This document outlines a four stage sugar crystallization control program. It provides details on process parameters like brix, level, temperature, crystal size, growth rate, etc. at each stage of boiling and tightening. Graphs tracking various parameters like level/brix curve, crystal content, purity, growth rate etc. over time are also included to allow for online monitoring and control of the crystallization process.

1. Ozein fully integrated suagr crystallization control program
" four stages control strategy"
I.
Time Masc. Vol. Level Masc.brix Masc.brix S.G. Masc.quan. Masc. solids Masc.sugar MA One crystal wt. Crystals quan. Crystal content Cr. growth ML sugar ML solids ML water ML brix ML purity ML sucrose ML super sat. ML quan. Evaporation H. Steam Vapour Vacuum Masc.Temp. PU time factor
min. m3 % % correc. % % tonne tonne tonne micron gm tonne % Masc. solids g/m2.min tonne tonne tonne % % solubility % g:g tonne tonne bar(a) Temp.° C mbar(a) °C 68 0.55
0.00 29.67 37.30 77.95 77.95 1.37 40.74 31.76 29.85 9 8.0919E-10 0.000 0.00 0.17 29.85 31.76 8.98 77.95 94.00 332.31 1.05 40.74 4.63 0.81 62.30 223.2319 70 69 0.53
12.22 34.52 43.40 79.08 79.08 1.38 47.57 37.62 35.36 75.9576 4.86448E-07 0.09 0.24 1.41 35.27 37.53 9.95 79.05 93.99 354.54 1.08 47.48 7.15 1.01 64.65 248.6039 73 70 0.51
24.44 39.38 49.50 80.22 80.22 1.39 54.54 43.75 41.13 142.915 3.24009E-06 0.59 1.35 2.64 40.54 43.16 10.79 80.00 93.92 375.73 1.14 53.95 9.66 1.16 64.21 243.7158 73 71 0.5
36.67 44.23 55.60 81.35 81.35 1.39 61.42 49.97 46.97 209.873 1.0261E-05 1.87 3.75 3.88 45.10 48.09 11.45 80.77 93.77 393.76 1.14 59.55 12.18 1.37 67.59 283.6004 77 73 0.48
48.89 49.08 61.70 82.49 82.49 1.40 68.52 56.52 53.13 276.83 2.35485E-05 4.30 7.60 5.12 48.83 52.23 12.00 81.32 93.51 406.95 1.18 64.23 14.70 1.37 67.31 280.1357 77 74 0.45
61.11 53.93 67.80 83.62 83.62 1.40 75.70 63.30 59.51 343.788 4.51019E-05 8.23 13.00 6.36 51.28 55.07 12.40 81.62 93.10 413.56 1.20 67.47 17.22 1.37 67.16 278.1695 77 75 0.42
73.33 58.79 73.90 84.76 84.76 1.41 82.96 70.31 66.09 410.745 7.69203E-05 14.04 19.97 7.60 52.06 56.27 12.65 81.65 92.51 411.64 1.20 68.92 19.73 1.37 67.14 277.9948 77 76 0.4
85.56 63.64 80.00 85.89 85.89 1.42 90.29 77.55 72.90 477.703 0.000121003 22.09 28.48 8.84 50.81 55.47 12.74 81.32 91.61 398.88 1.16 68.20 22.25 1.37 67.31 280.0969 77 77 0.38
97.78 68.49 86.11 87.02 87.02 1.43 97.70 85.02 79.92 544.661 0.00017935 32.73 38.50 10.08 47.19 52.29 12.68 80.49 90.25 372.26 1.08 64.96 24.77 1.37 67.73 285.349 77 78 0.34
110.00 73.35 92.21 88.16 88.16 1.43 105.18 92.73 87.17 611.618 0.000253959 46.35 49.99 11.31 40.82 46.38 12.45 78.83 88.01 327.74 0.95 58.83 27.29 1.37 68.51 295.4211 77 79 0.31
