SlideShare a Scribd company logo
1 of 22
Design of a sugar manufacturing
              plant




       Basics in process Engineering Design
Group Members
    Contents


         Preliminary stage
           •Finding the demands
           •Identifying various processes
           •Selecting a process
           •Find a suitable location
           •Block diagram for the selected process
           •Raw material specifications
           •Environmental considerations
           •Utility services
           •Energy sources
           •Identifying problems/ Limitations

         Mass balances
FindingMembers
  Group the demands

 Sri Lanka sugar demands 1993-2011             Year   Sugar demand, MT
                                               1993        457442
                                               1994        563275
                                               1995        487512
                                               1996        454339
                                               1997        609055
                                               1998        550000
                                               1999        541220
                                               2000        544220
                                               2001        560033
                                               2002        591661
Sources :Department of Census and Statistics   2003        570050
Pelwatte Sugar Industries Ltd                  2004        501151
Sevanagala Sugar Industries Ltd                2005        471376
Sri Lanka Customs                              2006        581019
Central Bank of Sri Lanka                      2007        507544
                                               2008        610378
                                               2009        498168
                                               2010        579336
                                               2011        640876
FindingMembers
Group the demands

Prediction through curve fitting

                                         700


                                         600                            y = 3.721x - 6906.
                                                                            R² = 0.147
                                         500
                 Suggar deamand,1000MT




                                         400


                                         300                                                        Linear (Series1)

                                         200


                                         100


                                          0
                                           1990   1995   2000          2005           2010   2015
                                                                Year

 Current demand 2013 – 584,373 MT                                               Our target – 59,181.5 MT/Yr

 Demand in 2015 – 591,815 MT                                                  200 working days – 12.33 MT/hr
Group Members
Identifying various processes



      Cane Sugar

      Beet Sugar

      Corn Sugar




 • Cane Sugar
                - Crystal, Powder, syrup        Both of Cane sugar industry
 • Beet Sugar and                              Beet sugar industry are
                - Crystal, Powder, syrup        used same process.
 • Corn Sugar
                - Sugar syrup (only used for sweeteners)
Group Members
  Identifying various processes

Cane sugar
                                           Beet sugar
Grown in Tropical climate areas within
                                           Grown in Sub-tropical climate areas
22°N-22°S
                                           Temperature of 15-22 C
at least 800-1000 mm/year
                                           Requires a good irrigation system and
Soil temperature is about 70-80°F
                                           law wind speeds
Temperature max growth at 27 C
                                           The process of manufacturing beet
For the better photosynthesis in leaves
                                           sugar is quite similar to that of sugar
sugarcane need plentiful sunshine.
                                           cane.
Product Members
Group specification

Cane Sugar

    Raw                Refined                Crystal (mill)
    Muscavado          Demerara               Caster
    Icing              Premium Liquid Sugar   Fine Liquid Sugar
    Invert             White Crystal          Refined - Fine Granulated

Mainly produce 3 types of sugar by Cane


   Row Cane sugar ( Brown sugar )


   Mill White sugar ( White Sugar)

   Refined sugar ( White Sugar )
Product Members
Group specification




                      We chose Raw Cane sugar ( Brown sugar )
Find a Members
Group suitable location

Requirements for sugar cane cultivation
Soil type                 medium to heavy well drained
Climate                   RH-70% (for optimum vegetation growth)
Rain fall                 at least 800-1000 mm/year
Temperature               max growth at 27 C
Wind                      High Wind exceeding 60 km/hr




                                                        Sri Lanka temperature profile
Find a Members
Group suitable location



                                                            A - South-east region
                                                            (Hambanthota, Embilipitiya)



B- North-west region (Mannar)




                          Source : https://sites.google.com/a/tcd.ie/sri-lanka/geography
Find a Members
Group suitable location

 Use factor rating method,
     A- South east region
     B- North west region

                                                             Rating
                  Critical Factor                Weight
                                                            A         B
   Rain fall for cultivation                         10      100       100
   Temperature for cultivation                        9      100       100
   Soil fertility                                     7       80        40
   Water supply                                       7       70        60
   Land cost and availability                         9       80        70
   Labour cost and avaliablity                        6       70        70
   Transport                                          5       60        80
                                         Score              4390      4050

                        More suitable location is South east region of Sri Lanka
Group Members
  Raw material specifications


Sugarcane will be grown in 1315 Ha
To get the maximum crop new sugarcane clone L-97-128 is recon

Other main raw materials for the sugar plants are lime and water.

Water can be delivered either from the Lunugamwehera irrigation system or
Udawalawe tank
Water from Lunugamwehera is small and most of the water from it is used
in agriculture already

Lime is used for the clarification of raw juice
Either imported or use CaCO3 found in south or north-western parts of Sri
Lanka We can’t use lime from corals
This is a food product, we have to use pure lime therefore it is
recommended to get lime from a foreign country.
Environmental considerations
 Selecting a processing method
 Group Members

Land usage
Land usage is too large for cane cultivation
 De-forestation
Change of animal habitats
De-fertilization of soil


Waste water
Inputs to the sugar plant are mainly sugar cane and some amount of water
 The water is used in milling as imbibition water and steam
 discharge water from pan boilers
Environmental considerations
Selecting a processing method
Group Members

Gas emissions
Emissions such as Sulpher Oxides and Nitro Oxides can be emitted from the
clarifier




