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= 13200
= 12100
= 550
= 105
= 15
= 120
= 105
= 14
= 62.0
= 250
= 14
A MASSECUITE % ON CANE = 24
(ONLY M & S GRADE SUGAR PRODUCTION)
B MASSECUITE % ON CANE = 11
C1 MASSECUITE % ON CANE = 3
C MASSECUITE % ON CANE = 6
= 2 Nos.
= 24
= 2 X 10 X 24
= 3744 / 1.1
= 3403 Tons
= 1 Nos.
= 24
= 1 X 6.5 X 24
2. RAW JUICE PIPE LINE :Existing two Nos. parallel battery of 10" dia
Velocity of Juice
= 2 M / Sec
Flow rate
= 0.785 d2 V
= 364.6 M3 / Hr
One battery is suitable for crush / day
= 364.6 X 1.04 X 24 / 1.3
Two battery are suitable for cane crush /day = 7001 X 2
= 7001 Ton.
= 14002 Ton.
/var/www/apps/conversion/tmp/scratch_2/259945708.doc
= 2 M / Sec
= 60 M
= 360 M3 / Hr
= 360 X 2
= 720 M3 / Hr
= 720 X 24 / 1.3
= 13292 Ton
T t0
Ln _________
Tt
H.S.
P
C
T
t0
t
K
K
= weight of juice in Kg . Hr
= Sp heat of juice (0.9)
= temp of heating vapour in OC
= Initial temp of juice in OC
= final temp of juice in OC
= coefficient of heat transfer in KCl / M2 / OC / hr
= 6T [ U / 1.8]0.8
= 750 Kcl / M2 / OC / Hr
t0
H.S.
=
=
= 660000 Kg / Hr
= 56OC
= 30OC
= 44OC
= 1.8
P.C.
T t0
_________ Ln _________
K
Tt
660000 X 0.9
57 - 30
------------------- Ln ------------750
57 44
= 792 Ln 2.07
= 792 X 0.72
= 578 M2
Therefore, capacity of existing VLJH are sufficient.
b) Juice heaters for RJ2 heating :P
C
T
= 660000 Kg / Hr
= 90OC
/var/www/apps/conversion/tmp/scratch_2/259945708.doc
t0
t
U
K
= 550 Kcl / M2 / OC / Hr
H.S.
P.C.
_________
K
= 45OC
= 70OC
= 1.8
T t0
Ln _________
Tt
660000 X 0.9
------------------- Ln
550
90 - 45
------------90 70
= 1080 Ln 2.25
= 1080 X 0.811
= 875 M2
Therefore, 3 nos juice heaters of 350 m2 heating surface each are sufficient.
c) Juice heater for S J1 Heating :-
P
C
T
t0
t
U
2 O
= 575 Kcl / M / C / Hr
H.S.
P.C.
_________
K
= 660000 Kg / Hr
= 100OC
= 70OC
= 88OC
= 1.67
T t0
Ln _________
Tt
660000 X 0.9
------------------- Ln
575
100- 70
------------100 - 88
= 1033 Ln 2.5
= 1033 X 0.92
= 950 M2
Therefore, 3 Nos. JH of 350M2 HS each are sufficient.
d) Juice heater for S J2 Heating :P
C
T
t0
t
U
= 660000 Kg / Hr
= 110OC
= 88OC
= 102OC
= 1.67
/var/www/apps/conversion/tmp/scratch_2/259945708.doc
K
K
H.S.
= 6T [ U / 1.8]0.8
= 6 X 110 [1.67 / 1.8]0.8
= 660 X 0.94
= 620 Kcl / M2 / OC / Hr
=
P.C.
_________
K
T t0
Ln _________
Tt
660000 X 0.9
=
------------------- Ln
620
= 958 Ln 2.75
= 958 X 1.01
= 967 M2
110- 88
------------110 - 102
No 1
= 435 HL
= 4.2 Meter
= 2.75 Meter
= 1.04
No 2
400 HL
4.2 Meter
2.50 Meter
= 3.75 Minutes
3.50 Minutes
Therefore, at 13200 TCD taking working height 2.5 meter and retention time 7 minutes. Capacity
of both juice sulphiter are sufficient.
