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- 1. Various terms Cane Primary juice Secondary juice Absolute juice Mixed juice Last mill juice 1
- 2. CANE Raw material is delivered to the cane carrier Raw material for Sugar Industry Absolute juice + fibre = cane 2
- 3. SECONDARYJUICE Diluted juice extracted from the mills in milling tandem Addition of water to the juice 3
- 4. ABSOLUTE JUICE Total juice extracted from the cane in milling tandem Absolute juice = Cane - fibre 4
- 5. Mixed juice Total juice extracted from the mills Mixer of primary juice and secondary juice Juice sent out from the mill house. 5
- 6. Last mill juice Diluted juice extracted by the last mill in milling tandem Imbibition water added – extracted juice. After extraction of the last mill juice the fiberous product is called as Bagasse 6
- 7. RESIDUAL JUICE Juice left in the bagasse If juice left over is in bagasse is more pol in bagasse is more 7
- 8. CLEAR JUICE After clarification juice getting from the clarifier Removal of mud in clarifier – getting clear juice Settling process taken place in clarifier. Clear juice sent to evaporator. 8
- 9. Sulphured juice Addition of so2 gas to the juice So2 gas act as bleaching agent 9
- 10. Un diluted juice With out addition of water in the juice Generally primary juice is undiluted juice. 10
- 11. Muddy juice Residue (mud along with juice) delivered from the clarifier Muddy juice sent to rotary drum vaccum filter for getting filtered juice and filter cake 11
- 12. Syrup Concentrated juice coming out from the evaporator 60 to 80% water evaporated in evaporator Addition of So2 gas in sulphitation tank to the syrup then sent to pans 12
- 13. Various terms : • Massecuite • Molasses • Filter cake • Press cake • Imbibition • Maceration • Bagasse 13
- 14. Massecuite • Mixture of sugar crystals and mother liquor (Molasses) • Different types of massecuites named as Am/c,Bm/c,Cm/c 14
- 15. Molasses • Effluent obtained from the centrifugals • Different types of molasses obtained • A-heavy, B-heavy, C-heavy, A-light, B-light, and C-light molasses 15
- 16. Filter cake Residue delivered from the vacuum filter It is used as a fertilizer Used as cattle feed with the combination of molasses 16
- 17. Press Cake Residue delivered from the filter press Used as manure and fertilizer Used as cattle feed 17
- 18. Imbibition “ Addition of water in the mills to the bagasse” bed before last mill Addition of hot water before the last mill The process in which water or juice is applied to bagasse to enhance the extraction of juice in the next mill Better extraction of juice Hot water temperature should be below 70c 18
- 19. Advantages of hot water Hot water ruptures some cells Sanitary and enzymatic reactions Efficient juice extraction 19
- 20. Advantages of cold water imbibition Reducing gums, waxes and pectin's Good for clarification 20
- 21. Types of imbibition 21 Two types of imbibition 1.simple 2.compound Generally compound imbibition is followed in sugar factory Imbibition water temperature should be around 650c to 750c.
