Report
ON
SUGAR MILL
(CHEMICAL ENGINEERING)
MADAN MOHAN MALVIYA UNIVERSITY OF TECHNOLOGY
(GORAKHPUR)
Training
at
bajaj hindusthan Sugar Mills
Limited.
Pratappur,district deoria
Uttar Pradesh
Submitted by:
Satwik (2016061047)
Rishabh Tiwari (2016061045)
Satyam (2016061048)
Aditya Gupta (2016061002)
Bimlesh Tiwari (2017062004)
Pranshu Kumar (2016061038)
Rahul kannaujia (2016061039)
From 8th December To 18th December 2018
Dedication
We dedicate this effort to our Parents, Teachers &
Learned Chemist and Engineers
Who guided
&
Encourage us during the
Preparation of this report
And we want to
say
ACKNOWLEDGEMENT
All the thanks and praises for god who gave guidance and wisdom to
mankind and enabled us to complete this task. We are very thankful to all our
Supervisors i.e. Mr. Akhileshwar (H.R.), Dr, R.N. Tripathi (Unit head), Er.
Amrendra Singh who helped us a lot to produce this report.
We are thankful to our department who accepted our request to do training in Bajaj
hindusthan Sugar Mills Limited. We are also grateful to all employees of the
Sugar Mills who guided us during the course of training. The behavior of all the
department supervisors is kind enough to us because they gave a lot of time to guide
us the mechanism of Chemical Department in which we worked.
We are also thankful to HOD Dr. Vithal L. Gole, who gave us all the valuable
support and opportunities to complete training program and compile this report.
Introduction to Sugar and Sugar Industry:
The word sugar originates from the Sanskrit word sharkara which means sugar. It may also be
traced through all the Aryan languages, as schaker in Persian, sukkar in Arabic, sincer in
Assyrian, zucchero in Italian, sucre in French, zucher in German, saccharum in Latin and
ozucarin Spanish etc stand as Testimony for its origin from sharkara.
Sugar is a major form of carbohydrates and is found probably in all green plants. It occurs in
significant amounts in most fruits and vegetables. There are three main simple sugars Sucrose,
Fructose and Glucose. Sucrose is in fact a combination of fructose and glucose and the body
quickly breaks down into these separate substances.
All energy stored in food is derived originally from the sun and it is made by green plant life. The
sun's energy acts upon the green chemical "chlorophyll" in the leaves of plants to produce sugars
and starches from the carbon-dioxide in the atmosphere and the water from the roots by a process
known as Photosynthesis. These carbohydrates (starches and sugar) acts as a plants food and
energy supply. The energy need of human body is largely dependent on the carbohydrates that
are derived from plants.
The sugar is one of the essential commodities of the life which plays very important role in the
dietary of human beings as it quickly raises the level of glucose in the blood.
The sugar can be produced by many of the sources, but two are the main sources for production
of sugar in India i.e. Sugarcane and Sugar Beet. The other sources are Maple, Palm, Coconut and
Apple, but these sources are costly and their production is in negligible quantities. But, the main
crop which is being used for production of Sugar all over the world is Sugarcane.
In a nut shell, the process for sugarcane refining is carried out in following steps
Pressing of sugarcane to extract the juice.
Boiling the juice until it begins to thicken and sugar begins to crystallize.
Spinning the crystals in a centrifuge to remove the syrup, producing raw sugar.
Refining the raw sugar by washing and filtering to remove remaining non-sugar
ingredients and color.
Crystallizing, drying and packaging the refined sugar.
For the sugar industry, capacity utilization is conceptually different from that applicable to
industries in general. It depends on three crucial factors the actual number of ton of
sugarcane crushed in a day, the recovery rate which generally depends on the quality of the cane
and actual length of the crushing season.
.
In India, the sugar industry possesses the organized and unorganized players. The unorganized
players mainly produce Gur and Shakkar, the less refined forms of sugar and the organized
players are Sugar Mills owners.
In the world, the Brazil is a country that is largest producer of sugarcane as well as
Refined Sugar.
Introduction to Mill:
Mill’s Products:
The mill’s chief output is White Refined Sugar, it also has following by products:-
1. Bagasse
2. Molasses
3. Press Mud
Mill’s Processing House:
There are four main house in the Sugar mill
1. Milling House
2. Boiler House
3. Power House
4. Boiling House
Processing of sugar cane for manufacturing of white
sugar in Pratappur SUGAR MILLS:-
MILLING
SECTION
CANE Unloader(4Nos.):
Canes are unloaded by trucks directly to feeder or also there are unloaders 4Nos. It
carries the sugarcane piles from trucks and trollies and put them into feeders.The
length was 15.5m.
