Contents :

1. Objective

2. Introduction

3. Mechanism of crystallization

4. Theoretical and practical aspects of pan boiling.

5. Concept of automation of pans.

6. Initiative taken for the season 2014-15 and

2015-16 and questionire
 Objective
• To develop a common understanding of the terms, methods
and mechanism of pan boiling as practiced at Barwani v/s
standards.
1. To introduce the unit operations of pan boiling with flow of
different materials.
2. Elaboration of mechanism of crystallization in pans.
3. To address the theoretical and practical norms of pan
boiling.
4. To introduce about the advancements during last years done
for better pan boiling done at pan station .
 Introduction

The objective of pan boiling is to evaporate water from

syrup in order to produce massecuites from where:

Product: sugar of desired quality , size and lustre is

separated along with ,

By product : Final molasses with minimum loss of sugar

is produced .
 Syrup From

A1 Pan Boiling
Evaporator

A1 Hy

Melter

Feed Box

STEAM

A1-XLR A1-XLR

A-1 Hy Pug mil

To melter

A1 -magma

A1 -C/F
Mechine

Hopper
 Syrup From
Evaporator
A/B Pan Boiling
A1 Hy

A-Hy

A-Hy and
Syrup + melt+AL A1Hy
Feed Box

STEAM STEAM
Elevator

A- A- B-
Crystallizer Crystallizer Crystallizer

A-Light

Pug mil

B- To A Pan
A-C/F M.
Sugar Mechine A-Hy V.
Silo
C.

B-Hy
B-magma
Hopper
Air Blow
 C-Pan Boiling

C.AW. Magma
for Melter
AH +B-Hy +CL

STEAM

CL C-
Crystallizer
CFW-magma to pug
mill C-C/F
Mechine
C-C/F
Mechine

Final Molasses
Pump
 Designing of Pan boiling scheme
( Theoreatical Aspects)
• Material balance as per desired Specification and Quality of
target product.
• Optimum use of water and steam.
• Optimum retention of materials at every stage
• Optimum recirculation of materials
• Sugar flows forward and non sugar backwards.
• Crystal size at different stages .
 Theory of Pan Boiling
• Solubility
• Solubility coefficient
Solubility of sucrose % water in impure solution
Solubility of sucrose % water in pure solution
• Saturated solutions
• Supersaturated solutions
• Degree of super saturation
• Super saturation coefficient
Sugar%water of super saturated sol. At t 0C
Sugar%water of saturated sol. At t 0C
• Boiling point elevation
• (Interrelations of the above.)
 Example for calculating Super Saturation
Coefficient
Suppose a saturated solution at 80 0C contains 363 parts of sugar
per 100 parts of water.

If concentration is raised by evaporation at 80 0C until 436 part

of sugar / 100 parts of water reached, then super saturation
coefficient – 436/363=1.20

Similarly, if cooled to 65.5 0C, a Super saturation of 1.2

attained, as at 65.5 0C a saturated solution would contain only
303 parts of sugar per 100 parts of water so:
- 363/303=1.20
Unsaturated phase (S.S. < 1.0):
The degree of super saturation is always less than 1.0. Clear juice, syrup, molasses
(below 75o Bx.) are examples of unsaturated phase.
In unsaturated phase no crystal present but added sugar crystal will dissolve.
Saturated Phase (S.S. = 1.0):
When degree of super saturation of any solution is becomes 1.0, then it is called
saturated phase.
The specialties of saturated phase are,
Crystal neither dissolves nor grows.
No new crystal formation.
Metastable phase (1.0 < S.S. < 1.20)
In metastable zone of concentration, the degree of super saturation varies in
between 1.00 to 1.20. All the pan boiling is done in this zone except graing.
The specialties of metastable zone are;
Crystals will grow in size.
Crystals will not grow in numbers i.e. no new crystal formation in absence or
presence of sugar crystals.
No chance for false grain formation.
Intermediate and Lbile Zones( SS> 1.2)
Different Stages during pan boiling
Different phases of saturation at different temperature
600.0 (schematic)
550.0
parts of sucrose per 100 parts

500.0

450.0
of water

400.0

350.0
S.S. =1.0
300.0
SS = 1.2
250.0
SS = 1.4
200.0 Temperature SS = 1.6
150.0
20 30 40 50 60 70 80 90 100 110
 Classen’s theory of pan boiling
Classen’s theory of pan boiling can be summerised as follows:
1. Depending upon the purity and temperature of mother liquor, there is
definite coefficient of super saturation at which the crystal will appear.

2. On account of presence of non-sugars, the low purity liquors are less

sensitive to the formation of false grain than the high purity liquor.

