MADANIT

WOLLEGA UNIVERSITY
FACULTY OF TECHNOLOGY
DEPARTEMENT OF CHEMICAL ENGINEERING
HOSTING COMPANY: FINCHA SUGAR FACTORY
TITLE: INTERNISHIP REPORT ON SUGAR PRODUCTION

DURATION TIME: FOUR MONTHS
BY GROUP MEMBER
NAME ID NO
1),OBSA CHIMDESSA…………………0898/15
2),YOHANNES JALETA.........................1125/15
3) DIRIBA GADISA………………………0370/15
ADVISOR NAME: MR. GADISA. M

SUMBMISSION DATE: 21/6/2011
WOLLEGA, ETHIOPIA
INTERNSHIP REPORT ON SUGAR PRODUCTION 2019
DECLARATION
We declare that the work which is being presented in the report on internship at FSF
ETHIOPIA for the completion of internship program carried out from November 2018-2019
February under the mentor of Department of chemical Engineering, in Wollega University.
All relevant resources of information used in these papers have been acknowledged.
Name of student: ID №
1) OBSA CHIMDESSA ………………... 0898/15

2) YOHANNES JALETA ……………………., 1125/15
3) DIRIBA GADISA …………………….0370/15
Certify that the above statement made by the candidate is correct to the best of our knowledge
and belief. Not only our but also the mentor and supervisor contribute the way of report
writing, fulfillments of body report and way of final presentation and they contribute in our
work by outlining training program operation in FSF. By these approval on what have to be
done continuous check, material support improvement of work and monthly and final
evaluation where performed by them. This report has been submitted for presentation with
our effort.
Name of Mentor ……………..
Name of adviser Signature ………….
Date ……………….
DEPARTEMENT OF CHEMICAL ENGINEERING Page i

Table of Contents
DECLARATION ..................................................................................................................................... i
ACKNOWLEDGEMENT ................................................................................................................... viii
ABIRIVETION ........................................................................................ Error! Bookmark not defined.
EXECUTIVE SUMMARY .................................................................................................................... x
CHAPTER ONE ..................................................................................................................................... 1
INTRODUCTION .................................................................................................................................. 1
1.1. Historical Back Ground of the Company ........................................................................ 1
1.2. Vision, Mission, Value of the Organization .................................................................... 2
1.2.1. Vision .................................................................................................................................... 2
1.2.2. Mission.................................................................................................................................. 2
1.2.3. Values ................................................................................................................................... 2
1.3. Organizational Structure ................................................................................................. 2
CHAPTER TWO .................................................................................................................................... 4
UNIT OPIRATION OF SUGAR PRODUCTION ................................................................................. 4
2.1. MATERIALS .................................................................................................................. 4
2.2. Methods of Sugar Production.......................................................................................... 5
2.2.1. Cane Preparation ................................................................................................................... 5
2.2.1.1 Cane Burning.............................................................................................................. 5
2.2.1.3 Cane Yard ................................................................................................................... 5
2.2.1.4 Weight Bridge .......................................................................................................... 5
2.2.1.5 Cane Unloading .......................................................................................................... 6
2.2.1.6 Cane table ................................................................................................................... 7

2.2.1.7 Main Cane Carrier ...................................................................................................... 8
2.2.1.8 Knives......................................................................................................................... 8
2.2.1.8.1. Factors Affecting the Efficiency of Cane Knives .................................................. 8
2.2.1.9 Cane Shredder ............................................................................................................ 8
2.2.2 Milling Parameters ...................................................................................................... 10
2.2.2.1. The Objectives of Mill Extraction ........................................................................... 10
2.2.2.2. Mill Rollers ............................................................................................................. 10
2.2.2.3. Juice Extraction ....................................................................................................... 11
2.2.2.3.1. Methods of Separation of Juice from Cane .......................................................... 11
DEPARTEMENT OF CHEMICAL ENGINEERING Page ii

2.2.3. Imbibition ............................................................................................................................ 12

2.2.3.1. Type of Imbibition and Method of Applying .......................................................... 13
2.2.3.2. Advantage and Disadvantage of Imbibition of Water ............................................. 13
2.2.4. Juice Weighting................................................................................................................... 14
2.2.5. Juice Heating ....................................................................................................................... 14
2.2.5.1. Primary Juice Heating ...................................................................................................... 14
2.2.5.2. Secondary Juice Heating ......................................................................................... 15
2.2.5.3. Clarified Juice Heating (Third Juice Heating) ........................................................ 15
2.2.5.4. Principles of Juice Heating (precondion) ................................................................ 15
2.2.6. Clarification and Evaporation ............................................................................................. 15
2.2.6.1. Clarification ............................................................................................................................. 15
2.2.6.1.2. Chemicals (Materials) Used In Clarification ....................................................... 16
2.2.6.1.3. Roll of Phosphate ................................................................................................. 17
2.2.6.4. Description of Equipment ....................................................................................... 17
2.2.6.4.1 .Storing Equipment................................................................................................ 17
. 2.2.6.4.2. Measuring Equipment ............................................................................... 17
2.2.6.4.3. Clarification Equipment’s .................................................................................... 18
2.2.6.5.Factors Affecting Efficiency of Clarifier ................................................................. 19
2.2.7. Evaporation ......................................................................................................................... 21
2.2.7.1. Arrangement of Evaporators ................................................................................... 21
2.2.8. Pan House and Crystallizer ................................................................................................. 22
2.2.8.1. Pan Boiling .............................................................................................................. 22
2.2.8.1.1. Types of Pan ......................................................................................................... 23
2.2.8.2. Crystallizer .............................................................................................................. 23
2.2.8.2.1. Rate of Crystallization.......................................................................................... 24
2.2.9. Centrifugation and Drier ..................................................................................................... 24
2.2.9.1. Types of Centrifugal................................................................................................ 24
2.2.9.1.2. Continuous Centrifugal Machines ........................................................................ 25
2.2.9.2. Sugar Drier .............................................................................................................. 25
2.2.9.2.1. Types of Sugar Drier ............................................................................................ 25
2.2.9.2.1.1. Static Bed Drier ................................................................................................. 25
2.2.9.2.1.2. Fluidized Bed Drier ........................................................................................... 26
2.2.10. Packing ..................................................................................................................... 26
DEPARTEMENT OF CHEMICAL ENGINEERING Page iii

2.2.11.Sugar Stories ............................................................................................................. 26

2.2.12. Boiler and Power Plant ..................................................................................................... 27
2.2.12.1. Objective of Boiler Plant................................................................................................ 27
2.2.12.2. Classification of Boilers ........................................................................................ 27
2.2.12.3. Boiler Auxiliaries .................................................................................................. 27
Boiler Auxiliaries are in the boiler circuit to increase the boiler efficiency ........................ 27
2.2.13. Ethanol Production............................................................................................................ 28
2.2.13.1. Theories of Yeast, Fermentation, Distillation and Molecular Sieved Dehydration
.............................................................................................................................................. 29
2.2.13.2. Chemistry of Ethanol Production by Yeast ........................................................... 29
2.2.13.3. Fermentation.......................................................................................................... 29
2.2.13.4. Distillation ............................................................................................................. 30
2.2.13.5. Molecular Sieve Dehydration (MSDH) ................................................................ 30
2.2.13.6. Process Description ............................................................................................... 30
CHAPTER THREE .............................................................................................................................. 32
MATERIAL AND ENERGY BALANCE ........................................................................................... 32
3.1. Over All Material Balance on Milling .......................................................................... 32
3.2. Material Calculation for Milling Section ...................................................................... 32
3.3. Material Balance in Clarification Plant ......................................................................... 35
3.3.1. Material Balance around Liming Tank ............................................................................... 36
3.3.2.Material Balance around Sulphited Tank ............................................................................. 36
3.3.3. Material Balance around Dorr-Clarifier .............................................................................. 36
3.4. Mass Balance and Energy Balance for Multiple- Effect Evaporators .......................... 37
3.5. Energy Balance on Evaporator ...................................................................................... 38
3.5.1. For the First Effect .............................................................................................................. 38
3.5.2. For Effect 2 ......................................................................................................................... 38
3.5.3. For Effect 3 ......................................................................................................................... 38
3.5.4. For Effect 4: ............................................................................................................... 38
3.6. Heat Transfer Rate ........................................................................................................ 38
3.7. Mass Balance On Centrifugal ....................................................................................... 39
3.7.3. Total Mass Balance ............................................................................................................. 39
CHAPTER FOUR................................................................................................................................. 41
OVERALL BENEFITS GAINED FROM INTERNSHIP ................................................................... 41
DEPARTEMENT OF CHEMICAL ENGINEERING Page iv

4.1. To Improve Practical Skill ............................................................................................ 41

4.2. To Up Grading Theoretical Knowledge ........................................................................ 41
4.3. Inter Personal Communication Skill ............................................................................. 41
4.4. Leadership Skill............................................................................................................. 42
4.5. Work Ethics ................................................................................................................... 42
CHAPTER FIVE ................................................................................................................................ 43
PROJECT IN FINCHA SUGAR FACTORY ...................................................................................... 43
5.1 PROBLEM IDENTIFICTION ....................................................................................... 43
5.2. Design of Belt Conveyor to Transport Limestone (CaCO3) From Store to Lime
Mixer. ................................................................................................................................... 43
5.2.1. Introduction ................................................................................................................ 43
5.3 Literature Review ........................................................................................................... 44
5.4 Scope .............................................................................................................................. 44
5.5. Statement of Problem .................................................................................................... 45
5.6. Objectives of Project ..................................................................................................... 46
5.6.1 General Objective ........................................................................................................ 46
5.6,2 Specific objectives....................................................................................................... 46
5.7. Materials and Methods .................................................................................................. 47
5.7.1. V- Belt and V-Grooved pulley design ................................................................................ 47
DISCUSION ......................................................................................................................................... 54
CHAPTER SIX ..................................................................................................................................... 55
CONCLUSION AND RECOMMENDATION .................................................................................... 55
6.1. Conclusion..................................................................................................................... 55
6.2. Recommendation ........................................................................................................... 58
Appendix ............................................................................................................................................... 60
REFERENCES ..................................................................................................................................... 62
DEPARTEMENT OF CHEMICAL ENGINEERING Page v

LIST OF FIGURE Page
Figure 1.1 Flow chart of organization .................................................................................... 3

Figure 2.1 Cane unloading ..................................................................................................... 7
Figure 2.2 Cane table ............................................................................................................. 7
Figure 2.3 shredder ................................................................................................................. 9
Figure 2.4.Milling Plant ....................................................................................................... 10
Figure 2.5 mill roller ............................................................................................................ 11
Figure 2.6 OC Filter ............................................................................................................. 19
Figure 2.7. Flow sheet of clarification ................................................................................. 20
Figure 2.8 Flow sheet of Crystallization .............................................................................. 23
Figure 2.9.Process Flow Sheet Of White Sugar Production ................................................ 31
Figure 3.1 Material Balance on Boiler ................................................................................. 40
Figure 5.1. Lime stone store ................................................................................................. 43
DEPARTEMENT OF CHEMICAL ENGINEERING Page vi

LIST OF TABLE Page

Table 2.1 calculations on Weight Bridge ............................................................................... 6
Table 2.2 Comparison of first knives’ set with that of the second knives set ........................ 9
Table 2.3 The Calanderia Tubes Of Evaporator .................................................................. 22
Table 5.1. Dimension of standard v-belt according to IS: 2494-1974 ................................. 47
Table 5.2.dimention of standard v-groove pulley according to IS: 2494-1974 ................... 47
DEPARTEMENT OF CHEMICAL ENGINEERING Page vii

