Shakarganj Mills Ltd - Allah Dita Hassan_2

SHAKARGANJ MILLS Ltd., JHANG

INSTITUTE OF CHEMICAL ENGINEERING & TECHNOLOGY, UNIVERSITY OF THE PUNJAB, LAHORE

INTERNSHIP

REPORT

Submitted to: Dr. Ayyaz Muhammad

Supervised by: Engr. Nawaz Kokab

Internee

Name: Allah Dita Hassan

Roll No. Eo8-PG18

Duration: 1st July-1st August 2010

Allah Dita Hassan (E08-PG-18)

TABLE OF CONTENTS

1. Acknowledgement

2. Introduction 3. Milling House

4. Boiler House

5. Production House

6. Remarks


ACKNOWLEDGMENT

“My cardial gratitude is for the well-esteemed organization Shakarganj for giving me an opportunity to enhance my practical knowledge in the field of Sugar Manufacturing.

This internship report could not have been completed without the help of capable and concerned individuals. First and foremost, I would like to thank Engr. Imtiaz Ahmed, General Manager of Production Shakarganj under the kind supervision of whom I have completed this report.

I would also like to thank the Engineers, Supervisors and In-charges of Boiler House, Power House, Mill House and Process House who very generously let me enhance my knowledge and also made me familiar with the professional attitude, manner and skills as well.

I would also like to thank Chemist. Nawaz Kokab, Engr. Muhammad Zeeshan for their help in each and every matter I encountered during the period of my internship. ”


INTRODUCTION The main business area is the production of refined cane sugar and sugar by-products. This is possible by believing in diversification through setting up new manufacturing facilities and equity participation. The manufacturing process of sugar and its by-products is as follow: Sugar obtained from sugarcane contains 99.5 percent sucrose, commonly known as cane sugar. Sucrose belongs to a group of carbohydrates called disaccharides. It is soluble in water, slightly soluble in alcohol and ether, crystallizes in long, slender needles, and is dextrorotatory. Upon hydrolysis, sucrose yields a mixture of glucose and fructose, which are levorotatory. The mixture obtained is known as invert sugar, and the process is known as inversion. Inversion is carried on in the human intestine through the aid of enzymes known as invertase and sucrose. When heated to temperatures above 180 ° C (356° F), sucrose becomes the amorphous, brown, syrupy substance called caramel. Sugar is not only used as a constituent in industrial and home made food, but also as raw material in fermentation to produce ethyl alcohol, butyl alcohol, glycerin and citric acid. Sugar is also an ingredient in transparent soaps and can be converted to esters which yield tough, insoluble and infusible resins.


MILL HOUSE

STEPS INVOLVED IN SUGAR MANUFATURING

1. Cane handling 2. Cane Preparation 3. Milling/Juice Extraction 4. Juice Purification 5. Evaporation 6. Raw Sugar Crystallization 7. Liquor Clarification 8. Refinery Sugar Crystallization 9. Drying and Packing

CANE HANDLING AND PREPARATION

This part of Milling House was established in 1973 with a crushing capacity of 5500 tons cane per day.

PROCESS

First of all when the sugar cane is taken from cane yard it is subjected for weighing, for this purpose we use Weigh Bridge. Three (3) weigh bridges are used, two (2) for Gross Wt. and 1 for Tare Wt. Then cane is unloaded, this is done by Electric Hoists. These Weigh Bridges are of “Avery England” Design. Two (2) Weigh Bridges are for Gross Weight and 01 Weigh Bridges is for Tare Weight. Capacity of the Weigh Bridges is 50 Tons. CANE UNLOADING

Cane Unloading is done with the help of Electric Hoists. Three Electric Hoist are attached to Mill Tandem .The Function of these Electric Hoists is to Lift the Cane loaded Truck and throw it to Dumping Carrier.

ELECTRIC HOIST

Motor Brake Type Steel wire rope Rope Dia 7/8 inch Gear Reduction gear Lifting Speed 3-20 ft/ min Lifting Height 20 m

After unloading the cane is to be fall on Dumping Carrier.


SLIDING PLATES

Length 6.5 feet Width 8-9 inches Roller Chain pitch 9 inches

CHAIN SPROCKET MECHANISM

When high torque load is to be transmitted. We use chain sprocket mechanism. By the Formula of power as torque is very high and speed is low then slippage

takes place. So belt could not be used there and chain sprocket mechanism is the better choice.

TANDOM # 01

Mill size 36 *72 inches Dia of Mill Roller shell 36 inches Length of mill roller shell 72 inches Crushing Capacity 5500 TCD (tons crushed per day) No of Mills 05

DUMPING CARRIER

It has 03 rows. Sliding plates are attached Length 60 feet Width 17 inches Linear Speed 24 feet/ mint Sliding Plate Length 5.5 feet Sliding Plate Width 8-9 inches Carrier Angle 18 degree Roller chain pitch 06 inches Gear ratio 1/80

LEVELER # 01

Chain Procketer Mechanism is used. No. Of arms 26 Speed 39 rpm Motor power 100 kW

6

LEVELER # 02

Speed 39 rpm No of arms 24


PUSHER DRUM

The function of the pusher drum is to push the compact sugar cane to the Fabiriser. Reduction Gear are applied.

Speed Ratio 22.4 Reduce Ratio 2.7 Dia of Drum 2250 mm Length of the Drum 7200 mm Motor power 1000 kW

FABIRIZER

Fabirizer does the same function in Tandom #1 as Shredder in Tandom #2.In Fabirizer it takes input feed from the top and pushes it to the bottom. It has anvil plate on the top. Then it has feed rake bar and rake bar under carrier. It is Turbine Driven.

Power 3 Mw Speed 1000 rpm No of holders 36 Stainless steel Bars 08 Hammers 108 Coupling type Spring Then after passing through the Fiberizer cane material is to be dropped on the

Rubber Belt Conveyor just over the top of which there is magnetic iron separator arrangement so that if any metallic particle is coming with the rupture cane material it will cling to that magnet. MAGNETIC IRON SEPARATOR

It separates iron and other magnetic particles from cane before it is conveyed to the mill. It is provided with a power of 18.5 kW.

RUBBER BELT CONVEYOR

The specifications of the rubber belt conveyor are as follows Linear speed 75 m/min Width 2000 mm Length 9320 mm Thickness 15 mm It is made up of 5-ply nylon imported. This belt is under magnet and the capacity of

this magnet is 18 kW. After this cane is material is dropped on the Rack Bar Carrier.

RACK BAR CARRIER

It helps in putting the feed in the mill machine by lifting it at a height with the help of plates on Y-type pad link chain. It is moving with Linear speed of 120 ft/min and inclined at an angle of 48o. Its width is 78 inch.


MILLS of TANDOM # 01

Tandem # 01 has got five (5) mills installed in it. MILL # 01

It’s Walker Design Australia. Separate Tail Bar drives for Mill Roller AND pressure Feed Roller. 02 Tail Bar are used.

