Solid Balance in Sugar industry process | Material Balance Calculation

Sugar Factory Material Balance Calculation for 3 m/c Boiling

In  sugar Industry for the raw sugar and plantation white sugar manufacture, generally followed the three massecuite boiling scheme. Here explained with one model example about 3 massecuite boiling material balance  Calculation. Also provide online calculation sheet for 3 m/c boiling scheme.

Solid Balance in Sugar industry process | Material Balance Calculation

A massecuite or Raw massecuite:

Generally A massecuite or Raw massecuite  purity is maintained from 80 to 90.  A massecuite is boiled either with B magma or dry seed as footing.  The A massecuite is further developed with syrup, melt and A-light molasses. In the same way Raw massecuite bolied with Run off from the refined house, syrup,  Magma, CAW sugar.

B massecuite:

Generally B massecuite purity is maintained from 65 to 75.  In most of cases B massecuite is grained by true seeding method. B massecuite is further developed with A heavy molasses and Syrup( syrup Optional).  B sugar diverted to A m/c in the form of melting or footing. Maximum industries followed B m/c in single curing and some time follows double curing as per the syrup purities.

C massecuite:

Generally the C massecuite purity is maintained 50 to 55 Generally C massecuite is grained either with mixture of AH + CL molasses (purity- 65-70) or only with CL molasses (purity- 63-64) by true seeding technique.  C massecuite is further developed with C light molasses and B heavy molasses.

Sugar Factory Material Balance Calculation for 3 m/c Boiling

For Three massecuite material balance purpose first we will find the Solids in syrup % cane. So calculate solids in syrup calculate by the following formulas.

  1. Solids in syrup%cane = Solids in Clear juice % cane.
  2. Solids in Clear juice % cane = Brix in clear juice x Clear juice % cane.
  3. Brix in Clear juice = Pol in clear juice / Purity in clear juice.
  4. Purity in clear juice = Calculate by the laboratory method.
  5. Pol in clear juice = Pol in Mixed juice % cane – Pol in filter cake % cane.

Collect the following data from lab analysis

Material Name Brix pty
Syrup 56.00 82.00
A m/c 89.00  88.00
B m/c 75.00 72.00
C m/c 102.00 55.00
AH 80.00 72.00
AL 75.00 90.00
BH 85.00 50.00
CL 78.00 65.00
White Sugar 100.00
B sugar 97.00 95.00
CFW 96.00 80.00
CAW 95.00 93.00
FM 88.00 30.00
A Fore Worker(Approximate) 99.20

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

100.00 Sugar 82 – 30 = 52.00
Syrup 82.00
30.00 FM 100 – 82 = 18.00
70.00

If syrup solids divided into 70 parts , 52 solids will be in sugar and 18 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

Solids in sugar = (52 x 14.56)/70 = 10.82.

Solids in FM= Solids in syrup – Solids in sugar = 14.56 – 10.82 = 3.74.

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

80.00 CFW 25.00
C m/c 55.00
30.00 FM 25.00
50.00

Solids in C m/c  = (50 / 25) x 3.74 = 7.48

Solids in CFW = Solids in C m/c  – Solids in Final Molasses  = 7.48 – 3.74 = 3.74.

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 3.74 = 2.00

Solids in C Light  = Solids in CFW  – Solids in CAW  = 3.74 – 2.00 = 1.74.

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

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

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

Solids in AH + BH = Solids in C m/c – Solids in CL = 7.48 – 1.74 = 5.74

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

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

Imaginary mixer (AH+BH) Purity = { [ 55 x 7.48 ] – [ 65 x 1.74 ] } / 5.74 = 51.97.

72.00 AH 1.98
AH+BH 51.98
50.00 BH 20.02
22.00

Solids in B Heavy  for C boiling = ( 20.02 / 22) x 5.74 = 5.23

Solids from AH for C boiling = 5.74 – 5.23 = 0.51.

