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4000 TCD

This document provides an energy balance for a sugar mill with a crushing rate of 4000 tons of cane per day. It details the steam requirements and heat transfer across the multiple effect evaporation system. Key details include: - The mill processes 4000 tons of cane per day in a 24 hour period - Total evaporation is 163.998 tons per hour - Exhaust steam requirement for the evaporators is 80.727 tons per hour - The quad-effect system uses steam at decreasing pressures and temperatures across four vessels - Heat is transferred between vessels and to heat juice in multiple stages

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2K views18 pages

4000 TCD

This document provides an energy balance for a sugar mill with a crushing rate of 4000 tons of cane per day. It details the steam requirements and heat transfer across the multiple effect evaporation system. Key details include: - The mill processes 4000 tons of cane per day in a 24 hour period - Total evaporation is 163.998 tons per hour - Exhaust steam requirement for the evaporators is 80.727 tons per hour - The quad-effect system uses steam at decreasing pressures and temperatures across four vessels - Heat is transferred between vessels and to heat juice in multiple stages

Uploaded by

NaeemSial
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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QUADRPUL EFFECT FOR CRUSHING RATE 4000 TCD

ENERGY BALANCE (WITHOUT FFE)


1. Cane Crushing 4000.000 TCD
2. Working Hours 24:00 Day
3. Cane Rate 166.667 TCH
4. Mix Juice % Cane 110.380 %Cane
5. Raw Juice 183.966 Tons/Hr.
6. Limed Juice 219.382 Tons/Hr.
7. Clear Juice 197.716 Tons?Hr.
8. Clear Juice Brix 13.138 %
9. Syrup Brix 65.000 %
10. Total Evaporation 157.754 Tons/Hr.
11. Syrup 39.962 Tons/Hr.
12. Imbibition 300.000 % Fibre
Pressure & Temperature Difference Quadrpul Effect (C & PSIA)
Steam 1st V 2nd V 3RD V 4th V

Pressure PSIA 28.8 21.50 14.50 8.20 2.30


Temperature 0C 120.00 111.11 100.00 85.00 55.00
Latent Heat Kcal/g 525.70 531.80 538.90 548.20 566.10

Sequence of Temperature
Temp. 0C D (Temp. Elev) 0C Juice Temp. 0C I n Temp. Diff. 0C

Exhaust Steam 120 - - -

1st Vessel Vap. 111.11 0.78 111.89 8.11

2nd Vessel Vap. 100.00 1.28 101.28 9.83

3rd Vessel Vap. 85.00 2.11 87.11 12.89

4th Vessel Vap. 55.00 6.11 61.11 23.89

Total 54.72
Vapour/Steam Consumption at Heaters

S# Description Temperature Rise 0C Heating Media

From To

1. Primary Heating 30.00 55.00 Vapour Line Juice Heater


2. “ “ “ “ “ 55.00 70.00 3rd Vapour at 85 0C
3. Secondary Heating 68.00 85.00 2nd Vapour at 100 0C
4. “ “ “ “ “ 85.00 103.00 1ST Vapour at 111.11 0C
5. Melt Liq. Heating 65.00 85.00 1st Vapour at 111.11 0C
6. Pre Juice Heating 98.00 112.00 Ex. Steam at 120.00 0C

Primary Juice Heating


1. By 3rd Vapour Vap.Temp. 85.00 0C =183.966 X0.92(70-55)/548.20 = 4.631 Tons/Hr
Latent Heat 548.20 kcal/kg

Secondary Juice Heating


1. By 2nd Vapour Vap.Temp.100.00 0C =219.382 X0.92(85-68)/538.90 = 6.370 Tons/Hr
Latent Heat 538.90 Kcal/kg
2. By 1st Vapour Vap.Temp.111.11 0C =219.382 X0.92(103-85)/531.80 = 6.831 Tons/Hr
Latent Heat 531.80 Kcal/kg

Melt Liquor Heating


1. By 1st Vapour Vap.Temp.111.11 0C = 1.03X37.183X0.720(85-65)/(531.80X.972) = 1.070 T/Hr.
Latent Heat 531.80 Kcal/kg

Pre Juice Heating


1. By Ex. Steam Temp.120.00 0C =197.716 X0.92(108-98)/525.70 = 3.460 Tons/Hr
Latent Heat 525.70 Kcal/kg

Through material balance vapour required for pan boiling 41.360 tons/hr at 24.820 % on cane

1. All raw pan boiling (by 1st Vapour) vapour required 22.720 Tons/Hr.
2. All Refine pans boiling (by 1st vapour) ) vapour required 18.640 Tons/Hr.
Total Vapour 41.360 Tons/Hr.