There are six (6) Roller mills. There are three (3) Pressure Feed Roller.

PRESSURE FEED ROLLERS 1 Pressure Feed Bottom Roller. 2 Pressure Feed Top Roller. 3 Under feed Roller.

MILL ROLLERS

1 Mill Top Roller. 2 Mill Feed Roller. 3 Mill Discharge Roller.

Mill Rollers are Turbine driven. Specifications of Turbine are:

Turbine power 850 kW Live Steam Pressure 23-24 kg/ cm2 Exhaust steam Pressure 01 kg/ cm2 Temperature 325-350 c Turbine Speed 1800 rpm Mill Roller Speed 5-6 rpm

MILL # 02 Last Four Mills of Tandom # 01 are works poor Design. It is 05 Mill Tandom. Single

Tail Box coupling is used to rotate both mill roller and pressure Feed Roller. Pressure Feed Roller is connected to Mill Roller with chain drive. Here slow Speed Gear is used instead of Bull Gear. Feed rake Bar is driven by Electric Motor.

PRESSURE FEED ROLLER

1 Pressure Feed Top Roller. 2 Pressure Feed Bottom Roller.

MILL ROLLERS 1 Mill Top Roller. 2 Mill Feed Roller. 3 Mill Discharge Roller.


These rollers are also Turbine driven. Turbine power is 600 kW MILL # 03

Same arrangement as Mill # 02 Turbine Power 600Kw

MILL # 04 Same arrangement as Mill # 03 Turbine Power 750 Kw

MILL # 05 Same arrangement as Mill # 04 Turbine Power 597 kW Gear Ratio 1/52 Mill Roller Speed 5-6 rpm Turbine Speed 1800 rpm

ROTARY JUICE SCREEN

Unscreened juice comes from storage tanks here it passes through rotary screener and screened juice is sent to the process house.

TYPES OF BEARING

ROLLER BEARING

As the name implies this type is Roller contact bearing. These are used for high strength and have a good alignment. These are used for low torque and high speed. GENERAL BEARING

These are sliding contact bearing and used for high torque and slow speeds.

TYPES OF COUPLINGS BUSH COUPLING

It has sliding contact. It don’t need lubrication .it is self-lubricant. Used where distances are minimum. It is used for power transmission. TAIL BOX COUPLING

It is used for larger distances. These are shock absorber. Used for high load transmission


STEAM TURBINES ON MILL HOUSE # 01

These mills are driven by Steam turbines which run by steam of high temperature and low pressure i.e. 350C and 24 kg/cm2, coming from boiler. Power specifications of turbines are given below

Mill 1 = 850 kW Mill 2 = 850 kW Mill 3 = 650 kW Mill 4 = 650 kW Mill 5 = 650 kW

These turbines control the rollers, which are joined with mills by box coupling. All of these turbines are two stage single disk turbines. The driving mechanism is such that we link a high-speed gear to the turbine by coupling and then link the high-speed gear to the slow-speed gear, we do this because we want to reduce the speed but enhance the power.

Turbine Pinion Gear High-Speed Gear Low-Speed Gear 6000 rpm 2000rpm 135-150 rpm 5-6 rpm

TANDOM # 02

Mill Size 38*78 inches Dia of Mill Roller Shell 38 inches Length of Mill Roller Shell 78 inches Crushing Capacity 7500 TCD (Tons crushes per day)

MAIN CARRIER Purpose of giving an angle to the main carrier is evenly distributed and compact

feeding. Length 150 ft Straight length 100 ft Elevated portion 50 ft Width 90 inch Before Shredder Width 90 inch After shredder Width 78 inch Angle Before Leveler 09 deg Angle after leveler 12 deg Linear Speed 30feet/ mint Motor Speed 980 rpm Motor Power 1 00 hp

LEVELER As the name implies it function is to provide evenly feed to cutters. Leveler arms 38 Leveler angle 6-7 degree Leveler Speed 36 rpm Supply source motor driven


Motor speed 980 rpm Motor Power 100 hp Coupling Bush

CUTTER # 01 Cutters are driven by backpressure Impulse Turbine. Bush coupling is uses to join

the driver shaft to the driven shaft. No. of knives 70 Hard face cutter Cutter speed 600 rpm Turbine Power 1200kw Live Steam Pressure 23-24 kg/cm2 Temperature 325-350c Exhaust Steam Pressure 01 kg/cm2 Turbine Speed 1500 rpm

CUTTER # 02 This cutter also uses Backpressure Impulse Turbine for its Operation . Bush Type

coupling is used . Reduction gears are used to reduce the Turbine speed . Live steam pressure and Exhaust steam pressure and temperature remain the same for all Backpressure Impulse Turbines

No. of knives 70 Turbine Power 750 kW Turbine Speed 1500 rpm Cutter Speed 600 rpm

CUTTER # 03 This cutter is driven by Electric Motor. No. of knives 52 Speed 600 rpm Motor power 600kW

CANE SHREDDER

The main function of the shredder is to rapture the structure in order to open the

cells of the cane .It is driven by Backpressure Impulse Turbine. This Shredder is covered by anvil plate .It is below the Shredder. It has very low spacing in mm with hammers. Shredder has Stainless steel hammers with beadings. Shredder gets feed from below and takes it above .that is why its anvil plate is below .Its BMA Design Germany.

Shredder Holders 57 No. of Bars 08 No. of Hammers 228 Weight of hammer 15.5 kg Turbine speed 1000-1100 rpm Turbine power 2000 kW


MAGNETIC IRON SEPARATOR

It’s ANDRIN France Design. Power 17.7 kW

MILLS of TANDOM # 02

No. Of Mills 04 It’s Walker Design Australia. All the four Mill units have same arrangements same

number of Mills.Trash plate is used to clean the mill rollers . Mill top roller has tail box coupling with the driving shaft of the Turbine and it drives Mill feed roller and Mill discharge roller. These Mill units are turbine driven and input live steam pressure , exhaust pressure and temperature conditions remains same for all the Turbines. Separate Tail box drive for Mill roller and Pressure Feed Roller.

MILL # 01

There are 6 rollers 1 Pressure Top Roller. 2 Pressure Bottom Roller. 3 Underfeed Roller.

MILL ROLLERS 1 Mill Feed Roller. 2 Mill Discharge Roller. 3 Mill Top Roller. These mills are Turbine driven Specifications of Turbine are: Turbine power 850 kW Speed 1000-1100 rpm Live Steam Pressure 23-24 kg / cm2 Exhaust pressure 01 kg / cm2 Temperature 325-350c

MILL # 02 Mill unit #2 has same arrangement same type of turbine as mill #01.

