Module 6: Pan Boiling

Module Introduction

Dear trainees! I welcome you to module three of the course ―Cane Sugar Manufacturing‖ In this
fifth module we will discuss sugar boiling (Pan boiling).

The module is divided into six units. The first unit deals with crystallization process in pans and
also discusses why sugar solution is boiled at lowest possible temperature. It explains the
materials that boil in pan and evaporator and compare and contrast the design aspect of the pans
and evaporators.

The second unit of the module focuses on the issues of major equipments at vacuum pan. It deals
about connections, parts of the pan and flow lines for syrup, wash, massecuite, molasses, re-melt
etc. In addition to these it describes about molasses conditioning, types of heating surfaces of
vacuum pan, mechanical stirrer and instruments that are used to control the boiling process in the
pan. Finally it deals about the causes and prevention of entrainments and the cleaning and
maintenance of vacuum pans.

The third unit is mainly devoted on the saturation coefficient and zones of supersatuation. It also
deals about crystallization velocity and factors on which crystallization velocity is governed. It
also describe about slurry is preparation and finally explain about conglomerates and false grain
formation.

The fourth unit of the module deals about the aim or target of pan boiling and describes the
various types of boiling system. It also discusses about crystal content of massecuite and
Cobenze diagram. At the end of the unit it mainly focuses about the calculation of mass of Brix,
evaporation of syrup, molasses, re-melt and different massecuites and amount of crystals
required for slurry preparation.

The fifth unit discuss about automation on pan floor. It describes variables used for automatic
pan boiling and pan cycle.

The sixth unit, the last unit of the module, focuses on continuous pan. It describes about
instrumentation and control of continuous pan as well as its operation like start up.

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Unit One

Pan Boiling
Unit Objectives
At the end of this unit training, the trainees will be able to:

 Explain properly what crystallization means in context of sugar industries.

 Describes properly the two simultaneous formed processes in pans during crystallization
process.
 Explain why the sugar solution has to be boiled at lowest possible temperature in the
process of crystallization in sugar boiling.
 Discuss the importance of syrup sulphitation
 Compare and contrast the materials boiled in pans and evaporators as well as the design
aspect of pans and evaporators.

1.1 Introduction
After concentration of clarified juice in the evaporators, the Brix content of syrup is on average
65 %. The concentration of syrup has to be carried further in order to obtain sugar in crystal
form. To achieve this, massecuites have to be evaporated to a Brix content of between 92 % and
96 %. The process of forming crystals by evaporation and concentration in known as pan
boiling. In this process, syrup of say 85 purity will produce crystal of 100 purity and final
molasses of say 35 purity.

1.2 Syrup Sulphitation

Syrup sulphitor is used for sulphitation of syrup. As syrup discharged from the evaporator, is
dark brown in color. In this equipment sulpher dioxide (SO2) gas is passes through syrup,
coming from evaporator for a pre decided period. During this course bleaching of syrup takes

place, and all ferric salts are reduced to ferrous salts which are colorless. Sulpher dioxide (SO2)
gas also has flanking action on amino group therefore Mailard reaction is also retarded, and
viscosity of the system is reduced to some extent.

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After sulphitation dark brown syrup is converted to light, pink and color like honey. This
equipment is simply a multi baffle, cylindrical vessel of 3 – 4 meter height, with or without multi
circulation system. Working height of the equipment is maintained up to 1.5 m, thereafter syrup
goes out off the vessel. In this way a static height of 1.5 m syrup column is maintained over
sulpher dioxide (SO2) coil/spurger. The syrup is poured from top of the sulphitor. A simple
sketch of the equipment, without multi circulation arrangement is given in Fig. 1.1 below

1.3 Crystallization
Crystallization process (See Fig. 1.2) not only removes dissolved sucrose from solution and
recovers it as solid sucrose crystals, but it is also a very powerful purification process.

Figure 1.2: Process of Crystallization in Vacuum Pan

A massecuite can be defined as concentrated sugar liquor in which crystallization has taken
place. It is, therefore, a mixture of crystals and mother liquor. A massecuite, depending on its
final concentration and purity, is a highly viscous material.

Therefore, the boiling of massecuite can only be carried out in specially designed ―evaporators‖
called vacuum pans.

A massecuite will have certain crystal content, which is the percentage of crystals in it. Crystal
content depends on the purity and final Brix of the massecuite.

If we consider syrup of 85 purity, giving crystals of 100 purity and final molasses of 35 purity,
the crystal content of a hypothetical massecuite will have to be:
100  ( 85  35 )
 76.9 %
( 100  35 )

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This, unfortunately, is physically impossible, as the massecuite would be a solid mass with no
spacing or voids between crystals. Therefore, it is not possible to exhaust the syrup of sugar in
one boiling.

To exhaust the maximum amount of sugar from the syrup, it must be exhausted in several steps,
hence the various grades of massecuites that are boiled, normally called “A”, “B” and “C” in a
three boiling system.
Massecuites, owing to their high concentration, must be boiled at reduced temperature, therefore,
at reduced pressure under vacuum. The saturated vapour temperature and absolute pressure, at
which vacuum pans are operated, vary from 13 KPa, at 52.6 0C to 15 KPa at 55.3
0
C. However, higher temperatures are reached in the massecuites due to the boiling point
elevation due to Brix and the hydrostatic head caused by the depth of massecuite below the strike
level. The influence of hydrostatic head has led to many changes in pan design to reduce the
boiling temperature.
The reason for boiling at a reduced pressure and a corresponding low saturated vapour
temperature is the decomposition of sucrose by inversion and of reducing sugars forming acid
products of very dark colour. The resulting increase in massecuite temperatures due to
hydrostatic head in poorly designed pans will cause melting in part of sugar crystals in a zone of
concentration below the saturation point.

1.4 Boiling of Syrup

Boiling of Syrup Accomplished by:-
1. Crystallization
2. Purification Process
Crystallization in pans consists of two simultaneous processes:
1. Further concentration of syrup (Evaporation)
2. Crystal formation and growth
During sugar boiling, sucrose from syrup is obtained in the form of crystals where as, non sugars
remain in the mother liquor. The mixture thus obtained is known as massecuite. The viscosity of
massecuite is higher than syrup resulting in to less fluidity.

As the nature of material to be handled in pans and evaporators is quite different, the design
aspect is also to be changed accordingly. Such as:

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(i) Diameter of tubes is bigger in pans than evaporators

(ii) Length of tubes is shorter in pans. For better circulation in pan mechanical circulators are
also provided especially for low grade pans.
Massecuites boiling is a delicate task and great skill is required for good quality production of
uniform grain sugar.
In the process of crystallization, the solution has to be boiled at lowest possible temperature
(under vacuum) in order to:-

1. Avoid sucrose destruction by heat

2. Formation of color to be minimized
3. To use low pressure steam
4. High heat transfer/latent (110 °C and 0.6 Kg/Cm2) heat or improves the heat transfer by
maintaining sufficient temperature difference between the steam/vapor and boiling
liquid, there maintaining a good evaporation rate.

Self Check Exercises

1. Define crystallization process and explain how it is going in sugar industries?

2. Why it is advantageous to operate vacuum pans under vacuum?

3. What are the two processes that are accomplished by boiling syrup?

4. Explain the two simultaneous processes during crystallization in the pan consist of.

5. What the major design changes of pans compared to that of evaporators?

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Unit Two
Vacuum Pans
Unit Objectives
At the end of this unit training, the trainees will be able to:

 Describe the major equipments at crystallization plant in sugar industries.

 Explain the purpose of different connections and parts of the pan and other major
equipments at a crystallization plant.
 Identify properly the flow line of different molasses, syrup, wash, massecuite, re-melt
condensate, etc in the pan plant.
 Discuss the objectives of molasses conditioning.
 Describe the three types of heating surfaces using in vacuum pan in sugar industries.
 Explain all the accessories of a batch vacuum pan consists of and the characteristics
which the have.
 Discuss about pan stirrers (mechanical circulator)
 Explain instruments that are used to control the boiling process in the pans.
 Describe the possible causes of entrainment in vacuum pans and list out prevention
mechanisms.
 Explain about the cleaning and maintenance of vacuum pans.

2.1 Introduction
A vacuum pan is essentially a single effect evaporator (See Evaporation). It is thus made up of a
heating surface and a body connected to a vacuum system. There are also the various
connections required for its proper functioning (See Fig. 2.3 and Fig.2.4).

Major Equipments at crystallization plant are:

I. Vacuum Pans
II. Pan Supply (Feed) Syrup, Molasses and Wash Tanks (Cases)
III. Massecuite Receivers
IV. Vacuum Crystallizers
V. Massecuite Pumps
VI. Massecuite Cooling Crystallizers

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I. Vacuum Pans: - It is the equipment in which crystallization and boiling takes place. Based on
the number of boiling system, there can be "A", "B" or "C", and "C/D" pans.

The number and capacity of each type of pan depends on the amount of material they handle
which in-turn depends on the cane crushing rate of the factory.
Pan station is positioned between evaporation plant and centrifugal plant, i.e. after evaporation
station and before centrifugal station. It is mostly at the same elevation with evaporation plant
but at higher elevation compared to centrifugal plant so that the flow of massecuite from
crystallization plant to centrifugal station is easier.

II. Pan Supply Tanks (Cases): - These are storage (buffer) tanks for syrup, molasses and wash
liquors from which feeding to pans is done. Their position can be at higher or equal elevation
with pans. Feeding from the tanks to pans is with the help of vacuum. Most of the time, these
tanks are rectangular boxes with open top arranged as shown on Fig 2.1. The number and
capacity of the tanks depends on the flow rate of the liquors or factory crushing rate and the
retention time required in the tanks.

Valve arrangements are provided between pans and the pan supply tanks (cases) so that each pan
can be used for each type of massecuite boiling flexibly. Pan supply tanks are insulated to
minimize heat loss from the liquors.

Molasses Diluters (Molasses Conditioning Tanks):-They are used to supply conditioned

molasses to the pans. These tanks are fitted with steam coils, hot water line, and thermometer for
measuring temperature. The contents of the tank must be well mixed by a stirrer or by air jet
mixer to prevent local hot spots with possible sucrose deterioration in the molasses

The conditioning of the molasses feed is essential to remove all traces of small crystals or grain.
Raising the temperature using steam dissolves the small crystals. The temperature of the
molasses must be controlled because if allowed to drop the small crystals will not be dissolved
and if the temperature is allowed to increase too much, decomposition or caramalization could
take place.
The functions of the molasses conditioning are:
 The molasses is heated so that it has a temperature higher than that of the pan in which
it will be introduced; mostly 75 OC. This has the advantage that the molasses will flush

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when entering the pan, thus promoting circulation and saves steam energy.

 The molasses is diluted with steam or hot water to have a 70O Brix. The brix is measured
by conductivity meter that operates valves to feed water or steam. The Brix of the feed can
be controlled by conductivity probe provided that the temperature is controlled at a fixed
temperature.

Figure 2.1: Molasses Conditioning

III. Massecuite (Strike) Receivers: - They are commonly called crystallizers although
crystallization is not expected in these units due short retention time of massecuite in them and
no proper cooling facility. Strike receivers are special surge vessels designed to receive the
massecuite as it falls from the pans. The strike receivers are fitted with stirring devices to keep
the crystals in suspension and prevent them settling on the bottom of the strike receiver.

