Sugar Factory Material Balance Calculation for 3 m/c Boiling
In sugar Industry for the raw sugar and plantation white sugar manufacture, generally followed the three massecuite boiling scheme. Here explained with one model example about 3 massecuite boiling material balance Calculation. Also provide online calculation sheet for 3 m/c boiling scheme.
A massecuite or Raw massecuite:
Generally A massecuite or Raw massecuite purity is maintained from 80 to 90. A massecuite is boiled either with B magma or dry seed as footing. The A massecuite is further developed with syrup, melt and A-light molasses. In the same way Raw massecuite bolied with Run off from the refined house, syrup, Magma, CAW sugar.
B massecuite:
Generally B massecuite purity is maintained from 65 to 75. In most of cases B massecuite is grained by true seeding method. B massecuite is further developed with A heavy molasses and Syrup( syrup Optional). B sugar diverted to A m/c in the form of melting or footing. Maximum industries followed B m/c in single curing and some time follows double curing as per the syrup purities.
C massecuite:
Generally the C massecuite purity is maintained 50 to 55. Generally C massecuite is grained either with mixture of AH + CL molasses (purity- 65-70) or only with CL molasses (purity- 63-64) by true seeding technique. C massecuite is further developed with C light molasses and B heavy molasses.
For Three massecuite material balance purpose first we will find the Solids in syrup % cane. So calculate solids in syrup calculate by the following formulas.
- Solids in syrup%cane = Solids in Clear juice % cane.
- Solids in Clear juice % cane = Brix in clear juice x Clear juice % cane.
- Brix in Clear juice = Pol in clear juice / Purity in clear juice.
- Purity in clear juice = Calculate by the laboratory method.
- Pol in clear juice = Pol in Mixed juice % cane – Pol in filter cake % cane.
Collect the following data from lab analysis
| Material Name | Brix | pty |
| Syrup | 56.00 | 82.00 |
| A m/c | 89.00 | |
| B m/c | 75.00 | 72.00 |
| C m/c | 102.00 | 55.00 |
| AH | 80.00 | 72.00 |
| AL | 75.00 | 90.00 |
| BH | 85.00 | 50.00 |
| CL | 78.00 | 65.00 |
| White Sugar | 100.00 | |
| B sugar | 97.00 | 95.00 |
| CFW | 96.00 | 80.00 |
| CAW | 95.00 | 93.00 |
| FM | 88.00 | 30.00 |
| A Fore Worker(Approximate) | 99.20 | |
Step 1 : Find the Solids in Sugar and Final molasses.
| 100.00 | Sugar | 82 – 30 = | 52.00 | ||
| Syrup | 82.00 | ||||
| 30.00 | FM | 100 – 82 = | 18.00 | ||
| 70.00 |
If syrup solids divided into 70 parts , 52 solids will be in sugar and 18 solids will be in final molasses.
Solids in Unknown 1 = ( Parts of Unknown 1 / Parts of known fraction ) x Solids in known fraction.
Solids in sugar = (52 x 14.56)/70 = 10.82.
Solids in FM= Solids in syrup – Solids in sugar = 14.56 – 10.82 = 3.74.
Step 2 : Find the Solids in C massecuite and CFW( C Fore Worker).
| 80.00 | CFW | 25.00 | ||
| C m/c | 55.00 | |||
| 30.00 | FM | 25.00 | ||
| 50.00 |
Solids in C m/c = (50 x 25)/3.74 = 7.48
Solids in CFW = Solids in C m/c – Solids in Final Molasses = 7.48 – 3.74 = 3.74.
Step 3 : Find the Solids in C Light and CAW( C After Worker).
| 93.00 | CAW | 15.00 | ||
| CFW | 80.00 | |||
| 65.00 | CL | 13.00 | ||
| 28.00 |
Solids in CAW = ( 15/ 28)/3.74 = 2.00
Solids in C Light = Solids in CFW – Solids in CAW = 3.74 – 2.00 = 1.74.
Step 4 : Find the Solids from B Heavy for C m/c boiling and solids from A heavy for C m/c Boiling.
C M/C boiling with AH , BH and CL.