= 200 Kg / Hr
= 5 Nos.
= 0.08 % on cane
= 200 X 3
= 600 Kg / Hr
= 390 Kg / Hr
= 750 Ton / Hr (juice)
= 13850
= 464 Ton / Hr
= 13200
= 5000 M2 / Hr
= 4000 M2 / Hr
= 1 Kg / Hr Sulphur
= 500 Kg / Hr
/var/www/apps/conversion/tmp/scratch_2/259945708.doc
OR
Suitable for cane crush/ day @ 0.08 % on cane
sulphur consumption
= 12 Ton / Day
= 15000
= 10"
= 25 M / Sec.
= 15000
Old Mill
No of plates
Area of 4 plates
=3
= PL 1250 A
= 3000 M3 / Hr
= 590 600
= 150
= 13500
/var/www/apps/conversion/tmp/scratch_2/259945708.doc
= 3 Nos.
= 180 M3 / hr
= 2 Nos.
= 36'
= 20'
= 5900
= 2. Hrs
= 13200
= 250 HL.
- 1 No
= 2 Meter
= 15 Minutes
= 13500
S. K.
2050
1850
1400
V. C.
1950
1800
1390
1st body
1200
1390
790
2nd body
1400
790
510
3rd body
750
790
510
4th body
700
790
510
VL / Dy. J.H.
300
290
300
16.
PAN STATION:-
a) A PANS
A massecuite % on cane
A massecuite produce / day
No. of A pans
Total capacity of A pans
= 24
= 13200 X 0.24
= 3168 Tons / day
= 4 nos. 120 Tons + 1 No. 60 ton
= 120 x 4 + 1 x 60
= 540 Ton
= 4 hours
= 24/4
=6
/var/www/apps/conversion/tmp/scratch_2/259945708.doc
= 3168 / 6
= 528 Tons
=11
= 550 X 0 .11
= 60.50 Ton / Hr
= 60 Ton/hr
= 60 X 0.25
= 15.0 Ton / Hr
= 15 X 4
= 60 Tons
= 60 Tons (sufficient)
= 60 Tons
c) C1 PANS
C1 massecuite % cane
C1 massecuite produce / day
No. of C1 pans
Capacity of C1 pans
Taking C1 m/c boiling time
Total no. Of strike / day /pan
Pan capacity required
=3
= 13200 X 0.03
=1
= 120 Ton
= 6 hours
=24/6
= 396 /4
= 396 Tons
=4
= 99 Tons
=6
= 13200 X 0.06
= 3 Nos.60 Tons
= 1 No. 80 Ton
= (3 X 60 ) + 80
= 7 hours
= 24/7
= 792 /3.5
= 792 Tons
= 260 Ton
= 3.5
= 226Tons
17.
A PANS
Assuming evaporation rate
Water required
H.S. of 120 ton pan
H.S. of 60 ton pan
= 40 kg/mt2/hr
= 45 kg/kg of vapour
= 565 mt2
= 238 mt2
/var/www/apps/conversion/tmp/scratch_2/259945708.doc
Water requirement
Total water requirement for A pans
B PANS
Assuming evaporation rate
Water required
H.S. of 56 Tons / Hr CV P
Water requirement = (1038X 25 X 45)/1000
Total no. of batch pan
=1
2
HS = 280 mt , ER
Water requirement = (280 X 30 X 45) / 1000
= 25 kg/mt2/hr
= 45 kg/kg of vapour
= 1038 mt2
= 1168 m3/hr
=1168+ 378
= 30 kg/mt2/hr
= 378 m3/hr
= 1546 m3 / hr
C1 PANS
Assuming evaporation rate
Water required
H.S. of pan
Water requirement
Total water requirement for C m/c pans
= 25 kg/mt2/hr
= 45 kg/kg of vapour
= 565 mt2
= (565 X 25 X 45)/1000
= 635 m3/hr
= 635 m3/hr
C PANS
Assuming evaporation rate
Water required
H.S. of 1 No 80 Tons pan
H.S. of 4 No 60 Ton pans
Total heating surface
Water requirement
Total water requirement for C m/c pans
= 25 kg/mt2/hr
= 45 kg/kg of vapour
= 418 m2
= 3 X 238 = 714 m2
= (714 + 418) X 25 X 45 /1000
= 1274 m3/hr
= 1274m3/hr
= 2000 m3 / hr
Hence, existing injection pumps capacity is sufficient to take crush upto 13200 TCD.