                                                     Baggase


Solid waste
Produces dust and ash which can cause skin diseases
 Baggase and filter cake are removed from milling and vacuum pumps
 Baggase can be used in boilers, filter cake can be used as fertilizer
Selecting Utility services
Group Members
          a processing method


Electricity


Used in crane system, cutters, and various kinds of motors, centrifugal
machines, juice clarifiers, driers, bucket elevators, air compressors, magnetic
separators, pump house, work shop facilities and lighting
Delivered from Ceylon Electricity Board national grid.
There is a potential to produce electricity by baggase coming out from
milling process
Power house steam turbines will use steam from boiler where the baggase
is burned
Start up of the power plant firewood can be used
Selecting Utility services
Group Members
          a processing method


 Steam

 Steam is the main utility for the operation in a sugar factory.
 Generated in boilers which Steam is used in different forms such as
 superheated stem etc.
 Superheated steam is used for operating mill house
 machinery, shredder, and power turbines
 Exhaust steam will be used process heating
 De-superheating unit and pressure reducing unit
 Superheated steam cannot be used for process heating purposes.
Selecting Utility services
Group Members
          a processing method


 Compressed air

 Used in pneumatic control system of the factory
 In vacuum filter to create vacuums in different levels
 Used in a pressure of 7bar so the sufficient air compressors are used

 Work shop facility

 Workshop facility to repair the factory machinery in factory itself
 Workshop machines such as lathe, milling, boring are essential

 Auto mobile repair centre

 Various vehicles are used in both sugar planting and the factory
 Vehicles may come up with various problems
Selecting Energy sources
Group Members
          a processing method

Electricity

Electricity from CEB and steam turbines are used in sugar factories
Electricity from CEB for lighting, for residences
Electricity from steam turbines for other uses [pumps, motors, compressors etc.]

Thermal Power – Steam

Super heated steam is used Mill turbines, shredder , power turbines
Exhaust steam from these processes is used in evaporation,
Vapor generated from evaporation can be used in pan boilers

Bio mass

Firewood for boiler startup
Baggase for boiler
Identifying processing method
Selecting a problems/ Limitations
Group Members


 Supposed to manufacture 59,181MT of sugar per annum
 Better to have line production instead of single line plant
 Or else use multiple lines for the unit operations which take long time to
 complete Those steps can be considered as the limiting factors
 Shredding and pan boiling are such unit operations.

 Problems arising in startup in the boiler plant
 As mentioned previously firewood can be used for startup the boiler until
 baggase lots are available for burning

 if manufacturing white sugar ,have to add another unit operation to the
 process which involves lots of chemicals
 What importing is white sugar
 Manufacturing white sugar will make a competition between Sri Lankan
 Sugar manufacturing and imported sugar
 Therefore the process is limited to brown sugar manufacturing.
References


1. E. Hugot. Handbook of Sugar cane Engineering, Third completely revised
edition: Elsevier science publishing company; 1986.

2. Rogger P. Humbert. The growth of sugar cane, Revised edition : Elsevier
science publishing company; 1968.

3. Verlas Dr. Albert Bartens KG. CANE SUGAR ENGINERING. Berlin, Germany;
2007.

4. Juliano José Corbi & Susana Trivinho-Strixino & Ademir dos
Santos. Environmental Evaluation of Metals in Sediments and Dragonflies
Due to Sugar Cane Cultivation in Neotropical Streams.
http://link.springer.com/content/pdf/10.1007%2Fs11270-008-9749-1
(accessed 17th December 2012).
References


5. K. A. Gravois,* K. P. Bischoff, S. B. Milligan, F. A. Martin, J. W. Hoy, T. E.
Reagan, C. A. Kimbeng, C. M. LaBorde, and G. L. Hawkins. Registration of
‘L 97-128’ Sugarcane.
https://www.crops.org/publications/jpr/pdfs/2/1/24 (accessed 16th
December 2012)


6. Sugar cane. http/www.wikipedia.org/sugarcane (accessed 10th
December 2012)
End of slides

More Related Content

What's hot

sugur manufacturing
 sugur manufacturing sugur manufacturing
sugur manufacturingsaeed memon
 
Sakthi sugar internship report
Sakthi sugar internship reportSakthi sugar internship report
Sakthi sugar internship reportKasiRajan25
 
Sugar Manufacturing Industry. Mini Sugar Plant. Sugarcane Mill. How Cane Suga...
Sugar Manufacturing Industry. Mini Sugar Plant. Sugarcane Mill. How Cane Suga...Sugar Manufacturing Industry. Mini Sugar Plant. Sugarcane Mill. How Cane Suga...
Sugar Manufacturing Industry. Mini Sugar Plant. Sugarcane Mill. How Cane Suga...Ajjay Kumar Gupta
 
Report on Sugar mill bisalpur by sachin kumar
Report on Sugar mill bisalpur by sachin kumarReport on Sugar mill bisalpur by sachin kumar
Report on Sugar mill bisalpur by sachin kumarsachin kumar
 
Iffco summer trainning presentation
Iffco summer trainning presentationIffco summer trainning presentation
Iffco summer trainning presentationhmthimanshu
 
Sugarmanufacture
Sugarmanufacture Sugarmanufacture
Sugarmanufacture amr adel
 
Organization Study at Nirani Sugars
Organization Study at Nirani SugarsOrganization Study at Nirani Sugars
Organization Study at Nirani SugarsProjects Kart
 
