Shree Datta Sakhar, Asurle-Porle.

Double Sulphitation Process

Crushing Capacity: 230 tch (5040 TCD in 24 hours)
(Quint System)
Whether 3 boiling "1" or 3.5 boiling "0" 0
INPUT DATA
1 Milling rate - To give value - tch 230.00 22 hrs
- Calculated - TCD 5060 5520
2 Cane -pol % 15.50 15.49
-fibre% 13.50
3 First expressed juice -bx 21.60
-purity 88.50
4 Mixed juice -purity 87.00 1.50
5 Last mill juice -purity 78.50 10.00
Delta purity PJ to MJ 1.50
6 Imbibition -%fibre 240.00 16.53
Mud solids in mixed juice - % cane 0.42
7 Bagasse -pol% 2.20
-moisture% 50.00 96.24
8 Quick lime [80% purity] -%cane 0.165
- purity 80%
9 Milk of lime -beaume 6.00
CaO % by weight for above Be -% MOL 5.36
Density of MOL kg/cu.m 1045.00
10 Commercial sulphur -purity 99.50
-%cane 0.05

11 Bagacillio mill wet(50% moisture) -kg/tch 8.00

12 Clarifier underflow % clear juice 0.15
13 Filtrate added to RJ, sulphitor,CJ (Y/N) (1/0) 1.00
14 Filter cake mud solids -%cane 0.65 FC % cane FC loss
15 Filter cake moisture -%cane 75.00 4.20 0.06
16 Pol % filter cake 1.50
17 Filter wash water
18 -Qty %dry matter 150.00
19 Clear juice - brix 15.00
- Purity 87.00 87.00
20 Syrup -brix 65.00
21 Purity product sugar 99.80
22 Melt brix with water addition 70.00

23 Massecuite (A+B+C1+c) Brix Purity Input

A-massecuite 91.00 90.40 90.25
Is B1/B2 m/c boiled(Y/N) 1
B-massecuite 98.00 77.00
B1-massecuite 94.00 78.30 78.30 %cane
B2-massecuite 96.00 67.00 32.33
10.75
C1 massecuite 98.00 58.00 4.42
C-massecuite (3.5 boil) 100.00 53.20 5.46
C-massecuite (3.0 boil) 100.00 57.50
24 B double curing (Y/N) (1/0) 0 52.97
25 Molasses(B1/B2 or B) Brix Purity
A-Heavy 82.00 78.30 0.06
A-Light 75.00 91.00 Recovery
B Heavy 85.00 58.00
B1 Heavy 83.00 58.20
B2 Heavy 84.00 46.00

B Light 80.00 71.00

B1-Light
CL molasses 78.00 60.00
 C1H molasses 74.00 40.00
Final Molasses (3.0 boil) 88.00 31.00
Final Molasses (3.5 boil) 88.00 30.50 30.50
Brix Purity
26 C-Fore sugar 96.00 84.00 RBHR 91.46
C- Fore magma 90.00 -
C- After sugar 93.00
C- After magma 90.00 -
Brix Purity
27 B1- Fore sugar - 84.00
B1- Fore magma 90.00 -
B- After sugar - 94.00
B- After magma 90.00 94.00
Brix Purity
28 B1- Fore sugar - 96.00
B1- Fore magma 90.00 96.00
B1- After sugar - 95.00
B1- After magma 90.00 95.00

29 B2- Fore sugar - 95.00

B2- Fore magma 90.00 95.00
B2- After sugar - 96.00
B2- After magma 90.00 94.00

30 C- grain 62.00

31 A fore sugar - Reference purity 98.50

32 Is Clear juice used for melting Y/N 1/0 0

33 B1+B2+C sugar magma brix 90.00

34 B + C sugar magma brix 90.00
35 Dust & rori sugar magma brix 90.00
36 B1+B2 molasses purity 52.00
37 A light boiled in B massecuite in % 0.00
38 C light boiled in B massecuite in % 0.00
39 Percentage of B seed for A footing - % Cane 0.00
40 Footing crystal size nm 350.00
41 Pan graining volume % 36.00
42 Required crystal size product sugar:
43 A. Small, nm (S grade) 800.00
44 , % of total A-sugar 50.00
45 B. Small, nm (M grade) 1200.00

46 Unknown losses % cane 0.10

Exhaustion Cry % Pty drop
61.00 50.09 11.95
61.41 45.20 20.10
40.94 37.33 21.00
61.39 32.66 22.70

13.77
J. P. Mukherji & Associates Pvt. Ltd.
MATERIAL BALANCE
Annexure - III A
Dalmia Bharat Sugar (EXISTING)
Page - 6/29
Unit - Datta Sakhar Karkhana 230 TCH

SUMMARY

Crushing Rate - tch 230.00 22.00 hrs

- TCD 5520.00

Material % Cane t/h m3/h Pol % Fibre % Moist. %

1 Cane 100.00 230.00 15.50 13.50

2 Bagasse 28.60 65.79 2.20 47.20 50.00
3 Imbibition 32.40 74.52 74.52 240.00
on Fibre %
% Cane t/h m3/h Pol % Brix % Purity
4 Primary Juice 19.12 21.60 88.50
5 Mixed Juice 103.38 237.77 224.31 14.38 16.53 87.00
6 Quick Lime 0.13 0.30
7 Milk of Lime 2.46 5.66 5.42
8 Sulphur 0.05 0.11
9 Sulphur Dioxide 0.10 0.23
10 Air for Sulphur Burning 1128.23
11 Filter Cake 4.20 9.66 1.50
12 Filter Wash Water 1.58 3.62 3.62
13 Centrate I to juice reaction tank 6.89 15.85 15.54
14 Raw Juice 103.38 237.77 228.62
15 Sulphured Juice 112.29 258.26 248.32
16 Clear Juice to Evaporators 104.06 239.34 227.94 14.23 16.36 87.00
17 Syrup 26.19 60.23 45.63 65.00
18 Melt 12.61 29.01 21.97 70.00 95.30

Pan Floor Material: Solids %C Qty t/h Brix % Pol % Purity Qty % cane

19 A Massecuite 29.42 74.37 91.00 82.12 90.25 32.33

20 B1 Massecuite 10.11 24.74 94.00 73.60 78.30 10.75
21 B2 Massecuite 4.24 10.17 96.00 64.32 67.00 4.42
21 C Massecuite 5.46 12.56 100.00 53.20 53.20 5.46

Total Massecuite % Cane 52.97

22 A Heavy Molasses 12.02 33.73 82.00 64.21 78.30 14.66

23 A Light Molasses 2.57 7.88 75.00 68.25 91.00 3.43
24 B1 Molasses 4.73 13.12 83.00 48.31 58.20 5.70
26 B2 Molasses 2.43 6.64 84.00 38.64 46.00 2.89
25 C Light Molasses 0.63 1.86 78.00 46.80 60.00 0.81
26 Final Molasses 3.14 8.22 88.00 26.84 30.50 3.57

27 B1 Magma 5.38 13.74 90.00 86.40 96.00 5.97

30 B2 Magma 1.82 4.65 90.00 85.50 95.00 2.02
28 CA Magma 1.69 4.31 90.00 83.70 93.00 1.87
29 CF magma 2.32 5.92 90.00 75.60 84.00 2.57

30 SUGAR BALANCE: % Cane 34 EXTRACTION: % Cane

Sugar in Cane 15.50 Mill Extraction 95.94
Sugar in Mixed Juice 14.87 Reduced Mill Extraction 96.24
Sugar in Bagasse 0.63 Boiling house recovery % Cane 92.64
Sugar in Filter Cake 0.06 Reduced boiling house recovery 91.46
Sugar in Final Molasses 0.96 Overall Extraction 88.88
Sugar in Sugar 13.75 Reduced Overall Extraction 88.02
Sugar Undetermined 0.10
Total Losses(Bag., F.Cake, Mol., Undeterm 1.75

Sugar Recovery % Cane 13.77

J. P. MUKHERJI & ASSOCIATES Pvt. Ltd.,
JUICE HEATER BALANCE Annexure - IV A
Dalmia Bharat Sugar (EXISTING) Page - 7/29
Unit - Datta Sakhar Karkhana 230 TCH

DESCRIPTION Heater No. ---> #1 #2 #3 #4

Heating Surface Area (HSA) m2 310 310 330 280

Type of heater Tubular Tubular Tubular Tubular

Provision of heating for the juice RJ-1 RJ-1 SJ - 1 SJ - 1
VLJH VLJH Conventional Conventional
Working / Standby Working Standby Working Standby

Crushing Rate tch 230 230 230 230

Total Juice Flow % Cane 103.38 103.38 112.29 112.29
Juice Flow per heater % total flow 100% 100% 100% 100%
Juice Flow per heater - t/h 237.77 237.77 258.26 258.26
Juice Flow per heater - m3/h 226.44 226.44 245.96 245.96

