Bahir Dar University: Design of Sugar Production Plant From Sugarcane

Design of sugar production plant from sugarcane
Bahir Dar University
Bahir Dar Institute Of Technology
Faculty of Mechanical and Industrial Engineering
Agro machinery and processing II
Project I
TITLE : design of sugar production plant from sugar cane

Group Name .........................................................................................id No.
1. Haimanot Yeserah ----------------------------------------------------------0701871
2. Chanie Abebe -----------------------------------------------------------------0701540
3. Tiruneh --------------------------------------------------------------------------------
4. Biniyam Tariku------------------------------------------------------------ 0701505
5. Mulusew ------------------------------------------------------------------------------
Submitted to: Mr.Tsega Y.& Wondyifrew
Submission date Jan.30/2018
Agro machinery design stream Page 1

Declaration
We are declare that this paper presents agro machinery and processing II projects on “design
of sugar production plat from sugar cane” is uniquely prepared by us for the fulfillment of
semester course by reviewing different reference books and journals.
Name ID No. Signature Date
1. Haimanot yeserah…………0701871 ------------------ ---------------

2. Biniyam Tariku……………0701505 ------------------- ----------------
3. Chanie Abebe……….…-….0701540 ------------------- ---------------
4. Mulusew mekuriaw……..…0702160 ------------------- ---------------
5. Tiruneh …………………… -------------------- ---------------
Approved by:
Signature Date
1. Mr. Wondyifrew ---------------------- ---------------------

2. Mr. Tsega.Y ---------------------- ---------------------


Table of Contents
Declaration ................................................................................................................................. 2
1. Introduction ........................................................................................................................ 7
1.1. Background ..................................................................................................................... 7
1.2. Proposed operations .................................................................................................. 10
1.2.1. Sugar cane farming ................................................................................................ 10
1.2.2. Sugarcane transportation ........................................................................................ 11
1.2.3. Cane weighing ....................................................................................................... 12
1.2.4. Sugarcane processing ............................................................................................. 12
1.2.5. Cleaning and grinding ............................................................................................ 13
1.2.6. Juicing .................................................................................................................... 13
1.2.7. Clarification ........................................................................................................... 13
1.2.8. Evaporation ............................................................................................................ 14
1.2.9. Crystallization ........................................................................................................ 14
1.3. Energy supply ............................................................................................................ 16
1.4. Water supply .............................................................................................................. 16
1.5. Problem statement ..................................................................................................... 17
1.6. Objective ................................................................................................................... 17
1.6.1. Main objective ....................................................................................................... 17
1.6.2. Specific objectives ................................................................................................. 17
Chapter two .............................................................................................................................. 18
2. Literature review .............................................................................................................. 18
2.1. Definition of sugar .................................................................................................... 18
2.2. Properties of sugar ..................................................................................................... 18
2.3. The sugar cycle.......................................................................................................... 18
2.4. Sugar Formation in Cane........................................................................................... 19
Chapter three ............................................................................................................................ 21
3. Process ............................................................................................................................. 21
3.1 flow sheet ....................................................................................................................... 21
3.2. Production process ........................................................................................................ 21
3.2.1. Harvesting .................................................................................................................. 21
3.2.2. Cane Sugar Production .............................................................................................. 22
3.2.3. Refined Sugar Production .......................................................................................... 25
Chapter four ............................................................................................................................. 30
4. Design of plant equipment’s ............................................................................................ 30
4.1. Design of sugar mill .................................................................................................. 30
4.2. Mill Bearings ................................................................................................................ 38
4.2. Evaporator selection .................................................................................................. 40
4.3. Crystallization ........................................................................................................... 42
4.4. Wet scrubbers (washing) ........................................................................................... 42
4.5. Crushing and grinding equipment ............................................................................. 43
4.6. Pump selection .......................................................................................................... 43
Chapter five .............................................................................................................................. 45
5. Plant layout and utilities................................................................................................... 45
5.1. Plant layout ................................................................................................................ 45
5.2. Utilities ...................................................................................................................... 48
Chapter six ............................................................................................................................... 51
6. Conclusion and recommendation ..................................................................................... 51
6.1. Conclusion................................................................................................................. 51
6.2. Recommendation ....................................................................................................... 51
REFRENCES ........................................................................................................................... 53


1. Introduction
Sugarcane processing is focused on the production of cane sugar from sugarcane. Other
products of the processing include bagasse, molasses, and filter cake. Bagasse, the residual
woody fiber of the cane, is used for several purposes: fuel for the boilers and lime kilns,
production of numerous paper and paperboard products and reconstituted panel board,
agricultural mulch, and as a raw material for production of chemicals. Bagasse and bagasse
residue from chemical production are categorized by the sugar industry and government
regulators as a co-product of cane sugar production. Bagasse and bagasse residue are
primarily used as a fuel source for the boilers in the generation of process steam. Thus,
bagasse is a renewable resource. Dried filter cake is used as an animal feed supplement,
fertilizer, and source of sugarcane wax. Molasses is produced in two forms: inedible for
humans (blackstrap) or as edible syrup. Blackstrap molasses is used primarily as an animal
feed additive but also used to produce ethanol, compressed yeast, citric acid, and rum. Edible
molasses syrups are often blends with maple syrup, invert sugars, or corn syrup.
The Ethiopian Government has strategic plan to expand and outsourcing the sugar cane
plantation and on farmers’ land particularly in lowland areas where rivers for irrigation are
available and agro climatic condition is favorable. Though it is believed that the development
of sugarcane production linked to Sugar factories development improves the living standard
of communities, the sought system in place may cause injustice and inequality as the expense
of the others stakeholder which can bring displacement, unfair compensation and less
income(FAO 2013 Working paper No.37)
1.1. Background
The Sugar cane plantation as well as the processing factories in Ethiopian have number of
contribution in reducing poverty through creation of job opportunities for both rural and
urban population where unemployment is a rampant problem in the country, contributes on
Gross National Product/ GNP/, producing ethanol and molasses as by product which directly
and indirectly substitutes a part petroleum importation and generate foreign currency as by
product used for fattening animals (FAO, 2013 Working paper No.37)

Sugar production has started with Awash River valley development in Wonji and Methera in
1954 and 1970 respectively. The Wonji was established by Dutch Company, HVA (Handlers
Vereenging Amsterdam) as joint venture between this company and the Ethiopian
government. The production of the firm has continued until the failure of the Imperial
government in 1974 as a joint venture. Since the imperial government failed, the sugar
factories have been nationalized and continued until now as a state property.
Ethiopia is endowed with large areas of suitable low lands, rivers and conducive climate for
sugar cane growth. The climate and soil types in the country have both proven to be highly
conducive for sugar cane growth and productivity. Various pre- feasibility and feasibility
studies of sugar projects conducted by the Ethiopian Sugar Industry Support Center Share
Company (ESISC) have indicated that many potential sites at the main river basins are
suitable for sugar cane plantation. These include 303,500 hectares of already identified
suitable net areas in 7 sites. However, the total area developed for the production of sugar
cane in the country is only about 8% of the total identified suitable areas.
Sugar has been defined by chemists as a substance which is soluble in water, has a sweet taste
and is capable of fermentation. The culture of sugar started at a very early period, sugar was
known in India and the Orient long before the Christian era. The Greeks and Romans knew of
the existence of sugar cane and probably of crystallized sugar, but the first positive evidence
of sugar in solid form dates from Persia about A.D. 500. So, in Sanscrit, sugar is called
sarKara and the word candy is also derived from the Sanscrit kanda. The practice of
sweetened food also dates from an early period in world history and antedates the knowledge
of sugar. In Northern Europe sugar came into use as an article of food during the time of the
Crusaders, but does not appear to have been generally known prior to the middle of the
thirteenth century. In 1148 the sugar cane, which had been brought from Asia, was
extensively cultivated in Cyprus. About 1505 it was introduced from Cyprus to the West
Indians. The discovery of America and the introduction of sugar cane in the new areas
resulted in the rapid deve10pment of sugar manufacture. About 1600 the production of raw
sugar in the West Indies and tropical America was said to be the largest industry in the world
of that day. Sugar refining is said to have been invented by a Venetian, around 1550, who