ACKNOWLEDGEMENT
First and foremost, we would like to acknowledge God who helps me and being with me
throughout my endeavor. And, we would like to express my deepest gratitude to the FSF
Company Supervisor Mr. Fasil and Mr. Alemayo for their assistance and consistent help
throughout my stay. And we would also like to thank my advisor Mr. Gadisa Mosisa (MA)
for his guidance, constructive comments and suggestions for better preparation of my
internship report. Finally, we would like to thank Wollega University and Chemical
Engineering Department, for giving me the chance of the internship program to improve my
interpersonal communication skills, practical skills, upgrade theoretical skills, team playing
skills, leadership skills.
DEPARTEMENT OF CHEMICAL ENGINEERING Page viii

ABIRIVETOIN
AIDF Air Induced Draft Fan
FSF Fincha Sugar Factory
HPRFDRE House of People Representative of Democratic Republic Of Ethiopia
IW Imbibition Water
MSDH Molecular Sieve Dehydration
OFAF Over Fire Air Fan
SJ Sulphited Juice
DEPARTEMENT OF CHEMICAL ENGINEERING Page ix

EXECUTIVE SUMMARY
An inter ship means knowledge developing program for engineering students. The company
have different departments which their own working principles. To execute the process & get
desired product each department works sequentially one another. This paper is written for
practical fulfillment of internship program which was planned to help apparent students to
understand practical knowledge of engineering projects. This includes design process,
implementation and evaluation in general. The paper includes the background of the host
company including its history, major production, the overall function, process product and
flow diagram of the process, working principles of each unit operation, mini project and etc.
The content of the paper has been divided in to six chapters and topics covered including the
introduction, sugar production, discussion and experience gained and conclusion and
recommendations. During the intern time, we have learnt dealing with different things from
different conditions starting from ethics and how to manage large companies along with what
is expected from me by applying the theoretical knowledge which is learned in the class into
practice.
DEPARTEMENT OF CHEMICAL ENGINEERING Page x

CHAPTER ONE
INTRODUCTION
1.1. Historical Back Ground of the Company
Fincha sugar Factory is located in Horro Guduru Wollega administrative zone of

Oromia regional state, Abay comman wereda 350km away from Addis Ababa. FSF is
situated at a wet kola agro-climatic zone receiving an average of 1300mm rain per annual.
The altitude ranges between 1400m downstream and 1650m upstream. The mean maximum
and minimum temperatures are 31 and 15 respectively. FSF has gone through decades of
difficulties and interruption before it comes to reality in the years 1995 -1998 of
intensive project implementation period.
FSF inaugurated by his Excellency Dr.Negaso Gidada in 1996 E.C. But founded since at
1990 and started to produce sugar in 1992.FSF is formally established according to
Ethiopian government proclamation number 25/1984 and the council of minister

regulation number199/1985, which gave the right to public enterprise supervisory
authority under the prime minister’s office to establish , manages and control public
enterprises.
FSF has paid a capital of birr 567, 000,000.The total cost of FSF is 1.8 billion birr which is
financed by government equity capital, soft loan and grants obtained from various
governments, international institution, local banks and the Ethiopian government.
According to the financial plan the Ethiopian government took its share (35%) of financing
the project while other sources financed the remaining (65%)
The major sources of finances are African development fund. However, the Swedish,
Australian and Spanish government has also played a significant role in financing this
huge project or factory.Housing and infrastructure development at cost of birr 71.8
million ,construction of 43.6km irrigation canal, installation of 340 pipes and 6 pump
station and the construction of 160km long internal access all weather rods in aggregate
casted birr 259.2 million, development of 6678 hectares of cane with a total cost of 245.3
million, Construction of their sub stations, installations of a 37km high standard electric
distribution line in addition to construction of small village which have grossly coasted
64.6million birr and Construction, erection and commissioning of the sugar and ethanol
1
plants coasted 649.5 million birr. A number of contractors and sub-contractors, both local
and foreign, have participated in the constructions of this huge sugar and ethanol
manufacturing complex namely:
Batu construction Enterprise

- A local Engineering company has participated in the construction of all housing &
development of infrastructure.
- Tikur Abbey construction has taken care of all civil works & installation of canal
pipes.
1.2. Vision, Mission, Value of the Organization

1.2.1. Vision
To create a leading sugar factory in producing sugar and ethanol at competitive production
cost and quality
1.2.2. Mission
Fincha as an agro industry is striving to increase stake holders’ satisfaction through core
business activity including:-
Expanding and optimizing sugar cane plantation of own and out growers cane
to meet own requirement and creating income for the out growers, sufficient
employment opportunities in plantation.
Producing and marketing sugar and downstream products participating in the
renewable energy sector through the integration of the national portfolio of
cost efficient bio fuel and bio energy assets.
1.2.3. Values
 Team work brings individual and organizational growth.
1.3. Organizational Structure

Fincha sugar factory is state owned enterprise accountable to Ethiopian sugar
development agency, which is established and mandated in accordance with proclamation
ratified by the house of peoples of representatives of the federal democratic republic of
Ethiopia (HPRFDRE) with the task to coordinate, supervise, control and support sugar
industries to insure the effectiveness.
DEPARTEMENT OF CHEMICAL ENGINEERING Page 2
General Manager
Agriculture Factory Human Finance vice Linguistic

operation operation resource manager managemen
manager manager management t
Seed Budget and Material

Technician Health
production finance planning
center
group management
Irrigation
group Sugar
Human Purchaser
resource
Maintenance vacancy
Electric
group management
power
Resource
management
Sugar cane
cutter and Ethanol
supply group group
Figure 1.1 Flow chart of organization

CHAPTER TWO
UNIT OPIRATION OF SUGAR PRODUCTION
2.1. MATERIALS
Sugarcane, with its high fiber and carbohydrate content constitutes an important renewable
source of energy. Sugarcane sets are planted in soil and the plant growth in the course of its
life cycle, during which it converts water and CO2 from atmosphere into carbohydrates in the
presence of sunshine, a phenomenon termed as photosynthesis.
The principal components of the cane stalks to be processed for commercial sugar production
are:-
Water ------------------------------70-75%
Sucrose ----------------------------10-17%
Reduced sugars ------------------ 0.4-2%
Organic non-sugar-------------- 0.5-1%
Mineral matters -------------------0.5-1%
Fiber-------------------------------10-16%
Besides these the composition of juice extracted from cane is marked by varying amounts of
mineral salts and organic compounds. The composition of sugarcane is conditioned by the
variety of cane, soils and agricultural factors in addition to the climate during the different
phases of growth of the plant.
Sugars in general are known as carbohydrates being formed of carbon, hydrogen and oxygen.
Simple sugars like glucose, fructose etc. are monosaccharaides which cannot be further
decomposed into simple carbohydrates by either acids or enzymes.
The sugar industry processes sugar cane and sugar beet to manufacture edible sugar. More
than 60% of the world’s sugar production is from sugar cane and the balance is from sugar
beet, but in FSF white sugar production is from sugar cane.
The extent to which an organization pays attention towards developments in the business
environment and the way it is prepared to respond determines it’s success and sustainability

in business it is engaged. This strategic planning of Fincha sugar factory (FSF) is therefore
prepared considering developments that took place in the environment.
2.2. Methods of Sugar Production

2.2.1. Cane Preparation
2.2.1.1 Cane Burning
Cane is burned before cutting when it is matured (18-24 months after planted).
Purpose of burning of cane:-
 To remove impurities
 To reduce transportation cost
 To increase extraction capacity
 To reduce loading
 To reduce sugar losses
Mature sugar canes are gathered manually and mechanically. Hand cutting is the most
common method, but some locations use mechanical harvesters. Canes are cut at ground
level, the leaves are removed and the top is trimmed by cutting off the last mature
joint. Cane is then tied in bundles and transported to a sugar factory. After cutting, cane
deteriorates rapidly, so the sugar cane cannot be stored for later processing without excessive
deterioration of the sucrose content.
2.2.1.3 Cane Yard

Cane yard is the temporary storage of the cane. After cutting the cane must reach for the
process at most within 24 hrs. .To avoids evaporation of water from the cane and inversion of
sucrose. It is not essential to stay 24 hrs. After cutting, but wait until their turn reach to be
unloaded.
2.2.1.4 Weight Bridge

Cane is delivered from the field to the factory by means of cane traveller’s (carts). The cane
is weighted before unloading by Weight Bridge. The weight bridge of this factory is
electrically weighing instrument based on load cell principle. It weighs trailer with its cane at
a time and having a capacity of 30000kg and size 12m x 3m plate form .It is important to
weigh the total impute of the cane to the factory that able to determine the quality of

production of the factory, loss by the weight bridge cane is transported to cane unloading
crane.
The main objective of the weight bridge is:-
 To accurately know the different cane varieties and calculate the yield of cane.
 To determine input and output capacity.
 To estimate the cost which is paid for the farmer whose the cane is belongs.
 To know the chemical control and determination of factory performance.
2.2.1.4.1. Working Principle of Weigh Bridge

First the cart came with a load (cane) is weighed and recorded. Then after the empty cart
while on the way to the field will be weighed, at the last the difference will be taken to get the
exact weight of the cane as follows:-
Net weight = Gross weight –Tare weight
Table 2.1 calculations on Weight Bridge

Shift Gross weight(kg) Tare weight(kg) Net weight(kg)
1 31970 18070 13900
2 49080 27600 21480
The weighed cane recorded depending on:

 field number
 cane variety
 month of planting
 number of cart used in 24 hour
 date of harvest
 date of plant
2.2.1.5 Cane Unloading

Is a process of dumping cane from cart, lorry, trailer etc., by material called fixed type crane
which have high lifting capacity. The cane fed to feeding table having crane is leveled by the
leveler without size reduction transported to main cane carrier. Then the cane is transported
to the first knife.

Figure 2.1 Cane unloading

2.2.1.6 Cane table
The feeding table is rectangular table having a dimension of 8m width and 12.5m long. It
carries about 275t/hr. The leveler is installed on the feeding table rotates in reverse
direction to the movement of the feeding table with 40rpm. The cane table feeds uniformly
over the horizontal cane carrier. Good cane preparation is defined as it should be
uniform having long fiber with minimum dust & having 85%-95% juice cells opened & it
should be consistently uniform all the time during whole crushing season.
Good cane preparation not only improves mill extraction, but also in FSF they use hot water
at 75% and juice for imbibition. This imbibition is said to be compound imbibition
Figure 2.2 Cane table

2.2.1.7 Main Cane Carrier
The function of this moving apron type conveyor, commonly known as cane carrier is
to convey sugarcane from the feed table to the knifes. A cane carrier should have
horizontal portion of 30m suitable for cane feeding and the inclined portion has a
slope of normally 18°.The capacity of cane carrier is 275t/hr. with the speed of 15m/min.
The main objective of cane preparation is:-
 They favour the capacity of the mills.

 To render the juice more readily available for the action of imbibition by
breaking and opening cane cells.
 They increase the extraction of the juice by breaking the rind of the cane.
2.2.1.8 Knives
The role of the knives is to break the rind of the cane to facilitate the disintegration of the
cells and extraction of juice. It also increases the bulk density of the cane by cutting it into
very small and short pieces.
2.2.1.8.1. Factors Affecting the Efficiency of Cane Knives
There are some factors which affects the efficiency of the cane knives directly. These factors
are listed as follows:-
Speed of rotation
Pitch of knives
Quality of knives
Cane variety
The radius of cutting circle
2.2.1.9 Cane Shredder
Shredder is essentially a hammer mill adapted to the function of sugar cane pulverizing and
swing hammer type shredders of different designs are common in sugar producing. The
hammers revolve on pivots. As the shredder starts rotating the hammers are thrown out
radially by centrifugal force. The shredders rotate at 1000-1200 rpm.
In Fincha sugar factory we do have two sets of knives seriously installed over the same
elevation (clearance).

