Introduction

Kessem sugar factory is one of sugar factory in Ethiopia which

is newly constructed project with capacity of 6000 TCD when

reserving for 10000 TCD.

Sugar manufacturing adopts methods as juice extraction by

milling, clarification by sulphitation, multiple effect pressure-

vacuum and three boiling system.

It produce first class white sugar and sells molasses.

Ethiopian Sugar Corporation Trainers

• On job training report presentation

• Prepared by

S/n Name Department

1 Mulugeta Bedasa Sugar Technology

2 Gudeta Gurmu >>

3 Lalise Legese >>

4 Gemechisa Megersa >>

5 Indale Feleke Chemical Eng

6 Getu Tesfaye >>

 Contents of presentation
 Cane Weightment
 Cane Preparation

 Juice Extraction
 Juice Clarification And Evaporation
 Crystallization

 Centrifugal Separation
 Drying
 Electric-weight bridge (2 SET)
Objectives of cane weightment
• Payment to farmers and planters for the sugar produced from
their cane
• Chemical control and determination of factory performances
• Statistical information regarding cane yields per hectare and
per field and performances of different varieties of cane
• Transport statistics for determination of tones per kilometre
costs of the vehicles
 Cane preparation
Objectives of cane preparation
To increase capacity by increase of bulk density of the feed

To assist extraction at the mills by breaking down the structure of the cane

To render the juice more readily available for the action of imbibition by breaking and opening cane cells

Cane preparation consists of:-

 Unloader

 Leveler.

 Cane table

 Cane carrier

 Shredder.

 Magnetic separator
Parameter; preparation index….above 92
 Milling Plant

Milling is the process by which pressure is applied to the prepared

cane to extra as much juice as possible from it

To help to extract the maximum juice , use of imbibitions water is

made.

The extracted juice is sent to process and the fibrous

material left after milling, known as final bagasse, is sent to the

boilers to be used as fuel for the generation of steam
 The Mill Tandem

•The combination of three sometimes four rollers arranged in

triangular form is the standard milling unit used in the cane
milling process
 Parts of mill

Mill roller:-top , feed and discharge

Donnelly chute
Underfeed roller
Trash plate
 Imbibition

• Imbibition is the application of water to the milling process

• Hot water is imbibited before the last mill and the juice from
the last mill is used as imbibitions water for the fourth mill.
• Juice from fourth mill is also used as imbibitions for third and
, from third is again used as imbibition for second mill, finally
juice from first mill and second mill is combined together to
form mixed juice.
 Parameters in juice extraction plant

 Mill extraction…… > 96%

 Hot water imbibition temperature ..(60-70)°c
 Mixed juice brix….14-16
 Bagasse moisture ….<50%
 Pol in bagasse …….. < 2.5%
 Juice Clarification
Objectives of Juice Clarification
To separate soluble and insoluble matter that
can precipitate
To reduce colour and turbidity of the juice
To produce clear juice of correct pH = 7.0
To kill or inactivate microorganisms in the
juice by heat treatment
 Juice Heating

Mixed juice heating (primary heating)

• Juice is heated to a temperature of 60 -65°C
and directed to liming and sulphitation.
• The main purposes heating is
To coagulate proteins
To destroys micro-organisms and enzymes
preventing loss of sucrose by
microbiological activity
 cont‘d

Second Heating(secondary heating)

 The sulphited and limed mixed juice is heated to
about 5 °C above boiling point.
Third Heating (Clear Juice Heating)
• The clear juice from the clarifier is heated to 110 -
115°C
• This brings the immediate start of evaporation in
the 1st vessel as the result evaporation efficiency is
raised.
• Therefore pressure in the juice will be above
atmospheric pressure and it is let to flash out
its air bubbles that would retard settling of
impurities in the clarifier.
shell and tube type heater
 Liming Preparation

 Lime (CaO) is the basic chemical for juice

clarification processes.
 The milk of lime (MOL) is prepared from lime
(CaO) by adding water in the cylindrical slaker.
 The prepared MOL (Ca(OH)2) slaked a minimum
of 8hrs before using for liming
 MOL neutralizes the acidity of the juice and also
reacts with phosphoric acid in the juice to
produce a precipitate.
 Sulpherdioxide (SO2) Gas Genaration