probably got the idea from China, where the art of refining sugar and making sugar loaves
had been practiced for centuries. The first Englishman who described the method of
crystallizing and purifying sugar was called Bartholomew, but the methods used were crude
until the introduction of vacuum boiling and de colorization by bone char around 1802. So,
many sugar refineries sprang up in the seaports of Great Britain and Western Europe. In 1605
the suggestion to use beets for making sugar was made by Oliver de Serres. He wrote a book
on "Art of agriculture and management of land" in which he stated: "The beet root when
boiled yields a juice similar to syrup of sugar, beautiful to look at because of its vermillion
colour". A German chemist, named Andrea Marggraf, made sugar from beet roots in 1747,
and some fifty years later one of his pupils, Franz Karl Achard, established a factory for
commercial manufacture of beet sugar. It was not, however, until the English blockade
against cane sugar imports and the impetus given by the Emperor Napoleon the First in 1811
to the growth of the sugar beet and to the discovery of the best methods to obtain the juice
and to extract the sugar from it, that the manufacture of beet sugar became a practical
proposition. Starting from 1830 the rise of beet sugar manufacturing was so rapid that within
50 years as much beet sugar as cane sugar was produced in the world. The overall world
sugar production was for 1982 estimated at 98.5 million tones /year, divided into: world cane
sugar production: 61.9 million tones/year, world beet sugar production: 36.6million
tones/year.
During the year 2011-2012, world sugar production and consumption were 172 million tones
and 159 million tons respectively (Food and Agriculture Organization (FAO), 2012). Sugar is
produced in temperate climates using sugar beet while in tropical climates, it is produced
from sugarcane. About 72 per cent of world sugar produced and over 80 per cent of sugar
traded is cane-sugar. Beet-sugar is mainly produced by the European Union (EU), while
cane-sugar is mainly produced in Brazil, India, Australia, China and Thailand (Wagner,
2007). According to the United States Department of Agriculture (USDA) (2012), nearly 50
per cent of the global sugar production comes from three major producing countries, namely,
Brazil, India and the EU. Hence, sugar is one of the most volatile commodities in the world
trade in terms of price and production.

1.2. Proposed operations
The flow chart begins with the growing of sugarcane by farmers which is later harvested for
two purposes, namely for;
a) production of sugar for the market, and
b) Use of cane as seed for subsequent plantings.
The sugar cane usually consists of 70% water, 14 - 16% fiber, 10-13% sucrose and 2.7%
soluble impurities. Studies have shown that only 10% of the sugar cane will eventually be
processed into commercial sugar.
Figure 1.1 sugar processing operation

1. Sugar cane farming
 Land preparation
 Sugarcane planting
 Cane weeding & harvesting
2. Sugarcane transport
 Sugarcane loading
 Sugarcane transportation and
3. Sugar processing
 Crushing
 Juicing
 Evaporation
 Crystallization
4. Waste management: Management of molasses, bagasse, filter mud & packaging waste
material
1.2.1. Sugar cane farming
Sugar cane supply for the sugar factory will be depending on out-grower farmers in the

Counties. It is expected that sugarcane growing for supply to the factory will be undertaken
as a monoculture with no crop breaks. Some maize farmers in the country are shifting to
sugar cane farming and other cash crops due to poor prices and unaffordable inputs. The
sugar farmers will use the mechanical land preparation approach to prepare their land for
sugarcane cultivation. The cane varieties to be grown by the farmers in the proposed Mill will
be determined
by the agronomist. The sugar cane cultivation will mainly rely on rain-fed cultivation.
Sugarcane weeding will be done both manually and mechanically by use of tractors. Disease
control in the sugar farms will be undertaken by use of herbicides. 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.
1.2.2. Sugarcane transportation
The sugar factory will process very large ton of cane, which will be obtained from individual
out growers and co-operative societies. Sugarcane delivery will be undertaken factory tractors
and contractors if necessary. Some farmers may also have the means to deliver the cane to
Sugar factory themselves. The key cane delivery will be undertaken along the existing road
network with the country road as the main artery. This is a gravel road which is usually
impassable during rainy seasons. Sugarcane farmers will be paid on the basis of the tonnage
of cane delivered to the factory. Mature cane will be cut manually through hand cutting. Hand
cutting is one of the most common method and key source of employment in Ethiopia and
other country. The cane will be cut at ground level, the leaves removed and the top trimmed
by cutting off the last mature joint. The cane will then be loaded and transported to the
factory by use of tractors. The remnant biomass will be retained in the farm as part of internal
manure. The tractors are the best option because they can maneuver their way along the
country gravel road which is usually impassable during rainy seasons .

1.2.3. Cane weighing
The sugar cane will initially be delivered to the factory premises initially by tractors due to
the state of the road and in future by trucks and trailers. The vehicles will enter the factory
premises at a gate to be opened immediately at the edge of the proposed site off the road and
then proceed to the weighbridge where the cane weight will be recorded by weighbridge
clerks. The cane-weighing will be done as transparently as possible using a modern and well
calibrated weighbridge. It will then be off loaded at the cane yard using gantry cranes, while
care is taken to ensure that the trash and other extraneous materials are removed from the
cane, before loading the product on the cane table awaiting paddling. During this stage
maximum care will be taken to ensure that cane is processed within 48hrs after harvesting in
order to ensure that it is in a fresh state. Laboratory tests will be carried out to establish brix,
pol, among others before cane is offloaded onto the mill. Old and fibrous cane will be
rejected at the cane yard.
1.2.4. Sugarcane processing
Raw sugarcane from the farm is usually refined in a sugar factory for human consumption.
the process flow hart in sugar processing with the key activities as; a) cane cleaning and
grinding, b) juicing, c) clarifying, d) evaporation, and e) crystallization. The main inputs in
sugarcane processing include; a) raw sugar, b) water, c) sulphur, c) limestone (calcium
carbonate), and d) energy.
Figure1.2. the process flowchart in sugar processing

1.2.5. Cleaning and grinding
The sugar cane stalks will be delivered, weighed and then transferred by an auxiliary carrier
or conveyor belt to the cane shredder trap (magnetic iron separator) where any metallic
materials, which can damage the crushers, will be trapped. It will then proceed to the various
preparatory devices and the prepared cane delivered into elevators/belt conveyor to feed in to
the first mill of the milling train. The milling train continues to extract the maximum sucrose
from the prepared cane with addition of hot water spray in last two mill which called
compound imbibition system. After final extraction of sucrose from the last mill the bagasse
is discharge into bagasse elevator leading to boiler/bagasse storage. The bagasse will be
properly secured in a well prepared bagasse holding area. During milling operation, the
spillage of sucrose rich juice will be controlled in order to avoid the release of high BOD and
COD effluent into the environment. This will be addressed by washing of the cane before
crushing under a closed loop system.
1.2.6. Juicing
The extracted juice is called primary and secondary juice. The primary and secondary juice
mixed in the mixed raw juice tank and pumped to rotary juice screen to remove cush-cush
from the juice. The strained juice is pumped to process through mass flow meter for juice
treatment. This juice is called mixed juice. The mixed juice is taken into primary heating
following by liming and secondary heating. After secondary heating the juice is flashed in its
flash tower for de-aeration and then reaches the juice clarifier to separate clear juice and
solids. To speed up the settling rate suitable flocculent is added around 3 ppm before entry to
juice clarifier. The clear juice from top layer of each compartment of the clarifier is drawn to
falling film evaporators to concentrate this thin juice from 12 brix to 65 brix. The mud from
bottom of the each compartment taken into the rotary vacuum filters to extract maximum
sucrose from this cloudy muddy juice and filtered residual is called filter mud. The extracted
juice is further send to defecation tank to follow the further treatment along with secondary
juice.
1.2.7. Clarification
In the Juice clarification for producing raw sugar the major clarification chemical used only is