The first set of knives rotates in the direction corresponding to the movement of the carrier
(i.e. counter clockwise direction) and the second set of knives rotates in the opposite direction
of the movement of the carrier(i.e. clockwise direction). In such a way the first set of knives
cut the cane into pieces and conveyed to the second set of knives for more size reduction. The
more size reduced cane will be obtained after the effect of knives.
Cane knives can be driven by:-
 Electric Motors or
 Steam Turbines
The trend in the sugar industry and in modern factories is to utilize electric motors to drive
cane knives and shredders, while mills are generally driven by steam turbines. One of the
advantages of the steam turbine is that its speed regulator allows some speed variation. Drive
transmission is done directly through a flexible coupling.
Belt:-used to transport the prepared cane from fiberize to diffuser.
Magnetic separation:-used to separate magnetic metals from the prepared cane.
Frist knife set Second knife set

Blade types is straight single sided Blade types is straight double sided
Number of blade is (56) Number of blade is (84)
Knifes width (2.134m) Knifes width (2.134m)
Diameter of knifes (1500mm) Diameter of knifes (1500mm)
Shaft diameter ( 250mm) Shaft diameter (250mm)
Table 2.2 Comparison of first knives’ set with that of the second knives set
Figure 2.3 shredder

2.2.2 Milling Parameters
In Fincha sugar factory there are four mills for extraction of juice from sugarcane. The
prepared cane from preparation plant feed to the first mill by gravity. The top roller is driven
by the prime mover. The feed & delivery rollers are meshing to the top roller by pinions.
Thus the top roller drives the other two rollers. In the three, rollers are arranged, by applying
hydraulic pressure on top roller, the layer of the prepared cane is compressed twice. In most
cases the opening ratio feed to delivery is 2:1.
During juice extraction, hot water is sprayed onto the sugarcane to dissolve any
remaining hard sugar. The prepared cane residue (bagasse) that remains at the last mill
with a moisture of 49-51% passes to the steam generating plant as a main fuel and the raw
(mixed juice) is pumped to the boiling house for further weighing clarification, heating,
evaporation and crystallization process.
Imbibition water
Milling Plant
Prepared cane Mixed Juice
Bagasse
Figure 2.4.Milling Plant
2.2.2.1. The Objectives of Mill Extraction
 To extract large possible quantity of sucrose in suitable commercial cost.

 To produce bagasse for power generation (less moisture and sucrose losses)
 To produce mixed juice nil of bagacillo to help in further operation
 To produce moisture less bagasse to increase boiler efficiency.
2.2.2.2. Mill Rollers
Is cast iron shell mounted shafts & rotates in bearing supporting the housing. The wear
of the rollers occurs due to corrosion of metal by the acid in the juice of sugar cane, friction
between scraper & trash plate to the roller, passage of tramp iron. In mill standard
design the maximum wear permissible in roller is approximately 4-6%.

Number of roller in each mill
Frist mill has 6 rollers

Second mill has 4 rollers
Third mill has 4 rollers
Fourth mill has 6 rollers
Figure 2.5 mill roller
2.2.2.3. Juice Extraction
Milling is the process of extracting juice from prepared cane or the process where bagasse is
removed. . The cane is made to pass through a succession of rollers that comprises the milling
tandem, and its juice is squeezed out as it goes through. To help to extract the maximum
juice, use of imbibition’s water is made. The extracted juice is sent to process and the fibrous
material left after milling, known as final bagasse, is sent to the boilers to be used as fuel for
the generation of steam.
2.2.2.3.1. Methods of Separation of Juice from Cane
The sugar content of cane is dissolved in juice contained in millions of plant cells. There are
two different systems of extracting the sugar containing juice from the cane. Such methods of
Extraction are: -
 By means of pressure in a number of mills provided with three rollers through which
the cane is forced.
 By means of diffusion, extracting juice by applying heat, immersion in water drum
and squeezing of the bagasse. In this room there is about 80% of the juice are
extracted by adding imbibition water and lime. The lime used for settling material by
increasing density difference.
Mill is a combination of three rollers
Top roller: - is driven from prime mover through a redaction gearing.it is controlled by
hydraulic drum may rise or float with the variation in the feed cane.it is flexible roller.
Delivery and feed roller: - are moved by the fraction of top roller .they are rigidly fixed on
their position.
The main objective of mill tandems;-
 Is to extract a maximum amount of juice from the prepared cane.

 To produce a bagasse with minimum amount of pol content.
First mill: - 65%of juice is extracted from the prepared cane in the first mill. The juice
extracted is called primary juice. To extract this juice the prepared cane is delivered to top
roller with the aid of under feeder when top roller rotates it produce frictional force with both
feed roller where the first extraction takes place and delivery roller where the second
extraction takes place.
Trash plate: - The plate is which act as a bridge between the feed and delivery roller. It
maintains a part of compaction achieved at the feed roll while turning the bagasse in to the
nip between the top and discharge roll. Also it conducts the bagasse from feed roller to the
real mill opening have the teeth cut in the side of feed roller.
Roller scraper: - it is fitted on the top and delivery rollers. Their purpose is to scratch of the
bagasse caught.
Second mill-fourth mill:-the left 35% of juice is extracted by these mills. This juice is called
secondary juice.
2.2.3. Imbibition
It is not possible to remove all juice from the bagasse by pressure. In order to obtain a
satisfactory extraction of sugar, it is necessary to dilute the juice remaining in the bagasse by
adding water. Therefore; imbibition’s is the process in which the water is put on the bagasse
to mix with and dilute the juice present in the bagasse. The water so used is termed as
imbibition’s water.

2.2.3.1. Type of Imbibition and Method of Applying
Simple imbibition’s:- where water only is applied to the blanket of the bagasse. This is
not practical in modern installation.
:- applicable to trains of four or more mills, where water is

applied to bagasse going to last mill. The last mill juice is returned to the next to last mill.
This juice in turn goes back to bagasse from the proceeding mill.
In Fincha sugar factory compound imbibition is practicing now a day. The other thing is
imbibition’s water is added over the second mill in Fincha sugar factory.
2.2.3.2. Advantage and Disadvantage of Imbibition of Water
Advantage
To reduce sugar losses

To avoid fermentation or inversion
To avoid high power consumption in heater
Disadvantage of imbibition
 High power consumption in evaporation.

 Increase water cost
 Increase moisture content of the bagasse
Brix, pol and purities
Brix: - is the weight of soluble solid in 100gm parts by weight of juice. Because of the
addition imbibition waters to the fourth mill the brix of mixed juice decreases from the first to
the last successive mills. The juice obtained from the mills has a brix value of 120 in FSF.
Pol: - is the apparent sucrose content of a mixed juice. Pol is also decreasing from the first to
last mills because of addition of imbibition water.
Purity: - indicates what percentage of the solid in a sugar solution is composed of sugar.
Purity = x100%
Factor affecting capacity of mills
Cane preparation: - the more the prepared cane the more the extraction.

Specific pressure:- The extraction increases rapidly as the pressure increases

Number of roller:-as the number of roller increase extraction also increases
2.2.4. Juice Weighting
In a sugar mill the main material whose weight must be determined is cane. The weight of
cane is the most important information, since other materials are always related to
cane weight. Therefore cane weighing is compulsory. Mixed juice is normally weighed or
measured. If the juice is measured samples of each measuring tank is taken to obtain an
average density of the measured juice and find the correct specific gravity. The volume of the
juice is converted to weight by multiplying it by its specific gravity. Imbibition water is also
weighed or measured. When it is measured, its volume is converted to weight multiplying
its, specific gravity. Weighing of bagasse is very inconvenient. Under normal conditions, the
factor relating cane, imbibition water and mixed juice is bagasse.
The purpose of mixed juice weighing carried out in sugar industries are:
 To determine the weight of bagasse supplied to boiler plant

 To determine the milling plant extraction
 To determine the boiling house recovery
2.2.5. Juice Heating
Weighed mixed juice is pumped to juice liming and Sulphitation station through primary
heater by weighed juice pump. The type of juice heaters normally used in sugar mill called a
shell and tube heat exchanger, essentially comprises of shell containing top and bottom tube
plates which hold the heat exchanging tubes in position. The juice follows upward downward
flow through the different passes, in order to achieve the required contact time, maintaining
the juice velocity at optimum for better heat transfer. The juice heaters are also called as
multi-pass juice heater. The juice flows inside the tubes while steam or vapors is applied on
shell side .
Juice heating is carried out in three stages .These are:-
2.2.5.1. Primary Juice Heating
In primary juice heaters the temperature of mixed juice is raised to 70-76°c with help of heat
exchanger. Primary juice heating has the following major purpose:

 It accelerates the reaction rate between juice acid and milk of lime during lime
process,( Acid +Base = salt +water)
 For avoiding fermentation
 Heating destroys the microorganisms and enzymes contained in juice and hence
preventing lose of sucrose by microbiological activity.
2.2.5.2. Secondary Juice Heating
Limed and Sulphited juice is heated to above the boiling point (to temperature of about 100-
105°c) before admitting it to clarifier’s that the pressure in the juice will be above
atmospheric pressure .Purpose of secondary heater is:-
 Removing air bubbles (contained in the juice) that would retard settling of impurities
in clarifiers are flashed out of the juice in the tank.
 Settle for the impurity to fall in the bottom
2.2.5.3. Clarified Juice Heating (Third Juice Heating)
Clarified juice is heated to about 110-115°c before it flows to evaporator, such heating of
clarified juice brings the immediate starting of boiling in the evaporator as result of which the
evaporation capacity of the vessel is raised.
2.2.5.4. Principles of Juice Heating (precondion)
For juice heating the steam or vapor comes in contact with the heating surface and
the temperature of juice at the other side is lower than that of steam. The steam is able to
transfer heat to the juice through the metal surface of the tube. This causes the temperature
reduction of the steam. This reduction is possible only if certain amount of steam condenses.
If there is no condensation of steam, there is no heat transfer from steam to juice. Therefore
superheat steam cannot be used for heating, because it has to lose the superheat first
before it can start condensing. The steam of very low pressure is not normally used
for heating even though its latent heat is higher.
2.2.6. Clarification and Evaporation
2.2.6.1. Clarification
It is a process by which the removal of suspended solids or impurities takes place.

2.2.6.1.1. Objective of Clarification
Separation of non-desirable or impurities from the juice

To separate soluble and insoluble mater that can be precipitated
To reduce colour and turbidity of the juice
To produce clear juice of correct PH=7
To kill or inactivate microorganisms in juice heat treatment
Condition for good clarification
 Loss of sucrose and formation of colour minimized

 Low viscosity
 Maximum temperature
 Optimum rotation time(2-3hrs)
 required amount of flocculants
 Proper PH(7-7.2)
 Mixed juice brix (should be 14-18%)
2.2.6.1.2. Chemicals (Materials) Used In Clarification
There are three chemicals which are used in FSF for purification of juice in general. This are:
 Lime (Cao); the treatment with lime is called “defecation”.

 Sulphurous acid; from SO2; treatment with SO2 is called “Sulphitation”.
 Phosphorous acid; from P2O5; treatment with P2O5 is called “phosphatation”
Advantage of lime on juice clarification
Eliminate (neutralize) the organic acid (oxalic acid and tartaric acid).
(i.e.3ca (OH) 2+p2O5 Ca3 (p2O5)2+3H2O)
Easily separating of juice from mud.