 SO2 gas used for the juice and syrup sulphitation

process
 The SO2 gas is generated by melting the solid
sulphure and then burning the melted sulphure
with oxygen in the furnaces
 The generated SO2 gas cooled with a series of
coolers until the temperature reaches about 65°C
 Here is the reaction in the sulpher
S + O2 SO2 + Heat (70 KCal/32gms)
 Short Retention Time clarifier(SRT)
• A more recent development in clarifier design is
the so-called rapid clarifier
• It is a tank without any tray. The juice entry and
outlet are designed such that the speed of juice
inside the clarifier is below the sedimentation
speed of mud (4.3 m/s) to avoid entrainment.
• The juice retention in this type of clarifier is 45 -
60 minutes compared to 2 - 3 hours in the
classical clarifiers.  
Filtration of Mud’s
 Evaporation
• The aim of evaporation is to concentrate clarified juice to a 65
upto 70 Brix, which will allow crystallization.
 Multiple Effect Evaporation
• Rillieux Principles
• 1. In a multiple effect evaporator, for each kilo of steam used, as
many kilos of evaporation will result as there are units in the set.
• 2. If vapours are withdrawn from any unit of a multiple effect
evaporator to replace steam in a concurrent process, the saving of
steam will be equal to the amount of vapour so used, divided by
the number of units in the set, and multiplied by the sequence
position of the unit from which vapour has been withdrawn.
• 3. In any apparatus in which steam or vapour is condensed, it is
necessary to continuously withdrawn the accumulation of non-
condensable gasses.
 Calandria Part (steam chest) Provisions of
an Evaporator
• The calandria part of an evaporator has the following
provisions:
 Cold water connections
 Exhaust steam (vapors) admission connection pipe
 Incondensable gases removal connection pipes
 Equalizer connection
 Condensate removal connection
 Insulation
 Safety valve
The Vapor Body Part Provisions of an Evaporator
 Sight glasses

 Caustic soda solution, hot and cold water supply

lines
 Entrainment separator
 Vacuum breaker

 Soda vent pipe

 Manholes

 Temperature and pressure gauges

 Parameters of clarification and evaporation
plant

 Milk of lime concentration…8-10Be`

 Pol in filter cake <2.5
 Temperature of cooled sulphur 60-65°C
 Outlet temperature of first heater…65-70°c
 Outlet temperature of second heater…100-105°c
 Outlet temperature of third temperature…110-
115°c
 Clear juice ph 6.8-7.2
 Con’t…
 Syrup 5.8-6.4
 Flocculants addition 2~4
 Flocculantpreparation concentration 0.05
Evaporation Section
 Pressure of steam goes into 1st effect evaporator <
0.22
 The out let brix is 60~70°Bx
 Last effect vacuum 0.06-0.08 mpa
Crystallization
 Vacuum Pans

• It is the equipment in which crystallization and boiling

takes place.
• The number and capacity of each type of pan depends on
the amount of material they handle which in-turn depends
on the cane crushing rate of the factory. Pan station is
positioned between evaporation plant and centrifugal plant
 Massecuite Systems (Boiling Schemes)

Three boiling system is used for boiling. Ingredients are as follow:

 Massecuite A: Using Magma B made of Sugar B and syrup as footing, boiling
with syrup, and re-boiling proper amount of Wash A to adjust the purity of
massecuite.
 Massecuite B: Using Magma C made of remelted Sugar C and Molasses A as
footing, boiling with Molasses A (Wash A)
 Massecuite C: Using Seed C as footing, boiling with Molasses B .
 Seed C preparation : is boiling with Molasses A as footing and added with powder
for crystallization. Boiling with Molasses B or Molasses A according to different
purity requirements
Three boiling system diagram
 Crystallizer
• The massecuite from the pans (“A”, “B”, or “C”) is dropped into a
strike receiver under the pans, from which it is gravited to the cooling
crystallizers.
• Crystallizers are fitted with agitators to:
 Renew the layer of mother liquor around the crystals and
ensure uniform supersatuation
 To bring fresh massecuite in contact with the cooling
surface.
 Parameters of crystallization
• Vacuum of pan 0.06-0.08mpa
• Brix of A massecuite 94-97°Bx
• Brix of B massecuite 95-97°Bx
• Brix of C massecuite 98-101°Bx
 Centrifugal
 The process of separation of sugar crystals from molasses in massecuite is

carried put in a machine called Centrifugal

 Batch Centrifugal

consists of a revolving cylindrical metallic basket designed to receive the

massecuites to be treated. The basket is carried on a vertical shaft driven by a

motor

 The basket wall is pierced with numerous holes to allow molasses to escape

and is constructed such that it can withstand the centrifugal force developed

during the operation

 Continuous Centrifugal
• To overcome the numerous disadvantages of the batch
centrifugal (complexity of operations, low
efficiency in the use of energy, dead times…), the continuous
centrifugals has been designed and perfected to the point that
they can be successfully used for purging low grade
massecuites.
 Parameters of centrifugal

 purity of final molasses … < 35

 Sugar Drying

• In order for sugar to be properly handled and successfully

stored, it has to be dried to a safe moisture level.
 Fluidized Bed Dryer

• The fluidized bed dryer consists of a vertical cylinder

separated into two compartments, upper and lower, by a
perforated plate containing gas distribution nozzles.
• Part of the lower compartment (wind box) receives hot air for
drying, which is produced by a steam heat exchanger mounted
in the main fluidizing air duct. The other section of the wind
box receives cold air.
 Cont…
• Sugar from centrifugal is fed into the upper compartment
expansion chamber) at the desired feed rate and forms a bed
about 300 mm deep on the perforated plate, where the hot air
passing through the plate fluids the sugar while drying it. The
nozzles in the perforated plate are specially designed to
distribute air evenly through the sugar and keep it uniformly
fluidized.
Flow chart of sugar process in KSF
Con’t…