milk of lime. This is added in lime defecation vessel under controlled automation to ensure
required level of pH of the final outlet juice. This limed juice is heated up to 102 C before
flash tower. This will be the common juice heating practice in the factory involving the
clarification of sugarcane juice for pure syrup production. The clarification process is
required in order to reduce particles in sugarcane juice before concentrating in evaporator to
produce pure syrup. This will involve the addition of carbon dioxide (CO2) and lime solution
to the primary heated juice to forms calcium carbonate (CaCO3) which will precipitates non-
sugar debris (fats, gums and wax) from the juice. This precipitate is called filter mud and it
will be separated from the juice by in rotary vacuum filter. The juice will then be filtered to
remove any remaining impurities. The chemical reaction, which occurs under controlled
conditions and as the calcium carbonate is precipitated, may result in some organic impurities
such as gums, amino acids and colour components which will be removed from the sugar
syrup.
1.2.8. Evaporation
The clear juice will then be concentrated into syrup by boiling using steam in a process called
evaporation. The main aim of this is water removal by multiple effect evaporation. Multiple
effect evaporation is the scheme where the juice is boiled in series 4 or 5 vessels, with the
steam being fed to vessel 1 only. The vapour from vessel 1 will boil the juice in vessel 2 and
the vapour from 2 will boil the juice in 3, and so on until vapour from the final vessel goes to
waste and the sugar is crystallized in vacuum pans. In this stage, some smoke will be
produced at the factory in the form of a mixture of particulate matter and gases such as
carbon dioxide and others like, H2S and CO. The effect of this shall however, be minimized
by discharging it using high elevation steel chimney constructed to an appropriate height of
not less than 5m as recommended by the Factories Act.
1.2.9. Crystallization
Crystallization of sugar is one of the most vital step in sugar milling which involves the
formation of solid crystals. In the crystallization stage, the syrup will be boiled at low
temperatures under partial vacuum and some sugar seeds added which will cause the
development and growth of sugar crystals and the outcome is called massecuite. This will
involve the feeding of pulverized sugar into the pan as the liquid evaporates, causing the
formation of a thick mass of crystals. The crystals will then be spun dry in a centrifuge to
produce crystal sugar. Crystallization is not only a means to convert the sucrose to a more
usable form, but also an important refining step since pure sucrose tends to crystallize out of
the solution, leaving most of the impurities in the associated syrup. The process will be
undertaken under reduced pressure of 75- 90kPa to allow a reduced boiling temperature (60-
70◦c) in order to avoid the formation of colored compounds. The vacuum condition will be
achieved by use of an air pump and vapour contact condenser. At this stage, there is a
likelihood of the release of some particulate matter to the environment but this will be
controlled as much as possible. The packaging of milled sugar may also involve emission of
particulate matter and use of non-biodegradable packaging (polythene) which is harmful to
the environment especially at the point of use.
Figure 2- 3: Multiple effect evaporation

1.3. Energy supply
The sugar factory will depend heavily on the bagasse for boiler and furnace start-up
operations with minimal use of wood to avoid deforestation. The amount of bagasse produced
by the factory is estimated to be adequate to provide the amount of heat required for the
boilers. Bagasse will constitute the main source of fuel for processing, with its combustion
being undertaken in a closed environment thus making it possible for complete combustion
for higher energy saving and minimal aerial discharges. In the future, the live steam
generated from the baggase fired boilers will be fed in to a steam turbine for electricity
generation to meet the factory needs with any excess distributed to other uses through out the
country Power. It is expected that power generated from the steam turbine alternator will be
sufficient to meet the entire electric power requirement for the total operation as well total
lighting requirements.
1.4. Water supply

The factory will require significant volumes of water in order to sustain various factory
processes as shown in Figure 2-4. During initial startup of milling, in the absence of hot
condensate from cane, the maximum water intake shall be around 7500 m3/day after which
the volume will reduce significantly. The installation of the water pumping station will be
undertaken carefully to avoid the disturbance of the riverine wetland.

1.5. Problem statement
In the current situation, consumption of sugar is increasing in Ethiopia. But when we

compared sugar production, it is still low level. Due to this reason, insufficient supply of
sugar is became current problem issue in our country. As a result, sugar production should be
given attention and maximized. This implies that insufficient supply of sugar will be avoided
if there is cooperative effort supply from society, government and Nongovernmental
organizations. This problem initiated us to do our project on sugar production.
1.6. Objective
1.6.1. Main objective
The main objective of this project is to design the layout and production process of sugar
production plant from cane sugar
1.6.2. Specific objectives
The specific objectives of this project are:
 To identify materials and components required in sugar production.
 To understand production process and flow sheets of sugar producing plant.
 To know factors affecting sugar production.
 To design the equipment’s used in sugar production plant
 To identify the utilities and plant layout of the sugar factory
 To be familiar in sugar production processes to increase sugar quality and quantity for
the future.

Chapter two
2. Literature review
2.1. Definition of sugar
Sucrose is common table sugar obtained from sugar cane and sugar beets. The chemical
Formula C12H22O11 which does not reduce Tollens or Feling’s reagents is determined by
the stereochemistry of the D-Glucoside and D-Fructroside linkage to form sucrose. The
results of X-ray studies and the Synthesis of +sucrose lead to the conclusion that (+) Sucrose
is a beta Dfructoside and an alpha D-Glucoside.
2.2. Properties of sugar
Sucrose, C12H22o11 is a disaccharide composed of α-glucose and β-fructose. lts use was at
first restricted to the wealthy, owing to its early high price, but ancient Chinese doctors and
those of other early people described it as a medicinal. Today our syrups, elixirs, and pills are
still compounded with sugar. Sucrose is said to be the first pure carbohydrate to separate from
the photosynthetic process. As such, it is the progenitor of all plant and animal substances
and the origin of coal and petroleum, our principal sources of heat and power. Refined sugar,
whether of cane or beet origin, is the organic substance produced in pure form in the greatest
volume, and is one of the purest of all substances produced in considerable volume. lts
analysis is, approximately: sucrose, 99.90%: invert sugar, 0.01%: asb (inorganic material),
0.03%: moisture, 0.03%: organic material, 0.03%. There is a slight variation in the non-
sucrose components between the canes refined a beet re-refined, but this is relatively
insignificant. It is the material of greatest food value economically, in the since that an acre
devoted to the cultivation of sugar, whether beet or cane, is capable of producing more
calories than any other food erop. It is the cheapest source of calories known. However, sugar
is all energy (Joules) and contains no proteins, virtually no minerals, and no vitamins, which
must come from supplementary diet materials.
2.3. The sugar cycle

When man consumes sugar his body needs oxygen to convert his basic fuel, blood sugar, into
energy and in the course of this reaction the body liberates carbon dioxide, which is exhaled,
whereas the plant inhales carbon dioxide in order to live and grow and exhales oxygen. The
process of sugar consumption is thus the reverse of sugar formation and is represented by the
equation:
C12H22O11 + 12O2 11 H2O + 12 CO 2+ (energy).
(Enzyme)
An enzyme is a natural organism which enables such changes as digestion to take place.
Sugar thus moves in a natural cycle, beginning with its formation in plants and completing its
course with its consumption and use for growth, the renewing of cells, and providing energy
for all our activities. Sugar is made by most plants but not usually in sufficient quantities to
be harvested commercially. It is obtained from the maple tree in Canada, from sorghum, from
certain palm trees and from the carob tree, but the two principal sources are:
 Sugar cane
 Sugar beets
While these plants provide sugar, their harvesting is not as simple as that for example of
wheat, barley or fruit. The sugar has to be extracted using technology which has been
developed over centuries.
2.4. Sugar Formation in Cane
Sugar cane is like a huge grass which grows perennially in tropical areas. It reaches a height
of 4 to 5 meters. The top of the cane is crowned by an erect tuft of short green leaves where
the process of photosynthesis takes place and the sugar is formed in the chloroplasts from
carbon dioxide in the air and water in the plant. The stem is divided into sections of 15 to 25
centimeters by 'nodes' or knots from which grow buds, concealed by long, drooping leaves.
The outside of the stalk of mature cane is hard and golden yellow in color, with spots of red
and green, and inside it are softer fibers of vascular bundles. The vascular bundles are tubular
channels within the stem which allow for the passage of plant food, dissolved in water, from

the roots to the leaves, and also the movement of the products of photosynthesis from the
leaves to the stalk for storage. The bud, situated at the node, shows clearly. If a cutting is
taken, including the bud, and planted in moist soil at a temperature of 19 to 22 0 C three
major growth processes begin.
First, the root primordia develop short 'sett' roots, enabling the plant to anchor itself in the
ground and to absorb water. Secondly a shoot is initiated in the bud. Thirdly, a permanent
root system emerges from the base of the bud this development uses the stored sugar for food
and energy until such time as the shoot can form leaves and the process of photosynthesis can
begin in the growing plant. When the plant is established, the 'sett' roots become defunct and
decay.
Cane does not need to be planted each year, for after it is cut the roots remain, and from
these sprout fresh shoots which flourish and grow, providing the text year's crop. This
process is called 'ratooning'. Cane usually contains 10-15% of sugar and a cane field will
yield anything from 45 to 90 tons of sugar cane/ha with is equivalent 4-.5 to 12 tons of sugar
per hectare.

