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You are at:Home»Sugar Refinery»Melt Clarification System Design Criteria for Sugar Refinery Process

Melt Clarification System Design Criteria for Sugar Refinery Process

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Syrup Clarification Design for Plantation white sugar manufacturing

In this article explained about the design criteria of syrup and melt clarification system required equipment capacity like buffer tank, melt heater, reaction vessel, aeration vessel, chemical holding and dosing tanks, dosing pumps capacity, pipe lines and flotation clarifier. Also provided online calculator for Syrup and melt clarification system chemical dosing.

The fundamental concepts Melt and Syrup Clarification systems given in the below link

Syrup Clarification System & Melt Clarification System in sugar Industry

Here we calculate syrup clarification system for 5000TCD plant (210TCH).

Reading Map - Quick Links

Toggle
  • 1.Buffer tank Capacity
  • 2. Syrup or Melt heater
  • Flotation Clarifier :
  • Chemical Dosing and its Pumps Capacity Calculation:
  • Chemical preparation and holding tanks capacity calculation

1.Buffer tank Capacity

It is required holding capacity of 30 to 40 minutes retention time. Buffer tank helps to maintain the constant flow of liquor (syrup or melt).

Here we take plant capacity 5000TCD

S.NO  Particulars Values UOM
1  Crushing rate 210 TCH
2  Syrup Brix 60 Brix
3  Syrup % cane 25 %
4  Density of syrup 1.2 gm/ml
5  Flow rate of syrup 25% on cane
 
    210 x 25%  
    52.5 T/hr
    52.5 / 1.2  
    43.75 M3/hr
    0.012153 M3/sec
6 Buffer tank capacity (35 min.) 0.012153 x 35 x 60  
    25.5 M3

2. Syrup or Melt heater

The material heated upto 80 to 85oC by using tubular heater or direct contact heater.

Heating surface calculation for tubular juice heater

Formula:

 S \times K = M \times C_{p} \times \log_{e} \left( \frac{T_{v} - t_{i}}{T_{v} - t_{o}} \right)

 

Where

    • S = Heat transfer surface area in m2
    • M = quantity of material to be heated kg/hr
    • Cp = Specific heat of material in Kcal/kg/oC.
    • ΔT = Temperature difference from inlet to outlet of the heated material in oC
    • ΔTm = LMTD = Log Mean Temperature Difference.
    • K = Overall heat transfer Coefficient Kcal/m2/hr/oC = 6 x Tv x [U / 1.8] 0.8
    • Tv = Heating vapour temperature
    • ti / to = syrup or melt inlet/outlet temperature.
    • U = velocity of syrup in tubes.

Here we consider some values for calculation.

S.NO  Particulars Values UOM
1  Crushing rate 210 TCH
2  Syrup Brix 60 Brix
3   Syrup % cane 25 %
4  Flow rate of syrup 210 x 25%  
    52.5 T/hr
    52500 Kg/hr
5  Vapour inlet temperature (Tv) 102 oC
6  Velocity of syrup (U ) 1.2 m/sec
7  Specific heat of syrup(Cp) 0.65 Kcal/kg/oC
8  Syrup Inlet temperature 60 oC
9  Syrup Outlet temperature 85 oC
10  Heat transfer coefficient 6 x 102 x (1.2/1.8 ) 0.8  
    442 Kcal/m2/oC/hr
11  Heating Surface 52500 x 0.65 x ln[(102-60)/(102-85)] / 442
    69.83 m2

For design of the tubular heater according to heating surface go through the below link

Tubular juice heater design calculation with online calculator.

For design of the direct contact heater go through the below link

Formulas for Design Direct Contact Heater (DCH) with Online calculation Sheet.

Reaction and Aeration Vessel: The retention time of the reaction vessel is considered 4 to 5 minutes retention time with agitator for uniform mixing. The RPM of the agitator was maintained 60 to 90.

1  Flow rate of syrup 43.75 M3/hr
    0.012153 M3/sec
2  Reaction vessel holding volume (4.5 min) 0.012153 x4.5 x 60  
    3.28131 M3
3  Aeration  vessel holding volume (1.5 min) 0.012153 x1.5 x 60  
    1.1 M3

Flotation Clarifier :

The Flotation clarifier holding volume is calculated on the basis of retention time. It will be provided for 35 minutes and the height of the clarifier is 1.7 to 1.75 meters. The center well of the clarifier height having 150mm to 200mm less than the clarifier height with 2 to 2.5 minutes of retention. Liquor outlet coil Dia is calculated on the basis of velocity 0.3 to 0.4 m/sec. Perforated holes to be provided below the coil and their number calculated on the basis of coil cross-sectional area (To be take 100 to 120% on coil cross section area).

