The average annual growth of sugarcane in agriculture sector is 2.6% against the overall growth of 3% in the agriculture sector of India. 20 to 25 % of the total sugarcane harvested goes into the making of jaggery. With this rapid increase of sugarcane production, jaggery production is subjected to increase. The energy efficient methods involving improved chulhas, furnaces can be utilized in jaggery production. The use of biomass derived fuels like briquettes can make a significant difference in jaggery production.

2. Chairman Student
DR.M.SINGARAVELU, C.Vijayanand,
Professor , M.Tech II year
Dept. of Bio-Energy , Dept. of Bio-Energy,
AEC & RI TNAU. AEC & RI TNAU.
Members
DR.N.O.GOPAL, DR.V. THIRUPATHI,
Professor, Associate Professor ,
Dept. of Bio-Energy, Dept. Of Food & Agricultural
AEC & RI TNAU. process engineering,
AEC & RI TNAU.

3.  Jaggery, commonly known as ‘gur’ in India is
a traditional, non-refined and centrifugal
sugary material
 Jaggery is a condensed form of sugarcane
juice produced by evaporation of moisture

5. Sugarcane after harvest to unit

7.  The power consumption for a 5 H.P. roller
crusher is 35 units to crush 100 kg of sugar
cane

16.  The bagasse is dried and used as fuel for jaggery
production
 Specific fuel consumption from 1.5 to 1.75 tons
bagasse per ton of jaggery
 However the quantity of bagasse available is not
sufficient for jaggery production

17.  The use of firewood as fuel is carried out
when adequate bagasse is not available
 The current methods under practice are very
low in thermal efficiency
 High amount of heat is lost in these
processes followed at present

18. 1. Poorly built heating furnaces and chulhas which supply
inadequate air supply resulting in incomplete
combustion
2. Heating pans for boiling sugarcane juice are inefficient,
giving uneven heat transfer
3. Excess fuel supply, replacement of bagasse by
firewood, rubber tyres

19.  Use of improved chulhas or furnaces for complete
combustion of bagasse or firewood
 Use of solar drying technologies for drying and
condensing of jaggery
 Use of agro residue fuels like briquettes
 Improved design of jagerry heating chulhas and furnaces
for greater thermal efficiency

20.  Jaggery plants are generally constructed by local
artisans
 It mainly consists of an underground furnace, like
an open cooking stove, (bigger version of a
biomass based cooking stove) with a pan
mounted on to it for evaporating the juice
 There are different types of jaggery furnace, single
pan furnace and multiple pan (three to four pans)
furnace

21.  In a single pan furnace all jaggery making
processes like sensible heating, chemical
addition, impurity removal, evaporation etc. are
carried out
 In a single pan as a batch process while in a
multiple pan furnace above jaggery making
processes are carried out in three to four pans in
a semi continuous mode

22.  For performance evaluation of a jaggery furnace it
is essential to establish mass and energy balance
 The mass balance study in jaggery processing
starts with the measurement of the crusher
performance
 A known quantity of cane is crushed

23.  The dried bagasse with moisture content of 8-10% is
used for firing in the furnace
 Jaggery produced per batch is measured
 The measurement of mass of bagasse fired and mass of
jaggery produced in a batch represent the performance
of furnace
 The measurement of oxygen, carbon monoxide and
temperature in flue gas in the furnace chimney is used
for thermal analysis

24.  The input streams for jaggery furnace consist of
juice, combustion air and bagasse
 The output streams are flue gas, liquid jaggery,
water evaporated from juice and wall loss from
furnace
 The mass and energy balances then calculated
for fuel feeding rate for controlled feeding and
normal fuel feeding

25. Conventional multi pan chulha

27. Improved 4 pan
chulha/furnace

32. Unit – MJ/h

40. Particula
rs
Heat supplied
MJ/h
Heat utilized
MJ/h
Heat loss
MJ/h
Thermal
efficiency
Type of
feeding
Presen
t
feedin
g
Control
feeding
Present
feeding
Control
feeding
Present
feeding
Control
feeding
Present
feeding
Control
feeding
Unit in
MJ/h
2846 2055 813 813 2033 1242 40% 65%

41.  The reduction in the fuel quantity by just
controlling the fuel feeding rate is about 33 to
28%. The saving in the fuel is mainly on account
of reduction in flue gas temperature from 900 to
700 deg C and reduction in unburnt loss
 The specific bagasse consumption is reduced
from 1.73 kg bagasse/kg jaggery to 2.39 kg
bagasse/kg jaggery, this leads to reduction of
0.66 kg bagasse/ kg jaggery

42.  Hence the controlled fuel feeding in the four
pan furnace is more energy efficient process
than the regular feeding of fuel
 As the efficiency of the process is increased
from 40% to 65 %

46.  The graphs indicate that the rate of drying of
jaggery increases rapidly with the forced
convection mode than natural mode
 The experimental study reveals that the rate
of drying of the jaggery samples of different
sizes was greater in forced convection than
natural convection

47.  However the cost of solar drying will be 40%
more than the conventional drying using
moulds ( wooden or clay)
 Solar drying of jaggery reduces
caramelisation and improves jaggery color
and quality
 Apart from these solar preheating of
sugarcane juice can prevent the loss of
sucrose upto 4%

48.  A study was conducted for the improvement
of efficiency of jagerry open pan furnace.
 A regular flat bottom main pan, gutter pan
and modified pan , gutter with fins at the
bottom were taken with sugar syrup for
jagerry production.

51.  The increase in area of heat receiving surface
due to fins was calculated as:
Increase in area = 2 total length of flat provided
X width of flat

54.  The heat transfer was observed to be high in
the modified jaggery pan and gutter pan
 The bagasse consumption for the conventional
pan was higher than that of the
improved/modified

57.  The average annual growth of sugarcane in
agriculture sector is 2.6% against the overall
growth of 3% in the agriculture sector of
India
 20 to 25 % of the total sugarcane harvested
goes into the making of jaggery

58.  With this rapid increase of sugarcane
production, jaggery production is subjected to
increase
 The energy efficient methods involving
improved chulhas, furnaces can be utilized in
jaggery production
 The use of biomass derived fuels like
briquettes can make a significant difference
in jaggery production

59.  Use of solar energy technologies for preheating
of sugarcane juice and drying of jaggery
 By implementing renewable energy technologies
and energy efficient methods higher thermal
efficiencies can be achieved
 Hence renewable energy and energy efficient
methods adoption will increase the output of
Jaggery industry

60.  Vishal, Pillai I.R. Thermal performance evaluation of a four pan
jaggery processing furnace for improvement in energy
utilization.
 Pattnayak P.K,. Misra M.K. Energetic and economics of
traditional gur preparation: a case study in Ganjam district of
Orissa, India. Department of botany, berhampur University,
berhampur, Orissa, India.
 Tiwari G.N, Sanjeev Kumar, Om Prakash. Evaluation of
convective mass transfer coefficient during drying of jaggery.
Center for Energy Studies, Indian Institute of technology, New
Delhi 110016, India

61.  S.I. Anwar. Fuel and energy saving in open pan furnace used in
jaggery making through modified juice boiling/concentrating
pans. Division of Agricultural Engineering, Indian Institute of
Sugarcane Research, Raebareli Road, Lucknow 226 002, UP,
India.
 Anil kumar, Tiwari G.N. Thermal modelling and parametric
study of forced convection green house drying system for
jaggery. Department of industrial and production, University
institute of technology, Rajiv Gandhi technology university
Bhopal, India.