Chapter three
3. Process
3.1 flow sheet
3.2. Production process
Sugarcane is a tropical grass belonging to the same family as sorghum, Johnson grass, and
corn (maize). Modern sugarcane is a complex hybrid of two or more of the five species of the
genus Saccharin. The production of cane sugar from sugarcane has three major steps:
harvesting, cane sugar production, and refined sugar production.
3.2.1. Harvesting
The primary goal of harvesting is to deliver to the processing mill good quality sugarcane
stalks with a minimum of trash. During harvesting, the cane tops and leaves are removed
because they contain little sucrose but are high in starch and reducing sugars, which reduces
sugar yields. Cane leaves also have a high silica content which contributes to mill roll wear.
Cane tops and leaves can be removed either by hand trimming after harvesting or by burning
the green cane prior to harvesting. Hand cutting is the most common harvesting method
throughout the world but some locations (e.g., Florida, Louisiana, and Hawaii) have used
mechanical harvesters for several years. After cutting, the cane is loaded by hand, mechanical

grab loaders, or continuous loaders. Cane is transported to the mills using trailers, trucks,
railcars, or barges, depending upon the relative location of the cane fields and the processing
plants. When the cane is cut, rapid deterioration of the cane begins by enzyme, chemical, and
microbial processes. Therefore, unlike sugar beets, sugarcane cannot be stored for later
processing without excessive deterioration of the sucrose content; the cane must be processed
within a short time after cutting.
3.2.2. Cane Sugar Production
A simplified process flow diagram for a typical cane sugar production plant is shown in
Figure 2-1. The cane is received at the mill and prepared for extraction of the juice. At the
mill, the cane is mechanically unloaded and placed in a large pile. Prior to milling, the cane is
cleaned, usually with high pressure water; a dry cleaning process is used in Hawaii. The
milling process occurs in two steps: breaking the hard structure of the cane and grinding the
cane. Breaking the cane uses rev olving knives, shredders, crushers, or a combination of these
processes. For the grinding, or milling, of the crushed cane, a three-roller mill is most
commonly used although some mills consist of four, five, or six rollers in a single mill.
Multiple sets of mills are used with combinations of 15 to 18 rollers being predominant.
Conveyors transport the crushed cane from one mill to the next. Imbibition is the process in
which water or juice is applied to the crushed cane to enhance the extraction of the juice at
the next mill. The common procedure is to send the juice from the crusher and the first two
mills for further processing. In imbibition, water or juice from other processing areas is
introduced into the last mill and transferred from mill to mill towards the first two mills while
the crushed cane travels from the first to the last mill. The crushed cane exiting the last mill is
called bagasse. A diffusion process, consisting of treating the crushed or shredded cane with
water to extract the juice, pressing the cane, and treating the press water, is used in some
processing facilities but handling the large amounts of press water is a major problem.
The juice from the mills or diffuser is strained to remove large particles and then clarified. In
raw sugar production, clarification is done almost exclusively with heat and lime (as milk of
lime or lime saccharate); small quantities of soluble phosphate also may be added. The lime
is added to neutralize the organic acids and the temperature of the juice rose to about 95EC

(200EF). A heavy precipitate forms which is separated from the juice in the clarifier. The
phosphate acts as a flocculating agent. There are many different forms of clarifiers, many
variations of the clarification process, and many different additives used as clarification aides.
The insoluble particulate mass, called "mud", is separated from the limed juice by gravity or
centrifuge. Clarified juice goes to the evaporators without additional treatment. The mud is
filtered and the filter cake is washed with water; the wash water is added to the juice
recovered during filtration. These juices may require further clarification before going to the
evaporators.
Evaporation is performed in two stages: initially in an evaporator station to concentrate the

juice and then in vacuum pans to crystallize the sugar. The clarified juice is passed through
heat exchangers to preheat the juice and then to the evaporator stations. Evaporator stations
consist of a series of evaporators, termed multiple-effect evaporators. This process typically
uses a series of five evaporators. Steam from large boilers is used to heat the first evaporator,
and the steam from the water evaporated in the first evaporator is used to heat the second
evaporator. This heat transfer process continues through the five evaporators and as the
temperature decreases (due to heat loss) from evaporator to evaporator, the pressure inside
each evaporator also decreases which allows the juice to boil at the lower temperatures in the
subsequent evaporator. Some steam is released from the first three evaporators, and this
steam is used in various process heaters in the plant. The evaporator station in raw sugar
manufacture typically produces syrup with about 65 percent solids and 35 percent water.
Following evaporation, the syrup is clarified by adding lime, phosphoric acid, and a polymer
flocculent, aerated, and filtered in the clarifier. From the clarifier, the syrup goes to the
vacuum pans for crystallization.
Crystallization of the sugar starts in the vacuum pans, whose function is to produce sugar
crystals from the syrup. There are several pan designs, each with different models and sizes.
Pan boiling may be batch or continuous processes; batch systems use a sequence of multiple
(2 or 3) pan boiling. In the pan boiling process, the syrup is evaporated until it reaches the
super saturation stage. At this point, the crystallization process is initiated by "seeding" or
"shocking" the solution. When the volume of the mixture of liquor and crystals, known as

massecuite, reaches the capacity of the pan, the evaporation is allowed to proceed until the
final massecuite is formed. At this point, the contents of the vacuum pans (called "strike") are
discharged to the crystallizer. Some mills seed the vacuum pans with isopropyl alcohol and
ground sugar (or other similar seeding agent) rather than with crystals from the process. The
function of the crystallizer is to maximize the sugar crystal removal from the massecuite.
From the crystallizer, the massecuite (A massecuite) is transferred to high-speed centrifugal
machines (centrifugal), in which the mother liquor (termed "molasses") is centrifuged to the
outer shell and the crystals remain in the inner centrifugal basket. The crystals are washed
with water and the wash water centrifuged from the crystals.
The liquor (A molasses) from the first centrifugal is returned to a vacuum pan and reboiled to
yield a second massecuite (B massecuite), that in turn yields a second batch of crystals. The B
massecuite is transferred to the crystallizer and then to the centrifugal, and the cane sugar is
separated from the molasses. This cane sugar is combined with the first crop of crystals. The
molasses from the second boiling (B molasses) is of much lower purity than the first
molasses. It is reboiled to form a low grade massecuite (C massecuite) which goes to a
crystallizer and then to a centrifugal. This low-grade cane sugar is mingled with syrup and
used in the vacuum pans as a "seeding" solution. The final molasses from the third stage
(blackstrap) is a heavy, viscous material used primarily as a supplement in cattle feed. The
cane sugar from the combined A and B masscults is dried in fluidized bed or spouted bed
driers and cooled. After cooling, the cane sugar is transferred to packing bins and then sent to
bulk storage; cane sugar is bagged in some areas. Cane sugar is then generally bulk loaded to
trucks, railcars, or barges. A large bulk sugar carrier is used to transport cane sugar from
Hawaii to the U.S. mainland.

3.2.3. Refined Sugar Production
A simplified process flow diagram for refined sugar production is shown in Figure 2-2. Cane
sugar is refined either at the same location where it was produced as part of an integrated
facility or at separate raw sugar refineries. The majority of the impurities in cane sugar are
contained in a thin molasses film adhering to the sugar crystal surface; only very small
quantities are occluded in the crystal. The initial step in cane sugar refining is washing the
sugar, called affination, to remove the molasses film. The washing involves mingling the
crystals with warm, almost saturated syrup to loosen the film. The crystals are then separated
from the syrup in a centrifugal and washed (in the centrifugal) with hot water or high purity
sweet water. If the refinery is part of the cane sugar production facility, the cane sugar may
be washed more heavily in previous steps and the affination step omitted.