CANE Scalpel: (03 Nos.)
CANE BLADE # 01
Motor 800KW, Knives 35 Nos is driven by electric motor. It chops up the cane and
also works the leveling of sugarcane. It has a clearance is about 2.5 Ft
CANE BLADE # 02
Motor 650KW, Knives 35 Nos cuts the cane into small pieces, its clearance
is about 12”
CANE BLADE # 03
Motor 800KW, Knives 80 Nos. It ultimately chops the cane into fine pieces at
minimum clearance of 2.5”.
SHREDDER:
Steam Turbine 3800KW, Swinging Hammers 88 Nos. It tears up the cane and ruptures
all the sugar cane cells. There were 23 discs in the Shredder.
MILLS TANDEM: (05 Nos.)
Mills tandem had 06 Mills which were running by steam turbines having power 1000KW
each. Shredded cane passes through a series of 05 mills for juice extraction. Imbibition
water is sprayed on last mills for maximum extraction of juice. This extracted mixed juice
is separated by rotary screens. Here, the pH of the juice is 5.6. Screened juice is sent to
Boiling House for processing and bagasse from last mills is send to boiler house by
baggase separators.
.BOILERS: (04 NOS.)
Main aim of boiler is to produce steam at pressure 24Kg/cm 2 and temperature of 400ºC.
Bagasse is send to boiler’s furnace where it is burnt and this gives steam. Huge amount of
bagasse is sent to bagasse yard, which is then sold. In case of lack of bagasse, furnace oil is
burnt as standby fuel.
03, Boilers (Capacity 80ton/hour)
01, Boiler (Capacity 40ton/hour)
POWER GENERATION HOUSE
STEAM TURBINE GENERATORS: (02 Nos.)
These are 03 Nos.,The steam given by boilers is used for the running of steam turbine
generators. 11MW power is used for the operation of all electric motors put in the
Mills.
02, Steam Turbine Generators (Capacity 5MW)
01, Steam Turbine Generators (Capacity 6MW)
BOILING HOUSE:
JUICE HEATERS:
1. Condensate & Primary Juice Heaters: (01 Nos.) (H.S. 350m2 each)
Concealed juice is passed to a juice heater and temperature is raised up to 70ºC by
using steam or vapours. There is a condensate heater and also a primary juice
heater.
2. Discharge Tanks: (01 Nos.)
Here milk of lime (M.O.L.) is added in heated juice and after some delay time,
juice is passed through secondary juice heaters. Here, the pH of the juice increases
to 7.2 to 7.3.
3. Secondary Juice Heaters: (02 Nos.)
Limed mixed juice is given to a secondary juice heaters and temperature is
increased up to 110ºC for further treatment in juice clarifiers.
03, Secondary Juice Heaters, (H.S. 380m2 each)
02, Secondary Juice Heaters, (H.S. 420m2 each)
4. Juice Clarifier (01 Nos.) (Rapidorr444)
After secondary heating poly electrolyte is used before entering of juice in
clarifiers it stays there for 2 to 2:30 hours for finishing the reaction between
M.O.L. and impurities of the juice. The impurities settle down in the clarifier.
Settling is increased by addition of poly electrolyte. The clear juice from clarifier is
removed and passed through rotary screens. This filtered juice is sent to a series of
evaporators. The muddy juice is taken out from the bottom of the clarifiers and is
sent to vacuum filters for filtration.
VACUUM FILTERS: (04 Nos.)
Muddy juice from the clarifiers is blended with Bagacillo in Mud Mixer and sent to the
vacuum filters. Vacuum filter drum rotates and mud moves over the drum. Hot water is
sprayed by Nozzles over the drum. Clear juice and washing water is sucked by tubes
by vacuum. Sucked filtered juice is returned to discharge tank and mud is sent
out by removing the mud from drums of vacuum filters. It acts as manure for cane
growth. Filtering area is about 53m2.
EVAPORATORS: (04 Nos.)
Juice from juice clarifier is called clear juice. It is taken into series of
evaporators. It is boiled with help of exhaust steam which is obtained from turbines of
mills and power generation house. The thick juice obtained from evaporators called
syrup and is fed to pans. The brix of this thick syrup is about 65-68%.
02, Evaporators, Capacity 5000m2, No. of tubes 14000
01, Evaporators, Capacity 4000m2, No. of tubes 10000
01, Evaporators, Capacity 1800m2, No. of tubes 6800
Condensor
Vapors from Evaporators and Vacuum pans are send to the condensers where
these vapors are changed into water and then this is further given to Injection tanks.
There were 8 condensors but the managing team worked only on two of them.
