CAPACITY (53> ice weighing equipment:- ; lo 025 ° aa eat give the true weighment with the accuracy 0.01 a %. «© Capacity of juice weighing scale:- The No. of tips should not exceed 25 tips/hrs. As there may be the possibility of error. Let, Crushing capacity = 2500 TCD MJc. % Cane Therefore, Cane crushed / Hrs. And [Link]. obtained /Hrs = 115 TCH Let us consider, 20 tips / Hrs. Each weighing required 115/20=5.75 =6.0 Ts/Tip ; [As per std. Specification the capacity of weighing tank for 2500 TCD plant is 6.5 TsTip. . of juice receiving tank should be such that it should contain two tips i. 65x 2 =13Ts.= 130 HL. Considering the froth, overflow & mud filtrate of about 50 % extra. Therefore capacity should be 130 + 65 = 195 HL. = 200 HL i.e. 20 Ts ¢ Raw juice pump capacity:- Let, Made. % Cane = 160 Vacuum filtrate 20 % = 20 Therefore total [Link]. =120% Capacity of factory 2500 TCD i.e. 115 TCH Therefore total [Link].= 115 x 1.20 = 138 Ts/Hrs. Let, juice density 1.06 Tim? Volume of juice = Weight / Density = 138/1.06 = 130m3/Hr. Considering 25 % more capacity of pump i.e. 130 + 32.5 = 162.5 m?/ Hr. As per Std. Specification pump capacity = 180 m’/ Hr. with 60 meter head. ¢ Imbibition water weighing scale Let, Capacity of plant =2500 TCD i erertahimbibiton Cane sm TCH lerefore quantity of water/Hr. = 115 = Letus consider 20 tips / Hrs. 2095 5 4025 8H Therefore capacity of water weighing tank . = 40.25/20 = 2.0TS/Hrs, 1|PageCAPACITY Imbibition water pump ca) pacity :- Note: The pump should be capable of handing water a Max. A.W. Cane = 35 And Crushing rate = 115 TCH Therefore, Total added water = 115x035 = 40.25 Ts /Hrs. Volume of water weight / density of water at 85°C 40.25/09 44.72 m'/ Hrs Considering 25% more capacity of pump i.e. 44.72+11,06 = 55.78 =60 m’/Hr. As per Std. Specification two water Pump of 60 m?/ Hrs. and 50 meter head, capable of handling up to 90° C temp. water. The imbibition water shall be apply before last mill through gun metal chockless type nozvles, Juice liming and sulphitation tank Reaction time in juice liming .and sulphitation tank Therefore total retention time in it should be 8 minutes, The working height of juice should not be less than 2 meter and not more than 2.9 Ln The working capacity should be 2/3 of total capacity of reaction tank, Let, Crushing rate = 2500 TCD i.e. 115 Ts/Hr. [Link]. % Cane = 100 ie. 115 Ts/Hr. ie. 115/1.06 = 108.5 m°/Hr. ive. 108.5/60 = 1.808 m*/min. Therefore volume of juice in 8 minutes = 1.808 x 8 = 14.46 me? = 14.5 HL. wa temp. 85-95°C should be 7 minutes. Let, Height of juice column = 2.9 and diameter = D wax D xh = 3.14/4 x D? x 29 4.46 x4 13.14 x 29 D = 2.52 meter Therefore — Volume 14.46 D 2.9 x 3/2 ‘And total height of the tank should be 2/3 of 2.9 = 4.35 meters, PageCAPACITY ¢ Calculation of reten! Total volume ( up Retention time Juice flow rate (1m Cylindrical volum Total volume = Cylindrical volume = 7/4 X Dxh Conocal volume = 1/3 (w4 x Dxh)h for SO: pip Calculation of No. of holes 200 mm diameter of pipe, ‘Suppose, Therefore, Area of pipe = w/4 x 0.785 x (200) = 31400 mm? 20% extra area = 31400 x 0.20 = 31400 + 6280 Therefore total area Now pipe hole diameter is 25 mm , therefore Area ofhole = 1/4 x D? = 0.785 x (25)° Total area Therefore [Link] holes required = Hole area Lime requirement & Equipmen! In sulphitation factory, the quick lime require: if'in terms of MOL is about 12-15 fits. ( having litrs. of [Link]. is required. Capacity of lime slaker:- Crushing capacity = 2500 TCD ic. 115 Consumption of lime = 0.17% Oncane = tion time in sulphitation tank:- to overflow height) minutes ) e + Conical volume (h= height of cylindrical portion) ht of vertical portion = heigl Iphitation tank:- e in sul 6280 37680 = 490.625 mm? 37680 = eee = 76.8 = 80 holes 490.625 . t= rent is about 0.17% on cane, and 8-9 Baume i.e. 15° Bx. ) for 1000 TCH ‘Therefore, requirement of lime/Hr. = (115 x 0.17)/ 100 195.5 = 200 0.1955 Ts/ Hr. Kgs/Hr. Kgs/Hr. Capacity of lime slacker should be 100 % extra i.e. 200 slacker .e. 200 x 2 = 400 Kgs / Hr. Therefore capacity of lime slaker should be 400 Kgs/Hr. % & speed of Sater should be 6-8 rpm. 3|PageCAPACITY Ady © Capacity of MOL storage tank; Storage tank capacity should be such that it should be storage at least 8 hrs. consumption Let, Crushing capacity = 2800 TCD ie. 115 TCH IfMJe. e cane = 100 then, = 115 Ts/ Hr, juice obtain = (11S x 1000 )/ 1.06 = 108490 lirts/Hr, Let, lime consumption ( MOL) =15 lits per 1000 litrs juice Then for 108490 lits =(15x 108490 )/ 1000 1627 litrs /Hr, = 1.627 m? /Hr. Therefore, MOL tank capacity for 8 Hrs. = 1.627 x 8 13.01 m° /8 hrs. = 130 HL. As per std. Specification two MOL tanks of 150 HL. Are required. (One is standby) Capacity of lime (MOL ) delivery pump.:- From the above MOL required /hrs = 1627 litrs/Hr. = 1.627 m? /Hr. Capacity of MOL pump should be 3 times of requirement. Therefore 1.627 x 3 = 4.88 m’/Hr. = 5 m/ir. As per Std. Specification capacity of MOL is 4.5 M? /Hr And 20 meter head ( One is standby ) Sulphur requirement & equipment Usually Sulphur consumption is in double sulphitation factory varies 0.05 to 0.07 cn cane, But for calculation purpose it generally taken 1.0% Practically 2/3 capacity of bumer i used for juice sulphitation & 1/3 capacity of bumer is used for syrup sulphitation, There are two types of Sulphur bumers 1) Batch type 2) continuous type. Capacity of batch type Sulphur bumer is to burn 20-35 kgs/m"/hr. ( Avg, 25 kgs/m*/hr.) & Continuous burner is 80 kgs/m?