Advantage of Sulphitation on clarification
 Neutralize excess quantity of lime added

(i.e.Ca (OH) 2 + H2SO3 CaSO3 + H2O)
 Fast crystallization of sucrose

 For whitening of sugar
 The mud settles more rapidly (hence improved capacity of clarifiers).

 They are less viscous and boil faster (better crystallization in consequence);
2.2.6.1.3. Roll of Phosphate
The phosphate content of the juice is the most important factor in efficient clarification. In
sugar cane the phosphates are found as inorganic as well as organic forms. It is obvious that
only the free phosphate ions (inorganic form) take part in juice clarification.
Therefore, the juice with adequate quantity of inorganic phosphate is most desirable. During
cane growing, if fertilizers are not properly applied, there may be more organic phosphate in
the juice than inorganic phosphate. Then the juice may not respond well to clarification.
It is demonstrated that the inorganic phosphate level in raw juice is less than 300 ppm, the
juice can’t be properly clarified and addition of phosphate is required.
The advantages of phosphate adding are:-
 Greater colloid elimination

 Fewer lime salts in clarified juice
 More rapid settling
 Faster mud filtration
The disadvantages of phosphate addition
 The precipitate tri-calcium phosphate is difficult to filter

 Increased mud volume
 Higher lime consumption and extra cost
2.2.6.4. Description of Equipment
2.2.6.4.1 .Storing Equipment
Receiving tank:-is used as storage equipment for the juice comes from extraction plant
before and after it enters the measuring tank.
. 2.2.6.4.2. Measuring Equipment
Measuring tank:-used to measure the amount of the raw mixed juice extracted and to know
the performance of extraction plant

2.2.6.4.3. Clarification Equipment’s
Sulphitation tank: -is a tank where Sulphitation process is takes place. SO2 eliminates some
of the colored matter and reduce colorless compounds like ferric salt. The Sulphitation tank
has two compartments. The first compartment is station where lime and juice are mixed and
the second compartment is where limed juice is mixed with SO2.
The chemistry of lime station (i.e. Cao+ H2O Ca (OH) 2 )
At this station the milk of lime suspension is added over the hot mixed juice to bring the PH
from 5-8.6. After liming station it reaches Sulphitation station and S02 gas is injected from
the bottom of the container with high pressure. This brings the PH from 8.8-7.2 which is
nearly neutral media.
The chemistry of sulphur station (i.e. S + heat SO2 (g))
This neutralized juice will be pumped to the Dorr clarifier. But on the way to Dorr clarifier;
the second heating will be applied to juice from Sulphitation station. This application of the
second heating brings the juice with a temperature from 100-103OC.
Flash tank: - is used for flashing air bubbles and vapor come from second heater by chemical
structure also as well as volatile components. This is used for properly juice in the clarifier. It
is a simple cylindrical tank located just above and a head of the clarifier, with a flue open to
the atmosphere.
Working Principle of Flash Tank
The juice from second heater is discharged to flash tank tangentially. Since this juice is
heated to 100-1030C it partially flash in to vapor when discharged in to this vessel at
atmospheric pressure. The vapor or the flashing from the suspended particles the air bubbles
attached to them and the juice is sent to the door clarifier.
Door clarifier: - It is equipment in which sedimentation process takes place. It is a vessel

which has four independents compartment which are sloppy towards the center. At the center
there is a slow rotating hallow shaft which has two main functions. First which supply juice
for each compartments and the second scrap the mud from tray by the scraper. The clear juice
from each compartment is drained by means of over flow tube.

Basic Factors Affecting Settling of Mud

 Fertilizer applied to sugar cane field
 Brix of the juice
 Temperature of the juice
 PH of the juice
 Method of liming of the juice
Working Principle of the Door Clarifier
Since the raw juice is limed, Sulphited and flocculated, therefore it is not difficult to settle the
mud from the juice because they facilitate the rate of settling and decrease the amount of
juice in the mud. The settling is done due to gravity or density difference. After settling, the
mud is scraped by the shaft and goes to OC filter for more clarification and the clear juice
goes to evaporator.
OC Filter: - is used to separate juice that rest in mud which comes from door clarifier.
Working Principle of OC Filter
First the mud comes from door clarifier is mixed with bagacillo in the mixer and flow to the
rotary drum. The rotary drum has lower and higher vacuum. When the drum rotates the mud
is attached to lower vacuum and the juice is sacked by higher vacuum. The lower vacuum is
showered by hot water to remove the juice from the mud. The juice filtered is called filtrate
and solid part is called filter cake. The filtrate is goes to receiving tank and mixed with raw
juice for further clarification whereas the filter cake is collected for fertilizer purpose in the
field of sugar cane.
Figure 2.6 OC Filter
2.2.6.5.Factors Affecting Efficiency of Clarifier
 The difference in the density between the particles and juice.

 The area and shape of the parties.

 The viscosity of the juice.

 Temperature of the juice.
 Reactions
Mixed Juice weighting
1st Heating (750c)
Liming
Sulphitation
2nd Heating (99-

102)
Flashing
Flocculent Addition
To 3rd heater
Door Clarifier Clear juice
Muddy Juice
Mud Bagacillo Mixer Sweeting of water
Filtrate
OC Filter
Filter cake
Figure 2.7. Flow sheet of clarification

2.2.7. Evaporation
Evaporation is generally refers to the removal of water, by aqueous solution of non-

volatile substances and used to concentrating juice. Juice evaporation is to remove by far the
greatest weight of material, water from the clarified juice (two third of water) without
effecting crystallization process. Hence, the evaporation process is the process of
concentrating juice from about 15 brix to 60-65 brix.
Composition of clear juice:-
Water (85%) (Source-from cane and imbibition water)

Solids (15%) (Sugar and Non sugar)
Exhaust steam (@1200c and 1.2 atm)
Feed (juice) Evaporator syrup (brix60-650)
Condensate (950c-1000c)
Objective of evaporator is:-
- To concentrate or increase the concentration of juice by removing of water

from it.
2.2.7.1. Arrangement of Evaporators
Based on the concept of steam economy two evaporator arrangements are realized.
 Single effect evaporators

 Multiple effect evaporators
Multiple-effect evaporators are the principal means (arrangement) in use for economizing on
energy consumption. They can be double, triple, quadruple, quintuple, sextuple, etc. As the
number of effects increases, energy (steam) saving increases, but the rate of evaporation
(which is minimum when the number of effects is greater than five and maximum when the
number of effects is three) decreases. The rate of evaporation falls with the number of effects
because the driving force, log-mean temperature difference, for heat transfer decreases.

In Fincha sugar factory multiple effect evaporators used in current time. These
evaporator consists of several vessels in series and these vessels are connected, so that the
vapor from one goes to the calanderia of the following vessels and ultimately to the last
vessel which is connected to a condenser. Steam is admitted to the first vessel. Juice enters
below the calanderia of the first vessel where it boils and goes out by means of a down take
to the next vessels and ultimately out from the last vessels as syrup. The water which is
evaporated from the evaporate section will be condensed and pumped to the boiler. The
calendric tubes of each of the five evaporators are identified with the following
Specifications.
Evaporator Tube outer Tube length Total surface

Diameter(mm) (mm) Heating(mm)
Frist effect 38 2.13 1400
Second effect 38 2.13 1400
Third effect 38 2.13 1100
Fourth effect 38 2.13 850
Fifth effect 38 2.13 850
Table 2.3 The Calanderia Tubes Of Evaporator

2.2.8. Pan House and Crystallizer
This is the area of a sugar plant where cane juice is treated, clarified concentrated and
then sugar is manufactured with proper procedure. And according to the process there is a big
list of machineries but in short we are giving here under about some main equipment’s
commonly used in all type of sugar industries.
2.2.8.1. Pan Boiling
Pan boiling is the process of forming crystals by mere evaporation and concentration. The
primary objective of pan boiling is to develop grain (formation of crystals). So, it is to
produce satisfactory sugar crystal from syrup or molasses.
The vacuum pan is an evaporative crystallizer which the degree of super saturation is
controlled by evaporating solvent as the solute crystallizer out.
Crystallization is an operation which is more than mere evaporation / concentration b/c it

must be performed in an orderly manner so as to yield a uniform product and obtain an

efficient extraction of the sugar. To achieve these, massecuite have to be evaporated to a brix
content of b/n 92 % and 96%
The pan boiling is essentially consists of the removal of water by evaporation in a single
effect vessel known as vacuum pan and crystalizing out sugar by increasing the
concentration.
The operation known in the sugar factory as sugar boiling is essentially the process of
crystallization, which is carried out in single effect vacuum evaporators designed for handling
viscous materials and known as vacuum pans. Thus, the vacuum pan is an evaporative
crystallizer in which degree of supper saturation is controlled by evaporating solvent as the
solute crystallizes out.
2.2.8.1.1. Types of Pan
Batch Vacuum Pan: - used in production of high grade sugar and low grade sugar except
“B” sugar.
Continuous Pan: -used in the production of B sugar.
2.2.8.2. Crystallizer
Crystallization is the process of forming crystals after the massecuite leaves vacuum pan.
Crystallizers are fitted with agitators to:
 Renew the layer of mother liquor around the crystals and ensure uniform super
saturation
 To bring fresh massecuite in contact with the cooling surface.
 Cooling can be achieved by natural cooling (air cooled) or
 By circulation of water in cooling element (water cooled)
SYRUP CRYSTALLIZATION PROCESS SUGAR 99.5%

BRIX 65c0 PURITY
83_85% PURITY
FINAL MOLASSES
33-35%PURITY
Figure 2.8 Flow sheet of Crystallization

2.2.8.2.1. Rate of Crystallization
The rate of crystallization depends on:-
The viscosity- the higher the viscosity of the mother liquor, the more difficult
for diffusion of molecule.
The temperature- higher temperature favours faster crystallization.
The super saturation- the higher the super saturation, the higher the rate of
crystallization.
The crystal surface area- Crystal surface area improves accommodation rate.
2.2.9. Centrifugation and Drier
For manufacture of plantation white sugar with Sulphitation process as followed in FSF the
syrup is generally subjected to three stages boiling, to prepare A, B and C
massecuite. The massecuite are centrifuged to separate the grains and mother liquor. High
grade(i.e. massecuite cured in vertical batch) , automatic recycling or semi-automatic
machines with application of sugar heated water wash or hot water wash and steaming
, heavy and light molasses are separated and stored separately. A light molasses is fed back to
a massecuite and a heavy is used to prepare B massecuite. Efficient separation of heavy and
light molasses is very important for proper pan boiling and quality of sugar.
For curing of C massecuite, continues type of centrifugal are generally used with application
of some water or diluents i.e. mixture of molasses and water in the feeding cup to improve
mobility or fluidity of massecuite. C massecuite are double cured by making magma of C-
single cured sugar in water or C- light molasses. C double cured sugar is melted and
used to build a massecuite. B single cured sugar is other melted like. Sugar or sometimes
used as footing for an A massecuite by making is magma.
2.2.9.1. Types of Centrifugal
2.2.9.1.1. Batch Centrifugal
Machines with flat bottom mechanical discharge, with capability of automated recycling are
in progressive use in Fincha sugar factory. Basically, these machines have a cylindrical
perforated basket duly ribbed for strength fitted to a shaft driven by AC or DC motor fitted at
the top. The basket is provided with supporting liners and fine screens for retention of
crystals in the basket and easy passage of molasses to the draining channel in the

monitor casing. Massecuite for purging is charged from top and sugar is discharged
through the bottom of the basket which during running operation is closed by stop
valve. The basket is provided with arrangement of water and /or steam wash application.
The molasses channel with separators is attached with monitor casing to fractionate heavy
and light molasses according to the timers for wash applications. Basket speeds are varied
during operation of charging curing and discharging etc. with the help of timers.
2.2.9.1.2. Continuous Centrifugal Machines
As its name implies this type of centrifugal machines are used to cure continuously low grade
massecuite of high viscosity at constant speed at constant speed of 1500-2000rpm.
The centrifugal is fed continuously by the massecuite and the cured sugar is discharged
continuously at high speed. Thus it avoids wastage of time and power in frequent
stoppage, starting the machine, charging and discharging less accelerating power is required.
Principle of operation of continues centrifugal machines This works on the layer

principle as massecuite centrifuged with center point and disintegrate molasses and sugar
from massecuite by the action of developed centrifugal force at high rpm. The first
component of centrifugal force along the basket wall expels out sugar from top edge of the
molasses. Centrifugal force exerting on the material depends up on the level of the gravity
factor which is directly proportional to the diameter of the basket and square of the speed.
Higher the viscosity of the massecuite it will require higher centrifugal force for centrifuging
and separating purpose
2.2.9.2. Sugar Drier
Sugar discharged from centrifugal is in moist condition, and cannot be stored as such. Thus
before packing it is dried and cooled to a reasonable limit for maintaining keeping quality.
For this purpose sugar driers are used.
2.2.9.2.1. Types of Sugar Drier
2.2.9.2.1.1. Static Bed Drier
In static bed which, tray remains static, both fluidization and shifting of sugar takes place
with air.

