & Composite PJ
• Fibre% and Pol%cane are not related to that particular
period of Pri. Bagasse sampling in F-1 & F-2 methods
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• Is it compulsory to adopt F-1, because it was mentioned by Hugot & N
C Verma ?
• Absence of technical justification for its preference over other two
methods
• F-3 appears to be relatively reliable since it has only one assumption
ie., fibre% cane where as other two methods assumes both fibre%
cane and pol% cane
• Many Engineers may not prefer this as it gives slightly lower values
• All these methods are not based on actual quantities of Primary juice.
• They also collect spot samples of primary bagasse

So, there should be a standard method which can give us

relatively accurate values of Primary extraction
 Proposed Approach
for
Primary Extraction

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 Proposed Approach
Pol in Primary Juice % Cane
PE (Pol Basis) = X 100
Pol % Cane

Pol in Primary Juice % Cane =

Pol % Primary Juice x Primary Juice % Cane
100
Primary Juice % Cane =
Weight of Primary Juice
X 100
Weight of Cane

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S. No Material Analytical value F-1 F-2 F-3 Pro
1 Primary Juice (Composite) Pol % Х √ √ √
2 1st Mill Discharge juice Purity √ √ √ Х
3 Primary Bagasse Pol % √ √ √ Х
4 Primary Bagasse Moisture % √ √ √ Х
Same
Values not measured but taken from different period’s reported data period
S. No Reported Value Depends on
1 Pol % cane Wt of Cane
2 Pol % Mixed Juice
3 Pol % Bagasse √ √ Х √
4 Mixed Juice % cane
5 Bagasse % Cane
6 Imbibition % Cane
7 Fibre % cane Bagasse % Cane
8 Moisture % Bagasse
√ √ √ Х
9 LMJ Purity
10 Pol % Bagasse
11 Weight of Primary Juice Х Х Х √
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Comparison between existing and proposed method
 Proposed Approach Requires

• Measurement of Primary Juice quantity

• Some Expenditure is involved
• Primary Juice Composite sample analysis (it is
regularly practice)
• Pol% Cane (as per normal practice)
With this, daily reporting of PE by both pol & juice
basis, is possible
 If weighment of Primary Juice is not adopted
• It is preferable to follow only one method by all factories till weighment of
primary juice is adopted- may the one prescribed by N C Verma
• At the time of reporting the PE results, name of the method shall be quoted
• Sampling of primary bagasse shall be for a longer duration of time and repeated
• For PJ sampling for the above method, discharge side juice shall be taken
• There shall not be any intermixing of other imbibition juices in PJ
• It is good to have prepared cane sample also for assessing pol and fibre%cane
• Atleast 2-3 repeat analysis to be carried out before drawing conclusions
• There should not be any variation in Pol and Fibre % cane
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 Benefits of the Proposed Approach
• Simultaneous determination of PE – by both Juice basis & Pol basis
• It is based on composite sampling and analysis
• Accurate Determination of Primary Extraction so, reliable
• No need for specialized exercise (analysis) for PE determination
• Can be confidently used for milling control & Improvement
• Increased number of readings
• Can be regularly reported in Shift wise, Daily, Monthly and all
periodical reports
• These PE values can be used as indicators of cane quality also
• They will help in controlling and improving cane quality
• May result in improving sugar recovery
 Pol% Cane vs. Varietal Composition
Recorded in Mill
24th Dec
20th Dec 21st Dec 22nd Dec 23rd Dec Trial
DMR
(24th Dec.)
Particulars
Avg Pol Avg Pol Avg Pol Avg Pol Avg Pol Avg Pol
%
% of % of of % of % of % of
variety variety variety variety variety variety

Varietal Early 88.81 12.80 81.00 12.80 77.00 12.80 79.00 12.80 84.21 12.80 75.00 12.80

Combin General 11.19 11.50 14.00 11.50 18.00 11.50 21.00 11.50 15.79 11.50 25.00 11.50
ation Rejected 0.00 10.04 5.00 10.04 5.00 10.04 0.00 10.04 0.00 10.04 0.00 10.04
Total 100 -- 100 -- 100 -- 100 -- 100 -- 100 --

Expected pol%cane
with above varietal -- 12.65 -- 12.48 -- 12.43 -- 12.53 -- 12.60 -- 12.48
composition
Recorded Pol%Cane
as per 12.56 12.57 12.40 12.60 12.63 12.43
DMR/Mill Trial
It could be seen from the above observations that there is a strong correlation between varietal composition and Pol% cane.
Similar relationship is also expected between cane quality and Primary extraction (Juice & Pol). Just like Net Juice and DMF, PE (Juice basis)
by the proposed
8/25/2020method, can be used for assessing cane quality, under streamlined working of the mill. 30
 An Overview of Existing and Proposed methods
S. No Material Existing Approach Proposed method
1 Primary Juice Quantity Arrived by calculation Actual measurement
2 Primary Juice analysis Short duration sampling Composite sample
3 Primary bagasse Quantity Arrived by calculation Not required
4 Primary Bagasse - Pol Spot sample analysis Not required
5 Primary Bagasse - moisture Spot sample analysis Not required
7 Primary bagasse Chances of analytical errors Not applicable
8 Pol% Cane Not determined Determined
Assumed value pertaining to different For the same period of
9 Pol% Cane
working period, taken from DMR working
Required. But not determined. Assumed
10 Fibre% cane value pertaining to different working Not required
period, taken from DMR
More frequent, daily, shift
11 Frequency of analysis Occasional, done as special analysis
wise, monthly etc
12 Accuracy of analysis Doubtful Chances of higher accuracy
Helping in identifying the
Doubtful Possible
variations in cane quality
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 In case of any comments or clarifications, you can contact me at;
jagdishnsi@gmail.com
7757019011

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 1st Mill 2nd Mill
Rotary Screen

Mixed juice
flow meter

1st MIll 2nd MIll

Unscreened
juice tank
Screened
juice tank
Mixed Juice
pump
8/25/2020 Choke less pump 33
 DSM/ Rotary Screen Rotary Screen

Flow Meter

1st Mill 2nd Mill

Unscreened
juice tank

Unscreened
juice tank
Choke less pump
Choke less pump

Screened Mixed juice

juice tank flow meter
Mixed Juice
8/25/2020 pump 34