/hr. 4[PageCAPACITY LB Let, Crushing capacity = 2500 TCD ie. 11S TCH Sulphur consumption = 0.1 % Therefore Sulphur requirement = (2500 x 0,1)/100 = 25 Tvday = 2.5/2 x 1000 Kev/Hr. = 114 Kes/Hr. For batch type Sulphur burner:- = 114/25 m? = 456m? = Y3 of 456 = 3.0m, = V3 of 4.56 = 1.5m Burner area required From that for juice sulphitation And for syrup sulphitation For continuous type Sulphur-burer:- = 114/80 m? 425. m P of 1.425 = 0.95 m? = 1.0m" 13 of 1.425= 0..5m° Burner area required : From that for juice sulphitation ‘And for syrup sulphitation For safety one burner of the same capacity shquld be as standby. Sulphur burns with oxygen and give Sulphur di oxide ( Sz) ie. S$ +Oz = SO: + 2217 keal 32 +32 = 64 fe kg Sulphur required one kg oxygen & reaction release 2217 kcal heat Sulphur combustion take place at a temp. 363° C. Theoretically in air 23.15 % oxygen, & by volume 20.84 % oxygen Therefore air requirement = 100/23.15 = 4.3 times of Sulphur weight. ‘Ait density at Std. Condition ie. 0°C and one atmospheric pressure is 1.294294 kg/m? ‘Therefore theoretically, for one kg of Sulphur require 43 times at but however itis not possible to have complete combustion practically. Hence 100 % excess air required ie.43 x 2= 8.6 = 90 As per Std. Specification := Burner cap. 70 kg, Burner area 0.6 m? ----3 Nos. Burner cap. 70 kg, Burner area 0.6 m? ---4 Nos. urner cap. 140 kg, Burner area 0,6 m? ----2 Nos. For 2500 TCD plant----- 5|PageCAPACITY A> « Air compressors: Generally when compressed air is used, air required for one kg Sulphur is about 6m’. The quantity corresponding to produced @ gas ‘of about 12% SO2 = 2500 TCD ie. 115 TCH Let, Crushing capacity Sulphur consumption = 0.1% Therefore, Sulphur required / day = ( 2500 x 0.1) 100 = 2.5 Ts/day Sulphur required / Hr. = (2.5 x 1000 )/ 22 = 114 kgs/Hr. Therefore, Air quantity required /Hr. = 114 x 6 im /Hr. = 684 m’/Hr. /3 of 684 m° /Hr. 13 of 684 m*/Hr. For juice sulphitation For syrup sulphitation ~ As per Std. Specification:- For juice sulphitation For syrup sulphitation — Two air compressors ( One as standby ) each has cable of supply 600 m’ /Hr free air at | kg/cm? pressure. And two air compressors ( One as standby ) each has cable of supply 300 m? /Hr free air at 1 kg/cm? pressure. Juice Heater:-Material of construction:- Shell:- M.S. ( Low carbon steel) upto 20 mm thickness IS 226/22(1962)Grade Structural tensile strength 42.5 (Std) Above 20 mm Is 2026/62 S.T. 42 -w ( Weldability) Tube plate:- 25 mm thickness : Tube:- Brass 70:30 (Cu: Zn) IS 407-1966 General heating arrangement for juice heater:- Vapour line juice heater installed in vapour line of the last body [Link].H.-— going to condenser. ( Temp. from 27 to 40°C ) RJc.H.—-- Raw juice heater, heating from 2” /3™ body vapour (Temp. from 30 to 72°C) Sulphur juice heater, heating from 1* SJe ( Temp. from 70 to 103°C ) [Link].H.-- Clear juice heating by exhaust. ( Temp. from 95 to 105 ° c) body vapour / exhaust. [PageCAPACITY LB * Calculation for heating surface:- Heat received by one fluids Heat received by other fluids QxCxx AT=S.x Kx ATp S = Heating surface K = Heat transfer coefficient (keal./ kg /Hr./m? ) ATm = Mean temp. difference ( logarithmic mean temp.) Q = Quantity of juice flow i.e. in kgs/He C;_ = Specific heat of juice (i.e. 0.9 kcal.) AT = Temp. difference between inlet & outlet juice ATm = Mean temp. difference ( logarithmic mean temp.) ATinet = A Toute Le. ATn A Tins log. — A Toute QxG (TT S = m—- X 2.303 Logi ---nnnn———vnan= (T~Toutiet Where K = Heat transfer coefficient V = Juice velocity taken as 2 m/sec. (ie 2x 3.28 = 6.56 fY/sec.) = 0.035 (T-32) (16.4 + V) T= Temp. of heating media meter in OR-- PageCAPACITY Lm * Juice heater capacity calculation:- ( For 1250 to 2000 TCD Plant) Mie. % Cane = 110. (including Oliver filtrate) Le Working Hrvday = 22 ( For design purpose) Exhaust pressure = 0.49 kg/cm’? ie 7 psig. Y Vibe Ho 2000 x 1.10 x 10" Q@ = 100 x 10° kgs/ Hr. GQ =09 K = 0.035 ( T-32) (16.4+V) = 0.035 ( 133~32)( 16.446) 79.18 BTU /ft?/Hr. PC. 79.18 x 4.88843 Keal/ m?/Hr/°C = 387 Keal/ m7/ Hr./ °C C1 BTU AP /Hr. PC. = 4.88843 Keal/m/ Hr/°C ) OR:- v 2 K = 6xT(——)"* = 6 x 56(——-)* = 365.55 Keal,/ m2 Hr/°C 8 18 Tint = 27°C, Tour = 40°C Let, T = 56, Therefore, T-Tiwa = > 56 =-27 56 - 27 Log. = Loge -ma—=-=-- = 2.303 login - = 0.5947 a 56 -40 56 - 27 K (Toute) 100x 10° x 0.9 Heating surface (H.S. ) x 0.5947 = 138.30 m? = 140 m? 8|PageCAPACITY ABs 2) Sulfur juice heating 1" stage :- 2000 x 1.10 x 10° Q = = 100 x 10° kgs/Hr. GQ = 144.26 x 4.88843 Keal//m’/ He/°C. = 705 Keal./ m°/ Hr./ °C (1 BTU/fP/Hr. PC. = 4.88843 Keal/ m’/Hr/°C ) T = 102°C, Tine = 65°C, Tour = 87°C Let, Therefore, T- Tine 102 - 65 102 - 65 Log. ~ = Loge~ T Tous - (102 + 87 Therefore, xc (T= Tinted) S = meeeenene x Loge ~ —- K (T= Toutes) 100x 10° "x 0.9 Heating surface (H.S. ) 115.25 m? 120 m? [PageCAPACITY 42> a ooh: 3) Sulphure juice heating 2" stage :~ 2000 x 1.10 x 10° = 100 x 10° kgs/ Hr. Qs G =09 K = 0.035(T-32) (164+V) = 0.035 (232-32) ( 16.4+6) = 156.8 BTU /f?/Hr. /C. = 144.26 x 4.88843 Keal./ m’/Hr/°C. = 766.6 Keal/ m’/ Hr/°C (1 BTU/f?/Hr. PC. = — 4.88843 Keal/ m?/Hr./°C ) Let, T= 111°C, Tins = 87°C, Touts = 102° Therefore, T Toute M1- 102 11-10: Therefore, s 4 (T= Toutes) | 100x 10° x 0.9 Heating surface (H.S.) = aa X 0.9810 766.6 _ 15.17 m? 120m? 10|PageCAPACITY A> 4) Raw juice heating :- 2000 x 1.10 x 10° , —- = 100 x 10° kgs/ Hr. Qa = GQ = K 0.035 (T-32) (16.4+V) 0.035 (119.4—32) (16.4 +6) 131.24 BTU /f?/Hr. PC. 131.24 x 4.88843 Keal/m’/ Hr/°C. = 641.57 Keal/ m’/ Hr/ °C. 4.88843 Keal./ m*/ Hr/°C ) (1 BTU/fP/Hr. fC, = Tinta = 40°C, Toie = 70°C Let, T= 93°C, Therefore, fete 93 - 40 93-40 Loge Be = 2.303 logo -----=----- = 0.8349 T Toute 93 - 70 93 - 70 Therefore, s = Heating surface (H.S. ) x 0.8349 [PageCAPACITY AD 2000 x 1.10 x 10° seen = 10004 10" keel Hr. 5) Clear juice Heating Ons C = 09 K = 0.035( T-32) (1644+) = 0.035 (232~32)( 16.4 +6) = 156.3 BTU /f? Hr. AC = 186.3 x 4.88843 Keal/m’/Hr/"C. = 766.8 Keal/ m’/ Hr/ °C (1 BTU RP Hr AC. = 4.88843 Keal/m?/Hr/°C ) Le T= TIC, Tine = 95°C, Toes = 105°C Therefore, T -Tiniet Il - 95 111 - 95 = Loge = 2.303 logio ------— = 0.9810 T -Toustiet 111 - 105 111 - 105 Therefore, Qxc (T-Tintes) S = ae x Loge —— kK (T= Toute) 100x 10° x 0.9 Heating surface (HS.) = aeosecererneeee X 0.9810 166.5 115.19 m? 120 m? Note:- The value of ‘T’ in calculation of ‘kK is calculated as follow At T=III°C then, value of T in F? =(18 x C) + 32 =(18 x11) + 32 = 231.8 = 232°F 12|Page« Calculatio CAPACITY 42> n of juice velocity in juice heater:- t ie 1S TCH 15 Ts/Hr juice flow 08,5 m'/Hr 6.03 m’/sec. = 42mm 2500 TCD plant Suppose. f Tudo. % cane= 100 ie | Ce = 115/1,06- I = 108.5/3600= ‘Suppose in juice heater tube diameter ind No, of tube perpass. = 13 worone m = 4 x D’= 0.785 x (0.042) of one tub then, area of one tube So . = 0,00138474 x 13= 0.018 m’ Quantity of juice flow Therefore 13 tube area Quantity of juice( m*/Sec.) therefore velocity of juice -- : Total area of tube = 0.03 /0.018 m°/m? = 1.67 m/sec. Total No. of tube, No. of tubes per pass, and No. of passes:- Tube inside diameter = 42 mm Tube outside diameter = 45mm, Therefore mean diameter = (45 +.42)/2 -= 43.5mm Heating surface of tube can be calculated on mean diameter. And effective tube length. Therefore HS. 9 = %X dm X Len XM . n= 120/(3.14 x 0.043 x 4) 0435 mtrs = 220 No, of tube We know, Q = A x V,Q= Quantity of juice mi/sec.,A = Cross sectional area of tube through juice is flowing. culation it is taken 2 mtrs/sec. V= Velocity of juice in mtr/sec. (In cal Suppose, 2500 TCD plant ie 115 TCH and Mc. %Cane= 100 i.e 115 Ts/Hr juice flow= 115/1.06= 108.5 m/Ht. = 108.5/3600= 0.03 m’/sec. Quantity of juice flow A=Q/V_ = 0.03/2 = 0.015 m Weknow, A= area = w4 x Di'x N = Therefore 0.015 = m/4 x (0.042)" x N aan 0.015 = 0.785 x (0.042) x N N= 0.015 / 0.785 x (0.042)? = 10.83 = 11 Nos. of tubes per pass. ‘And No. of passes= Total tubes / No. of tube per pass= 220 / I= 20 passes. 