2.2.9.2.1.2. Fluidized Bed Drier
In this type of drier tray is vibrating and sugar is fluidized by air. Shifting of sugar takes place
due to vibrating tray. Moving bed type fluidized bed drier are more common. It contains
double deck tray, having separated by a grid plate. Grid plate is a specially designed
perforated plate, having’ perforations with caps to ensure only air to come out and sugar does
not. On top deck, over grid plate, sugar is fluidized and, slides from one end to the other.
Bottom deck has partitions for hot air blowing and cold air blowing. Entire tray is covered
with a hood, in which fluidization is made.
2.2.10. Packing
Export raw sugar goes directly from the drier to the storage ware houses (silo) .In the ware
houses ,it is loaded in trucks that transport the same to shipping port .standard white and
refined sugar are packed in suck of 100kg.
2.2.11.Sugar Stories
For good keeping qualities of the sugar in a store, it is necessary to observe the following:-
 The sugar should be bagged dry, and not too hot. The sugar is at a temperature above
38°C it hardens in the sacks.
 The bottom layer of bags should be protected from dampness, by interposing a

grating or a bitumen-lined paper.
 The bags should be arranged in large stacks, cubical as nearly as possible, to decrease
the surface relative to the volume.
 The stacks should be covered with bitumen-lined paper, at the top and sides
It would be of advantage to maintain the humidity in the sugar store as uniform and as low as
possible. It should not rise above 65%.
Similarly, the sugar store should be kept at a temperature as uniform as possible. It should not
be opened except on dry and cooler days.
Finally packing is finished sugar bags are then transferred through conveyors to controlled
environment that particular place is called storage.

2.2.12. Boiler and Power Plant
Boiler is the equipment which is designed for the production of steam generation. Boilers use
bagasse as a main fuel source. Since bagasse is the solid fibrous material which leaves the
delivery opening of the last mill of the tandem, after extraction of the juice.
2.2.12.1. Objective of Boiler Plant
 To produce a steam sufficient for the production of electrical power and steam for the
other plant by using the condensate water and bagasse as the main input.
2.2.12.2. Classification of Boilers
The boilers are classified under two categories:

Fire tube or “fire in tube” boilers: - Long steel tubes through which the hot gasses pass from a
furnace and around which the water to be converted into steam.
Fire tube boilers products of combustion pass through the tubes, which are surrounded by
water.
Fire tube boilers have a lower initial cost, are more fuel efficient and easy to operate, but they
are limited due to lower capacity of 25tons/hr. and pressures @ 17.5 kg/cm2.
Water tube or “water in tube” boilers: - The water is passing through the tubes and the hot
gasses passing outside the tubes. These boilers can be of single- or multiple-drum type and
can be built to any steam capacity and pressure, have higher efficiency than fire tube boilers.
The types of boiler used in FSF are water tube boiler. In a water tube boiler feed water flows
through the tubes and enters the boiler drum. The circulated water is heated by the
combustion goes and converted in to steam at the vapor space in the drum. After the juice is
extracted from the cane the bagasse will travel to the boiler. This bagasse is a common fuel
sources for the boiler.
2.2.12.3. Boiler Auxiliaries
Boiler Auxiliaries are in the boiler circuit to increase the boiler efficiency
This Boiler Auxiliary are:-

Air heater:-raise the temperature of incoming air by means of flue gases leaving economizer.
Economizer: A heat recovering device in which the temperature of feed water is raised by
means of outgoing flue gases before it is delivered to the boiler or is a simple counter flow

heat exchanger which reduces boiler flue requirements by transferring from the flue gas to in
coming feed water.
Steam drum: Is a large cylindrical pressure vessel in which the saturated steam is separated
from the two phase mixture leaving the boiler tubes.
Super heater: Remove moisture from saturated steam.
De-aerator: Remove dissolved gases from water.
Feed water pump: pump and feed water to the boiler at high pressure.
Furnace: a place where combustion takes place
Feed water tank: a place where treated water is stored.
Air induced draft fan (AID Fan): They suck flue gases through the interior of the boiler and
dust extracting equipment the chimney
Over fire air fan (OFA Fan):supply air to the furnace at its bottom through air. Push air
through air pre heater, dampers various ducts burners and in to furnace heater
Forced draft fan (FD Fan):supply air to furnace at its top for bagasse combustion .It is used
for bagasse distribution and combustion by over firing process .They handle hot gases, ash
and particulates.
Capacity of the boiler
The FSF’s boiler is four in number and this boiler have the maximum capacity to produce 9
tons/hr. steam; used to rotate the turbine to generate electric energy as well as used for
factory process. In FSF there are two turbines and each turbine generates 1.2 MW. Totally
around 2.4 MW electricity can be produced.
2.2.13. Ethanol Production
Ethyl alcohol is produced from byproduct of sugar (i.e. molasses). Yeast used as a device for
the change of molasses in to alcohol. Molasses not the only raw material, and also used water
and nutrition, the main raw material are molasses, fertilizer and water. Molasses released
from sugar factory, which has sucrose, sucrose in molasses used as feed to yeast. Yeast
Reproduce in culture vessel; they used molasses as a food. Yeast changes sucrose in to
glucose and fructose by the enzymes of inverters later, glucose changes to alcohol and CO2
by the in enzyme.

2.2.13.1. Theories of Yeast, Fermentation, Distillation and Molecular Sieved

Dehydration
Yeast: - is a single celled microorganism that is capable of living with oxygen or without
oxygen this incredible organism is not only the basis for food and beverage production but is
also used as “manufactory” providing by products for bio chemical and life science
applications. Yeast used as avails for changing molasses and water in to alcohol or sucrose in
to glucose, then glucose in to alcohol and CO2. Type of yeast, which used for this application
are: - (1) saccharomyces serves and (2) saccharomyces pumped.
This type of yeast first reproduces in laboratory after laboratory, the scale up in culture
vessel.
2.2.13.2. Chemistry of Ethanol Production by Yeast
Yeast has two enzymes, which used in ethanol production; the first used to change such as to
glucose that is called inverts .The second is called zymase which converts glucose to alcohol,
CO2 and 2ATP
C12H22 O11 + H20 invert 2C6 H12O6 (Glucose + fructose)
C6 H12 O6 zymase 2C3 HOH + 2CO2 + 2ATP
C6H12O6 2C2 H5 OH +2CO2 +2ATP (210 k/mol)
2.2.13.3. Fermentation
Fermentation is a process in which chemical change takes placed by using micro-organism.

Some alcohol content forms interment. And also roast residue (w02) and growth (w out o2)
occurred. Fermentation worked under anaerobic and aerobic condition the reason is listed
above it also work by low temperature, low brix and the PH not basic bio-chemical operation
takes placed instrumentation, because yeast (biological organism) changes. Such are to
ethanol (chemical reaction).in the first two fermenter produced very less content of alcohol
and high ATP, because they worked by aerobic condition. The other the last two fermented
produced high alcohol content relative to the first two fermented.
1. C6 H12O6 C2H5OH + 4CO2 +36ATP
2. C6 H12O6 2C2 H5OH + 2CO2 +2ATP

At the last fermented expect 8% of alcohol content and 92% water and other impurities.
2.2.13.4. Distillation
It is the separation of a mixture in to its component parts or fractions depends on their boiling
point. Fractional distillation a selective distillation for this operation in case of their boiling
point difference for example in FSF ethanol production, the fractional distillation, and
separate ethanol and, water depend on their boiling temperature and high volatile. The
distillation column top to bottom is increase relative to ethanol so, ethanol first separate from
water. General fractional distillation worked by temperature difference.
2.2.13.5. Molecular Sieve Dehydration (MSDH)
The separation is difficult or impossible, when the amount of water reaches to 4% this
problems solved by designed molecular sieve dehydration process. Molecular sieve
dehydration has abed. They are made up of bronteyolate, and stainless steel. It works under
vacuum pressure and under normal pressure at the same time. Water enters in to beds and
alcohol passes at the side of beds this is adsorption processes done by vacuum pressure.
Water and beds have polarization. And the sites of beds are 3.2Ao.the separation of ethanol is
adsorption and water is absorption.
2.2.13.6. Process Description
The first step for production of ethyl alcohol molasses weights for in bulk tanks for some this,
molasses released into culture vessel and fermented. The weighted molasses and, water enter
into culture vessels (CV), and also used air, acid and nutrient used up to CV4. Yeast
preparation takes placed in this vessel (CV1 up to CV4) by aerobic reaction after yeast
preparation fermentation begins. Fermentation the propagated yeast released in to first in
fermented molasses dilated to very low brix for sample feed to yeast in fermented one and
two use aerobic reaction, but fermented 3 and 4 are an aerobic reaction. After fermentation,
proceed is to distillation. The clear holding wash enters in to distillation. Holding wash which
contains 8% of alcohol content, released in to primary columns. In this process the two
mixtures separate depend on their volatility. From this column produce 45% of alcohol. After
this, it released to rectifier column up to de aldehyde column to produce 96% alcohol then
recollery column after that molecular sieve dehydration (MSDH) The alcohol content, riches
to100%or 99% first alcoholic content ethanol, when feed to sieve 96% first alcoholic content
and water enter the beds. The water is absorption and ethanol is adsorption.
CANE BAGASSE BOILER

STEAM
FILTRATE
JUICE HEATER CLARIFIER FILTERS
FILTER CAKE
SYRUP EVAPORATOR
CLARIFIER RRRRRRRRRR
PAN CRYSTALLIZERS CENTERIFUGAL

A-Molasses
A-sugar
Figure 2.9.Process Flow Sheet of White Sugar Production

CHAPTER THREE
MATERIAL AND ENERGY BALANCE
3.1. Over All Material Balance on Milling
Cane + imbibition water = mixed juice + bagasse
Bagasse = cane + imbibition water - mixed juice
B=C+I-J
Where
c = prepared cane
I = imbibition’s water added per unit of cane
B = bagasse to boiler
J = juice to process Data
Imbibition
Juice Cane Milling Juice to process data
Bagasse
3.2. Material Calculation for Milling Section
Basic data and symbols
 Fiber per unit of cane, fc = 14.7%

