Juice Extraction System
1.Milling Tandem in milling sugar industry : The specific total mill power
= 70 to 164 kW/Ton fiber per hour . (Avg – 104)
2. Milling Tandem in Diffuser sugar industry : The specific total mill power
= 38.3 to 110 kW/Ton fiber hour . (Avg – 60.3)
3. Diffusers : The specific screen area = 6.6to 14.9 m2/Ton fiber per hour.
(Avg – 10.7 ).
Clarification
1.Juice Heaters : Total heating surface area = 4.29 to 13.1 m2/TCH (Avg –
8.0).
2. Every 10oC juice temperature rising required steam = 1.8 % on cane.
3. Steam required for Juice heating = 12 to 15% on cane. ( Vary according to
waste heat recovery from condensate or pans vapour or last effect vapour).
4. Head loss in tubular juice heater =12 to 16mwc & in plate type heater
(PHE) = 10 to 12mwc.
5. Trayless Clarifier : Total volumetric capacity = 0.75 to 1.73 m3/TCH (Avg
– 1.14).
6. Trayless Clarifier : Total cross sectional area = 0.2 to 0.22 m2 /TCH
7. Trayless Clarifier : Tray area = 0.22 to 0.33 m2/TCH.
8. Tray Type Clarifier : Total volumetric capacity = 2 to 3 m3/TCH (Avg –
2.5).
9. Tray Type Clarifier : Tray area =1.6 to 1.7 m2/TCH.
10. Tray Type Clarifier : Total cross sectional area = 0.38 to 0.42 m2 /TCH
11. Rotary Vacuum Filter : Total effective area = 0.6 to 0.7 m2/TCH.
12. Bagacillo requirement for vacuum filter = 7 to 8 kg per TCH
13. Bagacillo Qty available for 8mesh = 60 to 75 kg of bagacillo /m2/hr.
14. Air requirement for bagacillo conveying = 6.25 M3 of air will be required
per kg of bagacillo
15. Legment : Dead end Juice heater = 12mm, Dynamic = 15mm, Vapour
line juice heater = 15mm.
16. Sulphitor or Defecator working volume in M3 = TCH x (0.14 to 0.16)
(Avg – 0.15).
17. Air requirement of sulphur bunner in M3 = 8 t0 9 times of sulphur wt. in
kgs.
18. Syrup Sulphitor : Working volume of syrup sulphitor in HL = (0.02 x
TCD)
Evaporation
1.Multiple Effect Evaporation: Total heating surface area = 24.5 to 65.5
m2/TCH (Avg – 38.6).
2. Quad effect evaporator bodies heating surface / TCD = 1.5 ( Ex For
5000TCD plant = 7500m2 Heating surface required.
3. Quintuple effect evaporator bodies heating surface / TCD = 1.6 ( Ex For
5000TCD plant = 8000m2 Heating surface required.
4. (DEVC + Quad) effect evaporator bodies heating surface / TCD = 1.4
( Ex For 5000TCD plant = 7000m2 Heating surface required.)
5. Legment of Evaporators = 10mm.
6. Down take area = 1/6th to 1/8th on total dia of evaporator.
7. Vapour velocity in vapour space of evaporator body = 0.6m/sec.
8. Vapour space height in Robert type evaporators = 2 x calendria tube
height ( Note : for lost body it may 2.5)
9. Injection water pump : Total plant injection water pump capacity required
= (0.8 to 1 ) x TCD ( For raw m/c boiling it may 0.75 to 0.85 and for refinery
plant 0.9 to 1.1).
Crystalization
1.Vacuum pans : Total capacity = 1.25 to 1.90 m2/TCH (Avg – 1.52).
2. Steam required for m/c boiling in white sugar production = 17 to 23% on
cane. ( Vary according to the inlet liquor brix, type of the pan, m/c boiling
scheme).
3. Steam required for m/c boiling in Refined sugar production = 22 to 28%
on cane. ( Vary according to the inlet liquor brix, type of the pan, m/c boiling
scheme).
4. Syrup supply tanks required in HL =TCH x (6 to 8).
5. Supply tanks all molasses required in HL = TCH x (10 to 12).
6. S/V ratio for batch pans = 6 to 7 (Avg 6.6)
7. S/V ratio for continuous pans = 10 to 11.
8. Batch pan vapour outlet line dia =66.1 x SQRT(heating surface in m2).
9. Legment of pans = 16mm.
10. Dow take area of batch pan = 40 % on total dia of the pan.
11. Vapour velocity in vapour space of pan = 25 m/sec.
12. Crystallizers : Total capacity = 4.5 to 6 m3/TCH (Avg – 5.25 ).
13. S/V ratio for B m/c cooling crystalizer = 1.2.
14. S/V ratio for C m/c cooling crystalizer = 2.0.
15. Mono Vertical Crystalizer ( MVC ) capacity for C m/c cooling in Ton =
( TCD /10)
16. Condenser water requirement in M3 = (40 to 55) x ton of vapour to be
condense. ( For single entry = 40, Barometric = 47, Jet type = 55).
17. Spray Pond area : 750 kg/hr of warm water requires 1 m² of area of spray
pond ( Suppose spray pump capacity 2000m3/hr require spray area =
2000/0.75 = 2666 m² )
18. Horizontal cross-section of the body of the condenser = 0.16m2/ ton of
vapour to be condensed per hour.
19. Colour transfer from massecuite to sugar :(IU in G-10 method)
For 1st m/c in Sulphitation plant 1 to 1.5% ( ex: m/c colour 6000 then sugar
colour 60 to 90 IU)
Raw and refined sugar from its massecuite – 4 to 6% ( ex: m/c colour 14000
then sugar colour 560 to 840IU)
Centrifuging
1. Each Magma and seed pumps capacity required = (TCD x 0.008 ) T/hr.
2. B and C Sugar Melter capacity required (working volume) = (TCD x
0.004) M3
3. Thickness : 18g = 1.22mm , 16g = 1.625, 14g = 1.8mm.
These all thumb rules gives only approximate values for sugar industry
equipment sizing.
