AN EXPERIENCE OF SUGAR LOSSES REDUCTION IN
FINAL MOLASSES % CANE IN JDW-III GHOTKI.
Mohammad Atique Khan
Dy. General Manager (Prod.)
AN EXPERIENCE OF SUGAR LOSSES REDUCTION IN
FINAL MOLASSES % CANE IN JDW-III GHOTKI.
ABSTRACT:
Alhamdulillah we are achieving Highest Recovery in Pakistan from last 4 years in JDW-III
Ghotki (Except last year). This Highest Recovery was based on Sugar Cane quality & Sugar
extraction by mean of milling & processing. Highest Sugar content cane development &
procurement programming is play vital role in our plant. Plant Operation Conditions, Milling
Techniques, Process Description, Equipment Description, Juice Clarification, Fine Liquor
Production, Molasses reduction by mean of our boiling technique are considered in this
paper. Slurry preparation C-seed boiling and C- Continuous Pan boiling & boiling scheme
also explain by mean of necessary calculations.
INTRODUCTION:
We are reducing molasses % by mean of following few important modification and
installation of equipments.
Percentage of final molasses play an important role in recovery enhancement, therefore by
reduction of final molasses % cane, we can increase our recovery. We have high crusher juice
purity; we introduce some new techniques to lower the final molasses purity and % age of
final molasses. We achieved 4.19% final molasses % cane and 1.26 % sugar lost in final
molasses, by using described technique in last 4year (average).
No doubt final molasses % cane depend upon cane quality but also by using condensate
water for imbibition purpose, by controlling Dextran level, by achieving best juice
clarification, by controlling molasses recirculation & C-massecuite boiling techniques, final
molasses % cane may be reduced tremendously. All of these mentioned controlling parameter
are being discussed in this paper and also our last 4 years results are tabulated for reference.
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MOLASSES REDUCTION TECHNIQUES
1. IMBIBITION BY PURE CONDENSATE
2. DEXTRAN LEVEL CONTROLLING
3. SCUM DE SWEATING
4. JUICE CLARIFICATION
MASSECUITE CURING TECHNIQUES
5. A-HEAVY PURITY CONTROLLING
6. B-MASSECUITE
7. SUGAR SLURRY PREPARATION
8. C-GRAINING AND C-MASSECUITE
9. C-MASSECUITE CURING AND FINAL MOLASSES PURITY
10. C-MASSECITE CURING IN MODIFIED BASKET
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DETAIL OF MOLASSES REDUCTION ACHIEVEMENT BY USING
FOLLOWING TECHNIQUES.
1. IMBIBITION BY PURE CONDENSATE :
By using impurity free water, non sugar may be controlled for this purpose we have hot water
(condensate) reservoir of capacity 1000m³ and mill house imbibition tank capacity 25m³, its
temperature remained between 65-60°C. This condensate water is being used by mean of
auto controlling system based on cane crushing rate. Average water addition % on cane,
remained 40% for this purpose. To cool down the condensate water 4 cluster of capacity 25
M. Ton are being used for this purpose installed at hot water reservoir.
2. DEXTRAN LEVEL CONTROLLING:
Higher the Dextran level high will be Final Molasses % age, to control Dextran level in raw
juice, we used Bleaching powder and Biocide 15ppm on cane and kept Dextran level same by
proper sanitation at mill house and chemical treatment. Therefore we achieved Dextran level
12000-15000 PPM in mixed juice. Auto programming Dextran calculating apparatus Dr-2700
is in our laboratory being employed.
3. SCUM DESWEETING :
Scum of Talo refinery is desweeted in 3.5 meter dia scum clarifier & its sweet water is used
for preparation of lime saccharate and desweeted scum is sent in mud tank. Due to this
improvement in juice clarification is achieved and extra load of scum is reduced on juice
clarifier. Also having great advantages when cane crushing stopped and no way to dispose of
scum except in drain, during this period its sweet water is sent to pan storage tanks.
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4. JUICE CLARIFICATION:
st Clarification, final molasses % age will be decreased in our juice clarification, we get
clarification effect 12.5% and its ICUMSA unit remained 13500. Therefore for achievement
of best clarification, we are using sweet water of scum clarifier for preparation of lime
saccharate. Lime saccharate is being fed in suction line of defecated Pumps, which pH is
monitory auto by system, kept 7.2-7.4.
5. A-HEAVY PURITY CONTROLLING TECHNIQUE:
10-15 degree purity drop from A-Massecuite to A-Heavy is suggested as best for quality
sugar. Following consideration are carried out.
B-Seed 88 Purity and C-Seed 90 Purity is used for A-graining and good A-grain free of false
grain is used for A-massecuite exhaustion. Brix of A-Massecuite is maintained at 94 for
better curing.
For achievement of low purity A-Heavy, we are boiling three extra A-1 massecuite per shift
by using rejected runoff and also using 0.06 mm nickel working screen (1st used in C-curing)
for A-massecuite curing.
A-Massecuite Purity 81.77
A-Heavy Purity 64.80
A-Sugar Purity 97.40
6. B-MASSECUITE
We have 3 batch type Pan of 50m³ for B-Massecuite boiling A.H is taken as footing material
and it grained by using slurry. 2 part of this B-Grain is cut in B-vacuum crystallizer and
1/3 Part in used for B-massecuite boiling by feeding A-Heavy in these Pan till boiling is
completed. C-Light and B-heavy is strictly prohibited to use in B-massecuite boiling in any
stage, due to this C-Light and B-Heavy circulation is controlling. We obtained B-Massecuite
production and following results.