117.01 70.00 88 91.10 91.10 1.45 101.79 92.73 87.17 650 0.000304834 55.64 60.00 12.03 31.53 37.09 9.06 80.36 85.02 347.89 1.00 46.16 30.68 1.37 67.79 286.1263 77 80 0.294
°C S/w for S.c=1 81 0.288
Feed liqour's brix 70 % Pan volume 70 m3 Of seeding 332.315 % CC 60.00 % Masc. DS BPE 9.21 °C 82 0.276
End actual level 84 % Pan diameter m 5.2 m 70 316.49 % CC 54.66 % Masc. TΔ (steam to Masc.) 31.73 °C 83 0.27
Masc. head (L corr.) 4 % Hight above clandria 1.9 m 73 328.37 % U 393.05 w/m2k Masc. brix 91.10 % 84 0.236
Masc.brix corr.factor 0 % 77 347.89 % A 550 m2 Masc. Temp. 77 °C 85 0.154
Seeding Temp. 70 °C Seed crystal size MA 9 micron Q 6859.30 kw steam Temp. 108.73 °C 86 0.15
Seeding SS 1.05 % End grain size MA 650 micron Volume rate Bs 0.397 m3/min. Q 24693464 KW/hr. Steam Pressure 1.37 bar a 87 0.143
End ML ss 1 % Crystal numbers 1.82519E+11 Level rate Bs 0.499 %/min. steam 11.08 t/hr. Vapor pressure 0.28 bar a 88 0.139
Feed liquor purity 94 % Crystal quantity 55.64 Ton Masc.brix rate Bs 0.093 brix°/min. Vapour 11.64 t/hr. Latent heat Steam 2228 Kj/kg 89 0.135
Sugar purity 99.99 % Slurry required 443.08 ml Total evap. Bs 22.659 Tonne Vapour 30.68 t/cycle Latent heat Vapor 2338 Kj/kg 90 0.087
End boilling vol. 73.35 m3 Evapo. rate Bs 0.206 tonne/min. 91 0.085
Feed liq. quantity 132.47 Ton Above clandria volum 40.33 m3 Fed liqour rate 0.792 ton/min. 92 0.082
Feed liqour's purity 94 % Charge quant. @ 72 brix 44.11 Ton Feed liqour rate 0.601 m3/hr 93 0.079
Sugar purity 99.99 % Charge level 44.20 % Boiling rate 12.222 minutes 94 0.078
Crystal content 60 % Masc. DS Charge vol. 33.50 m3 Volume rateTs 0.478 m3/min. 95 0.075
Start boiling brix 77.95 % Seeding vol. 29.67 m3 Level rate Ts 0.600 %/min 96 0.073
Program logic flow chart End Tighten. ML brix 80.36 % Boiling end time 110 min. Masc.brix rateTs 0.419 brix°:min. 97 0.071
Legend: End masc. brix 91.10 % Crystal growth cycle time 117.01 min. Evapo.rate Ts 0.484 tonne/min. 98 0.07
Bs = End boiling ML brix 78.83 % Whole cycle time 158.22 min. Crystal size rate 5.478 micron/min. 99 0.068
Ts = End boiling brix 88.16 % Crystal growth rate 1.186 g/m2.min
ML = End boilng CC 50 % Masc. DS
Masc.= Cycle time controller 0.43 End boiling ML NS yield 50 % End CC 60 % Masc. DS
Pan dimensions of BMA design End boiling SS 0.95 % End boiling ML purity 88.01 % End ML NS yield 40 %
End ML purity 85.02 %
II.
Master controller ozein formula Masc. Brix = seed brix + {( Masc.Li - seed level ) / level rate} * brix rate IV.
List
boilling If Masc.Li (input level) = 85.95 % then Masc.brix= 87.00 % 110 Min. 12.53 Min. 0.2 -15
Time Masc. Vol. Level Masc.brix Masc.brix S.G. Masc.quan. Masc. solids Masc.sugar MA One crystal wt. Crystals quan. CC Cr. growth ML sugar ML solids ML water ML brix ML purity ML sucrose ML super sat. ML quan. Evaporation S1 at °C steam St. press. vacuum vac.press. Temp.
