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INTERNSHIPREPORT
PRODUCTION PROCESS
JDWSugarMillsLimitedUnit-I
15

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Contents
S.NO. TOPICS PAGE NO.
1 Acknowledgement 3
2 Executive summary 4
3 Introduction&history 5-6
4 Sugar cane 7
5 Growingthe cane 8
6 Harvesting&Extraction 9-10
7 Multiple Efface Evaporator 11
8 Description 12-13
9 Different Types of Feed Arrangement of Multiple Effact Evaporator 13-16
10 FallingFilm Evaporator 17
11
OperationPrinciple
18
12 Typical Examplesof Liquidssuitable for Falling Film Evaporator 19
13 Boiling 20
14 Storage 21
15 Recovery 22-24
16 Personal comments 25

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ACKNOWLEDGEMENT
All praises belong to almighty ALLAH who is the supreme Authority Knowing the
ultimate relations underlying all sorts of phenomenon going on in this universe
and whose blessings and exaltation flourished my thoughts and thrived my
ambitions to have the cherished fruit of my humblest thanks to the Holy Prophet
Hazrat Muhammad (Peace be upon him) who is forever a torch of guidance and
knowledge and knowledge for humanity as a whole.
I deem it my utmost pleasure to avail this opportunity to express gratitude and
deep sense of obligation to my reverend teachers, for their valuable and
dexterous guidance, scholarly criticism, untiring help, compassionate attitude,
kind behavior, moral support and enlightened supervision during the whole study
and completion of the project.
I am also gratitude to staff of JDW Sugar Mills Limited Unit-I. Especially
SHAHID JAMEEL (GM-Process)
ABDUL SALAM (Chief Chemist)
Who provides me useful information during the internship program. I am thankful
to all those people, who provide me valuable information.
Finally, I should like to extend heartfelt thanks to my adoring PARENTS, for their
day and night prayers, sacrifices, encouragement, moral and financial support
throughout the course of my study.
Muhammad Talha Majeed
B.E. (Chemical Engineering)INPROGRESS

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EXECUTIVE SUMMARY
This report is based on the activities performed during the internship at JDW
Sugar Mills Limited Unit-I. Internship duration was 15 days and it provided
practical knowledge of working in professional environment. This learning
experience is described in detail in the various sections of this report.
In the first section, there is some detail about the company. The history and
present status of the company is explained. The organization structure and the
details of its management along with its location are also discussed. I have also
discussed the operations, process and machine use in cement manufacturing.
The second section provides information about the activities that I performed
during the internship. I worked as an internee mainly in production department.
The third and last section includes the conclusion.

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GENERAL VIEW /History of JDW
JDW Group is the progressive industrial house of the country. Sugar
manufacturing is the core business of the Group and is also renowned for support
of innovative farming techniques which augment the core business. The Group
takes immense pride in social responsibility activities (social mobilization, women
enterprise development, supportto technical and primary education, micro credit
for the poor, infrastructure development, livestock development etc.) all aimed at
ameliorating social and economic conditions of the poor people in rural areas.
The Company has been successful in,
The Sugar Division comprises of three sugar mills Units, JDW Unit-I (20,500 TCD),
JDW Unit-II (8,500TCD) and JDW Unit-III (13,000 TCD) in the districts of Rahim Yar
Khan, Punjab and Ghotki, Sindh. With its combined crushing capacity of 42,000
TCD, it is one of the largest group in the sugar sector and contributes
approximately 15-17% of country’s sugar production.