Calculated HSA m2 310 310 330 280

No. of tubes per pass (Original) 23 23 25 18
Number of passes 16 16 24 28
Total No. of tubes 368 368 600 504
Tube material SS SS SS SS
Tube OD mm 45.00 45.00 45.00 45.00
Tube Thickness mm 1.22 1.22 1.50 1.50
Tube ID mm 42.56 42.56 42.00 42.00
Tube Length mm 6000 6000 4000 4000

Bleeding Effect Q -V Q-V Q - III Q - III

Heating medium temp. oC 60.27 60.27 100.25 100.25
Dynamic / Conventional (1 / 0) 1 1 0 0
Juice Inlet Temperature oC 30.00 30.00 68.00 65.00
Juice Outlet Temp. (attainable) oC 50.24 50.24 87.38 87.46

Juice Velocity (Original) m/s 1.92 1.92 1.97 2.74

Pressure Drop m 21.28 21.28 22.93 51.61

J. P. MUKHERJI & ASSOCIATES Pvt. Ltd., EVAPORATOR BALANCE
Annexure - V A
(PROPOSED)
Dalmia Bharat Sugar Page - 8/29
230 TCH
Unit - Datta Sakhar Karkhana
1.0 Basic Parameters
Factory crushing rate tch 230 22 hrs
Imbibition % fiber 240

t/h % cane
Raw juice 237.77 103.38
Sulphured juice 264.88 115.17
Clear juice 255.66 111.16
Clear juice brix 14.92
Syrup brix required brix 65.00
Condensate flash YES

2.0 Pan floor steam requirement at minimum demand t/h % cane

- A Pans 28.77 12.51 From Effect - 3
- B1 Pans 7.80 3.39 From LTEM - 3
- B2 Pans 3.50 1.52 From LTEM - 3
- C Pans 5.06 2.20 From Effect - 2
- Total 45.12 19.62
Exhaust for variable pan stm. demand 0.00 0.00 From Exhaust
- Molasses Conditioning 1.03 0.45 From Effect - 2
- Pan Washing 2.30 1.00 From Effect - 1
- Superheated Wash Water System 0.002 0.00 From Exhaust
- Sugar Drying 0.45 0.20 From Exhaust

Total pan demand 48.91 21.26

3.0 Juice heaters bleeding Effect Heating (Deg C) Bleeding Quantity

From To t/h % cane
Raw juice stage - 1 Effect - 5 Tubular 30.00 42.00 4.71 2.05
Raw juice stage - 2 Condensate PHE 42.00 53.00 0.00 0.00
Raw juice stage - 3 Effect - 4 DCH 53.00 72.00 6.63 2.88

Suphured juice stage - 1 Effect - 3 Tubular 68.00 77.00 4.11 1.79

Suphured juice stage - 2 Effect - 3 DCH 77.00 91.00 5.39 2.34
Suphured juice stage - 3 Effect - 2 DCH 91.00 102.00 4.30 1.87

Clear juice stage - 1 Effect - 2 DCH 96.00 105.31 3.44 1.50

Clear juice stage - 2 Effect - 1 DCH 105.31 114.01 3.25 1.41

Syrup Heating Effect - 2 Tubular 60.00 80.00 1.87 0.81

Melt Heating Effect - 2 DCH 55.00 75.00 0.24 0.10

Total 33.94 14.76

4.0 Evaporation
Total evaporation % Cane 87.88
t/h 202.12

Exhaust Quint - 1 Evapplus-1 Evapplus-2 Quint - 2 Quint - 3 Quint - 4 Quint - 5

Pressure Bara 2.40 1.91 1.53 1.22 1.45 1.01 0.60 0.20
Temperature 0
C 126.01 119.01 111.92 105.43 110.31 100.25 85.80 60.27

Evaporation from each body t/h 75.34 11.50 11.04 55.50 40.57 4.77 3.38
% Cane 32.76 5.00 4.80 24.13 17.64 2.08 1.47

Juice flow from each body t/h 262.35 127.00 48.50 37.45 108.95 68.39 63.61 60.23
Outlet brix Brix
0
14.92 30.82 18.46 23.91 35.93 57.24 61.54 65.00

Heating surface m2 2400 700 700 2600 2600 840 560

Specfic evaporation rate kg/h. m2/h 31.39 16.43 15.78 21.35 15.60 5.68 6.04
lb/h. ft2/h 6.43 3.37 3.23 4.37 3.20 1.16 1.24

5.0 Exhaust Steam consumption t/hr % cane

Exhaust steam to Effect - 1 75.34 32.76

Exhaust steam for raw juice heater 0.00 0.00
Exhaust steam for sulphured juice heater 0.00 0.00
Exhaust steam for clear juice heaters 0.00 0.00
Exhaust steam for variable pan steam demand 0.00 0.00
Exhaust steam for Sugar Drying & SHHW 0.45 0.20
Process Exhaust steam demand 75.80 32.96
Exhaust steam for Soda Boiling (Evap. Cleaning) 2.00% 1.61 0.70
Losses on total demand 4.00% 3.23 1.40
Total exhaust steam demand 80.64 35.06
 Shree Datta Sakhar, Asurle-Porle.
Double Sulphitation Process
Crushing Capacity: 340 tch (7500 TCD in 22 hours)
(Quint System)
Whether 3 boiling "1" or 3.5 boiling "0" 0
INPUT DATA
1 Milling rate - To give value - tch 340.00 22 hrs
- Calculated - TCD 7480 in 22 hrs 8160
2 Cane -pol % 16.00 16.00
-fibre% 13.50 22.18
3 First expressed juice -bx 22.18
-purity 89.03
4 Mixed juice -purity 87.53 1.50
5 Last mill juice -purity 79.83 9.20
Delta purity PJ to MJ 1.50
6 Imbibition -%fibre 240.00 16.93
Mud solids in mixed juice - % cane 0.42
7 Bagasse -pol% 2.06
-moisture% 49.00 96.68
8 Quick lime [80% purity] -%cane 0.180
- purity 80%
9 Milk of lime -beaume 6.00
CaO % by weight for above Be -% MOL 5.36
Density of MOL kg/cu.m 1045.00
10 Commercial sulphur -purity 99.50
-%cane 0.05

11 Bagacillio mill wet(50% moisture) -kg/tch 0.00

12 Clarifier underflow % clear juice 0.15
13 Filtrate added to RJ, sulphitor,CJ (Y/N) (1/0) 1.00
14 Filter cake mud solids -%cane 0.65 FC % cane FC loss
15 Filter cake moisture -%cane 75.00 2.60 0.05
16 Pol % filter cake 1.79
17 Filter wash water
18 -Qty %dry matter 800.00
19 Clear juice - brix 16.25
- Purity 87.53 87.53
20 Syrup -brix 66.50 65.19 35.03
21 Purity product sugar 99.84
22 Melt brix with water addition 70.00

23 Massecuite (A+B+C1+c) Brix Purity Input

A-massecuite 91.00 91.00 91.35
Is B1/B2 m/c boiled(Y/N) 1
B-massecuite 98.00 77.00
B1-massecuite 95.00 80.00 80.00
B2-massecuite 97.00 67.00

C1 massecuite 98.00 58.00

C-massecuite (3.5 boil) 100.00 55.50
C-massecuite (3.0 boil) 100.00 57.50
24 B double curing (Y/N) (1/0) 0
25 Molasses(B1/B2 or B) Brix Purity
A-Heavy 80.00 80.00 0.00
A-Light 75.00 93.35
B Heavy 85.00 58.00
B1 Heavy 82.00 61.20
B2 Heavy 86.00 46.75

B Light 80.00 71.00

B1-Light
CL molasses 80.00 65.00
C1H molasses 74.00 40.00
Final Molasses (3.0 boil) 88.00 31.00
Final Molasses (3.5 boil) 88.00 33.50
Brix Purity
26 C-Fore sugar 96.00 84.00 RBHR 90.41
C- Fore magma 90.00 -
C- After sugar 95.00
C- After magma 90.00 -
Brix Purity
27 B1- Fore sugar - 85.00
B1- Fore magma 90.00 -
B- After sugar - 94.00
B- After magma 90.00 94.00
Brix Purity
28 B1- Fore sugar - 97.00
B1- Fore magma 90.00 97.00
B1- After sugar - 95.00
B1- After magma 90.00 95.00

29 B2- Fore sugar - 96.00

B2- Fore magma 90.00 96.00
B2- After sugar - 96.00
B2- After magma 90.00 94.00

30 C- grain 65.00

31 A fore sugar - Reference purity 98.50

32 Is Clear juice used for melting Y/N 1/0 0

33 B1+B2+C sugar magma brix 90.00

34 B + C sugar magma brix 90.00
35 Dust & rori sugar magma brix 90.00
36 B1+B2 molasses purity 53.69 -0.000001
37 A light boiled in B massecuite in % 0.00
38 C light boiled in B massecuite in % 0.00
39 Percentage of B seed for A footing - % Cane 0.00
40 Footing crystal size nm 600.00
41 Pan graining volume % 36.00
42 Required crystal size product sugar:
43 A. Small, nm (S grade) 1200.00
44 , % of total A-sugar 25.00
45 B. Small, nm (M grade) 1800.00

46 Unknown losses % cane 0.10

WSSF EQUIPMENT CAPACITY Page 10 / 29

Plant Capacity tch 340.00 340.00

Code Description Units Capacity

0500 Juice treatment

0501 Juice weighing scale/ Mass Flow meter
-Juice quantity t/h 353.94 353.94 442.42 440.00
-W.Scale Type, MB/Electronic = "1/0" # 1.00 1.00
-Capacity of W. Scale t/tip 6.50 6.50
-No. of tips per hour - Actual tip/h 54.45 54.45
-No. of tips per hour - Acceptable - Minimum t/tip 25.00 25.00
-No. of tips per hour - Acceptable - Maximum t/tip 60.00 60.00

Available capacity OK OK OK
SHORT --- ---
0504 Weighed Juice buffer tank

Raw juice % cane #REF! #REF!