The washed raw sugar is sent to a premelter and then to a melter, where it is mixed with high
purity sweet waters from other refinery steps and is steam heated. The resultant syrup is
passed through a screen to remove any particulate in the syrup and sent to the clarification
step. The syrup from the crystal washing, called affination syrup, is transferred to a re melt
processing station or reused in the raw sugar washing step. In the re melt station, the syrup
volume is reduced to form the massecuite and the sugar crystals are separated from the syrup.
The separated liquor is blackstrap molasses. The sugar crystals are sent to a melter and then
to the clarification step. Sugar liquors from the melter are filtered to remove course material
and then sent to the clarification step. Two clarification methods are commonly used:
pressure filtration and chemical treatment. Because pressure filtration is labor intensive and
costly, chemical clarification is the preferred method. Two chemical methods are commonly
used: phosphatation and carbonation; both processes require the addition of lime. The
phosphatation uses phosphoric acid, lime (as lime sucrate to increase solubility), and
polyacrylamide flocculent to produce a calcium phosphate flock. Air flotation is usually used
to separate the floc from the liquor and the floc skimmed from the liquor surface.
Carbonation consists of adding lime to the raw melter liquid and then bubbling carbon
dioxide (CO2) through the liquor to produce a voluminous calcium carbonate precipitate. The
source of CO2 is boiler flue gas, which contains about 12 percent CO2 by volume. For oil or
coal-fired boilers, the flue gas is scrubbed twice (water and Na2CO3 solution) to remove
sulfur compounds; for bagasse-fired boilers, only water scrubbing is used. The clarifier
systems yield press cakes, muds, or scums which are treated to remove entrapped sugar, and
then sent to disposal.
Clarification and filtration remove suspended solids and colloidal matter; decolonization
removes soluble impurities by adsorption. Carbonaceous adsorbents made from naturally
occurring materials and synthetic resins are used as media for decolonization. The two most
common adsorbents are granular activated carbon and bone char, manufactured from
degreased cattle bones. Powdered carbon and synthetic resins are less commonly used. Bone
char or activated carbon is used in either fixed or moving bed systems. With fixed beds, the
sugar liquor is cycled through a series of beds until the final liquor color reaches a

predetermined level. At the end of the cycle, liquor remaining on the bed is removed by
flushing the bed with water (termed "sweetening off"). A moving bed system operates
continuously rather than cyclic and the adsorbent moves countercurrent to the flow of the
sugar liquor. Spent adsorbent is removed from the bed, regenerated (dried in kilns), and the
regenerated adsorbent is transferred by conveyor to storage or to the decolonization beds.
The decolorized sugar liquor is sent to heaters (not at all refiners’), followed by multiple-
effect evaporators, and then to the vacuum pans; this is the same sequence used in cane sugar
manufacture. Basic operation of the evaporators and vacuum pans is the same as for cane
sugar. An evaporator station consisting of five evaporators is commonly used. The sugar
liquor from the evaporators (thick juice) is transferred to the vacuum pans to further reduce
the liquor volume and form the massecuite. In refined sugar production, the most common
boiling system is the four-strike system. When the liquor in the pans has reached the desired
level of super saturation, the liquor is "seeded" to initiate formation of sugar crystals. The
seed is usually sugar ground in a mill with isopropyl alcohol or saturated syrup.
Crystallization proceeds to produce a massecuite with a sugar content as high as the
centrifugal can handle. At this point, the strike is discharged to a mixer and then to the
centrifugal. In the centrifugal, the white sugar is retained in the inner basket and the liquor
centrifuged to the outer shell. The sugar liquor is returned to a vacuum pan for further volume
reduction and white or brown sugar production. The white sugar is washed one time in the
centrifugal; the separated wash water, containing liquor and dissolved sugar, is returned to
the vacuum pans. The moist sugar from the centrifugal contains about one percent water by
weight.
White sugar designed for dry, refined granulated sugar is transported by conveyors and
bucket elevators to the sugar dryers. Granulated sugar represents the largest part of all
refinery production capacity and the entire capacity of many small refineries. Production of
other sugar products is briefly discussed at the end of this section.
The most common sugar dryer is the granulator, which consists of two drums in series. One
drum dries the sugar and the other cools the dried sugar crystals. Dryer drums typically
operate at a temperature of about 110EC (230EF). Fluidized bed dryers/coolers are used at

some facilities in place of the conventional rotary drum granulators. From the granulators, the
dried white sugar crystals are mechanically screened by particle size using a sloping, gyrating
wire mesh screen or perforated plate. After screening, the finished, refined granulated sugar is
sent to conditioning bins, and then to storage bins prior to packaging or bulk load out. Almost
all packaged sugar uses multiwall paper containers, cardboard cartons, or polyethylene bags;
bulk load out is the load out of the sugar to special bulk hopper cars or tank trucks.
In addition to granulated sugar, other common refined sugar products include confectioners'
(powdered) sugar, brown sugar, liquid sugar, and edible molasses. There are about six other
less common sugar products. Confectioners' sugar results from grinding granulated sugar in
specially designed hammer mills. Brown sugar is a soft sugar produced by treating various
purified and low purity syrups in vacuum pans followed by the same processing sequence as
white granulated sugar (i.e., volume reduction, seeding, massecuite formation, mixing, and
centrifugation). After cooling, the soft sugars are packaged in moisture-proof containers
while still moist. The brown coloration is enhanced by adding colored, molasses-flavored
syrup. There are two basic types of liquid sugars: one essentially all sucrose and the other
where about half of the sucrose has been converted to reducing sugars. Liquid sucrose is
produced either from melted granulated sugar or from decolorized, high-grade refinery
process liquors. Liquid sugars are shipped in rubber containers in freight trailers, railroad
tank cars, or by barge. Edible molasses is the concentrated extract of sugarcane that has been
clarified and concentrated. It often is a blend of various molasses from the sugar production
process designed to produce a specific flavor.


Chapter four
4. Design of plant equipment’s
4.1. Design of sugar mill

Assumptions to be considered:
 raw material – different verities of sugar cane

 Imbibitions percentage of cane-----------35±2%
 Bagasse percentage on cane--------------29±1%
 plant capacity- 500 TCD (tone of cane per day)
Cane crushed per hour (TCH) = (500 ton of cane/1 day) x (1 day /24 hr.)
A = 20.83 TCH
 The company will mainly produce white sugar (with possibility of producing brown
sugar).
 Bi products – molasses’ - Bagasse – used as a fuel.
 Approximately percentage of fiber in bagasse foe each mill
 first mill=34%
 Second mill=39%
 Third mill=45%
 Fourth mill=50%
Raw material storage
Cane yard (temporary raw material storage area). The amount of raw material store for the
night at the cane yard.
Over night provision = 12A + a
Where – A = quantity of cane crushed by the factory per hour
a = margin of safet
Lets assume a = 3A
Therefore; P= 12A + 3A = 15A
Our plant capacity is = 500TCD = 20.83 TCH

P = 15A
= 15*20.83 tch
=312.45tch
There fore the yard should be able to accommodate on overnight
amount of 312.45tch.
Material Balance on Milling
Where
 c = prepared cane
 I = imbibition’s water added per unit of cane
 B = bagasse to boiler
 J = juice to process
Data
F – Mass fraction of fiber in the cane
W – Moisture content in bagasse
Data’s taken from literature
Assumption f= 14% [mass fraction of fiber in the cane]
w = 45% [moisture content in bagasse]
.I=λƒ
Where – λ – ratio of weight of imbibitions’ water to weight of fiber

ƒ – Fiber content per unit of cane
I - quantity of imbibitions’ water added per unit of weight of cane
The optimum ratio is obtained at λ = 2λ
Therefore;
I=2ƒ
ƒ = 0.14 * C but C = 500 tcd
= 500 tcd/day * 1day/ (24*3600sec)*1000Kg/ 1ton
C = 5.79 Kg/sec
ƒ = 0.14 * 5.79 Kg/sec
= 0.82 Kg/sec
Therefore, I = 2 ƒ
= 2 * 0.82 Kg/sec = 1.64 Kg/sec
Assumption the bagasse in the juice is negligible
Over all material balance on mill station
C+I=B+J
But B = ƒ / w
= 0.82 Kg/sec / 0.45
= 1.83 Kg / sec
J=C+I–B
= 5.79 Kg/sec + 1.64 Kg/sec – 1.83 Kg / sec
= 5.6 Kg/sec
To find the volumetric flow rate of the juice
Let’s assume the juice brix is i.e. Bx = 15° by using the brix we can find the density of the
juice from the table
ρj = 1061 Kg/ m3

