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Capacity Calculation of Pan Section in
Sugar Industry | Boiling House
Capacity
Pan Section Capacity Calculation in
Sugar Industry | Crystallization
Sugar crystallization process takes place in pan section of sugar
plant. The equipment supply tanks, Batch/continuous pans, condensers, molasses conditioners, spray pond, crystallizers fall under pan section.
Capacity of Batch/Continuous pans
The boiling times considered for A, B & C massecuites are 3-4 hours, 4-6hours and 6-8 hours respectively . For refinery massecuite,2 to 3 hours is considered. Example: Crushing Capacity of the plant = 230 TCH “A” massecuite%cane = 25 to 30% “B” massecuite%cane = 12 to 13% “C” massecuite%cane = 6 to 8% ” A” Massecuite Quantity = 230 x 30% = 69 T/hr = 1656 T/day ” B” Massecuite Quantity = 230 x 13% = 30 T/hr = 720 T/day ” C” Massecuite Quantity = 230 x 8% = 18.5 T/hr = 444 T/day While considering batch pans with 60 Ton capacity each Quantity of Boiling No. of strikes per No. of pans Massecuite massecuite per Hours day per pan required strike in Ton
A 4 24 hours/4 = 6 1656/6 = 276 276/60 ≈ 5 nos.
B 6 24 hours/6 = 4 720/4 = 180 180/60 = 3 nos.
C 8 24 hours/8 = 3 444/3 = 148 148/60 ≈ 3 nos.
While considering Continuous pans for all massecuite boilings
For continuous pans, 10% to 20% extra capacity is to be considered. From the above For ” A” Continuous Pan = 69 T/hr x 110% ≈ 76 T/hr For ” B” Continuous Pan = 30 T/hr x 120% ≈ 35 T/hr For ” C” Continuous Pan = 18.5 T/hr x 120% ≈ 22 T/hr Grain and Molasses ratio for A, B & C massecuites is generally taken as follows ( It depends on grain size and purity of material) “A” Grain to Liquor (syrup/melt/AL) ratio – 1 : 1 to 2 “B” Grain to Liquor (A heavy) ratio – 1 : 2 to 3 “C” Grain to Liquor (B heavy/ C light) ratio – 1 : 3 to 4 B massecuite purity online calculation sheet | Sugar Technology C massecuite final purity calculation |Grain Quantity requirement for C CVP Quantity of Quantity of No. of strikes Massecui Boiling grain massecuite per day per No. of pans required te Hours required in per strike in pan Ton Ton
batch/continuous pans Note: It is not accurate capacity but it gives approximate value instantly Batch pans “A” Batch pan capacity in Ton – TCD x 0.06 ( Ex: 5000 x 0.06 = 300 T ) “B” Batch pan capacity in Ton – TCD x 0.04 ( Ex: 5000 x 0.04 = 160 T ) “C” Batch pan capacity in Ton – TCD x 0.03 ( Ex: 5000 x 0.03 = 150 T ) Continuous pans “A” Continuous pan capacity in Ton – TCD x 0.014 ( Ex: 5000 x 0.015 = 75 T/hr ) “B” Continuous pan capacity in Ton – TCD x 0.006 ( Ex: 5000 x 0.006 = 30 T /hr) “C” Continuous pan capacity in Ton – TCD x 0.004 ( Ex: 5000 x 0.004 = 20 T /hr) “A” Grain pan capacity in Ton – TCD x 0.025 ( Ex: 5000 x 0.025 = 125 T ) “B” Grain pan capacity in Ton – TCD x 0.01 ( Ex: 5000 x 0.01 = 50 T ) “C” Grain pan capacity in Ton – TCD x 0.01 ( Ex: 5000 x 0.01 = 50 T ) Low Grade Massecuite Treatment in Sugar Crystallization Process Sugar Seed Slurry Requirement Calculation for B and C massecuite Types of Graining Techniques in sugar crystallization process | Pan Boiling
Pan Supply Tanks
“A” massecuite feeding liquor (syryp/melt/A light) consider minimum 2 hours retention time “B” massecuite feeding liquor (A Heavy) consider minimum 3 hours retention time “C” massecuite feeding liquor ( B heavy/ C light) consider minimum 4 hours retention time Example: Crushing Capacity of the plant = 230 TCH Syrup % cane – 25 to 30% Melt % cane – 12 to 14% A light %cane- 2 to 3% A heavy%cane- 12 to 15% B heavy%cane – 6 to 7% C light%cane – 2 to 3% Syrup + melt + A light = 43% (average) = 230 x 43% ≈ 100 T/hr High grade massecuite supply tanks capacity = 100 x 2 hours = 200 / 1.25(density) = 160 M 3 = 1600 HL A heavy molasses quantity = 230 x 15% = 34.5 T/hr A heavy supply tanks capacity = 34.5 x 3 hours = 103.5 / 1.3(density) ≈ 80 M 3 = 800 HL B heavy + C light molasses quantity = 230 x 10% = 23 T/hr A heavy supply tanks capacity =23 x 4 hours = 92 / 1.3(density) ≈ 70 M 3 = 700 HL Thumb rules for finding the capacities of supply tanks in pan section High grade massecuite feed materials ( Syrup + melt + A light ) supply tanks capacity in HL = TCH x ( 7 to 8) Low grade massecuite feed materials ( A Heavy + B heavy + C light ) supply tanks capacity in HL = TCH x ( 7 to 8)