Strike receivers are horizontal cylindrical tanks with small openings only at top parts for
massecuite inlet when discharged from pans and as manhole for inspection and repair of internal
accessories. The volume of one strike receiver should be at least equal to the volume of a pan at
full strike. The number of strike receivers depends on the amount of massecuite boiled per hour
which means on the crushing rate of the factory.
Strike receivers are positioned under pans so that discharging of massecuite from pans to them
can easily be done by gravity.

IV. Seed Receivers/Vacuum Receivers: - They are cylindrical tanks with stirrers. Vacuum
receivers (vacuum crystallizers) are used to store the immature that contains small crystals and
require further growth while are used for the storage of seed magma. They are interconnected to

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the pans, by the cut over line, Slight glasses are provided on the ends so that the level inside the
receiver can be seen. When cutting or transferring a seed between a pan and a receiver there must
be a difference in vacuum between the two vessels.

Care must be taken as the last bit of massecuite leaves the receivers or pans that air is not sucked
in as well, because this air could cause entrainment as it breaks through the massecuite layer on
its way to the condenser and vacuum pump.

After cutting or transferring of seed the cut over line to be steamed out and drained the melt to
pan wash tank or to re-melt station in order to avoid mixing of seed for different grade of boiling.

V. Massecuite Pumps: - They are special designed pumps to handle high viscosity material and
used to transfer massecuite from strike receivers to

 Centrifugal machines for ―A‖ (High Grade) massecuite and

 To cooling crystallizers for low grade massecuite, especially final massecuit

 Massecuite pumps are mostly rotary or gear type positive displacement pumps.

VI. Cooling Crystallizers or Continuous Crystallizers: - These types of crystallizers are d

esigned for low grade massecuites. They give more consistent molasses exhaustibility. But the
efficiency of continuous crystallizers depend upon the design of the crystallizer based on positive
displacement of the mass and thus not allowing any intermixing of different crops.

The important design features appear to be the avoidance of pumping the cooled stiff massecuite
to centrifugal pug mill which can be done by installing continuous battery above the pug mill for
gravity flow.

The continuous crystallizers could be a horizontal type or vertical type. Both types are water-
cooled crystallizers.

They are positioned at higher level of centrifugal machines to allow gravity flow of the
massecuite to the machines.

The capacity of these crystallizers is designed to give enough retention (cooling) time of
massecuites inside them.

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Crystallization in Pans
Crystallization starts in the vacuum pan in which most of the work is done by evaporation of
water. It is then completed in the crystallizers and crystals are finally separated in the
centrifugals.

The work done in the vacuum pans has an important effect on subsequent factory processing
(centrifugals, drying) and on boiling house recovery and steam economy.

Crystallization in pans consists of two simultaneous processes:

(a) Evaporation
(b) Crystal Growth
To prevent sucrose destruction and formation of objectionable substances (colour), the process
has to be carried out at the lowest possible temperature. Vacuum pans are always operated under
vacuum.

2.2 Types of Heating Surface

Three types of heating surfaces are used in vacuum pans:
(a) Steam Coils (See Fig.2.2)
(b) Calandrias (See Fig.2.3)
(c) Steam Plates (See Fig.2.5)

Steam coil vacuum pans are now completely obsolete and are not made any more. They used
large diameter copper coils supplied with relatively high pressure steam. They wear costly to
maintain but gave good results on “C” massecuites as the graining volume was small and
adjustable. Steam Plate pans have not proved popular in the cane sugar industry, however they
perform well in the beet industry or in sugar refineries.

Most Vacuum pans are now of the calandria type (See Fig.2.3). The massecuite climbing up the
tubes and returning to the bottom of the pan by means of a down take.

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Figure 2.2: Steam Coil Pan

Figure 2.3: Pan with Mechanical Circulator (WEBER - Type)

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Calandria pans are of two types:

(a) Batch Pans
(b) Continuous Pans

Figure 2.4: Calandria Pan 45 m3

2.3 Batch Vacuum Pans

A batch vacuum pan consists of:
(a) A vessel in which a sugar solution is evaporated and crystallized to form a massecuite.
(b) A calandria which consists of vertical tubes expanded between two tube plates to give the
heating surface, through which heat is transferred to the massecuite inside the tubes.
Ratios of heating surfaces (S) to strike volumes (V) Vary with the type of massecuite
boiled, from 6.6 m2/m3 for refinery work, 5.8 to 6.0 m2/m3 for “A” massecuites, 4.5 to
5.0 m2/m3 for “C” and “B” massecuites respectively.
(c) A conical bottom which accommodates a feeding arrangement and a massecuite
discharge valve.

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(d) Separators to trap particles of sugar solution entrained by the vapour stream.
(e) A condenser to condense the vapor and maintain vacuum.
(f) A vacuum pump to start the vacuum and extract incondensable gases.
(g) Facilities for draining condensates and removing incondensable gases.
(h) A proof sticks to sample the massecuite.
(i) Instruments, valves, sight glasses, etc.

Figure 2.5: Horizontal Vacuum Pan (With Steam Plates)

A Batch Vacuum Pan Should Have The Following Characteristics:

(i) Good circulation with no stagnant zones to promote good mixing of crystals and
mother liquor.
(ii) Good evaporation rate.
(iii) Low massecuite head (hydrostatic pressure) at the end of a strike. A maximum
massecuite level of 1.50 m above the upper tube plate should not be exceeded, 1.35 m
being the ideal arrangement.
(iv) Fast discharge.

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2.3.1 Design of Batch Vacuum Pans

There are three types of batch pans:
Types 1: Most common, pans with fixed calandrias and a central down take.

 The down take has typically a diameter of about 40 to 50 % of the pan diameter in
latest designs.
 The calandria is designed with tubes of between 80 to 150 mm diameters, but the
majority of pans use 100 mm. Today, brass tubes, due to their high cost, have been
replaced with stainless steel tubes. Mild steel and 3 CR 12 tubes are sometimes used
as well.
 Length of tubes varies from 600 mm to 1000 mm in modern pans.
 Tubes are expanded at both ends into mild steel tube plates – steam or bled vapour
flows outside the tubes with the massecuite inside them. Proper removal of
condensate and incondensable gases from the calandria is critical.
Type 2: Pan with a floating calandria and an annular down take.
The interest in this type of pan has bee greatly reduced by the difficulty in designing
them in larger sizes. They can only accommodate a special type of stirrer.
Type 3: Horizontal pan with a heating element shaped like a series of plates mounted
lengthwise in the pans. This type has never become popular but has been developed
by FCB into the first industrially successful continuous vacuum pan (See Fig.2.5).

2.3.2 Pan Stirrers

Circulation can be much improved by the installation of a mechanical circulator or stirrer (See
Fig.2.4 on page 15). Increases in capacity of up to 30 % have been reported on poor circulation
“C” pans. The installation is easily done in calandria pans with central down takes.
 Typical Installed Power: 0.25 HP/HL of Massecuite.
 Two Speed Stirrers: 50/30 rpm. Enable stirring to be continued to the end of the strike.
Webre, the initiator of mechanical circulation gives the following results:

Massecuite

Massecuite “A” “B” “C”

Reduction in Boiling Time (%) 15 - 20 20 - 30 40 - 50

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Valves

For the proper operation of a vacuum pan a number of valves are required to control the various
inlets and outlets and also to isolate the pan if necessary (See Fig.2.4). These various valves are
as follows:
(a) Steam Control Valve
(b) Valve On the Vacuum System (Optional)
(c) Feed Valves for Syrup, Molasses and Water
(d) Massecuite Discharge Valve
(e) Condenser Water Valve
(f) Incondensable Gases Extraction Valves
(g) Valve to Break The Vacuum
(h) Pan Steaming or Washing Valve
(i) Graining (Seeding) Valve
(j) ―Cut Over‖ Valve, to Link the Pan to the Other Pans on the Station
(k) Automatic Control Valves if Installed
(l) Wash Water Valve, Also Used As Drain Valve to Waste

2.3.3 Instruments
To control the boiling process in the pan, the latter must be equipped with at least a minimum of
instruments, namely:

(a) A Pressure Gauge on the Heating Steam

(b) A Vacuum Gauge
(c) A Thermometer to Get Massecuite Temperature

(d) A Conductivity Meter for the Massecuite (See Automatic Pan Boiling)

(e) A Sampling Cock or Proof Stick

(f) A Graduated Scale for the Pan Capacity

(g) Control Instruments, When Installed.

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Figure 2.6: Batch Type Pan with Internal Condenser

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Figure 2.7: Original 1813 Howard Vacuum Pan

2.4 Condensers and Entrainment

Ideally, each pan should be fitted with its own condenser and vacuum pump. To reduce costs and
water consumption, central condensers for all pans are used in some countries. Central systems
must be fitted with boosters to maintain vacuum when a pan is started. These can be ejectors
(Water or steam) or vacuum pumps.

A condenser requires about 30 Kg of water per Kg of vapour to be condensed.

Entrainment can occur in pans just as it does in evaporators. It occurs mainly when there are
sudden changes in vacuum and in steam pressure (e.g. during cutting over). It can cause
appreciable sugar losses (Especially in high purity massecuites) and is a source of pollution of
effluents.
Entrainment can be prevented by:
(a) Boiling under steady conditions.
(b) Having sufficient space between the massecuite and the top of the pan (about the same as
between tube plate and massecuite level).
(c) Fitting entrainment separators and keeping them clean.
(d) Making sure that the drains from the separators are not blocked.

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2.5 Cleaning and Maintenance

Just like an evaporator body, the vacuum pan is liable to scale formation, but to a lesser extent.
More often scaling is due to sugar deposits or massecuite accumulation. Periodic boiling with
water or light syrup is good for maintaining pan performance. Every month or so mechanical
cleaning of the tubes may be necessary.
During the inter-crop maintenance of the apparatus must be done, along the same line as for
evaporator:
 Cleaning of the Tubes
 Hydraulic Testing of Calandria and Body
 Checking the Tubes and Body Wall Condition
 Maintenance of Valves
 Removal of Scales on Body Walls and In Entrainment Separators
 Calibration of Instruments
Self Check Exercises
1. Explain the major equipments at a crystallization plant.
2. Describe why molasses conditioning is essential.
3. Describe the three types of heating surface area that are used in vacuum pans.
4. Discuss the characteristics of a batch vacuum pan.
5. Compare and contrast the three types of batch vacuum pans.
6. Describe the importance of pan stirrers (Mechanical circulators) in vacuum pan during
sugar boiling process.
7. Discuss all the instruments that are used to control the boiling process in the pan.
8. Explain the main causes of entrainment in the sugar oiling in the pan.
9. Discuss the major prevention mechanisms of entrainment in the sugar boiling processes
in the pan.
10. List out all the maintenance of the apparatus that must be done during the inter-crop on
pan.
11. Describe briefly the various types of heating surfaces that have been used in vacuum
pans. What is nowadays the most popular and why?
12. What are the advantages that have been obtained with the introduction of mechanical
circulation in vacuum pans?

