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.

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.

$Solids \ in \ sugar = \frac{ Parts \ in \ sugar}{Parts \ in \ syrup} \times \ Solids \ in \ syrup$

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

Some related articles:

Daily Manufacturing Report (DMR) Cum Chemical Control (Sugar Lab) Calculation Sheet

Three and half massecuite boiling material balance calculation | Sugar Industry 3& 1/2 massecuite boiling scheme material balance

Sugar Tech | Sugar Technology related articles with online calculators

Calculator to Find liquid volume for vertically mounted cylindrical volume and also find the volume in cylindrical tank partitioned portion.

Formula for evaluating Horizontal Cylinder volume at different levels (vacuum crystallizer volume at different sight).

Hi friends Thanks for reading the material balance calculation. I Hope you liked it. Give feed back, comments and please share it.

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 .

29 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?