Q = J / ρj
5.6kg/sec
=1061 Kg/ m3
= 0.0053 m3 / sec
= 19.08 m3/ hr
Clarification
Lime station
From literature for the manufacture of raw sugar by ordinary defecation one should allow for
0.5 – 0.8 Kg of CaO per t.c.
Taking the average value = 650 g CaO
The lime prepared at 15° Bx, say 148g CaO Per liter. Therefore the quantity of milk of lime
per 500 t.c.d is then:
500 t.c.d ∗ 650g CaO per t.c.d
=
148g cao per liter
= 2195.945 l/hr
= 2.196 m3/ hr
The mixing tank should have a working volume of
5
V = 60 (2.196m3 /hr + Q)
5
= 60 (2.196m3 / hr + 19.08 m3/hr)
=1.8m3
The following table gives recommendations on cane preparation equipment Installed Specific
powersand tip speeds.
Table 1 Cane Preparation Equipment Installed Power
Description Specific Tip Speed Tip Clearance

Power [m/s] [mm]
[kW/tfh]

Leveller knives 6 50 1000
First knives 15 60 150
Second knives (heavy 30 60 50

duty)
Shredder 60 100
Total 111
Southern African 84
industry average
Table 2 of required installed power for a milling tandem
Number of mills Specific power per mill[kW/tfh]
Four mills 22
Five mills 20
Six mills 18
Diffuser + two mills 25
Therefore for our design we select four mills having 22 specific powers per mill
Mill Capacity CalculationsThere are a large number of formulae for the calculation of the
capacity of a milling tandem
Hugot gives the following formula:A = 0.8 c·n√N · (1 − 0.06 · n · D) · L · D2/f
Where
 c is a factor dependent on the cane preparation equipment,c= 1.3 if the tandem is

preceded by a shredder
 n is the mill speed in rev/min
 N is the number of rollers in the tandem
 L is the length of the roll in meters
 D is the mean diameter of the rollers in meters
 f is the fiber percent cane
Fiber index is calculated using the formula
= Fiber % of bagasse x 1.75 x 10 kg/m3
= 0.34 x 1.75 x 10 = 5.95 kg/m3 (for 1st mill)
= 0.39 x 1.75 x 10 = 6.825 kg/m3 (for 2nd mill)
= 0.45 x 1.75 x 10 = 7.875 kg/m3 (for 3rd mill)
= 0.5 x 1.75 x 10 = 8.75 kg/m3 (for 4th mill)
Fiber loaded in various mill the following formula
FL=1000x AxF/60x3.14xDxNxl (Kg/m2)
Where,
A=Total Cane crushing per hour = A = 20.83 TCH
F=Fiber percentage of cane (i.e-14%)
D=Pitch Circle Diameter of the Top Roller
N=Speed of the Roller (rpm)
L=Length of the Roller
Fl=1000*20.83TCH*0.14/60*1.143m*3rpm*2.133m
=355.5kg/m2

Fiber % of Bagasse Approximately percentage of fiber in bagasse foe each mill
 first mill=34%
 Second mill=39%
 Third mill=45%
 Fourth mill=50%
Discharge roller setting
Fiber Load
Dr=Fiber Index (m)
355.5kg/m2
Dr= 5.95kg/m3
=59.8m (1st mill)

355.5kg/m2
Dr=6.825kg/m3
=52.08m (2nd mill)

355.5kg/m2
Dr=7.875kg/m3
=45.2m (3rd mill)

355.5kg/m2
Dr= 8.75kg/m3
=40.6m
Feed Roller setting
Fr=mill ratio x Discharge work opening
Cane throughput=20.83 TCH
Fiber percent of Cane=14%=0.14
Fiber throughput = Cane throughput x fiber % of Cane
= 20.83TcH x 0.14
=48.6Kg/min
Let assume the fiber fill in the discharge opening=850Kg/m3

fiber throughput
Described volume in the discharge opening =
fiber fill in discharge opening
48.6Kg/min
850Kg/m3
=0.0572m3/min
n MTd+MDD
Average peripheral velocity of top discharge rolls (VtD)= 2 × 2
3×2π rad/min 1.143m+1.143m

= ×
2 2
= 10.77m/min
described volume in discharge opening
Discharge Work Opening (woD) = VtD x Length of roll
0.0572m3/min
=
10.77m/min x 2.133m
= 25mm
Feed roller setting = 2 x 25mm = 50mm
Offset Distance from center of top roll to Ow = (MDT / 2 + woF)

25
center of radius for trash plate surface(Ow) 1.143m
+0.05m
= 2
25

=24.86mm
Radius of Trash Plate in working Rw= MDT / 2 +1.75 * woF

position(Rw) =(1.143m/2)+1.75*0.05m
=0.659m=659mm
Length of vertical line from centre point of Lw= MDT / 2 +1.75 * woF – l
top roll to top surface of Trash Plate(Lw) =(1.143m/2)+1.75*50mm-1
=658mm
4.2. Mill Bearings

Bearing Pressures
The maximum pressure that a bearing can withstand is mainly a function of the bearing
material.
The bronzes that are common in sugar mills have a recommended maximum bearing
pressures of up to 100 MPa for phosphor bronze and 50 MPa for tin-bronzes. Standard sugar
mill practice limits the bearing pressure to about 10 MPa.
Materials for Plain Bearings
The two essential elements in a plain bearing are the bearing or bearing material itself, and
the shaft or moving member. The bearing or bearing material is located in a housing or
structure, and may or may not be integral with it.
Separating these two elements is the lubricant, introduced, generally in the case of sugar
mills, by external pressure feeding.
The material of the shaft or journal is established from considerations of strength and rigidity,
and will invariably be steel. Because the conditions under which bearings must operate in
service may vary over a wide range, it is necessary that bearing materials be used which have
certain desirable properties. Among these, we must include such factors as
 mechanical strength

 softness and low melting point
 low modulus of elasticity
 corrosion resistance
 high thermal conductivity
 Economic considerations.
Since these factors cannot all be obtained to a desirable degree in a single material, it is
necessary in practice to make a compromise.
The most common bearing materials consist of;
a. white metals
b. copper base alloys
c. Aluminum-base alloys
Typical Sugar Mill Bearings
Typically sugar mill bearings are tin bronzes with the following compositions.
Cu 84%
Sn 10%
Pb 3%
Zn 3%
Lubrication
Sugar mill shafts do not turn sufficiently fast for a hydrodynamic film of lubricant to be
formed between the journal and the bearing. Consequently hydrostatic lubrication is required.
This is achieved by supplying lubricant to the bearing under pressure. Under these conditions,
attention must be given to the adequate supply of lubricant at all times, and in particular to
the location of oil Supply holes and grooves. Bitumen based lubricants are often used in sugar
mill bearings.

4.2. Evaporator selection
The selection of the most suitable evaporator type for a particular application will depend
On the following factors:
1. The throughput required.
2. The viscosity of the feed and the increase in viscosity during evaporation.
3. The nature of the product required; solid, slurry, or concentrated solution.
4. The heat sensitivity of the product.
5. Whether the materials are fouling or non-fouling.
6. Whether the solution is likely to foam.
7. Whether direct heating can be used.
A selection guide based on these factors is given in table given below
Table .Evaporator selection guide
Auxiliary equipment
Condensers and vacuum pumps will be needed for evaporators operated under vacuum. For
aqueous solutions, steam ejectors and jet condensers are normally used. Jet condensers are

direct-contact condensers, where the vapour is condensed by contact with jets of cooling
water. Indirect, surface condensers, are used where it is necessary to keep the condensed
vapour and cooling water effluent separate. Multiple effect evaporation
Select kesthner evaporation with tubes 1.2m – 1.5m long tubular calanderia, stainless steel ,
for the reason that :
It gives short retention time.
It provides a large area of heating surface due to its long tubes
Material and energy balance required condition
In order to obtain the maximum performance from the first vessel of any evaporator, the
clear juice entering that vessel must be at a temperature above the juice boiling in the vessels
by 3-5°C. This will be done by the 3rd heater heat up to 110 °C.
as sugar solution becomes more concentrated, it’s boiling point increases relative to water
at the corresponding pressure. This increase is known as boiling point elevation (B.P.E) and is
directly proportional to the brix or solid content of the solution extra amount of heat will be
required to raise the boiling temperature of the liquor at various concentrations in an
evaporator. The B.P.E being small in the first effect and increasing to a maximum in the last
vessel, thus the effective temperature difference across the evaporator will be reduced by the
sum of B.P.E’s. The B.P.E is given by:
B.P.E = 2.4B/ (100-B), where B – Brix of solution
The juice level in the evaporator should be controlled at 20% of the height of tubes in kestner
evaporator. The final brix of the syrup should not exceed 68 - 70°B.
Material and energy balance
Assume - clear juice brix = 17 -18; take 17.5 and
- syrup brix 65 – 68 take 66.5