Sugar Boiling in Sugar Crystallization Process
Sugar Boiling in Sugar Crystallization ProcessSugar Boiling in Sugar Crystallization Process
Sugar Boiling in Sugar Crystallization ProcessKiruthikaGuna1
 
Presentation sugar mill
Presentation sugar millPresentation sugar mill
Presentation sugar millHamza Nawaz
 
54846022 a-ppt-on-sugar-industry
54846022 a-ppt-on-sugar-industry54846022 a-ppt-on-sugar-industry
54846022 a-ppt-on-sugar-industryMohan Raj
 
A Study on Sugar Industry at Chamundeshwari Sugar
A Study on Sugar Industry at Chamundeshwari SugarA Study on Sugar Industry at Chamundeshwari Sugar
A Study on Sugar Industry at Chamundeshwari SugarProjects Kart
 
Mango pulp industry v chandana dipthi
Mango pulp industry v chandana dipthiMango pulp industry v chandana dipthi
Mango pulp industry v chandana dipthiANIKET KULKARNI
 
Sugarcane industry waste utilization
Sugarcane industry waste utilizationSugarcane industry waste utilization
Sugarcane industry waste utilizationTamanna Agarwal
 
Sip project at (sumul dairy)by Dharti G joshi "Effectiveness of Training and...
Sip  project at (sumul dairy)by Dharti G joshi "Effectiveness of Training and...Sip  project at (sumul dairy)by Dharti G joshi "Effectiveness of Training and...
Sip project at (sumul dairy)by Dharti G joshi "Effectiveness of Training and...Gunvant Joshi
 

What's hot (20)

Sugar mill
Sugar millSugar mill
Sugar mill
 
Sugar industry by h luqman
Sugar industry by h luqmanSugar industry by h luqman
Sugar industry by h luqman
 
sugur manufacturing
 sugur manufacturing sugur manufacturing
sugur manufacturing
 
Sakthi sugar internship report
Sakthi sugar internship reportSakthi sugar internship report
Sakthi sugar internship report
 
Sugar Manufacturing Industry. Mini Sugar Plant. Sugarcane Mill. How Cane Suga...
Sugar Manufacturing Industry. Mini Sugar Plant. Sugarcane Mill. How Cane Suga...Sugar Manufacturing Industry. Mini Sugar Plant. Sugarcane Mill. How Cane Suga...
Sugar Manufacturing Industry. Mini Sugar Plant. Sugarcane Mill. How Cane Suga...
 
Report on Sugar mill bisalpur by sachin kumar
Report on Sugar mill bisalpur by sachin kumarReport on Sugar mill bisalpur by sachin kumar
Report on Sugar mill bisalpur by sachin kumar
 
Sugar1
Sugar1Sugar1
Sugar1
 
Iffco summer trainning presentation
Iffco summer trainning presentationIffco summer trainning presentation
Iffco summer trainning presentation
 
Sugarmanufacture
Sugarmanufacture Sugarmanufacture
Sugarmanufacture
 
Organization Study at Nirani Sugars
Organization Study at Nirani SugarsOrganization Study at Nirani Sugars
Organization Study at Nirani Sugars
 
Sugar Boiling in Sugar Crystallization Process
Sugar Boiling in Sugar Crystallization ProcessSugar Boiling in Sugar Crystallization Process
Sugar Boiling in Sugar Crystallization Process
 
Presentation sugar mill
Presentation sugar millPresentation sugar mill
Presentation sugar mill
 
54846022 a-ppt-on-sugar-industry
54846022 a-ppt-on-sugar-industry54846022 a-ppt-on-sugar-industry
54846022 a-ppt-on-sugar-industry
 
A Study on Sugar Industry at Chamundeshwari Sugar
A Study on Sugar Industry at Chamundeshwari SugarA Study on Sugar Industry at Chamundeshwari Sugar
A Study on Sugar Industry at Chamundeshwari Sugar
 
Mango pulp industry v chandana dipthi
Mango pulp industry v chandana dipthiMango pulp industry v chandana dipthi
Mango pulp industry v chandana dipthi
 
Presentation on sugarcane
Presentation on sugarcanePresentation on sugarcane
Presentation on sugarcane
 
Sugarcane industry waste utilization
Sugarcane industry waste utilizationSugarcane industry waste utilization
Sugarcane industry waste utilization
 
IFFCO AONLA BARIELLY summer Training file.pdf
IFFCO AONLA BARIELLY summer   Training file.pdfIFFCO AONLA BARIELLY summer   Training file.pdf
IFFCO AONLA BARIELLY summer Training file.pdf
 
Sugars
SugarsSugars
Sugars
 
Sip project at (sumul dairy)by Dharti G joshi "Effectiveness of Training and...
Sip  project at (sumul dairy)by Dharti G joshi "Effectiveness of Training and...Sip  project at (sumul dairy)by Dharti G joshi "Effectiveness of Training and...
Sip project at (sumul dairy)by Dharti G joshi "Effectiveness of Training and...
 

