Basics in process Engineering Design Design of a sugar manufacturing plant
Sugar plant design
Jan 18, 2015
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Basics in process Engineering Design
Design of a sugar manufacturing plant
Group MembersContents
Preliminary stage• Finding the demands• Identifying various processes• Selecting a process• Find a suitable location• Block diagram for the selected process• Raw material specifications• Environmental considerations• Utility services• Energy sources• Identifying problems/ Limitations
Mass balances
Group MembersFinding the demands
Sri Lanka sugar demands 1993-2011
Sources :Department of Census and Statistics Pelwatte Sugar Industries Ltd Sevanagala Sugar Industries LtdSri Lanka CustomsCentral Bank of Sri Lanka
Year Sugar demand, MT1993 4574421994 5632751995 4875121996 4543391997 6090551998 5500001999 5412202000 5442202001 5600332002 5916612003 5700502004 5011512005 4713762006 5810192007 5075442008 6103782009 4981682010 5793362011 640876
Group MembersFinding the demands
Prediction through curve fitting
Current demand 2013 – 584,373 MT
Demand in 2015 – 591,815 MT
1990 1995 2000 2005 2010 20150
100
200
300
400
500
600
700
f(x) = 3.72120701754386 x − 6906.76934385965R² = 0.14750235816799
Year
Sugg
ar d
eam
and,
1000
MT
Our target – 59,181.5 MT/Yr
200 working days – 12.33 MT/hr
Group MembersIdentifying various processes
Cane Sugar
Beet Sugar Corn Sugar
• Cane Sugar - Crystal, Powder, syrup Both of Cane sugar industry • Beet Sugar and Beet sugar industry are - Crystal, Powder, syrup used same process. • Corn Sugar - Sugar syrup (only used for sweeteners)
Group MembersIdentifying various processes
Cane sugarGrown in Tropical climate areas within 22°N-22°Sat least 800-1000 mm/yearSoil temperature is about 70-80°FTemperature max growth at 27°CFor the better photosynthesis in leaves sugarcane need plentiful sunshine.
Beet sugar Grown in Sub-tropical climate areasTemperature of 15-22 CRequires a good irrigation system and law wind speedsThe process of manufacturing beet sugar is quite similar to that of sugar cane.
Group MembersProduct specification
Row Cane sugar ( Brown sugar )
Mill White sugar ( White Sugar)
Refined sugar ( White Sugar )
Cane Sugar
Mainly produce 3 types of sugar by Cane
Raw Refined Crystal (mill)
Muscavado Demerara Caster
Icing Premium Liquid Sugar Fine Liquid Sugar
Invert White Crystal Refined - Fine Granulated
Group MembersProduct specification
We chose Raw Cane sugar ( Brown sugar )
Group MembersFind a suitable location
Requirements for sugar cane cultivation
Soil type medium to heavy well drainedClimate RH-70% (for optimum vegetation growth)Rain fall at least 800-1000 mm/yearTemperature max growth at 27°CWind High Wind exceeding 60 km/hr
Sri Lanka temperature profile
Group MembersFind a suitable location
B- North-west region (Mannar)
A - South-east region (Hambanthota, Embilipitiya)
Source : https://sites.google.com/a/tcd.ie/sri-lanka/geography
Group MembersFind a suitable location
Use factor rating method,A- South east regionB- North west region
More suitable location is South east region of Sri Lanka
Critical Factor Weight RatingA B
Rain fall for cultivation 10 100 100Temperature for cultivation 9 100 100Soil fertility 7 80 40Water supply 7 70 60Land cost and availability 9 80 70Labour cost and avaliablity 6 70 70Transport 5 60 80
Score 4390 4050
Group MembersRaw material specifications
Sugarcane will be grown in 1315 HaTo get the maximum crop new sugarcane clone L-97-128 is recon
Other main raw materials for the sugar plants are lime and water.
Water can be delivered either from the Lunugamwehera irrigation system or Udawalawe tank Water from Lunugamwehera is small and most of the water from it is used in agriculture already
Lime is used for the clarification of raw juiceEither imported or use CaCO3 found in south or north-western parts of Sri Lanka We can’t use lime from coralsThis is a food product, we have to use pure lime therefore it is recommended to get lime from a foreign country.