B-Massecuite : 66.18
B Sugar : 88.12
B-H Purity : 44.85
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7. SUGAR SLURRY PREPARATION TECHNIQUE :
Slurry machine horizontal type containing 16 Nos. of S.S Bar of Ø24mm are used for
preparation of fine paste of sugar, (Slurry) for graining B/ C- massecuite, containing uniform
crystals. It play vital role for boiling a good quality C-massecuite.
8. C-GRAINING AND C-MASSECUITE:
C-grain is basic necessary requirement for reduction of final molasses quantity. For boiling of
C-grain 40m³ Pan is used, we drop 5 Pan in a day, initially 3/4 A Heavy & 1/4 C–Light of
quantity 20 [Link] is taken in Pan as footing material. Slurry is used for graining purpose.
After feeding slurry we used exhaust steam instead of vapor. The steam consumption
remained between 3.0 – 3.5 M .Ton, Pan take 2.25 hrs for completion of boiling, its
dropping purity kept 60°- 61° by fed in C- Light and B-Heavy as per requirement. Regular
hard and dust free grain is obtained. This grain is fed in C-Conti Pan for producing a
C-massecuite and run on routine practice.
1) C-Massecuite Graining Purity 62.59
2) C-Massecuite Cut Purity 60.40
3) C-Massecuite Purity 51.80
9. C-MASSECUITE CURING AND FINAL MOLASSES PURITY.
6 No. vertical crystallizer of capacity 175m³ each used for cooling and reheating in two
heaters. Seven [Link] machine of BMA K1100 are used for curing. Nickel Screen of
0.06mm are implying as working Screen, replaced after 15 days and re-used in A-centrifugal
machines. Results obtain are given below.
1) Final Molasses Purity 31.21
2) Final Molasses Brix 94.81
3) C-Sugar Purity 78.79
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10. C-MASSECUITE CURING IN MODIFIED BASKET:
C –Massecuite curing in new Basket of having perforated Area equal to Ø8” instead of 6”
(inches) pipe area following results are obtain at 65A load
Final Molasses C-Sugar
Brix Purity Brix Purity
96.60 31.08 99.00 81.51
Comparison of old and new baskets is given
OLD NEW
1. Opening Area of Holes 0.015m² 0.0365m²
2. Basket middle line holes Nos. 216 286
3. Basket Middle line holes Dia 8mm 12mm
4. Molasses Pipe Dia 6” 8”
RESULTS:
This year molasses results are tabulated as reference:-
1 Final Molasses Brix 94.506
2 Final Molasses Pol 29.589
3 Purity Final Molasses 31.210
4 Molasses % Cane 4.3763
5 Sugar Lost in Molasses % cane 1.2949
CONCLUSION:
By implying described techniques, we reduced final molasses % cane.
I. Final Molasses % age cane
II. Sugar lost in final molasses
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ACKNOWLEDGMENT :
I am highly thankful to the management of JDW-III for allowing this presentation in PSST
Annual Convention. I am deeply indebted to our General Manager Mr. Dr. Barat Ali Ch. and
General Manager (Tech). Mr. Javed Anwar for Valuable guidance. Also Head of Department
of Mechanical, Electrical for given important technical information.
REFERENCE:
1. Spontaneous foamy for mentioned of C-Massecuite.
By H.A Naqvi PSST Annual Convention 43.
2. A Study of controlling parameter of sugar lost in Final Molasses.
By Muhammad Atique Khan PSST Annual Convention 44.
3. Final Molasses Purity.
By Sheikh Inam Hussain PSST Proceeding.
4. Factor affecting the final Molasses quality.
By Muhammad Atique Khan Annual convention PSST 45
5. New Looks at Pan boiling and crystallization.
By Abdul Aziz Tahir PSST 45
6. Sugar Refining.
By Usman Khan at workshop 1998.
7. An Experience of scum sweet water uses.
By Muhammad Atique Khan Annual Convention PSST 50
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FOUR YEARS RESULTS:
Sr.# Season 2008-09 2009-10 2010-2011 2011-2012
1 Total Days 94 117 121 117
2 Cane Crushed (M. Tons) 552,646 786,256 1,051,524 1,135,063
62483.50 M.T 83696.750 M.T 115033 M.T 120721 M. T
3 Sugar Production
(1249670 Bags) (1673935 Bags) (2300660Bags) (2414427Bags)
4 Recovery % 11.30 10.64 10.94 10.63
Average Cane Crushed/Day
5 (M. Tons)
5879 6720 8690.28 9701.39
6 Mill Extraction 95.10 95.59 95.76 95.94
7 Primary Juice Purity 83.69 81.33 82.38 81.14
8 Pol % Cane 13.28 12.59 12.78 12.51
Average Added water %
9 Cane
37.79 36.10 34.45 39.11
10 Pol% Bagasse 1.93 1.711 1.761 1.62
11 Fiber % cane 15.10 14.70 13.78 14.10
12 Pol % Mud 2.24 2.37 2.70 2.33
13 Pty. Final Molasses 33.46 32.06 32.47 31.21
14 Molasses % Cane 4.05 4.41 3.95 4.37
Sugar Lost in Molasses %
15 cane
1.25 1.31 1.20 1.29
16 Total Losses 1.98 1.94 1.84 1.88
