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EQUIPMENT DESIGNS
Equipment designs and manufacturing drawings are offered for a range of sugar processing
equipment as detailed below:
Shredders / Cane Knives – Heavy Duty
Diffusers (Cane and Bagasse)
Juice Heaters
Vapour Heaters (Direct Contact type)
Evaporators
Kestner type
Robert type
Entrainment Separators (Vertical Chevron – Internal & External)
Condensers for Evaporators & Pans (Internal & External)
Batch Vacuum Pans & Stirrers
Continuous Vacuum Pans
Vertical Crystallisers
Massecuite Reheaters
Remelters
Sugar Driers
Sugar Refining Equipment
Direct White Sugar process
Rotary Distribution System
Fluegas Scrubbers
Miscellaneous Equipment
Tongaat Hulett Sugar Equipment Designs
Shredders / Cane Knives (Heavy Duty)
The Tongaat Hulett heavy duty shredder is a robust swing hammer pulveriser. The design
incorporates high operating efficiency, low maintenance costs and resistance to damage in service.
The patented rotor design gives overlapping coverage of the full shredder width with reversible
swing hammers. The shredders have been installed worldwide for the last 25 years and are reliable
and proven. The rupturing of the cane cells by the shredder leads to high extractions being
obtained in both milling trains and diffusers.
Cane & Bagasse Diffusers
The Tongaat Hulett Diffuser is a variant of the moving bed diffuser. The basic design is a counter
current contactor where juice is pumped (with a high percentage of recycle) onto a moving bed of
prepared cane between 1.5 and 1.8 meters deep contained in a vessel approximately 60 meters long
and divided into 10 to 14 stages. Typically the diffuser would have a working width between 6 and
12 meters. The prepared cane entering the diffuser is heated by juice which has been raised to a
high temperature in juice heaters giving an average temperature in the diffuser of 85°C. The cane
bed is moved across the top of a fixed screen by a series of chains with slats between them. The bed
is prevented from blinding with fines and over-compaction by sets of patented lifting screws which
break up the bed at two points in the diffuser. The bagasse is dewatered by one or two dewatering
mills after exiting the diffuser.
The diffuser at Komati
Each diffuser is individually designed to suit the conditions and process specifications that the
customer has supplied. Extraction can be as high as 98.5% if high imbibition rates are used with
well prepared cane, but if a lower figure is all that is required then the diffuser size and imbibition
rates can be reduced accordingly. Extensive use is made of 3CR12 in the construction of the diffuser
to prevent corrosion and in addition a controlled liming system can be specified to control the juice
pH to ±7.
There are currently eight Tongaat Hulett diffusers in operation. Six in South Africa; at Felixton (2),
Amatikulu, Maidstone and Komati (2), one in Kenya at Mumias and one in Louisiana, USA at
Enterprise. Two more are under construction for commissioning in 2007, one at Savannah in
Mauritius and the other at the new Skeldon factory in Guyana and a third is in the design phase for
Bharat in India.
One of the major advantages of selecting diffusion is the ability to recycle mud from the clarifier,
thereby removing the need for a filter station. Mud recycle is used at all Tongaat Hulett’s South
African sugar mills that use diffusers.
A number of papers on the performances and advantages of the TH diffusers have been written and
presented at various national and international conferences.
A list and details of the TH diffusers supplied to customers since 1984 is shown below:-
TH Designed Diffuser Installations
* Planned commissioning year
Country Mill
Capacity
TCH
Width
m
Number
of Stages
Date
Installed
South Africa
South Africa
South Africa
South Africa
South Africa
Kenya
USA
Amatikulu
Felixton
Komati
Maidstone
Komati
Mumias
Enterprise
600 x 2
225
300
225
300
300
12
12
6,5
9
6,5
9
9
14
12
12
12
12
12
12
1982/83
1993
1995
1998
1997
1999
Mauritius Savannah 350 9 12 2007 *
Guyana Skeldon 350 9 12 2007 *
India Bharat 250 6.5 12 2008 *
Hippo Valley Mixed Juice Heaters
Juice Heaters
Tongaat Hulett offer the design of vertical shell and tube heat exchangers for heating raw and/or
clarified juices to achieve the necessary process stream temperatures and for heat recovery
throughout the factory, making use of low grade vapour, evaporator vapour and condensate
streams.
The designs can be optimized in terms of pressure drop (pumping requirements), heat recovery
and size to meet required heat balance targets.
Tongaat Hulett also have the capability and expertise to perform a pinch technology analysis to
identify the optimal heat recovery layout as an additional process design service.
Vapour Heaters (Direct Contact Type)
Tongaat Hulett offer the design of direct contact vapour heaters which allow the possibility of using
lower grade vapour for heating various liquid streams, thereby increasing the steam economy of the
factory.
A list of TH design vapour heaters supplied to clients over recent years is given below:-
Tongaat Hulett Designed Vapour Heater Installations
Mill Service Diameter
mm
Date of
Intallation
Amatikulu
Malelane
Pongola
Savola
Press Water Heater
Press Water Heater
Primary Mixed Juice
Heater
Carbonatation Heater
1454
2100
2180
1984
1998
1998
2005
Press Water Heater (Malelane)
Evaporators
Tongaat Hulett TEG are experienced in designing both long tube climbing film (Kestner type) and
Robert type evaporators complemented by the design of very efficient vertical chevron entrainment
separators. Expertise in both steam chest design (in particular the removal of incondensable
gases) and juice/syrup feeding and distribution, ensures optimal performance and maximum heat
transfer coefficients. In addition, our multiple effect evaporator design procedure employs process
models to distribute heating surface area between the effects most efficiently and can be used for
the specification of the entire evaporator station, including all associated condensate receivers and
flash vessels.
