The slide show presents a preliminary literature study for a sugar plant design. Hop you will get something valuable out of it....:)

1. Design of a sugar manufacturing
plant
Basics in process Engineering Design

2. Group Members
Contents
Preliminary stage
•Finding the demands
•Identifying various processes
•Selecting a process
•Find a suitable location
•Block diagram for the selected process
•Raw material specifications
•Environmental considerations
•Utility services
•Energy sources
•Identifying problems/ Limitations
Mass balances

3. FindingMembers
Group the demands
Sri Lanka sugar demands 1993-2011 Year Sugar demand, MT
1993 457442
1994 563275
1995 487512
1996 454339
1997 609055
1998 550000
1999 541220
2000 544220
2001 560033
2002 591661
Sources :Department of Census and Statistics 2003 570050
Pelwatte Sugar Industries Ltd 2004 501151
Sevanagala Sugar Industries Ltd 2005 471376
Sri Lanka Customs 2006 581019
Central Bank of Sri Lanka 2007 507544
2008 610378
2009 498168
2010 579336
2011 640876

4. FindingMembers
Group the demands
Prediction through curve fitting
700
600 y = 3.721x - 6906.
R² = 0.147
500
Suggar deamand,1000MT
400
300 Linear (Series1)
200
100
0
1990 1995 2000 2005 2010 2015
Year
Current demand 2013 – 584,373 MT Our target – 59,181.5 MT/Yr
Demand in 2015 – 591,815 MT 200 working days – 12.33 MT/hr

5. Group Members
Identifying various processes
 Cane Sugar
 Beet Sugar
 Corn Sugar
• Cane Sugar
- Crystal, Powder, syrup Both of Cane sugar industry
• Beet Sugar and Beet sugar industry are
- Crystal, Powder, syrup used same process.
• Corn Sugar
- Sugar syrup (only used for sweeteners)

6. Group Members
Identifying various processes
Cane sugar
Beet sugar
Grown in Tropical climate areas within
Grown in Sub-tropical climate areas
22°N-22°S
Temperature of 15-22 C
at least 800-1000 mm/year
Requires a good irrigation system and
Soil temperature is about 70-80°F
law wind speeds
Temperature max growth at 27 C
The process of manufacturing beet
For the better photosynthesis in leaves
sugar is quite similar to that of sugar
sugarcane need plentiful sunshine.
cane.

7. Product Members
Group specification
Cane Sugar
Raw Refined Crystal (mill)
Muscavado Demerara Caster
Icing Premium Liquid Sugar Fine Liquid Sugar
Invert White Crystal Refined - Fine Granulated
Mainly produce 3 types of sugar by Cane
 Row Cane sugar ( Brown sugar )
 Mill White sugar ( White Sugar)
 Refined sugar ( White Sugar )

8. Product Members
Group specification
We chose Raw Cane sugar ( Brown sugar )

9. Find a Members
Group suitable location
Requirements for sugar cane cultivation
Soil type medium to heavy well drained
Climate RH-70% (for optimum vegetation growth)
Rain fall at least 800-1000 mm/year
Temperature max growth at 27 C
Wind High Wind exceeding 60 km/hr
Sri Lanka temperature profile

10. Find a Members
Group suitable location
A - South-east region
(Hambanthota, Embilipitiya)
B- North-west region (Mannar)
Source : https://sites.google.com/a/tcd.ie/sri-lanka/geography

11. Find a Members
Group suitable location
Use factor rating method,
A- South east region
B- North west region
Rating
Critical Factor Weight
A B
Rain fall for cultivation 10 100 100
Temperature for cultivation 9 100 100
Soil fertility 7 80 40
Water supply 7 70 60
Land cost and availability 9 80 70
Labour cost and avaliablity 6 70 70
Transport 5 60 80
Score 4390 4050
More suitable location is South east region of Sri Lanka

12. Group Members
Raw material specifications
Sugarcane will be grown in 1315 Ha
To get the maximum crop new sugarcane clone L-97-128 is recon
Other main raw materials for the sugar plants are lime and water.
Water can be delivered either from the Lunugamwehera irrigation system or
Udawalawe tank
Water from Lunugamwehera is small and most of the water from it is used
in agriculture already
Lime is used for the clarification of raw juice
Either imported or use CaCO3 found in south or north-western parts of Sri
Lanka We can’t use lime from corals
This is a food product, we have to use pure lime therefore it is
recommended to get lime from a foreign country.

