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.
- 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.
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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35 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?
siva alluri
(January 12, 2018 - 1:54 pm)Thank you sir
Please go through the link
https://www.sugarprocesstech.com/massecuite-boiling/
Here explained about imaginary mixer calculation of A1H + BH
Saurabh gupta
(April 12, 2022 - 12:03 pm)First ensure the % of AH % and Bh% Consider let Ah 25% and BH 75 %
And Pty of AH =72 & BH= 50 ( Consider) the Pty of AH+BH = (25*72+75*50)/100=55.5
Apply Formula for Solid AH(72) 5.5
AH+BH(55.5)
BH(50) 16.5 sol . this ……….
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?
siva alluri
(March 23, 2018 - 4:57 pm)Go through the below the link
https://www.sugarprocesstech.com/daily-manufacturing-report-dmr/
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?
siva alluri
(March 23, 2018 - 4:56 pm)Go through the below the link
http://www.sugarprocesstech.com/daily-manufacturing-report-dmr/
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
Liverton Sifunda
(March 9, 2022 - 2:36 pm)Very useful knowledge. Thank you sir.
siva alluri
(March 24, 2022 - 4:11 am)welcome
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
kiran Shelar
(May 29, 2020 - 6:46 am)very important and useful
siva alluri
(June 21, 2020 - 10:00 am)Thank you
deepak
(August 20, 2020 - 3:47 pm)Sir please give information about SULFATE REMOVAL SYSTEM with calculation.
Sunil Pisal
(April 5, 2021 - 4:48 pm)How to find clear juice % cane ?
siva alluri
(April 26, 2021 - 4:05 am)Clear juice%cane = Lime/sulphited juice % cane after heating (before entering into clarifier ) – Mud%cane + vacuum filter cake wash%cane
Nadeem Mansur Nadaf
(November 23, 2021 - 7:24 pm)How to find clJ%cane
Shreeshail Patil
(August 10, 2023 - 12:28 pm)Sir so much thanks use full solid balance find out examle given
Ishant Kumar Srivastava
(July 25, 2022 - 11:11 am)Sir how to calculate Syrup %cane without using Solid balance??? Pls reply
siva alluri
(August 20, 2022 - 1:47 pm)The following formula gives approximate value
Syrup%cane = Mixed juice %cane x Mixed juice Brix /Syrup Brix
SAKTHIVEL SUBIRAMANIYAN
(October 13, 2022 - 10:32 am)Syrup % cane = 100- (Brix in syrup – Brix in Clear juice / Brix in syrup)
Wiseman mkhize
(April 27, 2023 - 11:12 pm)Hi please explain more or in detail about Overall recovery
SAKTHIVEL SUBIRAMANIYAN
(October 13, 2022 - 10:31 am)Sir,
Please update any Sugar Daily manufacturing report format and calculation for B Heavy and syrup diversion to ethanol.
siva alluri
(October 14, 2022 - 5:41 am)Ok we will update
P G K NAIDU
(May 16, 2023 - 9:53 am)Doing well siva sharing good things related to our industry very nice
siva alluri
(June 8, 2023 - 2:28 pm)Thank you sir
Shreeshail Patil
(August 10, 2023 - 12:34 pm)Sir one more request solid balance report
To find out massecute percentage on cane ……. please put reg..,……
siva alluri
(August 11, 2023 - 5:17 am)Ok we will update it