Individual Evaporation of the Vessel


4th Vessel X -
3rd Vessel X + 4.631
2nd Vessel X + 4.631 + 6.370
1st Vessel X + 4.631 + 6.370 + 6.831 + 1.070 + 41.360
4X + 13.893 + 12.740 + 6.831 + 1.070 + 41.360 =75.894
X =157.754 – 75.894 = 81.860/4 =20.465 Tons/Hr.
X = Vapour to condenser 20.465 TPH

4th Vessel 20.465 20.465


3rd Vessel 20.465 + 4.631 25.096
nd
2 Vessel 20.465 + 4.631 + 6.370 31.466
st
1 Vessel 20.465 + 4.631 + 6.370 + 6.831 + 1.070 + 41.360 80.727
Total Evaporation 157.754 T/Hr.
Total Exhaust Steam Required for Evaporators 80.727 Tons/Hr.

Exhaust Steam Requirement for Process House

1 Evaporators 80.727 Tons/Hr.

2 Pre Juice Heating 3.460 Tons/Hr.

Total 84.187 Tons/Hr.


QUADRPUL EFFECT FOR CRUSHING RATE 4000 TCD
ENERGY BALANCE (WITHOUT FFE)
13. Cane Crushing 4000.000 TCD
14. Working Hours 24:00 Day
15. Cane Rate 166.667 TCH
16. Mix Juice % Cane 109.400 %Cane
17. Raw Juice 182.334 Tons/Hr.
18. Limed Juice 219.004 Tons/Hr.
19. Clear Juice 197.334 Tons?Hr.
20. Clear Juice Brix 10.981 %
21. Syrup Brix 65.000 %
22. Total Evaporation 163.998 Tons/Hr.
23. Syrup 33.336 Tons/Hr.
24. Imbibition 300.000 % Fibre
Pressure & Temperature Difference Quadrpul Effect (C & PSIA)
Steam 1st V 2nd V 3RD V 4th V

Pressure PSIA 28.8 21.50 14.50 8.20 2.30


0
Temperature C 120.00 111.11 100.00 85.00 55.00
Latent Heat Kcal/g 525.70 531.80 538.90 548.20 566.10

Sequence of Temperature
Temp. 0C D (Temp. Elev) 0C Juice Temp. 0C I n Temp. Diff. 0C

Exhaust Steam 120 - - -

1st Vessel Vap. 111.11 0.78 111.89 8.11

2nd Vessel Vap. 100.00 1.28 101.28 9.83

3rd Vessel Vap. 85.00 2.11 87.11 12.89

4th Vessel Vap. 55.00 6.11 61.11 23.89

Total 54.72
Vapour/Steam Consumption at Heaters
S# Description Temperature Rise 0C Heating Media

From To

1. Primary Heating 30.00 55.00 Vapour Line Juice Heater


2. “ “ “ “ “ 55.00 70.00 3rd Vapour at 85 0C
3. Secondary Heating 68.00 85.00 2nd Vapour at 100 0C
4. “ “ “ “ “ 85.00 103.00 1ST Vapour at 111.11 0C
5. Melt Liq. Heating 65.00 85.00 1st Vapour at 111.11 0C
6. Pre Juice Heating 98.00 112.00 Ex. Steam at 120.00 0C

Primary Juice Heating


1. By 3rd Vapour Vap.Temp. 85.00 0C =182.334 X0.92(70-55)/548.20X.950 = 4.831 Tons/Hr
Latent Heat 548.20 kcal/kg

Secondary Juice Heating


2. By 2nd Vapour Vap.Temp.100.00 0C =219.001 X0.92(85-68)/538.90x.950 = 6.690 Tons/Hr
Latent Heat 538.90 Kcal/kg
3. By 1st Vapour Vap.Temp.111.11 0C =219.001 X0.92(103-85)/531.80X.950 = 7.178 Tons/Hr
Latent Heat 531.80 Kcal/kg

Melt Liquor Heating


4. By 1st Vapour Vap.Temp.111.11 0C = 1.03X28.217X0.720(85-65)/(531.80X.972) = 0.810 T/Hr.
Latent Heat 531.80 Kcal/kg

Pre Juice Heating


5. By Ex. Steam Temp.120.00 0C =197.334 X0.92(108-98)/525.70X.950 = 3.635 Tons/Hr
Latent Heat 525.70 Kcal/kg

Through material balance vapour required for pan boiling 34.250 tons/hr at 20.55 % on cane

1 All raw pan boiling (by 1st Vapour) vapour required 19.510 Tons/Hr.
2. All Refine pans boiling (by 1st vapour) ) vapour required 14.740 Tons/Hr.
Total Vapour 34.250 Tons/Hr.

