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.
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 = (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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