 Fiber of first mill, f1 = 33%
 Fiber of second mill, f2 = 40%
 Fiber of third mill, f3 = 44%
 Fiber of fourth mill, f4 = 47%
 Fiber of fifth mill, f5 = 50%

 Cane crushed, c = 100%

 Weight of mixed juice per unit of cane, Q
 Weight of bagasse per unit of cane, b
 Imbibition per unit of cane, Iw = 0.3098
 Fiber content of bagasse, fb
Basic equation
a. Over all balance
Cane (c) Bagasse (b)

Mill station
Fiber % cane Fiber bagasse (fb)
(fc)
Mixed juice (mj)
Input = out put
C + Iw = Q + b
100% + Iw = Q + b
1 + Iw = Q + b b = C + Iw – Q …………………….(1)
a. Fiber balance
fcC = fsbs =>bs = ……………………………(2)
b. Mixed juice (from equation 1 and 2 ): -
Mj = (bs= ) V + Iw = ( ) ton /hr + 0.3098
= ton/hr
Bagasse determination (b1, b2, b3, b4, b5)
 Fiber balance around first mill set:-
fc C = f1b1 => b1 = = 44.5% unit
fc C = f2b2 => b2 = =36.8% unit
 Fiber balance around third mill set:-

fcC = f3b3 => b3 = =33.4% unit
 Fiber balance around fourth mill set:-

fcC = f4b4 => b4 = = 31.3% unit
 Fiber balance around fifth mill set:-

fcC = f5b5 => b5= = 29.4% unit

 Hence from equation 1, Q = 1 t – b = 1 + 0.3098 – 0.294 = 1.016

Juice entering and leaving a group of mills
o Juice determination around mill one:-
C Crusher + 1st mill

b1 b1
j1
C = j1 + b1 => j1 = C = b = 100% - 0.445% =0.555
Juice around mill:-
b1 Second mill b2
j1 f2 j1 b1 = j2 b2
j2
j2 = :- j2 = 0.643
o Then from equation 4, to get j3:-
j3 = j2 + b2 – b1 = 0.643 + 0.368 – 0.445
= 0.566
o Juice around third mill: -

J5
b2 Third mill b3
f2 f3
j3
b2+ j5 = b3 + j3
b2 f2+ j5 = b3f3 + j3
j5 = b3 + j3 - b2 j5 = b3f3 + j3 - b2 f2
= 33.4% 44% + 0.566 - 36.8% 40%
= ( 0.334 ) ( 0.44 ) + 0.566 - ( 0.368 ) ( 0.40 )
= 0.5658

o Juice around fourth mill: -

Iw
b3 Fourth
j4 mill b4
f3 f4
j4
b3 + Iw = j4 + b4
b3f3 + Iw = j4 + b4 f4
= (0.334)(0.44) + 0. 3098 -(0.313)(0.47)
= 0.3097 j4 = b3 f3 + Iw - b4 f4
 Juice around fifth mill
b4 jFifth
5 mill b5
f4 f5
j5
b4 = j5 + b5
j5 = b4 f4 - b5 f5
b4f4 = j5 + b5f5 =>
= (0. 313)(0.47) – (0.294)(0.50)
= 0.00011
3.3. Material Balance in Clarification Plant
Basic data
Cane crushed =49.15ton/hr
Weight of net mixed juice =44.73ton/hr(Wm)
Average ton % lime for 100ton cane =0.172(i.e. 0.142ton/hr milk of lime)
Average kg % of sulphur per 1000ton cane =0.049% of cane
Average amount of so2 =0.07ton/hrs
Filtrate on cane(Fc) 14% =0.14*49.15ton/hr =6.88ton/h

3.3.1. Material Balance around Liming Tank
Milk of lime (M)
Liming tank
Raw juice (R) Lamed juice
R+M=L
R = 44.726 + (0.14 * 49.15) = 51.607 ton/hr
L = 51.607 + 0.14 = 51747
3.3.2.Material Balance around Sulphited Tank
So2
Sulphitation
Limed juice sulphited juice (sj)
tank
@75o (L)
L + S = Sj
51.747 + 0.07 ton/hr = 51.817 ton/hr
Sj = 51.817 ton/hr
3.3.3. Material Balance around Dorr-Clarifier
Flocculants (F)
Sulphited
Juice (Sj) Dorr-clarifier Clarifier juice
Mud juice (M)

Where
Flocculants = 4ppm on weight of juice
F = 4 * 10-6 * 51.817 = 0.000207 ton/hr
Sj = 51.817 ton/hr
Hence
C = Sj + F –M

= 51.817 + 0.000207 – (3.5% * 51.817)=50.0036 ton/hr

Bagacillo
Muddy juice(M) OC- filter Filter Cake
Filtrate
Filter cake (F’’)
M+B =F’+F’’
Where B= 0.6*0.06*9.98=0.36t/hr
F’ = 0.04*49.15= 1.966t/hr
F’’ =M+B - F’ = 9.98 + 0.36 - 1.966 = 8.37t/hr
3.4. Mass Balance and Energy Balance for Multiple- Effect Evaporators
V1 V2 V3 V4
Juice P1 p2 p3 Syrup (P4)
Mass balance
Min-M out + M gen= Macc.
At steady state
Mgen and M acc.= 0
So, M in=M out or juice in = juice out + vapor
F –V- P = 0
BFF=BPP+XVV
BFF=BPP + 0 = BFF juice = Bsyrup P
BF= brix of feed and BF brix of final product.
Therefore general mass balance
F juice –V1-4 – P

V1-4= total vapor of water = V1+V2+V3+V4
Energy balance
Energyin – energyout + energygeneration- energyconversion = energyaccumulation
Qin – Qout + Qgen-Qcon = Qacc.
For steady state evaporator
Qgen, Qcon and Qacc. =0
So, Qin = Qout
Qin: steam enters evaporator and the heat of juice enters.
Q of steam= msteam hs
Q of juice= FhF
Hf= Cp juice (Tjuice-Tr)
3.5. Energy Balance on Evaporator
3.5.1. For the First Effect
mj s + Fjuice Cpjuice (Tjuicein – T1) =V1
3.5.2. For Effect 2
V1 + (Fj-V1) C.P1 (T1-T2)= V2
3.5.3. For Effect 3

V2 + (Fj-V1- V2 – V3) cp2(T2-T3)= V3
3.5.4. For Effect 4:
V3 + (Fj-V1- V2- V3-) cp2(T3-T4)= V4
Where, Cp1, Cp1, Cp2, Cp3 are the specific heat capacity of juice to the 1st, 2nd, 3rd and 4th
respectively,
, , and latent heat of vapor,
T1, T2, T3 and T4, 1st, 2nd, 3rd, and 4th evaporator temperature respectively
For effective evaporation, control the following problems by operator:
3.6. Heat Transfer Rate
The total heat flux across the heating surface of a heater is given by a usual formula
Q= UA∆T
Where Q= total heat flux
U= overall heat transfer coefficient
A= area of heating surface
∆T= temperature drop of condensing steam to boiling juice
3.7. Mass Balance On Centrifugal
3.7.3. Total Mass Balance
From 100% solid in syrup which could be splitted into three products, A/B/C sugar and final
molasses.
Ps = 85, P A/B/C – s = 99.5
Pmol = 33,
Where, Ps – party of syrup
Pmol – party of final molasses
P A/B/C-s – parity of “A/B/C” sugar
Using Co Benz’s diagram the splitting in as follows
99.5 (52/66.5)*100 = 78.2%
85
33 (14.5/66.5)*100 = 21.8%
Out of 100 % solid in syrup, 78.2 % in produces as “A/B/C” sugar while 21.8% in produced
as final molasses.
Centrifugal Force = mv2
C.F= W2r = (2πr)*
= W* ( )
Put G =
Centrifugal force = weight*gravity factor
C.F=W*G
Where N = rpm of the basket

D = diameter of basket
W = weight of massecuite
r = radius of the basket
Flue gas
Bagasse Steam
Water Boiler Ash
Fuel
Figure 3.1 Material Balance on Boiler
B + W + f = F + S + A …………………..Overall balance
Where, B=Bagasse, W=water, f=fuel, F=Fuel gas, S=Steam, A=ash

CHAPTER FOUR
OVERALL BENEFITS GAINED FROM INTERNSHIP
From our internship program we have gained so many benefits which were important for our
basis of knowledge and lead us good experience for the future, as well as good opportunity
from different occupation. During our internship program we have so many knowledge’s
gained these are;
Inter connecters of materials from different fields of study

Inability to see all the apparatus and function on multidisciplinary teams
Understanding of professional and ethical responsibility
Recognition of the need for and ability to engage in lifelong learning
According to this the following are benefits of internship are aspects;
4.1. To Improve Practical Skill
During our internship program we got:-
- Increase self-confidence and independent professional after graduation
- We have seen procedure how the Forman and technician performs their job
- We have seen the difference between theoretical and practical skill
4.2. To Up Grading Theoretical Knowledge
In our staying Fincha Sugar Factory we upgrade our theoretical knowledge by referring
different books such as E. Hugot and manual that prepared on different machine parts that
found in factory’s library. Again this internship program initiate to more a theoretical part we
have seen in the practice. While we are discuses with our factory advisor we get some
information that develops our theoretical knowledge
4.3. Inter Personal Communication Skill

During working our task we ask the advisor and company technicians to get more
information to solve the problems. This improves our interpersonal communication skill with
worker of the company

4.4. Leadership Skill
In our company we have been able to see different people in hierarchy work and the workers
under them, but on other side we learn how to communicate with person among: Good
speaking ability
4.5. Work Ethics
Cooperation: each worker should interact and cooperate with each other while working.
Punctuality: this is arriving at a time to work of the company to begin and ending with point
of time.
Honesty: regarding this value, each worker regardless of his status should abstain from bud
behavior such as cheating, bias, corruption and etc.
Office discipline: in work place we did not disturb working environment
Reliability: the worker should be qualified for the part he has supposed to performing.

CHAPTER FIVE
PROJECT IN FINCHA SUGAR FACTORY
5.1 PROBLEM IDENTIFICTION
There are many problems in Fincha Sugar Factory:
1) Bagasse handling system.

2) Ways of transporting lime stone (CaCO3) from store to lime mixer.
3) During bagasse burning in furnace facilitating the bagasse by human power.
4) Weakness of using the sugar cane at specified time (i.e.in 24hr).
5) Stack of electric motor due to over current and etc.
6) Hydrostatic effect on pan
5.2. Design of Belt Conveyor to Transport Limestone (CaCO3) From Store to Lime
Mixer.
5.2.1. Introduction
From above problem identified, you try to solve /design ways of transporting lime stone from
storage to lime mixer by using belt conveyor. Because there is many human power used,
down time, small efficiency and factory needs at that place.
Figure 5.1. Lime stone store

Belt conveyor is the transportation of material from one location to another. Belt conveyor
has high load carrying capacity, large length of conveying path, simple design, easy
maintenance and high reliability of operation. Belt Conveyor system is also used in material
transport in foundry shop like supply and distribution of molding sand, molds and removal of
waste. This paper provides to design the conveyor system used for which includes belt speed,
belt width, motor selection, belt specification, shaft diameter, pulley, gear box selection, with

the help of standard model calculation. During the project design stage for the transport of
raw materials or finished products, the choice of the method must favor the most cost
effective solution for the volume of material moved. It flexibility for adaptation and its ability
to carry a variety of loads and even be over loaded at times. The belts are used to transmit
power from one shift to another by means of pulleys which rotate at the same speed or at
different speeds.
5.3 Literature Review
The main objective of this paper was to analysis the gravity Roller Conveyor, the detail
study of existing gravity roller and optimizing its parts by using aim was to create a modified
design to achieve larger scale production of idler which enhance the efficiency and
productivity. The remedies on various problems was given in this paper. Rohini Sangolkar et
al. [8]: In this paper the study of structural analysis was done. The modelling is done by using
Creo Software and the FEA is performed to obtain variation of stress at critical location of
system using the ANSYS software and applying the boundary conditions to evaluate the total
deformation, equivalent stress and shear stress. ASTM A-36 hot rolled steel bar and nylon 66
materials was studied for rollers in system and belt respectively.
5.4 Scope
The present scenario of factory is high weight belt conveyor that causes various issues for
workers like back and muscles strain at time of maintenance due to heavy weight of system
and technical issues like difficulty in maintenance of critical components. The detail study of
current belt conveyor system with its design and specifications and finding suitable method
for optimization of current design, and later wards results of redesign compile as modeling
will be done using CATIA software and analysis of components will done using ANSYS
software. Results of Linear static, Model and Transient analysis of existing design and
optimized design are compared to prove design is safe. Optimization leads to give an
appropriate optimum design for carrying the same load while saving the material of system,
weight reduction and power conservation of the system.