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Unit Three

Process of Pan Boiling

Unit Objectives
At the end of this unit training, the trainees will be able to:

 Define and briefly explain the saturation coefficient and coefficient of supersaturation.
 Identify and explain briefly the three zones of supersaturation.
 Explain the crystallization velocity and on which the crystallization velocity is
governed on.
 Discuss the factors on which the rate of crystallization depends on.
 Describe the two crystal formation (Nucleation) processes.
 Explain briefly the different slurry preparation methods.
 Describe the conglomerates and false grain formation.
 Explain the steps on the bringing together.

3.1 Introduction
Crystallization is an operation which is more than mere evaporation/concentration because it
must be performed in an orderly manner so as to yield a uniform product and obtain an efficient
extraction of the sugar.

Sugar is soluble in water and its solubility varies in proportion with temperature. When a
solution contains the total amount of sugar, it can dissolve; we say that it is saturated.
In sugar factories, we deal with impure solutions and it is important to note that in the case of
sugarcane, impurities present reduce or increase the solubility of sugar depending on their
composition.
We have the saturation coefficient (S) which is defined as follows:
O
Weight of Sugar % Water in the Im pure Solution @ T C
S 
Weight of Sugar ( Pure ) % Water @ T O C

This coefficient varies with the purity of the solution (See Fig.3.1).

A sugar solution can also be under-saturated or supersaturated.

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The coefficient of supersaturation (S‟) is defined as:

Weight of Sugar % Water Dissolved in the Supersaturated Solution @ T O C

S' 
Weight of Sugar % Water Dissolved in the Supersaturated Solution @ T O C

Figure 3.1: Change of Saturation Coefficient with Purity

Example: A concentrated pure sucrose solution contains 350 g sucrose/100 g water. The
temperature is 70 0C. What is the supersaturation coefficient?
Answer: Using sucrose solubility table or the saturation curve in Fig. 3.2, we find that at 70 0C a
saturated pure sucrose solution contains 323.7 g sucrose/100 g water
Supersaturation Coefficient = 350 ÷ 323.7 % = 1.08
 If the supersaturation coefficient is greater than 1, the solution is supersaturated.

 If the Supersaturation coefficient is less than 1, the solution is under-saturated, and if

equal to1, the solution is saturated.

The above calculation is applicable to pure sucrose solutions only. For impure solutions, the
calculation is more complex.

For crystallization to take place, we must have a supersaturated solution that is a solution
containing more sugar than it should (Supersaturation Coefficient > 1).

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According to their supersaturation coefficient, sugar solutions may be classified into

supersaturation zones (See Fig. 3.2 below).

Figure 3.2: Supersaturation Curves for Pure Sucrose

3.2 Zones of Supersaturation

Three zones of supersaturation are defined;

1. The METASTABLE zone, which is just above the saturation line and in which existing
sugar crystals will grow but new ones, can not be formed.
2. The INTERMEDIATE zone where new crystals may be formed, but only in the presence
of other sugar crystals.
3. The LABILE zone is which crystals are formed spontaneously.

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Figure 3.3: Saturation Zones for Sucrose

In industrial practice, the existence of the intermediate zone is doubtful and more importance
should be given to the limit between the metastable and labile zones. That limit varies with the
purity of the solution (See Fig.3.4). We can see that a higher supersaturation in needed in the
case of low purity products to reach the labile zone.

Figure 3.4: Metastable and Labile Zones

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3.3 Crystal Growth

The governing factor in sugar boiling is the crystallization velocity. This determines the
evaporation rate in the pan, and consequently the boiling time and pan capacity.
Crystallization Velocity is governed by:
(a) The rate at which sucrose molecules are transported through the mother liquor, i.e.
diffusion.
(b) The rate at which the sucrose molecules will be accommodated on the crystal surface, i.e.
accommodation.

3.4 Rate of Crystallization

The rate of crystallization depends on:
(a) The Viscosity
(b) The Temperature
(c) The Supersaturation
(d) The Purity of The Mother Liquor
(e) The Crystal Surface Area

3.4.1 Viscosity
The higher the viscosity of the mother liquor, the more difficult for diffusion of sugar molecules
through the liquor and the poorer the mixing between mother liquor and sugar crystals.

3.4.2 Temperature
It is commonly known that rate of crystallization invariably increases with temperature. Thus
higher temperature favors faster crystallization.

3.4.3 Supersaturation
Supersaturation represents the driving force for crystallization. The higher the supersaturation,
the higher the rate of crystallization. In practice, the supersaturation must not exceed a threshold
value.

3.4.4 Purity
Crystallization falls very rapidly as the purity of the mother liquor decreases, as shown in Fig.
3.5 below;

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Figure 3.5: Relationship of Rate of Crystallization and the Purity of the Mother Liquor

3.4 5 Crystal Surface Area

Crystal surface area improves accommodation rate. Not that smaller crystal provides more
surface area for the same mass.

3.5 Sugar Boiling Process

3.5.1 General
The sugar boiling process can be divided into four stages:
(a) Concentration of the Sugar Solution
(b) Crystal Formation and Bringing Together of Crystals into A Pied-De-Cuite.
(c) Developing of the Footing (Or Pied-De-Cuite) Into A Strike In Two or More Stages
(d) Final Tightening (Brixing) of the Massecuite

3.5.2 Sugar Solution Concentration

A mixture of appropriate purity of syrup and/or running is fed to the pan until the calandria is
just covered. This volume of mixture of syrup and runnings is called the graining charge or
volume. The whole of the calandria must be covered before steam is turned on.

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Steam admission should be controlled to prevent high evaporation rates which could result in
carry over of the liquor into the vapour steam.
The purpose of this concentration is to achieve a distinct level of supersaturation.

3.5.3 Pied-De-Cuite Preparation

The Pied-De-Cuite (Footing) can be obtained in several ways.
 Grain formation in the pan
 Grain may be obtained from a seed tank
 Finely grained product of a strike (usually last) is mingled with syrup into a magma and
store in a seed tank

3.6 Grain Formation

Nucleation, i.e. crystal formation can be achieved in two ways:
(a) Spontaneous formation, by shock seeding or
(b) Seeding with fine crystals by true seeding

3.6.1 Spontaneous Nucleation

Spontaneous nucleation basically involves increasing the degree of super saturation to a point in
the labile zone where crystal nuclei are formed spontaneously.
In practice, the operator estimates this point by:

(i) The reading of pan control equipment

(ii) The physical appearance of the concentration solution.
(iii) The fluidity of the splashes on the sight glass. This concentrating is maintained until
sufficient crystals are formed as judged by the pan boiler. The solution is the diluted with
more feed or water to restore conditions to metastable zone.

3.6.2 Seed with Fine Crystals

(a) Shock Seeding
With shock seeding, a small amount of powdered sugar is added to induce the formation of new
nuclei. When sufficient nuclei are present, feed is introduced and boiling continued in the
metastable zone. In the case of shock seeding, the supersaturation is not raised as high as in
spontaneous nucleation.

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(b) True Seeding

With true seeding the solution is concentrated to the metastable zone and the required number of
seed crystals is added in slurry form. The system is maintained in the metastable zone so that the
crystals introduced will grow and no new crystals will form.
The purpose of true seeding is to introduce into the pan the same number of crystals as will be
present in the completed strike, i.e.

 No of Sugar Particles = Number of Sugar Crystals in the Finished Strike

The advantages are:
(1) Controlling the Number of Crystals
(2) Controlling Size of Crystals in Finished Strike

3.6.3 Slurry Preparation

1,500 g of refined sugar and 4 L of methylated spirits are placed a cylindrical container with
1,500 ball bearings of 9.5 mm. diameter. The container is rotated for 24 hours at 60 rpm.
The volume of slurry used per m3 of massecuite:

„B‟ Massecuite: 7 to 15 mL – Average 10 mL

„C‟ Masseccuite: 40 to 100 mL – Average 70 mL
Refinery Massecuite: 4.4 to 5.5 mL
Caster sugar of icing sugar may be used to prepare slurry but the weight used must be adjusted if
the sugar contains starch.

3.7 Measurement of Supersaturation while Boiling

In the old days, techniques used were highly subjective, e.g.
(a) Behavior of a small sample of the massecuite placed between the thumb and finger and
drawn slowly apart.
(b) Observation of splashes against the sight glass

Several methods have been proposed to which a distinct physical property of the massecuites is
determined, such property being more or less related to the degree supesaturation of the mother
liquor.

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Example:  Determination of Refractive Index

 Viscosity
 Boiling Point Elevation
 Electrical Conductivity

3.8 Conglomerates and False Grain

3.8.1 Conglomerates
Conglomerates are crystals which have grown together. They are formed at the beginning of the
boiling process when the grain is brought together. They contain pockets of mother liquor and
during fugalling the water contained is not expelled completely

Conglomerates are source of color in refined sugars. They are formed due to poorly constructed
pans where circulation is inadequate

3.8.2 False Grain

False grain is innumerable tiny new crystals which are visible. They can occur at all stages of the
boiling process and caused in areas of too high a degree of supersaturation e.g. top layer of
massecuite in poor circulation pans. They may results from a high rate of evaporation.

When still in the pan, be dissolved by raising the temperature of the massecutie by lowering the
vacuum, or by washing the strike with water.

3.9 Bring the Grain Together

Once the grain is established, it must be built up very carefully otherwise false grain will be
formed.

Crystals at this stage are still microscope and very widely dispersed, so that local rises in
supersatuiration can easily occur with an excessive evaporation rte. for this reason , the sucrose
crystals are grown so that they practically full the spaces occupied by the syrup or mother liquor
before the volume of the strike is increased.
During crystallization the deposition of sugar on the crystals reduces the concentration of the
mother liquor, evaporation of water from the solution tends to concentrate the mother liquor.
These two factors must be balanced to maintain constant supersaturation.

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The crystallization rate is proportional to crystal surface area. This means that to maintain
constant supersaturation the evaporation rate must also be proportional to the surface area of the
crystals. When the grain has just formed its surface area is very small, and the evaporation rate
must be very small as well i.e. the evaporation rate at this stage must be practically zero.
However, with steam shut off circulation will be impeded. In practice, a small stream of water is
fed into the pan and steam is adjusted to boil this water out as fast as it is run in. This water is
termed movement water. It is not needed if the pan is fitted with a stirrer.
As the crystals size increase the movement water is gradually shut off and the net rate of
evaporation increased.
The crystals are now close together instead of being in separated by a very large volume of
mother liquor.

3.9.1 Crystal Growing

When the crystals have been brought together, liquor (syrup or molasses) is fed into the pan for
growing the crystals in the massecuite. The size of the crystals continues to grow and the volume
of the strike naturally increases. When the volume of the massecuite has reached the pan
capacity, feeding is stopped while steam flow is maintained to continue evaporation and increase
the Brix of the massecuite.