Total mass balance C = V + S ………………….(1)

Component mass balance C * Bs = V
XBv + SXBS 18 * 0.175 = VX0 + SX0.665
S = 4.7 Kg/ s
Substituting the above value in equation (1) we get V = C – S = (18 – 4.7) Kg/s =
13.3Kg/s,
this is the amount of water evaporated from the juice, which is 74% of the total clear juice
flow rate
 i.e. 13.3 * 100 = 73.7%
4.3. Crystallization
Crystallization is used for the production, purification and recovery of solids. Crystalline
products have an attractive appearance, are free flowing, and easily handled and packaged.
The process is used in a wide range of industries: from the small-scale production of
specialized chemicals, such as pharmaceutical products, to the tonnage production of
products such as sugar, common salt and fertilizers.
Select A rotating – coil water cooling crystallizer
A capacity of 6.4 m3 / t.c.h is recommended for water – cooled crystallizers for all
massecuites.
For our capacity 500 t.c.d
500 t.c.d *6.4 m3/ t.c.h = 133m³/hr.
 133m³ a rotating coil water cooling crystallizer is selected
4.4. Wet scrubbers (washing)

In wet scrubbing the dust is removed by counter-current washing with a liquid, usually water,
and the solids are removed as a slurry. The principal mechanism involved is the impact
(impingement) of the dust particles and the water droplets. Particle sizes down to 0.5 _m can
be removed in suitably designed scrubbers. In addition to removing solids, wet scrubbers can
be used to simultaneously cool the gas and neutralize any corrosive constituents.
Spray towers, and plate and packed columns are used, as well as a variety of proprietary
designs. Spray towers have a low pressure drop but are not suitable for removing very fine
particles, below 10 _m. The collecting efficiency can be improved by the use of plates or
packing but at the expense of a higher pressure drop. Venturi and orifice scrubbers are simple
forms of wet scrubbers. The turbulence created by the venturi or orifice is used to atomize
water sprays and promote contact between the liquid droplets and dust particles. The
agglomerated particles of dust and liquid are then collected in a centrifugal separator, usually
a cyclone.
4.5. Crushing and grinding equipment

Crushing is the first step in the process of size reduction; reducing large lumps to manageable
sized pieces. For some processes crushing is sufficient, but for chemical processes it is
usually followed by grinding to produce a fine-sized powder.
4.6. Pump selection
Pumps can be classified into two general types:

1. Dynamic pumps, such as centrifugal pumps.
2. Positive displacement pumps, such as reciprocating and diaphragm pumps.
The single-stage, horizontal, overhung, centrifugal pump is by far the most commonly used
type in the chemical process industry. Other types are used where a high head or other special
process considerations are specified. Pump selection is made on the flow rate and head
required, together with other process considerations, such as corrosion or the presence of
solids in the fluid.

Figure Centrifugal pump selection guide. Ł Single-stage >1750 rpm, multi-stage 1750 rpm
Centrifugal pumps are characterized by their specific speed. In the dimensionless form,
specific speed is given by:
Where N = revolutions per second,

Q = flow, m3/s,
H = head, m,
g = gravitational acceleration m/s2.
NO. Activities Pumps that will be used including the

stand by
1 To bring the juice to meaning cylinder 2, centrifugal pump (radial flow)
2 To take the juice from mixed tank to 1st 2 >> >> >>
heater
3 To take the juice for sulphitation and 2 >> >> >>

liming
4 To take juice to door clarifier 2 >> >> >>
5 To take juice to 3rd heating 2 >> >> >>

6 To take juice from 3rd heating to 2 >> >> >>

evaporation
7 To take from temporary storage tanker to 2 >> >> >>

pans
8 To take masscults from crystallizer to 2 >> >> >>

centrifugal and back to pans
9 To take an to take mud to filtration 2 >> >> >>
10 To take final molasses 2 >> >> >>
11 To take injection water to condensers 2 >> >> >>
12 To force out mud flow Dorr 2 >> >> >>
13 Condensate pumps 2 centrifugal
Chapter five
5. Plant layout and utilities
5.1. Plant layout
The sequence of the main equipment items shown symbolically on the flow-sheet follows
that of the proposed sugar plant layout. Some license must be exercised in the placing of
ancillary items, such as heat exchangers and pumps, or the sugar plant layout will be too
congested. But the aim should be to show the flow of material from stage to stage as it will
occur, and to give a general impression of the layout of the actual sugar production process
plant. The equipment should be drawn approximately to scale. Again, some licence is allowed
for the sake of clarity, but the principal equipment items should be drawn roughly in the
correct proportion. Ancillary items can be drawn out of proportion. For a complex process,
with many process units, several sheets may be needed, and the continuation of the process
streams from one sheet to another must be clearly shown. One method of indicating a line
continuation is shown in Figure below; those lines which are continued over to another are
indicated by a double concentric circle round the line number and the continuation sheet

number written below. The table of stream flows and other data can be placed above or below
the equipment layout. Normal practice is to place it below. The components should be listed
down the left-hand side of the table, as in Figure. For a long table it is good practice to repeat
the list at the right-hand side, so the components can be traced across from either side. The
stream line numbers should follow consecutively from left to right of the layout, as far as is
practicable; so that when reading the flow-sheet it is easy to locate a particular line and the
associated column containing the data. All the process stream lines shown on the flow-sheet
should be numbered and the data for the stream given. There is always a temptation to leave
out the data on a process stream if it is clearly just formed by the addition of two other
streams, as at a junction, or if the composition is unchanged when flowing through a process
unit, such as a heat exchanger; this should be avoided. What may be clear to the process
designer is not necessarily clear to the others who will use the flow-sheet. Complete,
unambiguous information on all streams should be given, even if this involves some
repetition. The purpose of the flow-sheet is to show the function of each process unit; even to
show when it has no function.
The economic construction and efficient operation of a process unit will depend on how well
the plant and equipment specified on the process flow-sheet is laid out.
The principal factors to be considered are:
 Economic considerations: construction and operating costs.

 The process requirements.
 Convenience of operation.
 Convenience of maintenance.
 Safety.
 Future expansion.
 Modular construction.
Costs: The cost of construction can be minimized by adopting a layout that gives the shortest
run of connecting pipe between equipment, and the least amount of structural steel work.
However, this will not necessarily be the best arrangement for operation and maintenance.

Process requirements: An example of the need to take into account process considerations
is the need to elevate the base of columns to provide the necessary net positive suction head
to a pump or the operating head for a thermo syphon re boiler
Operation: Equipment that needs to have frequent operator attention should be located
convenient to the control room. Valves, sample points, and instruments should be located at
convenient positions and heights. Sufficient working space and headroom must be provided
to allow easy access to equipment.
Maintenance: Heat exchangers need to be sited so that the tube bundles can be easily
withdrawn for cleaning and tube replacement. Vessels that require frequent replacement of
catalyst or packing should be located on the outside of buildings. Equipment that requires
dismantling for maintenance, such as compressors and large pumps, should be placed under
cover.
Safety: Blast walls may be needed to isolate potentially hazardous equipment, and confine
the effects of an explosion. At least two escape routes for operators must be provided from
each level in process buildings.
Plant expansion: Equipment should be located so that it can be conveniently tied in with any
future expansion of the process. Space should be left on pipe alleys for future needs, and
service pipes over-sized to allow for future requirements.
Modular construction: In recent years there has been a move to assemble sections of plant
at the plant manufacturer’s site. These modules will include the equipment, structural steel,
piping and instrumentation. The modules are then transported to the plant site, by road or sea.
The advantages of modular construction are:
1. Improved quality control.

2. Reduced construction cost.
3. Less need for skilled labour on site.
4. Less need for skilled personnel on overseas sites.

5.2. Utilities
The word “Utilities” is now generally used for the ancillary services needed in the operation
of any production process.
1. Electricity.
2. Steam, for process heating.
3. Cooling water.