MILL # 03 Mill unit has same arrangement as above. Turbine power 750 kW Maximum Speed 2200 rpm Driven Speed 1000-1100 rpm Temperature 325-350 c


MILL # 04 Mill unit has same arrangement as above. Turbine power 1044 kW

REVERSE PRESSURE GEAR/ BACK GEAR

This gear rotates the turbine in reverse direction slowly as in case when some obstacle comes in the mill roller to release it. It is driven by electric Motor.

ROTARY JUICE SCREEN As in Tandem # 01.

STEAM TURBINES ON MILL HOUSE # 02

These mills are driven by Steam turbines which run by steam of high temperature and low pressure i.e. 350C and 24 kg/cm2, coming from boiler. Power specifications of turbines are given below

Mill 1 = 850 kW Mill 2 = 850 kW Mill 3 = 850 kW Mill 4 = 1040 kW These turbines control the rollers, which are joined with mills by box coupling. All of

these turbines are two stage single disk turbines. The driving mechanism is such that we link a high-speed gear to the turbine by coupling and then link the high-speed gear to the slow-speed gear, we do this because we want to reduce the speed but enhance the power.

Turbine Pinion Gear High-Speed Gear Low-Speed Gear 6000 rpm 2000rpm 135-150 rpm 5-6 rpm Multiple stage turbines are also used. Stages are increased to increase the power

output required. More steam is consumed in these turbines.

MILLING / JUICE EXTRACTION PROCESS for TANDOM # 01

Milling Process starts from the Mill Machines.

MILLING MACHINE It separates the juice from cane fibers by pressing it between different rulers,

leaving Bagasse behind. This juice is collected in tank and sent further for sugar preparation.

From rack bar carrier cane material come in Mill 1, which is a six-roller mill. Three of them are called Pressure Feeders


1 Top Pressure Feeder Roller

2 Bottom Pressure Feeder Roller

3 Force Feed Roller

And two of them are called Mill Rollers

1 Top Roller 2 Feed Roller 3 Discharge Roller

ROLLER

It is a cylindrical structure present in milling machine which processes the cane fibers. It has grooves on it to avoid slippage when cane is passed through it.

Length 72 inch Diameter 36 inch

NOTE:This is also called as the mill size.

SPECIFICATIONS OF MILL 02, 03, 04, 05 In TANDEM #1 these 4 mills are 5 roller mills having no Force Feed Roller.

PROCESS

When the cane material enters the mill (1) machine it first passes through the pressure feeder top and bottom where lot of juice is extracted from that cane material which is then forward to the mill rollers through pressure chute box where it come first b/w top roller and feeder roller where again by pressing b/w these rollers juice is and then cane material is pass through trash plate to the discharge roller then material is subjected to next mill (2), this process is repeated to mill 5. But in mill 4 and 5 water is also added in the dumpy cane material so that the cane juice which is remaining in the dumpy Bagasse material could be extracted. The specifications of the water used in the mill 4 and 5 are as follows:

Temperature of Water 60-70oC Ratio of use 100 tons / 22 tons

PRESSURE CHUTE BOX

Nose plates are used between the pressure feeder top and pressure feeder bottom. It conveys bagasse in compact shape from pressure feeders to mill feeders. It consists of two plates.


NOTE: In compact form more juice can be extracted from bagasse.

TRASH PLATES A trash plate or Trash turner, supported on a trash bar is placed as to guide the

cane from feed opening to the delivery opening, maintaining it under some pressure and confining its path.

MILL AND TRASH PLATE SETTING GROOVES

The roller shell is provided with circumferential grooves of V section in order to improve the grip of the rollers on the cane and to give improved juice drainage. ARCHING

To make small teethes or welded spots on roller surface to avoid slippage.

SCRAPER It conveys bagasse from discharge mill ruler to rack bar carrier of next mill

machine. Then by this complete procedure near about all the juice is extracted and the

remaining material, called as Bagasse, is then dropped on the main bagasse carrier.

BAGASSE CARRIER The specifications of the main bagasse carrier are as follows

Length of the chain 80 ft Width 1850 mm Linear speed 97 ft /min


This material is shifted to outside as a by-product. It is also used for burning purposes in boilers.

EXTRACTED JUICE FLOW

The extracted juice from Mill 1 and Mill 2 is directly shifted to Rotary-Kiln which rotates at a very high speed such that any bagasse material present in juice clings to the inner walls of the rotary screen and the pure juice is brought on the D.S.M. and the juice from the Mill 4 and Mill 5 is brought to the Mill. Then juice from D.S.M. screen is brought in the CLEAR JUICE TANK / RAW JUICE TANK from where it is forwarded to the PROCESS HOUSE as shown in the flow chart diagram below.

(Juice Flow Chart Diagram for MILL HOUSE # 01)

NOTE: Working rpm are less because if we operate at 1200 rpm the there are vibrations due to which there is a chance of collapse of structure.

MILLING/JUICE EXTRACTION PROCESS for TANDOM #

02 From rack bar carrier cane material come in Mill 1, which is a six-roller mill. Three of them are called Pressure Feeders

1 Top Pressure Feeder Roller 2 Bottom Pressure Feeder Roller 3 Force Feeder

And three of them are called Mill Rollers 1 Top Roller 2 Feed Roller


3 Discharge Roller ROLLER

It is a cylindrical structure present in milling machine which processes the cane fibers. It has grooves on it to avoid slippage when cane is passed through it.

Length 78 inches Diameter 38 inches

NOTE: This is also called as the mill size.

SPECIFICATIONS OF MILL # 02, 03, 04

In TANDEM 2 these 3 mills have also 6 roller mills.

PROCESS

The cane material first pass through the pressure feeder top and bottom where lot of juice is extracted from that cane material which is then forward to the mill rollers where it come first b/w top roller and feeder roller where again by pressing b/w these rollers juice is.

Then cane material is pass through the discharge roller then material is subjected

to next mill (2), this process is repeated to mill 4. But in mill 4 water is also added in the dumpy cane material so that the cane juice which is remaining in the dumpy Bagasse material could be extracted.

The specifications of the water used in the mill 3 and 4 are as follows

Temperature of Water 60-70oC Ratio of use 100 tons / 22 tons Then by this complete procedure near about all the juice is extracted and the

remaining material, called as Bagasse, is then dropped on the main bagasse carrier.

BAGASSE CARRIER The specifications of the main bagasse carrier are as follows

Length of the chain 80 ft Width 1850 mm Linear speed 97 ft/min

This material is shifted to outside as a by-product. It is also used for burning purposes in boilers.

EXTRACTED JUICE FLOW

The extracted juice from Mill 1 and Mill 2 is directly shifted to Rotary-Kiln which rotates at a very high speed such that any bagasse material present in juice clings to


the inner walls of the rotary screen and the pure juice is brought on the D.S.M. and the juice from the Mill 3 and Mill 4 is brought to the Mill 1 indirectly.

Then juice from D.S.M. screen is brought in the CLEAR JUICE TANK / RAW JUICE TANK from where it is forwarded to the PROCESS HOUSE as shown in the flow chart diagram below.