3.9.2 Final Tightening (Brixing)

Depending on the strike and on the characteristics of our pan we can either choose to perform a
gradual tightening (during the whole strike) or tighten only at the end of the strike. Once the
desired Brix has been obtained, steam is closed, the vacuum is broken and the discharge door is
opened to drop the strike.
The maximum tightening compatible with the equipment is effected. In general the flowing
values are obtainable.
 „A‟ Massecuite about 920 Brix
 „B‟ Massecuite about 930 Brix
 „C‟ Massecuite about 95 – 960 Brix
During the crystals growing and tightening phases we must avoid too high a concentration of the
mother liquor, otherwise we shall reach the labile zone and have the formation of false grains.

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Graining Volume: It is the volume of liquor in which seeding or graining is done. It is usually
the smallest volume necessary to operate a pan, i.e. just covering the calandria when the strike is
made from an already prepared seed or pied –de-cuite we call the minimum volume the footing
volume.
The ratio between the graining (or footing) volume and the final volume of the pan must be such
as to allow the sugar–crystals to reach the size required for the strike being boiled. In calandria
pans the graining volume varies between 30 – 35 % of the final volume. In some modern pans
we can go down to 25 %. The old coils pans offered the advantage of having a lower graining
volume.
Cuttings or Cut Over: Even with the smallest volume of footing we cannot in one single A-
strike reach the required size of sugar crystals. We must then resort to ―cutting over’ i.e. the seed
or footing is boiled to capacity and then subdivided several times before being dropped as
massecuite .The ratio between seed and massecuite varies between 1:15 and 1:10 for “A” and
“B” strikes.
Grain Size: In general in raw sugar factories we have crystals of the following sizes:

“C” Seed ........................................ 0.1 mm

“C” Massecuite …………………… 0.25 — 0.30 mm
“B” Massecuite …………………… 0.75 — 1.00 mm
“A” Massecuite …………………… 1.00 — 1.25 mm
Especially if „A’ and „B‟ sugars are bagged, and also with sugar produced by the CAB system.
With the introduction of continuous centrifugals for „B‟ and „C‟ massecuites and the gradual
replacement of batch type centrifugals with continuous machines the sizes of „B‟ and „C‟ crystals
have decrease considerably. Likewise, unless required to produce large crystals the normal
crystals sizes when producing very high Pol sugar (V.H.P) are as follows:
„C‟ Seed = 0.1 mm
„C‟ Massecuite = 0.15 mm — 0.20 mm
„B‟ Massecuite = 0.30 mm — 0.38 mm
„A‟ Massecuite = 0.65 mm — 0.75 mm
Only „A‟ sugar is the commercial product in the V. H .P. process.
Boiling Rates: The boiling rate of a pan is the volume of massecuite boiled per hour.

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Vol. of Footing ……………… 80 HL

Vol. of Massecuite…………. 240 HL
Boiling Time ………………. 4 hr
(240  80) HL
Rate of Boiling ( Mean) ......................  40 HL / hr
4 hr

The rate of boiling varies all along the strike. Very high at first and very low at the end, due to
the low circulation rate (See Fig.12) resulting from boiling point elevation (See Unit on
―Vaccum Pans‖). Very frequently it is not worth while to boil a strike at a height greater than
1,400 mm above tubular plate or even more than one meter in the case of “C” massecuties.
This is however only an indication, since the practical height will vary with the characteristics of
the pan and whether we have forced circulation or not.

Figure 3.6: Variation of Circulation Speed during a Strike

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Self Check Exercises

1. Draw a diagram showing the various zones of supersaturation. Explain their relation
to what can happen during the pan boiling operation.

2. How can the temperatures of a massecuite influences its degree of supersaturation

(Sketch a diagram)? Explain what can happen during the boiling process.

3. Explain the difference between shock seeding and true seeding. Why should we try
to achieve true seeding?

4. The Intermediate Supersaturation Zone apparently does not exist. Explain how this
zone could have been imagined.

5. What are the factors that affect the rate of crystallization? Explain why we cannot
exceed a certain boiling rate during a strike.

6. Why are false grains harmful to pan boiling? How can we eliminate them?

7. Sketch a diagram showing the boundary between the metastable and labile zones at
different purities. How does it concern pan boiling operation?

8. What is the difference between ―Shock Seeding‖ and ―True Seeding‖ (Full Pan
Seeding)? Why should we prefer ―True Seeding‖?

9. What are the differences between boiling a massecuite one from a ―Pied de Cuite‖
(magma) and boiling from a graining?

10. Explain briefly how we prepare ―Slurry‖ from sugar boiling. Why do we aim at a
very fine slurry particles?

11. What are the factors that affect the rate of crystallizations of sugar in the vacuum pan?

12. Explain the difference between ―Shock Seeding‖ and ―True Seeding‖. What is
recommended and why?

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Unit Four

Massecuite Systems (Boiling Schemes)

Unit Objectives
At the end of this unit training, the trainees will be able to:

 Discuss the aim (target) of sugar boiling in a pan.

 Define terms like Brix, purity, crystal content and explain the formula crystal content
of massecuite and Cobenze diagram.
 Describe the straight two, three, modified three boiling system and boiling scheme
with boiling back boiling systems.
 Explain briefly evaporation and dilution formula.
 Calculate the various results associated with pan boiling like mass of Brix,
evaporation of syrup, molasses, re-melt and different massecuites.
 Calculate the number of sugar crystals and amount of slurry required in pans.

4.1 Introduction
The aim of pan boiling is to extract, as commercial sugar, the maximum amount possible of the
sugar originally present in the juice and to eliminate the impurities in the form of final molasses
containing the least amount of sugar possible. Thus, the lower the purity of final molasses, the
higher the recovery of commercial sugar.
So, our targets would be to produce:
(a) Commercial Sugar of Good Quality
(b) Low Purity Final Molasses.
Before going and further we shall see certain basic definitions and formulae.

A. Brix
The exact definition Birx is fairly complicated. For all practical purposes we can say that:
The Brix of a solution is the mass of dry matter dissolved per cent solution (mass % mass).
B. Purity
The Pol Purity (or Apparent Purity) is the percentage of Pol in the Brix (i.e. Pol % Brix)
The Clerget Purity is the percentage of sucrose in the Brix (Sucrose % Brix).

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The True Purity is the percentage of sucrose in the true dry matter. For the boiling schemes
calculations we shall make use of apparent purity.
C. Crystal Content
Crystal content is the percentage of sugar in crystalline form in the Brix. If we centrifuge a
massecuite Brix ―B‖ and Purity ―J‖, and we obtain sugar crystals of purity ―S‖ and molasses of
purity ―M‖, the crystal content of that massecuite is then equal to:
(J  M ) B
Crystal Content of the Mas sec uite 
(100  M )

Generally, the crystal content is expressed as % Brix;

100 ( J  M )

(100  M )

Assuming the purity of the sugar to be 100.

D. Cobenze Diagram
This is a short-cut to determine easily the components in a mixture or in a separation. We can
make use of it to determine the weight of sugar to be obtained from a massecuite or the quantities
of products to give a mixture of known purity.
Example:
Suppose a massecuite of 850 purity yields sugar at 990 and molasses at 620 purity.

We proceed as follows:

 Mass of Brix (or Solids) in the sugar produced for 100 Brix contained in the original
massecuite
23
  100
37

 62.16

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And:
 Mass of Brix in the molasses % Brix in the massecuite
14
  100
37

 37.84

The same principle is used to calculate mixtures.

The sugar crystals on growing extract sugar from the mother liquor thus reducing its purity. This
drop in purity tends to slow down the crystallization process. There is thus a practical limit in the
exhaustion of sugar solutions hence in the purity drop that we can achieve.
Purity drops obtained in Mauritius are generally of the order indicated below:
Massecuites Limits Mean Values
A 15 – 25 20

B 15 – 25 20

C 20 – 30 25
0
Juice purities being around 85 it is not possible for us to obtain molasses of purity less than 60 -
650. Such molasses still too rich in sugar to be discarded. It is thus necessary to boil them again
so as to recover some more sugar. According to the number of times that we boil we have TWO
BOILING or THREE BOILING schemes. We even have some rare factories using FOUR
BOILING schemes.
(a) Exhaustion of Liquors: The impurities present retain with them a certain amount of sugar.
(b) Viscosity: After two or three boiling the product obtained is sometimes very viscous.

4.2 The Straight Two (2) Boiling System

Such a scheme is represented in Fig.4.1. We assume the following purities:

Syrup = 860, Sugar = 990 and Final Molasses = 300. The ―C‖ sugar is not of
commercial quality and returned to process.

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Figure 4.1: Straight Two (2) Boiling Scheme

This scheme is the simplest one possible and is, however, difficult to achieve in practice since it
is not always easy to obtain a 280 drop in purity.
We shall calculate, by means of Cobenze diagrams, the Brix balance for Fig. 4.1.

(a) It is clear that the syrup entering the boiling house yields two final products :
(i) Sugar at 990 Purity (ii) Final molasses at 300 Purity

For every 100 Kg of Brix contained in the syrup:

56
  100
69

 81.2 Kg of Brix Come Out in the Sugar

And
13
  100
69

 18.8 Kg of Brix Come Out in the Final Molasses

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And we can record them on the diagram.

(b) We next see the ―C‖ massecuite : It separates into two products, ―C‖ sugar at 860 and final
molasses at 300

If ―Y‖ Kg of Brix is contained in the ―C‖ massesuite, then;

28
  Y
56

 Kg of Brix Contain in the Final Molasses, which we have calculated as 18.8 %

So,
56
Y   18.8 %
28

 37.6 Kg of Brix Contain in the " C" Mas sec uite % Brix in the Syrup

Kg of Brix in the " C" Sugar Brix in the Syrup  37.6  18.8  18.8 %

(C) Since only “A” molasses is used to boil the “C” massecuites, it must contain the same
mass of Brix as the “C” massecuite, namely 37.6 %.
(D) The mass of Brix in the “A” massecuites is the sum of the Brix contained in syrup
And “C” Sugar, i.e. 100 + 18.8 %.

(E) Since the “A” massecuites yield commercial sugar and “A” molasses, the mass of
Brix in these two products must be the same as for “A” massecuite:
(F) Total mass of Brix in massecuites boiled % Brix in syrup;
 118.8 (" A" Mas sec uites )  37.6 (" C" Mas sec uites )

 156.4

 This is a very low figure and is hardly every achieved in practice.

The two boiling scheme not being easily achieved, we shall examine the three boiling scheme.

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Purity If “C” Massecuite

It would seem logical to think that the lower the purity of “C” massecuite, the lower would be
the purity of the final molasses. This is not always true. In Mauritius, 54 – 550 is normally the
lowest practical purity and 60 – 610 the highest purity, and under our local conditions, we cannot
be far out if we boil “C” massecuite between 57 – 580. We thus determine the best purity for
our particular case and we adjust the purity of the “B” massecuite such as to obtain “B”
molasses purity suitable for obtaining “C” massecuite of the chosen purity.
For the needs of these lectures, we have chosen a purity of 580

4.3 Straight Three Boiling System

This scheme is sketched in Fig. 14 for the purpose of comparison, we shall keep the same inflow
and out flow purities and a “C” massecuite of 580 purity.