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INTRODUCTION SUGAR
Sugar Knowledge International Limited, known throughout the world's
sugar industry as SKIL, was established in 1980 to provide consultancy
services to the cane sugar sector. It was intended that advice would be
available for both agricultural and factory operations. From these modest
beginnings it has grown into a company providing a broad range of
professional services for all aspects of the beet and cane sugar industries.
Sugar is made by some plants to store energy that they don't need straight
away, rather like animals make fat. People like sugar for its sweetness and its
energy so some of these plants are grown commercially to extract the sugar
Sugar is produced in 121 Countries and global production now exceeds 120
Million tons a year. Approximately 70% is produced from sugar cane, a very
tall grass with big stems which is largely grown in the tropical countries. The
remaining 30% is produced from sugar beet, a root crop resembling a large
parsnip grown mostly in the temperate zones of the north.
12 CO2 + 11 H2 O = C12 H22 O11 + 12 O2
carbon dioxide + water = sucrose + oxygen

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SUGAR CANE
Sugar cane is a genus of tropical grasses which requires strong sunlightand
abundantwater for satisfactory growth. TheLatin names of the species
include Saccharum officinarum,S. spontaneum,S. barberiand S. sinense. As with
most commercial crops, thereare many cultivars available to the cane farmer,
usually hybrids of severalspecies. Somevarieties grow up to 5 metres tall.
The cane itself looks rather like bamboo cane and it is here that the sucrose is
stored. In the right climate the cane will grow in 12 months and, when cut, will re-
grow in another 12 months provided the roots are undisturbed.A typical sugar
content for mature cane would be 10% by weight but the figure depends on the
variety and varies from season to season and location to location. Equally, the
yield of cane from the field varies considerably but a rough and ready overall
value to use in estimating sugar production is 100 tons of cane per hectare or 10
tons of sugar per hectare.

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GROWING THE CANE
Sugar cane is a sub-tropical and tropical crop that prefers lots of sun and lots of
water - provided that its roots are not waterlogged. It typically takes about 12
months to reach maturity although the time varies widely around the world from
as short as six months in Louisiana to 24 months in some places. Where it differs
from many crops is that it re-grows from the roots so the plant lasts many cycles
[or 'ratoons', a word derived from the Spanish to sprout] before it is worn out.
HARVESTING
ugar cane is harvested by chopping down the stems but leaving the roots so
that it re-grows in time for the next crop. Harvest times tend to be during the
dry season and the length of the harvest ranges from as little as 2 ½ months
up to 11 months. The cane is taken to the factory: often by truck.

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EXTRACTION
The first stage of processing is the extraction of the cane juice. In many factories
the cane is crushed in a series of large roller mills: similar to a mangle [wringer]
which was used to squeeze the water out of clean washing a century ago. The
sweet juice comes gushing out and the cane fibre is carried away for use in the
boilers. In other factories a diffuser is used as is described for beet sugar
manufacture. Either way the juice is pretty dirty: the soil from the fields, some
small fibres and the green extracts from the plant are all mixed in with the sugar.

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MULTIPLE EFFACT EVAPORATOR
The multiple effect evaporator was invented by an African-American inventor and
engineer Norbert Rillieux.
Although he may have designed the apparatusduring the 1820s and constructeda
prototype in 1834, he did not build the first industrially practical evaporator until
1845. Originally designed for concentrating sugar in sugar cane juice, It has Since
became widely used in all industrial application.

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DESCRIPTION
In Multiple effect evaporator, liquid (Juice, water etc.) is boiled in a sequence of
vessels, each held at lower pressure than the last, because the boiling
temperature of water decreases as pressure decreases, The vapor boiled off in
one vessel can be used to heat the next, and only the first vessel (at the highest
pressure) requires an external source of heat while in theory, evaporators may be
built with an arbitrarily large number of stages, evaporators with more the four
stages are rarely practical except in systems where the liquor is the desired
product. Multiple effect evaporator commonly uses sensible heat in the
condensate to preheat liquor to be flashed. In practice, the design liquid flow
paths can be somewhat complicated in order to extract the most recoverable
heat and to obtain the highest evaporation rates from the equipment. Multiple
effect evaporator plants in sugar beet factories have up to eight effects. Six effect
evaporator recovery of black liquor.