(Juice Flow Chart Diagram for MILL HOUSE 2)


PROCESS DIAGRAM OF MILLING HOUSE


ASPECTS TO BE IN MIND OF THE SUPERVISORS AND MANAGER OF

MILLING HOUSE

There are several important aspects to extraction which involve the energy balance of the factory, the efficiency of extraction and therefore ultimately the profitability of operations:

The manager needs to process the cane as soon as possible if sugar losses are to be avoided yet needs to have a sufficient supply in storage for times when cutting and transport are stopped, whether deliberately or not. Typically, cane is processed within 24 hours of cutting;

Cane preparation is critical to good sugar extraction, particularly with diffusion extraction. This is achieved with rotating knives and sometimes hammer mills called "shredders". However shredding requires extra energy and more equipment;

The extraction is actually conducted as a counter-current process using fresh hot water at one end being pumped in the opposite direction to the cane. The more water that is used, the more sugar is extracted but the more dilute the mixed juice is and hence the more energy that is required to evaporate the juice;

The more accurately that the mills are set [adjusted], the drier is the residual fiber and hence the less sugar remaining in the fibre;

A typical mixed juice from extraction will contain perhaps 15% sugar and the residual fiber, called bagasse, will contain 1 to 2% sugar, about 50% moisture and some of the sand and grit from the field as "ash". A typical cane might contain 12 to 14% fiber which, at 50% moisture content gives about 25 to 30 tons of bagasse per 100 tons of cane or 10 tons of sugar.

MILL HOUSE OUTPUT

Screened cane juice and bagasse is the output of the Mill House. Bagasse is then further used in Boiler House as a fuel for the production of

steam This steam is then further subjected to the Power House for the production

of electricity.


BOILER HOUSE What Is a Boiler?

It is a device for heating water or generating steam above atmospheric pressure. All boilers consist of a separate compartment where the fuel is burned and a compartment where water can be evaporated into steam.

TYPES OF BOILERS

1 Water Tube Boiler

In water tube Boiler a number of water tubes are arranged in and around the furnace. Water circulates in the tubes and outside is the fire. This type generally gives high steam production rates, but less storage capacity. water tube boilers are also capable of high efficiencies and can generate saturated or superheated steam. The ability of water tube boilers to generate superheated steam makes these boilers particularly attractive in applications that require dry, high-pressure, high-energy steam, including steam turbine power generation.

2 Fire Tube Boiler

In fire Tube Boiler There is a fire in the tubes and water is present outside the tubes in the big vessel or cylindrical drum. Fire-tube boilers usually have a comparatively low rate of steam production, but high steam storage capacity.

Shakrganj has got five (5) boilers installed. Their description is as follows:


Boiler # 01

Make Stork Babcock and Wilcox Fuel Bagass / Sui gas / Biogas Capacity 40 Tons / hr Heating Surface 1348 m2 Working Pressure 23-24 kg/ g.cm2 Steam Temperature 325-350 oC Bagass Pole 1.5 Moisture in Bagass 50%

Boiler # 02

Make FCB France Fuel Bagass / Sui gas / Biogas Capacity 80 Tons / hr Heating Surface 2071 m2 Working Pressure 23-24 kg / cm2 Temperature 350 oC

Boiler # 03, 04, 05

Make Yushmine Japan / Itefaq Brothers Fuel Bagass / Sui gas / Biogas Capacity 80 Tons / hr Heating Surface 2220 m2 Working Pressure 23-24 kg/ cm2 Steam Temperature 350 oC


BAGASSE CARRIERS The bagasse is carried to the furnace of the boilers through a rubber

belt conveyor.

Main Bagasse Carrier # 01 Length 94 m Width 02 m Linear Speed 26 Feet/ min Bagasse elevator is produced from Tandom # 01 to Boiler # 01.

Main Bagasse Carrier # 02 Length 50 m Width 02 m Linear Speed 30 Feet / min Bagasse elevator is produced from Tandom # 02 to Boiler #02 Return Bagasse Carrier is attached to Boiler # 04. Surplus Bagasse Carrier is attached to Boiler # 05.

BOILER WATER TREATMENT ORIGIN OF THE PROBLEM 1-Scaling

Total hardness in the water if not properly removed will cause in scale formation. A layer of scale on the metal surface of the boiler will acts as an insulator and reduces the rate of heat transfer from hot zone to water. A layer of scale as thick as the surface of the boiler will reduce boiler efficiency by some 20%.

Scaling results in More fuel will be used to maintain boiler output at acceptable level. Since heat transfer is retarded the metal become hotter to a point where

it deforms and even rapture with disastrous results.

2-Corrosion The most common source of corrosion in boiler systems is dissolved gas:

oxygen, carbon dioxide and ammonia. Of these, oxygen is the most aggressive. The importance of eliminating oxygen as a source of pitting and iron deposition cannot be over-emphasized. Even small concentrations of this gas can cause serious corrosion problems.


WATER TREATMENT PLANT

This is the plant where water is purified from unwanted particles which make the consumption of oil less in furnace for burning water. It consist of two sections

a. Reverse Osmosis Plant (R.O. Plant) b. Demineralization Plant (D.M. Plant)

Water Demineralization Plant

A Demineralization Plant consists of two pressure vessels containing cation and anion exchange resins. Various types of ion exchange resins can be used for both the cation and the anion process, depending on the type of impurities in the water and what the final water is used for. Typically, the cation resin operates in the hydrogen cycle. The cat ions in the water (i.e. calcium, magnesium and sodium) pass through the cation exchange resin where they are chemically exchanged for hydrogen ions.

The water then passes through the anion exchange resin where the anions (i.e. chloride, sulphate, nitrate and bicarbonate) are chemically exchanged for hydroxide ions. The final water from this process consists essentially of hydrogen ions and hydroxide ions, which is the chemical composition of pure water.

Simple demineralisation plant consist of Composite resin vessels with charge of strong cation and anion resin; control-panel encompassing a conductivity measurement and alarms, etc; acid and caustic injection facility from bulk, semi-bulk or carboy containers.

This plant also has the same purpose as R.O. Plant but its total capacity is 45 tons per hour.

There are 3 small tanks series and 3 larger tanks series through which raw water passes for treatment. Each first tank (small and large) contains Hydrochloric Acid (HCl). Each 2nd tank (small and large) contains NaOH. After that water passes through 3rd tank of each series from where it is sent out to condensate storage plant. Each 3rd tank contains both HCl and NaOH.

Water treating capacity of small tank series is 15 tons per hour and that of large tank series is 30 tons per hour which makes a total of 45 tons per hour.

Water from Water Treatment Plant is sent to Condensate Storage Plant. RO Reverse Osmosis Plant

Reverse osmosis plants have at their heart a membrane that if damaged reduces output, increases costs and gives poor water quality so it is important to keep it clean and operating efficiently.