Juice quantity t/h #REF! #REF!
cu.m/h #REF! #REF!
cu.m/min #REF! #REF!
Retention time required min 7.00 10.00
Holding volume of the tank cu.m #REF! #REF! tank-14.4

Weighing scale 1 1
Capacity t/h 190.00

0507 Weighed Juice Pump no 2.00

-Juice quantity % cane 104.10 104.10 8.00 203.2
t/h 353.94 353.94
m3/h 340.32 340.32 0.09
-Recirculation capacity required % 20.00% 20.00% 2.92
-Pump capacity required m3/h 408.39 408.39

-Pump No. #1 #2 #3
-Pump capacity available m3/h 180.00 180.00 0.00
-Working or standby W / SB W W SB
60 60 60

Available capacity OK
SHORT

0510 Juice sulphiter

0510a Reaction tank no 1.00 2.00
Dia m 4.20 5.25 2.91 4.00
Working height m 3.00 2.20 3.20 2.75
-Working volume m3 41.54 47.60 21.27 34.54
-Quantity of juice to be treated m3/h 378.58 378.58 378.58
-Retention time available minutes 6.58 7.54 3.37
-Retention time required minutes 7.00 7.50 7.00

Available capacity OK ---

SHORT SHORT

0512 Sulphited juice receiving tank no 1.00

Dia m 3.63 0.00
Height m 3.00 4.00
Volume m3 31.03 0.00
Total Volume m3 31.03 0.00
Quantity of juice m3/h 378.58 378.58
-Retention time available minutes 4.92 0.00
-Retention time required minutes 5.00 5.00

Available capacity OK ---

SHORT SHORT

0513 Sulphiteded Juice Pump no 2.00 8.00 203.2

-Juice quantity % cane 115.80 115.80
t/h 393.73 393.73
m3/h 378.58 378.58 0.11 3.24
-Recirculation capacity required % 20.00% 20.00%
-Pump capacity required m3/h 454.30 454.30

-Pump No. #1 #2 #3
-Pump capacity available m3/h 180.00 180.00 0.00
-Working or standby W / SB W W SB
-head m 60 0 80
Available capacity OK ---
SHORT SHORT
-Recirculation capacity available %

Flash tank no 1.00

-Juice quantity % cane 115.80 115.80

t/h 393.73 393.73
m3/h 378.58 378.58

- - Inlet temp of juice deg C 103.00 103.00

- -- Outlet temp of juice deg C 100.00 100.00

- - Flash area reqd sqm 9.33 9.33

WSSF EQUIPMENT CAPACITY Page 11 / 29

0600 Clarification and filtration

0602 Clarifier no 2.00

-Quantity of juice to be treated m3/h 378.58 378.58

- m3/ 45 minutes 283.94
-Diameter of Clarifier mm 7320 24 0
-Height ft 6096
-Total volume m3 256.54 38.00
-Net volume(4 comp) m3 230.89 36.10
-Total volume available m4 279.02 48.13
-Retention time available h 0.74
-Retention time required h 2.25

Available capacity working with 4 comp OK ---

SHORT SHORT

Clear juice receiving column no 1.00 2

-Quantity of Clear juice m3/h 357.76 357.76
m3/min 5.96 5.96
- Height m 1.42 1.49
- Dia m 2.85 0.81 Total
Volume of the tank m3 9.05 0.76 9.82
Retention time required min 5.00 5.00 5.00
Retn time available min 1.52 0.13 1.65

Clear Juice pumps no 2.00

-Juice quantity % cane 109.43 109.43

t/h 372.07 372.07
m3/h 357.76 357.76
-Recirculation capacity required % 20.00% 20.00%
-Pump capacity required m3/h 429.31 429.31

-Pump No. #1 #2 #3
-Pump capacity available m3/h 180.00 180.00 0.00
-Working or standby W / SB W W SB

Available capacity OK --- --- --- ---

SHORT SHORT SHORT --- ---

10 3.0487804878 12 3.658536585
20 6.0975609756 24 7.317073171
58.410172516 84.11064842

0607 Rotary Vacuum filters no 3.00

-Filter size , dia x length mm 2438 x 4876 2438 x 4876 3050 x 6100
-Filter size , dia x length ft 8 X 16 8 X 16 10 X 20
-Filtering area m2 37.50 37.50 58.46
-Total filtering area available m2 >>> 133.46
-Filtering area required per tch m2/tch 0.65
-Total filtering area required m2 221.00 221.00
0
Available capacity OK
SHORT SHORT #REF! ---

no 4.00
0613 Vacuum pump for RVF #1 #2 #3 #4 #1 #2
-Capacity available m3/h 725.00 725.00 720.00 1220.00
-Drive Motor Motor Motor Motor
-Working or standby W / SB SB W SB W
-Capacity required per filtering area m3/m2/h 20.00 20.00 20.00 20.00
-Vacumm pump capacity required m3/h 750.00 750.00 720.00 1169.20
m3/min 12.50
Available capacity OK --- --- #REF!
SHORT SHORT SHORT SHORT #REF!

Mud Mixer #1 #2
- Quantity of mud to be handled m3/hr
- Length m 3.60 0.00
-Width m 0.89 0.91
- Height m 0.91
- Effective Capacity cum 0.00 0.00

Available capacity OK
SHORT
WSSF EQUIPMENT CAPACITY Page 12 / 29

Mud recirculation tank #1 #2

- Retention time min 15

-Clarifier underflow % clear juice % 0.15
- Vol for retention time cum 12.14
- Dia 1.80
- height 1.21
- Capacity for 230 tch cum 3.08 12

- Dia
- height
- Capacity cum 12 12

Mud recirculation pump

#1 #2 #3 #4
- Quantity of mud to be handled t/h 0.51
-Mud quantity % cane 0.15
t/h 51.00
m3/h 46.36
-Recirculation capacity required % 20.00%
-Pump capacity required m3/h 55.64

-Pump No. #1 #2 #3
-Pump capacity available m3/h 60.00 60.00 0.00
-Working or standby W / SB W SB W

Available capacity OK OK OK --- ---

SHORT --- --- --- ---

Cake wash water pump

- Filter wash water
-Filter cake % cane 4.20 %cane
t/h 14.28 #VALUE!
-Wash water quantity t/hr 21.42
-Recirculation capacity required % 20.00% 20.00%
-Pump capacity required m3/h 25.70 #VALUE!

-Pump No. #1 #2 #3 #4
-Pump capacity available m3/h 25.00 15.00 0.00 0.00
-Working or standby W / SB W SB W SB

Available capacity OK --- #VALUE! --- ---

Filterate Receiving tank 30 cum/hr 3 nos
Quantity of Filterate cum/hr 15.54
Retention time min 10.00 dia height Volume
Holding volume cum/hr 2.59 2.50 4.50 22.09
SHORT --- #VALUE! --- ---
Filterate Pumps
Quantity of Filterate m3/h 15.54
-Recirculation capacity required % 20.00%
-Pump capacity required m3/h 18.65
m3/h 18.60 30 cum/hr 3 nos
SHORT --- #VALUE! --- ---

0618 Bagacillo blower #1 #2

-Blower capacity m3/min 121.50 0.00
m3/h 7290.00 0.00
-Bagacillo qty. required kg/tch 10.00
-Air required per kg of bagacillo m3/kg 7.00
-Blower capacity required m3/h 23800.00 16200
m3/min 396.67 270
Available capacity OK SHORT
SHORT

0619 Bagacillo piping

-Bagacillo pipe diameter mm 515.00 375.00
-Design velocity m/s 25.00 25.00 12
-Bagacillo duct diameter mm 460.00 0.00 550.00

Available capacity OK OK OK
SHORT --- ---

Bagacillo screens
7.4
Bagacillo Screen
Screen area required per TCH sqm 0.065
Areq required sqm 22.10 22 sqm

Cyclone separator #1 #2
- Dia m 1.595 1.595
WSSF EQUIPMENT CAPACITY Page 13 / 29

- height m 2.420 2.420

- capacity avaialble m3 0.000 0.000
- capacity required m3 0.00 0

Cake collection bin

- Filter cake % cane 4.20
t/h 14.28

- storage time required hrs 1.00

- capacity of mud storage bin tons 17.14

0700 MOL and SO2 preparation dia 1400.00 mm

0702 Lime slaker Length 4000.00 mm
-Capacity kg/h 0.00 0.00
-Lime consumption (max.) % cane 0.13 #REF!
-Capacity suitable for working hours hours 12.00 12.00
-Lime slaker capacity required kg/h 900.00 #REF!