COOLING TOWER
No. of cells
Capacity of each cell
=5
= 2000 m3/hr
/var/www/apps/conversion/tmp/scratch_2/259945708.doc
18.CRYSTALLIZERS :A CRYSTALLIZER
A massecuite % cane
A M /C produced
A M/ C produced per hour
Total no. of A crystallizer
Capacity of each crystallizer
Total capacity of A crystallizers
Taking retention time of A M/C in crystallizer
Massecuite handled per hour
= 24
= 3168 Tons / day
= 3168 / 24
=7
= 65 Ton
= 455 Ton
= 3 Hour
= 455 / 3
=132 Ton
At the rate of 24 % A- M/C % cane this crystallizer capacity is sufficient for = 13500 TCD
B MASSECUITE VERTICAL COOLING CRYSTALLIZER (TWIN)
Capacity
Temperature of massecuite going in B vertical crystallizer
Out let massecuite temperature
Rate of cooling / hour
Total time required for cooling
Crystallizer capacity is sufficient to take crush upto 16000 TCD, hence sufficient
C VERTICAL CRYSTALLIZER
C vertical crystallizer capacity
6 nos. horizontal C crystallizer capacity
Total capacity of C crystallizer for cooling
Total retention time required for cooling in C crystallizers
Massecuite handled / hour
Hence, @ 6% C m/c % cane C vertical crystallizer
=350 ton
=360 ton
=710 ton
=22 hours
=710 /22
= (32.30 x 24 x 100)/6
= 32.30 Ton/hr
=12920 TCD
Therefore, capacity of horizontal and vertical crystallisers for C massecuite cooling are sufficient.
/var/www/apps/conversion/tmp/scratch_2/259945708.doc
19.
CENTRIFUGALS
ACENTRIFUGALS
Total massecuite produce
No of Buckau Wolf machine 1 T / Charge machine
No of NHEC 1.25 T / Charge machines
Buakau Wolf Machine, No. of cycle / machine / hr
(After change in Dc drive)
NHEC machine, No. Of cycle / machine / hr
Total massecuite cured
= 12 ton/hr/machine
= 48 ton/hr
= 8 ton / hr / machine
=24 ton / hr
= 48 + 24 = 72 ton / hr
= (72 X 22 X 100) / 11 = 14400 TCD
C1 CURING
3 nos. NK - 1500, capacity
Total massecuite handled
This is sufficient to take crush
(@ C1 massecuite % cane = 3 )
= 9 ton / hr / machine
= 27 ton / hr
= (27 X 22 X 100) / 3 = 19800 TCD
C CURING
7 no. NK 1500, capacity
Total massecuite handled
This is sufficient to take crush
(@ C massecuite % cane = 6)
Therefore, capacity of C continuous machines are sufficient.
= 6 Ton / hr / machine
= 42 ton / hr
= (42 X 22 X 100) / 6 = 15400 TCD
CAW CURING
DC - 12 machine 1 no, capacity
SC 1350 - KT - 1 no, capacity
NK - 1100 1 no, Capacity
Total magma handled
Total (CFW + C1FW) magma
(C + C1) massecuite
So, these machines are sufficient to take crush
= 8 ton / hr
= 8 tons / hr
= 8 ton / hr
= 24 ton / hr
= 35 % of (C+ C1) massecuite
= 9 % cane
= (24X22 X 100 X100) / (9 X 35)
= 16760 TCD
Therefore, capacity of CAW continuous machines are sufficient.
/var/www/apps/conversion/tmp/scratch_2/259945708.doc
20.
Total capacity
Taking total melt quantity
Retention time in melter
This is sufficient to handle melt
Where (1.25 = specific gravity of melt)
This is sufficient to take crush
21.