Kestner Evaporator &
Separator at Malelane
Robert Evaporator at
Si
A list of the TH designed Kestner and Robert evaporators which have been supplied to customers
since 1993 is shown below
Kestner Type
Mill
Unit Size
Heat Transfer Area
m2
Date of
Installation
Felixton
Komati
Triangle/Zimbabwe
Umfolozi
Malelane
Komati
Hippo Valley-Zimbabwe
4 x 5800
2 x 3800
2 x 3100
1 x 3500
1 x 1000
2 x 3800
1 x 5800
1985
1993
1996
1997
1998
1998
1999
Robert Type
Mill
Unit Size
Heat Transfer Area
m2
Date of Installation
Felixton
Felixton
Komati
Triangle/Zimbabwe
Felixton
Komati
Komati
Simunye
Xinavane/Mozambique
Mhlume
2 x 1430
4 x 1000
2 x 1000
1 x 2000
1 x 1430
1 x 2000
1 x 1000
3 x 2200
1 x 2000
3 x 270
1985
1985
1993
1994
1996
1998
1998
1998
2000
2002
Entrainment Separators
Tongaat Hulett provide a very successful design of entrainment separator that is suitable for
installation in batch pans, continuous pans, evaporators and separator vessels. The design
incorporates vertical chevron plates that disengage the liquid particles by repeated changes in
vapour direction and impingement against the plates. The entrapped liquid is drained back into the
vessel.
The design is in a modular form with easy access to the chevron plates by hinged sides. This allows
rapid cleaning of the separator module if necessary. The number and configuration of the separator
modules is defined by the evaporation rate, disengagement height and diameter of the vessel in
which they are to be installed.
Under steady operating conditions which meet the design specifications an entrainment level
below 20 ppm can be expected and pressure drops across the separators will be less than 5mm
water gauge.
This design of separator is included in all the Tongaat Hulett designs of pans and evaporators and
has also been very successful as a “retro-fit” to existing vessels with entrainment problems.
Vertical Chevron Plate (VCP)
Entrainment Separator being installed
Condensers (Internal & External) for Evaporators & Pans
Tongaat Hulett offer the design of efficient disc and doughnut “rain tray” type condensers for both
internal fitment or external installation to a final effect evaporators, continuous vacuum pans or
batch vacuum pans. The condensers are designed to operate on an approach temperature of ± 3°C.
A list of both internal and external Tongaat Hulett condenser designs which have been supplied to
clients and installed since 1993 are shown below:-
External Condensers
TH Designed Internal
Condenser Installation
(Komati)
Tongaat Hulett Raintray Condenser
Internal Condensers
Mill
Size Diameter
mm
Duty Date of
Installation
Simunye – Swaziland
Maidstone
Triangle – Zimbabwe
Komati
Komati
Komati
Komati
Ubombo – Swaziland
Triangle – Zimbabwe
Triangle – Zimbabwe
Triangle – Zimbabwe
Darnall
Komati
Komati
Komati
Komati
1800
2 x 1700
1170
2 x 1026
1520
2 x 1472
1624
1340
2050
1250
2000
1130
1800
2280
1500
2000
A-Batch Pan
Final Effect
C-Cont Pan
B/C Cont Pan
A Cont Pan
A/B/C/ Seed
Final Effect
B-Cont Pan
Final Effect
B-Cont Pan
A-Cont Pan
B-Cont Pan
A-Cont Pan
A-Batch Pan
B-Cont Pan
Final Effect
1991
1991
1993
1993
1993
1993
1993
1994
1994
1994
1995
1995
1998
1998
1998
1998
Mill
Size Diameter
mm
Duty Date of
Installation
Maidstone
Pongola
Felixton
Clewiston – USA
Maidstone
Pongola
Simunye – Swaziland
Entumeni
Xinavane – Mozambique
Xinavane – Mozambique
Xinavane – Mozambique
Mhlume – Swaziland
1840
910
2250
1500
1250
1800
1300
3 x 1100
3 x 3200
2 x 1820
1200
590
C-Cont Pan
C-Cont Pan
5th Effect
W- Batch Pan
Batch Pan
A-Cont Pan
C-Cont Pan
Batch Pans
Batch Pans
Batch Pans
5th Effect
Final Effect
1994
1995
1996
1996
1994
1998
1999
2000
2000
2000
2000
2001
Batch Vacuum Pans & Stirrers
Tongaat Hulett designed batch pans are conventional vertical tube calandria pans with a central
downtake, which have been designed for A,B and C massecuites and refined massecuites. They are
low head designs with excellent circulation characteristics which are able to operate with high
viscosity massecuites without the need for a stirrer. The pans are designed to accommodate both a
stirrer and an internal chevron entrainment separator, for improved performance.
85m3 Stirred A Seed Batch Pan at Komati
Batch pans of the TH design, without stirrers, are used extensively in raw cane sugar factories
owned and operated by TH. When fitted with a stirrer, these pans have been successfully used as
seed pans in raw cane sugar factories and have proved successful in producing white sugar in cane
sugar refineries and “back end” refineries attached to raw cane sugar factories.The TH stirrer
design was originally developed for the TH central refinery and compares favourably in terms of
performance with the design of other impellers used extensively in the raw sugar and beet
industries. Later designs have been optimized for lower purity massecuites.