Most reverse osmosis membranes are formed from hollow fiber or thin film composite sheets with the membrane allowing passage of pure water and rejecting the dissolved solids contained in the water. As water passes along the


membrane surface the solids concentration increases and some sparingly soluble salts start to exceed their solubility and precipitate. When precipitated onto the membrane surface this causes fouling that may reduce output and increase product water conductivity. The worst of these solids being calcium carbonate and calcium sulphate and so the prevention of their precipitation is vital if the membrane is to function efficiently.

Raw water comes in R.O. Plant which is first treated with Caustic Soda (NaOH) and Sulphuric Acid (H2SO4) and then passed through a filter having 12 filters of 5 micron type. After that it is passed through five membrane systems (First it enters in three of them and then after that in the rest two of them), having each 6 membranes. Water is also flushed with Sodium BiSulphate during this process with a 60 % recovery of water.

Then the water is sent to condensate storage plant. The capacity of R.O. Plant is 30 tons per hour.

RO Membrane Antiscalant

Effective membrane Antiscalant should be:

(1)-Safe to use and safe to handle (2) Good scale inhibitors.

(3) Membrane compatible (4) Effective across a wide range of ph.

(5) Compatible with other products. (6) Cast effective.

Water from Water Treatment Plant is sent to Condensate Storage Plant.

CONDENSATE STORAGE PLANT These are large storage tanks, three (3) in number which collect purified

water from Water treatment plants and store it. This stored water is passed to Boiler through water pump system when required.

One is large size have a capacity of 565 m3 and two are small size have a

capacity of 230 m3. WATER PUMP/FEED STATION

Water from condensate storage plant is brought to Water Pump Station from where it is pumped to Boiler.

First of all the water is sent to Deaeration Tank with the help of five (5) Make-Up pumps. In Deaeration tank there are two chambers i.e. Vertical and Horizontal. In Vertical chamber water from Make-Up pumps is showered through which steam passes which make its way out after combining with the air and


gases present in the water. Water is then collected in the horizontal tank and sent to Boiler with the help of nine feed pumps (among which 5 are electric feed pumps and 4 are Turbe feed pumps). Temperature of water in Deration Tank is 110oC and pressure of 40 kg/cm2.

With the help of feed pumps water is sent to steam drum of boiler which is the upper drum. Water from upper drum comes in the tubes which goes to mud drum (Below the furnace) passing the furnace. Water is then heated in these tubes in the furnace. In feed water station there are eight 08-turbo pumps. Of them four (4) are small in size.

Power 225 hp Speed 2980 rpm Capacity 96 Tons Pressure 35-kg/ cm2 Temperature 110 oC

Two (2) pumps are of medium size.

Power 215 hp Speed 2900 rpm Capacity 100 Tons Pressure 30 -kg/cm2 Temperature 110 oC

Two (2) pumps are of large size.

Power 300 hp Speed 2900 rpm Capacity 188 Tons

MAKE UP WATER STATION

Total pumps in this station are four (4) in number. Two (2) are 40hp and two (2) are 30 hp power capacity.

Pump Speed 1470 rpm Capacity 60 m3 / hr

DEARATION STATION

This station has also three (3) storage tanks. Two have a capacity of 22 Tons and one has a capacity of 33 Tons storage availability. Then there is reserve storage tank.


Deaerator

Mechanical and chemical Dearation is an integral part of modern boiler water protection and control. Deaeration, coupled with other aspects of external treatment, provides the best and highest quality feed water for boiler use. Simply speaking the purposes of deaeration are

1. To remove oxygen, carbon dioxide and other non-condensable Gases from feed water.

2. To heat the incoming makeup water and return condensate to an optimum temperature for:

a. Minimizing solubility of the undesirable gases

b. Providing the highest temperature water for injection to the boiler

Reasons To Deaerate

The most common source of corrosion in boiler is dissolved gas: oxygen, carbon dioxide and ammonia. Of these, oxygen is the most aggressive. The importance of eliminating oxygen as a source of pitting and iron deposition cannot be over-emphasized. Even small concentrations of this gas can cause serious corrosion problems.

Operation.

Mechanical deaeration is the first step in eliminating oxygen and other corrosive gases from the feed water. Free carbon dioxide is also removed by deaeration, while combined carbon dioxide is released with the steam in the boiler and subsequently dissolves in the condensate. This can cause additional corrosion problem.

LIVE STEAM HEADER This live steam header is used to store the steam.

Header Dia 1524 mm Length 6705 mm

FURNACE

It is the room where fuel is burnt or combustion process of fuel takes place. There are two burners on the side wall which start the burning process. Four of the side walls of the furnace are covered with


tubes containing water which is heated to steam. There are bagasse openers on front wall which serve as the inlet of bagasse in furnace. Types of fuels being used

1. Bagasse 2. Sui Gas 3. Bio Gas 4. Furnace oil

The temperature of furnace rises to 1100 oC. The ash of bagasse and other

hot gases passes through 3 different zones where it gives heat to the tubes. After furnace baffle contains super heater and Economizer where more heat is absorbed from Boiler Flue gases.

REFRACTORY

These are walls made of refractory bricks. It makes the path of Boiler Flue gases longer before it is exited through I.D. fan. In this way we are able to get more heat from these gases to increase temperature of steam

SUPER HEATER

A bank of tubes, in the exhaust gas duct after the boiler, used to heat the steam above the saturation temperature.

A superheater is a device in a boiler that heats the steam generated by the boiler again, increasing its thermal energy and decreasing the likelihood that it will condense inside the head.

Superheaters increase the efficiency of the boiler, and were widely adopted. Steam which has been superheated is logically known as super heated steam.

ECONOMIZER

A heat exchanger that transfers heat from Boiler Flue Gases to Boiler Feedwater. U type tubes are used for this purpose

Flue gases from large boilers are typically 450 - 650°F.Economizers

recover some of this heat for pre-heating water. The water is most often used for boiler make-up water or some other need that coincides with boiler operation. Economizers should be considered as an efficiency measure when large amounts of make-up water are used.

AIR PRE-HEATER

This air pre-heater is used to heat the air inducted to the boiler by the hot flue gases. Thus raising the temperature of inlet air up to 110 oC.

In this chamber there are 2260 tubes each of 16 ft length and 3 inch diameter. Ash and other particles goes down into the dust collector and Boiler Flue gases rises up. Air from atmosphere is passed through outside of these


tubes which absorbs the heat of gases Hence the steam coming out of Boiler has a temperature of 350 oC and pressure of 23 kg/cm2

FANS

There are three types of fans being used in boiler house which helps in the movement of air and gases in the boiler.

1 Induced Draft Fan (ID Fan) It draws hot waste gases coming from furnace into dust collector

and passes it to atmosphere through stack. Gases have a temperature of 220oC.

The gas has already passed through the air heaters and precipitators before it has reached these fans.