Figure 4.2: Straight Three (3) Boiling Scheme

Purity Drops in “A” and “B” Massecuites = 14o

(Note Chosen to obtain 58o in “C” Massecuites)
Total Solids in All Massecuites % Solids in Syrup: ―A” = 118.8
―B” = 57.1
―C” = 37.6
213.5

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This figure of 213.5 is very high and represents an increase of 37 % as compared with the total
solids for the two boiling scheme.
This will result, for the same amount of commercial sugar produced, in the following
(a) Need for greater pan capacity
(b) Need for greater centrifugal capacity
(c) Need for greater crystallizer capacity
(d) Greater steam requirement on the pan floor
(e) Probably greater sugar losses.
Otherwise a reduction in crushing rate would be necessary.
Consequently high purity drops are the key to a good boiling house performance However, if
purity drops of 280 are not easy to achieve at all times, one should easily obtain more than 140
drops.

4.3.1 Modified Three Boiling Systems

Since we have seen that it is easy to obtain 200 drop in purity, we must modify slightly our
boiling scheme (See Fig. 4.3.).
In order to obtain “B” sugar of good quality, we must add some syrup to the “B” massecuite so
as to raise its purity. In the same way, we must add some “A” molasses on the “C” strike when
we perform seeding so as to improve the quality of the seed and yet achieve our goal of 580
purity on the “C” strikes.

Figure 4.3: Modified Three (3) Boiling System

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Total Solids in Massecuites: “A” = 96.3

“B” = 50.0
“C” = 37.6
183.9 % Solids in Syrup

“A” Sugar % (“A” + “B”) Sugar = 72.0

4.4 Boiling Scheme with Boiling Back

If we have very high purity drops or else we have syrup of low purity we can still perform a two
boiling scheme but with boiling back of “A” molasses on “A” massecuite so as to reduce its
purity and obtain the desired purity of “C” massecuite (See Fig.4.4)

Figure 4.4: Boiling Scheme with Boiling Back

Total Solids in Massecuites % Solids in Syrup: “A” = 133.2

“B” = 37.6
170.8

4.4.1 Double Magma System or “C”.”B”.”A”. Boiling Scheme

In this system, graining is only done for the “C” massecuite and the “C” sugar is made into a
magma with clear juice: the “C” magma being used as a footing to start “B” massecuites. “B”
massecuites. Are boiled on “A” molasses and “B” sugar is made into a magma to serve as a
footing for “A” massecuites. Syrup is used on “A” massecuites only and “A” sugar is the
commercial product. This system results in about 10 % to 12 % more massecuites boiled than the
other systems discussed, but because the magma footings provide larger initial crystals, this

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helps to accelerate the crystallization rate with the result that “B” and “A” massecuites are
boiled in shorter times. Typical values for the “C”.”B”.”A” scheme is illustrated in Fig. 4.5.

N.B: Solids are shown within Brackets (Total Brix in Massecuites = 241 %)
Figure 4.5: Double Magma System or ―C”.”B”.”A” Boiling Scheme

4.5 Evaporation and Dilution Formulae

If we take a mass of product ―W‖ with a Brix equal to ―By‖, the mass of solids (or Brix) in the
product will be equal to:
W  By
Mass of Solids ( Brix ) 
100
If we know the mass of solids (Brix) we can write:
100
W  Solids 
By

If we evaporate or dilute the by- product to a Brix “By1”, we shall have a new mass of product;
100
W1  Solids  1
By

4.6 Steam Requirements

By means of the diagrams for the various boiling schemes, we can have the masses of solids in
the various products and hence we can calculate the mass of water evaporated.

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The amount of steam required to evaporate one tonne of water varies according to different
authors, but on the whole we can assume 1.2 tonnes. This comprises losses by radiation and the
preheating of the various products in the pan prior to evaporation.
As an example we shall calculate the needs for the boiling scheme in Fig.4.3 on page 52 which
used in many factories.
The Brix of the various products met in the process must be known. This can be obtained from
the laboratory bulletins, but, for our calculations, we shall use the following values.
Brix of Syrup = 600
“A” Massecuite = 920
“B” Massecuite = 930
“C” Massecuite = 950
“A” and “B” Molasses = 750
“C” Re-melt = 650
Tonnes of Clarified Juice per Hour = 150
Brix of Clarified Juice = 12.50

4.7 Calculations
Mass of Brix (Solids) per Hour:
150  12.50
  18.75 Tonnes
100

Evaporation of Syrup in “A” Massecuite:

77.5 100 100 
  18.75     8,400 Kg of Water Evaporated per Hour
100  60 92 

Evaporation of Syrup in “B” Massecuite:

22.5 100 100 

  18.75     2,500 Kg of Water per Hour
100  60 93 

Evaporation of “A” Molasses in “B” Massecuite:

27.5 100 100 
  18.75     1,300 Kg of Water per Hour
100  75 93 

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Evaporation of “A” Molasses in “C” Massecuite:

10.3 100 100 

  18.75     500 Kg of Water per Hour
100  75 95 

Evaporation of “B” Molasses in “C” Massecuite:

27.3 100 100 

  18.75     1,400 Kg of Water per Hour
100  75 95 

Evaporation of “C” Re-melt in “A” Massecuite:

18.8 100 100 
  18.75     1,600 Kg of Water per Hour
100  65 92 

TOTAL  15,700 Kg of Water Evaporated per Hour

 Amount of Steam Required by the Pan–Station = 15,700 Kg  1.2 = 18,840 Kg

 Let us say, 19 Tonnes per Hour

Naturally by this method, we can not calculate the amount of steam required to evaporate the
feed water added directly into the pans during boiling. Still, we can have a fair estimation of the
steam requirements of the station.

4.8 Crystal Content and Other Calculations

4.8.1 Crystal Content

The sugar content of a massesuite is the Pol % gm or Brix  Purity =  Bm 

Pm 

 100 
The crystal content, or crystal % massecuite, is the recoverable sugar in the massecuite, i.e. Pol
% g  recovery.

The usual recovery formula is the SJM formula, namely:

Ps ( Pm  Pr )
Pm ( Ps  Pr )

Where/ Ps = Purity of Sugar = 100

Pm = Purity of Massecuite
Pr = Purity of Running

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100 ( Pm  Pr )
Re cov ery 
Pm ( 100  Pr )
So, Crystal Content or Crystal % Massecuite
 Pm  100 ( Pm  Pr )
  Bm   
 100  Pm ( 100  Pr )

( Pm  Pr )
 Bm  .........................................................(1)
( 100  Pr )

Where/ Bm = Brix of Massecuite Crystal % Brix (in Massecuite)

( Pm  Pr ) 100
 Bm  
( 100  Pr ) Bm

100 ( Pm  Pr )
 ......................... ...................................................( 2 )
( 100  Pr )

4.8.2 Number of Sugar Crystals

If we assume a sugar crystal to be a cube, its volume is equal to (l3). The size “l” being usually
measured in millimeters.
1 cc = 1 mL = (103) mm3

So, 1 liter = 106 mm3

(l 3 )
Thus the Volume of a Sugar Crystal:  Litre
10 6
(l 3 )
Its Mass is:   D Kg
10 6

Where/ D = Density of Sugar = 1.6 (Hugot)

So, a strike of 60 tonnes, of Brix 95 and crystal content % Brix of 40, contains:
95 40
60,000   Kg of Sugar Crystal.....................................( 3 )
100 100
60,000  0.95  0.40  10 6
Crystals
l3 D

 14.25  10 9 Crystals of 1 mm in Size

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4.9 Amount of Slurry Required

Theoretically, if we determine the number of nuclei contained in 1 mL of slurry, we can
determine the volume of slurry required to perform a seeding.

It is easier to calculate the mass of sugar required for seeding

Let us say that we shall seed a “C” strike with slurry of 10 microns in size to obtain “C” crystals
of 0.25 mm.
The ratio of masses, nuclei to crystal is approximately (10  103)3 : (25  10-2)3

If we assume the same mass of sugar crystal as in (3) above, the mass of sugar in slurry:
3
 0.010 
 60,000  0.95  0.40    ............................................( 4 )
 0.25 

 1.46 Kg

If we known that with 2 Kg of sugar we produce 3.2 Kg of slurry, then the mass of slurry
required is:
1.46  3.2

2.0

 2.336 g

From (4) we can see that the coarser our slurry, the larger the mass required, until it becomes
unpractical. Thus, in the above example, if the slurry particles were 40 microns in size, we would
require 149.5 Kg of slurry!!

More Precision
Normally, the size of slurry particles lies between 10 and 15 microns, and the size of “C”
massecuite crystals between 0.2 and 0.3 mm.
The shape of a slurry particle is almost spherical, so that its volume is almost equal to:
4 l3

3 8
According to certain authors, the volume of a sugar crystal is equal to 0.7.L.3.
Consequently, the ratio of masses, nuclei to crystal:

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n  4/3   l3 /8  D

n  0.7 L3  D

0.524 l 3

0.7 L3

(l3 )
 0.75 ...................................................................................( 5 )
( L3 )

If we use (5) in the equation (4) above, we get:

3
 0.010 
60,000  0.95  0.40     0.75
 0.25 

 1.46  0.75  1.095 g

Self Check Exercises

1. Explain why the presence tendency is to operate vacuum pans from “VP1” (Bleeding
from the first evaporator body) rather than from exhaust steam.
2. Why should we aim to obtain maximum purity drop when boiling massecuite?
3. Explain briefly how we prepare slurry used for graining. How do we estimate the
amount required to grain a strike (Pan Boiling)?
4. Explain why we boil various grades of massecuites (“A”, “B”, “C”) on the pan station.

5.

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The above diagram illustrates the CBA boiling scheme used in a sugar factory. The purities of the
various products are given. The factory has a throughput of 200 tonnes juice / hour at a mean
Brix of 12.5o.

Calculate:
(a) The Brix flow in each product for every 100 parts of Brix entering in the syrup.
(b) The “VP3” bleeding for the “A”- Continuous pan, given the following Brixes:
Syrup = 70o, “B”- Magma = 88o, “A”- Massecuite = 93o
 Assuming 1.15 Kg vapour per Kilo of Evaporation
(c) The average capacity of the “B” – Magma pump feeding the continuous pan, given the
bulk density of the magma to be 1.4 Kg/L.
6.

Above is the modified two (2) boiling scheme used by a sugar factory with the purities of the
various products. The factory has a juice throughput of 200 tonnes / hour at a Brix of 12.5o.
Calculate:
(a) The amount of Brix each component stream for every 100 parts of Brix entering in syrup.
(b) The vapour bleeding from the evaporator required by the continuous “C”- Massecuite pan
given the following.
 Brix of “C”- Massecuite = 95o
 Brix of “A”- Molasses = 80o.
 Vapour requirement = 115 % Evaporation in the pan.
(c) The capacity of the final molasses pump, given that the Brix of molasses is 88o and the
bulk density 1.40 Kg/L.

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7.

The above diagram shows the three massecuite boiling system used by a sugar factory. The
purity of each product is given. The factory has a throughput of 200 tonnes of juice/hour at a
Brix of 12.5o.
Calculate:
(a) The amount of Brix found in each product shown for every 100 parts of Brix entering in
the syrup.
(b) Calculate the amount of ―VP2‖ vapour required per hour by the ―C‖- pan, being given that
, ―A” and “B” molasses are sent to the pan at a Brix of 75o and “C” – massecuite is boiled
to a Brix of 95o. Assume that 120 Kg vapour is required for every 100 Kg of water
evaporated in the pan.
(c) Calculate the capacity of the “A” – molasses pump in liter per minutes if the bulk density
of the molasses is 1.30 Kg/L at a Brix of 80o.
8.