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DIFFERENT TYPES OF FEED ARRANGEMENT OF
MULTIPLE EFFECT EVAPORATORS
1. FORWARD FEED
ARRANGEMENT
In this arrangement the feed and steam is introduced in the first effect and
the pressure in the first effect is highest and pressure in last effect is
minimum, so transfer of feed from one effect to another came be done
without pump.

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1. BACKWARD FEED ARRANGEMENT
In this arrangement feed is introduced in last effect and steam is introduced in
first effect and steam is introduced in first effect. For transfer of feed, it required
pump since the flow is from low pressure to high pressure. Concentrated liquid is
obtained in first effect.

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2. MIXED FEED ARRANGEMENT
In this arrangement feed is introduced in intermediate effect, flows in forward
feed to the end of the series and is then pumped back to the first effect for final
concentration. This permits the find evaporation to be done at the highest
temperature.

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TECHINICAL FEATURE AND ADVANTAGES OF MULTIPLE
EFFECT EVAPORATER
 Great reliability.
 Concentrations up to 65-70 Bx.
 No thermic damage thanx to the low temperature of concentration (max
60/65) and to the extremely raped process.
 Long production autonomies.
 Include heat exchangers for product heating and cooling.
 Evaporation capacities from 1000 – 15000litter/hours.
 Completely automated control with supervision.
 Compact and robout design.
FALLING FILM EVAPORATOR
A falling film evaporator is an industrial device to concentrate Solutions, especially
with heat sensitive components. The evaporator is a special type of heat
exchanger.

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OPERATION PRINCIPLE
In a falling film evaporator, the solution to be evaporated flows rapidly as a thin
film down inside the vertical tube wall the vaporization takes place inside the
tubes due to external heating of tubes.Evaporated vapours flows downwards
parallel to liquid flow. Evaporated vapour and concentrated liquor are separated
in bottom in chamber of calandria and in vapour head, where the vapors and
liquor separated by gravity and / by centrifugal force.

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WHY WE USED FALLING FILM EVAPORATOR
In order to increase their power yield falling film evaporator allow advanced
steam saving concept to be implemented for sugar production. This publication
shares the experiences and results of a full evaporator set with falling film
evaporator in a cane sugar factory with particular view to scaling and Non
Condensable gases. Which both have a distinct heat transfer reducing effect in
falling film evaporator.
ADVANTAGES
 Low retention time.
 Excellent droplet separation.
 Good heat transfer capability with small change in
time(time difference)
 capacity range from 0-100%.
 Liquid viscosities up to 500CP
 Lower circulation energy then in forced circulation.
 Accepts some solids amounts.
APPLICATION 1
 Heat sensitive liquors.
 Pure or moderate fouling liquors.
 Rather high viscous solutions.

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TYPICAL EXAMPLES OF LIQUIDS SUITABLE FOR FALLING
FILM EVAPORATOR
 Weak sulphuric acid solitons.
 Pure phosphoric acids.
 Waste water and acid.
 Weak fertilizer liquors.
 Sugar and sugar by products.
APPLICATION 2.
 Thin and even tuice film.
 Nonexistent of hydrostatic head.
 No tube deformation.
 Substantiallyreduced entertainment.
 Low sugar inversion/losses and better juice qualitywith
low color.
 Multieffect arrangement ensuring steam economy.

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BOILING
The final raw sugar forms a sticky brown mountain in the store and looks
rather like the soft brown sugar found in domestic kitchens. It could be used
like that but usually it gets dirty in storage and has a distinctive taste which
most people don't want. That is why it is refined when it gets to the country
where it will be used. Additionally, because one cannot get all the sugar out
of the juice, there is a sweet by-product made: molasses. This is usually
turned into a cattle food or is sent to a distillery where alcohol is made.