3. The greater the number of times the syrup and molasses are boiled,
the more difficult the granulation becomes.

4. In order to separate sugar from impure solution by the process of

crystallization, a driving force in the form of super saturation must be
first established.
Mechanism of crystal growth
Concentration of sucrose molecules

Sucrose cystal

Equilibrium

Adsorption layer
Stagnant Layer

Bulk solution
 Factors affecting Crystallization
1. Vacuum/Temp. in Pan:
Vacuum in Pan should be maintained 630-650 mm of Hg and
temperature 65 0C

2. Temperature of feeding material:

Temperature of Syrup/Melt/Mol. Should be maintained 70 0C(
slitely higher than the temperature of pan in boiling)

3.Brix of feeding material:

( As high as possible)
 Factors affecting Crystallization
4. Effect of impurities ( Purity of feed material)
• Non sugar in the mother liquor increases the solubility of
sucrose, thus presence of non sugars makes more difficult to
diffuse out the sucrose from the mother liquor. crystal growth
suffered badly due to the presence of organic and inorganic
non sucrose.
• These non sugars increase viscosity.
• The presence of RS in mother liquor decreases the solubility
of sucrose, and makes easy to diffuse the sucrose from
mother liquor to crystal.

• RS / ash ratio
 Factors affecting Crystallization
5. Circulation

It decreases the effect of viscosity for cystal growth by

making more molecules available to nuclie. Futher
reduces chance of localized heating.
• Natural circulation
The circulation of material due to boiling and due to
design of pan ( Circulation ratio 40%)
• Forced circulation
Mechanical circulators
 Benefit of mechanical circulators
• Saving in strike time of up to 20%
• Good circulation maintained through the strike
• Provide more uniform grain
• Increased pan capacity by 20-30%
• Increase in crystal yield up to 5%
• Sugar conglomerates counts have been reduced by about
80%
• Strike level in pans can be raised by 30-40 cm with the use of
stirrer
• Increase in heat transfer coefficients from 0.78 kW/m2/oC to
0.87 kW/m2/oC with stirrer
 Factors affecting Crystallization

6.Viscosity
• Viscosity retards diffusion of sucrose molecule
• Poor exhaustion, abbrated crystal growth,
circulation in pan are the other results of viscosity.
1. At fixed concentration,
The viscosity of a sugar solution decrease rapidly
with increase temperature.
2. At fixed temperature,
The viscosity of a sugar solution increase rapidly
with increase concentration.
C-Massecuite Temperature vs Viscosity graph
Viscosity ( poise)

1500

1000

500

10 20 30 40 50 60 70

Temperature (degree C)

Ref: Peter Honig

 Factors affecting Crystallization

7.Hydrostatic head
• S/V ratio -6 to 7
• Tube length mm max 1m.
• Graining volume 35 %
• Height of maccecuite 1.5 m
• Natural circulation
• Temp difference in the mass.
 Factors affecting Crystallization
8. No and size of nuclie ( MA and CV)
• The combination of crystal contents and crystal size
determines the crystal surface area available for sucrose
deposition (avoiding the formation of false grain).
• The same crystal contents with smaller crystal have more
surface area than larger crystals.
• Small crystals reduce the purging capacity of the centrifuges
and increase the molasses recirculation.
• Small crystal may pass throughout the centrifuges screen slots
and increase the molasses purity.
 Factors affecting Crystallization
9.Graining Techniques:

• Waiting method – Concentrate the graining media until

labile zone of super saturation reached.
• Shock seeding (babooning) method- Concentrate the
graining media up to metastable zone. Then finely white
sugar (seed) is fed, and finally super saturation reached in
intermediate zone.
• Seeding method - Concentrate the graining media up to
metastable zone, then slurry is provided.
• Dry Seeding – Direct seed magma taken in pan up to tube
plate level and then boiling of pan carried in metastable
zone.
 Factors affecting Crystallization
10.Vapour pressure in calendria
11.Bx of massecuite
12. Removal of NCG and condensate.
13. Automation :
a. The boiling of Massecuite in Batch Pan is very critical
operation, because the super saturation of boiling liquid
inside the pan should be maintained within a very narrow
range. It is very difficult to maintain Super saturation within
desired limit by manual operation.
b. Consistent boiling with syrup/molasses charge will required
less steam for evaporation due to reduced evaporation rate
and also chances of false grain and consequent water/steam
demand will be reduced.
c. Replacement of human/manual error.
VARIOUS PRINCIPLES USED FOR AUTO PAN
CONTROL
•Boiling point rise
•Conductivity / Resistivity measurements
•Viscosity/consistency measurements
•Radioactive density determination
•Measure of Refractive index
 PAN

LS
CE Brix Sensor

LT

CT

H
Local SP CIC

CY
I/P

CCV
PAN Feed Line

PAN BRIX CONTROL LOOP

 Terminologies used in auto feed
system

Analog Signal
Signal is Variable
0 – 20 mA, 4 – 20 mA, 1 – 5 V or 0 – 10 V DC

Digital Signal
Signal is True or False.