13|PageCAPACITY A © Juice inlet pipe diameter:- Each compartment contain two passes except inlet and outlet. Therefore, [Link] compartment are even = 12 No. of passes are even =22 For Krrup designs, H.S. = 120 m?, No. of passes = 20, No. of tubes/pass =11 And total No. of tubes = 220 Weknow, Q= A XV — Where Q= Volumetric juice flow in m? / sec. A= Cross section Area of pipe in m? V = Velocity in m/sec. As recommended by Hugot, velocity of juice in inlet pipe = 1.22 m/sec. Therefore, A =Qwv wW4xD? = 0.03/1.22 0.785 x D°= 0.02459 D = 0.176 mtrs. = 176mm Therefore juice inlet pipe diameter may be 6” to 8” ¢ Steam or vapour pipe diameter:- 1) For Raw juice heater:- Juice heater for Raw juice and Sulphur juice are interchangeable , therefore we have to calculate to consider vapor bleeding from second body Let, Q= Volumetric vapour flow in m?/sec. A = Cross section area of inlet pipe in m? V = Velocity of vapour in m/sec. QxCyx AT i Wx HL Quantity of juice flow in kg/Hr. Q GQ Specific heat of juice AT Temp. different between inlet and outlet w Vapour consumption in kg/Hr. Hr Latent heat of vapour in Kcal/kgCAPACITY B® For raw juice AT = 30°C Ky = (17S x 10° 0.9.x 30)/ 543.14 = 8695.25 ke/Hr = 2415 kg’see ic Specific volume Vy = 2.128 m’/kg Therefore, Q = WXVy = 2415 x 2.128 = 5.139 msec V_ = Vapour velocity = ‘120 f/sec. Or 36.59 m/sec. Therefore, A =Qv = 5.139/36.59 = 0.1405 m? w4x DP =QVv 0.1405 D = 0.423 mtrs. = 423 mm = 16.6 inch. Therefore, Vapour inlet pipe diameter must be 16 to 18 inch. 2) Sulphur juice heater 1* stage:- AT = 8765 = = 22°C H. = 537.8 Keal /kg Therefore, QxGx aT Wo = For Sulphur juice AT = 22°C He = (175.x 10° x 0.9 x 22)/ 537.8 = 6442.915 kg/Hr ie. = 1.7897 kg/sec Specific volume Vy = 1.5915 m°/kg 15|PageCAPACITY LD Therefore Q = WAVY = 178075 18018 = 2.848 m/sec V = Vapour velocity = 111 fsec. Or 37.54 m/sec Therefore, A = QV = 2.848/37.54 = 0.0759 m? w4xD'= QV = 00759 D = 0.320 mtrs Therefore, Vapour inlet pipe diameter must be 14 inch. 3) Sulphur juice heater 2" stage:- 102 - 87 = 15°C aT = H, = 532: Keal/kg Qx Cx AT Vv =o - For Sulphur juice AT = 15°C HL = (175 x 10° x 0.9.x 15 )/532 = 4440.79 kg/Hr i.e. = 1.2335 kg/sec Specific volume Vs = 1.1855 m/kg Therefore, Wx Vp = 1.12335x 1.1855 = 1.4623 m/sec, v = Vapour velocity = 90 fU/sec. Or 27.44 misec. Therefore, A =Qv = 1.4623/27.44 = 0.05329 m? = 0.05329 = 260 mm = 10.25 inch, Vapour inlet pipe diameter must be 10 to 12 inch. Therefore, 16|PageCAPACITY AD ° Condensate outlet pipe diameter:- Lea Q-AxV Volumetric condensate flow in m'/sve o = A = Cross section area of the condensate pipe inm? WV = Velocity of condensate in m/sec. (ie. 0.6 to 0.75 m/sec) W = Weight of condensate i.e. 2.415 kp/sec Therefore, 1000 kg = Im’ volume. Q = GIS x 1)/ 10° = 0.002415 m/sec. Now let, condensate velocity = 0.6 m/sec. Therefore, A =74x DP = QV = 0,002415/06 D — = 0.0715 mtrs. = 71.5 mm = 2.81 inch Therefore, condensate out let pipe diameter must be 3 to 4 inch, All juice heaters are interchangeable therefore all Juice heater condensate pipe diameter must be 3 to 4 inch. Non- condensable gas outlet pipe diameter- Let, _H.S.=200 m? or Say 2140 [Link]. For 700 [Link]. H.S. hon-conderisable gas Pipe should have a cross section area at least 1 Sq. inch required, Therefore, For 2140 H.S, required 2140/700 = 3.057 [Link] Area = A = n/4 x D? = 3.057 D = 1.97 [Link] Therefore, non-condensable 8as pipe diameter must be 2 inch. 17|PageCAPACITY * Tube plate diameter:- ( Rhombus or Diameter ) Area of the Rhombus is equal to the area occupied by one tube A’=2 x% x base x height A = base x height xh But _h = psind = 0.866 p Therefore, A= Px 0866p = 0.866 p? If ‘a tubes then, An = 0.866? xn ut t0 Provide baffle plates for the juice Passes, actual area of the tube plate will: be greater. To compensate this, « Proportionality factor “B’ is to be taken in ) account. ( Value of B= 0.6 . Therefore area of plate = wW4 xD? = 0.866 p? x n)/B Dp (0.866 p? x nx 4) /a x06 . D The holes for the tubes are 0.8 mm larger than the tube diameter. is ie. = 10 mm as Per std. Specification for 45/42 Therefore, p= L + O.D. Of tube = 10 + 458 = 558 Therefore, Tube plate diameter — If No. of tubes 374, then D= 136 x 56x 374= 14728 = 18|PageCAPACITY A ¢ Details of juice heater for various TCD plant:- Tube dimensions are same for all juice heaters i.e O.D. 45 mm , 1.D. = 42 mm L = 4060, Ler = 4000 mm, ~ 11250-2000 | 2500-3000 | 4000-5000 TCD plant | TCI TCD plant 120 3 2 [Total [Link] tubes 220 3] No. of passes 20 4] No. of tubes/pass {oii ; $__ [Juice inlet pipe diameter 6-8inch | 8-10 inch | 10-12 inch 6 | Condensate pipe line diameter 3inch 3-4 inch 4 inch 7} Tube plate diameter_in mm 1130 mm_ [1500 mm | 1800 mm 8] Amonia pipe line diameter TSinch. | 2inch | 2.5-3 inch 97 Vapour line diameter for S.-H. 1" | 10 inch 14 inch 16 inch stage 10] Vapour line diameter for R.J.H, I4inch_| 16-18inch | 20 inch I | Exhaust line diameter for [Link],2™ | 8 inch | 10-I2inch | 12 inch stage & Cl. Jc. Heater 12_[uice flow in m’ /Hr. 94.32 165.24 235.80 For effective use of this equipment it is advisable that the juice velocity should not be less than 1.5 m/sec. Le. 5 fU/sec. The best velocity is in between 1.5 - 2.0 m/sec, ie. 5-65 flsec. . ¢ Continuous clarifier:- Juice retention time in different types of clarifier varies with the make of clarifier. 