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The diagram illustrates the “CBA” (or double magma) boiling scheme used in the sugar factory.
The purities of various products are given. The factory has a through put of 120 tonnes / hour at
15o Brix.
(a) Calculate the Brix flow in each product for every 100 parts of Brix entering in syrup?
(b) Calculate the vapour bleeding per hour required for “B”– Massecuite pan, given the
following Brixes.
“A” – Molasses = 80°, “B”– Massecuite = 93°, “C” – Magma = 85o

 Assume 1.2 Kg vapour per kilo of evaporation.

(c) Calculate the capacity of “C” – Magma pump, given the bulk density of the magma to be
1.4 Kg/L.
9.

(a) Calculate the Brix content of each product as a percentage of the Brix of entering in the
syrup.
(b) Calculate the amount of “VP2” vapour required by the continuous pan boiling “A”.
Massecuite, given the following:

Capacity of the Factory = 250 tonnes of juice / hr @ 12.8o Brix

Brix of “A”-Massecuite = 92o, Brix of Syrup 65o, Brix of “C”-Magma = 88o
Vapour consumption = 1.2 Kg for each kilo of evaporation.
(c) Calculate the capacity of the final molasses pump in m3/hr if the Brix of the molasses is
85o and the bulk density of 1.35 tonnes/m3.

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10.

Above is the flow diagram of the massecuite system used in a sugar factory, with the purities of
the various products:
Calculate:
(a) The amount of Brix in each products stream for every 100 parts of Brix entering in the
syrup.
(b) The vapour demand (“VP1”) for the “C”-Massecuite continuous pan if factory handles
150 tonnes of juice per hour at a Brix of 12o and a Brix of the various products are as
follow:
“A”- Molasses = 80o Brix,

“C” – Massecuite = 96o Brix

 Assume a vapour consumption of 1.2 Kg for every kilo of water evaporated.

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Unit Five
Automatic Control of Sugar Boiling

Unit Objectives
At the end of this unit training, the trainees will be able to:

 Explain the steps to follow when introducing automation on pan floor.

 Describe all the variables used for automatic pan boiling.
 Discuss the basic condition for successful pan automation.
 Explain briefly about level control indicator.
 List out all the basic requirements for an automated pan.
 Describe briefly pan cycle of the two basic types of boiling preparing the footing.

5.1 Introduction
Crystallization depends very much on supersturation which is related to the consistency of the
massecuite. Over the years, pan boilers had developed an evaluation of the consistency based on
the rupture of a syrup film, between the thumb and the finger, and the malleability of a
massecuite lump.
These evaluations being very subjects and variable, it was thought that measuring physical
characteristic of the massecutie (like conductivity) would be more worthwhile. It is good to note
that as far back as 1813, Howard equipped pan with a thermometer to help in conducting the
boiling operation (See Fig 2.7 on page 21).
The steps to be followed when introducing automation on the pan floor, especially if the
personnel are not familiar with it, are:
1. Installing measuring instruments to test their reliability and allow the personnel to
become familiar with them.
2. Add recording instruments to keep data and record‖ good strikes’ which will be used as
standards.
3. Equip the pan with automatic valves and controllers. We have two options:
a. On site controllers, directly accessible to the pan boilers
b. Remote controllers in central control room.

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Nowadays with the flexibility of computer controls, the tendency is to have a control room on
the pan floor, which is also duplicated in the central room.

5.2 Variables Used For Automatic Pan Boiling

The following variables bear a relation with the supersaturation of a massecuite and can be used
for the control of pan boiling:
1. Electrical Conductivity: One of the first measurements to be used to quantify consistency
2. Boiling Point Elevation
3. Radio Frequency Signals (R.E. Proves)
4. Viscosity
5. Gamma Rays
6. Refractive Index
7. Microwaves
These various methods are described more in details below:

5.2.1 Basic Conditions for Successful Pan Automation

Two conditions are essential for good pan boiling, whether manual or automatic:
1. A Constant Vacuum
2. A Stable Steam Pressure
In addition, with pan automation, it is desirable to have;
 Dilution of the feed of to the pans to a constant Brix (700)
 A constant feed temperature (70 0C)
 Graining at a constant purity (700 for “C” Massecuite)
 Some factories with continuous pans, like Omnicane at La Baraque, have installed
fully automated conditioning station that prepares syrup and ―A” and ―B”
molasses at 700 Brix and 70 0C. One can at least install conditioners, with steam
injection controlled by a thermostat, to remelt small sugar particles in the feed.

5.2.1.1 Constant Vacuum

The vacuum in the pan determines the temperature in the vapour space above the massecuite,
consequently the temperature of the massecuite. It is measured by a gauge or sensor connected to
the vapour space. Change in temperature, at the same concentration, will change the
superasturation of the massecuite.

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Ideally each vacuum pan should be fitted with an individual condenser so as to have a constant
vacuum. In such cases, the water fed to the condenser is controllers to maintain the vaccum
constant.
In practice, usually the continuous pans are equipped with an individual condenser, whilst the
batch pans operate on centralized vacuum systems. With this system, we have to throttle the
value on the vacuum line and may be use an auxiliary air pump to maintain the vacuum.
5.2.1.2 Steam Pressure
This is less critical than vacuum. Nowadays most pan stations work on evaporator bleedings
which tend to be stable. We should, however, maintain our evaporation rate by compensating
drop in juice flow with hot condensate.

5.3 Variables Used For Control of Pan Boiling

1. Electrical Conductivity (Fig. 5.1(a) and Fig.5.1(b))
The most common control systems for pan boiling
There are a relation between conductivity and supersaturation. This relation is not an absolute
value. It is empirical and varies not only with the purity of the mother liquor. It is, therefore,
important to boil at constant purities. Conductivity setting will have to be altered several times
during the season.

Figure 5.1(a): SUMA Cuitometer

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Figure 5.1(b): DDS Electro Pneumatic Conductivity Controller

The conductivity reading varies with the distance between the electrodes (concentric electrodes
are therefore preferred) and with scaling of the electrodes which must be kept clean (steam
injection, removal electrodes, etc.)
Electric current; low frequency alternating with an amperage of 0.2 – 0.5 A.
Conductivity cannot be used for a very high purity strikes (Refinery)
The best position for the electrodes is at the bottom of the pan about 1/3 radius away from the
outside of the pan.

2. Boiling Point Elevation

Boiling point elevation (B.P.E.) is also a measure of supersaturation. B.P.E based instruments
consist of an accurate thermometer in the massecuite and a second thermometer in water in as
mall pilot pan connected to the vapour space of the pan ( before the separator). Because of the
effect of static head on the temperature of the massecuite, the B.P.E instruments can only be used
to measure supersaturation accurately at one level in a batch (usually at graining level) (Fig.
5.2(a) and (b)). With continuous pans which operate at a fixed massecuite level and computers
which can calculate the boiling temperature of massecuite from a pressure reading (and obviate
the need for a pilot pan), B.P.E may become more popular for pan control.

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3. Radio Frequency Signals (R.F. Probes)

A relatively new development. It is particularly useful for refinery strikes which cannot be
controlled by conductivity because of their high purity.

The R.F. probe works at a frequency of 32 mHz and produces two signals: a resistivity and a
capacitance signal which can be used to measure the Brix, crystals content and conductivity. The
R.F. probe does not scale and is, therefore, used on continuous pan which is cleansed at long
intervals. More details are given in the additional notes provided.

Figure 5.2 (a): Typical arrangement of Vacuum Pan Control Using Boiling Point Elevation

Figure 5.2 (b): Vacuum Pan Control Using Boiling Point Elevation

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4. Viscosity
Viscosity can also be used to control strikes. The readings are influenced by air and steam
bubbles with massecuites, and rheometres. Basically, a rheometre consist of a small motor on the
outside of the pan. A shaft through the pan and a small stirrer which rotates in the pan. The
resistance to rotation is a measure of the tightness of the massecuite (See Fig.5.3).
There is a mechanical problem with this type of instruments. When a very tight massecuite is
dropped, it can bend the shaft of the rheometre.
A pan stirrer is a crude rheometre

Figure 5.3 (a): Viscosity and Supersaturation of Sucrose Solution in the Temperature Range
between 65 and 75 oC, Maximum. Supersaturation Deviation + 0.005

Figure 5.3 (b): Relation between Viscosity and Saturation Number at Different Temperature (In
accordance with ICUMSA)

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Figure 5.3 (c): Relation between Supersaturation, Viscosity and Temperature

Figure 5.3: Changes in Viscosity
5. Gamma Rays
A radioactive isotope placed in a special box on the outside wall of the pan can be used to send
gamma rays to a counter across the massecuite. It measures the Brix of the massecxuite. This
type of instruments can only be used by people who have been especially trained. It is potentially
hazardous.

6. Refractive Index
The refractometre is attached to the wall of the pan with the prism assembly bin the pan. The
refractive index is used in high purity products. The instruments are suitable only for refinery
strikes before the massecuite is tightened. They can be very useful to find the graining point.
Cleaning is a problem.

7. Microwaves
Microwaves act more on water molecules than other molecules. Consequently, a food with high
moisture content will heat up faster than one containing less water. This has been used as basis
for an equipment to determine water content of a massecuite, consequently its solid content or
Brix. Microwaves normally have a frequency around 2.5 GHz. In this type of equipment, there is

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a transmitter and a sensor. The signal received by the sensors is compared to the original signal
transmitted. According to the Brix of the product, there is a damping of the signal strength and a
phase shift of the waves. These two values are used to generate a signal which is proportional to
Brix and is used for control purposes (See Fig. 5.4 and Fig. 5.5)

Figure 5.4: Principles of Measuring Concentration with Microwaves

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Figure 5.5: Microwave Control of Sugar Boiling

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5.4 Level Indication

In manual mode, the pan boiler can follow the level of the massecuite through the sight glasses.
When we automate need an indication of the level and also a signal that we can use in our
control programme. The first means used was just level electrodes which, by conductivity
through the massecuite, were used light up indicator lamps. It also changed settings in control
programmes by steps.
Nowadays we more usually make up use “DP” Cells (Differential Pressure) fitted at the bottom
of the pan to determine the height of massecuite. Thus we get a continuous monitoring of the
level and a smoother control (close steps)

5.5 Automated Pans

An automated pan sketched in Fig. 5.6. The basic requirements are;
1. A Vacuum Control
2. A Measurement of the Massecucite Tightness
3. A Level Indicator
4. An Automated Valve to Feed Syrup/Molasses
5. An Automated Valve to Feed Water
6. An Automated Valve to Feed Slurry
Formerly most control systems were pneumatic and liable to many faults due to oil-contaminated
compressed air. Nowadays we use electronic controllers and I/P converters (current to air
pressure) to active the control valves

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Figure 5.6: Automatic Control of Vacuum Pan

