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).
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:
Where
S = Heat transfer surface area in m2
M= Quantity of material to be heating 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 consider 4 to 5 minutes retention time with agitator for uniform mixing. The RPM of the agitator 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 calculated on the basis of retention time. It will be provided 35 minutes and height of the clarifier having 1.7 to 1.75 mtrs. Center well of the clarifier height having 150mm to 200mm less then the clarifier height with 2 to 2.5 minutes retention. Liquor outlet coil Dia calculate on the basis of velocity 0.3 to 0.4 m/sec. Perforated holes to be provided below the coil and its 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 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 preparation tank |
Online Calculator for Chemical Dosing Calculation for Syrup and Melt Clarification Systems
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18 thoughts on “Melt Clarification System Design Criteria for Sugar Refinery Process”
Neeraj kumar rajput
(May 10, 2018 - 7:23 pm)please upload the calculation of ion exchange colu
m
siva alluri
(May 13, 2018 - 4:49 pm)Mr. Neeraj kumar rajput
We will try to provide ion exchange calculation
Narayan Mahana
(June 30, 2018 - 6:20 am)Pl.upload the calculation for spray pond pipeline.
siva alluri
(June 30, 2018 - 1:28 pm)Ok we will upload soon
Prashant sharma
(July 11, 2018 - 5:55 pm)please upload the air requiment calculation in melt or syrup clarification system.
siva alluri
(July 12, 2018 - 1:29 pm)Ok we will provide soon
brijendra singh
(July 15, 2018 - 5:14 pm)pls ,upload air req.during areation in melt and syrup clarification system
Uday Pratap Singh
(April 9, 2019 - 10:24 am)semikestner tube length 6.0 meter ,used conventional body (tube length 2.0meter)with s.kestner.
PRADEEP SAXENA
(April 10, 2019 - 12:35 pm)Please upload calculation of filtrate clarification system
Pradeep saxena
Chief process Manager
Twenty one sugar Latur
siva alluri
(April 13, 2019 - 5:33 pm)OK sir we upload soon regarding the FCS calculation
Uday Pratap Singh(A.G.M.Process Havalga unit)
(May 24, 2019 - 5:05 am)Sir, Syrup cooling Arrangement calculation from 50 tonne syrup at 60 degree brix ,temp 65 degree to cool 32 degree and water inlet temp is 29 degree .please help cooling arrangement cooling surface in this respect.
siva alluri
(May 25, 2019 - 4:38 pm)It is very simple please go through the below link ( liquid – liquid heater)
https://www.sugarprocesstech.com/liquid-liquid-heater/
Amarjeet Yadav
(June 25, 2019 - 5:56 am)Dear Sir,
Please update V.C.P Pan detail and working and proses .
ankit kumar
(January 2, 2021 - 2:21 pm)you can mail me for vany query regarding calculation
ASHOK KUMAR SINGH PARMAR
(November 12, 2021 - 2:21 am)please give calculation of lime sucrate preparation. how much water/cao/sugar solids in 1 kg of lime sucrate.
siva alluri
(January 2, 2022 - 9:13 am)50% water, 25% lime at 10 Be, 25% melt at 65 brix
MIR RIAZ
(February 27, 2022 - 6:44 am)This is to much important for to designed or modification, alteration in process House. very help full.
I request to seniors please give major points which related to Melt Liquor to clear , Deep bed filter and fine liquor.
all employees prays for you who will share the basic knowledge. specially chemists.
Regards.
Mir Riaz Ahmed Talpur
MIR RIAZ
(February 27, 2022 - 6:51 am)Seniors and Director/Specialist, sugar Technologies .
I request to you please work on Talo process clarification, just from Remelt liquor to fine liquor, all equipment calculate and designed, all applied chemicals preparation and holding tnaks, applied chemicals PPM, using method. retention time of remelt-clear-fine liquor tanks and Talo-clarifier Deep bed filters capacity and retention time calculation, all gravels sizes with area and height as per diameter. color removl %, brix, temperatures all basic points upload on this web site.
please help to all employees of sugar mills who belong to process, or production department.
Regards….
Mir Riaz Ahmed Talpur………Chemist