Transcript total sugar production (india )

by
GENESIS MEMBRANE SEPRATECH
Mumbai, India.
PVT. LTD.
Tel.: 91-22-5775456; Fax: 91-22-5790608; E-mail:[email protected]
PRODUCTION OF SUGAR
(Million Tonnes)
TOTAL SUGAR PRODUCTION (INDIA )
17
Prodcution as of April 2012
is
16
15
14
13
12
11
10
9
8
87
88
89
90
91
92
YEAR
93
94
95
96
97
98
PRODUCTION OF CANE ( INDIA )
PRODUCTION OF CANE
(MILLION TONNES)
286
266
246
226
206
186
88
89
90
91
92
93
YEAR
94
95
96
97
98
NO. OF PLANTS WITH CAPACITY
There are 671 sugar mills in India.
Below 1250
140
NO. OF PLANTS IN INDIA
Of 1250
120
1251-2000
2001-2500
100
2501-3500
Above 3500
80
60
40
20
0
CAPACITY
In 1950, there were 139 sugar factories in the
country with an annual installed capacity of 1.67
million tonnes.
Today, India has about 671 sugar factories with
an annual sugar production of 24.1 million
tonnes.
India has 20% of the total sugar mills in the
world and accounts for about 15% of the global
production.
Introduction

India is the second largest producer of sugar
from cane after Brazil.

Production capacity is 24 million tons / year.

The total sale value in 1999 is 5 billion US$.

Total capital employed around 4 billion US$.

Better quality cane with higher sucrose content has
been the biggest contributor to this industry.

However manufacturing techniques have not changed
much.

The average recovery varies from as low as 7% to as
high as 13% whereas sucrose content in the cane can
be 18%.

Efforts are directed towards better manufacturing
technique to achieve higher yield.
BLOCK DIAGRAM FOR CANE SUGAR PRODUCTION
CANE
CaO
CRUSHING
STEAM
LIMING
HEATING
THIN JUICE
RAW JUICE
CRYSTALLIZATION
MOLASSES
EVAPORATION
THICK JUICE
RAW SUGAR
SUGAR MANUFACTURE
(CANE MILLLING)
Sugar Cane
Cane Carrier
Cane leveller or kicker to feed the cane
cutting knives uniformly
Cane cutter-Ist cutting the cane to pieces
Mincer - IInd stage of cutting to finer pieces
Milling Tandem
Comprising of Six mills
SCHEMATIC ARRANGEMENT FOR
JUICE CLARIFICATION
Raw Juice pH 5.0
Heated to 650C on Juice Heaters
Simultaneous Liming and Sulphitation and the final
pH is kept around 7.0/7.2
Heated to 102 0 C on Juice Heaters.
CLARIFIER
Subsequently juice is allowed to settle for 2.5 hours. The CLEAR
supernatant juice is separated for further processing. The non-sugars
precipitated as calcium sulfite complex compounds are further treated
on Rotatory Vacuum Filters (RVF) for futher extraction of residual juice.
SUGAR MANUFACTURE (CONTD.)
Prepared cane is subjected to twelve compressions which helps to squeeze
the juice with application of high pressure. At final stage water is added and
then squeezed so that no sugar is left when the material leaves the Mills.
The product after milling or extraction of juice is known as bagasse.
Juice delivered to the Boiling House
for Clarification and Sugar Boiling
Bagasse Bye Product
(Fibre + Water + Little salts)
Used as fuel in Boilers
5% sold to paper industries
CLARIFIER
Muddy Juice
Clear Juice (15o Brix)
Rotatory Vacuum Filter
Filter cake or Press
Mud (Bye product.
Sold to farmers to
be used as manure
for the cane fields)
Filter Juice
(Back to the Juice
tank to be mixed
with raw juice and
re-processed)
Vapour Cell
(For part Evaporation)
Quadruple Effect Evap.
(Evaporation of water
up to 75%)
Concentrated material
(called “SYRUP”of 60 Brix)
Sulfitation
Sulfited syrup pH 5.0
BOILING PROCESS IN VACUUM PANS
I Stage:
Syrup + B-seed + Melt from C-double cured Sugar
A-massecuite
Batch Centrifugal
A-Light & A-Heavy Molasses
Finished Product Sugar
Hopper-Drying & Cooling
Grader
Powder
Graded Sugar
Weighing
Stitching
Sugar Godown
II Stage:
A - Light & A - Heavy Molasses
B-Massecuite
Continuous Centrifugal Machines
B - Seed.
Magmised and used as
seed for A-massecuite.
B - Heavy Molasses.
III Stage:
B - Heavy Molasses + C - Light Molasses
C - Massecuite
Continuous Centrifugal Machines
Magmised
Second Curing
Continuous Centrifugal Machines
Final Molasses to storage tanks
(A bye-product sold to distilleries
producing rectified spirit,
alcohol, etc. )
C - Double Cured sugar
C- Light Molasses (Rich in sugar and therefore
(Melted to give clear melt.
sent back to the process for
This is pumped to the pan
C-Massecuite boiling)
floor and boiled with
syrup to produce
A - massecuite)
CORELATION OF PERMEATE FLUX WITH
CONCENTRATION ON SPRIAL MEMBRANE
Permeate flux in LMH
30
25
Repeat the four-step process under
20 Point #1.

15
10
At 35 o C
At 40 o C
At 45 o C
At 50 o C
At 55 o C
At 60 o C
5
0
5
10
15
20
25
Concentration in Brix
30
35
Permeate Flux (lmh)
CORELATION OF PERMEATE FLUX WITH
TEMPERATUE ON SPIRAL MEMBRANE
30
25
30.6 Brix
25.1 Brix
19.0 Brix
13.6 Brix
09.8 Brix
20
15
10
5
0
30
50
Temperature (o C)
70
CORELATION OF PERMEATE FLUX WITH
Permeate Flux (lmh)
CONCENTRATION ON TUBULAR MEMBRANE
80
70
60
50
40
30
20
10
0
At 35 o
At 40 o
At 45 o
At 50 o
10
16
21
22
Concentration (brix)
24
C
C
C
C
CORELATION OF PERMEATE FLUX WITH
TEMPERATURE ON TUBULAR MEMBRANE
Permeate Flux (lmh)
80
70
60
50
40
21 Brix
16 Brix
10 Brix
30
20
10
0
30
50
Temperature (o C)
70
Loss of Sucrose (%)
CORELATION OF % LOSS OF SUCROSE
WITH CONCENTRATION
4
3.5
3
2.5
2
1.5
1
0.5
0
0
10
20
Concentration (Brix)
30
CORELATION ON DEGREE OF DESALTING
DEGREE OF
DEASHIFICATION
WITH CONCENTRATION
70
65
60
55
50
45
40
35
30
10
20
CONCENTRATION (BRIX)
30
Hot Water 550C
2500 l/hr
Chemical
Mixed Juice
10,000 l/h
Brix : 15
Purity : 76-80
Temp : 50-55oC
Desalted Juice
6,000 l/h
Brix : 22 -23
Purity : 89 - 91
Temp : 45-50oC
To Evaporator
Settling
Tank
Clear juice; 7,500 l/h
5,000 l/h
4,500 l/h
Clear Juice
12,000 l/h
Brix : 11.5 – 12.0
Purity : 82 - 84
6,000 l/h
Brix : 1.5
Partly to
Cane
Washing
500 l/h Filter
Residue to
RVF
STAGE - I CLARIFICATION OF MIXED JUICE
STAGE – II DESALTING &
PRECONCENTRATION OF
CALRIFIED MIXED JUICE TO 23 BRIX