- 22. 22 Imbibition is the process which is generally adopted in all the strength milling tandem in one form or other. Simple Imbibition: The process of adding water alone to the bagasse is known as simple imbibition. Hot water addition between 3 and 4 mill Juice withdrawal by individual mills No recirculation of juice
- 23. Compound Imbibition: Water is added to the bagasse going to the last mill. The juice from last mill is added to the bagasse coming to the penultimate mill and the juice from the penultimate mill is sent to the preceding mill and so on. Depending upon the number of stages this is also known as double, triple, quadruple compound imbibition and so on. 23
- 24. Maceration Raw sugar is produced from juice in sugar cane crushed by a series of mills. To improve the extraction a liquid bath is applied to the cane between mills. This liquid bath, commonly called maceration, consists of water and some of the produced juice. Although the extraction is improved with higher water content in the maceration, the total juice output is restricted by the storage capacity of the plant. The aim of maceration control is to manipulate the added water within the process limits placed by the storage capacity whilst optimising sugar extraction Steeping of bagasse in excess water Generally it is followed in diffusers 24
- 25. Bagasse “ Insoluble matter (fibre) in the cane. After extraction of juice the residue coming out from the last mill Generally used as a fuel in boilers 25
- 26. Sugar Industry can be divided into. 1) Mill House. 2) Boiling House. 26
- 27. Mill House 1) Cane Carriers 2) Cane Kicker 3) Cane Leveler 4) Cane Cutter 5) Cane Shredder 6) Mills 27
- 28. Cane Carrier Carries the cane Distant location to mill house Like a conveyor. 28
- 29. Cane Kicker It kicks the cane It eliminates choking To maintain a uniform level It increases crushing without effecting milling efficiency 29
- 30. Cane leveller It levels the cane in cane carrier It cuts the cane but levels the cane in cane carrier. Leveller comprises a set of knives which cut the whole cane The pitch between the two knives kept three inches apart The clearance between leveller and cane carrier is 5” – 10” 30
- 31. Cane cutter It cuts the cane into pieces. It comprises knives of similar design of cane leveller The pitch between the two knives is 1.5 in The clearance between tip of the knife and cane carrier surface is 3” – 5” 31
- 32. Cane shredder Ruptured the cane. Improves the preparation of cane and preparatory index Capacity increased without effecting extraction It is generally driven by electric motor through flexible coupling 32
- 33. Mills Extraction of juice from the cane. Getting mixed juice. Milling tandem consists of 4to 5 mills Three rollers present in each mill Good preparation of cane results better extraction 33
- 34. 34 Sugar Industry can be divided Mill House (Cane carriers Cane cutters etc.,) Boiling House
- 35. Boiling House 1. Juice weighing scale. 2. Juice heaters 3. L & S Tank. 4. Clarifier. 5. Evaporator 6. Sulphitation Tank 35
- 36. 7. Pans 8. Crystallizer 9. Centrifugal 10. Hopper 11. Grader 36
- 37. Juice weighing scale Weighment of mixed juice. Generally it is a 3 to 5 ton capacity Mixed juice weighment and counting of weighing tank 37
- 38. Juice Heater Heating of the juice. It is a heat exchanger Horizontal and vertical types of juice heaters Mixed Juice heats upto 700C L & S juice heats upto 1000C – 1050C 38
- 39. L & S Tank Mixing tank Mixing of lime, SO2 with mixed juice. To maintain PH 6.8 to 7.2 SO2 gas for neutralizing and bleaching the juice Lime used for PH and settling agent 39
- 40. Clarifier Clarification of the juice Removal of mud Getting clear juice 40
- 41. Evaporator Evaporates water in juice Concentrated juice. Brix will be raised from 150 to 600 brix 60 to 80 % of water in the juice will be evaporated 41
- 42. Sulphitation tank. Addition of SO2 gas. SO2 Gas for bleaching purpose 42