1 Multifeed———- 4 Hrs, : 2) Rappi-Dorr- 3 to 3.5 Hrs. 3) Graver- ——-- 3.0 Hrs, 4) fanenenencnn - 2.5 Hrs. Capacity of different dimensions of 444 clarifier are as follows, Height of clarifier -. ~ 6.097 mis. (20 fs. ) Tray area of clarifier 16 m/ TCH PageCAPACITY ABN * Clear juice pump capacity:- Let, Quantity of clear juice = 100 % [Link]: + 20% filtrate = 120% therefore, ClJe. quantity at 115 TCH Volume of clear juice 1S x 1.20 = 138 Ts/Hr, weight / de = 138 /1.06 = 130 m/Hr, Consider 25 % excess capacity of pump i.e 130 x 0.25 = 32.5 = 130 + 32.5 = 62.5 m/Hr. = 160 m/Hr. Therefore, AS per Std. Specification gives jumps of 150 m?/Hr, * two clear juice centrifugal p With not less than 30 mtrs. Head, : * Mud withdrawal quantity & Pump capaci Generally the mud in the subsider is considered to be about 25 % of the total ing 3 Hrs. residence time in clarifier. . Juice handled, consideri = 2500 TCD ice, 115 TCH Let, Crushing capacity [Link], %Cane= 100 ie. 115 Ts/Hr, Oliver filtrate 20% = 115 x09 — 23 Ts/Hr. Therefore, Total juice to be handle = 115 + 23 = 138 Ter, Volume of juice = weight/density : = 138/1.06 = 130 m/Hr, 25% mud quantity = 130 x 0.25 = 32.5 m°/Hr. mud quantity P ie. 32.5 x 0.20= 6.5 mtr Considered 20 % excess capacity of pum Therefore, Pump capacity should be 3 2.5 +6.5 = 39 ¢ Rotary vacuum filter:- The capacity of rotary vacuum filter is expressed in terms of length and diameter, The normal size and fil tering area are as follows. From the practical experience, the requirement of filtering area is taken as 0:6 to 0.7 m/TCH &.g. for 2500 TCD plant i.e. 115 TCH, Filtering area requirement 0.65 x 115 =74 m2 As per Std. Specification two 8° x 16° size vacuum filter are given. O|PagePF * Syrup sulphitation tank:- CAPACITY Reaction time in syrup sulphitor should be 10 minutes S Id be minimum 1.5 meters. 2 Syrup column above gas coil shoul 1, Height of tower above syrup column eheni be 2.5 times of syrup column. 68 Het plant capacity =2500 TCD ie. 118 TCH MJe. = Cl. Je = 100 % on cane Ne Quantity of Cle. = 115 TwHr Quantity of syrup 18/4 = 28.75 Tse. Density of syrup 2 Tsim? = 28.75/1.2 = 23.958 m/Hr, Therefore, Volume of syrup Volume of syrup/min 28.958/60 = 0.399 m/min 0.4 m/min Volume of syrup/10 min = 0.4 x 10-4407 10 minutes = 40 HL Syrup column is 2 meter Therefore, Cross section area of tank =4m'72m =2m Therefore. Diameter of tank =---n/4 xD =2 rs, D = 1.6 meter Picight of above syrup column = 2.5 x9 = Smtrs. Total height of tank 5+2 =7 mers, fore, for 2500 TCD plant, Syrup sulphitation tank having diameter 1.6 meter meter required. working height 2 meter and total height 7 Evaporator:- is ia serving as a heat exchanger . When two fluids = K.x S.x(T,- Q Quantity of heat transmitted K = Co-efficient of heat transmitted s Heat exchange surface area Ti = Temp. of hot fluid 2 = Temp. of cold fluid Coefficient of heat transmitted *K* ig given by, 1 | = Va + eh + Ie = Co-efficient of heat transfer from hot fluid to solid surface a b = Co-efficientof heat transfer across solid surface c = Co-efficient of heat transfer from Solid surface to cold fluid = Thickness of metal wall ( Tube ) e The height of | cylindrical Portion of vesse| above height of the tube & diameter of central well should be % to 1/8 of LD. of vessel, According to Tromp, the height of | cylindrical ortion of vesse| be 2.5 times of the height of tube, : ani should 21|Page7 y STEAM CAPACITY ABN Saturated Steam :- Steam is said to be saturated on being brought in contact with water of same temp.” as the steam. There is no evaporation of this water. Super Heated Steam :- Super heated steam is Steam at higher temp. than saturated steam at same Pressure. Thus when brought in contact with water of saturation temp. evaporation will continue until the steam becomes saturated again, Latent Heat :- (1) The quantity of heat required to change unit weight of water into steam at the ‘same temp. in Kcal /kg. Sensible Heat :- (9) The quantity of heat Supplied to unit weight of water ti raise it from freezing point. to T°C,, in Keal /kg : Total Heat :- (A) The quantity of heat supplied to unit weight of water staring at O°C to change it tosteam at T°C in Kcal. /kg. ie. 4= ory = Super Heated Steam :- If heat transmission from saturated steam to metal is excellent super heated steam gives on the contrary a poor heat transfer coefficient. Jero Sehek states super heat is permissible up to temp. of 160°C . Webre indicates that the degree of super heat not exceeding 155 °C would’not have any effect on heat transmission in multiple effect. Boiling Point :- a) Boiling point depends on the pressure. 6) Boiling point of sugar solution ie juice under a given pressure increases with, the concentration of solution i.e Brix of solution, ©-g. Under atmp. Pressure M. Jc. Boil at 100.35°C instead of 100°C ie. 0.25°C is boiling point elevation due to brix of MJc. From the table 32.2 in Hugot, for high purities the boiling point elevation is of order of magnitude of, e = 2B/(100-B) = B.P. elevation in °C B= Brix of solution.y yy a CAPACITY Hydrostatic Pressure :- manen @ Pressure “P* is exerted on ihe surface of liquid, the pressure to which a ees shld ‘nereased by pressure of liquid corresponding to the depth. Heating Surface of Evaporator Station:- HS = wie W = Quantity of water to be evaporated ( kg/hr.) ) E = Evaporation rate ( kg/m? / hr, n quadruple are as follows, 2 3 Theoretically evaporation rat Quadruple body No." 4 300-2520 29 kg/m? /hr Calculate H.S, of individual body of quadruple with following dada and eg. arrangement. Crushing rate = 2500 TcD ie 115 TCH MiJc = ClJc. % cane = 100 ie. 115 Ts/hr. = 115000 kg/hr. Clear juice Brix = 15.00 Syrup Brix = 60.00 Vapour bleeding:~ J) Raw juice ( From 20 to 70°C ) From 2° body vapour ( Vacuum 200 mm ) 2) S.J. I" heating (65 to 90°C ) From 1" body vapour ( Vacuum Zero) Sol" — Heat required for Rte, heating from 20 to 70°C ~“Q@ x Gx aT = 115000 x 0.9 x (70-20 y = 5175000 Keal. Vacuum in second body = 200 mm, Therefore, latent heat in second vapour vapour = 543 Kcal. re required = 5175000/543 = 9530 kgs. Therefore, — Amount of heat Heat required for Sul. Jc. heating from 65 to 90°C =Q x Gx aT = 115000 x 0.9 x (90-65 ) = 2587500 Keal. Vacuum in first body = Zero mm, Therefore, latent heat in frist Vapour vapour = 538.9 Keal, Therefore, Amount of heat Fequired = 2587500/538.9 — 4801.44 kgs, 23|PageSuppose. : “X" quantity of vapour goes from last body of quadruple to condenser Therefore, Evaporation in 4 body = X 3% body = X 2” body = X + 9530 1 body = X + 9530 + 4801 Total evaporation = 4 X + 23861 We know Total evaporation = 115000 [( 60 - 15/60 ] = 86250 kgs Therefore, 4X+23861 = 86250 kgs X = 15597 kgs Let, Evaporation rate in quadruple, I Quadruple body No. 2 3 4 30-2520 20. kg/m?