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Importance of in-line colour measurement of sugar
for product quality and factory performance
By Tim Diringer and Bjarne Christian Nielsen
Copyright Neltec 2012
20 Years ago the first colour measurement has been installed in
the Danish Assens factory
Today more than 100 instruments are installed all
over the world
Definition of process control
Process control is the method to keep the process and the quality of the final product inside the targets, by controlling and regulating various process parameters
Definition of process control
Process
product
input
Influencing parameters
Online data collection in a sugar factory
Diffuser: Temperature, flow rate
Purification: pH, level, temperature, turbidity, colour
Evaporators: Temperature, pressure, level
Crystallisation: Temperature, pressure , level, density
Centrifugals: ???
Control, alternator,699, 700- boiler, 643, 644, 647, 656- cane throughput, 76, 166- chemical, 577 – 600- clarification, 227, 228, 236- condenser, 330- conveyor, 74-76- crystallizer, 417- diffuser, 160, 165 – 168- evaporator, 300, 301- flocculant addition, 349- juice flow, 199- mill, 141-144- pan boiling, 388-398- rotary drum filter, 248, 257, 258, 260- sugar dryer, 479- turbine, 700
Peter Rein, Cane Sugar Engineering page 755
centrifugation
Sugar massecuite
Spray waterLayer thickness
• Leaving syrup on the crystals reduces pol, increases ash and leads to caking
• A combination of the two above (very common)
How centrifugals influence sugar quality
The centrifugals influence the sugar quality and the mill profit in 3 ways:
Overwashing dissolves good sugar, generates more molasses and decreases capacity
Nowhere in processing
can so much sugar
be lost so quickly
and with so little notice
as in centrifugation
To avoid sugar losses the operator must see the result of the centrufigation process and act accordingly
Step by step to operational
measurements
Lab measurements
Lab measurements
time delay
Lab measurements
time delay
No information about origin of error
A factory with an output of 1200 t/d raw sugarproduces 50 t raw sugar per hour
50g of sugar are used for the analysis
This is 0,000050 % of the total amount of sugar
If a sample for determing the colour in soloutionIs taken every 2 hours
On-line measurement
fast results
no information about origin of error
On-line measurement of each batch centrifugal
tells something about origin of errors.
Measurement of a colour profile for each batch centrifugal
pinpoints the origin of the error
very operational
The instrument
The Neltec ColourQ is the ideal tool to control product quality and to pinpoint process problems
Installation on a belt conveyor
installation on a screw conveyor
optimizing the centrifugals
1st step:
Get an overview of the centrifugal performance
2nd step:
learn to interprete the colour profiles
Colour of sugar in centrifugals 1 and 4 is 40 % higher
than the colour of sugar in centrifugal 3
Spray nozzles of centrifugal number 1 hve been replaced
Backing screen of centrifugal 4 has been washed
Improvements at Manildra-Harwood Mill
• Amount of sugar within the specs increased
Improvements at Manildra-Harwood Mill
• Molasses purity was reduced from 44 to 41
Improvements at Manildra-Harwood Mill
• The amount of massecuite required to produce 100 tons of sugar was reduced from 200 tons to 195 tons
To rely on the data collected inline, the following aspects must be fullfiled:
Accuracy of the instrument
Reliability of the calibration
Lab control in a refinery
To ensure product quality, in line measurement is necessary
In line colour measurement helps the operators to understand the
process
Time span from occuring to solving of a problem is reduced
dramatically
Capacity increases and sugar losses decrease
Conclusions
"To measure is to know"
(Lord Kelvin, 1883)
Thank you for your attention!
Questions?