Specifications are: Rated Power 290 kW Rated Voltage 440 V Rated Current 495 A Speed 737 rpm Power Factor 0.8 Rotor Speed 358 rpm Mass 3912 kg Insulation type F

2 Forced Draft Fan (FD) Fan It takes air from atmosphere and passes it through the air pre-

heater tubes, which is then blown into the furnace from its base through dumping gate. This warm air helps in combustion and spreading bagasse.Each unit has forced draught fan. The fan draws warm air from the top of the boiler house through large air heaters becoming the primary and secondary air used for the boiler combustion process. The air heater warms the incoming air by transferring heat energy from the outgoing flue gases.

Specifications are: Speed 980 rpm Rated Voltage 440 V Rated Current 233 A Rotor Current 413 A Mass 2415 kg

3 Secondary Fan It also takes air from atmosphere and blows it into the furnace. It

helps in spreading the Bagasse in furnace and also to suck bagasse from bagasse delivering tubes. This fan is only used when Bagasse is used as fuel otherwise it is kept off.


Secondary Fan is also admitted turbulently to complete the combustion. This fan supplies air to the furnace from the bottom surface to ensure complete combustion.

Specifications are: Speed 1400 rpm Power 80-90 kW Voltage 440 V

ASH DUST COLLECTOR DISPOSAL SYSTEM

It collects the dust and poisonous particles from the exit flu gases. The gases which are left over the complete process of steam generation are full of poisonous particles and dust as well. These gases cannot be allowed to pass in the atmosphere as such so we have to treat them for the removal of these poisonous particles of a boiler called Dust Collector.

Working of Dust Collector

The flu gases from the third pass of the boiler come into a first portion where the blades are arranged in a sequence, the gases strike these blades and at that time heavy particles settle down and the remaining gases flows to the 2nd portion which is called as Cyclone.

Flu gases first strike to the circular portion of the cyclone where the blades are arranged when the flu gasses strikes the blades the heavy particles are settle down and the remaining gases again go upward in the pipe where a circular blade is circulating at a very high speed creating the swirling action due to which heavy particles settle down and remaining almost non dangerous gases flows to the I.D. fan which let them go outside in atmosphere. ROTARY VALVE

The main part of dust collector is the rotary valve. In this valve there are many blades having no gap between the blade and body of valve. These blades rotate at a very high speed due to which vacuum is produced which is enough to capture the dust particles.

ROTARY SCREEN

Ash from the rotary valve comes into the rotary screen which then throws the ash into ash container. It contains many blades which rotates and lead the ash to the container.

The detailed picture of Water-tube steam boiler with two drums is

given below:


A. Smoke uptake B. Economizer

A heat exchanger that transfers heat from Boiler Flue Gases to Boiler Feedwater.

C. Steam outlet Saturated steam from the Steam Drum to the Super heater.

D. Cyclone A device inside the steam drum that is used to prevent water and solids from passing over with the steam.

E. Stay tube For super heater

F. Stays For super heater tubes

G. Superheated steam outlet H. Super heater

A bank of tubes, in the exhaust gas duct after the boiler, used to heat the steam above the saturation temperature.

I. Super heater Headers Distribution and collecting boxes for the super heater tubes.

J. Water drum K. Burner


L. Water wall Header Distribution box for water wall and down comers.

M. Foting N. Water wall

Tubes welded together to form a wall. O. Back side water wall P. Boiler hood Q. Water wall Header

Collecting box for water wall and risers. R. Riser

Tubes in which steam is generated due to high convection or radiant heat. The water-steam emulsion rises in these tubes toward the steam drum.

S. Down comer A tube through which water flows downward. These tubes are normally not heated, and the boiler water goes through them to supply the generating tubes.

T. Steam drum Separates the steam from the water.

U. Economizer Header Distribution box for the economizer tubes.

KEY FACTORS FOR BOILER EFFICIENCY CALCULATIONS

Flue gas temperature (Stack temperature) Fuel specification Excess air Ambient air temperature Radiation and convection losses. Flue Gas Temperature This process of conduction between a solid surface and a moving liquid

or gas is called convection.

High boiler efficiency is the result of specific design criteria, including

Number of boiler passes Burner / boiler compatibility Repeatable air/fuel control Heating surface Pressure vessel design Boiler efficiency calculations that are accurate and representative of

actual boiler fuel usage require the use of proven and verified data, including:

Proven stack temperature Accurate fuel specification Actual operating excess air levels


Proper ambient air temperature Proper radiation & convection losses

BOILER INPUT

Boiler input are Bagass, Sui Gas, Bio Gas, feed Water, Air Supply.

BOILER OUTPUT

Output is Saturated Steam, which is used in the Process House, Power House and Mill House.


PRODUCTION HOUSE

The cane juice from the juice tank of Milling House come to production House where it is further purified and crystalline sugar is obtained from it. First of all cane juice in production house flowing from flow meter comes into the heater, which heats the juice. Heaters are 14 in number. They are classified as

1 Primary Heaters 2 Secondary Heaters Among 14 heaters 6 are Primary Heaters (3 for Tandem # 01 and 3 for Tandem

# 02) and 8 are Secondary Heaters (4 for each Tandem)

PRIMARY HEATERS First of all juice comes into the Primary Heaters where the temperature is

maintained at 65 - 77�C. These are Shell & Tube Vertical heaters having tubes of specif ications given below

Outer Diameter 38 mm Inner Diameter 35.5 mm Length 4500 mm After passing through primary heaters the juice is then sent to

Lime Dozer.

LIME DOZER In this tank, Slaked Lime Ca(OH)2 is added to the heated cane

juice. This slaked is formed by the following reaction and then brought to the l ime dozer. The reaction is

CaO + H2O. Ca (OH) 2 The purpose of Lime Dozer is to maintain a PH of 7.8-8.1 Lme Dozer is used to

1 Remove the impurit ies 2 Remove the trapped air

Now this juice, mixed with Lime, obtained from Lime Dozer is

passed through Reaction Tank and then 4 Retention tanks . They are equipped with agitated stirrers which are used for mixing of l ime.

The juice after that is stored in Defecated Juice Storage Tanks from where it is pumped to Secondary Heaters with the help of centrifugal pumps.

SECONDARY HEATERS These heaters are same in structure as primary heaters and also

serve the same purpose. But the temperature of Juice is raised to 104-107�C. There are total 08 secondary Heaters. 04 for each Tandem.

Heater inlet temperature 60-70 C


Heater outlet temperature 101-106 C

Heating Surface 234 m2

No of Tubes 468

After Secondary Heaters, juice is sent for Clarif ication. Before entering Clarif ier Tank , juice is passed through Flash Tank.

FLASH TANK

I t helps in removing vapors and to avoid bubbling of heated juice in clarif ier. When juice is passed into the Clarif ier from the Flash Tank, an Electrolyte is mixed with the juice. As a result of which the particles of heavy weight sett les down in Clarif ier and clear juice comes separates.

