3 Material and Energy Balance and Equipment sizing

3.1 Material balance

3.1.1 General material balance

Since the process is continuous, steady and non-reactive the general material balance is look like

Input output

C+Imb+lime=B+FC+El+E2+Mo+S

Since direct measurement of these values are very difficult we follow the component method

starting from the starting point. And we discuss the result. But first

The 21ton cane feed per hour contain

Water =21*0.7=14.7

Sucrose=2160.14-2.94

Non-sucrose reducing sugar=21*0.005=0.105

Fiber=21*0.13=2.73

Ash and other impurities=21*0,025–0.525

Milk of lime needed per hour=21*0.5kg=0.0105, Sulphur= 210.9kg=0.019

3.1.2 Milling plant

Imb=0.25*21=5.25

Sucrose extracted=0.95*2.94, -2.793

Un-Extracted

COSE2.94-2.793=0.147

Bagasse water content=2.7340.147=2.877

Bagasce amount= 2.73F+0.1475+2.877B=5.754

3.1.3 Clarification units

Table3:11nput to clarification unit

Water= initial water + imbibition water - water lost with bagasse=14.7+5.25-2.872=17.078

Sucrose=2.793

RS=0.105

Impurity=0.5250

Total juice=water+sucroce+RS+impurity=20.50 1

DS= 16.7

Milk of lime=0.5kg/ton of came=0.0105

Sulphur for juice sulphitation=0.00945

Sludge removed=0.96 0.525+0.0105+0.00945=0.52395

Total filter cake amount=0.52 395+0.02793+0.00105+1.7078=2 26073

Remaining impurities=0.525-0.504–0.021

Remained sucrose= 2.793-2.793-1%=2.76507

Remained RS=0.105-0.105.1%=0.10395

Remained water=17.078-17.078 - 10%=15.3702

Total CI=0.021+2.76507+0.10395+15.3702=18.26021

of solids ((0.021+2.76507+0.10395 m (18.26022))*100=15.8269% this show very good

concentration of sugar.

The remaining sulphur used in syrup sulphitation process. The amount of sulphur attached with

syrup and the amount of syrup released with sulphur is equal. Thus assume as there is no sulphur

that transported to evaporation unit and no change in amount of other components of evaporation

un it inputs.
3.1.4 Evaporation unit

Tablet: Inputs to evaporation system

Remained sucrose= 2.793-2.7931%=2.76507

Remained RS=0. 105-0.105*16=0.10395

Remained water=17.078-17.078-10%=15.3702

Total C] (solution)=0.021 +2.76507 +0.10395+15.3702=18.26022

Fof solid= ((0.021+2.76507+0.10395(18.26022)) *100=15.8269%

Evaporated water=0.85-15.3702= 13.06467=EI

Remained water=15.3702-E1=2,30553

Total C] (solution) =18.26022-E1=5.19555

Total olid =0.021+2.76507+0.10395–2.89002

Esolide (0.021+2.76507+0.10395 / 5.19555) *100=55.625", this is not satisfactory result

because the brix must be between 60-65 Br. to correct this problem we can the following two

measures

• Reduce loss of sucrose with bagasse and filter cake, but has its own cost.

Increase the evaporation load, this has very large cost of energy. Thus the first method is

preferred

3.1.5 Crystallizer unit

Table5: Input to crystallizer unit

Remaining impurities=0.525-0.504=0.021

Remained sucrose= 2.793-2.793*12=2.76507

Remained RS=0.105-0.105*1%=0.10395

Remained water=15.3702-El=2.30553

Total

solution) =18.26022-E 1=5.19555

Total solid =0.021+2.76507+0.10395=2.89002

solid= ((0.021+2.76507+0.10395W 5.19555) *100=55.625%

The weight of sucrose= 0.92*2.76507=2.5438644

Weight of reducing sugar=0.33*0.10395=0.0343035

Sucrose in molasses=2.76507-2.5438644=0.2212056

Reducing sugar in molasses=0.10395-0.0343035=0.0696465

Total agar in molasses=0.0696465+0.2212056 =0.2908521

Water required to dissolve this=0.2908521/2.6287=0.110645

Water to be evaporated=E2=2.30553-0.31-0.110645=1.884885

Remained water=0.31+0.110645=0.420645

Total solid crystal= (RS Himpurity) +(sucrose) =25438644+0.0343035+0.021-2.599 1679

l Centrifugation unit

Table6: Input to centrifugation system

Total sugar in molasses=0.0696465+0.2212056 =0.2908521

The weight of sucrose=0.92*2.76507=2.5438644

Weight of reducing sugar=0,330,10395=0.0343035

Sucrose in molasses=2.76507-2.5438644–0.2212056

Reducing sugar in molasses=0.10395-0.0343035=0.0696465

Remained water=0,31 +0.110645=0.420645

Total solid crystal= RS+impurity+sucroce=2 5438644+0.0343035+0.021=2.5991679

Solid=total solid crystal+moisture=2.5991679+0.31 =2.90917

Molasses=0.290852 1+0.110645=0.4014971

Thus the weight of molasses that added to solid=0.1*0,4014971=0,04014971

Total sugar crystal=0.0401 4971+2.90917=2.94932

Total molasses=0,4014971-0.04014971=0.46135

3.1.7 Drier unit

Input to the system

Total sugar crystal=0.04014971 +2 90917=2.94932

Moisture removed from the crystal=2.94932*4/1000=0.0118

The final sugar Crystal =2.94932-0.0118=29375

3.1.8 Summary on Calculation Results of Material Balance

Now wecan calculate the general material balance in both rate formand amount for as following

C+Imb+lime=B+FC+El+E2+Mo+Sugar

C=2 Itonhr.

Imb water=5.25onhr.

Milk of lime=0.010stowhr.

B=5.754owhr.

FC=22513ton/hr.

El=13.0647 ton/hr.

E2 -1.885ton/hr.

Mo = 36113ohr.

Sugar crystal =293&torhr.