A list of TH designed batch pans and stirrers supplied since 1985 is shown below:-
Tongaat Hulett Designed Batch Pan Installations
Mill
Unit Size m3 Duty
Massecuite
Date of
Installation
Felixton
Felixton
Komati
Komati
Clewiston – USA
Komati
Xinavane – Mozambique
Mhlume – Swaziland
Huletts Refinery – White Sugar
1 x 85
1 x 85
1 x 42,5
1 x 42,5
3 x 60
1 x 85
1 x 42,5
1 x 37,5
1 x 50
A
B/C
A
B/C
Refined
A
A
White
White
1985
1985
1993
1993
1996
1998
2000
2000
2002
Tongaat Hulett Designed Batch Pan Stirrer Installations
Mill
Unit Size
m3
Duty
Massecuite
Date of
Installation
Triangle – Zimbabwe
Malelane
Simunye
Komati
Komati
Komati
Triangle
Triangle
Clewiston – USA
Mhlume
Huletts Refinery
2 x 35
2 x 85
2 x 56,7
1 x 42,5
1 x 42,5
1 x 85
1 x 85
3 x 56,6
3 x 60
3 x 37,5
1 x 50
White
White
B/C
A
B/C
A Seed
A
A
White
White
White
1992
1993
1998
1998
1998
1996
1999
2002
Continuous Vacuum Pans
The Tongaat Hulett design continuous vacuum pan is a world leader in cost effective and quality
continuous pan boiling. The design incorporates a vertical tubed calandria for efficient heat
transfer and massecuite flow, patented transfer ports for plug flow and flexibility in terms of
throughput and product. The Tongaat Hulett CVP is a low head design with excellent natural
circulation characteristics which saves power and construction costs relative to forced circulation
systems and eliminates the need for a strike receiver. This feature allows it to operate efficiently
with high viscosity massecuites and good heat transfer characteristics enabling it to be operated
utilizing lower pressure steam than would be required for batch pans. The pan is simple in design
and robust and can be equipped with controls ranging from sophisticated to basic depending on
the customers requirements. When boiling low to medium purity massecuites, conductivity can be
used for automatic control of individual compartments and for high purity massecuites, the
Duotrac Digital Radio Frequency Probe is recommended. The massecuite capacities of CVP's
installed to date have ranged from 40 m3 to 180 m3 .
A new continuous pan has been developed by Tongaat Hulett. This new design consists of two
stacked calandrias stacked inside a cylindrical vessel. The 120m3 continuous A pan to be installed
at Xinavane Mill in Mozambique has the same basic footprint as an 85m3 batch pan.
The first Tongaat Hulett CVP was installed in South Africa in 1981 and the first outside Southern
Africa in Germany in 1986. To date, 166 units have been installed or are under construction
worldwide in the beet and cane industries by Tongaat Hulett and Fletcher Smith Ltd. They can be
found in the following countries:
The Americas: USA, Mexico, Brazil, Colombia, Guadeloupe, Venezuela, Belize, Nicaragua,
Guatemala, Guyana and Jamaica.
Europe: England, Germany, France, Hungary, Finland, Sweden, Poland and Ireland.
The Far East: Pakistan, Philippines, Indonesia, Iran, Thailand, Fiji and Vietnam.
Africa: South Africa, Zimbabwe, Malawi, Nigeria, Senegal, Egypt, Reunion, Zambia, Swaziland,
Mozambique, Mauritius and Kenya.
The Tongaat Hulett CVP design has been awarded the South African AS&TS National Award for
Technology and the South African Institute of Chemical Engineers Innovation Award.
A number of papers on the operation and performance of the TH Continuous pans have been
written and presented at various national and international conferences.
Installations by Region
Africa 45
Americas 64
Europe 10
Far East 31
Pakistan 22
Total 172
UNDER CONSTRUCTION – New design Round Pan
No. FACTORY Country Duty m3 Year
1 Xinavane (vertical pan) Mocambique Cane A 120 2008
2 Mafambisse (vertical pan) Mocambique Cane A 100 2008
3 Xinavane (vertical pan) Mocambique Cane B 100 2009
No. FACTORY Country Duty m3 Year No. FACTORY Country Duty m3 Year
1 Maidstone R.S.A. Cane A 110 1981 81 San Antonio Nicaragua Cane A 120 1998
2 Felixton R.S.A. Cane A 120 1984 82 Pichichi Colombia Cane C 65 1998
3 Felixton R.S.A. Cane A 120 1984 83 Gniezno* Poland Beet C 44 1998
4 Felixton R.S.A. Cane B 76 1984 84 Umfolozi R.S.A. Cane C 100 1998
5 Felixton R.S.A. Cane B 76 1984 85 Ubombo Ranches Swaziland Cane A 129 1998
6 Felixton R.S.A. Cane C 76 1984 86 Indolampung 2 Indonesia Cane B 140 1998
7 Felixton R.S.A. Cane C 76 1984 87 Indolampung 2 Indonesia Cane C/D 140 1998
8 Hippo Valley Zimbabwe Cane C 120 1986 88 Nakambala Zambia Cane C 120 1998