- 43. Pans Crystals preparation Massecuite preparation. Preparation of A, B & C massecuites Massecuite is a mixture of sugar crystals and mother liquor 43
- 44. Crystallizers Growth of the crystals Storage purpose. Air cooled, water cooled, vacuum crystallizers 44
- 45. Centrifugals Separation of crystals and molasses Single curing and double curing Heavy mollasses and light mollasses are obtained B-seed ,C-seed, A-sugar are generated 45
- 46. Hopper Getting dry sugar Removal of slumps. Removal of conglomerates Removal of moisture 46
- 47. Grader Sieves the sugar crystals Uniform size of sugar crystals Grading of Sugar 47
- 48. DOUBLE SULPHITATIONFLOW CHART 48 CANE CARRIER CANE LEVELLER CANE KICKER CANE CUTTER CANE SHREDDER MILLS
- 49. 49 MIXED JUICE WEIGHING SCALE JUICE HEATERS LIME AND SULPHITATION TANK L & S JUICE HEATERS CLARIFIER FROM MILLS LIME SO2 FLOW CHART
- 50. FLOW CHART cont’d 50 EVAPORATER SULPHITATION TANK PANS CRYSTALIZERS FROM CLARIFIER SO2
- 51. FLOW CHART cont’d 51 CENTRIFUGAL HOPPER ELEVATOR GRADER FROM CRYSTALIZERS MOLASSES BAGGIN G
- 52. 52 Preparatory devices Mills Classification Manufacturing of Sugar Sugar Milling section Cane Lime SO2
- 53. 53 Cane Carrier Cane kicker Cane leveller Cane cutter Cane shredder Cane Mills Mixed juice Bagasse Boiler Milling section
- 54. Cane Carrier Carries the cane It is long conveyer belt around to 20 to 30 Mts length It constructed with mild steel framing with two ends chains of the roller type. Divided into 3 portions horizontal, inclined, and the head. 54
- 55. Cane kicker Kicks the cane Uniform level in the carrier Eliminates choking It is increases crushing without effecting milling efficiency. 55
- 56. Cane leveller Levels the cane It helps to maintained uniform level. Leveller comprises a set of knives which cut the whole cane into small pieces 56
- 57. Cane cutter Cuts the cane into fine pieces. It comprises knives of similar design of leveller. The pitch between two knives is 1½’ 57
- 58. Cane shredder Ruptures the cane. It improves preparation of cane and preparation into index. Driven by electric motor through a flexible coupling 58
- 59. Mills Milling tandem consists of 4 – 5 mills 30 – 40 % juice extracted in first mill. Mill consists of a three rollers. Good preparation cane results better extraction. After extraction remaining cane named as bagasse Bagasse used as fuel in boiler. 59
- 60. DOUBLE SULPHITATIONFLOW CHART 60 CANE CARRIER CANE LEVELLER CANE KICKER CANE CUTTER CANE SHREDDER MILLS
- 61. 61 MIXED JUICE WEIGHING SCALE JUICE HEATERS LIME AND SULPHITATION TANK L & S JUICE HEATERS CLARIFIER FROM MILLS LIME SO2 FLOW CHART
- 62. FLOW CHART cont’d 62 EVAPORATER SULPHITATION TANK PANS CRYSTALIZERS FROM CLARIFIER SO2
- 63. FLOW CHART cont’d 63 CENTRIFUGAL HOPPER ELEVATOR GRADER FROM CRYSTALIZERS MOLASSES BAGGIN G
- 64. 64 Juice weighing scale Juice Heater L & S Tank L & S Juice heater Clarifier Clarification section Evaporater Sulphitation tank Syrup V. Filter F.Cake F. Juice J.W. Tank Lime SO2 PH =6.8 – 7.2 700c 1050c SO2 Clear Juice
- 65. Juice weighing scale Juice will be weighed Weighing capacity of tank is 3 to 5tons Weighment and counting of tanks will be taken place 65
- 66. Juice heater • Heating of juice upto 700c • Heating for precipitation purpose 66
- 67. L & S Tank Addition of lime upto PH 6.9 to 7.2 Addition of SO2 gas Bleaches the juice. 67
- 68. L & S Juice heater Heating of the juice upto 1100c 68
- 69. Clarifier Getting clear juice Withdrawal of mud Mud sent to Rotary drum vacuum filter. Getting filter cake, filtered juice 69
- 70. Evaporator Syrup PH should be 3.8 to 4.2 Evaporates water Getting syrup 70
- 71. DOUBLE SULPHITATIONFLOW CHART 71 CANE CARRIER CANE LEVELLER CANE KICKER CANE CUTTER CANE SHREDDER MILLS Bagasse Mixed juice
- 72. 72 MIXED JUICE WEIGHING SCALE JUICE HEATERS LIME AND SULPHITATION TANK L & S JUICE HEATERS CLARIFIER FROM MILLS LIME SO2 FLOW CHART
- 73. FLOW CHART cont’d 73 EVAPORATER SULPHITATION TANK PANS CRYSTALIZERS FROM CLARIFIER SO2
- 74. FLOW CHART cont’d 74 CENTRIFUGAL HOPPER ELEVATOR GRADER FROM CRYSTALIZERS MOLASSES BAGGIN G