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STORAGE
The final raw sugar forms a sticky brown mountain in the store and looks rather
like the softbrown sugar found in domestic kitchens. It could be used like that but
usually it gets dirty in storage and has a distinctive taste which most people don't
want. That is why it is refined when it gets to the country where it will be used.
Additionally, because one cannot get all the sugar out of the juice, there is a
sweet by-product made: molasses. This is usually turned into a cattle food or is
sent to a distillery where alcohol is made.

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SUGAR IS REFINED
Raw sugar is made in tropical countries where sugar cane can be grown
profitably. It is then shipped in bulk to a refinery in the country where the sugar is
required. It now has to be finally cleaned up, purified and made ready for the
consumer.It helps to think of refining as a series of steps from left to right where
colour and non-sugars are concentrating to the left and pure sugar is
concentrating to the right. However the raw sugar comes into the process to the
left of centre, not at one end. In the description that follows the flow of sugar is
followed first and then the remainder of the process is reviewed.
AFFINATION
The first stage of processing the raw sugar is to soften and then remove the layer
of mother liquor surrounding the crystals with a process called "affination". The
raw sugar is mixed with a warm, concentrated syrup of slightly higher purity than
the syrup layer so that it will not dissolve the crystals. The resulting magma is
centrifuged to separate the crystals from the syrup thus removing the greater
part of the impurities from the input sugar and leaving the crystals ready for
dissolving before further treatment. The liquor which results from dissolving the
washed crystals still contains some colour, fine particles, gums and resins and
other non-sugars.

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CARBONATATION
The first stage of processing the liquor is aimed at removing the solids which
make the liquor turbid. Coincidentally some of the colour is removed too. One of
the two common processing techniques is known as carbonatation where small
clumps of chalk are grown in the juice. The clumps, as they form, collect a lot of
the non-sugars so that by filtering out the chalk one also takes out the non-
sugars. Once this is done, the sugar liquor is now ready for decolourisation. The
other technique, phosphatation, is chemically similar but uses phosphate rather
than carbonate formation.

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DECOLOURISATION
There are also two common methods of colour removal in refineries, both relying
on absorption techniques with the liquor being pumped through columns of
medium. One option open to the refiner is to use granular activated carbon [GAC]
which removes most colour but little else. The carbon is regenerated in a hot kiln
where the colour is burnt off from the carbon. The other option is to use an ion
exchange resin which removes less colour than GACbut also removes some of the
inorganics present. The resin is regenerated chemically which gives rise to large
quantities of unpleasant liquid effluents. The clear, lightly coloured liquor is now
ready for crystallisation except that it is a little too dilute for optimum energy
consumption in the refinery. It is therefore evaporated prior to going to the
crystallisation pan.
BOILING PAN
In the pan even more water is boiled off until conditions are right for sugar
crystals to grow. You may have done something like this at school but probably
not with sugar because it is difficult to get the crystals to grow well. In the factory
the workers throw in some sugar dust to initiate crystal formation. Once the
crystals have grown the resulting mixture of crystals and mother liquor is spun in
centrifuges to separate the two, rather like washing is spin dried. The crystals are
then given a final dry with hot air before being packed and/or stored ready for
despatch.

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RECOVERY
The liquor left over from the preparation of white sugar and the washings from
the affination stage both contain sugar which it is economic to recover. They are
therefore sent to the recovery house which operates rather like a raw sugar
factory, aiming to make a sugar with a quality comparable to the washed raws
after the affination stage. As with the other sugar processes, one cannot get all of
the sugar out of the liquor and therefore there is a sweet by-product made:
refiners' molasses. This is usually turned into a cattle food or is sent to a distillery
where alcohol is made

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Personal Comments
1. JDW SUGAR is a very good and largest company of
Pakistan.
2.Employees are well mannered and their behavior is
ideal.
3. The control system of company is excellent.
4. The CHIFE CHEMIST is very good and he guided me
very well.
5. I must have to mention the excellent condition of
cleanliness in this company.
6. I wish I could join this company after the
completion of my engineering.