GENESIS MEMBRANE SEPRATECH PVT. LTD. Mumbai, India.

Tel.: 91-22-5775456; Fax: 91-22-5790608; E-mail:genesis@bom5.vsnl.net.in

by

8

9

10

11

12

13

14

15

16

17

87 88 89 90 91 92 93 94 95 96 97 98

YEAR

PR

OD

UCTIO

N O

F S

UG

AR

(Million T

onnes)

TOTAL SUGAR PRODUCTION (INDIA )

Prodcution as of April 2012 is

186

206

226

246

266

286

88 89 90 91 92 93 94 95 96 97 98

YEAR

PR

OD

UC

TIO

N O

F C

AN

E (

MIL

LIO

N T

ON

NE

S)

PRODUCTION OF CANE ( INDIA )

NO. OF PLANTS WITH CAPACITY

0

20

40

60

80

100

120

140

NO

. O

F P

LAN

TS I

N I

ND

IA

CAPACITY

Below 1250

Of 1250

1251-2000

2001-2500

2501-3500

Above 3500

There are 671 sugar mills in India.

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.

CANE

CRUSHING

BLOCK DIAGRAM FOR CANE SUGAR PRODUCTION

LIMING HEATINGTHIN JUICE

EVAPORATIONCRYSTALLIZATION

MOLASSES

RAW SUGAR

CaO STEAM

THICK JUICE

RAW JUICE

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 TandemComprising 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 Bagasse Bye Product for Clarification and Sugar Boiling (Fibre + Water + Little

salts)

Used as fuel in Boilers

5% sold to paper industries

Muddy Juice Clear Juice (15o Brix)

Rotatory Vacuum Filter Vapour Cell (For part Evaporation)

Filter cake or Press Filter Juice Quadruple Effect Evap.Mud (Bye product. (Back to the Juice (Evaporation of waterSold to farmers to tank to be mixed up to 75%)be used as manure with raw juice and for the cane fields) re-processed) Concentrated material

(called “SYRUP”of 60 Brix)

Sulfitation

Sulfited syrup pH 5.0

CLARIFIER

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. B - Heavy Molasses.Magmised and used as seed for A-massecuite.

III Stage:B - Heavy Molasses + C - Light Molasses

C - Massecuite

Continuous Centrifugal Machines

Magmised Final Molasses to storage tanks

(A bye-product sold to distilleries producing rectified spirit, Second Curing alcohol, etc. )Continuous Centrifugal Machines

C - Double Cured sugar C- Light Molasses (Rich in sugar and therefore(Melted to give clear melt. sent back to the process forThis is pumped to the pan C-Massecuite boiling)

floor and boiled with syrup to produceA - massecuite)

Repeat the four-step process under

Point #1.

0

5

10

15

20

25

30

5 10 15 20 25 30 35Concentration in Brix

Perm

eate

flux

in L

MH

At 35 o CAt 40 o CAt 45 o CAt 50 o C

At 55 o CAt 60 o C

CORELATION OF PERMEATE FLUX WITH

CONCENTRATION ON SPRIAL MEMBRANE

CORELATION OF PERMEATE FLUX WITH TEMPERATUE ON SPIRAL MEMBRANE

0

5

10

15

20

25

30

30 50 70

Temperature (o C)

Perm

eate

Flu

x (

lmh)

30.6 Brix25.1 Brix19.0 Brix13.6 Brix09.8 Brix

0

10

20

30

40

50

60

70

80

10 16 21 22 24

Concentration (brix)

Perm

eate

Flu

x (

lmh)

At 35 o CAt 40 o CAt 45 o CAt 50 o C

CORELATION OF PERMEATE FLUX WITH

CONCENTRATION ON TUBULAR MEMBRANE

0

10

20

30

40

50

60

70

80

30 50 70

Temperature (o C)

Perm

eate

Flu

x (

lmh)

21 Brix16 Brix10 Brix

CORELATION OF PERMEATE FLUX WITH TEMPERATURE ON TUBULAR MEMBRANE

0

0.5

1

1.5

2

2.5

3

3.5

4

0 10 20 30

Concentration (Brix)

Loss

of Sucr

ose

(%

)CORELATION OF % LOSS OF SUCROSE

WITH CONCENTRATION

30354045505560

6570

10 20 30

CONCENTRATION (BRIX)

DEG

REE O

F D

EASH

IFIC

ATIO

N

CORELATION ON DEGREE OF DESALTING

WITH CONCENTRATION

Hot Water 550C2500 l/hr

STAGE – II DESALTING &PRECONCENTRATION OFCALRIFIED MIXED JUICE TO 23 BRIX

STAGE - I CLARIFICATION OF MIXED JUICE

Chemical

Mixed Juice10,000 l/hBrix : 15Purity : 76-80Temp : 50-55oC

Desalted Juice6,000 l/hBrix : 22 -23Purity : 89 - 91Temp : 45-50oC To Evaporator

Clear juice; 7,500 l/h

5,000 l/h4,500 l/h

500 l/h FilterResidue to

RVF

6,000 l/hBrix : 1.5Partly to

CaneWashing

Clear Juice12,000 l/hBrix : 11.5 – 12.0Purity : 82 - 84

SettlingTank