9 Zeil Germany* Beet C 115 1986 89 Moses Lake** U.S.A. Beet B 120 1998
10 Darnall R.S.A. Cane C 86 1987 90 Kopingebro Sweden Beet C 110 1998
11 Mirpurkhas Pakistan Cane C 68 1987 91 Gora Slaska* Poland Beet C 88 1998
12 Shahtaj Pakistan Cane C 68 1987 92 East Grand Forks U.S.A Beet B 50 1999
13 Leopoldsdorf Austria* Beet C 90 1988 93 Abou Kourkas Egypt Cane C 80 1999
14 Brothers Pakistan Cane A 55 1989 94 Komati R.S.A. Cane A 130 1999
15 Brothers Pakistan Cane A 55 1989 95 Komati R.S.A. Cane B 130 1999
16 Gunung Madu Indonesia Cane C/D 120 1990 96 Sucoma Malawi Cane B 120 1999
17 St. James U.S.A. Cane C 50 1990 97 Dwangwa Malawi Cane A 105 1999
No. of CVPs on A-massecuite duty 46 27.5%
No. of CVPs on B-massecuite duty 42 25.1%
No. of CVPs on C-massecuite duty 79 47.3%
Total No. of CVPs 167
18 Malelane R.S.A. Cane C 120 1990 98 Enterprise U.S.A. Cane B 180 1999
19 Turenki (moved to Sakyla) Finland* Beet C 65 1989 99 Enterprise U.S.A. Cane C 180 1999
20 York England Beet C 55 1990 100 Sterling U.S.A. Cane C 100 1999
21 Usine du Gol Reunion Cane A 145 1991 101 Carlow** Ireland Beet B 150 1999
22 Richard Toll Senegal Cane A 120 1991 102 El Palmar Venezuela Cane C 100 1999
23 Don Pedro Philippines Cane A 105 1991 103 La Gloria Mexico Cane B 140 1999
24 Brothers Pakistan Cane B 102 1991 104 Puunene Hawaii/USA Cane C 100 2000
25 Brothers Pakistan Cane C 97 1991 105 Simunye Swaziland Cane C 120 2000
26 East Grand Forks U.S.A. Beet B 120 1992 106 Maidstone R.S.A. Cane B 58 2000
27 Bunga Mayang Indonesia Cane C/D 150 1992 . . 107 Belle Vue Mauritius Cane A 105 2000
28 Ramzan Pakistan Cane A 55 1992 108 Puunene Hawaii/USA Cane A 100 2000
29 Ramzan Pakistan Cane B 102 1992 109 Raceland USA Cane A 150 2000
30 Ramzan Pakistan Cane C 97 1992 110 Tarlac Phillipines Cane A 110 2000
31 Ramzan Pakistan Cane A 55 1992 111 San Antonio Nicaragua Cane B 120 2000
32 Usine du Gol Reunion Cane C 97 1992 112 San Antonio Nicaragua Cane C 120 2000
33 El Modelo Mexico Cane C 97 1992 113 Appleton Jamaica Cane A 40 2000
34 Shakjarganj Pakistan Cane C 97 1992 114 Constancia Mexico Cane C 89 2001
35 Shakjarganj Pakistan Cane A 102 1992 115 San Francisco Mexico Cane C 89 2001
36 Choudhary Pakistan Cane A 55 1993 116 Queseria Mexico Cane C 89 2001
37 Choudhary Pakistan Cane A 55 1993 117 Cam Ranh Vietnam Cane A 95 2001
38 Choudhary Pakistan Cane B 102 1993 118 Cam Ranh Vietnam Cane A 95 2001
39 Choudhary Pakistan Cane C 97 1993 119 Cam Ranh Vietnam Cane B 120 2001
40 Mataram Indonesia Cane C/D 150 1993 120 Cam Ranh Vietnam Cane C 120 2001
41 Batangas Philippines Cane C 100 1993 121 Khuzestan 1 Iran Cane C 120 2001
42 Petoehaza Hungary* Beet B 105 1993 122 Xinavane Mozambique Cane A 43 2001
43 Sucoma Malawi Cane C 70 1993 123 Bukidnon Philippines Cane B 135 2001
44 El Palmar Venezuela Cane A 100 1993 124 Khuzestan 2# Iran Cane C 120 2001
45 Haseeb Waqas Pakistan Cane A 55 1992 125 Khuzestan 3# Iran Cane C 120 2001
46 Haseeb Waqas Pakistan Cane A 55 1992 126 South Minnesota USA Beet B 150 2001
47 Haseeb Waqas Pakistan Cane B 102 1992 127 South Minnesota USA Beet C 120 2002
48 Haseeb Waqas Pakistan Cane C 97 1992 128 Colonial USA Refin B 57 2002
49 Komati R.S.A. Cane A 105 1994 129 Bukidnon Philippines Cane C 180 2002
50 Komati R.S.A. Cane B 75 1994 130 St. James USA Cane A 140 2002
51 Komati R.S.A. Cane C 75 1994 131 San Rafael Mexico Cane C 115 2002
52 Sheikhu Pakistan Cane C 97 1994 132 Bukidnon Philippines Cane A 180 2003
53 Mendota** U.S.A. Beet B 120 1994 133 Santa Teresa Brazil Cane C 120 2003
54 Mitr Phol Thailand Cane A 170 1994 134 Ameca Mexico Cane B 100 2004
55 Triangle Zimbabwe Cane C 86 1994 135 Constancia Mexico Cane B 100 2004
56 Trangkil Indonesia Cane C/D 79 1994 136 Queseria Mexico Cane B 100 2004
57 Bacita# Nigeria Cane C 68 1994 137 Brawley (ex-Sidney) USA Beet B 100 2004
58 Maidstone R.S.A. Cane C 120 1995 138 Xinivane Mozambique Cane A 75 2004
59 Ubombo Ranches Swaziland Cane B 110 1995 139 Victorias Philippines Cane C 200 2004
60 Scottsbluff U.S.A. Beet B 75 1995 140 Enterprise U.S.A. Cane A 160 2004
61 Hillsboro** U.S.A. Beet B 120 1995 141 San Rafael Mexico Cane B 120 2004
62 Indolampung (PT Sweet) Indonesia Cane A 140 1995 142 San Miguel Mexico Cane C 120 2004
63 Indolampung (PT Sweet) Indonesia Cane B 140 1995 143 Tamazula Mexico Cane C 100 2005
64 Indolampung (PT Sweet) Indonesia Cane C/D 140 1995 144 Tala/IJM Mexico Cane C 180 2005
65 Triangle Zimbabwe Cane B 120 1995 145 Korach Thailand Cane C 250 2005