Similar to Sugar plant design

Shree Renuka Sugars Ltd Corporate Presentation
Shree Renuka Sugars Ltd Corporate PresentationShree Renuka Sugars Ltd Corporate Presentation
Shree Renuka Sugars Ltd Corporate PresentationAICL Communications
 
Moon in the Mirror: Support Prices to Farmers
Moon in the Mirror: Support Prices to FarmersMoon in the Mirror: Support Prices to Farmers
Moon in the Mirror: Support Prices to FarmersRamanjaneyulu GV
 
Draft LIVES project implementation plan
Draft LIVES project implementation planDraft LIVES project implementation plan
Draft LIVES project implementation planILRI
 
Regional perspective – Southern Africa: production, constraints, market, future
Regional perspective – Southern Africa: production, constraints, market, futureRegional perspective – Southern Africa: production, constraints, market, future
Regional perspective – Southern Africa: production, constraints, market, futureCIMMYT
 
Wheat Research and Production in Sudan: Current Status and Trends
Wheat Research and Production in Sudan: Current Status and TrendsWheat Research and Production in Sudan: Current Status and Trends
Wheat Research and Production in Sudan: Current Status and TrendsCIMMYT
 
Organization study at gem sugars
Organization study at gem sugarsOrganization study at gem sugars
Organization study at gem sugarsProjects Kart
 
Presentasion for ici 2021 #rr
Presentasion for ici 2021 #rrPresentasion for ici 2021 #rr
Presentasion for ici 2021 #rrWage Karsana
 
Tim Rainey - Tameside MBC - channel shift
Tim Rainey - Tameside MBC - channel shiftTim Rainey - Tameside MBC - channel shift
Tim Rainey - Tameside MBC - channel shiftSocitm
 
Climate Smart Agriculture, Food Security and Water in Africa's Drylands: Less...
Climate Smart Agriculture, Food Security and Water in Africa's Drylands: Less...Climate Smart Agriculture, Food Security and Water in Africa's Drylands: Less...
Climate Smart Agriculture, Food Security and Water in Africa's Drylands: Less...World Resources Institute (WRI)
 
Shekhar kishore, vamnicom
Shekhar kishore, vamnicomShekhar kishore, vamnicom
Shekhar kishore, vamnicomShekhar Kishore
 
A competitive South African Wheat Industry Is Paramount To Food Security
A competitive South African Wheat Industry Is Paramount To Food SecurityA competitive South African Wheat Industry Is Paramount To Food Security
A competitive South African Wheat Industry Is Paramount To Food SecurityCIMMYT
 
Wim 2010 Raymond Philippe Sal Or Desal
Wim 2010 Raymond Philippe   Sal Or DesalWim 2010 Raymond Philippe   Sal Or Desal
Wim 2010 Raymond Philippe Sal Or Desalrphilippe
 
Training report on rajasthan state ganganagar sugar mill
Training report on rajasthan state ganganagar sugar millTraining report on rajasthan state ganganagar sugar mill
Training report on rajasthan state ganganagar sugar millAbhishekMalethia1
 
130220 out of Pesticide trap: Learning from NPM experiences in AP
130220 out of Pesticide trap: Learning from NPM experiences in AP130220 out of Pesticide trap: Learning from NPM experiences in AP
130220 out of Pesticide trap: Learning from NPM experiences in APRamanjaneyulu GV
 
6.4 danny fausto-_niche_marketing_philippines
6.4 danny fausto-_niche_marketing_philippines6.4 danny fausto-_niche_marketing_philippines
6.4 danny fausto-_niche_marketing_philippinesSilvia Sperandini
 
Over view of Knowledge Park at Godavari By Samden Sherpa, ICIMOD
Over view of Knowledge Park at Godavari By Samden Sherpa, ICIMODOver view of Knowledge Park at Godavari By Samden Sherpa, ICIMOD
Over view of Knowledge Park at Godavari By Samden Sherpa, ICIMODAPGYF2012
 
Present status of_coconut_sector_in_sri_lanka
Present status of_coconut_sector_in_sri_lankaPresent status of_coconut_sector_in_sri_lanka
Present status of_coconut_sector_in_sri_lankaHarshana Jayarathna
 

Similar to Sugar plant design (20)

Shree Renuka Sugars Ltd Corporate Presentation
Shree Renuka Sugars Ltd Corporate PresentationShree Renuka Sugars Ltd Corporate Presentation
Shree Renuka Sugars Ltd Corporate Presentation
 
Moon in the Mirror: Support Prices to Farmers
Moon in the Mirror: Support Prices to FarmersMoon in the Mirror: Support Prices to Farmers
Moon in the Mirror: Support Prices to Farmers
 
Cane sugar engineering
Cane sugar engineeringCane sugar engineering
Cane sugar engineering
 
Draft LIVES project implementation plan
Draft LIVES project implementation planDraft LIVES project implementation plan
Draft LIVES project implementation plan
 
Regional perspective – Southern Africa: production, constraints, market, future
Regional perspective – Southern Africa: production, constraints, market, futureRegional perspective – Southern Africa: production, constraints, market, future
Regional perspective – Southern Africa: production, constraints, market, future
 
Wheat Research and Production in Sudan: Current Status and Trends
Wheat Research and Production in Sudan: Current Status and TrendsWheat Research and Production in Sudan: Current Status and Trends
Wheat Research and Production in Sudan: Current Status and Trends
 
Organization study at gem sugars
Organization study at gem sugarsOrganization study at gem sugars
Organization study at gem sugars
 
Presentasion for ici 2021 #rr
Presentasion for ici 2021 #rrPresentasion for ici 2021 #rr
Presentasion for ici 2021 #rr
 
Tim Rainey - Tameside MBC - channel shift
Tim Rainey - Tameside MBC - channel shiftTim Rainey - Tameside MBC - channel shift
Tim Rainey - Tameside MBC - channel shift
 
Climate Smart Agriculture, Food Security and Water in Africa's Drylands: Less...
Climate Smart Agriculture, Food Security and Water in Africa's Drylands: Less...Climate Smart Agriculture, Food Security and Water in Africa's Drylands: Less...
Climate Smart Agriculture, Food Security and Water in Africa's Drylands: Less...
 