/ he Then, We have, Body No. | Total Evaporation ER. Heating Surface in | inkg in kgs/m? /hr. m eT 15597 20 15597/20 = 780 m’ 15597 20 "115597720 = 780 me 25127/20 = 29928730 = 1000 m™ [PageCAPACITY * Calculation of vapour pipe size:- Vapour veloc Effect in meter / sec_as follows, ] Triple | Exhaust steam to P38 30 Meter/see | ] 30-35 Meter/see. | “4 ] | first effect Vapour from | First effect [Vapour from 40-45 Meter/sec | Quad 25-30 Meter/sec 30-35 Meter/sec. 35-40 Meter/sec. LB Quintuple 25-30 Meter/sec. 30-35 Meter/sec. 30-35 Meter/sec. 0-60 Meter/sec. | 40-45 Meter/sec. 35-40 Meter/sec. third effect | Le a et | Vapour from = 50-60 Meter/sec. | 40-45 Meter/sec. forth effect | Vapour from 50-60 Meter/sec. fifth effect L Vapour velocity from the last effect going to condenser may be higher than 60 msec. But not exceed 75 m/sec. 8) Vapour going out by Weight/sec. say ‘P° for possible variation, Therefore, P; = 1.1 x P 6) Then from steam table of saturated steam the specific volu corresponding to vapour temp. from this we can calculate Pass per second. Pi x sp. Vol. of vapour at TC Therefore, This increase by 10 % SO as to allow fixed so that Cross section area of Pipe ‘S’ 25|PageCAPACITY iar ¢ Steam required for process:- Let, Crushing rate 100 TCH; Latent heat of Exhaust = 535 Keal/kg [Link]. = Clic. % cane. = 100 ; vapour 1" body = 538.9 [Link]. Heating 30 to 70°C ; am "= 543 SJ, Heating = 65 to 90°C ; 34 = 550 SJ; Heating = 90 to 103°C; a" = 566 CliJc. Heating = 95 to 105°C; Clic. Brix % =15° ; Syrup Brix % = 60° 4 © Case) Steam required without vapour bleeding:- 1) Steam requirement for Raw juice heating from 30 to 70°C. Q@ x Gx AT — 100x 09 x (70- 30) 6.728 Ts/hr. Latent heat 535 2) Steam requirement for Sulphur juice heating from 65 to 103°C. _ XG x AT 100 x 09x (103 - 65) wee eeeeneeeeceeecccccncenenee = 6.393 Ts/hr. Latent heat 535 3) Steam requirement for clear juice heating from 95 to 103°C. Qx Gx AT 100 x 0.9 x (108 - 95) Saran ancnncnrcernne SE eenecnneneennenennnnnnnnnnnnnne = 1.682 Ts/hr. Latent heat 535 4) Evaporation in evaporator 60 - 15 : = see X 100 = 75.00 % 75 Therefore steam required for each body = ----- = 18.75 4 Steam requirement for pan varies from 20 to 30 % on cane. Let us assume 25 % on cane. Thus, total steam requirement-- For Raw juice = 6,723 Sul,juice = 6.393 ,Cl. juice = 1,682 Evaporator 8.750 ,Pan = 25.000 Miscellaneous 5.000 Total 3.55 Ts/hr = 64 Ts/hr. 26|PageCAPACITY LB * Case IT) Steam required with vapour bleeding from 1" body of quad to [Link]. & S.J, heater:- 1) Steam requirement for Raw juice heating from 30 to 70°C. Qx Gx ar 100% 09x (70 - 30) = 6.68 Ts/hr. Latent heat 538.9 : 2) Steam requirement for Sul. Je. I" heating from 65 to 90°C. QxaQx aT 100 x 0.9 x (90 - 65) = = = 4.175 Ts/hr. Latent heat 538.9 Total vapour from 1* of quad for Rc. & [Link] first heating is 6.68 + 4.175 = 10.855 Ts/Hr. 3) Steam requirement for Sul. Jc. 2™ heating from 90 to 103°C. Q@xGx AT — 100x 09 x (103 - 90) = 2.187Ts/hr. Latent heat “935 4) Steam requirement for clear juice heating from 95 to 103°C. Q@x Gx AT — 100 x 0.9 x (105 - 95) Fee = = 1.682 Ts/hr. Latent heat 535 5) Evaporation in evaporator 60 - 15 in4" body 3 body 2” body 1" body Total evaporation 4X + 10.855 = 75,X = 16.036 Therefore, Exhaust required for quad =16.036 + 10.855 =26.891 Ts/hr, Steam requirement for Pan varies from 20 to 30 % eee © on cane. Let us assume Thus, total steam requirement--- For Sul,juice 2 heating 2.187,Cl. Juice 1,682 Evaporator =26,89] Pan 25.000 Miscellaneous 5.000 Total 0.76 % on cane 27/PageCAPACITY ae * Case III) Steam required with vapour bleeding from 1" body of quad to Pans. ( two pans ie 12.5 % steam on pan flower ) and S,Ji heater, & 2" body of quad to [Link]. Heater :- : 1) Steam / vapour requirement for V.L.J.H. From 30 to 40°C QxGQx aT 100 x 0.9 x (40 - 30) 1.590 Ts/hr. Latent heat 566 2) Steam requirement for Raw juice heating from 40 to 70°C. QxQx aT 100 x 0.9 x (70 - 40) oo noooee = 4,972 Ts/hr. Latent heat 543 3) Steam requirement for Sul. Jc. 1“ heating from 65 to 90°C. Qx Gx aT 100 x 0.9 x (90 - 65). oy = 4.175 Ts/hr. Latent heat 538.9 4) Steam requirement for Sul. Jc. 2" heating from 90 to 103°C. QxGx AT 100 x 0.9 x (103 - 90) _— ™ —- 2.187Ts/hr. Latent heat 535 5) Steam requirement for clear juice heating from 95 to 103°C. Qx Cx AT 100 x 0.9 x (105 - 95) = 1,682 Ts/hr. Latent heat 6) Evaporation in evaporator 60 - 15 FF seeeeneeeennnnnn x 100 = 75.00 % 60 in4" body = X +1.590 3" body =X +1.590 2" body = X +1.590 +4972 I* body = X +1.590 +4.972 + 4.175 + 12.500 Total evaporation 4X + 32.97,4X +32.979 = 75 X = 10.505 28|PageCAPACITY ZEN Therefore, Exhaust required for quad = = 10.505 + 1.590 + 4.972 + 4.175 + 12.500 = 33.742 Ts/hr. Steam requirement for pan varies from 20 to 30 % on cane. Let us assume 25 % on cane Thus, total steam requirement--- For Sul juice 2 heating = 2.187,CI. Juice=1.682,Evaporator=33.742 Pan = 12.500 ( Two pans) Miscellaneous 5.000 = 55.111 % on cane * Case IV) Steam required with vapour bleeding from V.C. to all Pans. ;1" body of quintuple to S.J, heater, & 2™ body of quintuple to [Link]. Heater :- 1), Steam requirement for Raw juice heating from 30 to 70°C. " Q@xG x aT 100x 09x (70-30) 6.630 Ts/hr. Latent heat 543 2) Steam requirement for Sul. Jc. I" heating from 65 to 90°C. QxGx AT 100 x 0.9 x (90 - 65) = = 4.175 Ts/hr. Latent heat 538.9 7 3) Steam requirement for Sul. Jc. 2° heating from 90 to 103°C. QxC x AT 100 x 0.9 x (103 - 90) 2.187 Ts/hr. Latent heat 535 4) Steam requirement for clear juice heating-from 95 to 103°C. Q@x Cx AT — 100x 09x (105 - 95) = = = 1.682 Ts/hr. Latent heat 535 1) Evaporation in evaporator:- The all vapors of V.C. are given to all pans + therefore evaporation in quintuple 75-25 = 50% on cane : = 75.00 % On in 5" body = X,in4™ body = x, 3" body =X 2” body = X +6.632, 1% body = = X +6.632+4.175 SX + 17.439,5X +17.439 =50 X = 6512 Therefore, Exhaust required for quintuple = = 6511 + 6.632+ 4.175 = 17321 Tyhr, Steam requirement for pan varies from 20 to 30 % on cane, Let us assume 25 % on cane. Total evaporation 29|PageCAPACITY AD Thus, total steam requirement--- For Suljuice 2™ heating = 2,187 Cl. juice = 1.682 Evaporator 17321 Pan nil Miscellaneous = 5.000 on cane Total ¢ Vacuum Pans.:- Designing and performance of vacuum pan depends on ratio of their heating surface to working capacity. : HS. of pan in m? v Working capacity in m This S’V ratio is depends upon, (a) Type of Steam used for heating. (b) Type of massecuite to be handle. Type of pan | Type of ] Steam pressure [Optimum S/V | Steam used (kg/cm?) Ratio (_m?