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

95.00 B sugar 22.00
B m/c 72.00
50.00 BH 23.00
45.00

Solids in B m/c  = ( 45/ 23)/5.23 = 10.23

Solids in B Sugar = Solids in B m/c  – Solids in BH  = 10.23 – 5.23 = 5.0.

Step 6 : Find the total Solids in A Heavy.

Total Solids in AH = solids in B m/c + Solids from AH for C boiling = 10.23 + 0.51 = 10.74.

Step 7 : Find the solids in A m/c and AFW

99.20 AFW 16.00
A m/c 88.00
72.00 AH 11.20
27.20

Solids in A m/c  = ( 27.2 / 11.2) x 10.74 = 26.08.

Solids in AFW = Solids in A m/c  – Solids in AH  = 26.08 – 10.74 = 15.34.

Step 8 : Find the solids in Hopper Sugar and A Light.

100.00 Hopper 9.20
AFW 99.20
90.00 AL 0.80
10.00

Solids in Hopper sugar  = ( 9.2 / 10.0) x 15.34 = 14.11.

Solids in AL = Solids in AFW – Solids in Hopper Sugar =  15.34 – 14.11 = 1.23.

Step 9 : Find the solids in Dry Seed.

Solids in dry seed = Solids in hopper sugar – Solids in bagging sugar = 14.11 – 10.82 = 3.29.

Step 10 : A m/c Solid balance.

Solids Purity Solids x Purity
Syrup 14.56 82.00 1193.9
Dry Seed 3.29 100 329.0
AL 1.23 90.00 110.6
B Sugar 5.00 95.00 475.0
CAW 2.00 93.00 186.0
Total 26.08 2294.55

Expected A m/c Purity = 2294.55 / 26.08 = 87.98.

Step 11  : Calculate all material % cane

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

Material Solid% Brix% %Cane
SYRUP 14.56 56.00 26.00
A m/c 26.12 89.00 29.35
B m/c 10.24 75.00 13.65
C m/c 7.49 102.00 7.34
AH 10.76 80.00 13.44
AL 1.23 75.00 1.64
BH 5.23 85.00 6.16
CL 1.74 78.00 2.23
B sugar 5.01 97.00 5.16
CFW 3.74 96.00 3.90
CAW 2.01 95.00 2.11
FM 3.74 88.00 4.25

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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 .

15 thoughts on “Solid Balance in Sugar industry process | Material Balance Calculation

    Sunil ohri

    (November 19, 2017 - 10:39 am)

    The content and calculations is very useful for sugar technoligists .Thanks for sharing.

      siva alluri

      (November 20, 2017 - 4:14 am)

      Thank you sir
      please share your sugar tech friends

    Ricardo Sandrin

    (January 11, 2018 - 6:31 pm)

    Very good material! Sir, can you please give more information about the imaginary mixer of AH + BH? How can I obtain this value?

    minn nyo

    (February 22, 2018 - 8:42 am)

    Thank u sir

    Tushar S. Trivedi

    (March 23, 2018 - 6:05 am)

    Can you provide a simple material balance based on 100 MT of sugar cane in terms of sugar, molasses, mud, evaporated water, bagasse, waste and unrecovered losses?

    Tushar S. Trivedi

    (March 23, 2018 - 6:08 am)

    Can you provide material balance in terms of 100 MT of sugarcane giving sugar, bagasse, molasses, mud, waste, evaporated water and unrecovered losses?

    Bhavsar Shrikant

    (May 15, 2018 - 5:58 pm)

    Nice
    Good idea
    Thanks

    gurursharan kumbar

    (August 2, 2018 - 8:55 am)

    Dear sir
    sugar gradation purpose what is the gauge of mesh from top to bottom

      siva alluri

      (August 13, 2018 - 2:36 pm)

      Ok Mr.gurursharan kumbar we will provide soon article regarding on this topic

    gurursharan kumbar

    (August 8, 2018 - 10:23 am)

    Dear Sir,
    thanks for solid balance & steam% cane on line calculation regarding

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