Available capacity OK --- #REF!

SHORT SHORT #REF!
MOL vibro screen
Quantity of Mol cum/hr 5.42
Preperation time per day 6.00
MOL quantity to be handle cum/hr 21.68 25 cum/hr
#1
diameter mm 1525.00
Mesh mesh 80.00

0705 MOL storage tanks #1 #2 #3 new #6

-size of storage tanks, diameter m 2.10 2.10 2.75 3.80
- height m 2.16 2.16 2.48 2.20
-Capacity of storage tank, each m3 7.48 7.48 14.73 24.95 0.00
-Total capacity of storage available m3 29.69 24.95
-MOL quantity, @ 8 Be' % cane 2.69 2.69
m3/h 9.13 9.13
-Storage time available h 3.25 2.73
-Storage time required - minimum h 8.00 8.00
-Total capacity of storage - required m3 73.07 73.07

Available capacity OK 3 nos of 25 cum

SHORT
MOL Pumps
-MOL quantity, @ 6 Be' % cane 7.48 7.48
-MOL quantity require m3/h 9.13 0.00
-considering 100 % extra m3/h 18.27 0.00
-MOL pump capacity require m3/h 18.27 0.00
m3/h 19.00 0.00 19 cum/hr and 30 mtr head 2 nos
-Working or standby W / SB 1W 1SB 6 cum/hr and 30 mtr head 3 nos
#1 #2 #3
Capacity m3/h 10.00 10.00 10.00
Head m 20.00 20.00 20.00

Sulphur burners
0707 Sulphur burners - for juice #1 #2
-Sulphur burners Type Cont. Cont.
-Tray area m2 -- --
-Capacity, each kg/h 140.00 140.00
-Working / Standby W / SB W SB
-Total capacity of continuous burner kg/h 140.000
-Sulphur consumption for juice % cane 0.035
-for capacity calculation % cane 0.076
kg/h 258.40

Available capacity OK ---

SHORT SHORT ---

0708 Sulphur burners - for syrup #1 #2

-Sulphur burners Type Cont. Cont.
-Tray area m2 -- --
-Capacity, each kg/h 100.00 100.00
-Working / Standby W / SB W
-Capacity Available in working kg/h 100.00
-Sulphur consumption for syrup % cane 0.015
-for capacity calculation % cane 0.024
kg/h 81.60

Available capacity OK OK ---

SHORT --- --- ---
WSSF EQUIPMENT CAPACITY Page 14 / 29

0710 Air compressors/Blowers for sulphur burners

Air compressor/blowers (for juice & syrup) #1 #2
-Capacity available m3/h 600.00 600.00
-Working / Standby W / SB W SB
- - Total capacity of blowers 600.00
-Delivery pressure required kg/cm2(g) 1.00 1.00
-Total working capacity available m3/h
-Air required per kg of sulphur m3/kg 9.86
-Total air required m3/h 1380.00

Available capacity OK ---

SHORT SHORT

Air compressor (forsyrup) #1 #2

-Capacity available m3/h 400.00 400.00
-Working / Standby W / SB W
-Delivery pressure required kg/cm2(g) 1.00
-Total working capacity available m3/h 400.00
-Air required per kg of sulphur kg/kg 9.86
-Total air required m3/h 990.00

Available capacity OK ---

SHORT ---

Unsulphured syrup tank #1 #2

- Quantity of syrup to be handled % cane 0.00 0.00
t/h 0.00 0.00
m3/hr 0.00 0.00

- Dia m 5.00 5.00

- height m 5.00 5.00
- capacity avaialble m3 98.13 98.13
- capacity required m3 0.00 0.00
- Retention time required hrs 1.50 1.50
- Retention timeavailable hrs #DIV/0! #DIV/0!

0821 Syrup sulphiter

-Working / Standby W / SB W W
-Quantity of syrup to be treated m3/h 68.49 70.51 1.14
-Diameter m 2.20 2.94 Existing juice sulphiter dia
-Parellel Height m 0.00 3.30
-Working height m 2.45 2.00
-Working volume of sulphiter m3 9.31 13.57
-Retention time available minutes 8.16 11.55
-Retention time required minutes 20.00 20.00

Available capacity OK ---

SHORT SHORT
Syrup Pump Proposed Proposed
-Syrup quantity % cane 26.96 26.96
t/h 91.66 91.66
m3/h 70.51 70.51
-Recirculation capacity required % 25.00% 25.00%
-Pump capacity required m3/h 88.13 88.13
m3/h 90.00 90.00 90.00 cum cap with 30 mtr head 2 nos
-Pump No. #1 #2 #3 30.00 cum cap with 30 mtr head 3 nos
-Working or standby W / SB
Existing
-Pump No. #1 #2 #3
-Pump capacity available m /h3
60.00 60.00 60.00
-Working or standby W / SB W SB
Available capacity OK ---
SHORT SHORT
-Recirculation capacity available % 85.10%

0900 Crystallisation
0901 Syrup & molasses storage tanks Tank size Capacity No. of Total
Length Diameter Height Each tank tanks cap.
m m m m3 m3
- Sulphured syrup 15.00 3 45.00 45.00
- Melt 15.00 2 30.00 30.00
- AL 15.00 1 15.00 15.00
- AH 15.00 3 45.00 45.00
- AH 0.00
- B1H 15.00 2 30.00 30.00
- BL 15.00 0 0.00 0.00
- B2H 15.00 0 0.00 0.00
- CL 15.00 1 15.00 15.00
12
WSSF EQUIPMENT CAPACITY Page 15 / 29

Syrup & molasses storage tanks Quantity Tank cap. Retention time Available capacity
available Available Required OK SHORT
m /h
3
m3 Hrs Hrs
-Sulphured syrup 70.00 45.00 0.64 2.00 --- SHORT 95
-Melt 39.00 30.00 0.77 1.00 --- SHORT
-AL 16.00 15.00 0.94 2.00 --- SHORT
-Total Sy + Melt + AL 2.35 5.00 --- SHORT
-AH 45.00 45.00 1.00 4.00 --- SHORT 135
- B1 19.00 30.00 1.58 6.00 --- SHORT 84
- B2 9.00 0.00 0.00 6.00 --- SHORT 54
-CL 4.00 15.00 3.75 6.00 --- SHORT
-Total 8.68 27.00 --- SHORT

0902 Molasses conditioners AH B1H B2H CL

-Capacity available t 17.14 7.14 4.29 2.86
m3 12.00 5.00 3.00 2.00
-Quantity m3/h 45.00 19.00 9.00 4.00
-Retention time available min 16.00 15.79 20.00 30.00
-Retention time required min 20 20 20.00 20

Available capacity OK --- --- --- OK

SHORT SHORT SHORT --- ---

0903 Vacuum pans

Massecuite A B1 B2 C Grain Total
Type Batch Batch Batch Batch Batch
Capacity Available
-Pan Capacity each, ( i ) 80 0.00
-Pan Capacity each, ( ii ) 60 45 0.00 45 0.00
-Pan Capacity each, ( iii ) 70 45 0.00 45
-Pan Capacity each, ( iv ) 0 0.00 0 --
-Pan Capacity each, ( v ) 0 -- -- -- --
- Batch pans t 210 90 0.00 90 0 390
- Continuous pans t/h --- 35 --- 25.00 --- ---
Massecuite Quantity Average % cane 35.57 12.00 6.00 8.00 --- 61.57
t/h 120.93 40.80 20.40 27.20 --- 209.33
Massecuite Quantity Maximum % cane 35.57 12.00 6.00 8.00 --- 61.57
t/h 120.93 40.80 20.40 27.20 29.47 238.80
No. of strikes per day 6 4 4 3 6.00 ---
Capacity required ---
- Batch pans t 483.73 244.80 122.40 217.60 117.87 1186.39
- Continuous pans t/h --- 49 26 33 --- ---
Available capacity OK --- --- --- --- --- ---
SHORT SHORT SHORT SHORT SHORT SHORT SHORT
Short by t -273.73 -154.80 -122.40 -127.60 -117.87 -796.39