COOLING TOWERS: (6Nos.)
There are 6 cooling towers which are used to lower the temperature of water in the
injection tank. There is a fan for each cooling tower, 1500 rpm and motor that rotates it
has power of 40KW.
VACUUM PANS: (FOR A, B & C MASSECUITES)
04, Batch Pan, Capacity 70Ton each, H.S. 380m2
01, Continues Pan, Capacity 102m3 each, H.S. 948m2
The syrup is given to pans where it is again boiled to produce mixture of crystals and
molasses called Massecuite. There are 02 pans used for A Massecuite, 02 pans utilized
for B Massecuite and 01 pans for C Massecuite. Massecuite prepared in the A-Pans,
is fed in the relative crystallizers. Similarly B and C Massecuite which are
prepared in relative pans, are given into relative crystallizers.
MASSECUITE CRYSTALLIZERS: (6 Nos.)
Massecuite obtained from pans is send to crystallizers for crystallization by motion
of massecuite by scrolls moved by gear and motor. The massecuite is then moved to
centrifugal station by massecuite pumps. There are 4 crystallizers for vacuum pans. 02
vertical crystallizers are also placed to cool down the Massecuite B and C before
sending to centrifugal section.
CENTRIFUGES K-1100:
Massecuite is passed through Centrifuges in which the crystals of sugar and molasses
are separated. First molasses separated is, “A” Heavy which is again boiled in B-Pans
for B-Massecuite. B-Massecuite is again send through Centrifuges for segragration of
sugar crystals and molasses. This obtained molasses called B-Heavy is again boiled in
C-Pans for C-Massecuite. C-Massecuite is again send to Centrifuges for
segragration of sugar crystals and final molasses. This final molasses is put out in
molasses ponds for sale as a raw material for distilleries and sugar crystals separated
from B & C Massecuite are used as seed in pans and sugar crystals obtained from A-
Massecuite taken into sugar remelter.
Centrifuge for A-Heavy
Centrifuge for B-Heavy
Centrifuge for C-Heavy (Double Cure)
Centrifuge for C-Heavy
SUGAR REMELTER: (Capacity 30ton/hour.)
Here sugar is remelted by hot water and steam which has 02 Nos. stirrers. This remelt
is called raw liquor. This raw liquor is passed to Talo station.
TALO CLARIFIER:
Raw liquor before sending into clarifier is treated with h3po4, color quest, lime
sucrate and Talo float. These are used to separate remaining impurities in sugar. In
Talo clarifier with some delay time these impurities float in clarifier and clear liquor
is removed from bottom side. Floated impurities called scum. It is removed from
clarifier by shredder driven by gear and motor. The clear (fine) liquor is sent to pan
station. The removed serum is sent back to discharge tank.
PANS: (06 Nos.) (Capacity 70 ton each)
Fine liquor is taken to pan. It is then boiled to get brix for crystallization. Small fine
crystals of seed ,which is obtained from the sugar grader not bagable, is fed into it.
Appropriate crystal size is obtained by further boiling called refine massecuite.
Prepared massecuite is put into the crystallizers. it is then pumped to refine
Centrifuges for segregration of crystals and molasses.
CENTRIFUGES TSK (05 Nos.)
Refine Centrifuges are automatic batch Centrifuges. It separates fine sugar crystals and
molasses. This molasses is used again for making more refine massecuites. Fine
crystals (Sugar) is dropped into hopper which then take it to sugar dryer.
SUGAR DRYER: (03 Nos.)
While sugar is passed through the dryers, remaining moisture is removed by blowing
hot air into them. Hot air is passed by fans called blowers which is used for this
purpose.
SUGAR ELEVATORS: (03 Nos.)
Elevators lift the dried sugar through buckets to a certain height and fed to the
sugar grader for its size wise separation.
SUGAR GRADERS: (04 Nos.)
Here, sugar moves over the graders which is moving to and fro. At sugar grader
frames are there made of screens different mesh are put. By this fine, very
small crystals (seed) and extra-large size crystals are separated and sugar crystals
of required size goes into sugar bins.
SUGAR BINS (03)
Sugar bins are used for holding bag of sugar.
AUTOMATIC WEIGHING MACHINE (02 Nos.)
Automatic weighing machines are installed under sugar bins, machine drops sugar bag after
50Kgs accurate weight into poly propylene bag attached under it. These are done manually.
The weight of these bags is checked by electronic weigh machine. After that the sewing of
bags is done by sewing machines (02 Nos.) placed on a wooden conveyors. These sewed
bags are sent to sugar warehouse where it is stacked up to the height of 50 layers by sugar
stacker’
.
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