- 75. Double sulphitation process Milling section Clarification section Manufacture of sugar 75
- 76. Manufacture section 76 PANS Crystallizers Centrifugals Elevator Godown Hopper Grader Molasses Syrup
- 77. Pans Preparation of massecuite Massecuite is a mixture of crystals and molasses Preparation of A, B, C massecuite 77
- 78. Crystallizers Growth of crystal Storage of massecuite Air cooled , water cooled , vacuum cooled and monovertical crystallizers 78
- 79. Centrifugals Separation of crystals and molasses Single curing and double curing operations A, B , C massecuites cured by batch and continuous machines 79
- 80. Hopper Hot air blower , cold air blower are attached to the hopper It is a vibrating screen Wet sugar converted into dry sugar 80
- 81. Elevator Conveying equipment Lifts sugar into some distant height for easy passage of bagging 81
- 82. Grader Sieving will be taken place Consists of 5 chutes Bold sugar and powdered sugars are recirculated 82
- 83. Godown Bag consists of 100 kgs Sugar bags are stored in place called godown 83
- 84. DOUBLE CARBONATATION FLOW CHART 84 CANE CARRIER CANE LEVELLER CANE KICKER CANE CUTTER CANE SHREDDER MILLS
- 85. 85 MIXED JUICE WEIGHING SCALE JUICE HEATERS LIME AND CARBONATATION TANK L & C JUICE HEATERS CLARIFIER FROM MILLS LIME CO2 FLOW CHART
- 86. FLOW CHART cont’d 86 EVAPORATER CARBONATATION TANK PANS CRYSTALIZERS FROM CLARIFIER CO2
- 87. FLOW CHART cont’d 87 CENTRIFUGAL HOPPER ELEVATOR GRADER FROM CRYSTALIZERS MOLASSES BAGGIN G
- 88. 88 Preparatory devices Mills Classification Manufacturing of Sugar Sugar Milling section Cane Lime CO2
- 89. 89 Cane Carrier Cane kicker Cane leveller Cane cutter Cane shredder Cane Mills Mixed juice Bagasse Boiler Milling section
- 90. Double carbonation process Milling section Clarification section Manufacture of sugar 90
- 91. Cane carrier Carries the cane Long conveyor belt Carrier divided into three portions, horizontal , inclined and the head 91
- 92. Cane kicker All steel construction mounting on the cane carrier and fixing upon the shaft 48 no. of blades welded on it It eliminates chocking Does not cut the cane but helps to maintain uniform level 92
- 93. Cane leveler Levels the cane in cane carrier Leveler comprises of a set of knives which cut the whole cane into small pieces 93
- 94. Cane cutter Cut the cane into fine pieces Comprise knives of similar design of leveller 94
- 95. Cane shredder Cuts the cane into very fine pieces It improves the preparation of cane and preparatory index 95
- 96. Mills Milling tandem consists of 4 or 5 mills 60 to 70% juice extracted in first mill Good preparation of cane results better extraction of the juice 96
- 97. DOUBLE CARBONATATION FLOW CHART 97 CANE CARRIER CANE LEVELLER CANE KICKER CANE CUTTER CANE SHREDDER MILLS
- 98. 98 MIXED JUICE WEIGHING SCALE JUICE HEATERS LIME AND CARBONATATION TANK L & C JUICE HEATERS CLARIFIER FROM MILLS LIME CO2 FLOW CHART
- 99. FLOW CHART cont’d 99 EVAPORATER CARBONATATION TANK PANS CRYSTALIZERS FROM CLARIFIER CO2
- 100. FLOW CHART cont’d 100 CENTRIFUGAL HOPPER ELEVATOR GRADER FROM CRYSTALIZERS MOLASSES BAGGIN G
- 101. Double carbonatation process can be divided into Milling section Clarification section Manufacture of sugar 101
- 102. 102 Juice weighing scale Juice Heater L & C Tank L & C Juice heater Clarifier Clarification section Evaporater Carbonatation tank Syrup V. Filter F.Cake F. Juice J.W. Tank Lime CO2 PH =6.8 – 7.2 700c 1050c CO2 Clear Juice
- 103. Juice weighing scale Weighment tank Generally 3 to 5tons capacity Mixed juice weighed 103
- 104. Juice heater Juice heats up to 70c Horizontal ,vertical types used Vertical type juice heater preferred Heating for precipitation purpose 104
- 105. Lime and carbonatation tank Addition of lime and carbon dioxide Maintain ph of 6.8 to 7.2 Mixed tank Carbon dioxide is used for bleaching and nuteralising purpose 105
- 106. L & C juice heater Juice heats up to 110c Generally two juice heaters used 106