0907 Seed crystallisers Dry seed Dry seed B seed

-Capacity available t 65.00 65.00
-Capacity required t 0.00

Available capacity OK OK OK
SHORT --- ---

0908 Vacuum crystallisers

Massecuite A B1 B2 C
-Capacity available t 90.00 75.00 75.00 75.00
-Capacity required t 0.00 0.00 0.00 0.00

Available capacity OK OK OK OK OK
SHORT --- --- --- ---

Receiving crystallisers
0910 A - Receiving crystallisers

-Capacity, each t 85
-No. of crystallisers 3
-Total t 255.00

0911 B - Receiving crystallisers

For Conti pan
-Capacity, each t 65.00
-No. of crystallisers 1
-Total t 65.00

0913 C - Receiving crystallisers

For Conti pan
-Capacity, each t 65.00
-No. of crystallisers 1
-Total t 65.00
WSSF EQUIPMENT CAPACITY Page 16 / 29

0911 Cooling crystallisers

0914 Massecuite B C
Type - Horizontal / Vertical Vertical Vertical
- Twin / Mono Mono Twin
Capacity available ---
-Capacity, each t 300.00 200.00
-No. of crystallisers 1 2
-Total t 300.00 400.00

-Massecuite quantity estimated % cane 12.00 8.00

-Massecuite quantity for cap calculation % cane 12.00 8.00
t/h 40.80 27.20
-Retention time available h 7.35 14.71
-Retention time required h 10.00 24.00

Available capacity OK --- ---

SHORT SHORT SHORT

1000 Centrifugals

1001 Batch Centrifugals A A

Make and/or type Krupp / NHEC Krupp / NHEC

Massecuite quantity - % cane 32.00 32.00
- t/h 108.80 108.80
- t/day 2611.20 2611.20
Hours working per day - hrs 21 21
Massecuite quantity for capacity calculation - t/h 124.34 124.34
Type Batch / Continuous Batch Batch
Capacity per charge -t 1.75 1.25
Number of charges per hour - Nos 18 18
Capacity of each machine - t/h 31.50 22.50
Total capacity available - t/h 94.50 90.00
Capacity per day - t/day 1984.50 1890.00
No. of machines available - Nos 3 4
No. of machines required - Nos 3.95 5.53
No. of machine for standby duty - Nos 1.00 1.00
Total No. of machines required - Nos 4.95 6.53
Available capacity OK --- ---
SHORT --- ---
say - Nos 5 7
- Nos

1005 Continuous Centrifugals B1 B2 CAW Total B1

(B and CAW)
Make and/or type Nk-1503 Nk-1503 NK-1503 Nk-1100
Massecuite quantity - Average - % cane 12.00 6.00 3.08 12.00
- t/h 40.80 20.40 10.46 40.80
- t/day 979.20 489.60 251.07 979.20
Hours working per day - hrs 21 21 21 21
Massecuite quantity for capacity calculation - t/h 46.63 23.31 11.96 58.58 46.63

Capacity of each machine (0.06 mm screen) - t/h 14.00 14.00 14.00 10.00 10.00
Total capacity available - t/h 28.00 28.00 14.00 20.00
No. of machines available - Nos 2 2 1.00 5 2
Number of machines required - Nos 3.33 1.67 0.85 5.85 4.66
Rounded off - Nos 3.00 2.00 1.00 6.00 5.00
Available capacity OK --- --- OK --- OK
SHORT SHORT --- --- SHORT SHORT
SPARE - Nos 1.00 1
Total machines required 7.00

9 Continuous Centrifugals (CFW) CFW C1FW Total CFW

Make and/or type NK1503 NK1503 NK1100

Massecuite quantity - Average - % cane 8.00 0.00 8.00
Massecuite quantity - Average - t/h 27.20 0.00 27.20
- t/day 652.80 0.00 652.80
Hours working per day - hrs 21 21 21
Massecuite quantity for capacity calculation - t/h 31.09 0.00 31.09

Capacity of each machine (0.05 mm screen) - t/h 8.00 10.00 6.00

Total capacity available - t/h 16.00 0.00 12.00
No. of machines available - Nos 2 0 2.00 2
Number of machines required - Nos 3.89 0.00 3.89 5.18
Rounded off - Nos 4.00 4.00 5.00
Available capacity OK --- OK --- ---

SHORT SHORT --- SHORT SHORT

say - Nos 0 0.00
SPARE - Nos 1 0 1.00 1

Total required 5.00 6.00

WSSF EQUIPMENT CAPACITY Page 17 / 29

1038 FM storage tanks #1 #2 #3

-Capacity each tank cu.m 7000.00 7000.00 7000.00
t 9800.00 9800.00 9800.00
-Total capacity available t 29400.00
-Final molassess production t/h 12.60
-tank capacity required ton 0.00 27216.08 20935.44
(at 50 % production in 165 days)

Available capacity OK --- OK ---

SHORT --- --- SHORT

Massecuite pumps for % cane T/hr Pump cap Nos Cap T/hr Stand by Head

-A 39.01 132.64 198.96 3.00 40.00 1.00 15.00

- B1 12.91 43.90 65.85 2.00 35.00 25.00
- B2 4.86 16.52 24.77 2.00 25.00 1.00 15.00
-C 6.36 21.61 32.42 2.00 25.00 25.00

- B1 magma 7.16 24.33 36.50 1.00 25.00 1.00 30.00

- B2 magma 2.15 7.32 10.98 1.00 15.00 1.00 20.00
- CAW magma 1.95 6.63 9.94 1.00 15.00 20.00
- CFW magma 3.08 10.46 15.69 1.00 15.00 1.00 20.00

Molasses pumps for % cane T/hr Cum/hr Pump cap Nos Cap T/hr Stand by

- AH 17.15 58.31 44.85 67.28 2.00 20.00 1.00

- AL 6.00 20.39 15.68 23.53 1.00 20.00
- B1 7.10 24.15 18.58 27.87 1.00 20.00
- B2 3.23 10.97 8.44 12.66 1.00 20.00 1.00
- CL 1.27 4.32 3.32 4.98 1.00 20.00
- FM 4.08 13.86 10.66 15.99 1.00 20.00 1.00
- Melt 14.88 50.58 38.91 58.37 2.00 20.00 1.00

Sugar Melter
- Quantity of melt % cane 12.61
t/h 42.88
m3/hr 32.48
m3/min 0.54
- melter number #1
- Dia m
- height m
- capacity m3
- Retention time available min
- Retention time required min 30.00
- capacity required m3 16.24
- capacity required T 21.44
- capacity available T 20.00
- retention time avaialble min 1.09

Sugar melt pumps

- Quantity of melt % cane 50.58
t/h 82.12
m3/hr 62.21

- Recirculation capacity required % 50.00%

- Pump capacity required m3/hr 93.00

1100 Sugar handling

1101 Single tray grass hopper*****

1102 Sugar elevators #1 #2

-Capacity - each t/h 20.00 20.00
-Total Capacity Available t/h 40.00
-Actual sugaar quantity t/h 55.12
-Capacity required t/h 47.25
(equivalent for 3 new m/cs)
Available capacity OK ---
SHORT SHORT

1104 Sugar grader #1 #2

-Capacity - each t/h 20.00 20.00
- -Total capacity avaialble t/h 40.00
-Actual sugar quantity t/h 55.12
-Capacity required t/h 47.25
(equivalent for 3 new m/cs)
-Required 2.3625
Available capacity OK OK
SHORT ---

1106 Sugar Bin

Recovery - Maximum % cane 14.00

Total sugar produced t/h 47.6 Qtls Bags
t/day 1143 11430 22860.00 1905
Grades M-30 S-30
Distribution % 20.00% 80.00%
Quantity of sugar t/day 228.60 914.4 1028700
WSSF EQUIPMENT CAPACITY Page 18 / 29

Bins capacity - No. 1 t 80 200

- No. 2 t 120
- No. 3 t -
Total t 80 320
Retention time Available hours 8.40 8.40
Retention time preferable hours 16 16

Available capacity OK --- --- No addition

SHORT SHORT SHORT
Short by t/day 148.60 594.40
Bin capacity required @ 16 hrs ret. Time t 99.07 396.27
Add 1 No addition
WSSF EQUIPMENT CAPACITY Page 19 / 29

1200 Condensing Station

1205 Injection Pump

a) Water for condensation:
Vapour from evaporator t/h 15.00 #REF!
Vapour from pans t/h 80.00 85.00
Total t/h 95.00 #REF!
% cane 27.94 Theoritical requirement
Vapour load - Maximum @ 35 % on cane % cane 30 27.94
t/h 102 95.00 5700
Temperature difference of hot & cold water Deg C 8.00 10.00
Water required for condensation kg/kg of vap 71.50 57.20
Total water required for condensation t/h 7293.00 5434.00