Here we know only CL. So Take (AH + BH ) imaginary mixture for C m/c boiling.
Solids in AH + BH = Solids in C m/c – Solids in CL = 7.48 – 1.74 = 5.74
[ C m/c solids x C m/c pty ] = [ (AH+BH) solids x (AH+BH) pty ] + [ CL solids x CL pty ]
Imaginary mixer (AH+BH) Purity ={ [ C m/c solids x C m/c pty ] – [ CL solids x CL pty ] } / (AH+BH) solids.
Imaginary mixer (AH+BH) Purity = { [ 55 x 7.48 ] – [ 65 x 1.74 ] } / 5.74 = 51.97.
| 72.00 | AH | 1.98 | ||
| AH+BH | 51.98 | |||
| 50.00 | BH | 20.02 | ||
| 22.00 |
Solids in B Heavy for C boiling = ( 20.02 / 22) x 5.74 = 5.23
Solids from AH for C boiling = 5.74 – 5.23 = 0.51.
Step 5 : Find the Solids in B m/c and B sugar.
| 95.00 | B sugar | 22.00 | ||
| B m/c | 72.00 | |||
| 50.00 | BH | 23.00 | ||
| 45.00 |
Solids in B m/c = ( 45/ 23)/5.23 = 10.23
Solids in B Sugar = Solids in B m/c – Solids in BH = 10.23 – 5.23 = 5.0.
Step 6 : Find the total Solids in A Heavy.
Total Solids in AH = solids in B m/c + Solids from AH for C boiling = 10.23 + 0.51 = 10.74.
Step 7 : Find the solids in A m/c and AFW
| 99.20 | AFW | 16.00 | ||
| A m/c | 88.00 | |||
| 72.00 | AH | 11.20 | ||
| 27.20 |
Solids in A m/c = ( 27.2 / 11.2) x 10.74 = 26.08.
Solids in AFW = Solids in A m/c – Solids in AH = 26.08 – 10.74 = 15.34.
Step 8 : Find the solids in Hopper Sugar and A Light.
| 100.00 | Hopper | 9.20 | ||
| AFW | 99.20 | |||
| 90.00 | AL | 0.80 | ||
| 10.00 |
Solids in Hopper sugar = ( 9.2 / 10.0) x 15.34 = 14.11.
Solids in AL = Solids in AFW – Solids in Hopper Sugar = 15.34 – 14.11 = 1.23.
Step 9 : Find the solids in Dry Seed.
Solids in dry seed = Solids in hopper sugar – Solids in bagging sugar = 14.11 – 10.82 = 3.29.
Step 10 : A m/c Solid balance.
| Solids | Purity | Solids x Purity | |
| Syrup | 14.56 | 82.00 | 1193.9 |
| Dry Seed | 3.29 | 100 | 329.0 |
| AL | 1.23 | 90.00 | 110.6 |
| B Sugar | 5.00 | 95.00 | 475.0 |
| CAW | 2.00 | 93.00 | 186.0 |
| Total | 26.08 | 2294.55 |
Expected A m/c Purity = 2294.55 / 26.08 = 87.98.
Step 11 : Calculate all material % cane
Material % Cane = Solids in material x 100 / Brix % material
| Material | Solid% | Brix% | %Cane |
| SYRUP | 14.56 | 56.00 | 26.00 |
| A m/c | 26.12 | 89.00 | 29.35 |
| B m/c | 10.24 | 75.00 | 13.65 |
| C m/c | 7.49 | 102.00 | 7.34 |
| AH | 10.76 | 80.00 | 13.44 |
| AL | 1.23 | 75.00 | 1.64 |
| BH | 5.23 | 85.00 | 6.16 |
| CL | 1.74 | 78.00 | 2.23 |
| B sugar | 5.01 | 97.00 | 5.16 |
| CFW | 3.74 | 96.00 | 3.90 |
| CAW | 2.01 | 95.00 | 2.11 |
| FM | 3.74 | 88.00 | 4.25 |
Daily Manufacturing Report (DMR) Cum Chemical Control (Sugar Lab) Calculation Sheet
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