Molasses Conditioners capacity
For its capacity, consider extra 10 to 20% on molasses production Example: Crushing Capacity of the plant = 230 TCH A heavy%cane- 12 to 15% B heavy%cane – 6 to 7% C light%cane – 3 to 4% A heavy molasses quantity = 230 x 15% = 34.5 T/hr A heavy molasses conditioner capacity = 34.5 x 110% = 38 T/hr B heavy molasses quantity = 230 x 7% = 16.1 T/hr B heavy molasses conditioner capacity = 16.1 x 110% = 18 T/hr C light molasses quantity = 230 x 4% = 9.2 T/hr C Light molasses conditioner capacity = 9.2 x 110% = 11 T/hr
Capacity calculation of crystallizers
Crystallizers are used for cooling and holding of the massecuite. Air cooled type crystallizers are used for high grade massecuites, receiving crystallizers of continuous pans and for seed crystallizer. Water cooled crystallizers are used for low grade massecuites for proper cooling and better exhaustion. A – Massecuite – ( 2 hours cooling purpose + 2 hours curing purpose) – Air cooled B – Massecuite – ( 6 to 8 hours cooling purpose + 3 hours curing purpose) – Air cooled + water cooled C – Massecuite – ( 20 to 24 hours cooling purpose + 4 hours curing purpose) – Air cooled + water cooled Each crystallizer capacity should be 10 to 15% more than the existing pan capacity. For example, if a 60 T (42 m³) pan is considered, then the capacity of crystallizer can be taken as 70 T (48 m³). For an air cooled type crystallizers is considered for “C’ massecuite then cooling time can go upto 72 hours. So, proper design of cooling elements used in crystallizers enables the cooling time to come down to 18 to 24 hours. Application of Crystallizers in Sugar Industry | Crystallizer Capacity Calculation Example: Crushing Capacity of the plant = 230 TCH “A” massecuite%cane = 25 to 30% “B” massecuite%cane = 12 to 13% “C” massecuite%cane = 6 to 8% ” A” Massecuite Quantity = 230 x 30% = 69 T/hr ” B” Massecuite Quantity = 230 x 13% = 30 T/hr ” C” Massecuite Quantity = 230 x 8% = 18.5 T/hr Crystallizer capacity for “A” massecuite Quantity of “A” massecuite for (2+2) hrs = 69 x 4 = 276 Tons ≈ 300 Ton Total volume of “A” crystallizers = 300 /1.45 = 206 M 3 = 2060 HL ( sp.gr =1.45 ) So total capacity split is into number of crystallizers and each crystallizer shall have 10 to 15% more capacity than that of the pan. Generally, total capacity of “A” massecuite crystallizers are made equal to total capacity of “A” pans. Capacity of “B” massecuite Crystallizer
Quantity of “B” massecuite for (7+3) hrs = 30 x 10 = 300 Tons
Total volume of “B” crystallizers = 300 /1.5 = 200 M 3 = 2000 HL ( sp.gr =1.5 ) The total capacity is split into water cooled and air cooled crystallizers in the ratio of 7 : 3 or 8 : 2 Crystallizer capacity for “C” massecuite Quantity of “C” massecuite for (24 +4) hrs = 18.5 x 28 = 518 Tons ≈ 550 Ton Total volume of “C” crystallizers = 550 /1.5 = 370 M 3 = 3700 HL ( sp.gr =1.5 ) The total capacity is split into water cooled and air cooled crystallizers in the ratio of 8 : 1 Vertical Crystalliser Design Calculation for Sugar Massecuite Cooling Concepts of Vertical Crystallizer in Sugar Plant | Mono Vertical Crystallizer Vacuum crystallizers : The capacity of Vacuum crystallizer for A, B & C massecuites should be equal to the capacity of existing batch pans used for grain/footings of the massecuite. usually, one crystallizer per massecuite is considered.