COAGULANT SOLUTION

The coagulant used is a high molecular weight, branched-long chain polyelectrolyte. Water is mixed with it to make a saturated solution.

JUICE CLARIFIERS There are 04 clarifiers. Electrolyte is added .Impurities are sticken with electrolyte and settle down in form of mud.Mud and other material is separated from the mixed juice, from here juice passes to Clear juice screens. On top of screens heavy particles are settled,juice is collected down in clear juice tank.

In Clarifying Tanks, the coagulant solution with the heavy and mud particles settles down in the base of the Clarifier whereas the Clear juice comes at the top of it. This clear juice is then separated from the Mud and sent to storage tanks From Clarif ier there are two outlets, one for clear juice that takes it to the clear juice storage tank and the other for the mud mixed juice which is sent to Vacuum Filter through B.D. Mixer Tank (Bagasse Dust).

Flow Meter is attached to pipe lines comming from Mill house to measure the flow of cane juice. Pipe line from Tandom #01 has a dia of 08 inches and pipe line from Tandom#02 has a dia of 10 inches. This is first heated in the primary heaters to raise its temperature. There are six primary heaters 03 for each Tandom line.

1 Juice inlet Temperature 30-35 C

2 Juice outlet Temperature 70-75 C

3 Heater Tube material Stainless steel

4 Heater Tube dia 35.5 mm

5 Length of the Heater 4500 mm

6 Heater Tube thickness 2.5 mm

7 No of P.H. Tubes 696


8 Heating Surface 349 m2

9 Heater Type Shell and Tube Heater

B.D. MIXER TANK

Small particles of Bagasse from Mil l house are brought into this tank which is mixed up to form a paste.

VACUUM FILTER The paste from B.D. Mixer tank is pumped to Vacuum Filter Tank where Mud is completely separated and removed. Vacuum Filter is a rotating drum containing tubes having vacuum of 35-40 cm of Hg. This drum rotates at a very slow speed i.e. 0.5 rpm. When it is rotated, mud become attached with the walls and at the same t ime mud is treated with hot water from the top. The sweetness which is called POL is 75%. The waste makes a layer outside the drum called as MUD CAKE. I t contains only 2.5% sweetness. The waste is collected on carrier which takes it to the Compost Plant. Fermented is added to the waste for its treatment. This waste is then used for fert i l izing purpose. The juice obtained from clear juice screens comes in Clear Juice Storage Tanks.The temperature of juice reduces to 90-96�C which is then reheated to 100-110�C with the help of pre-heaters. Then the juice is sent to evaporators.

PREHEATER Clear juice is pre heated before feed to the Evaporator.

Juice inlet Temperature 90-96 C

Outlet temperature 100-110 C

No of Tubes 564

Heating Surface 282 m2

EVAPORATORS This is the system where the water is evaporated and the juice is concentrated at the same time. First of al l the juice comes into an Evaporator which is called as Vapor Cell . Exhaust steam from mil l house is used to start the working of Vapor Cell. Vapours are condensed after passing the last evaporator. There are sets of 4 evaporators after the Vapor Cell through which the juice passes. This method of boil ing is called Quadruple Effect or Quintuple Effect. All of the evaporating cells contains a large number of tubes arranged longitudinally having a vacuum of 60-65 cm of Hg. Diameter of each tube is 35 mm. The juice enters from the bottom of the evaporator and


comes with the help of these tubes. After heating it bubbles and comes back down through downtake. And then it enters into the next evaporator. In this way it passes through four of the evaporators by the same procedure.

Vacuum is created in the last Evaporator of 60-65 mm / hg.

Temperature of vapours 110 C

Temperature at Evaporator-1 110 C

Temperature at Evaporator -2 90 C

Temperature at Evaporator-3 75-80 C

Temperature at Evaporator-4 60-65 C

From Quad juice is sent into Syrup bottle and then to Syrup storage tank where syrup is stored.From syrup storage tank it is send to Raw Pan-A.

Raw Pan-A : Syrup and B-seed is added in it.A- Massecuite is formed in pan-A. Purity A-Massecuite: 80-82% Brix Degrees: 96-97 Then A-Massecuite is send to A-crystall izer , i ts purpose is for growth ,enchancement and time is given for cooling. From here it then goes to A-Pug mil l.And by here it is send to A-Centrifugal machine, it consists of screens and separate out three things. 1.A-Wash 2.A-Heavy 3.A-Melt` A-Heavy purity: 58-60% A-Heavy brix: 80-85 A-Wash purity: 70-75% A-Wash brix: 80-85 A-Melt brix: 60-65 A-Melt is send into decolorizing plant. A-Wash and A-Heavy are send in Raw Pan -B .

Raw Pan-B: A-Wash, A-Heavy along with C-Seed (double cure) is send into Pan-B. In it B-Massecuite is formed.


B-Massecuite purity: 68-72% B-Massecuite brix: 97-98 B-Massecuite is send into B-Crystall izer for same purpose as in A-Crystall izer.From here it is carried into B-Centrifugal machine.It also consist of screens and separates out two things. 1.B-Seed 2.B-Heavy B-Heavy purity: 50-52% B-Seed is sent into Raw Pan-A. B-Heavy is sent into Raw Pan-C.

Raw Pan-C: B-Heavy along with C-Light enters into Raw Pan-C. C-Massecuite is formed in it. C-Massecuite purity: 58-62% C-Massecuite brix: 101-103 Syrup is then sent into Vertical Crystall izer, where water moves in no. of pipes continuously to cool syrup. From there syrup is sent into Cassette Crystall izer.Syrup is sent into Reheaters ,where it is heated.It is heated to saturate syrup.Syrup from there is send into C-Pug Mil l . I t is f lowed into C-Centrifugal machine, which consists of screens and separates out Final Molasses and C-seed (single cure). Final Molasses purity: 32% Final Molasses brix degrees: 92 C-Seed enters in Pug Mil l and is carried to C-Centrifugal(double cure). It separates out two things. 1.C-Seed(double cure) 2.C-Light C-Seed(double cure) is send into Raw Pan-B and C-Light is send into Raw Pan-C.


A - Raw Pan

A – Crystallizer

B -Raw Pan

A - Massecuite

B - Massecuite

C - Raw Pan

Vertical Crystallizer

B - Crystallizer

Cassette Crystallizer

B – Pug Mill Reheaters A –Pug Mill

C-Pug Mill

C –Centrifugal Machine (single cure)

B HeavyB Seed

PROCESS FLOW DIAGRAM OF RAW CRYSTALLIZATION PANS

A Melt

A Wash A-Heavy

Centrifugal (Doudle cure) Pug Mill

A-Centrifugal Machine

B –Centrifugal Machine

C-Seed Final Molasses

Double cure (C-Seed)

C-Light


MELT CLARIFICATION

Buffer Tank: A-Melt separated from A-Centrifugal machine comes into it.It is used as astorage tank having capacity of 65m3. Supply Tank: It is also used as a storage tank having capacity of 75m3. This storage is done at different sections and is helpful to start process of sugar when continuity process is stopped at some. From Supply Tank, Liquor is sent to Liquor Heater where its temperature is increased to 80-90oC.Melt is heated so that it may be reacted efficiently and to get optimum condition. After this, Liquor is ready to be refined further.