66 Abbeville France Beet B 68 1995 146 Magdalena Guatemala Cane A 200 2005
67 Manuelita Colombia Cane C 120 1996 147 Magdalena Guatemala Cane C 130 2005
68 Richard Toll Senegal Cane A 145 1996 148 Magdalena Guatemala Cane C 130 2005
69 La Gloria Mexico Cane C 60 1996 149 Tala Mexico Cane B 250 2006
70 Victorias Philippines Cane A 130 1996 150 Benito Juarez Mexico Cane C 120 2006
71 Eston R.S.A. Cane A 86 1996 151 Savannah Mauritius Cane A 170 2006
72 Pongola R.S.A. Cane C 65 1996 152 Savannah Mauritius Cane C 80 2006
73 Darnall R.S.A. Cane B 86 1996 153 Magdalena Guatemala Cane A 200 2006
74 Gardel Guadeloupe Cane A 90 1996 154 Hawaiin & Philippines Co. Philippines Cane C 120 2006
75 Wahpeton** U.S.A. Beet B 150 1996 155 Surin Thailand Cane C 250 2007
76 Twin Falls** U.S.A. Beet B 160 1996
77 Triangle Zimbabwe Cane A 160 1997 156 Sonedco Philippines Cane C 120 2007
78 Labasa Fiji Cane C 125 1997 # Purchased, built and delivered but not commissioned
79 Trapiche Brazil Cane C 120 1997 * in conjunction with Wiedeman KG, FS licencees.
80 Tower Hill Belize Cane C 73 1997 ** Stacked configuration of multiple sections
Vertical Crystallisers
Tongaat Hulett vertical crystalliser design incorporates finned static cooling elements which are
scraped by rotating arms. This promotes heat transfer and the rotor and stator geometry allows
heating surface to volume ratios in excess of 2:1 without crystal settling out on the elements. The
crystallisers are designed to handle high viscosity C massecuites and can be fitted with either
hydraulic drives or electrical variable speed drives. These vertical crystallisers have been installed
in most of the latest mill expansions in Southern Africa.
A list of TH designed Vertical Crystallisers installed for customers since 1993 is shown below: -
Vertical Crystallisers at Komati Tongaat Hulett Vertical
Crystalliser
Tongaat Hulett Designed Vertical Crystalliser Installations
Mill Capacity
m3
Duty Date
Komati
Komati
Triangle
Triangle
Bois Rouge – Mauritius
Ubombo
Pongola
Komati
Komati
Xinavane – Mozambique
Xinavane – Mozambique
Eston
Cameroon
Komati
2 x 110
4 x 110
110
110
160
120
160
110
2 x 110
2 x 120
1 x 160
160
2 x 90
2 x 110
A
C
B
C
C
C
C
A
C
C
A
B
C
C
1993
1993
1994
1994
1995
1998
1998
1998
1998
2000
2000
2001
2001
2005
Massecuite Reheaters
The Tongaat Hulett design provides efficient reaheating of low grade massecuite after cooling
crystallisers, and prior to centrifugation. The unit employs finned tubes carrying warm water to
heat the massecuite and achieves a low resistance (pressure drop) to massecuite flow whilst
requiring only a small temperature difference for heating. The result is a unit that requires a low
head (gravity feed) to drive the massecuite flow whilst ensuring a minimum of re-dissolution of
crystal. The design is backed by many years of production experience on some of the most viscous
massecuites in the cane sugar industry.
A list of the TH designed reheaters which have been supplied to customers since 1992 is shown
below:-
Tongaat Hulett Designed Reheater Installations
Mill Size m2 Date -Year
Felixton
Komati
Bois Rouge – Mauritius
Komati
Xinavane - Mozambique
1858
1240
1858
1240
1240
1992
1993
1995
1998
2000
C Massecuite Reheater at Komati
Remelters
The TH remelter design is a multi compartment system comprising an optimum number of tanks
fitted with vortex tubes and stirrers and direct steam heating spargers, where appropriate, for
complete dissolution to take place.
A list of TH designed remelters which have been supplied to customers since 1993 is shown below:-
Tongaat Hulett Designed Remelter Installations
Mill Size (m3 ) Duty -Grade Date -Year
Komati
Triangle – Zimbabwe
Triangle – Zimbabwe
Triangle – Zimbabwe
Maidstone
Clewiston – USA
Triangle – Zimbabwe
Xinavane – Mozambique
15
6
3
6
30
3
6
A
A
A
White
B/C
White
White
C
1993
1993
1995
1995
1996
1997
1998
2000
Triangle A 2005
Sugar Driers
The Tongaat Hulett Rotary Cascade Sugar Drier design draws on well established conventional
technology, but has a number of attractive features of its own. A unique seal design provides
maximum integrity against air/sugar leakage, ensuring high levels of energy efficiency and plant
hygiene. The drier internals provide positive sugar transport and high air-sugar contacting
efficiency. Finally, the wheel-driven (rather than chain-driven) drum is a clean and quiet
installation.