Capacity of condenser Coefficients of Evaporation rate for batch pans depend on the purity of material and hydro-static head of the massecuite. Hence, if the massecuite level increases in pan then evaporation rate will be decreased. As per Mr. E.Hugot, the evaporation rates in kg/m² /hr are as follows
Initial Final
Footing Pan 85 17
A-Masseccutie 71 32
B-Masseccutie 46 11
C-Masseccuite 36 17
For the purpose of condenser capacity calculations, batch pan
evaporation rates are to be considered between 50 to 60 in kg/m² /hr and for continuous pans between 20 to 30 kg/m² /hr Average evaporation rate in Batch Pans A massecuite – 60 kg/m² /hr , B massecuite – 55 kg/m² /hr &
Cmassecuite – 50 kg/m² /hr
Average evaporation rate in Continuous pans
A massecuite – 30 kg/m² /hr , B massecuite – 25 kg/m² /hr & C massecuite – 20 kg/m² /hr Example: If the heating surfaces of a 60 MT batch pan is 282 m², then the condenser capacity required is 282 m² x 50 kg/m² /hr = 14100 kg/hr ≈ 14.1 T/hr If the heating surfaces of a 35 MT/hr continuous pan is 650 m² , then the condenser capacity required is 650 m 2 x 25 kg/m² /hr = 16200 kg/hr ≈ 16 T/hr
Injection water System and Condensers
The vapour condensation quantity is that of vapour from pan section and evaporator last effect. Vapour produced from pan section = 18 to 25% on cane ( For back- end refinery plants, it goes upto 28% on cane ) Vapour produced from last effect evaporator body = 5 to 8 % on cane Water required for condensing the vapour calculated on the basis of cooling water ratio.
= Total heat of the vapour = 621 Kcal/kg @ 55 0 C
Definitions in Steam Properties and Online Steam Table For Saturated steam To = Condenser outlet warm water temperature in 0 C Ti = Condenser inlet cold water temperature in 0 C Example: Crushing Capacity of the plant = 230 TCH To = Condenser outlet warm water temperature = 47 0 C Ti = Condenser inlet cold water temperature = 36 0 C So, Total vapour quantity for condensing = 230 x 33% = 80 T/hr Cooling water ratio = (621 – 47) / (47 – 36) = 52.2 T/hr i.e, 52.2 tons of water is required for One ton of vapour.
Total water required for condenser = 80 x 52.2 = 4176 T/hr
Condenser System for vacuum creation and their types with design criteria
Injection water pump capacity
Operating Injection water pump capacity = 4000 M 3 /hr Installed Injection water pump capacity = 50 % more than the requirement = 4000 x 150% = 6000 M 3 /hr ( Split the total capacity into 2 x 50% capacity of the pumps and 1 x 50% as a standby)
Spray pond capacity
Theoretically, 750 kg/hr of warm water requires 1 m² of area of spray pond. As per the latest trends of designs, 900 to 1000kg/hr of warm water requires 1 m 2 area of spray pond. Spray Pond area required = 4000M3/hr / 900 kg/hr = 4000 x 1000 / 900 = 4444 m 2 ≈ 4500 m 2