Group MembersSelecting a processing methodEnvironmental considerations
Land usage
Land usage is too large for cane cultivation
De-forestation
Change of animal habitats
De-fertilization of soil
Waste water
Inputs to the sugar plant are mainly sugar cane and some amount of water
The water is used in milling as imbibition water and steam
discharge water from pan boilers
Group MembersSelecting a processing methodEnvironmental considerations
Gas emissions
Emissions such as Sulpher Oxides and Nitro Oxides can be emitted from the
clarifier
Solid waste
Produces dust and ash which can cause skin diseases
Baggase and filter cake are removed from milling and vacuum pumps
Baggase can be used in boilers, filter cake can be used as fertilizer
Baggase
Group MembersSelecting a processing methodUtility services
Electricity
Used in crane system, cutters, and various kinds of motors, centrifugal
machines, juice clarifiers, driers, bucket elevators, air compressors, magnetic
separators, pump house, work shop facilities and lighting
Delivered from Ceylon Electricity Board national grid.
There is a potential to produce electricity by baggase coming out from
milling process
Power house steam turbines will use steam from boiler where the baggase
is burned
Start up of the power plant firewood can be used
Group MembersSelecting a processing methodUtility services
Steam
Steam is the main utility for the operation in a sugar factory.
Generated in boilers which Steam is used in different forms such as
superheated stem etc.
Superheated steam is used for operating mill house machinery, shredder,
and power turbines
Exhaust steam will be used process heating
De-superheating unit and pressure reducing unit
Superheated steam cannot be used for process heating purposes.
Group MembersSelecting a processing methodUtility services
Compressed air
Used in pneumatic control system of the factoryIn vacuum filter to create vacuums in different levels Used in a pressure of 7bar so the sufficient air compressors are used
Work shop facility
Workshop facility to repair the factory machinery in factory itselfWorkshop machines such as lathe, milling, boring are essential
Auto mobile repair centre
Various vehicles are used in both sugar planting and the factory Vehicles may come up with various problems
Group MembersSelecting a processing methodEnergy sources
Electricity
Electricity from CEB and steam turbines are used in sugar factoriesElectricity from CEB for lighting, for residencesElectricity from steam turbines for other uses [pumps, motors, compressors etc.]
Thermal Power – Steam
Super heated steam is used Mill turbines, shredder , power turbinesExhaust steam from these processes is used in evaporation,Vapor generated from evaporation can be used in pan boilers Bio mass
Firewood for boiler startupBaggase for boiler
Group MembersSelecting a processing methodIdentifying problems/ Limitations
Supposed to manufacture 59,181MT of sugar per annumBetter to have line production instead of single line plantOr else use multiple lines for the unit operations which take long time to complete Those steps can be considered as the limiting factorsShredding and pan boiling are such unit operations.
Problems arising in startup in the boiler plantAs mentioned previously firewood can be used for startup the boiler until baggase lots are available for burning
if manufacturing white sugar ,have to add another unit operation to the process which involves lots of chemicalsWhat importing is white sugarManufacturing white sugar will make a competition between Sri Lankan Sugar manufacturing and imported sugarTherefore the process is limited to brown sugar manufacturing.
References
1. E. Hugot. Handbook of Sugar cane Engineering, Third completely revised edition: Elsevier science publishing company; 1986.
2. Rogger P. Humbert. The growth of sugar cane, Revised edition : Elsevier science publishing company; 1968.
3. Verlas Dr. Albert Bartens KG. CANE SUGAR ENGINERING. Berlin, Germany; 2007.
4. Juliano José Corbi & Susana Trivinho-Strixino & Ademir dos Santos. Environmental Evaluation of Metals in Sediments and Dragonflies Due to Sugar Cane Cultivation in Neotropical Streams. http://link.springer.com/content/pdf/10.1007%2Fs11270-008-9749-1 (accessed 17th December 2012).
References
5. K. A. Gravois,* K. P. Bischoff, S. B. Milligan, F. A. Martin, J. W. Hoy, T. E. Reagan, C. A. Kimbeng, C. M. LaBorde, and G. L. Hawkins. Registration of ‘L 97-128’ Sugarcane. https://www.crops.org/publications/jpr/pdfs/2/1/24 (accessed 16th December 2012)
6. Sugar cane. http/www.wikipedia.org/sugarcane (accessed 10th December 2012)
End of slides
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