- 107. Clarifier Called rapi Dorr Four compartments consists of 200 to 300 tons capacity Separate juice with drawl and mud with drawls are provided Settling process takes place Mud is sent to vaccum filter for getting filtered juice and filter cake 107
- 108. Evaporator 60 to 80% of water evaporated Concentrated juice called syrup 108
- 109. Carbonatation tank Carbon dioxide gas added in second time For bleaching purpose 109
- 110. DOUBLE CARBONATATION FLOW CHART 110 CANE CARRIER CANE LEVELLER CANE KICKER CANE CUTTER CANE SHREDDER MILLS
- 111. 111 MIXED JUICE WEIGHING SCALE JUICE HEATERS LIME AND CARBONATATION TANK L & C JUICE HEATERS CLARIFIER FROM MILLS LIME CO2 FLOW CHART
- 112. FLOW CHART cont’d 112 EVAPORATER CARBONATATION TANK PANS CRYSTALIZERS FROM CLARIFIER CO2
- 113. FLOW CHART cont’d 113 CENTRIFUGAL HOPPER ELEVATOR GRADER FROM CRYSTALIZERS MOLASSES BAGGIN G
- 114. Double carbonatation process can be divided into Milling section Clarification section Manufacture section 114
- 115. Manufacture section 115 PANS Crystallizers Centrifugals Elevator Godown Hopper Grader Molasses Syrup
- 116. Pans Preparation of massecuite Mixture of crystals and mother liquor is called massecuite Preparation of A, B and C massecuite. 116
- 117. Crystallizers Growth of crystals Acts as a storage tank Different types of crystallizers like air-cooled, water cooled, vaccum cooled and monovertical crystallizers. 117
- 118. Centrifugals Separation of crystals and molasses Single curing and double curing operations Batch type and continuous type centrifugals. Batch type used for A – massecuite curing Continuous type is used for B & C – massecuite curing 118
- 119. Hopper Vibrating screen Hot air blowers and cold air blowers are attached Removing of conglomerates sugar 119
- 120. Grader Sieving taken place 4 or 5 chutes are used Bold grain and powdered sugar is recirculated 120
- 121. Preparatory devices Cane kicker Cane leveler Cane cutter Cane shredder 121
- 122. CANE KICKER All steel construction suitable for mounting on the cane carrier and fixing upon the shaft the required no. of blades welded on it. Total no.of blades around 48 Speed of the kicker about 70r.p.m 122
- 123. CANE LEVELLER It comprises a set of knives which cut the whole cane into small pieces Knives worked with high clearance 4 to 10 inches Pitch between two adjacent knife blades is 3inches 123
- 124. CANE CUTTER It comprises a set of knives which cut the whole cane into fine pieces Clearance of about1” to1.5” Pitch between two sets of knives is 2inches 124
- 125. CANE SHREDDER It driven by an electric motor through a flexible coupling Hammers are fixed to shaft they are mild steel about 8’long 2.5” wide each weighing 1.75to 3.5lb. Fitted at head of the tandem between crusher and cutter 125
- 126. PREPARATORY DEVICES Cane kicker Cane leveler Cane cutter Cane shredder 126
- 127. Function of Cane Kicker It cut the cane and helps to maintain a uniform level It eliminates chocking Increases crushing 127
- 128. Function of Cane Leveler It levels the cane in cane carrier It cuts the whole cane into small pieces 128
- 129. Function of Cane Cutter Depending on TCD of plant cane cutters should be 1 to 3 It cuts the whole cane into fine pices 129
- 130. Function of Cane Shredder It cuts the whole cane into very fine pieces It gives almost the same extraction as a three roller mill It adds both to capacity and extraction 130
- 131. FUNCTIONS OF CANE CRUSHER Assist intensive preparation of cane Extract more juice 131
- 132. TYPES OF CRUSHER Krajewski crusher Splitter or fultron crusher 132
- 133. Krawjewski crusher It has double helical teeth on the circumference of the rollers Improves extraction It has three roll crusher Speed 25% greater than the mills 133
- 134. SPLITTER or FULTRON CRUSHER It has deep circular grooves with spiral horizontal grooves on the roller Improves crushing rate Spiral grooves assist feeding It has three roll crusher 134
- 135. Pitch of the splitter is in conventional design 1 to 1.5inch Increase rate of crushing pitch is usually 3inches It runs at a greater speed 40 to 50% greater speed than the mill Provided sometimes messchaert grooving 135