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5.6 Pan Cycles

We have two basic types of boiling:
(a) A Graining Strike (Usually a ―C‖ Massecuite)
(b) Boiling from A Seed or Footing (―A‖ and ―B‖ Massecuite)

(a) Graining Strike (Fig. 5.7)

1. We start with an empty pan which has been steamed following as previous strike. An
appropriate mixture (Usually Syrup and ―A‖- Molasses for a ―C‖- Strike) is drawn into
the pan to cover the tubular plate (tot1).
2. The mixture is concentrated to the set-point chosen for graining (t2). The level is kept
constant automatically by the syrup/molasses feed valve to compensate evaporation.
3. The syrup/molasses valves is closed and the set-point is maintained by the water feed
valve. A timer allows the systems to stabilize and automatically operate the slurry valve
to perform graining (t2 t3).
4. During the development of the sugar crystals, the concentration is kept constant by the
feed water valve, allowing the crystals to be ―Brought Together‖. A second timer fixes
this period of ―Bringing Together‖, according to our previous experience. After the set
time. (t4), the water valves is closed and the molasses valve opened.
5. The addition of molasses allows the crystals to grow further and produce a rise in the
level of massecuite. According to requirements, the set point will produce the necessary
tightening of the strike to the final level (t5).
6. It is a final strike; there is a final tightening stage (t5 t6) to the set-point value. The feed
valve is closed automatically.
7. An alarm will signal the completion of the strike (t6). The steam valve is closed, the
vacuum broken and the massecuite discharged.
8. If the strike has to be cut to allow further growing of the crystals (Fig.5.8), the massecuite
is tightened less. After cutting, the molasses feed valve is opened again and new set-
points are chosen to produce a greater tightening of the massecuite. When the pan
capacity level is reached, the molasses feed valve is closed and when the set-point for
final tightening is reached, we stop the pan as explained above.

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Figure 5.7: Diagram of Strike with Graining

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Figure 5.8: Diagram of Graining Strike and Cutting

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In some cases, ―thinning out‖ is used by certain pan boilers to adjust the amount of seed crystals
required (Fig. 5.9).

Figure 5.9: Conductivity Curve of Graining (With Thinning Out)

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(b) Boiling from “A” Footing (Fig. 5.10)

1. The volume of footing required is drawn into the pan (1) and the steam valve opened.
2. The syrup/molasses feed valve is opened and the consistency automatically maintained
according to the value chosen for the various levels, giving us the chosen trend for the
tightening curve (1 and 2).
3. At the final level chosen (2), the feed valve is closed automatically. The tightening is
contained to the chosen set-point (3). The alarm signals the end of the strike, the steam
valve is closed, the vacuum broken and the pan discharged.

Figure 5.10: Boiling Strike from a Footing

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5.7 Preparing the Footing

In the case of a non-automated boiling from a magma footing, the pan boiler must |clean ―the
magma from all broken crystals and chose the best ones for the strike. This operation normally
cannot be done without human supervision. So for automated pans, we must prepare the footing
and keep it in a feed receiver (under vacuum or not).
In the case of the “CBA” systems, we often also grain for the “B”– Massecuite so as to avoid
claiming the “C”- Magma.
Fig. 5.11 below Illustrates A Pan Microscope to Examine Sugar Crystals In Situ.

Figure 5.11: Pan Microscope

5.8 Computer Programmes

Nowadays most control systems use computer programmes to which we supply the necessary
data.

5.9 Radio Frequency Probe

5.9.1 General Description

The DUOTRAC rapid frequency (R.F) probe is an instrument which measures complex
impedances. The unit consists of a probe body on the end of which is mounted an enclosure
housing the electronics.

The probe may be fitted into the side of, or underneath a pan used for boiling sugar to provide
simultaneous measurement of massecuite series resistance and series capacitance which are
available as two separate 4 - 20 milliamp out put signals.

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These signals may be used individually or in combination for control depending on the
application. For example, on beet massecuites, the series resistance signal correlates closely to
massecuite Brix, whereas the series capacitance signal is influenced more by mother liquor Brix.
For improved control of continuous pans, a signal highly biased towards crystal content may be
derived by linear combination of the two signals in a predetermined ratio. The method of
measurement and the use of the two signals to derive an optimum signal for control are patented
and make the DUOTRAC probe superior to other R.F. probes which only provide a single output.

For control of can sugar refinery white pans where ash is low, the series capacitance signal gives
good results. This signal provides a measure of liquor Brix at the beginning of the boil which can
be used to establish seeding point. Also, this signal responds to crystal content during the boil
and can also be used to control boiling up of the pan to strike.

The instrument can also be used for Brix measurement and control on various liquors.

The probe is available in two lengths, a long version suitable for use in continuous pan or in
batch pans, and a short version for Brix measurement of liquors, or for use in pans where there is
a space restriction or where the probe may be subjected to severe forces.

With each probe, a calibrator and calibration data sheet is provided to facilitate workshop
calibration to a standard range. The electronic circuit of all probes is identical, except for a plug
in range card which may vary for different applications.

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Chart Showing Control and Reference Signals

Over A Typical Batch Boiling Cycle – White Sugar
Beet Massecuite

Control Signal = Nuclear Density Meter

RS Signal = R.F. Probe Series Resistance
XS Sign = R.F. Probe Series Capacitance

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Self Check Exercises

1. What should we try to control the vacuum in a pan? How do we achieve this?
2. Describe briefly the stages in the boiling of a “C”– Massecuite strike.
3. Explain briefly the steps we should take to shift from a fully manual control of the
pan boiling operation to an automated one.
4. By means of a drawing, illustrate the basic controls required to automate the boiling process
in a vacuum pan.
5. What are the factors affecting boiling point elevation in vacuum pans?
6. Sketch the recording of an automated “C”– Boiling and indicate the different stages from
start to finish.
7. How does the level of massecuite in the vacuum pan affects its degree of supersaturation.
8. Why must we make more cutting on “A”– massecuite strike than on a “C”- massecuite?
9. Why is it a bit more complicated to automate “C”– strike than “A”– and “B”– strikes?
10. Describe or illustrate the basic controls on an automated batch vacuum pan.
11. Why is it desirable to control the vacuum in pans specially those fitted with automatic
controls?
12. Briefly describe different physical properties that we can measure and use for automatic
control of sugar boiling.
13. Compare the automatic of the boiling processes in “A” or “B” vacuum pan with that of a
“C” vacumm pan. Illustrate the two boiling cycles by a means of a curve.
14. Make a sketch to illustrate the basic requirements for automating a vacuum pan.
15. Describe briefly how we boil commercial strike (massecuite) starting from magma as
footing.
16. Draw a recording of conductivity measurements during the boiling of a “C”-Massecuite
from slurry. Explain the various stages on recording.
17. Why is it important to have vacuum control on automated vacuum pans?

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Unit Six
Continuos Vacuum Pans

Unit Objectives
At the end of this unit training, the trainees will be able to:

 Discuss the working principle of continuous pan and explain its advantages and
disadvantages compare to the batch pan.
 Describe about the heating surface and strike volume ratio of continuous pan for
different strikes.
 Discuss about instrumentation and control of continuous pan.
 Explain briefly continuous pan operation, start up and shut down procedure..

6.1 Introduction
The continuous vacuum pan has been of increasing interest to technologists in recent years
because of the rapid increase in manpower costs. Economic saving is expected by an increase in
throughput, by the reduction of downtime common with batch bans when stopping and starting,
and by an improved steam consumption of the pan floor. Continuous vacuum pans were first
developed, mainly in France by FCB, to boil beet sugar massecuites as far back as 1968, and
have now been used for all types of cane sugar massecuites.

6.2 Development of Continuous Pans

Several types of continuous pans were designed, namely the circular type and the horizontal
type. A circular pan was designed by the French engineer, F. Langrenet, while working with
Emile Hugot in Reunion Island. The tubes are arranged vertically as for an ordinary batch pan. A
Langreney’s circular continuous pan is used on "C" massecuite at Union St Aubin Sugar factory
in Mauritius (See Fig. 6.1) The German firm B.M.A. also tried a vertical crystallization tower.
(See Fig. 6.2).
The horizontal model is cylindrical in shape, fitted with a heat exchanger along the longitudinal
axis of the vessel. The first horizontal pan (FCB) used for boiling "C" massecuite used vertical
plate elements for boiling the massecuite. Later, banks of horizontal tubes were used in the heat
exchanger. Through much research and pioneering work, Huletts Sugar Ltd developed its own

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continuous pan which uses vertical tubes in a calandria positioned lengthwise in a horizontal pan.
This design proved satisfactory for boiling "A", "B" and "C" massecuites. The largest mill in
South Africa, Felixton, has six continuous pans with vertical tubes boiling all massecuites.

Figure 6.1: Langreney Continuous Pan

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Figure 6.2: B.M.A. Crystallization Tower

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6.2.1 Constriction and Design

The vertical tube calandria has proved superior in performance to both vertical plate elements
(FCB) and banks of horizontal tubes stacked vertically in later designs (FCB).

As far as boiling cane sugar massecuites is concerned, the vertical tube calandria has been
retained in all continuous pans both in South Africa (Huletts) and Australia (S.R.I/Tully Pan).

The continuous pan consists of 12 compartments with the calandria arranged along the length of
the pan in the centre. The calandria is divided into two equal halves lengthwise by a baffle plate.
The compartments are formed by baffles arranged across the width of the pan to result in 12
separate compartments. These are equal in size and communicate by means of crossover ports
from the first to the last. In the latter and adjustable vertical weir is provided to discharge the
finished massecuite into a barometric seal leg.

The bottom of the pan is streamlined to promote massecuite flow and eliminate stagnant zones.
Feed inlets and movement steam inlets are installed below the lower tube plate of the calandria.

The massecuite rises in the tubes and flows down in the wide space provided between the pan
walls and the calandria, thus following a similar pattern of circulation as in batch calandria pan.
Although the vertical and transverse baffles are welded to the vessel walls at the bottom and
sides of the compartments, they stop at a certain height above the calandria, leaving sufficient
space below the top wall of the vessel for vapour from the boiling massecuite to escape to the
condenser, which is centrally positioned on top of the pan. Sight glasses and lights are fitted
along the length of the pan to allow operators to observe the boiling of massecuites.

6.2.2 Heating Surface and Strike Volume Ratio

The calandria is made up of 100 mm tubes between 1.2 m and 1.3 m in length for the “A” and
“B/C” pans respectively. Steam is admitted from both ends of the calandria and to volume ratio
is very large being 10:1 in these pans, allowing low pressure steam to be used for boiling “B”
and “C ” massecuites. Operation (See Fig.6.3).
A continuous pan has to be supplied with a footing (Seed or Magma) prepared in a conventional
batch pan. The footing from the batch pan is dropped into a seed receiver, from which it is
pumped by means of a variable pump to compartment ―1‖ of the continuous pan. Massecuite, as
it increase in volume due to feeding, overflows continuously to the succeeding compartment

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until the finished product overflows the off-take weir into a transfer crystallizer. Each
compartment is fed with either syrup, “A” or “B” molasses, depending on the type of massecuite
made. The feed to each compartment is automatically controlled. Balancing water is also
supplied to each compartment. The quantity admitted is carefully regulated. Level of massecuite
in the pan is kept about 500 mm above the tube sheet.