As stated earlier, A-Melt is transformed to liquor. This liquor is purified by clarification for production of refined sugar as this liquor still contains impurities mainly coloring and colloidal matters. it is send to reation tank 1

Reation Tank 1: Before entering liquor in tank we add talofloc in it. It is compound used to decolorize the melt .Tank contains stirrers in it , mixing takes place.

Reaction Tank 2: Before entering liquor in tank we add in it phosphoric acid and lime sucrate are used . Tanks contain stirrers in them and by stirring reaction is completed. Liquor is now send to Areation Bottle ,in it air is injected to melt by force . Flotation Tank Before entering in it we add Talofloat in it. Talofloat is l ight molecular weight , i t st icks impurit ies with itself and f loats at the top.This f loated material is removed from top and is called Scum.Scum is send to Surplus tank.The clear l iquor is removed from bottom of f lotation clarif ier.The l iquor is passed through a circular coil. From there it goes into clear l iquor tank.There are two clear l iquor tanks and are used for storage. Sulphitation Tower The clear juice or Liquor is brought for Sulphitation in which SO2 is bubbled from the bottom. SO2 is removed from top of tower. Sulphur dioxide is passed through clear l iquor to give brigtness to l iquor. Clear l iquor is pumped into Sulphited melt tank and then to Smear tank at pan floor.


Clarification and filtration of liquor further removes the colloidal matters and decolorize the liquor. Filtration is effected with pressure-filters and Deep bed Filters.

PRESSURE FILTER It is a large tank that contains 18-20 longitudinal plates. These plates are covered with a heavy canvass clothes. Then liquor is passed through it under high pressure of about 2.5-3 kg/cm2. It enters from one side and exit from other side. Small particles which act as impurity are removed in it. DEEP-BED FILTER This is an advance and modern technique for the purification of the mother liquor. There are 4 large containers for this purpose and each contain three different layers of different materials.

1 Carbon 2 Sand 3 Small stones All these three materials are so stable that even concentrated acids and base have

no effect on them. It is used to remove the dust particles as well as other small particles in the liquor. There are layers of different sized small stones of 3mm, 6mm, 12mm and 18mm.

1 Carbon 2 Sand 3 Small Stones The Polish Liquor passes through these layers due to which even very small

suspended impurities are also removed. After this process liquor is called as refined liquor and it goes forward for the refine crystallization pan. Polish Melt Tank: The filtered clear liquor is send for final polishing and melting in Polish melt tank and it is send to Pan Station.

REFINE CRYSTALLIZATION

This process of crystallization is same as Raw Crystallization process. The decolorized liquors stream directed to crystallization and finishing processes is white to pale yellow in colour with solid contents of 60 to 65 degree brix.

The decolorized liquor is sent to vacuum pans for production of refined sugar. In refined sugar production usually the boiling system used is three to four strike system. When the liquor in the pans reaches the desired level of super saturation seed is added to initiate the formation of sugar crystals.


Crystallization is further preceded to form Massecuite with high crystal contents. At this point the strike is discharged in crystallizers from where it is sent for centrifuging.

The white sugar is retained in inner basket and mother liquor passes through the basket perforation and again sent to vacuum pans for future exhaustion of sugar retained in it.

The white sugar retained in centrifugal is washed with hot water and steam. There are two such machine used for the purpose of centrifugation.

1 Old called as Broad Bent 2 New called as Silver Webelle The separated sugar and other impurit ies are called as RUNOFF. This

is sent back to masscut (A). sugar is added according to the colour changing by refinery.

1s t is called as R1.

2nd is called as R2.

3rd is called as R3.

During this process of grading purity is not affected. It remains same while its colour changes only. These crystals are termed as “Refined Sugar Crystals”

DRYING, GRADING AND PACKING

The separated white sugar crystals discharged from the centrifuges still contain up to 1% moisture. This is removed by passing the sugar into a dryer, through which filtered, heated air given by radiators is passed.

The moisture level of the sugar is reduced to about 0.02%. Fluidized bed dryers are used for sugar drying. Hot air is used for drying the refined sugar in a cross current flow in fluidized bed dryers. Sugar after drying is cooled . And then is sent to Elevator and Grader . After grading the finished refined sugar is sent to bins prior to packaging. This sugar is then packed according to the grades i.e. R1 is known as the extra white sugar. It is packed in double polythene plastic bags. While R2 and R3 simple bags having weight of 50kg.

All this process is done in Bag House. After the packing in sugar bags, sugar is stored in Go-downs.


PROCESS FLOW DIAGRAM OF REFINE CRYSTALLIZATION PANS

R1 - Pan

R1 – Crystallization

R2 - Pan

R1 – Massecute

R2 - Massecute

R3 - pan

R3 -Massecute

R2 - crystallization

R3 - Crystallization

Broad-Bants Broad-Bants

R2 –sugar R3 –sugar

Runoff-1

Runoff-2

Runoff-3

Driers

Grader

Hot Air Radiator

Syrup Tank

Storage Godown

R1

sugar

Silver Webull

Packing


REMARKS

I would say it an awesome experience visiting the Shakarganj Sugar Industry, the largest industry of Asia in the arena of Sugar Manufacturing, as I found a platform for my theoretical knowledge to be enhanced and groomed up in a very good fashion with a touch of professional attitude as well.

I have seen the implementation of the theoretical knowledge I had gained in the

first five (5) semesters of my Engineering Degree Tenure. I must appreciate the regularity, punctuality, devotion and the sense of

professionalism I found in the staff of Shakarganj Sugar Mills Ltd. no matter he was a GM or any other ordinary worker. I found each and everyone sincere to one’s duties.

I am supposed to admire the environment formulated by the staff here in Shakarganj Suagr Mills Ltd. It is excellent and I found myself, in the beginning of my internship period, in a place of which I was familiar a lot.

All the staff of Shakarganj Sugar Mills Ltd. is very cooperative and they made possible for me to learn the mechanism and use of the industrial machinery and equipment.

It would be injustice not to thank the Service Staff of Technical Office for providing refreshment to me and the fellow internees of me as well as they placed us in a recess to get our observation shared with each other every day.

At Shakarganj Sugar Mills Ltd. quality products are manufactured for to be up to the mark of customer requirement and satisfaction.

I have tried my best to put my Experiences and Observations in black and white; I have obtained in Shakarganj Suagr Mills Ltd., in this report.

I look forward to keep on enhancing my knowledge and sequel of this internship in my Educational Carrier and Practical Life as well.


Documents

Shakarganj Mills Ltd - Allah Dita Hassan_2