# Solid Balance in Sugar industry process | Material Balance Calculation

## Sugar Factory Material Balance Calculation for Three Massecuite 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.

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.

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 = (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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## 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

#### 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

#### siva alluri

(May 16, 2018 - 2:09 pm)

Thank you Mr.Bhavsar Shrikant

#### 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

#### siva alluri

(August 13, 2018 - 2:34 pm)

Thank you Mr gurursharan kumbar