13. Environmental considerations
Selecting a processing method
Group Members
Land usage
Land usage is too large for cane cultivation
 De-forestation
Change of animal habitats
De-fertilization of soil
Waste water
Inputs to the sugar plant are mainly sugar cane and some amount of water
 The water is used in milling as imbibition water and steam
 discharge water from pan boilers

14. Environmental considerations
Selecting a processing method
Group Members
Gas emissions
Emissions such as Sulpher Oxides and Nitro Oxides can be emitted from the
clarifier
Baggase
Solid waste
Produces dust and ash which can cause skin diseases
 Baggase and filter cake are removed from milling and vacuum pumps
 Baggase can be used in boilers, filter cake can be used as fertilizer

15. Selecting Utility services
Group Members
a processing method
Electricity
Used in crane system, cutters, and various kinds of motors, centrifugal
machines, juice clarifiers, driers, bucket elevators, air compressors, magnetic
separators, pump house, work shop facilities and lighting
Delivered from Ceylon Electricity Board national grid.
There is a potential to produce electricity by baggase coming out from
milling process
Power house steam turbines will use steam from boiler where the baggase
is burned
Start up of the power plant firewood can be used

16. Selecting Utility services
Group Members
a processing method
Steam
Steam is the main utility for the operation in a sugar factory.
Generated in boilers which Steam is used in different forms such as
superheated stem etc.
Superheated steam is used for operating mill house
machinery, shredder, and power turbines
Exhaust steam will be used process heating
De-superheating unit and pressure reducing unit
Superheated steam cannot be used for process heating purposes.

17. Selecting Utility services
Group Members
a processing method
Compressed air
Used in pneumatic control system of the factory
In vacuum filter to create vacuums in different levels
Used in a pressure of 7bar so the sufficient air compressors are used
Work shop facility
Workshop facility to repair the factory machinery in factory itself
Workshop machines such as lathe, milling, boring are essential
Auto mobile repair centre
Various vehicles are used in both sugar planting and the factory
Vehicles may come up with various problems

18. Selecting Energy sources
Group Members
a processing method
Electricity
Electricity from CEB and steam turbines are used in sugar factories
Electricity from CEB for lighting, for residences
Electricity from steam turbines for other uses [pumps, motors, compressors etc.]
Thermal Power – Steam
Super heated steam is used Mill turbines, shredder , power turbines
Exhaust steam from these processes is used in evaporation,
Vapor generated from evaporation can be used in pan boilers
Bio mass
Firewood for boiler startup
Baggase for boiler

19. Identifying processing method
Selecting a problems/ Limitations
Group Members
Supposed to manufacture 59,181MT of sugar per annum
Better to have line production instead of single line plant
Or else use multiple lines for the unit operations which take long time to
complete Those steps can be considered as the limiting factors
Shredding and pan boiling are such unit operations.
Problems arising in startup in the boiler plant
As mentioned previously firewood can be used for startup the boiler until
baggase lots are available for burning
if manufacturing white sugar ,have to add another unit operation to the
process which involves lots of chemicals
What importing is white sugar
Manufacturing white sugar will make a competition between Sri Lankan
Sugar manufacturing and imported sugar
Therefore the process is limited to brown sugar manufacturing.

20. References
1. E. Hugot. Handbook of Sugar cane Engineering, Third completely revised
edition: Elsevier science publishing company; 1986.
2. Rogger P. Humbert. The growth of sugar cane, Revised edition : Elsevier
science publishing company; 1968.
3. Verlas Dr. Albert Bartens KG. CANE SUGAR ENGINERING. Berlin, Germany;
2007.
4. Juliano José Corbi & Susana Trivinho-Strixino & Ademir dos
Santos. Environmental Evaluation of Metals in Sediments and Dragonflies
Due to Sugar Cane Cultivation in Neotropical Streams.
http://link.springer.com/content/pdf/10.1007%2Fs11270-008-9749-1
(accessed 17th December 2012).

21. References
5. K. A. Gravois,* K. P. Bischoff, S. B. Milligan, F. A. Martin, J. W. Hoy, T. E.
Reagan, C. A. Kimbeng, C. M. LaBorde, and G. L. Hawkins. Registration of
‘L 97-128’ Sugarcane.
https://www.crops.org/publications/jpr/pdfs/2/1/24 (accessed 16th
December 2012)
6. Sugar cane. http/www.wikipedia.org/sugarcane (accessed 10th
December 2012)

22. End of slides