/m’ ) 1) Coil pan [Live steam 05104.0 3.91046 2) Calendria pan. | Exhaust T0310 491066 | 3) Calendria pan ] Vapour 0.0 1004 66 t07.2 4) Continuous Vapour 0.0004 10.0 to 10.5 Pan, | S/V Ratio of 1) Coil pan = 4.65 m/m? 2)Calendria pan = = 6.60 m2/m? 3) Continuous pan 10.5 m/m? (a) Massecuite % Cane Method Pan Capacity can be calculated by (b)- Solid balance Method 30/PageCAPACITY A> ¢ Pan Capacity By Massecuite % Cane Method:- Let, Capacity of plant = 2500 TCD A= massecuite % cane = 25 B- massecuite % cane = 12 C- massecuite % cane = 10 Boiling time for, A-massecuite «= 4 Hr. B- massecuite =6Hr. C- massecuite =8Hrs. Quantity of massecuite Produced per day:~ A- massecuite = 2500 x 0.25 = 625 Ts/day B- massecuite = 2500 x 0.12 = 300 Ts/day C-massecuite = 2500 x 0.10 = 250 Ts/day No. of strikes per day: ‘A- massecuite = 6 strikes B- massecuite strikes C- massecuite =3 strikes Quantity of massecuite per stike:- ‘A- massecuite =625/6 = 104.166 Ts / strike B- massecuite =300/4 = 75,000 Ts / strike C- massecuite =250/3 = 83,330 Ts/ strike Let, Each pan of 40 Ts Capacity. The No. of pan required for: A- Boiling = 104.166/40 = 2.60 B- Boiling = 75.000/40 = 1.88 C- Boiling = 83.330/40 =2.08 Therefore, Total pans required for 2500 TCD plant are 7 Nos. of capacity 40 Ts. Each * Calculation for H.S. required for calendria pan:- One a = 0.7 m? volume of massecuite (Density = 1.428) For40 Ts. Pan = 40 x 0.7 = 28m? volume Therefore, SIV =66 S/28 =66 S 66 x 28 = 184.80m? = = 185 m? HS, For 50 Ts. Pan = 59 Therefore x 0.7 = 35m) Siv $/35 185 m? Hs, 31[PageCAPACITY No. of tubes for pan :- Weknow HS =ay Dab an @ For 188 m° H.S., Diameter of tube = 100 mm , Length of tube = 800 mm Therefore N = No. of tube can be calculated as, IRS = 3.14 x 0.100 x 0800 x N N = 736.46 = 736 No. of tubes * Pan Capacity By Solid Balance Method:- Let 1) Crushing capacity = 2500 TCD Plant 1). Three massecuite boiling system 2) B+ Massecuite single cured. Half used for A- footing, & remaining melt. 3) A+ Massecuite single cured 4) A+ Massecuite boiling on syrup + melt + A-light + B-seed + dry seed. S) B- massecuite boiling on A-heavy molasses. 6) C-Massecuite boiling on A-heavy + B-heavy + C-light molasses. [Particular [Brix % [Pol % Purity % cane Mic 117.06 14.28 84.00 100 Cide — T= 84.50 100 Fiher cake | — 20 = 3.00 Final molasses "90.00 128.80 32.00 Syrup 60.00 [—— = TAMe 92.00 82.80 90.00 "BMe 95.00 7125 75.00 CMe 100.00 58.00 58.00 Atheavy $5.00 163.75 75.00 70.00 163.00 Beheavy 85.00 46.75 Clighat — = 60.00 ‘Ac sugar (washed) purty = 100 & Unwashed sugar purity = 98 B- sugar (washed) purity = 97.0 CFW sugar purity = $2.00 & CAW sugar purity = 94 La, Mic. % cane = 100, Therefore MiJc. quanti fom polin Me. = (2500 x 14.28) /100 = 357 Tsiday, ‘Quantity of F.C day =( x 2500) /100. 'y per day = 2500 Ts,/day. = 15 Tsiday Tons pln Fc = (2500 x 20)/100 = 15 Twday. pol in Cl. Je = (387-15) = s Total brix in CI Je og a = (355.5 /84.50) x 100. = 420.71 Tsiday i.e Solids ii Total Non-Sugar in CLJe. = (420.7) - 355.5) = 65. 21 Teiday 32) PageCAPACITY Lay sy Non-Sugar in F.M, = (90,00 - 28.80 )= 61.20 Therefore, Total N.S. in ClJc. Theoretical production of FM, = x 100 . NSS. in FM 65.21 x100 = 106.55 Ts./day. 61.20 Total brix (solids) in F.M.= (106.55 x 90)/ 100 = 96 Ts/day Solids A) Production of C-M/c. 24 solids in F.M. = 50 Solids in C-M/c. CFW 26 ga \ 7 CMe 96 solids in F.M. =(96 x 50)/24 58 = 200 solids in C-M/c. / \ FM 24 32 Solids in CFW = Solids in C-M/c. - Solids in F.M. = 200 - 96 = 104 Now solids in CAW ="? cAW 2 " 34 solids in CFW. = 12 Solids in CLL, 94 \ / cFW 104 solids in CFW. =( 104 x 12)/34 82 = 36.7 solids in C.L. ¢ \ CL. 2 60 34 Solids in CAW = Solids in CFW. - Solids in C.L = 104 - 36.7 = 673 ~~~ This will goes in to melt, * According to process adopted 67.3 solids in CAW goes to Haul i therefore ,Total pol in in CAW = (67.3 x 94) 100 = 63: 262 Ts 6 vemelt. Composition of C-M/e = AH, + Cl. + BH. Therefore, 33|PageCAPACITY : ak Solids in C-M/e. = Solids in AH + Solids in Cl. + Solids in BH. 200 = Solids in AH + 36.7 + Solids in BH. 163.3 = Sblids in( AH + BH) Total pol inC-M/c, = (58 x 200)/100 = oe Total pol in CL = (36.7 x 60)/100= 22. Therefore, Total pol in( AH + BH.) 116 - 22.02 ) = 93.98 ue Therefore, Purity of( AH + BH) mix. = (93,98/ 163.3 )x 100 = 57. AH 2.55 20solids in(AH+BH) = 17.45 Solids in BH. sy / 163.3 solids in (AH + BH) = ( 163.3 x 17.45 )/20 os. ° = 142.48 solids in BH. di \ BH. = Therefore, Solids in AH = Solids in (AH + BH ) - Solids in BH. = 163.3 - 142.48 = 20.82 Solids in AH. C-Mic is made by AH +BH +CL Therefore , Solids in C-M/c = Solids in AH + Solids in BH. + Solids in CL. 200 = 2.82 + 142.48 + 36.7 B) Production of B-M/c.:- Solids in B-M/c Which wii give 142.48 solids in BH. B-sugar 20 22 solids inBH = 42 Solids in B- M/c, / 97.00 \ (_B- M/ec) 142.48 solids in BH = (142.48 x 42 )/22 75 = 272 solids in B-M/c / \ BH, (55) 22( 42) Therefore, Solids in B-sugar = Solids in B-M/e — =272 - 142.48 = 129.52 Solids in B-sugar, Solids in BH. } 80 10 A-boiling as [Link] & melt ie 12932/2 = 6476 Solids in B-seed & 64.76 sol; nn Te will go to ids in melt, MPageCc) CAPACITY A> Composition of B-M/c. = AH Solids in B-M/c 7 272 ‘lids in AH. Used in B-M/c “lids in AH. Used in B-M/c. But,Total solids in AH = Solids in AH used in (B-M/c + C-M/c ) = 272 + 20.82 = 292.82. i.e total solids in AH. Production of A-M/c.:- Total solids in [Link]. = Total solids in ‘Syrup. From A-Mic Production , Ah & Unwashed sugar obtain. ‘Unwashed sugar 15 8 Solids in AH = 23 Solids in A- M/c. 98.00 / ( A- Mic) 292.82 solids in AH = (292.82 x 23) /8 90 = 841.86 solids in A-M/c AH. 8 75.00 Solids in unwashed sugar = Total solids in A-M/c - Total solids in AH 841.86 - 292.82 49.04 ie solids in unwashed sugar. Now solids in A-Sugar ( washed ) & A-light, washed sugar 8 100 4. (Unwashed) 10 Solids in unwashed sugar Solids in AL Sugar $49 solidsin unwashed sugar = ( $49 ¢ 2)/10 /% \ 109.8 Solids in AL AL 2 90.00 10 Now, Solids in washed sugar = Solids in unwashed sugar - Solids i = 54904.