S.NO  Particulars Values UOM
1  Flow rate of syrup or melt 43.75 M3/hr
    0.012153 M3/sec
2  Flotation Clarifier holding volume (35 min) 0.012153 x35 x 60
    25.52 M3
3  Height of the clarifier 1.7 to 1.75 mtrs
4  Dia of the clarifier SQRT [(25.52/ (0.785 x 1.75 )]
    4.310 mtrs
5  Center well ( melt inlet well)  
6  Volume of center well (2.5min.) 0.012153 x 2.5 x 60
    1.82295 M3
7  Height of the center well 150mm less then clarifier height
8  Dia of the center well SQRT [(1.82/ (0.785 x 1.60 )]
    1.205 mtrs
9  Melt outlet Coil Dia    
10  Velocity in Outlet coil 0.3 m/sec  
11  Coil Dia 0.012153 / 0.3  
    0.04051 m2
    SQRT [(0.04051/ (0.785)]
    0.227167549 mtr
   Say 250 mm
12  Opening area for coil 120% on coil cross sectional area
    (0.785 x 0.250 x 0.250) 120%
    0.058875 m2
13  Each hole dia consider 25 mm
    0.0004906 m2
14  Number holes required 120  

Chemical Dosing and its Pumps Capacity Calculation:

S.No  Description Values UOM Remarks
1  Crushing Rate 210 TCH  
2  Syrup brix 60 %  
3  Syrup % cane 25 %  
4  Colour Precipitant (CP) 200 PPM  150 to 200 ppm
5  Phosphoric Acid Dosing ( in P2 O5) 150 PPM  150 to 300 ppm
6  Flocculent Dosing 14 PPM  10 to 15 ppm
7  P2 O5 % in given H3PO4 65 %  
8  Density of  H3PO5  1689 kg/M3  
9  Density CP 1.16 gm/ml  
10  Syrup Flow Rate 52.5 T/hr Crushing rate x Syrup % cane
11  Solids in syrup 31.5 T/hr Liquor flow Rate x Liquor brix%
   In the same way calculate solids in melt for melt clarification system
Colour Precipitant
1  Colour Precipitant required 6.3 Kg/hr Solids in syrup x CP in PPM
2  Density CP 1.16 gm/ml  
    5.43 Lt/hr 6.3 / 1.16
3  CP Pump Capacity required 10 Lt/hr without dilution
    100 Lt/hr With 10% dilution
Phosphoric Acid
1  Phosphoric Acid (in P2O5) required 4.725 Kg/hr Solids in syrup x P2O5 in PPM
2  Phosphoric Acid (in H3PO4) required 7.27 Kg/hr Phosphoric Acid (in P2O5) / (P2 O5 % in given H3PO4)
3  Phosphoric Acid (H3PO4) required 4.30 Ltrs/hr 7.27 / 1.689
4  Acid Pump Capacity required 10 Lt/hr Without dilution
    100 Lt/hr With 10% dilution
Flocculent
1  Flocculent  required 0.441 Kg/hr Solids in syrup x Floc. in PPM
   Flocculent Dosing (0.1% concentartion)
2  Flocculent solution quantity 441.0 Lts/hr 0.441 / 0.1%
3  Flocculent pump capacity 661.5 Lts/hr 150% on 441
Lime Sucrate
   1 Kg of P2 O5 required 1.2 kg of Cao
1  Cao required 5.67 Kg of Cao/hr Phosphoric Acid in P2O5 x 1.2 ( 4.725 x 1.2)
2  Milk of lime Brix 14 %  
3  Cao Concentration @ 14 brix 75 gm/1000ml  
4  MOL % in Lime Sucrate 25 %  
5  MOL required 63 Ltrs/ hr 4.725  x 1000 / 75
6  Lime Sucrate required 252 Ltrs/ hr 63 / 25%
7  Lime Sucrate pump capacity 378 Ltrs/ hr 150% on 252
    400 Ltrs/ hr  

Chemical preparation and holding tanks capacity calculation

 Colour Precipitant Dosing tank
1
 Colour Precipitant required 5.4 Lt/hr  
2  Colour Precipitant Dosing tank capacity 54.3 Lt/hr For 10 hrs
   Consider 200 Ltrs Without dilution
    500 Lt With 10% dilution
Phosphoric Acid dosing tank
1  Phosphoric Acid (in H3PO4) required 4.30 Lt/hr  
2  Phosphoric Acid Dosing tank capacity 43 Lt/hr For 10 hrs
   Consider 200 Ltrs Without dilution
    500 Lt With 10% dilution
Flocculent preparation and holding tank capacity
1  Flocculent solution quantity 441 Lts/hr  
2  Flocculent preparation tank 2646 Ltrs/ 6hrs  
3  Flocculent Holding tank 2910.6 Lts 10% extra on the preparation tank
Lime Sucrate preparation and holding tank capacity
1  Lime Sucrate required 250 Ltrs/ hr
2  Lime Sucrate preparation tank 2000 Ltrs/ 8 hrs
3  Lime Sucrate Holding tank 2200 Ltrs/ hr 10% extra on the preparation tank

Online Calculator for Chemical Dosing Calculation for Syrup and Melt Clarification Systems

Click Here

 

Syrup Clarification Design for Plantation white sugar manufacturing | Melt Clarification System Design Criteria for Sugar Refinery Process | Fundamental concepts of syrup and melt clarification systems in sugar industry process| Melt Clarification System Design Criteria for Sugar Refinery Process | Syrup Clarification Design for Plantation white sugar manufacturing

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