Condenser sizes
Total water consumption cu.m/h 7293.00 pans Cap Retn time
Pump capacity, total cu.m/h 1600.00 T hrs
No. of pumps required Nos. 4.56 Evaporator
Rounded to Nos. 5 A 80
Spare Nos. 1 B2 80
Total No. of pumps required Nos. 6 B/CGrain 60
No. of pumps available Nos. 0 b1 35 3.50
c 25 5.00
Available capacity OK ---
SHORT SHORT

1206 Cooling Tower

Water used for condensation cu.m/h 7293.00

Vapour condensed cu.m/h 102.00
Total water to be cooled cu.m/h 7395.00

Capacity of each cell cu.m/h 3500.00

No. of cells required Nos. 2.11
Rounded to Nos. 2
No. of cells available Nos. 3

Available capacity OK OK
SHORT ---

Nos Cap
1207 Condensers T/hr
- Condenser for evaporator 2 25
- Condenser for A pans 3 20
- Condenser for B pans 1 25
- Condenser for C pans 1 20
- Condenser for Grain pan 1 15
Total 8
J. P. Mukherji & Associates Pvt. Ltd.
MATERIAL BALANCE
Annexure - III B
(PROPOSED)
Dalmia Bharat Sugar Page - 20/29
340 TCH
Unit - Datta Sakhar Karkhana
SUMMARY

Crushing rate -tch 340.00 22.00 hrs

-TCD 7480.00

Material % Cane t/h m3/h Pol % Fibre % Moist. %

1 Cane 100.00 340.00 16.00 13.50

2 Bagasse 27.88 94.80 2.06 48.42 49.00
3 Imbibition (Inclusive of Centrate-II ) 32.40 110.16 110.16 240.00
Centrate II to imbibition 9.51 32.33 on Fibre %
% Cane t/h m3/h Pol % Brix % Purity
4 Primary Juice 19.75 22.18 89.03
5 Mixed Juice 104.10 353.94 333.90 14.82 16.93 87.53
6 Quick Lime 0.14 0.49
7 Milk of Lime 2.69 9.13 8.74
8 Sulphur 0.05 0.17
9 Sulphur Dioxide 0.10 0.34
10 Air for Sulphur Burning 1667.82
11 Filter Cake 2.60 8.84 1.79
12 Filter Wash Water 5.20 17.68 17.68
13 Centrate I to juice reaction tank 9.51 32.33 31.69
14 Raw Juice 104.10 353.94 340.32
15 Sulphured Juice 115.80 393.73 378.58
16 Clear Juice to Evaporators 109.43 372.07 354.35 14.06 16.06 87.53
17 Syrup 26.96 91.66 69.44 65.19
18 Melt 13.53 45.99 34.84 70.00 96.63

Pan Floor Material: Solids %C Qty t/h Brix % Pol % Purity Qty % cane

19 A Massecuite 32.27 120.58 91.00 83.13 91.35 35.47

20 B1 Massecuite 11.15 39.91 95.00 76.00 80.00 11.74
21 B2 Massecuite 4.28 15.01 97.00 64.99 67.00 4.42
21 C Massecuite 5.78 19.65 100.00 55.50 55.50 5.78

Total Massecuite % Cane 57.40

22 A Heavy Molasses 12.47 53.01 80.00 64.00 80.00 15.59

23 A Light Molasses 4.09 18.54 75.00 70.01 93.35 5.45
24 B1 Molasses 5.30 21.96 82.00 50.18 61.20 6.46
26 B2 Molasses 2.52 9.97 86.00 40.21 46.75 2.93
25 C Light Molasses 0.92 3.92 80.00 52.00 65.00 1.15
26 Final Molasses 3.26 12.60 88.00 29.48 33.50 3.71

27 B1 Magma 5.86 22.12 90.00 87.30 97.00 6.51

30 B2 Magma 1.76 6.65 90.00 86.40 96.00 1.96
28 CA Magma 1.59 6.02 90.00 85.50 95.00 1.77
29 CF magma 2.52 9.51 90.00 75.60 84.00 2.80

30 SUGAR BALANCE: % Cane 34 EXTRACTION: % Cane

Sugar in Cane 16.00 Mill Extraction 96.41
Sugar in Mixed Juice 15.43 Reduced Mill Extraction 96.68
Sugar in Bagasse 0.57 Boiling house recovery % Cane 92.12
Sugar in Filter Cake 0.05 Reduced boiling house recovery 90.41
Sugar in Final Molasses 1.09 Overall Extraction 88.81
Sugar in Sugar 14.19 Reduced Overall Extraction 87.41
Sugar Undetermined 0.10
Total Losses(Bag., F.Cake, Mol., Undeterm 1.81

Sugar Recovery % Cane 14.21

J. P. MUKHERJI & ASSOCIATES Pvt. Ltd.,
JUICE HEATER BALANCE Annexure - IV B
Dalmia Bharat Sugar (PROPOSED) Page - 21/29
Unit - Datta Sakhar Karkhana 340 TCH

DESCRIPTION Heater No. ---> #1 #2 #3 #4 #3 #4

New New New New New New
Heating Surface Area (HSA) m2 520 520 520 520 580 580

Type of heater Tubular Tubular Tubular Tubular Tubular Tubular

Provision of heating for the juice RJ-1 RJ-1 RJ-2 RJ-3 SJ - 1 SJ - 1
VLJH VLJH Dnyamic Dnyamic Conventional Conventional
Working / Standby Working Standby Working Standby Working Standby

Crushing Rate tch 340 340 340 340 340 340

Total Juice Flow % Cane 104.10 104.10 104.10 104.10 115.80 115.80
Juice Flow per heater % total flow 100% 100% 100% 100% 100% 100%
Juice Flow per heater - t/h 353.94 353.94 353.94 353.94 393.73 393.73
Juice Flow per heater - m3/h 337.08 337.08 337.08 337.08 374.98 374.98

Calculated HSA m2 520 520 520 520 580 580

No. of tubes per pass (Original) 38 38 38 38 42 42
Number of passes 20 20 20 20 20 20
Total No. of tubes 760 760 760 760 840 840
Tube material SS SS SS SS SS SS
Tube OD mm 45.00 45.00 45.00 45.00 45.00 45.00
Tube Thickness mm 1.20 1.20 1.20 1.20 1.20 1.20
Tube ID mm 42.60 42.60 42.60 42.60 42.60 42.60
Tube Length mm 5000 5000 5000 5000 5000 5000

Bleeding Effect 8 8 4 4 3 3
Heating medium temp. oC 60.00 60.00 85.04 85.04 99.23 99.23
Dynamic / Conventional (1 / 0) 1 1 1 1 0 0
Juice Inlet Temperature oC 30.00 30.00 58.05 58.05 68.00 68.00
Juice Outlet Temp. (attainable) oC 50.39 50.39 79.66 79.66 87.13 87.13

Juice Velocity (Original) m/s 1.73 1.73 1.73 1.73 1.74 1.74

Pressure Drop m 17.99 17.99 17.99 17.99 18.22 18.22

J. P. MUKHERJI & ASSOCIATES Pvt. Ltd., EVAPORATOR BALANCE
(PROPOSED) Annexure - V B
Dalmia Bharat Sugar 340 TCH Page - 22/29
Unit
1.0 - Datta
BasicSakhar Karkhana
Parameters
Factory crushing rate tch 340 22 hrs
Imbibition % fiber 240
t/h % cane
Raw juice 353.94 104.10
Treated juice 400.97 117.93
Clear juice 400.04 117.66
Clear juice brix 14.94
Syrup brix required brix 66.50
Condensate flash YES

2.0 Pan floor Steam Requirement at Average Demand t/h % cane

- A Batch Pans 47.35 13.93 From Effect - 3
- B1 Pans 12.96 3.81 From Effect - 3
- B2 Pans 5.27 1.55 From Effect - 3
- C Pans 7.51 2.21 From Effect - 3
- Total 73.08 21.49
Exhaust for varible pan stm. demand 0.00 0.00 From Exhaust
- Pan Washing 3.40 1.00 From Effect - 1
- Molasses Conditioning 1.07 0.31 From Effect - 3
- Sugar Melting (B + C Sugar) 0.86 0.25 From Effect - 3
- SHHW System 0.15 0.04 From Exhaust
- Sugar Drying 0.71 0.21 From Exhaust

Total Pan Demand 79.27 23.32

3.0 Juice Heaters Bleeding Effect Heating ( 0C) Bleeding Quantity

From To t/h % cane
Raw Juice Heating Stage - 1 Condensate Tubular 30.00 45.00 0.00 0.00
Raw Juice Heating Stage - 2 Condensate PHE 45.00 58.05 0.00 0.00
Raw Juice Heating Stage - 3 Effect - 4 DCH 58.05 72.00 7.24 2.13