A list of the TH designed sugar driers which have been supplied to customers since 1995 is given
below:-
TH Designed Rotary Cascade Sugar Drier Installations
Mill Capacity (t/h) Duty Date
Triangle- Zimbabwe
Bois Rouge
Darnall
60
10
60
VHP
VHP
VHP
1995
1998
2001
10 t/h White Sugar Dryer at Bois Rouge Reunion
Sugar Refining Equipment
Tongaat Hulett designs for sugar refining equipment have been developed and perfected in our
large sugar refinery in Durban. We can offer designs for sugar melters, carbonatation systems, ion
exchange decolourisation, ion exchange vessels and distributors, filtration, evaporators, white
batch vacuum pans, condensers, pan stirrers and continuous recovery pan boiling.
Tongaat Hulett Refinery - Durban
White sugar Mill (WSM ) Technology and the Rotary Distribution System (RDS)
A process to produce white sugar directly from cane juice has been developed by TH in partnership
with SA Bioproducts. The process uses ultra filtration and ion exchange to remove impurities prior
to crystallisation. In 2006 a plant designed to produce 36 000 tons of white sugar per annum was
commissioned.
To accommodate large scale ion exchange, TEG developed the Rotary Distribution System (RDS).
This is a mechanical device that allows a batch process to be configured in a way that approaches
continuous operation. On the WSM plant, stationary ion exchange vessels are connected using the
RDS to achieve simulated moving bed operation. The RDS has a much wider application and can
be used for industrial chromatographic separations for example.
LINK to WSM Process – See document
The Rotary Distribution System
Fluegas Scrubbers
The Tongaat Hulett boiler fluegas scrubber is based upon the irrigated sieve plate concept which
has a number of advantages over spray scrubbers. It is very resistant to fouling with smuts or
fibres and operates with a low pressure drop of ± 100mm water gauge. Particulate emission levels
are typically less than 100mg/Nm3 . The scrubber can be designed to operate on bagasse or coal
fire boilers and have good turn down capability. Apart from the scrubbers fitted at the Tongaat
Hulett Sugar mills, seven have been designed and installed in Mauritius, one at Simunye in
Swaziland and one a Komati, the capabilities ranging from 25 to 125 MCR t/h.
Tongaat Hulett Designed Boiler Fluegas Installations
Mill
Boiler MCR Capacity t/h Diameter m Date of Installation
Mon Desert Alma Mauritius
Rose Belle – Mauritius
Beau Champ – Mauritius
FUEL - Mauritius
Simunye – Swaziland
Riche-en Eau – Mauritius
Amatikulu
50
70
25 x 2
140 x 1
100 x 1
125 x 1
43 x 1
80 x 2
4.2
4.7
3.1
6.4
5.3
8.6
4.7
4.2
1995
1995
1996
1996
1997
1998
1998
2002
Komati 150 6.2 2006
Water Circuit Clarifiers at Felixton Fluegas Scrubber at Beau Champ
Miscellaneous Equipment
Other equipment designs are available for sugar processing and sugar factory services, including :
Entrainment Separators (Internal and External)
Strike Receivers
Seed Receivers (with Continuous Pans)
Syrup Clarifiers
Sugar / Bagasse Cyclones
Flash Tanks
Hilo unloaders
Static (in-line) mixer for juice liming and syrup clarifiers
Molasses conditioning (blow-up) tanks
Technology & Engineering Group
SUGAR ENGINEERING AND PROCESSING CONSULTANTS REFERENCE
LIST
Major projects, design and consulting work carried out since 1981 is summarised below :-
1981 Integration of a new ethanol plant at Triangle Sugar Mill in Zimbabwe.
1982 Installation of a 110 m3 continuous A pan at Maidstone Sugar Mill.
1982 Expansion of Triangle Sugar Mill from 270 to 375 tons cane per hour. This included the installation of a new cane diffuser, a boiler, a turbo-alternator, extensions to evaporators and centrifugal modifications.
1983 Design, construction and project management of a new sugar mill at Felixton to crush 600 tons per hour (current value U$ 250 million). Most process equipment, including A, B and C continuous pans, diffusers, batch pans, evaporators, vertical crystallisers and syrup clarifiers were designed in-house.
1984 Modernisation and expansion of the Mount Edgecombe Sugar Mill evaporator system, including a 3 200 m2 Kestner evaporator.
1985 Installation of new 110 TPH melt station at Tongaat Hulett Sugar Refinery.
1986 Installation of 120 m3 continuous C pan at Hippo Valley Sugar Mill in Zimbabwe.
1987 Installation of a syrup flotation clarifier at Triangle Sugar Mill, Zimbabwe.
1987 Expansion of Tongaat Hulett Sugar Refinery to 600 000 ton p.a. output, incorporating the installation of additional filters, stirred white sugar pan and additional second stage ion exchange decolourisation system.
1987 Design and installation of a 2500 ton white sugar conditioning plant at Tongaat Hulett Sugar Refinery in consultation with Bosch & Associates. Capital value $5.5 million.
1988 Expansion of Darnall Sugar Mill from 270 to 310 tons cane per hour - major plant changes included the installation of evaporators and a continuous C pan.
1989 Modernisation of Maidstone pan floor including the installation of 2 x 51 m3 batch pans.
1990 Installation of a 110 m3 continuous C pan at Malelane Sugar Mill.
1990 Installation of new 85 m3 white refined batch pan with stirrer at Malelane Sugar Mill and the installation of a pan stirrer in existing an 85 m3 pan.
