Three and half massecuite boiling material balance calculation |Sugar Tech

Sugar Industry 3& 1/2 massecuite boiling scheme material balance 

Planitation white sugar  industry process three massecuite boiling scheme is not giving lower purity of C massecuite and final molasses. In three massecuite boiling scheme also difficult to getting maximum ” M ” size sugar. In this situation it is better to go four massecuite boiling scheme.  But due to installed equipments does not permit to follow four massecuite boiling scheme, then a short alternative of half massecuite either between A and B masscuite or B and C massecuite is followed.  Then the boiling scheme is called as “Three and half massecuite” & the intermediate massecuite is called as A1 or B1 or C1 massecuite depending on it’s graining material used.

Here given one example for three and half massecuite boiling scheme.

Sugar Industry three and half massecuite boiling scheme material balance | Sugar Industry 3& 1/2 massecuite boiling scheme material balance

Sugar Factory Material Balance Calculation for 3 m/c Boiling

Take one example for the three and half massecuite boiling scheme calculation:

Collect the following data from lab analysis

Calculate the syrup solids from the below formulas.

  • Solids in syrup%cane = Solids in Clear juice % cane.
  • Solids in Clear juice % cane = Brix in clear juice x Clear juice % cane.
  • Brix in Clear juice = Pol in clear juice / Purity in clear juice.
  • Purity in clear juice = Calculate by the laboratory method.
  • Pol in clear juice = Pol in Mixed juice % cane – Pol in filter cake % cane.
Material Name Brix Purity
SYRUP 56.00 85.00
A m/c 92.00 90.00
A1 m/c 93.00 80.00
B m/c 95.00 72.00
C m/c 99.00 56.00
AH 80.00 76.00
AL 75.00 91.00
A1H 77.00 65.00
BH 85.00 51.00
CL 78.00 65.00
White Sugar 100.00
A1 sugar 99 98.00
B sugar 96.00 94.00
CFW 93.00 80.00
CAW 95.00 93.00
FM 88.00 30.00
AFW 99.40

Step 1 : Find the Solids in Sugar and Final molasses.

100.00 Sugar 85 – 32 = 53.00
Syrup 85.00
32.00 FM 100 – 85 = 15.00
68.00

If syrup solids divided into 68 parts , 53 solids will be in sugar and 15  solids will be in final molasses.

Solids in Unknown 1 = ( Parts of Unknown 1 / Parts of known fraction ) x Solids in known fraction.

Solids \ in \ sugar = \frac{ Parts \ in \ sugar}{Parts \ in \ syrup} \times \ Solids \ in \ syrup

Final sugar solids (Solids in sugar) = (53 x 15)/68 = 11.69.

Solids in FM= Solids in syrup – Solids in sugar =15 – 11.69= 3.31.

Step 2 : Find the Solids in C massecuite and CFW( C Fore Worker).

80.00 CFW 24.00
C m/c 56.00
32.00 FM 24.00
48.00

Solids in C m/c  = (48 /24) x 3.31 = 6.62

Solids in CFW = Solids in C m/c  – Solids in Final Molasses  = 6.62 – 3.31 = 3.31.

Step 3 : Find the Solids in C Light and CAW( C After Worker).

93.00 CAW 15.00
CFW 80.00
65.00 CL 13.00
28.00

Solids in CAW  = ( 15/ 28) x 3.31 = 1.77

Solids in C Light  = Solids in CFW  – Solids in CAW  = 3.31 – 1.77 = 1.54.

Step 4 : Find the Solids  from B Heavy for C m/c boiling and solids from A1 heavy for C m/c Boiling.

C M/C boiling with A1H , BH and CL.

Here we know only CL. So Take (A1H + BH ) imaginary mixture for C m/c boiling.

Solids in A1H + BH = Solids in C m/c – Solids in CL = 6.62 – 1.54 = 5.08

[ C m/c solids  x  C m/c pty ] = [ (A1H+BH) solids x (A1H+BH) pty ] + [  CL solids x  CL pty ]

Imaginary mixer (A1H+BH) Purity ={ [ C m/c solids  x  C m/c pty ]  – [  CL solids x  CL pty ] } / (A1H+BH) solids.

Imaginary mixer (AH+BH) Purity = { [ 56 x 6.62 ] – [ 65 x  1.54] } / 5.08 = 53.28.

65.00 A1H 2.28
A1H+BH 53.28
51.00 BH 11.72
14.00

Solids in B Heavy  for C boiling = ( 11.72 / 14) x 5.08 = 4.25

Solids from A1H for C boiling = 5.08 – 4.25 = 0.83.

Step 5 : Find the Solids in B m/c and B sugar.

94.00 B sugar 21.00
B m/c 72.00
51.00 BH 22.00
43.00

Solids in B m/c  = ( 43/ 22) x 4.25 = 8.31

Solids in B Sugar = Solids in B m/c  – Solids in BH  = 8.31 – 4.25 = 4.06.

Step 6 : Find the Solids in A1H and AH for B m/c .

65.00 A1H 4.00
B m/c 72.00
76.00 AH 7.00
11.00

Solids in A Heavy  for B m/c  boiling = (7/11) x 8.31 = 5.29

Solids in A1H for B m/c  boiling = 8.31 – 5.29 = 3.02.

Total solids in A1 H = Solids in A1H for B m/c + solids in A1H for C m/c = 3.02 + 0.83  =3.85.

Step 7 : Find the Solids in A1 m/c  and A1 sugar.

98.00 A1 sugar 15.00
A1 m/c 80.00
65.00 A1H 18.00
33.00

Solids in A1 m/c  boiling = (33/18) x 3.85 = 7.06

Solids in A1H for B m/c  boiling = 7.06- 3.85 = 3.21.