- oats \gar - Solids in AL = 439.24 ie solids in Washed sugar, 35|Pagevy CAPACITY A> © Composition of A-M/c.:- Solids in dry seed = Solids in A-M/c - Solids in (Syrup + B-seed + AL + Melt) = 841.86 - [420.71 + 64.73 + 109.8 +( 64.73 + 67.3)] = 114.59 Therefore, . Solids in syrup ie ClJc. 420.71 Solids in A-M/c, 841.86 Solids in B-M/c. 272.00 Solids in C-M/c. 200.00 Therefore, 200 solids in A-M/c. solids in B-M/c. 47.53 solids in C-M/c. 100 solids in Syrup gives-—— Example: Crushing rate = 4000 TCD Cle. % Cane =100 ie 4000 Ts/day Brix % [Link]. = 16.00 Calculate pan capacity separately for A-M/c, B-M/c, & C-M/c. Solutio Clear juice/day — - + = 4000 Ts. Total brix ( Solids) . = (4000 x 16)/ 100 = 640 Ts /day We know that, 100 solids in syrup gives— 200 solids in A-M/c. 65 solids in B-M/c 50 solids in C-M/c. Therefore, A 640 Ts solids in in Syrup = 640 x 200/100 = 1280 Ts solids in A-Mic = 640 x 65/100 416 Ts solids in B-M/c 640 x 50/100 = 320 Ts solids in C-M/c Let, A-Méc Brix = 94.00 B-Mc Brix = 96.00 C-M/e Brix =100.00 AMe Produced / day= (1280 x 100)/94 = 1362 Ts /da B-Mlc produced /day*(416 x 100)/96 = 433 Tsiday C-Mle produced / day =(320 x 100)/100 = 320 Ts /day 36|PageCAPACITY AS Tan ing ti of MIC per a -of MIC] Boiling time | [Link] Qty. oF pid |e strikes/day ay 244 =6 136. AMe | 1362 Ts His. oes 24/6 =4 433/4 BMc 433 Ts His. a 1 =3 320/3 CMe 3207s 8 His. 248 = If capacity of pan 50 Ts. Then, . = 227/50 = 5Nos. pans No. of pans for A-M/c. ee No. of pans for B-M/c. = 108/50 No. of pans for C-M/c, = 109/50 Nos. pans Total pans requirement = 5 +2+2 = 9 Nos. of capacity 50 M.T. each * Vapour pipe Size of the calendria pan :- Rate of evaporation in vacuum pan depends on following factor, 1) Type of pan 2) Heating medium 3) Type of massecuite 1) Stage of massecuite boiling 2) Pressure of steam / vapour The rate of evaporation varies from 25 to 75 kg/om?/ Hr. For calculation purpose it is considered as 65 kg/em?/ Hr. Let, a)HS, =I. b) Temp. of vapour out =5 ©) Velocity of vapour out = $5 meter / sec. HD) Vapour produced / hr, = H.S, x Evaporation rate 185 x 65 = 12025 kg/hr, 12025 + 1202.50 2) Specific volume of S60 S84 m? ic volume of vapour at 55°C is 9.584 3) Therefore, Volume of vapour = ( 13227.5 Rinse 3600 = 35.215 m/sec, 85 m? (40 M.T. pan capacity) °C 10 % more Now vapour velocity is $5 m/see, 4) Therefore Volume of vapour = Cross section area x velocity Q = wMxDyxy : 35.215 .785 x D? x 55 D =0.9031 Meter = 900 mm 37|PageVv . CAPACITY a eork: © Steam consumption at Pan station :- i ic it la, ‘Steam consumption at pan station is calculated by following formula, oes i. Bx% Mic - Bx% Molasses Stgam consumption = K x Q x [ -~ ] Bx% Mic Where, K = constant = 1.5 for batch type pan. = 1.2 for continuous pan Q = Quantity of massecuite. Le, = Brix % M/c = 96.00 ; Brix % molasses = 70 & Qty. of Mic = 400 MT Calculate steam consumption for batch pan to pe 400 M.T. Mic ? 96 - 70 Steam consumption = 1,5 x 400 x [ n--sm=noeeese] 96 162.5 Ts steam for 400 M.T. M/c. . 162.5 /400 = 0.40 Ts /ton of massecuite IfQ= Mic % Cane , then steam consumption is steam % cane * Condensate pipe size of pan:- Let, 1) H-S of pan = 185 m? ( for 40 M.T. Cap. pan) 2) Temp. of condensate = 90° C 3) Velocity of condensate out = 1.0 m/sec, & 4) Average evaporation rate 65 kg/em?/Hr. Now, 1) Vapour produced / Hr. 1.25 ms after pump delivery HS. x Evaporation rate 185 x 65 2025 kg/Hr. = 12025 + 1202.5 = 13227.5 kg/Hr, 10 % Extra 2) Condensate produced Vapour Produced Therefore, Condensate = 13937 5! kg/Hr. 3) Specific volume of condensate at 90° as C = 0.96534 (by steam stable) ‘Volume of condensate = wines : (azs X 0.9653 ) 3600 = 0.003549 m°/see, 4) Volume of condensate = Cross secti * Cross secti it nie ae a ve X Velocity of, Condensate D = 0.0672385 meter” 7.2385 mm = 2.647 inch = 3.0 inch 38/PageVv CAPACITY A> Vacuum & Condensing Equipment :- vacuum The multiple effect evaporator and Pans in a sugar factory operate under as such suitable equi ae He pment is required to produced vacuum, Which is Beaded in losed vessel called as condenser . Cold water is pumpe Coase of vapour coming from pans or evaporator. oe The is placed at such a height that water after serving dense the fe ce flow out by gravity together with the condensed vapour. Te calc a oa barometric chamber extended at bottom by a barometric, I di Pin into well open to atmosphere since vacuum na aie ore 10-20 % of pereet vaccum and since the liquid in the barometer is w: 4 feet) Free eine height of column should be of the order of 10 meter ( 34 feet) : 0.76 : "ie as 10. 3 mirs. ( where 13.6 is density of mercury relative to water) * Sizing of condenser:- In case of baffles th Y Necessity of allowing An adequate area forthe passage of vapour, Hence for a given method of breaking crane ater the weight of body of condenser cust exceed a certain minimum, ‘Te obtain an adequate efficiency of heat exchange, \¢ interval between baffles is limited by 1) For condenser without bafifl 2) es; the height of body should be 4.50 mtrs, For condenser with baffle, height of body should be 2.4 to 3.9 mtrs Area of cross section of condenser is Proportional to uantity of atk quantity of vapour to be * General practice is to allow 0.16 m/tonne of vapour condensed/hr, 1 Heating surface of pan is 195 ™? & rate of evaporation ; Tot aprsh obecondensed Sperone 5.0 hah = 185%50 "Mh, ther aa 9250 ker = 9.95 Thr. 8. Cross sectional arca of cond = 9.25% 0.16 a = 1.48 m?CAPACITY AB a oe: D = 137m. And height should be 4.5 mt for condenser without baffles. Condenser for 2500 TCD plant:~ . 1) One No. Multi jet condenser for Evaporator suitable for 750 mm diameter vapour pipe. . ; " 2) Five Nos. multi jet condenser suitable for 60 tonnes pans i.e vapour pipe diameter 1100 mm 60 Tons pans -—- Vapour condensation 2000.00 Kgs/Hr. 80 Tons pans-—--- Vapour condensation 27000.00 Kes/Hr. © Injection Water:- Requirement of injection water depends upon, 1) Temp. of injection water 2). Vapour produced. ‘The quantity of injection water( Cooling water) necessary for condensation of the vapour is found by equating the heat given up by vapour in condensing to the heat absorbed by the cold water. Let, W. = Weight of cooling water in kg/kg of vapour to be condensed. 