5.5. Statement of Problem
The current design for belt conveyor is heavy weight that includes the critical parts like
roller, roller shaft, supporting brackets, L channel base frame which directly affects on excess
use of material with increase in costs, so that power consumption and also the maintenance is
more due to heavy weight system. To overcome these problem redesign of existing system
and analysis with optimization will be done
There are many types of belts, from those;
1. Flat belt: is mostly used in the factories and workshops, where a moderate amount of
power is to be transmitted from one pulley to another, when the two pulleys are not more than
8 meters
2. V_ belt: is mostly used in the factories and workshops, where great amount of power is to
be transmitted from one pulley to another, when the two pulleys are very near to each other.
3. Circular belt or rope: is mostly used in the factories and workshops, where a great
amount of power is to be transmitted from pulley to another, when the two pulleys are more
8m apart. Hence, the two pulley of my design are very near to each other we have to design
V-belt are made up of fabrics and cords molded in rubber and covered with fabric and rubber
.These belt are molded to a trapezoidal shape and are made endless. The included angle for
the v- belts usually from 30o to 40o.the power is transmitted by wedging action between the
belt and v-groove in the pulley results in higher force of friction .A little consideration will
show that the wedging action transmitted torques will be more if the groove will require more
force to pull the belt out of the groove which will result in loss of power and excessive belt
wear due to friction and heat .Clearance must be provided at the bottom of the grooves in
order to prevent touching of the bottom as it becomes narrower from wear. In Fincha sugar
factory the lime stone is transported by human power. This need many power and it take
many cost that affect the budget of the company. In order to solve the problem we design the
belt conveyer that used to transport the lime stone from its storage to the clarification
.because this is use with less power as well less time.
Advantage of the project
 it save power
 it use to save time
 It save cost

5.6. Objectives of Project
5.6.1 General Objective
The general objective of this project is solving the problem of transporting limestone
(CaCO3) from store to lime mixer by designing the belt conveyor and to solve the problem of
the company.
5.6,2 Specific objectives
 To reduce human power used

 To reduce injure happened during transportation
 To reduce down time
 Safely using of lime stone (CaCO3)
V-belt Drive Design Process
 Need rated power of the driving motor/prime mover.

 Service factor based on type of driver and driven load.
 Center distance (adjustment for center distance must be provided or use idler pulley)
nominal range D2 < C < 3(D2 + D1)
 Power rating for one belt as a function of size and speed of the smaller sheave
 Belt length (then choose standard size).
 Belt length correction factor.
 Number of belts
 Initial tension in belts
Types of v-belt and pulley
According to Indian standards (IS: 2494-1974),the v-belt are made in five type i, e A,B,C,D
and E. the dimension for standard v-belt are shown below.

Table 5.1. Dimension of standard v-belt according to IS: 2494-1974

The dimension for the standard v-grooved pulley according to IS: 2494-1974, are shown
below.
Table 5.2.dimention of standard v-groove pulley according to IS: 2494-1974

5.7. Materials and Methods
5.7.1. V- Belt and V-Grooved pulley design
Based on my input power of motor (5kw) we can select B –type of belt from standard V-
belts according to is: 2494 -1974

Where D=2r1; diameter of gear box pulley
d=2r2; motor pulley
x – Center to center distance
θ – Angle of contact
L- Length of the belt
α– Angle between contact points to center of the pulley.

Design of V- grooved pulley
From selected motor the speed is 1445 rpm and 5 kW power
The smallest pulley (motor Pulley) we selected d = 200mm
The largest pulley (gears box pulley) diameter is D= 400mm
Density of pulley made from cast iron is 7200 kg/m3 and allowable Stress 2.1 Mpa.
From above given data we can calculate the parameter necessary to design V- grooved
pulley. From speed ratio:
Nm/Ng = D/d Ng =Nm d/D = (1445*200)/400=722.5rpm
Ng = 722.5 rpm where Ng-speed input of gear box side
Angle of contact for motor pulley (θd)
Θd=1800-2sin-1((400-200)/2*800)

Θd=1640
Angle of contact for gear box pulley (θD)
θD=180+2sin-1((D-d)/2x)
θD=180+2sin-1((400-200)/2*800)
θD=180+2SIN-1(0.125)
θD= 180 + 15.96
θD= 195.960
Design of V- belt
From standard table 5.1 we take B –type of V- belts that have width (b) 17mm= 0.017 m
Thickness (t) =11 mm = 0.011m
Groove angle (2β) = 38,β =190
Then the calculation for design parameter is shown below;
Speed of belt,
V = πdNm/60=(π*0.2m*1445rmp)/60
V= 15.13 m/s
Mass of belt per meter length, m = Area * length * density
M /L = A*ρ , but A= width * thickness
= 17 mm* 11 mm
= 1.87*10-4 m2
M/L = 1.87*10-4 * 7200 kg /m3
= 1.35 kg/m
Centrifugal tension (TC )
TC = MV2

TC= 1.35 kg/m*(15.13)2
TC = 309.04N
The maximum tension in the belt, T
T= Stress *Area
T= δ*A
T= 2.1 *106*1.87*10-4
T=392.7N
The tension in the tight of the belt (T1) and the tension in the slack side of the belt (T2)
T=T1+TC
T1=T-TC = 392.7N-309.04N
T1= 83.66N
We also know that, from tension, friction, angle of contact and groove angle relation
2.3 Log (T1 /T2) = πθdcosec β
2.3 log (T1/T2) =0.25*1640*csc190
2.3log (T1/T2) = 2.21
T1/T2= 9.16 T2= T1/9.16 So, T2= 83.66N/9.16= 9.13N
Power transmitted per belt, P
P= (T1-T2)*V
P= (83.66N-9.13N)*15.13m/s
P=1127.64W
Number of belt required, n
n= Total power transmitted /Power transmitted per belt

n= 50,000w/1127.64w =4.12
Length of the belt,
L=π/2* (d+D) +2x+ (d+D) 2/4x
L= π/2(0.6+0.4) +2*0.8+ (0.2+0.4)2/4*0.8
L = 2.65m
L= 1.04+34.64+6.29*10-3 L= 35.69m
T1 = 2.3 T2 =2.3*924.3N T1= 2125.9N

Idler design
Idler – is used to support the load moving on the v- belt by rotating in the same direction to
the belt rotation.
The idler we design for my belt conveyer is :
We take an idler diameter (di) = 60mm
The length of the idler depending on belt conveyor width and clearance taken (wi)
=600+2*100= 800mm The number of idler we use for my design is depending on:
Length of the flat belt
Weight of lime stone
So, the number of idler in tight side or upper part can be arranged parallel with 0.5m apart to
one another, then;
Nit = Center to center length (X) /0.5
Nit = 17.32/0.5 =34.64 =35
And, the number of idler in slack side or lower part can be arranged parallel with 3m apart to
one another, then;
Nis = Center t center length (X)/3
Nis = 17.32/3=5.7 = 6

Gear Box Selection
We select gear box from the factory work shop for the following reasons;
i. The gear box is found in the market, so it is possible to buy

ii. The gear box has a constant speed output
iii. To save design time
From previous calculation, the input speed of gear box is 722.5 rpm but we want to reduce
this speed in to 240 .83 rpm at output of gear box .So we select 1:3 speed ratio gear box from
the factory work shop The gear box we selected have ;
The driver shaft diameter is 35 mm
Gib –head key with width (w) =d/4 =35/4=8.75mm
Length (l) =3.5d/2=3.5*35/2=61.25mm
Thickness (t) = 2w/3 = (2*8.75)/3=5.83mm

Bearing selection
A bearing is a machine element which support another moving machines element .It permits
a relative motions between the contact surfaces of the members, while carrying the load .So
from types of rolling contact bearing we select for my shaft, rolling Ball bearing .The ball
bearing consist of an inner race, which is mounted on the shaft or journal and an outer race
which is carried by the housing or casing
I.e. inner race= shaft diameter =35 mm
So, from standard dimensions and designations of Ball bearings we take bearing bore of 35
mm due to shaft diameter
Bore diameter (mm) = 35 mm
Outside diameter (mm) =80 mm Width (mm) = 21mm
Totally, four (4) the same size ball bearing is used in my design

Lubrication of Ball bearing
The ball bearing is lubricated for the following purposes;
 To reduce friction and wear between sliding part of bearings

 To prevent rusting or corrosion of the bearing surfaces
 To protect the bearing surface from water, dirt and etc.
In general oil or light grease is used for lubrication of ball bearing

DISCUSION
Material handling is an important part of the industry and consuming a considerable

proportion of the total power supply. Material handling system contains various types like
Lifts, AGV’s, Conveyors, etc. from that conveyors are used mostly in industries for
continuous handling. Conveyors are further classified in various types like, belt conveyor,
roller conveyor, chain conveyor, screw conveyor, pneumatic conveyor, roller belt conveyor,
etc. Belt conveyor is used to transport material from one location to another. Belt conveyor is
a commonly used equipment of continuous transport it has a high efficiency, large conveying
capacity and it can be achieved at different distances, different materials transported.