1991 Design of a phosphatation clarifier for Zuenoula, Ivory Coast.
1991 Design and installation of a Hilo unloader and cane conveyor system at Mt Edgecombe sugar Mill.
1992 Installation of pan stirrers in B and C massecuite pans at Royal Swazi Sugar Corporation’s Simunye Sugar Mill.
Installation of 2 x 45 tons/hour coal-fired boilers at Tongaat Hulett Sugar Refinery.
1992 Design of a 70 m3 continuous C pan at Sucoma Sugar Mill in Malawi.
1993 Installation of 8 MW turbo-alternator at Tongaat Hulett Sugar Refinery.
1992-94 Partial design and project management of three irrigation schemes in Northern Kwa-Zulu Natal. Total area irrigated 5300 Ha with a capital value of $28 million
1993 Design of diffuser, evaporators, pans, crystallisers and reheater for the new Komati Sugar Mill in Mpumalanga, South Africa.
1993 Design and installation of a syrup clarifier at the Mount Edgecombe Sugar Mill.
1994 Installation of bagasse depithing station at Darnall Sugar Mill, for supply of fibre to a paper mill.
1994 Design of a new C station for Triangle Sugar Mill, Zimbabwe, including an 86 m3 continuous C pan and 110 m3 continuous vertical C crystallisers.
1994/95 Expansion of Maidstone Sugar Mill from 360 to 440 TCH. TMD managed the project involving U$ 15 million capital expenditure. New equipment included a 300 TCH cane diffuser, 120 m3
continuous C pan and a brown sugar packing station.
1995 Design of a 110 m3 continuous B pan at Ubombo Ranches Sugar Mill - Swaziland.
1995 Design of an expansion at Triangle Sugar Mill in Zimbabwe, to expand capacity to 430 TCH. New equipment installed included a 120 m3 continuous B pan.
1995 Design of an 86 m3 continuous A pan at Eston Sugar Mill.
1995 Relocation of a 60 tons steam/hour boiler ex Empangeni Sugar Mill to Darnall Sugar Mill.
1995 Design of a 65 m3 continuous C pan for Pongola Sugar Mill.
1995 Design of two boiler scrubbers for Mon Desert Alma Sugar Mill in Mauritius. One for a 50t/h MCR bagasse boiler and one for a 70t/h MCR bagasse boiler including the design of the ash sluicing systemns.
1995 Design of a 160 m3 vertical C crystalliser and 1858 m2 C massecuite reheater for Bois Rouge Sugar Mill in Reunion.
1996 Design of two boiler scrubbers for 25t/h MCR bagasse boilers at Rose Belle Sugar Mill in Mauritius.
1996 Design and installation of a 86 m3 continuous B pan and boiler smuts handling plant at Darnall sugar Mill.
1996 Design of a boiler scrubber for a 140t/h MCR bagasse/coal fired boiler at Beau Champ Sugar Mill in Mauritius.
1996 Design and installation of a 1430 m2 Robert evaporator at Felixton Sugar Mill.
1996 Design of three 60 m3 stirred stainless steel refined sugar batch pans with welded calandrias together with condensers for U S Sugar Clewiston Mill in Florida USA
1996/97 Consulting on energy efficiency and steam control for Al Khaleej Sugar Refinery in the UAR in conjunction with Pinchtech SA. Design of a vapour melter for Al Khaleej Sugar Refinery.
1997 Design of a refined sugar melter for U S Sugar Clewiston Mill in Florida USA
1997 Design and installation of a 160 m3 continuous A pan at Triangle Sugar Mill in Zimbabwe
1997 Design of a 600 m2 C massecuite reheater for Mon Tresor Sugar Mill in Mauritius.
1997 Design of a 100 m3 continuous C pan and a 3500 m2 2nd effect Kestner evaporator and separator vessel for the Umfolosi Sugar Mill expansion.
1997 Design and installation of plate heaters, plate evaporator and a thermo-compressor at Tongaat Hulett Sugar Refinery as part of energy economy consultations in conjunction with Pinchtech S.A.
1997 Design of a boiler scrubber for a 100t/h bagasse/coal fired boiler at Flaq United Estates Limited Sugar Mill in Mauritius.
1997 Design of a 120 m3 continuous A pan for Ubombo Ranches Sugar Mill in Swaziland.
1997 Design of a direct contact presswater heater for Malelane Sugar Mill.
1997/98 Design and installation of 25kg and 50 kg packing lines at Tongaat Hulett Sugar Refinery.
1997/98 Conceptual process design, equipment specification and design for the expansion of the Komati Sugar Mill from 225 TCH to 500 TCH with an intermediate phase of 375 TCH. Equipment designed included a 225 TCH diffuser, 130 m3 continuous A pan, 130 m3 continuous B pan, 85 m3 stirred A batch pan, two 3800 m2 Kestner evaporators and separators, 2000 m2 Robert evaporator, 1000 m2 Robert evaporator, 110 m3 A crystalliser, two 110 m3 C crystallisers, 1240 m2 C massecuite reheater, seed receivers, blowup tanks and condensate tanks.
1998 Design of a boiler scrubber for a 125 t/h MCR bagasse boiler at Simunye Sugar Mill in Swaziland.
1998 De-bottlenecking Entumeni Sugar Mill with modifications to the diffuser drive, evaporators and cooling towers.
1998 Design of a 10 t/h refined sugar rotary cascade dryer/cooler for Bois Rouge Sugar Mill in Reunion.
1998 Design of a 160 m3 continuous A pan, a 160 m3 vertical C crystalliser and two direct contact juice heaters for Pongola Sugar Mill.
