Sugar Industry Three and half 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 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.
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.
| 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.
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 |
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