The Sustainability of the Present Ethanol Production and Future Expansion in ...
The Sustainability of the Present Ethanol Production and Future Expansion in ...The Sustainability of the Present Ethanol Production and Future Expansion in ...
The Sustainability of the Present Ethanol Production and Future Expansion in ...
 
Shekhar kishore, vamnicom
Shekhar kishore, vamnicomShekhar kishore, vamnicom
Shekhar kishore, vamnicom
 
Amul
AmulAmul
Amul
 
A competitive South African Wheat Industry Is Paramount To Food Security
A competitive South African Wheat Industry Is Paramount To Food SecurityA competitive South African Wheat Industry Is Paramount To Food Security
A competitive South African Wheat Industry Is Paramount To Food Security
 
Wim 2010 Raymond Philippe Sal Or Desal
Wim 2010 Raymond Philippe   Sal Or DesalWim 2010 Raymond Philippe   Sal Or Desal
Wim 2010 Raymond Philippe Sal Or Desal
 
Training report on rajasthan state ganganagar sugar mill
Training report on rajasthan state ganganagar sugar millTraining report on rajasthan state ganganagar sugar mill
Training report on rajasthan state ganganagar sugar mill
 
130220 out of Pesticide trap: Learning from NPM experiences in AP
130220 out of Pesticide trap: Learning from NPM experiences in AP130220 out of Pesticide trap: Learning from NPM experiences in AP
130220 out of Pesticide trap: Learning from NPM experiences in AP
 
6.4 danny fausto-_niche_marketing_philippines
6.4 danny fausto-_niche_marketing_philippines6.4 danny fausto-_niche_marketing_philippines
6.4 danny fausto-_niche_marketing_philippines
 
Over view of Knowledge Park at Godavari By Samden Sherpa, ICIMOD
Over view of Knowledge Park at Godavari By Samden Sherpa, ICIMODOver view of Knowledge Park at Godavari By Samden Sherpa, ICIMOD
Over view of Knowledge Park at Godavari By Samden Sherpa, ICIMOD
 
Present status of_coconut_sector_in_sri_lanka
Present status of_coconut_sector_in_sri_lankaPresent status of_coconut_sector_in_sri_lanka
Present status of_coconut_sector_in_sri_lanka
 

Recently uploaded

Interior Design for Office a cura di RMG Project Studio
Interior Design for Office a cura di RMG Project StudioInterior Design for Office a cura di RMG Project Studio
Interior Design for Office a cura di RMG Project StudioRMG Project Studio
 
Unit1_Syllbwbnwnwneneneneneneentation_Sem2.pptx
Unit1_Syllbwbnwnwneneneneneneentation_Sem2.pptxUnit1_Syllbwbnwnwneneneneneneentation_Sem2.pptx
Unit1_Syllbwbnwnwneneneneneneentation_Sem2.pptxNitish292041
 
Pearl Disrtrict urban analyusis study pptx
Pearl Disrtrict urban analyusis study pptxPearl Disrtrict urban analyusis study pptx
Pearl Disrtrict urban analyusis study pptxDanielTamiru4
 
10 Best WordPress Plugins to make the website effective in 2024
10 Best WordPress Plugins to make the website effective in 202410 Best WordPress Plugins to make the website effective in 2024
10 Best WordPress Plugins to make the website effective in 2024digital learning point
 
Making and Unmaking of Chandigarh - A City of Two Plans2-4-24.ppt
Making and Unmaking of Chandigarh - A City of Two Plans2-4-24.pptMaking and Unmaking of Chandigarh - A City of Two Plans2-4-24.ppt
Making and Unmaking of Chandigarh - A City of Two Plans2-4-24.pptJIT KUMAR GUPTA
 
cda.pptx critical discourse analysis ppt
cda.pptx critical discourse analysis pptcda.pptx critical discourse analysis ppt
cda.pptx critical discourse analysis pptMaryamAfzal41
 
Karim apartment ideas 01 ppppppppppppppp
Karim apartment ideas 01 pppppppppppppppKarim apartment ideas 01 ppppppppppppppp
Karim apartment ideas 01 pppppppppppppppNadaMohammed714321
 
How to Empower the future of UX Design with Gen AI
How to Empower the future of UX Design with Gen AIHow to Empower the future of UX Design with Gen AI
How to Empower the future of UX Design with Gen AIyuj
 
guest bathroom white and blue ssssssssss
guest bathroom white and blue ssssssssssguest bathroom white and blue ssssssssss
guest bathroom white and blue ssssssssssNadaMohammed714321
 