= 32 m3
= 16 %
= 25 mins.
= (60 X 32) / 25
= 76.8 X 1.25
= 76.8 M3 / hr
= 96 tons / hr
GRADER
No. of graders
Taking utilization capacity of each grader
Capacity of all graders = (20 X 5) X 0.75
Taking 11.5 recovery
This is sufficient to handle sugar
This is sufficient to take crush = (1650 x100) / 11.5
=1650 ton
22.
= 5 nos.
= 200 bags / hour
= 5 x 200 x 22
=17600 Qtls./day
= 11.50
= (17600 x 100 X 100) / (85 X 11.50)
= 18000 TCD
= 1 nos.
= 200 bags / hour
= 1 x 200 x 22
= 4400 Qtls./day
= 11.50
= (4400 x 100 X 100) / (15 X 11.50)
= 25500 TCD
Therefore, capacity of power Build weighing machines with stitching machines are sufficient at
12500 TCD.
/var/www/apps/conversion/tmp/scratch_2/259945708.doc
R. J. Weighing Scale
R. J. Pipe Line
V. L. J. H. / Dy J.H.
5
6
7
8
9
R. J2. Heating
S. J1 Heating
S. J2 Heating
juice Sulphitor (2 NOS)
Sulphur furnace
10
Air Compressure
11
12
13
14
15
Clarifier
clear juice pumps
Syp. Sulphitor
16
17
Semi Kestner
18
Vapour cell
19
Quad Body
1st
2nd
3rd
4th
Velocity of vapours in:
SK header 30"(in 2 parts)
For quad Ist body 30"dia
R.J./S.J.1 heating 32" dia
S.J2 heating 24'dia
Existing Capacity
10 Ton / Tip, 2 Nos.
6.5 Ton / Tip, 1 Nos.at 25 Tip / Hr max.
12" dia , 2 Battery, 'at velocity 2.0 m/s
14" dia header, 'at velocity 2 m/s
300 M2 X 2 Nos. Valocity 2 M / Sec.
290 M2 X 1 Nos.
360 M3 / Hr X 4 Nos. Head 60 M two remain
in operation
2
O.K.
O.K.
O.K.
O.K.
O.K.
O.K.
O.K.
O.K.
O.K.
O.K.
O.K.
O.K.
O.K.
O.K.
O.K.
O.K.
O.K.
O.K.
O.K.
O.K.
O.K.
O.K.
O.K.
O.K.
O.K.
O.K.
O.K.
O.K.
O.K.
/var/www/apps/conversion/tmp/scratch_2/259945708.doc
BASIS:
A MASSECUITE % CANE
B MASSECUITE % CANE
C1 MASSECUITE % CANE
C MASSECUITE % CANE
= 24
= 11
=3
=6
S.
NO
1
EQUIPMENT
A PANS
B PAN (CVP)
DETAIL OF EQUIPMENTS
4 NOS. X 120 TONS EACH
1 No X 60 Ton
60 TONS/HR
C1 PANS
O.K.
C PANS
O.K.
O.K.
O.K.
COOLING TOWER
A CRYSTALLIZERS
B VERTICAL
CRYSTALLIZER
C VERTICAL AND
HORIZONTAL
CRYSTALLIZERS
C1 CRYSTALLIZER
A C-F MACHINES
550 TONS
8
9
10
11
12
13
14
15
16
17
CAPACITY
AT 13200 TCD
O.K.
O.K.
O.K.
O.K.
7 NOS. NK 1503
O.K.
1 NO. DC 12
1 NO. SC1350 KT
1 NO.- NK 1100
O.K.
B/C SUGAR
MELTER
GRADERS
2 NOS 16 M3 / HR EACH
O.K.
5 NOS X 20 TON / HR
O.K.
POWER BUILD
AUTO WEIGHING
MACHINES
O.K.
B CONTINUOUS
MACHINES
C1 CONTINUOUS
MACHINES
C CONTINUOUS
MACHINES
CAW MACHINES
O.K.
O.K.
/var/www/apps/conversion/tmp/scratch_2/259945708.doc