1° =Total heat of vapour in Keal/kg T, = Temp. of outlet water( Hot water) in °C Tz _ =Temp. of injection water ( Cold water) in °C Therefore, Cooling water ratio = W Normally temp. of injection water in the range of 32 to 35°C. With i te | .. With the good d condenser it should be normally possible to get difference 10°C betwees inlet a ana water temp. eg. Let, Crushed re 00 TCH ix of ClJuice = 15 & Clear juice % cane = ees 5 & Clear juice % cane =100 Temp. of inlet water = 36°C & Temy in 1p. of out let water = Total heat in vapour at 660 mm Vacuum = 619 Keal, hkg ane 40 PageCAPACITY Solution:- 619 - 47 = 52 kg/kg of vapor 47 - 36 Weight of clear juice = 100 Ts/Hr. ‘Weight of water evaporate in multiple effect evaporator:- 65-15 = 100 x — = 16.92 Ts 65 Weight of vapour going from last body of evaporator: 76.92 = = 19.23 Ts, Therefore, Injection water requirement:- Quantity of vapour x injection water requirement 19.23 x 52 999.96 Ts/Hr. = 999960 kgs/Hr. i.e lits/Hr. = 10,00,000 lits/Hr, Injection pump :~ MPageCAPACITY BN * Centrifugal:- Centrifugal capacity depends on := 1) Quantity of massecuite & Quality of massecuite, 2) Gravity factor. (Diameter of basket & rpm.) 2 Timecycle (Depending in grain size, viscosity, GF. & capacity) 5) Curing scheme. The capacity of machine means quantity of massecuitecured/ ‘machine/eycle. IF there is double curing then, [Link] A & B after worker machine will be half of Generally time cycle of high speed machines are as, For A-— 3 minutes / charge or cycle For B— 4 minutes / charge or cycle For C-— 10 minutes / charge or eycle AC- drive machines ( Four speed) Flat botom machine pm are 50, 200, 750, 1500 (50 for plough) Normal size of machine --—---—- 30 inch x 48 inch (Height x Diameter ) 700 kg /eycle capacity find steep cone machine pm -—-—- 250, 500, 1000 Motor slip is 4% i.e actual speed should be 4% less. DC- drive machines:- gat bottom machine rm ———— 200, 1260-1300 (35-50 for plough) [Link] machine pm ——--—- 250, 1099 : Solution:- Quantity of massecuite ame 25% -— 2500 x 0.25 625 Ts/da BME — 10% 2500 x 0.19 7 CMe 109% 250 Ta 2500 x 0.10 = 250 "Te/da, 2/Page— CAPACITY aaa Let, Time cycle for A- massecuite machine =: 3 minutes, For calculation consider say 5 minutes. Then, No. of cycle /Hr/ machine = 60/5 = [2eyeles Massecuite cured /Hr. / machine = 12 x 700 = 8400kg/Hr. 8.4 Ts/Hr. Therefore, No, of A-machines = 28.41/8,4 = 3.38 = 4Nos. For A- fore workers ---4 Nos, and Avafter Workers --- 2 Nos. machine Let, B-continuous machine capacity = 12 Ts/ Hr Therefore, No. of machine for B-inassecuite = 11.36/12 ‘Let, C-continuous machine capacity = 6 Ts/Hp, Therefore, [Link] machine for C-massecuite = 11,36/6 2Nos For C-fore workers ~—-2 Nos. and Cafter works, No. required. No. (1 standby) * Capacity of Hot & Cold air blower for drying of sugar on hopper:- : 3000 x px h By Hugot's Formula, A =... ee He Hy Weight of air to be passed in ke/Hr, Weight of sugar to be dried in ky/Hr. cist contain of sugar in unit sugar ~ Weight of water vapour contained in saturated ai {rom the diver in kg /:1000 kg of sugar, He = Weight of water contained in saturated air at temp. of entry of air to Heater in kg 1000 ky of sugar. ‘Let, Sugar bags produced/Hir.= 145 Bags/r Propping sugar moist%= 1% Fu in unit sugar = 0,9] Hi = 0.049 x 1000 (49 at 40°C outlet temp.) (19 at 26°C inlet temp, ) 3000 x 145000 x 0.91 “= 14500 ke/tir, ir at temp. of exit Density of air = Therefore, Volume of air 1.129 mikg = 14500/ 1.129 =| Hr. = ye Considering 2594 extra capacity, Gm ain = 7858 8°/min, BlPave— CAPACITY wus, * Final Molasses Storage Tanks:- As per Govt. Specification:= Capacity of plant Volume of tank [Link] tanks 1250 3000 m? 2Nos, 2000 3000 m? 3 Nos. 2500 4000 m? 3 Nos. 3500 4000 m? 4 Nos. 4000 4000 m° 5 Nos. 5000 4000 m? 6 Nos, Two manhole:- 1) Attop 2) At bottom Molasses storage tanks should be away from sugar godowns, spray pond, effluent drain ete : Tank design :- IS- 5521-80 recommended. Capacity Diameter Height Thickness of plates in mm (In meter) It mivyv VI& VII Top plate 1)3000m? 20 9, 75 12 12 12 10 og 06 5 mm 2)4000m’ 23 9.75 12:12 12 10 08 06 5 mm Shell plate thickness :- It should not be less ‘han calculated from following formula or as Per specification IS-803-96 $0 (Height in meter of plate -0.03 )x Density of molasses x diameter of tank T=” 168 a Allowable stress Kplem?( 1680) x Joh efficiency factor (0.7 ) Let, Factory capacity = 1250 Tp, Avg. molasses % cane = 4% Duration of season = 160 di + Total molasses production = 160 x 1250", 0.04 Volume. of mola: es sses = 2 Add 10 % foaming a 7 93333 m Total volume af molasses = 53333 4 533,33 = 5866.63 m? AS per Govt, specifi ication Therefore, 5866.63 » Capacity of tank 3000 m 13000 = 2N, © 2Nos. tanks required, HPae 3CAPACITY * Calculation for shell plate thickness Volume of tank = 3000 mi? Diameter of tank = 20 meter Height of tank = 9.75 meter Nos. of courses ( Plate circles) 9.95 /1.5 = 6.5 = 7 Nos AS per IS-803-76 minimum all 7 courses of 1.5 meter wit Width of shell plate 1.5 meter, We know, therefore there ate in idth & last one is 0.75 meters, 50 ( Height in meter of plate - 0.03 ) x Density of molasses x diameter of nk Te ee Allowable stress Kg/em? ( 1680 ) x Joint efficie ney factor (0.7) 1 Course:- 50(9.75-0.3) x 1.45 x 20 = 1680 x 0.7 = 11.65 mm =12mm Ti= 12'+ 1.5 cosrosion allowance Tt = 135=14 mm thickness of | course plate, Similarly, 2" Course:- $019.75 - 15) 03}, 145 x 20 The Pr ay = 9.8mm =10mm T= low 15 corrosion allowance 12 mm thickness of Pied course plate, 501(9.75~3.0) . 1, 03)x 145 x 29 ; = = ee 7.95 mm =08 mm The 8 +15 Corrosion allowance T= 95=19 mM thickness of 3/4 Course plate.4"\Course.. 45/PageCAPACITY: 50 [(9.75-4.5) - 0.3} x 1.45 x 20 T= _ = 6.1mm = > 1680 x 0.7 Tx= 7 + 1.5 corrosion allowance Ty= 8.5=10 mm thickness of 4" course plate. S* Course: 50 ((9.75-6.0) - 0.3]x 1.45 x 20 — = 425mm 1680 x 0.7 5 + 15 corrosion allowance , 6.5 =08 mm thickness of 5" course plate, 6" Course: 50 [(9.75-7.5) - 0.3}x 1.45 x 20 Té ——— =2.40 mm 1680 x 0.7 7mm =5mm But, tube plate thickness for Ts & T; Tube plate thickness to be consider 6.0 mm. . 46|Page