DAKSHIN BIHAR GRAMIN BANK: REDEFINING THE DIGITAL BANKING EXPERIENCE WITH A U...
DAKSHIN BIHAR GRAMIN BANK: REDEFINING THE DIGITAL BANKING EXPERIENCE WITH A U...DAKSHIN BIHAR GRAMIN BANK: REDEFINING THE DIGITAL BANKING EXPERIENCE WITH A U...
DAKSHIN BIHAR GRAMIN BANK: REDEFINING THE DIGITAL BANKING EXPERIENCE WITH A U...Rishabh Aryan
 
world health day 2024.pptxgbbvggvbhjjjbbbb
world health day 2024.pptxgbbvggvbhjjjbbbbworld health day 2024.pptxgbbvggvbhjjjbbbb
world health day 2024.pptxgbbvggvbhjjjbbbbpreetirao780
 
Iconic Global Solution - web design, Digital Marketing services
Iconic Global Solution - web design, Digital Marketing servicesIconic Global Solution - web design, Digital Marketing services
Iconic Global Solution - web design, Digital Marketing servicesIconic global solution
 
guest bathroom white and bluesssssssssss
guest bathroom white and bluesssssssssssguest bathroom white and bluesssssssssss
guest bathroom white and bluesssssssssssNadaMohammed714321
 
Color Theory Explained for Noobs- Think360 Studio
Color Theory Explained for Noobs- Think360 StudioColor Theory Explained for Noobs- Think360 Studio
Color Theory Explained for Noobs- Think360 StudioThink360 Studio
 
Map of St. Louis Parks
Map of St. Louis Parks                              Map of St. Louis Parks
Map of St. Louis Parks CharlottePulte
 
Karim apartment ideas 02 ppppppppppppppp
Karim apartment ideas 02 pppppppppppppppKarim apartment ideas 02 ppppppppppppppp
Karim apartment ideas 02 pppppppppppppppNadaMohammed714321
 
The spirit of digital place - game worlds and architectural phenomenology
The spirit of digital place - game worlds and architectural phenomenologyThe spirit of digital place - game worlds and architectural phenomenology
The spirit of digital place - game worlds and architectural phenomenologyChristopher Totten
 
Piece by Piece Magazine
Piece by Piece Magazine                      Piece by Piece Magazine
Piece by Piece Magazine CharlottePulte
 
怎么办理英国Newcastle毕业证纽卡斯尔大学学位证书一手渠道
怎么办理英国Newcastle毕业证纽卡斯尔大学学位证书一手渠道怎么办理英国Newcastle毕业证纽卡斯尔大学学位证书一手渠道
怎么办理英国Newcastle毕业证纽卡斯尔大学学位证书一手渠道yrolcks
 
Top 10 Modern Web Design Trends for 2025
Top 10 Modern Web Design Trends for 2025Top 10 Modern Web Design Trends for 2025
Top 10 Modern Web Design Trends for 2025Rndexperts
 

Recently uploaded (20)

Interior Design for Office a cura di RMG Project Studio
Interior Design for Office a cura di RMG Project StudioInterior Design for Office a cura di RMG Project Studio
Interior Design for Office a cura di RMG Project Studio
 
Unit1_Syllbwbnwnwneneneneneneentation_Sem2.pptx
Unit1_Syllbwbnwnwneneneneneneentation_Sem2.pptxUnit1_Syllbwbnwnwneneneneneneentation_Sem2.pptx
Unit1_Syllbwbnwnwneneneneneneentation_Sem2.pptx
 
Pearl Disrtrict urban analyusis study pptx
Pearl Disrtrict urban analyusis study pptxPearl Disrtrict urban analyusis study pptx
Pearl Disrtrict urban analyusis study pptx
 
10 Best WordPress Plugins to make the website effective in 2024
10 Best WordPress Plugins to make the website effective in 202410 Best WordPress Plugins to make the website effective in 2024
10 Best WordPress Plugins to make the website effective in 2024
 
Making and Unmaking of Chandigarh - A City of Two Plans2-4-24.ppt
Making and Unmaking of Chandigarh - A City of Two Plans2-4-24.pptMaking and Unmaking of Chandigarh - A City of Two Plans2-4-24.ppt
Making and Unmaking of Chandigarh - A City of Two Plans2-4-24.ppt
 
cda.pptx critical discourse analysis ppt
cda.pptx critical discourse analysis pptcda.pptx critical discourse analysis ppt
cda.pptx critical discourse analysis ppt
 
Karim apartment ideas 01 ppppppppppppppp
Karim apartment ideas 01 pppppppppppppppKarim apartment ideas 01 ppppppppppppppp
Karim apartment ideas 01 ppppppppppppppp
 
How to Empower the future of UX Design with Gen AI
How to Empower the future of UX Design with Gen AIHow to Empower the future of UX Design with Gen AI
How to Empower the future of UX Design with Gen AI
 
guest bathroom white and blue ssssssssss
guest bathroom white and blue ssssssssssguest bathroom white and blue ssssssssss
guest bathroom white and blue ssssssssss
 
DAKSHIN BIHAR GRAMIN BANK: REDEFINING THE DIGITAL BANKING EXPERIENCE WITH A U...
DAKSHIN BIHAR GRAMIN BANK: REDEFINING THE DIGITAL BANKING EXPERIENCE WITH A U...DAKSHIN BIHAR GRAMIN BANK: REDEFINING THE DIGITAL BANKING EXPERIENCE WITH A U...
DAKSHIN BIHAR GRAMIN BANK: REDEFINING THE DIGITAL BANKING EXPERIENCE WITH A U...
 