Limed Juice Heating Stage - 1 Effect - 3 DCH 68.00 85.00 9.92 2.92
Limed Juice Heating Stage - 2 Effect - 3 DCH 85.00 95.00 5.98 1.76
Limed Juice Heating Stage - 3 Effect - 2 DCH 95.00 103.00 4.83 1.42

Clear Juice Heating Stage - 1 Effect - 2 PHE 95.00 104.17 6.40 1.88
Clear Juice Heating Stage - 2 Effect - 1 PHE 104.17 113.12 6.30 1.85

Filtrate Heating Effect - 2 DCH 55.00 55.00 0.00 0.00

Syrup Heating Effect - 3 DCH 64.05 85.00 1.80 0.53

Total 42.47 12.49

4.0 Evaporation
Total evaporation % Cane 91.23
t/h 310.18

Exhaust Quint - 1 Quint - 2 Quint - 3 Quint - 4 Quint - 5

Pressure Bara 2.30 1.84 1.40 0.98 0.58 0.20
Temperature 0
C 124.67 117.68 109.17 99.23 85.04 60.27

Evaporation from each body t/h 113.48 100.56 90.94 2.03 3.18
% Cane 33.38 29.58 26.75 0.60 0.93
Condensate from each body t/h 112.18 99.48 90.08 2.02 3.17
Juice heater condensate available for flash t/h 0.00 6.30 6.40 0.00 7.24
Pan condensate available for flash t/h 0.00 0.00 0.00 73.08 0.00
Condensate for flashing t/h 0.00 105.78 200.66 271.94 273.96
Condensate temperature in Cigar 0
C 122.05 109.17 99.23 85.04 84.94

Juice flow from each body t/h 400.04 286.56 186.00 95.06 93.03 89.86
Outlet brix 0
Brix 14.94 20.85 32.13 62.86 64.23 66.50
Average brix 0
Brix 17.89 26.49 47.49 63.54 65.36

Quantity of heat loss due to radiation t/h 0.00 0.00 0.00 0.00 0.00
Qty of Heat loss due to non condensibles t/h 0.00 0.00 0.00 0.00 0.00
Quantity of Juice flash vapours t/h -3.22 0.00 0.00 0.00 0.00
Quantity of Condensate flash vapours t/h 0.00 1.61 3.81 8.39 8.45
Quantity of Flash vapours for evaporation t/h -3.22 1.61 3.81 8.39 8.45

Heating Surface (Working Set) m2 5600 5600 5600 650 650

Specific evaporation rate Kg/ m2/ h 20.26 17.96 16.24 3.12 4.89
lb/ ft2/ h 4.15 3.68 3.33 0.64 1.00

Specific Evaporation Rate (Targeted) Kg/ m2/ h 25.00 18.00 15.00 10.00 10.00
J. P. MUKHERJI & ASSOCIATES Pvt. Ltd., EVAPORATOR BALANCE
(PROPOSED) Annexure - V B
Dalmia Bharat Sugar 340 TCH Page - 23/29
Unit - Datta Sakhar
Required Karkhana
Heating Surface (As Targeted) m2 4540 5590 6070 210 320

Dessin coefficient Kg/ m2/ h 0C 3.70 2.74 1.54 0.78 0.43

Overall H.T.Coefficient W/ m2 0K 2104 1532 826 266 211
BTU/ ft2 0F 370.54 269.87 145.44 46.90 37.19

Apparent temperature drop 0

C 5.48 6.55 10.54 4.00 11.40
True temperature drop 0
C 5.91 7.27 12.35 7.48 15.17

Vapour temperature 0
C 118.76 111.49 99.14 91.66 76.49
Pressure in each body bara 1.95 1.54 1.00 0.76 0.42
Pressure in body Bar (g) 0.91 0.50
Vacuum in body Inches of Hg 6.93 16.86
Flap valve to reduce the pressure ∆t 0.00 0.00 0.00 0.00 0.00

Total temperature drop calculated 0

C 48.18
Total temperature drop available 0
C 64.40

5.0 Exhaust Steam consumption t/h % cane t/h % cane

Exhaust steam to Effect - 1 113.48 33.38 JH 42.47 12.49

Exhaust steam for Raw Juice Heater 0.00 0.00 Pans 79.27 23.32
Exhaust steam for Sulphured Juice Heater 0.00 0.00 Evap 3.18 0.934
Exhaust steam for Clear Juice Heaters 0.00 0.00 Flash -10.59 (3.115)
Exhaust steam for SHHW System 0.15 0.04
Exhaust steam for Sugar drying 0.71 0.21
Process Exhaust Steam Demand 114.34 33.63 114.33 33.63 0.006661
Exhaust for evaporator soda boiling 2.00% 2.38 0.70 2.38 0.70
Losses & other uses @ ….on total demand 2.00% 2.38 0.70 2.38 0.70
Total Exhaust Steam Demand 119.11 35.03 119.10 35.03 0.006661
J1.0
P MUKHERJI & ASSOCIATES PVT LTD
Basic Parameters EVAPORATOR BALANCE Annexure-V-B
(PROPOSED) Page-24/29
Factory crushing rate tch 340
Dalmia Bharat Sugar 340 TCH
Imbibition
Unit- Datta Sakhar Karkhana % fiber 240
t/h % cane
Raw juice 353.94 104.10
Sulphured juice 400.88 117.91
Clear juice 393.90 115.85
Clear juice brix 14.77
Syrup brix required brix 66.50
Condensate flash YES

2.0 Pan floor Steam Requirement at Average Demand t/h % cane

- A Pans 47.35 13.93 From Effect - 3
- B1 Pans 12.96 3.81 From LTEM - 3
- B2 Pans 5.27 1.55 From LTEM - 3
- C Pans 7.51 2.21 From Effect - 3
- Total 73.08 21.49
Exhaust for variable pan stm. demand 0.00 0.00 From Exhaust
- Molasses Conditioning 1.07 0.31 From Effect - 3
- Pan Washing 3.40 1.00 From Effect - 1
- Superheated Wash Water System 0.15 0.05 From Exhaust
- Sugar Drying 0.71 0.21 From Exhaust

Total Pan Demand 78.41 23.06

3.0 Exhaust Steam

- Pressure Bara 2.40
- Temperature 0
C 126.01

3.0 Juice Heaters Bleeding Effect Heating (Deg C) Bleeding Quantity

From To t/h % cane
Raw juice stage - 1 Effect - 5 Tubular 32.00 45.27 7.75 2.28
Raw juice stage - 2 Condensate PHE 45.27 58.21 0.00 0.00
Raw juice stage - 3 Effect - 4 DCH 58.21 72.00 7.16 2.11
Raw juice stage - 4 72.00 72.00 0.00 0.00

Suphured juice stage - 1 Effect - 3 Tubular 68.00 77.00 6.22 1.83

Suphured juice stage - 2 Effect - 3 DCH 77.00 91.00 8.16 2.40
Suphured juice stage - 3 Effect - 2 DCH 91.00 102.00 6.51 1.91
Suphured juice stage - 4 102.00 102.00 0.00 0.00

Clear juice stage - 1 Effect - 2 DCH 96.00 105.31 5.30 1.56

Clear juice stage - 2 Effect - 1 DCH 105.31 114.52 5.30 1.56
Clear juice stage - 3 Exhaust PHE 114.52 114.52 0.00 0.00

Filtrate Effect - 3 65.00 65.00 0.00 0.00

Syrup Heating Effect - 3 Tubular 64.24 85.00 1.79 0.53
Melt Heating Effect - 3 DCH 55.00 75.00 0.86 0.25

Total 49.05 14.43

4.0 Evaporation
Total evaporation % Cane 92.54
t/h 314.64

Exhaust Quint - 1 Evapplus-1 Evapplus-2 Quint - 2 Quint - 3 Quint - 4 Quint - 5

Pressure Bara 2.40 1.91 1.53 1.22 1.45 1.01 0.60 0.20
Temperature 0
C 126.01 119.01 111.92 105.43 110.31 100.25 85.80 60.27

Evaporation from each body t/h 113.29 17.54 17.81 83.40 73.08 3.93 5.59
% Cane 33.32 5.16 5.24 24.53 21.49 1.16 1.65

Condensate from each body t/h 111.99 17.33 17.61 82.51 72.40 3.90 5.61
Juice heater condensate available for flash t/h 0.00 0.00 0.00 0.00 0.00 6.22 7.16
Pan condensate available for flash t/h 0.00 0.00 0.00 0.00 0.00 86.04 0.00
Condensate for flashing t/h 0.00 17.33 17.33 99.84 187.66 280.02 283.96
Condensate Temperature in Flash Tank 0
C 123.42 116.40 109.57 110.31 100.25 85.80 85.63