Individual Evaporation of the Vessel


4th Vessel X -
3rd Vessel X + 4.831
2nd Vessel X + 4.831 + 6.690
1st Vessel X + 4.831 + 6.690 + 7.178 + 0.810 + 34.250
4X + 14.493 + 13.380 + 7.178 + 0.810 + 34.250 =70.111
X =163.998 – 70.111 = 93.887/4 =23.472 Tons/Hr.
X = Vapour to condenser 23.472 TPH

4th Vessel 23.472 23.472


3rd Vessel 23.472 + 4.831 28.303
2nd Vessel 23.472 + 4.831 + 6.690 34.993
1st Vessel 23.472 + 4.831 + 6.690 + 7.178 + 0.810 + 34.250 77.231
Total Evaporation 163.998 T/Hr.
Total Exhaust Steam Required for Evaporators 77.231 Tons/Hr.

Exhaust Steam Requirement for Process House

1 Evaporators 77.231 Tons/Hr.

2 Pre Juice Heating 3.635 Tons/Hr.

Total 80.866 Tons/Hr.


Medium Pressure Steam Required at 3 kg/Cm2

1. At. Ref. Cent. Station @ 7.0% of Refine Sugar 0.980 Tons/Hr


2. At. Sugar Dryer @ 5.0% of Refine Sugar 0.700 Tons/Hr
3. For Raw Centrifugal @ 2.50% of Total Mass. (A+B+C+C.Mag) 1.790 Tons/Hr.
4. For Pan Washing @ 2.50 % on Cane 4.167 Tons/Hr.
5. Total 7.637 Tons/Hr.

STEAM REQUIRMENT OF PROCESS HOUSE

STATION TONS/HR. % CANE

Evaporators 77.231 48.520

Pre Juice Heating 03.635 02.181

Washing Steam 07.637 04.582

Total 88.503 53102

Boiler Load With 3% Line Losses 91.160 54.700


BAGASSE PRODUCTION/CONSUMPTION & SAVING
1. Cane 4000 TCD
2. Working Hours 24:00 Hrs.
3. Cane Rate 166.667 TCH
4. Bagasse Pol ( Assumed) 2.10 %
5. Bagasse Moisture (Assumed) 52.50 %
6. Dry Mater Bagasse 47.50 %
7. Last Mill Juice Purity (Assumed) 68.00 %
8. Brix % Bagasse 3.09 %
9. Fibre % Bagasse 44.41 %
10. Fibre % cane (Assumed) 12.70 %
11. Bagasse % Cane 28.600
12. Bagasse Production 47.667 Tons/Hr

Total Boiler Load 91.160 Tons/Hr

Steam Bagasse Ratio 1.930 Tons/Ton

Total Bagasse Consumed 47.233 Tons/Hr

Bagasse Production 47.667 Tons/Hr

Bagasse Consumed 47.233 Tons/Hr

Bagasse Saving 0.434 Tons/Hr

Bagasse Saving per Day 10.416 T/day


TANDEM # 01 & TANDEM # 02.

AVAILABLE EXHAUST STEAM FOR PROME MOVER’S

ESTIMATED CALCULATION’S
DATA

BOILER = 03 No. 80 T/Hr + 40 T/Hr + 40 T/Hr = 160 T/Hr

TANDEM # 01 = Having Turbines in 3 Mill & 4 Mills having Moto ringed

TANDEM # 02 = Having turbines in each Mills

CANE CUTTER = Turbines driven at T-# 01 & Motor driven at T-# 02

SHREDDERS = Turbines Driven on each tandem

POWER HOUSE = Rated Capacity ( 4 & # ) KW Shinko Turbine

ANALYSIS DATA.

1. Fiber % Cane of the season 2021-2022 = 13.25


2. Primary Cane Cutter required power ( T#-01) = 5Kw/t.p.h
3. Secondary Can cutter required power (T#-01) = 8Kw/t.p.h
4. Cane shredder required power
5. Mills (T#-01 & T#-02) = 12K.w/t.p.h
6. Single stage shinko steam consumptions(All Mill)= 14.5Kg.Kw.
7. Power House turbines steam consumption (Multistage) 11 Kg/Kw
8. CRUSHING RATE = 6500 TCD Or 271 T/hr
9. Fiber in Tons = 35.90 T/hr.

CANE CUTTER ( primary)

Required Power (Kw) = 179.5 kw.

Steam Consumption = 2.60 T/hr

CANE CUTTER (Secondary )


Required Power (kw) = 287 kw

Steam consumption = 4.16 T/hr

SHREDDER ( T# 01 & T#-02)

Required Power Kw) shredder = 1077 kw.

Total required power on Both shredder = 31.23 T/Hr.

MILLS (07 No ) TANDEM # 01 & 02

Required power /mill = 430.8kw required per Mill

Total required Power/07 Nos Mills = 3016kw

Total required steam = 43.732 T/hr

Power House load at 0.87 kw/Ton of cane

Required power = 62.62t/Hr

Total Available Steam = 144T/hr.

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