world health day 2024.pptxgbbvggvbhjjjbbbb
world health day 2024.pptxgbbvggvbhjjjbbbbworld health day 2024.pptxgbbvggvbhjjjbbbb
world health day 2024.pptxgbbvggvbhjjjbbbb
 
Iconic Global Solution - web design, Digital Marketing services
Iconic Global Solution - web design, Digital Marketing servicesIconic Global Solution - web design, Digital Marketing services
Iconic Global Solution - web design, Digital Marketing services
 
guest bathroom white and bluesssssssssss
guest bathroom white and bluesssssssssssguest bathroom white and bluesssssssssss
guest bathroom white and bluesssssssssss
 
Color Theory Explained for Noobs- Think360 Studio
Color Theory Explained for Noobs- Think360 StudioColor Theory Explained for Noobs- Think360 Studio
Color Theory Explained for Noobs- Think360 Studio
 
Map of St. Louis Parks
Map of St. Louis Parks                              Map of St. Louis Parks
Map of St. Louis Parks
 
Karim apartment ideas 02 ppppppppppppppp
Karim apartment ideas 02 pppppppppppppppKarim apartment ideas 02 ppppppppppppppp
Karim apartment ideas 02 ppppppppppppppp
 
The spirit of digital place - game worlds and architectural phenomenology
The spirit of digital place - game worlds and architectural phenomenologyThe spirit of digital place - game worlds and architectural phenomenology
The spirit of digital place - game worlds and architectural phenomenology
 
Piece by Piece Magazine
Piece by Piece Magazine                      Piece by Piece Magazine
Piece by Piece Magazine
 
怎么办理英国Newcastle毕业证纽卡斯尔大学学位证书一手渠道
怎么办理英国Newcastle毕业证纽卡斯尔大学学位证书一手渠道怎么办理英国Newcastle毕业证纽卡斯尔大学学位证书一手渠道
怎么办理英国Newcastle毕业证纽卡斯尔大学学位证书一手渠道
 
Top 10 Modern Web Design Trends for 2025
Top 10 Modern Web Design Trends for 2025Top 10 Modern Web Design Trends for 2025
Top 10 Modern Web Design Trends for 2025
 