- 136. FUNCTIONS OF MILLS Three rollers consists a mill 4 to 6 mills consists of a milling tandem Circumferential grooving, messchaert grooving are used for grooving on mill rollers 136
- 137. Grooves is generally used for increasing juice handling capacity First mill at high pressure –for better extraction Last mill is for lowest speed Applying for maximum loads for first and last mill 137
- 138. Hydraulic pressure provided to all mill rollers Handling and conveying between the mill rollers is intercane carrier Imbibition-hot water provided between 3 and 4 mills 60 to 70% extraction taken place at first mill itself 138
- 139. Top halves of roller journal brasses should not rest on the bottom halves while mill is working Mills having higher pressure and lower speed achieve highest performance 139
- 140. CANE CRUSHER Crusher have helical teeth on the circumference Assist intensive preparation Generally it is two roller crusher nowadays it has three roller crusher It assist feeding 140
- 141. It runs at a greater speed 40 to 50% greater speed than mills Sometimes circular grooves and spiral horizontal grooves are used 141
- 142. MILLS Generally it has three rollers Three rollers consists a mill Circumferential grooving,messchaert grooving are generally used Imbibition water used between 3 and 4 mill 142
- 143. Used for crushing and extraction of juice Hydraulic pressure is required for rapid extraction purpose Runs slowly 143
- 144. Grooving Mill rollers were smooth it exists in some countries Advantage with smooth rollers wear and tear in them is much less Moisture content of the bagasse is lowered Mill rollers with fine, medium or coarse grooving adopted in most of the sugar industries 144
- 145. Advantages of grooving Crushing rate is very high Facilitate drainage Break up the bagasse completely Facilitate the extraction of juice 145
- 146. Types of grooving Circumferential grooving Messchaert grooving 146
- 147. Circumferential grooving These are made along the length of the rollers on circumference Groove forms isosceles triangle with an apical angle of 550-600 Pitch of the groove separates the axes of two successive teeth Depth of the groove is slightly less than the pitch 147
- 148. Specifications Angle is-600 Height is 0.85” Pitch is 0.80” Angle of the groove at the top and bottom rollers is identical 148
- 149. Specifications Fine grooves is 5-20mm pitch Medium grooves is 25-50mm pitch Coarse grooves is above 50mm pitch 149
- 150. Advantages of circumferential grooving They increase gripping effect Facilitates drainage of juice Cause better rupturing of the pitch of cane cells 150
- 151. Messchaert grooving Improve gripping effect Provided free drainage Messchaert grooving rendered 2% higher extraction 10 to 15% greater mill capacity 151
- 152. Lesser power consumption Deep circumferential grooves spaced about 4 inches apart Provided on all mill rollers 152
- 153. Specifications Width is1/2 “to 3/16” on the feed rollers Depth 1” and should not deeper than 1.5” Pitch is 3” to 4” on the discharge roller 153
- 154. Good results Apply maximum load on the first and last mill Lesser loads on the intermediate mills 154
- 155. Factors Mills Mill rollers Imbibitions Preparation of cane 155
- 156. Good milling Feed should enter to avoid choking All hydraulics should float freely Top halves of roller journal brasses should not rest on the bottom halves while the mill is working Max. lift of crusher top roller is 1.5 inch to 2 inch 156
- 157. Juice should be free flowly down the entire length of the feed roller in full quantity Juice being discharged with considerable force Proper imbibition Proper maintance 157
- 158. Regrooving according to life of the roller Proper lubrication of cane carrier and inter cane carrier No vibration or undue noise from mills 158
- 159. Causes of vibration Insufficiently strong foundation Fault alignment Defective lubrication system 159