I/P Converter
Current to Pneumatic Converter.
4 – 20 mA Convert to 3 – 15 psi pneumatic signal
Control Valve
Used to open close to pass the feed to pan as per
controller
 Batch Pan Automation Benefits:

• Reduction of boiling time = 20–30 %

• Reduction of energy (steam, vacuum) = 20-30 %

• Reduction of losses in final molasses = 1–2 %

 Practical Norms for Pan boiling
1. Purity drops in individual pan boiling
2. Crystal % m/c
3. Exhaustion % m/c
4. Sugar colour and colour of different ingradients.
5. Loss in final molasses
6. Stock of different molasses.
7. Boiling time.
8. MA and CV of product.
9. Unknown loss
 Pan boiling parameters
A M/C A1 M/C B M/C C M/C
Vaccum (mm Hg ) 650 650 650 650
Temp 60 60 60 60
Type of nuclie Dry seed Slurry Slurry Slurry
Size of seed/ slurry (mm) 0.3-0.7 0.003-0.005 0.003-0.005 0.003-0.005
Grain check size 0.025-0.040 0.025-0.040 0.025-0.040
Cutting grain size 0.9-1.2 0.160-0.190 0.140-0.160 0.09-0.120
Dropping grain size 1.1 and above 0.280-0.350 0.270-0.300 0.18-0.20
Water consumption % mc .5 .5 1 1
Pty of footing 92-99 80-82 75-77 60-64
Pty of cutting 94 80-82 72-74 57-59
Pty of massecuite 91.34 81.18 72.64 51.68
Bx of massecuite 90.92 89.8 93.51 100.28
pty of heavy molasses 75.74 64.48 49.59 31
Bx of Heavy molasses 77.14 81.03 83.58 87.46
Pty drop 15.6 16.7 23.05 20.68
Cystal % massecuite 58.5 42.2 42.8 30.1
Exhaustion % mac 70.4 57.9 62.9 58.0
Boiling time (Hr) 2.5 -3 3-4 4.5-5.5 6.5-8
Colour (IU in thousands) 8-12 12-14 20-25 NA
 Improvements done at pan station

• Mechanical circulator installation (two nos)

• Auto feed system for C pans
• Modified boiling scheme for A1 m/c production.
• Bx control system for Melt.
• Syrup ph and flow stabilization.
• DSM screen for Melt
• Pneumatic discharge valves
 Questionnaire
1. Use of automation results……………………….
a) Increase man power
b) Make process complicated
c) Consistency in process
d) Wastage of money

2. Objective of pan boiling is…..………………….

a) To evaporate water
b) To obtain desired crystal size
c) To make good quality sugar
d) All of above
 Questionnaire

3. Pan boiling consist the operation …………….

a) Clarification
b) Evaporation
c) Centrifugation
d) Drying

4. If SS coefficient of a solution is < 1 then solution is called……….

a) Unsaturated
b) Saturated
c) Super saturated
d) None of above
 Questionnaire
5. Pan boiling is preferred in……………………….
a) Intermediate zone
b) Metastable zone

c) Unsaturated zone
d) Labile zone

6. Vacuum in Pan during boiling should be maintain………….

a) 400-450 mm
b) 500-600 mm
c) 650-700 mm
d) 630-650 mm
 Questionnaire
7. Auto feed control system controls ….……………….
a) Temperature of massecuite
b) Pressure of calendria
c) Brix of massecuite
d) Level of massecuite

8. Temperature of feeding material in to pan should be……….

a) 450C - 500C
b) 650C - 700C
c) 750C - 850C
d) 1100C - 1200C
 Questionnaire
9. Massecuite level in pan should be………………....
a) > 2 meter above top tube plate
b) > 3 meter above top tube plate
c) Blow top tube plate

d) < 1.5 meter above top tube plate

10. ……………. Is used to open or close to passes of a pipeline.

a) Control valve
b) Transmitter
c) Sensor
d) Flow meter
 Questionnaire
11. I/P converter converts……………………….
a) Pressure in to current

b) Current in to temperature
c) Temperature in to current
d) Current in to pressure

12. Which of the following statement is true ?

a) Exhaustion is directly proportional to the viscosity
b) Exhaustion is inversely proportional to the viscosity
c) Exhaustion is not affected by viscosity

d) Better exhaustion results higher molasses purity

 Answer sheet
1 c) Consistency in process

2 d) All of above

3 b) Evaporation

4 a) Unsaturated

5 b) Metastable zone

6 d) 630-650 mm

7 c) Brix of massecuite

8 b) 650C - 700C

9 d) < 1.5 meter above top tube plate

10 a) Control valve

11 d) Current in to pressure

12 b) Exhaustion is inversely proportional to the viscosity