Sugar plant design

  • 1. Design of a sugar manufacturing plant Basics in process Engineering Design
  • 2. Group Members Contents Preliminary stage •Finding the demands •Identifying various processes •Selecting a process •Find a suitable location •Block diagram for the selected process •Raw material specifications •Environmental considerations •Utility services •Energy sources •Identifying problems/ Limitations Mass balances
  • 3. FindingMembers Group the demands Sri Lanka sugar demands 1993-2011 Year Sugar demand, MT 1993 457442 1994 563275 1995 487512 1996 454339 1997 609055 1998 550000 1999 541220 2000 544220 2001 560033 2002 591661 Sources :Department of Census and Statistics 2003 570050 Pelwatte Sugar Industries Ltd 2004 501151 Sevanagala Sugar Industries Ltd 2005 471376 Sri Lanka Customs 2006 581019 Central Bank of Sri Lanka 2007 507544 2008 610378 2009 498168 2010 579336 2011 640876
  • 4. FindingMembers Group the demands Prediction through curve fitting 700 600 y = 3.721x - 6906. R² = 0.147 500 Suggar deamand,1000MT 400 300 Linear (Series1) 200 100 0 1990 1995 2000 2005 2010 2015 Year Current demand 2013 – 584,373 MT Our target – 59,181.5 MT/Yr Demand in 2015 – 591,815 MT 200 working days – 12.33 MT/hr
  • 5. Group Members Identifying various processes  Cane Sugar  Beet Sugar  Corn Sugar • Cane Sugar - Crystal, Powder, syrup Both of Cane sugar industry • Beet Sugar and Beet sugar industry are - Crystal, Powder, syrup used same process. • Corn Sugar - Sugar syrup (only used for sweeteners)
  • 6. Group Members Identifying various processes Cane sugar Beet sugar Grown in Tropical climate areas within Grown in Sub-tropical climate areas 22°N-22°S Temperature of 15-22 C at least 800-1000 mm/year Requires a good irrigation system and Soil temperature is about 70-80°F law wind speeds Temperature max growth at 27 C The process of manufacturing beet For the better photosynthesis in leaves sugar is quite similar to that of sugar sugarcane need plentiful sunshine. cane.
  • 7. Product Members Group specification Cane Sugar Raw Refined Crystal (mill) Muscavado Demerara Caster Icing Premium Liquid Sugar Fine Liquid Sugar Invert White Crystal Refined - Fine Granulated Mainly produce 3 types of sugar by Cane  Row Cane sugar ( Brown sugar )  Mill White sugar ( White Sugar)  Refined sugar ( White Sugar )
  • 8. Product Members Group specification We chose Raw Cane sugar ( Brown sugar )
  • 9. Find a Members Group suitable location Requirements for sugar cane cultivation Soil type medium to heavy well drained Climate RH-70% (for optimum vegetation growth) Rain fall at least 800-1000 mm/year Temperature max growth at 27 C Wind High Wind exceeding 60 km/hr Sri Lanka temperature profile
  • 10. Find a Members Group suitable location A - South-east region (Hambanthota, Embilipitiya) B- North-west region (Mannar) Source : https://sites.google.com/a/tcd.ie/sri-lanka/geography
  • 11. Find a Members Group suitable location Use factor rating method, A- South east region B- North west region Rating Critical Factor Weight A B Rain fall for cultivation 10 100 100 Temperature for cultivation 9 100 100 Soil fertility 7 80 40 Water supply 7 70 60 Land cost and availability 9 80 70 Labour cost and avaliablity 6 70 70 Transport 5 60 80 Score 4390 4050 More suitable location is South east region of Sri Lanka
  • 12. Group Members Raw material specifications Sugarcane will be grown in 1315 Ha To get the maximum crop new sugarcane clone L-97-128 is recon Other main raw materials for the sugar plants are lime and water. Water can be delivered either from the Lunugamwehera irrigation system or Udawalawe tank Water from Lunugamwehera is small and most of the water from it is used in agriculture already Lime is used for the clarification of raw juice Either imported or use CaCO3 found in south or north-western parts of Sri Lanka We can’t use lime from corals This is a food product, we have to use pure lime therefore it is recommended to get lime from a foreign country.
  • 13. Environmental considerations Selecting a processing method Group Members Land usage Land usage is too large for cane cultivation  De-forestation Change of animal habitats De-fertilization of soil Waste water Inputs to the sugar plant are mainly sugar cane and some amount of water  The water is used in milling as imbibition water and steam  discharge water from pan boilers
  • 14. Environmental considerations Selecting a processing method Group Members Gas emissions Emissions such as Sulpher Oxides and Nitro Oxides can be emitted from the clarifier Baggase Solid waste Produces dust and ash which can cause skin diseases  Baggase and filter cake are removed from milling and vacuum pumps  Baggase can be used in boilers, filter cake can be used as fertilizer
  • 15. Selecting Utility services Group Members a processing method Electricity Used in crane system, cutters, and various kinds of motors, centrifugal machines, juice clarifiers, driers, bucket elevators, air compressors, magnetic separators, pump house, work shop facilities and lighting Delivered from Ceylon Electricity Board national grid. There is a potential to produce electricity by baggase coming out from milling process Power house steam turbines will use steam from boiler where the baggase is burned Start up of the power plant firewood can be used
  • 16. Selecting Utility services Group Members a processing method Steam Steam is the main utility for the operation in a sugar factory. Generated in boilers which Steam is used in different forms such as superheated stem etc. Superheated steam is used for operating mill house machinery, shredder, and power turbines Exhaust steam will be used process heating De-superheating unit and pressure reducing unit Superheated steam cannot be used for process heating purposes.
  • 17. Selecting Utility services Group Members a processing method Compressed air Used in pneumatic control system of the factory In vacuum filter to create vacuums in different levels Used in a pressure of 7bar so the sufficient air compressors are used Work shop facility Workshop facility to repair the factory machinery in factory itself Workshop machines such as lathe, milling, boring are essential Auto mobile repair centre Various vehicles are used in both sugar planting and the factory Vehicles may come up with various problems
  • 18. Selecting Energy sources Group Members a processing method Electricity Electricity from CEB and steam turbines are used in sugar factories Electricity from CEB for lighting, for residences Electricity from steam turbines for other uses [pumps, motors, compressors etc.] Thermal Power – Steam Super heated steam is used Mill turbines, shredder , power turbines Exhaust steam from these processes is used in evaporation, Vapor generated from evaporation can be used in pan boilers Bio mass Firewood for boiler startup Baggase for boiler
  • 19. Identifying processing method Selecting a problems/ Limitations Group Members Supposed to manufacture 59,181MT of sugar per annum Better to have line production instead of single line plant Or else use multiple lines for the unit operations which take long time to complete Those steps can be considered as the limiting factors Shredding and pan boiling are such unit operations. Problems arising in startup in the boiler plant As mentioned previously firewood can be used for startup the boiler until baggase lots are available for burning if manufacturing white sugar ,have to add another unit operation to the process which involves lots of chemicals What importing is white sugar Manufacturing white sugar will make a competition between Sri Lankan Sugar manufacturing and imported sugar Therefore the process is limited to brown sugar manufacturing.
  • 20. References 1. E. Hugot. Handbook of Sugar cane Engineering, Third completely revised edition: Elsevier science publishing company; 1986. 2. Rogger P. Humbert. The growth of sugar cane, Revised edition : Elsevier science publishing company; 1968. 3. Verlas Dr. Albert Bartens KG. CANE SUGAR ENGINERING. Berlin, Germany; 2007. 4. Juliano José Corbi & Susana Trivinho-Strixino & Ademir dos Santos. Environmental Evaluation of Metals in Sediments and Dragonflies Due to Sugar Cane Cultivation in Neotropical Streams. http://link.springer.com/content/pdf/10.1007%2Fs11270-008-9749-1 (accessed 17th December 2012).
  • 21. References 5. K. A. Gravois,* K. P. Bischoff, S. B. Milligan, F. A. Martin, J. W. Hoy, T. E. Reagan, C. A. Kimbeng, C. M. LaBorde, and G. L. Hawkins. Registration of ‘L 97-128’ Sugarcane. https://www.crops.org/publications/jpr/pdfs/2/1/24 (accessed 16th December 2012) 6. Sugar cane. http/www.wikipedia.org/sugarcane (accessed 10th December 2012)