CHAPTER SIX
CONCLUSION AND RECOMMENDATION
6.1. Conclusion
We conclude that every chemical Engineering students working in such like factories
can get good knowledge and tangible information that learned theoretically in the class
and can do practically in the factory. We developed our skills during this practice and
confidence to deal with problem arises in the factory, community and other technological
world.
The present process aims at covering theoretical and practical aspects of each and
every operation involved in the present process of white sugar manufacture from sugar cane
and deals with recent techniques established in various cane sugar producing countries
of the world. During this four month internship program we had been able to see: how to
operate machines, how to process the productive of factory, communicate with workers at
work place, with the manager in the office and how to solve the problem arises in the factory.
We conclude that every chemical Engineering students working in such like factories can get
good knowledge and tangible information that they learned theoretically in the class and can
do practically in the factory. This internship program played a great role to break the
convection thought that the student and other skilled labors. We developed my skills during
this practice and confidence to deal with problem arises in the factory, community and other
technological world. The internship program essential for any chemical engineer in order to
develop Practical skill, communication skill, team playing skill, Work ethics..
The present process aims at covering theoretical and practical aspects of each and every
operation involved in the present process of white sugar manufacture from sugar cane and
deals with recent techniques established in various cane sugar producing countries of the
world. Moreover different technological options have also been discussed, as for instance, in
juice extraction from cane apart from milling. The cane received in the factory yard is fed to
the carrier by mechanical un loader from trucks and trailers while the cane carts are manually
emptied. The cane is passed through preparatory devices like knives, for fine cutting before
being subjected to crushing in a milling tandem comprising 4 to 6 four roller mills. Fine
preparation, with its impact on final extraction, is receiving special attention and shredders

and particularly the fiberizes are gaining popularity. The mills are of modern design, being
equipped with turbine drive, special feeding devices, efficient compound imbibition system
etc.
Diffusion has been described in details and in the section on cane juice clarification various
processes tried out have been dealt with although sulphitation and carbonation processes have
been discussed at great length.
White sugar by sulphitation process the raw juice after being heated to 65-75°C is treated
with phosphoric acid, sulphur dioxide and dilute lime solution for removal of impurities in
suspension in a continuously working apparatus. The treated juice on boiling is fed to
continuous clarifier from which the clear juice is decanted while the settled impurities known
as mud are sent to continuous vacuum filter for removal of unwanted stuff. The clear juice
with about 85% water is concentrated in a multiple effect evaporator under vacuum to yield
syrup with about 35% water content. The syrup is again treated with sulphur dioxide before
being sent to the pan station for crystallization of sugar.
Imbibition: In the milling process, the first mill extracts 50-70% of the total juice contained in
the prepared cane, the remaining offering resistance to removal from fibre by simple
compression in rollers. With a view to extracting the remaining juice it is imperative to resort
to 'imbibitions' which consists in spraying diluted juice or water on the bagasse emerging
after each mill in the milling tandem.
In juice clarification the raw juice is turbid and contains undesirable impurities which have to
be eliminated so that the concentrated clear juice or syrup is suitable for sucrose
crystallization in boiling strikes from which white sugar is produced. Thus, the treatment in
purification should impart transparency to juice and syrup. Various chemicals and number of
organic and inorganic substances have been proposed so far for bringing about the desirable
results in clarification. Sulphur is an important chemical used in plantation white sugar
manufacture for generating SO2in the clarification house.
The main function of the evaporator station is to concentrate clear juice containing around
85% water, and transform it into syrup containing 35% water with minimum expenditure of
steam without bringing about any change in the composition of dissolved constituents, which
would affect adversely the recoverable sugar at the crystallization stage. At the time of

commencement of this operation the condenser water is started and vacuum developed in the
last body connected to a condenser.
Evaporation or heating in any process operation like juice heating, pan boiling or juice
concentration depends on the rate at which the heat is transferred from the hot condensing
steam or vapor to the cooler liquid through the tube walls. Thus in an evaporator evaporation
will be rapid when the heat transmission rate is high.
The process of pan boiling for plantation white sugar manufacture differs considerably from
that followed in raw sugar plants and also sugar refineries, in as much as the objectives in this
case are to produce white crystalline sugar from syrups of purities varying from 77 to 86 and
at the same time to ensure minimum loss of sugar in final molasses.
However to bring down the final molasses purity, the final massecuite purity has to be as low
as practicable, which many times calls for practicing four stage boiling in place of the
conventional three massecuite system These massecuites are designated by letters as A, B, C
depending on first, second or third stage of boiling respectively.
The 'Molasses' is the mother liquor separated from sugar crystals during centrifuging of
massecuite. When the molasses is separated with minimum washing in centrifuges or without
any application of water it is comparatively of high brix and low purity and is denoted as
heavy molasses like A Heavy from A massecuite B heavy from B massecuite. Separation of
heavy molasses is followed by liberal wash or resorting to second time curing in centrifugal.
The liquor thus obtained is of higher purity than the heavy molasses and is named as light
molasses and from A massecuite A light is obtained after A heavy is separated and similarly
for 'B' and 'C'.
Final molasses is that mother liquor obtained from final massecuite from which sugar can no
longer be crystallized out economically with the present technological practices.
In a similar fashion the sugars from different massecuites are known as A Sugar, B Sugar
etc., the sugar from first curing in case the massecuite is double cured is known as fore cured
sugar of that massecuite and from second curing as after worker sugar.
In a batch centrifugal machine the basket is a cylindrical drum with perforations, supported
on a heavy vertical shaft with drive arrangement at the top. Normally the basket is open at the
top as well as at the bottom and whereas bottom is closed by a cone at the time of taking the
massecuite charge or during running, the top is kept open while charging, the exception being
the conical self-discharging machines with no bottom cover. The perforated basket is lined
with wire gauze and a perforated brass liner for allowing the separated molasses to flow out,
while retaining the sugar crystals.
 During this four month internship program I had been able to see:-
 How to operate machines
 How to process the productive of factory.
 Communicate with workers at work place, with the manager in the office.
 How to solve the problem arises in the factory
Generally, as chemical engineers I identify the problem in order to maximize the efficiency
of the factory and I design the lime stone transporter by belt conveyor
6.2. Recommendation
Fincha Sugar Factory is a huge industry in Ethiopia .but the condition is difficult for worker.
Such as:-
- High temperature around pre-heaters and evaporators

- There is contamination of environment by non-condensable gas.
- Steam line is not properly safe.
- There is no material for saving carbon dioxide that come from by-product of ethanol.
- Roads are contaminated by ash (byproduct of the boiler).
- Water which used for washing of cane is not recycled.
- The bagasse handling system of the factory is not safe or it is not protected from rain.
- The company have shortage of safety materials.
- Also the road that use for transportation is not safe.
In order to minimize such kind of problems, factory is better to perform the following
recommendation.
- No measurement was taken around evaporator and heater, in our point of view better
insulation should be introduced
- Steam line should be well insulated.
- Rather than manual cleaning, it should be cleaned mechanically and adding chemical.
- The factories better to be building bagasse storage house.

- The water that used for washing cane better to be recycled and re used
- They should have to overcome the shortage of safety material.

Appendix
Ash – The residue remaining after burning of all organic matter.
Bagacillo – Very fine particles of bagasse separated either from final bagasse for filtration
aid or from preclarification juices.
Bagasse- The residual obtained from crushing cane. Its components are fiber, pith, water,
solids, lost sucrose all water insoluble in the cane.
Brix- Amount of soluble solid found in solution (mass as part of sucrose per 100 parts of
solution).
Cane– The raw material used for production of sugar.
Clarified juice- The juice obtained after clarification and used as evaporator feed.
Final molasses – The molasses obtained from the last stage of massecuite
Filter cake – The residue removed by filtration of the muddy juice in the process of
clarification including any added filter aid.
Latent Heat: is the amount of Heat Energy required to transform water at the boiling point
(saturated liquid) to steam.
Imbibition water- The water added to the second mill (in FSF) units to dilute and displace
juice left in the bagasse, to reduce sugar loss in it.
Magma – A mechanical mixture of sugar crystals with a liquid such as syrup, juice, wash or
water.
Massecuite – The mixture of crystals and mother liquor obtained from the evaporation of
sugar boiling in vacuum pan. Massecuites are classified according to the descending purity as
A, B, C. etc.
Molasses – The mother liquor of massecuite separated from the crystal. It is distinguished by
the same term as massecuite which it was extracted (A, B, C, molasses).
Mixed juice- The juice sent from the extraction plant to the boiling house.

Pol – The apparent sucrose content of a sugar product determined by direct or single
polarization.
Purity – The percentage ratio of sucrose or pol (by weight) to the total soluble solids or brix
in a sugar product.
Pty = pol/ brix *100
Reducing sugars - The reducing substances in the cane and its products calculated as invert
sugar. (Glucose, Fructose)
Refined sugar – high purity white sugar manufactured from re melted raw sugar.
Raw sugar – The product of cane sugar factories which is an intermediate crystalline product
resulting from the evaporation of water from sugar cane stalk juice.
Seed – A finely powdered sugar used for starting crystallization of the massecuite. Usually it
is used in the form slurry for low grade massecuite and magma is used for high grade
massecuite.
Syrup – The concentrated juice from the evaporators.

REFERENCES
1. Hand Book of Cane sugar engineering e-hugot 3rd edition. 1986
2. Sugar Technology A.R Sapronov – 1983
3. Hand Book of Cane Sugar technology R.B.L MATHUR – 1978
4. Cane Sugar Hand book Spencer and Meaden – 9th Edition.
5. Principles of Sugar Technology Pieter Honig Vol. 1,2,3 – 1963
6. Cane Sugar Hand Book – 12th Edition James C.P. Chen Chunge Chichon – 1993.
7. Different data books from the factory

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WOLLEGA UNIVERSITY

DEPARTEMENT OF CHEMICAL ENGINEERING

HOSTING COMPANY: FINCHA SUGAR FACTORY

TITLE: INTERNISHIP REPORT ON SUGAR PRODUCTION

ADVISOR NAME: MR. GADISA. M

1) OBSA CHIMDESSA ………………... 0898/15

Name of Mentor ……………..

Name of adviser Signature ………….

DEPARTEMENT OF CHEMICAL ENGINEERING Page i

2.2.1.6 Cane table ................................................................................................................... 7

DEPARTEMENT OF CHEMICAL ENGINEERING Page ii

2.2.3. Imbibition ............................................................................................................................ 12

DEPARTEMENT OF CHEMICAL ENGINEERING Page iii

2.2.11.Sugar Stories ............................................................................................................. 26

DEPARTEMENT OF CHEMICAL ENGINEERING Page iv

4.1. To Improve Practical Skill ............................................................................................ 41

DEPARTEMENT OF CHEMICAL ENGINEERING Page v

LIST OF FIGURE Page

Figure 1.1 Flow chart of organization .................................................................................... 3

DEPARTEMENT OF CHEMICAL ENGINEERING Page vi

LIST OF TABLE Page

DEPARTEMENT OF CHEMICAL ENGINEERING Page vii

DEPARTEMENT OF CHEMICAL ENGINEERING Page viii

AIDF Air Induced Draft Fan

FSF Fincha Sugar Factory

HPRFDRE House of People Representative of Democratic Republic Of Ethiopia

MSDH Molecular Sieve Dehydration

OFAF Over Fire Air Fan

DEPARTEMENT OF CHEMICAL ENGINEERING Page ix

DEPARTEMENT OF CHEMICAL ENGINEERING Page x

1.1. Historical Back Ground of the Company

Fincha sugar Factory is located in Horro Guduru Wollega administrative zone of

Ethiopian government proclamation number 25/1984 and the council of minister

Batu construction Enterprise

1.2. Vision, Mission, Value of the Organization

 Team work brings individual and organizational growth.

1.3. Organizational Structure

Agriculture Factory Human Finance vice Linguistic

Seed Budget and Material

Figure 1.1 Flow chart of organization

DEPARTEMENT OF CHEMICAL ENGINEERING Page 3

Reduced sugars ------------------ 0.4-2%

Organic non-sugar-------------- 0.5-1%

Mineral matters -------------------0.5-1%

DEPARTEMENT OF CHEMICAL ENGINEERING Page 4

2.2. Methods of Sugar Production

Purpose of burning of cane:-

2.2.1.3 Cane Yard

2.2.1.4 Weight Bridge

DEPARTEMENT OF CHEMICAL ENGINEERING Page 5

The main objective of the weight bridge is:-

2.2.1.4.1. Working Principle of Weigh Bridge

Net weight = Gross weight –Tare weight

Table 2.1 calculations on Weight Bridge

The weighed cane recorded depending on:

2.2.1.5 Cane Unloading

DEPARTEMENT OF CHEMICAL ENGINEERING Page 6

Figure 2.1 Cane unloading

Figure 2.2 Cane table

DEPARTEMENT OF CHEMICAL ENGINEERING Page 7

2.2.1.7 Main Cane Carrier

The main objective of cane preparation is:-

 They favour the capacity of the mills.

2.2.1.8.1. Factors Affecting the Efficiency of Cane Knives