Step 8 : Find the Solids in AH and Syrup for A1 m/c boiling.

85.00 Syrup 4.00
A1 m/c 80.00
76.00 AH 5.00
9.00

Solids in A Heavy  for A1 m/c  boiling = (5/9) x 7.06 = 3.92

Solids in Syrup for A1 m/c  boiling = 7.06 – 3.92 = 3.14.

Total solids in AH = Solids in AH for A1 m/c + solids in AH for B m/c = 3.92 + 5.29 = 9.21.

Step 9 : Find the solids in A m/c and AFW

99.40 AFW 14.00
A m/c 90.00
76.00 AH 9.40
23.40

Solids in A m/c  = (23.4/9.4) x 9.21 = 22.93.

Solids in AFW = Solids in A m/c  – Solids in AH  = 22.93 – 9.21 = 13.72.

Step 10 : Find the solids in Hopper Sugar and A Light.

100.00 Hopper 8.40
AFW 99.40
91.00 AL 0.60
9.00

Solids in Hopper sugar  = (8.4/9) x 13.72 = 12.80.

Solids in AL = Solids in AFW – Solids in Hopper Sugar =  13.72- 12.80 = 0.92

Step 11 : Find the solids in Dry Seed.

Solids in dry seed = Solids in hopper sugar – Solids in bagging sugar =13.72 – 11.69 = 2.03.

Step 12 : A m/c Solid balance. (This step help to cross check the calculation)

Solids Purity Solids x Purity
Syrup  11.86 85.00 1008.3
A1 sugar 3.21 98.00 314.5
Dry Seed 1.12 100 111.6
AL 0.91 91.00 83.2
B Sugar 4.06 94.00 381.7
CAW 1.77 93.00 164.9
Total  22.94 2064.23

Expected A m/c Purity = 2064.23/ 22.94 = 89.98. ( Given A m/c purity is 90. So our calculation having no mistakes)

Step 13  : Calculate all material % cane

Material % Cane = Solids in material x 100 / Brix % material

Material Solid% Brix% %Cane
SYRUP 15.00 56.00 26.79
A m/c 22.94 92.00 24.93
A1 m/c 7.06 93.00 7.59
B m/c 8.32 95.00 8.75
C m/c 6.62 99.00 6.68
AH 9.21 80.00 11.52
A1H 3.85 77.00 5.00
AL 0.91 75.00 1.22
BH 4.25 85.00 5.00
CL 1.54 78.00 1.97
A1 Sugar 3.21 99.00 3.24
B sugar 4.06 96.00 4.23
CFW 3.31 93.00 3.56
CAW 1.77 95.00 1.87
FM 3.31 88.00 3.76

Three and half massecuite boiling material balance calculation |Sugar Tech | Sugar Industry 3& 1/2 massecuite boiling scheme material balance

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Post Author: siva alluri

The aim of this Blog "sugarprocesstech" is Providing basic to advance knowledge in sugar process industry and providing maximum calculation regarding capacity and equipment design online calculators .

16 thoughts on “Three and half massecuite boiling material balance calculation |Sugar Tech

    Revansidha.K.patane

    (November 18, 2017 - 8:46 am)

    Tks vv good imf tks

      siva alluri

      (November 20, 2017 - 4:14 am)

      Thank you sir
      please share your sugar tech friends

    MANDHATA PATEL

    (November 20, 2017 - 4:35 am)

    thanks sir,. nice work

      ALOK KUMAR DWIVEDI

      (November 21, 2017 - 7:35 am)

      You have written so beautifully but it will not follow in up region as I calculated

        siva alluri

        (November 21, 2017 - 8:20 am)

        Ok kumar sir,
        suggest the your boiling scheme, what your region follows

    Ranjit kawade

    (December 8, 2017 - 1:19 am)

    So Nice Information in this Website.
    Thank you so much.
    I Have also Completed Bsc (Sugar Technology)
    Rajarambapu institute of technology Islampur

      siva alluri

      (December 8, 2017 - 1:56 pm)

      This website invite to all sugar technologists to share knowledge

      sandesh patil

      (January 23, 2018 - 5:47 pm)

      good information in this web side
      i also pass out in rajarambapu institute of suger technology islampur

    Vijaykumar Dure

    (March 25, 2018 - 8:46 am)

    R / sir this site is very very Good learning about sugar plant for overall calculation means fully basic terms Thanks so much .

    Javier Ibáñez

    (April 12, 2018 - 4:34 pm)

    Este site es muy bueno…felicitaciones!

    Javier Ibáñez

    (April 12, 2018 - 4:37 pm)

    I would like to know if you have material to calculate and make management in difussers.

      siva alluri

      (April 16, 2018 - 1:24 pm)

      We will published an article on diffusers soon

    Yibeltal tesfa

    (April 18, 2018 - 8:19 am)

    Wow I am very impressive on your notes, but I have a question for u I am not understand on the difference b/n three and half boiling and four boiling scheme based on there operational system

      siva alluri

      (April 19, 2018 - 3:38 pm)

      Thank you Mr.Yibeltal tesfa
      The main difference between 3 1/2 & 4 m/c boiling scheme is
      The entire molasses diverted to next massecuite without deviation upto end ( it may take little bit high purity material for purity balance )
      I.e Syrup to A m/c → A Heavy molasses to B m/c → B molasses to C m/c → C molasses to D m/c Then it is called 4 massecuite boiling
      For purity balance purpose (FM purity) or crystal size purpose or quality purpose some times introduces one massecuite boiling in-between two massecuites with partial quantity molasses
      I.e suppose B2 m/c introduced in-between A and B massecuites then
      AH diverted to B2 m/c as per requirement purity and remaining AH diverted to B m/c. So the complete AH molasses not diverted to B2 m/c
      So it is called 3 1/2 massecuite.

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