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 A_{1} or B_{1} or C_{1} 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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