min. m3 % % correc. % % tonne tonne tonne micron gm tonne % Mac. Solids g/m2.min tonne tonne tonne % % solubility % g:g tonne total( tonne) % bar a correction bar a correction °C
If time = 79.00 Min. Masc. level 76.73 % then Masc.brix= 85.28 % 75.00 Min. -4.00 Min. -0.1 +10
Time Masc. Vol. Level Masc.brix Masc.brix S.G. Masc.quan. Masc. solids Masc.sugar MA One crystal wt. Crystals quan. CC Cr. growth ML sugar ML solids ML water ML brix ML purity ML sucrose ML super sat. ML quan. Evaporation S1 at °C steam St.press. vacuum vac.press. Temp.
min. m3 % % correc. % % tonne tonne tonne micron gm tonne %Masc. solids g/m2.min tonne tonne tonne % % solubility % g:g tonne total( tonne) % bar a correction bar a correction °C
Alkhaleej Sugar Co. Or SS > 1.2
III.
AKS
If Act. ML brix 81.000 % if Act. ML brix 79.000
Color codes: Calc. I of option A
inputs ML soilids 54.06 T 47.81 T
Rates ML solids 63.72 % 69.07 %
Rates controller CC 36.28 % Masc. solids 35.08 % Masc. solids
ML pu 90.59 % 90.76 %
ML "SS" 1.12 % 0.99 %
sugar Quant. 30.77 T' 25.8316 T
One crystal wt. 0.00 gm 0.00014 gm
MA 533.55 micron 503.31 micron
Cr. growth 9.87 g/m2.min 9.31 g/m2.min
ML S/W 386.20 g % g water 341.44 g % g water
8.17
Energy
balance of
boiling and
tightening
stages
Online tracking of key parameters using the actual measured brix of ML and
Masc. by refractometer and microwave devices.
51.75
mother liqour
85.95
85.28
Boiling time difference
87.00 97.51
Sugar crystallization sequence cycle with parameters set paths using rates method for R4 sugar grade boiling.
Measuring of crystallztion rate's progress using boil up 's master controller "feed liquor rate or level / brix curve"
Boiling time difference
boilling stage
tightening stage
12.68
If the actual time is
87.00 10.04
massecuite
97.47
boiling rate status faster than set rate
52.40 80.517
56.17
If the actual time is
47.31
12.71
79.7468.37
Optin (A) : Level controller
steam press.rate control
407.24
65.08373.141.43 84.83
Option(B) : Time controller
17.47
Calc. II of option B
seeding volumes , levels
Super saturation controller
85.2879.00 61.04 86.351.41
Boiling rate status and correction
Final strike quantities,value
Sugar crystals values
Level/brix curve controller
boling time progress
76.73 23.7273.64
0.00017767
9.57125E-05
boiling rate status
32.43
441.7969.22
38.23542.95
20.90
343.961.08
slower than set rate
1.18 344.1481.55
285.16
vac. press. rate control
77.00
278.65
Self adjustment of the tracked crystallization rate and
key parameters using steam and vacuum loops
288.65
1.37
steam press.rate control vac. press. rate control
77.00
270.16
92.14
1.57
1.37
24.70
1.27
90.29
68.88
0
20
40
60
80
100
70
75
80
85
90
95
0 12 24 37 49 61 73 86 98 110 117
level %brix %
Time minutes
level / brix curve: boiling + tightening stages
mass. brix%
mass. level%
0.60
0.80
1.00
1.20
1.40
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
SS %CC %Masc DS Crystal content and SS figure
Crystal content
supersaturation coefficient
Time minutes
80.00
82.00
84.00
86.00
88.00
90.00
92.00
94.00
96.00
76.00
77.00
78.00
79.00
80.00
81.00
82.00
0 12 24 37 49 61 73 86 98 110 117
ML purity %ML brix %
Time minutes
Mother liquor quality
ML brix %
ML purity %
0.00
10.00
20.00
30.00
40.00
50.00
60.00
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
0 12 24 37 49 61 73 86 98 110 117
crystal weight
Ton
crystal growth
g/m2.minute
Time minutes
Crystal growth figure
Crystal growth
crystal quantity
0
100
200
300
400
500
600
700
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
0 12 24 37 49 61 73 86 98 110 117
MA micronEvapn. ton
Time minutes
Crystal size & evaporation raise
Evaporation ton
Crystal size micron