1998 Design of a 1000 m2 1st effect Kestner evaporator and separator for Malelane Sugar Mill.
1998 Design of a 120 m3 vertical C crystalliser for Ubombo Ranches Sugar Mill in Swaziland.
1998 Designs for the Phase 1 expansion of the Simunye Sugar Mill including a new cane knife rotor and an expanded evaporator station including three 2200 m2 Robert evaporators, two louvre entrainment separators for existing evaporators and a new condenser.
1998 Design of 120 m3 continuous B pan for Sucoma Sugar Mill in Malawi.
1998 Design of 105 m3 continuous A pan for Dwangwa Sugar Mill in Malawi.
1999 Design of a boiler scrubber for 43t/h MCR bagasse boiler at Riche en Eau Sugar Mill in Mauritius.
1999 Independent assessment, audit and report on the Plate Evaporators at Hippo Valley Sugar Mill in Zimbabwe with regard to performance, operation, suitability, design and meeting supply warranties.
1999 Designs for the Phase 2 expansion of the Simunye Sugar Mill including a 120 m3 continuous C pan with external condenser, Hilo offloader, feeder table and cane carrier.
1999 Investigation and recommendations for improvements to the Hippo Valley Sugar Mill juice heaters, evaporator configurations and evaporator operations. Designs were supplied for four 349 m2 mixed juice heaters and vertical louvre entrainment separators for the 1st effect Kestner evaporators and the 4th effect Robert evaporators.
2000 Conceptual process design, equipment specification and design for the rehabilitation and expansion of Xinavane sugar mill to 120 TCH. Equipment designed included 43m3 continuous C pan, 30 t/h sugar dryer, two 120 m3 vertical crystallisers, 43m3 batch pan, 2000m2 1st effect Robert evaporator, remelter, reheater, entrainment separators and condensers. Designs for cane preparation included a Hilo offloader, cane knife and shredder.
2000 Assessment of the constraints to optimal crushing capacity and identification of bottlenecks in processing for the Hippo Valley Sugar Mill in Zimbabwe. Recommendations included modifications to the
diffusers, changes in the boiling schemes and optimisation of existing equipment in the boiling and crystallisation sections.
2001 Design of a 90m3 vertical C crystalliser and a 920m2 massecuite reheater for STE Engineering to be installed in a sugar mill in the Congo owned by SOMDIAA.
2001 Design of 3 vacuum pan stirrers and entrainment separators for retro-fitting into existing white sugar pans at Mhlume Sugar Mill in Swaziland.
2001 Design of a 160m3 vertical B crystalliser for Eston Sugar Mill
2002 Design of a triple effect Robert evaporator set (3 x 270m2 ) for the refinery at Mhlume Sugar Mill.
2002 Design of three entrainment separators for new kestner and semi-kestner evaporators at Ubombo Ranches Sugar Mill.
2002 Process design specification for the expansion of Malelane Sugar Mill to a crush of 2.2 million tons of cane in 38 weeks. High level studies for the requirements for a further increase to 2.4 million tons and for a refinery expansion to 400 000 TPA were also carried out.
2002 Capacity increase design for the SASA Sugar Export Terminal.
2003 Design of two entrainment separators to replace existing Poly-baffle separators in 1st and 2nd effect Kestner evaporators at Komati Sugar Mill.
2003 Design of a stainless steel boiler scrubber for a boiler burning grape pomace for Vin-O-Kem (Pty) Ltd.
2003 Energy survey and proposals to reduce the quantity of coal consumed for Simunye Sugar Mill in Swaziland.
2003 Investigation of energy saving measures that could be implemented at Komati Sugar Mill to allow an increase in crushing capacity without requiring an expansion of boiler capacity.
2003 Desktop design for a 40 000 TCD raw sugar mill in the Sudan. 2003 Investigation and reporting on the factory requirements to enable Komati Sugar Mill to crush 2.6 million tons of cane in a 38 week season.
2003 Design for the expansion of Xinavane Sugar Mill to a throughput capability of 150 TCH.
2004 Design of two phosphotation clarifiers for STE Engineering to be installed in sugar mills in the Cameroon and Chad.
2004/5 Design, procurement and project management of a R50 million WSM slipstream plant at Felixton Sugar Mill to produce white sugar directly at a rate of 8 tons /hour.
2004/5 Design procurement and project management of 3 RDS units for the WSM slipstream plant at the FX sugar mill.
2005 Technology and engineering input to the Feasibility Study for Metahara Sugar Factory in Ethiopia to provide capacity to produce 26t/h of EEC2 refined sugar with integration into the existing factory to provide maximum energy efficiency.
2005 Design of two 110m3 C massecuite vertical crystallisers for Komati Sugar Mill.
2005 Design of irrigated sieve tray boiler scrubber for a new 150 t/hour boiler at Komati
2005 Design of improved 350 TCH cane diffusers for the Fives Cail Group to be installed under licence in Savannah Mill Mauritius and Skeldon Mill in Guyana.
2005 Design of a direct contact vapour heater for carbonatation in the Savola Refinery, Saudi Arabia.
2006 Technology and engineering input to the Feasibility Study to expand Metahara Sugar Factory, Ethiopia, to 700 TCD with allowance for an ethanol production capability and co-generation.
2007 Design Of the XN Expansion to 380 tch (from 150 tch)
2007 Design of the proposed Mafambise expansion to 200 tch