Figure 6.3: Cross Section of Tongaat-Hulett Continuous Pan

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Continuous pans have proved easy to operate and control. Molasses or syrup feed should be at a
constant Brix. When pans have to be stopped for and length of time, steam is shut off. The pan
can be restarted in a relatively short time. With “A” massecuite, it is necessary to slacken the
massecuite a little before shutdown. This is necessary to prevent severe encrustation on walls and
inside tubes: if the pan is slackened off, it can be left out of operation even during a few days, in
necessary, and will start up again without trouble.

The problem of encrustation of walls and tubes of “A” pan when the massecuite was at 85 purity
was severe. A pan can run for two weeks before having to boil it out with water. A system of fine
sprays which supply small quantities of water onto the internal surfaces clean (Baffles and sides).
Stopping every two weeks is still necessary. On “B” and “C” pans, encrustations are not serious,
and the pans can be operated for long periods without requiring a water boil-out.

6.3 Instrumentation and Control

The continuous pan of this design is ideally suited for automatic control of the boiling (See Fig.
6.4). Each of the 12 compartments is provided with a conductivity control loop which allows the
input of “A” and “B” molasses and water to be carefully regulated by an automatically
controlled valve, as shown. In operation, admission of feed is decreased gradually from the first
to about the third but last compartment, while the last three compartments are fed with water
only to allow for increased tightening of the massecuites. This especially applies to “B” and “C”
massecuites.

With regard to the “A” massecuite, the use of radio frequency probes is preferred to that of
conductivity probes, which scale frequently and quickly. The R.F. probes measure electrical
properties of “A” massecuite in the range of 20 MHZ to 50 MHZ and are used with a
Microprocessor, which allows the boiling to be effectively controlled. Such equipment was being
used on “C” massecuite at Deep River Beau Champ factory in 1994, with much success.

Apart from the 12 control loops for boiling the massecuite, the pan is fitted with two additional
control loops, namely: a calandria pressure loop regulating the flow of steam (Vapour) to the
calandria and an absolute pressure control loop regulating the water flow to the condensers and
ensuring a steady vacuum in the pan. In conjunction, both loops allow the T between steam in
the calandria and vapour to the condenser (tv) to be maintained.

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Figure 6.4: Basic Processes Flow Sheet

Comments
(i) The continuous pan now provides fully automated and continuous operations to cater
for all massecuites.
(ii) Owing to the use of adequately selected control instruments, it will boil consistent
quality “B” and “C” massecuites regularly.
(iii) With the application of R.F. probes, “A” massecuite can be boiled without ―false
grain‖ to give VHP sugar of lower color index and high quality.
(iv) Better steam economy can be achieved from the use of continuous pans, which
operate very well on sub- atmospheric vapour.

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6.4 Continuous Vacuum Pans in Cane Sugar Factories (Five-Cail Babcock

Patent)

6.4.1 General
The entirely continuous manufacture of sugar, from beets or from sugar cane, is a goal striven for
by operators as well as by manufactures and research centers.
The crystallization of sugar in vacuum pans and the centrifuging of the first –strike massecuite
were formerly batch processes.

Credit must go to FIVES-CAIL BABCOCK for having been the first to provide a solution
allowing continuous, industrial sugar crystallization.

This new continuous vacuum pan concept was developed by the F.C.B. Research center after 10
years of theoretical studies followed by computer simulations and testing in experimental
stations.

Today, this concept is applied industrially in both beet and cane sugar factories and in refineries
for all the crystallization strikes and within a production range covering the full requirements of
operators.

It can thus be stated that this technique will be called upon in the coming years to replace the
batch vacuum pans, which, even though they have been modernized and automated, can not offer
the advantages of a continuous system.

6.4.2 Operating Principle

The originality of the system lies in the fact that the successive operations encountered in
conventional batch crystallization are performed in ―Space‖ instead of in ―Time‖.

In fact, the horizontal body is divided into a certain number of compartments by transverse and
longitudinal partitions. The massecuite flows from one compartment to the next through a series
of orifices provided at the base of the partitions.
A bank of longitudinal tubes arranged in vertical rows provides the calories necessary.
The first compartment is supplied with magma which is itself obtained either from washed
mingled or unmingled sugar, or from a footing formed in a batch pan.
Each compartment receives syrup or a run off depending on the considered strike.

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The massecuite progresses from compartment to compartment and reaches the end of the pan.
Depending on the case, it is extracted either by a variable speed positive displacement pump or
simply through an adjustable overflow followed by a barometric column.
The stirring of the massecuite takes place mainly by natural convection; it rises between the
vertical rows of tubes and falls again within the space between the tube bank and the shell. In
addition, steam injectors performing the same functions as the mechanical agitator in batch pans
are provided along the lower surface. This injection, ensuring very good homogeneity of
temperature and super- saturation, reduces the risk of spontaneous false crystal formation and
allows the production of well formed crystals. To crate this agitation, use is made of the non
condensable vapors from the heating elements.

6.4.3 Description of Pan (See Fig. 6.5)

The continuous vacuum pan is made of the following:
 A hoop-reinforced horizontal cylindrical steel shell (1) with two reinforced flat end faces
acting as a support.
 A bank (6) of horizontal heating tubes (7) arranged in vertical rows (8). The tubes are
secured at their ends to the end faces by means of patented sealed devices (11) allowing
their free expansion. The tubes lead out onto steam (9) closed by bolted lids (10) giving
easy access to the tubular plates.
 Steel partitions, one being longitudinal (3) and the other transverse (4) dividing the shell
into a certain number of compartments communicating with each other through orifices at
the lower part of the partitions.
 A magma inlet (15) located at the top of the end face delimiting the first compartment,
and syrup or runoff and wash water inlets made up either of rotary distributor or of caps
placed in suitable locations. The massecuite is extracted from the last compartment
through a nozzle at the lower part of the pan for utilization in refinery or through an over
flow in the case of “A”, “B” or “C” strikes. Valves are distributed over the lower surface
of the shell to allow rapid draining.
 A dome carrying an entrainment separator (12) with steam outlet nozzle (14) and
baffle plate (13) installed on top the pan.
 A double steel envelope encircling the lower shell for pans operating on high-
purity products (refinery).

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 The following accessories: manhole, round sight glasses for lighting and
observation equipped with washing device, vacuum breaker, atmospheric valve,
sampling cocks, visual flow indicators for the syrup or runoff inlets, pressure, and
vacuum gauges and thermometers.
 A control and measurement installation (Pneumatic or electronic depending on the
case) with possibility of manual emergency action.

1. Shell 9. Steam Box

2. End Faces 10. Covers
3. Longitudinal Partition 11. Sealing Device
4. Transverse Partitions 12. Dome
5. Steam Inlet 13. Baffle Plate
6. Heating Element 14. Steam Outlet
7. Tubes 15. Magina Inlet
8. Tube Rows 16. Drai

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6.5 Pan Operation

The operation of the pan is fully automatic and is hence limited so simple periodic supervision of
the different operating parameters, the most important of which are recorded on diagrams.

The variation in the flow of massecuite produced is obtained by acting on the pressure setting of
the steam entering the heating elements.

In the event of excessively abrupt variations in the external conditions (characteristics of

products, values of auxiliaries, etc,) audible or visible alarms are actuated to point out the need
for corrective action to re-establish the proper operating conditions.

6.5.1 Start-Up of Pan

The start – up of the continuous vacuum pan is very similar to that of a batch pan: after the
footing is drawn in until it covers the heating elements, the syrup or runoff feed is continued until
the level reaches the normal operating point. At this point, the control systems for continuous
and automatic operation of the vacuum pan go into service. For high – purity strikes, start-up can
take place easily by graining in the pan itself.

6.5.2 Boiling Schemes and Flow Diagrams

We have seen that there are several boiling schemes (or Massecuite systems) that can be used in
the boiling house.
1. To evaluate or compare these schemes we can use a Brix flow diagram, on a percent
basis.
2. These Brix flow diagrams can be drawn using Cobene Diagrams.
3. The Cobene Diagrams is calculated from the purity of the various products. The
purities are indicted in the flow diagrams as degree purity (xo).
4. Solving the various Cobene Diagrams allows as obtaining the amount of Brix we will
obtain in each product as a percentage of the Brix in the syrup (x % in the diagrams).

Calculating Actual Product Amount

1. The Brix input to the Boiling House is that found in the syrup and equal to tht in the
Mixed Juice.

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Tonnes Juice
So Brix Input   Brix of Juice
Hour

150 Tonnes Juice

Ex :  12 O  18 Tonnes Brix / hr
Hr

2. The amount of Brix/ hr in any product is thus:

18 Tonnes Brix / hr  % age of the product in the Brix Flow Diagram

3. Mass of Product  O
Br / 100 = Mass of Brix in Product
Amount of Brix / hr in any product  100
So O
 Mass of Pr oduct / hr
Brix of Pr oduct

Ex : 24,000 Kg Brix / hr of Pr oduct of 80 O Brix is :

24,000
 100  30,000 Kg / hr of Pr oduct
80
3. Most products being in liquid form we obtain their volume by dividing by the bulk
Density.
30,000 Kg / hr
From above :   20,000 L / hr
1.5 Kg / L

Thus: Purity Cobenze % age Brix in all products

% age in any product  Brix input / hr = Mass Brix in product / hr

Mass Brix in Pr oduct / hr

O
 100  Mass Pr oduct / hr
Brix

Mass Pr oduct / hr
 Volume of Pr oduct / hour
Bulk Density ( Kg / L)

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Self Check Exercises

1. What are the advantages of the continuous pan? Any disadvantage?

2. What has been the reason for developing the low head vacuum pan? What is the present
trend?
3. Why is it important to have a good clarification in a vacuum pan? What are the
improvements that have been made to achieve this?
4. Why do we have to make various grades of boiling (“A”, “B”, and “C”)?
5. What are the advantages of a central vacuum system for a pan station?
6. Sketch a continuous pan to show the basic components of the system.
7. How do we control the sizes of the sugar crystals on batch pans and continuous pans?
8. Give a brief description of the main modification made to vacuum pans to improve their
performance.
9. Why very often it is not recommended to boil a vacuum pan to its maximum capacity?
10. What are the advantages of offered by the continuous vacuum pan?
11. Explain the idea behind Webre’s design of a ―Low Heat Vacuum Pan‖. What are the
advantages obtained?
12. Explain what a ―Cutting‖ in sugar boiling is. Why must we make more cutting with
“A” –Massecuite than with “C” –Massecuite?
13. Describe briefly the various stages in boiling a “C”-Massecuite from slurry.
14. How do we proceed to adjust the crystal size of a massecuite in batch pan and in
continuous pans?
15. How can drawing the boiling scheme we use, and calculate the various products, be
useful to us?
16. Make a sketch to illustrate a continuous vacuum pan showing the main points.
17. Explain how nowadays we can use low pressure vapours from the evaporator (“VP2”
and “VP3”) on the pan station.
18. What are the main modifications made to the usual batch vacuum pan to improve its
performance?
19. Make a sketch of a continuous pan showing that the various automated control installed.

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