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.

Solid Balance in Sugar industry process | Material Balance Calculation

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.

Sugar Factory Material Balance Calculation for 3 m/c Boiling

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 = \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

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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 .

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?

    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

    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.

    gurursharan kumbar

    (August 8, 2018 - 10:23 am)

    Dear Sir,
    thanks for solid balance & steam% cane on line calculation regarding

    kiran Shelar

    (May 29, 2020 - 6:46 am)

    very important and useful

    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.

    P G K NAIDU

    (May 16, 2023 - 9:53 am)

    Doing well siva sharing good things related to our industry very nice

    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..,……

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