4. Water for general use.

5. Demineralized water.
6. Compressed air.
7. Inert-gas supplies.
8. Refrigeration.
9. Effluent disposal facilities.
Electricity: The power required for electrochemical processes; motor drives, lighting, and
general use, may be generated on sugar factory, but will more usually be purchased from the
local supply Company (the national grid system in the UK). The voltage at which the supply
is taken or generated will depend on the demand. For a large site the supply will be taken at a
very high voltage, typically 11,000 or 33,000 V. Transformers will be used to step down the
supply voltage to the voltages used on the site. In the United Kingdom a three-phase 415-V
system is used for general industrial purposes, and 240-V single-phase for lighting and other
low-power requirements. If a number of large motors are used, a supply at an intermediate
high voltage will also be provided, typically 6000 or 11,000 V.
Steam: The steam for process heating is usually generated in water tube boilers; using the
most economical fuel available. The process temperatures required can usually be obtained
with low-pressure steam, typically 2.5 bar (25 psig), and steam is distributed at a relatively
low mains pressure, typically around 8 bar (100 psig). Higher steam pressures, or proprietary
heat-transfer fluids, such as Dowtherm will be needed for high process temperatures.
Combined heat and power (co-generation) the energy costs on a large sugar factory can be
reduced if the electrical power required is generated on sugar plant and the exhaust steam
from the turbines used for process heating. The overall thermal efficiency of such systems
can be in the range 70 to 80 per cent; compared with the 30 to 40 per cent obtained from a
conventional power station, where the heat in the exhaust steam is wasted in the condenser.
Whether a combined heat and power system scheme is worth considering for a particular site
will depend on the size of the site, the cost of fuel, the balance between the power and heating
demands; and particularly on the availability of, and cost of, standby supplies and the price

paid for any surplus power electricity generated. On any site it is always worthwhile
considering driving large compressors or pumps with steam turbines and using the exhaust
steam for local process heating.
Cooling water: Natural and forced-draft cooling towers are generally used to provide the
cooling water required on a site; unless water can be drawn from a convenient river or lake in
sufficient quantity. Sea water, or brackish water, can be used at coastal sites, but if used
directly will necessitate the use of more expensive materials of construction for heat
exchangers
Water for general use: The water required for general purposes on a site will usually be
taken from the local mains supply, unless a cheaper source of suitable quality water is
available from a river, lake or well.
Demineralized water: Demineralized water, from which all the minerals have been removed
by ion-exchange, is used where pure water is needed for process use, and as boiler feed-
water. Mixed and multiple-bed ion-exchange units are used; one resin converting the captions
to hydrogen and the other removing the acid radicals. Water with less than 1 part per million
of dissolved solids can be produced.
Refrigeration: Refrigeration will be needed for processes that require temperatures below
those that can be economically obtained with cooling water. For temperatures down to around
10ŽC chilled water can be used. For lower temperatures, down to _30ŽC, salt brines (NaCl
and CaCl2) are used to distribute the “refrigeration” round the site from a central refrigeration
machine. Vapor compression machines are normally used.
Compressed air: Compressed air will be needed for general use, and for the pneumatic
controllers that are usually used for chemical process plant control. Air is normally
distributed at a mains pressure of 6 bar (100 psig). Rotary and reciprocating single-stage or
two-stage compressors are used. Instrument air must be dry and clean (free from oil).

Chapter six
6. Conclusion and recommendation
6.1. Conclusion
Sugar is a highly consumable commodity in the world. This implies that it has a power that
negatively or positively affects the world economy. As a result, we conclude that the major
issue area at which government, society and other nongovernmental organizations must to
participate cooperatively. Otherwise, it is impossible to avoid shortage of sugar.
Even though the initial cost of sugar plant is very high, almost all, waste products of sugar
processing plant has other extra advantages. This means that the sugar factory will not have
waste material lost that may negatively affect its economy. Due to this reason, we conclude
that the sugar manufacturing factories are most probably productive and highly productive.
Again according to our country Ethiopia, sugar consumption becomes growing increasingly.
So, sugar production needs large area and combined effort of government with society along
with constructive attention.
As we know, the most wasting and available raw material in sugar production is water.
Intern, the most abundant resource in the world is water. Based on this fact we conclude that
the efficiency and continuity of sugar production is easy except its initial and running costs.
6.2. Recommendation
Farmers should be advised by the Ministry of Agriculture to balance between sugar cane
growing and food production.
 Early maturing cane varieties should be introduced in the area. This will enable
farmers to earn money early enough from sugar cane than presently is the case.
 Farming contract between farmers and sugar production factory should provide
for farmers earn early from the sugar cane if they so wish before they mature
 In order to increase quality of sugar, government should have streamline
management policy of issuing of permits for cane and beet farms.
 Use of child labour on sugar cane farms should be stopped.

 Farmers should be encouraged to use organic manure instead of industrial

fertilizers on the farms.
 The factory should install an efficient waste water treatment plant and regularly
monitor and record
 The quality of all water discharged from the plant and the factory into the natural
environment.
 There should be Sugar Cane Farmers Association to develop a mechanism that
will be responding to labour shortages during harvesting of cane.

REFRENCES
1. A.A. Girei and D.Y. Giroh (2012). Adamawa State Community and Social
Development Agency, PMB2110, Yola, Nigeria, 2012
2. Abadie, A., and Imbens, G.W. (2002). Simple and Bias-Corrected Matching
Estimators. Tech. rep. Department of Economics, UC Berkeley. http;//emlab.
berkeley.edu/users/imbens
3. Abdullahi, S. (2000) , “Problems and prospects of sugar industry in Nigeria” A
paper presented at a SugarDevelopmentandInvestmentForum.pp2-7
4. "Agribusiness Handbook: Sugar beet white sugar"(PDF). Food and Agriculture
Organization,United Nations. 2009.
5. Badger, P.C. 2002. “Ethanol from cellulose: A general review”. p. 17–21. In: J.
Janick and A. Whipkey (eds.), Trends in new crops and new uses. ASHS Press,
Alexandria, VA.
6. Bhoopathy, R. 1998. “Biological treatment of swine waste using anaerobic

baffled reactors”, Bioreactor Technol.,64:1−6
7. Chauhan, M.S., Dikshit, A.K., “Indian distillery Industry : problem and prospects
of decolouristion of spent wash”, 2012 International conference on future
environment and energy IPCBEE vol 28920120,p.119
8. Cheung S.W. and Anderson B.C., “Laboratory investigation of ethanol

production from municipal primary wastewater”, Bioresour Technol., 59, 1997,
81−96
9. Coulson and Richardson’s (2005): chemical engineering Designtext book.
10. Kaur P.P. Arneja J.S. and Singh J., “Enzyme hydrolysis of raw rice straw by
crude cellulose from Trichodermareesei”, Bioresour Technol.,66, 1998, 267−9.
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Design of sugar production plant from sugarcane

Bahir Dar University

Bahir Dar Institute Of Technology

Faculty of Mechanical and Industrial Engineering

Agro machinery and processing II

TITLE : design of sugar production plant from sugar cane

1. Haimanot Yeserah ----------------------------------------------------------0701871

2. Chanie Abebe -----------------------------------------------------------------0701540

4. Biniyam Tariku------------------------------------------------------------ 0701505

Submitted to: Mr.Tsega Y.& Wondyifrew

Submission date Jan.30/2018

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Name ID No. Signature Date

1. Haimanot yeserah…………0701871 ------------------ ---------------

1. Mr. Wondyifrew ---------------------- ---------------------

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Figure 1.1 sugar processing operation

1.2.1. Sugar cane farming

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1.2.2. Sugarcane transportation

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1.2.4. Sugarcane processing

Figure1.2. the process flowchart in sugar processing

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Figure 2- 3: Multiple effect evaporation

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1.4. Water supply

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1.5. Problem statement

In the current situation, consumption of sugar is increasing in Ethiopia. But when we

1.6.1. Main objective

1.6.2. Specific objectives

The specific objectives of this project are:

 To identify materials and components required in sugar production.

 To understand production process and flow sheets of sugar producing plant.

 To know factors affecting sugar production.

 To design the equipment’s used in sugar production plant

 To identify the utilities and plant layout of the sugar factory

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2.1. Definition of sugar

2.2. Properties of sugar

2.3. The sugar cycle

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C12H22O11 + 12O2 11 H2O + 12 CO 2+ (energy).

2.4. Sugar Formation in Cane

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3.1 flow sheet

3.2. Production process

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3.2.2. Cane Sugar Production

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Evaporation is performed in two stages: initially in an evaporator station to concentrate the

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3.2.3. Refined Sugar Production

= 500 tcd/day * 1day/ (243600sec)1000Kg/ 1ton