Juice flow from each body t/h 404.50 291.21 273.67 255.86 172.46 99.38 95.45 89.86
Outlet brix 0
Brix 14.77 20.52 21.83 23.35 34.65 60.13 62.60 66.50
Average brix 0
Brix 17.65 21.18 22.59 29.00 47.39 61.36 64.55

Quantity of heat loss due to radiation t/h 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Qty of Heat loss due to non condensibles t/h 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Quantity of Juice flash vapours t/h -3.66 0.00 0.00 0.00 0.00 0.00 0.00
Quantity of Condensate flash vapours t/h 0.00 0.27 0.41 1.49 3.81 8.82 8.48
Quantity of flash vapours t/h -3.66 0.27 0.41 1.49 3.81 8.82 8.48

Heating surface m2 4800 700 700 5200 5600 1200 1200

Specfic evaporation rate kg/h. m2/h 23.60 25.05 25.44 16.04 13.05 3.28 4.66
lb/h. ft2/h 4.83 5.13 5.21 3.28 2.67 0.67 0.95

kg/h. m2/h 25.00 15.00 15.00 18.00 15.00 10.00 10.00

m2 4530 1170 1190 4630 4870 390 560

Dessin coefficient kg/h. m2. 0C 3.79 3.25 2.75 2.93 2.61 1.64 1.06
Overall H.T.Coefficient Btu/h.ft2. 0F 377.59 330.3 283.0 267.84 179.73 68.77 64.21
W/m2. K 2144.04 1875.66 1607.20 1520.87 1020.53 390.47 364.62
DRAFT
J P MUKHERJI & ASSOCIATES PVT LTD EVAPORATOR BALANCE Annexure-V-B
(PROPOSED) Page-25/29
Dalmia Bharat Sugar 340 TCH
Unit- Datta Sakhar Karkhana

Apparent temp. drop 0

C 6.23 7.70 9.25 5.47 5.01 2.00 4.41
True temp. drop 0
C 6.74 8.26 9.86 6.53 8.02 5.35 8.38

Vapour temperature 0
C 119.27 111.01 101.15 112.74 104.71 99.37 90.99
Pressure in each body bara 1.98 1.51 1.08 1.60 1.22 1.01 0.74
Pressure in body Bar (g) 0.95 0.48 0.04 0.57 0.19
Vacuum Inches Hg 7.48

Flap valve to reduce the pressure ∆t 0

C 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Total temperature drop calculated 0

C 35.02
Total temperature drop available 0
C 65.74

5.0 Exhaust Steam consumption t/h % cane t/h % cane

Exhaust steam to Effect - 1 113.29 33.32 JH 49.05 14.43

Exhaust steam for raw juice heater 0.00 0.00 Pans 78.41 23.06
Exhaust steam for sulphured juice heater 0.00 0.00 Evap -2.16 (0.635)
Exhaust steam for clear juice heaters 0.00 0.00 Flash -11.15 (3.281)
Exhaust steam for variable pan steam demand 0.00 0.00
Exhaust steam for SHHW System 0.15 0.05
Exhaust steam for Sugar Drying 0.71 0.21
Process Exhaust steam demand 114.15 33.57 114.15 33.57 0.0012 0.0003
Exhaust steam for Soda Boiling (Evap. Cleaning) 2.00% 2.43 0.71 2.43 0.71
Losses on total demand 4.00% 4.86 1.43 4.86 1.43
Total exhaust steam demand 121.44 35.72 121.44 35.72 0.0012 0.0003

6.0 Total Process Steam Demand t/hr % cane

Total Exhaust steam required 121.44 35.72
Live steam for process 0.00% 0.00 0.00
Total Process steam demand 121.44 35.72

DRAFT
J. P. MUKHERJI & ASSOCIATS Pvt. Ltd.,
Annexure - VIII A
Dalmia Bharat Sugar CONDENSATE BALANCE Page - 26/29
Unit - Datta Sakhar Karkhana 340 TCH

Sr. No Description Condensate Condensate

Grade - I Grade - II
t/hr t/hr

1.00 Condensate Availability

1.01 Raw Juice heaters heating 0.00

1.02 Sulphured Juice heaters 1st stage 0.00
1.03 Sulphured Juice heaters 2nd stage 0.00
1.04 Sulphured Juice heaters 3rd stage 0.00
1.05 Clear Juice heaters 1st stage 6.40
1.06 Clear Juice heaters 2nd stage 6.30
1.07 Clear Juice heaters 3rd stage 0.00
1.08 Quint. 1st effect 112.18 0.00
1.09 Quint. 2nd effect 99.48
1.10 Quint. 3rd effect 90.08
1.11 Quint. 4th effect 2.02
1.12 Quint. 5th effect 3.17
1.13 Pans 73.08
Total condensate flashed at evaporator station -19.04

From Co-gen :
1.13 DEC turbine Condensate 15.00
1.14 Dearator condensation 7.00
1.15 Make up from feed water reheater 10.00
1.16 Make up from Ejector 0.50
Sub Total 144.68 261.49
Loss 2 % on total 2.89 5.23
Total condensate availability 141.78 256.26

Total (Grade I+ Grade II) condensate % Cane 117.07%

2.00 Condensate Consumed

2.01 Grade - I condensate required for steam Generation 145.00

Grade - II condensate utilised for Sugar Plant

2.02 Imbibition 77.83
2.03 MOL preparation 8.64
2.04 Filter cake wash water 17.68
2.05 Molasses conditioning water 4.56
2.06 Pan Movement water 12.33
2.07 Centrifugals 6.80
2.08 Melting of B+C sugar 9.41
2.09 Floor washings @ 2 % on cane 6.80

Sub Total 145.00 144.06

3.00 Net Condensate Availability

3.01 Condensate Available 141.78 256.26

3.02 Condensate consumed 145.00 144.06
3.03 Deficit / Surplus -3.22 112.20

Net Surplus (Grade I+ Grade II) condensate 108.98

Net Surplus condensate % Cane 32.05
4.00 D M water requirement 3.22
Note:- Figures from Co-gen to be confirmed by SDSK
J. P. MUKHERJI & ASSOCIATS Pvt. Ltd.,
Annexure - VIII A
Dalmia Bharat Sugar CONDENSATE BALANCE Page - 27/29
Unit - Datta Sakhar Karkhana 340 TCH

Note:- Figures from Co-gen to be confirmed by SDSK

 340.00

HSA E. R Extra Sp. Volum Q

m2 Kg/ m2/ h m3/kg m3/s
25.00 Exhaust Header 2800 35.00 0% 0.78 21.16
2800 35.00 0% 0.78 21.16

30.00 1st Effect 2400 35.00 0% 0.96 22.38

2400 35.00 0% 0.96 22.38

30.00 2nd Effect 2800 30.00 0% 1.24 28.94

2800 30.00 0% 1.24 28.94

35.00 3rd Effect 2800 25.00 0% 1.73 33.71

2800 25.00 0% 1.73 33.71

40.00 4th Effect 650 20.00 0% 2.83 10.24

55.00 5th Effect 650 20.00 0% 7.66 27.65

Bleeding
RJ3 4th Vapour 7.24 10% 2.83 6.27

SJ1 3rd Vapour 9.92 10% 1.73 5.26

SJ2 3rd Vapour 5.98 10% 1.73 3.17
SJ3 2nd Vapour 4.83 10% 1.24 1.83
SJ3 1st Vapour 4.83 10% 0.96 1.42

CJ1 2nd Vapour 6.40 10% 1.24 2.43

CJ2 1st Vapour 6.30 10% 0.96 1.85

RJ Exhaust 7.24 10% 0.78 1.72

SJ Exhaust 20.73 10% 0.78 4.92
CJ Exhaust 12.70 10% 0.78 3.02

Pans 100.00 70.42 464.79 60.00 10% 1.73 14.77

100.00 70.42 464.79 60.00 10% 1.73 14.77
B1CVP 1100.00 25.00 10% 1.73 14.57

A 28.41
B1CVP 12.96
Molasses Conditioning 1.07
Sugar Melting 0.86
Total 47.63 10% 1.73 25.23
V D Header
m/s m mm
25.00 1.04
1468
25.00 1.04

30.00 0.97
1378
30.00 0.97 For 1400 - 33.35 m/s

35.00 1.03
1451
35.00 1.03 For 1400 - 37.01 m/s

40.00 1.04
1465
40.00 1.04 For 1400 - 46.56 m/s

45.00 0.54 538

55.00 0.80 800

45.00 0.42 587

40.00 0.41 518

40.00 0.32 409
35.00 0.26 344
35.00 0.23 227

35.00 0.30 408

30.00 0.28 482

25.00 0.30
25.00 0.50 0.701
25.00 0.39

40.00 0.69 970

40.00 0.69 966 1529
40.00 0.68 681

700.00 495

40.00 0.90 896