DESIGN OF A SUGAR PLANT TO PROCESS 250 TONNES 'PER HOUR OF SUGARCANE ADEDIDGBA ADESHINA SUNDAY

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1 DESIGN OF A SUGAR PLANT TO PROCESS 250 TONNES 'PER HOUR OF SUGARCANE BY " ADEDIDGBA ADESHINA SUNDAY 2004/20847EH " DEPARTMENT OF CHEMICAL ENGINEERING, FEDERAL UNIVERSITY OF TECHNOLOGY, MINNA, NOVEMBER, 2007

2 DECLARATION I, Adedigba A. Sunday (2004/20847EH) hereby declare that this design project, "Design of a sugar plant to process 250 tonnes per hour of sugarcane, ", carried out under the supervision of DR. D. Aloko and presented in partial fulfillment of the requirement for the award of Bachelor of Engineering (B. Eng.) degree in Chemical Engineering has not been presented for any degree elsewhere, to the best of my knowledge. Adedigba Sunday '\ [ I (y u'1- Date 11

3 I CERTIFICATION This is to certify that this research project titled "Design of a sugar plant to process 250 tonnes per hour of sugarcane" was carried out by Adedigba Sunday (2004/20847EH) and. submitted, to the Department of Chemical Engineering, School of Engineering and Engineering Technology, Federal University of Technology, Minna, Niger State, in partial fulfillment of the requirement for the award of Bachelor of Engineering (B. Eng.) degree in Chemical Engineering. ~(- Dr. D. Aloko (Project Supervisor) Dr. M. O. Edoga (Head of Department) Date External Examiner Date 111

4 DEDICATION To my friend,partner, and my love,oluwafunmike Aina lawai who has been a source of joy,strength and courage during the course of this programme.to you I say I cannot thank myself for your love,patience and endurance.

5 ACKNOWLEDGMENTS Every accomplishment in life is a result of the contribution of many individuals who both directly and indirectly share their gift, talent, wisdom with us all. This project is no exception.i Appreciate the effort of my supervisor Dr. D. Aloko for his support and understanding during the course of this project. r am indebted to my beloved partner, Oluwafunmike Aina LawaI for her support and understanding during the course of this programme. r appreciate the contribution of my father Pa. S.B. Adedigba. r give post-obit appreciation to my beloved mum, late Madam Esther Abeke Adedigha.she saw me to the point where r have no reason to fear the future, and r saw her to the point where she had no course to regret eternity.mama till we meet to part no more. r am indebted to my siblings Mrs. D.Ogunkanmbi, Mrs., jennet Olapade, Mr. Lawrence Adedigba and Mr. Timothy Adedigba.To my mother - in -law, Mrs. Comfort LawaI, r say thank you for your prayers. \ r appreciate all my friends,nike, Ruth,Tope, Odun,Rukkayat,Tom, Adisa, Opc.Afolayan,Racheal,Kunle, and.others. r extend my gratitude to Engr. Jerry peters for his support. Finally my gratitude goes to the almighty God for his love, wisdom; protection throughout my stay in Minna, and for miraculous things he did during the course of this programme. To him alone be the glory. 0 Lord r pour this to you as a drinking offering. 11

6 ABSTRACT This project was.carried out to design a sugar plant to process 250 tonnes per hour of sugarcane. MathCAD professional was employed to carry out the material balances, enthalpy balances, equipment design and economic viability of the plant. The cane was shredded and the juice extracted at a milling efficiency of 95%,the juice was clarified and. excess water was removed in multiple effect evaporators to form a thick syrup. 92% of the sucrose was recovered as crystals in a vacuum pan and the resulting "magma" spun in a centrifuge to separate the remaining syrup. The raw sugar was then refmed by removing impurities and colorants. The results of the calculations show that the plant has a capacity of 5.08 x 10 4 kg/hr of white sugar; the yield of white sugar from sugarcane is 20.32%. The plant has a Net Profit ofn8.277 x and cash flow of N-1.464x loll. The economic viability is real with a rate of return of 36.14% and a payback period of at most 3 years. viii

7 TADLI~ OF CONTENTS COVER PAGE TITLE PAGE DECLARATION CERTIFICATION DEDICATION ACKNOWLEDGEMENT GROUP E MEMBERS ADSTRACT TADLE, OF CONTENT LIST OF TABLES LIST OF FiGURES i ii iii. iv v vi vii viii ix xvi xvii 1.0 INTRODUCTION 1.1 Aim and objectives 1.2 Problem Statement 1.3 Approach CHAPTER TWO 2.0 LITERATURE REVIEW 2.1 History of Sugar 3 4 Ix

8 2.2 Types of Sugar Uses of sugar Sugat:canc Cane agriculture Cane agronomy ' Cane management New cane developments Sugar Beet Process Routes for the Production of Sugar I>roduction of sugar from sugarcane Production of sugar from sugar beet Detailed Description of the Selected Technology Extraction Clarification and Evaporation Crystallization Centrifuging ClIAI'TER TIlItEI!: 3.0 Material Dalance I"eed Stock (sugar cane) Compositions Material Balance arowld each of the Unit Operations Equipments 30 x

9 CHAPTER FOUR 4.0 Energy Balances 4.1 Thermodynamics Properties Heat Capacity Coefficients of the Components Heat of Formation of the Components 4.2 Formulation of Energy Balance Equation Energy Balances Calculations CHAPTER FIVE 5.0 Process Flow Diagram CHAPTER SIX Equipment Design Design of Crusher Sizing ofthe Clarifier Tank : Evaporator Design Crystallizer Design Sizing of the Affination Tank Equipment Design of Adsorption Column Design Specification Design of dryer 132 CHAPTER SEVEN 7.0 Equipment Optimization Equipment Optimization: Storage Tank Optimization of the Converter using the Principle of Minimizing 136 CHAPTER EIGHT 8.0 Quality Control and Safety 8.1 Waste generation Wastewater xi

10 Solid wastes Air pollutants 8.2 Economic usage of water 8.3 Safety CHAI'TER NIN}: 9.0 PROCESS CONTROL AND INSTRUMENTATION 9.1 Product Quality 9.2 Product Quantity I)iant Safety tvlanual or Automatic Control Control System 150. CHAPTER TKN 10.0 Environmental Acceptability Definition of the problem Identification of possible pollutants 10.3 Effects of the pollutants Effects of carbon dioxide Effects of carbon monoxide Effects of nitrogen oxides )(ii

11 Effects of hydrocarbons Effects of particulate matters Pollution treatment and prevention strategies 158 CHAPTER ELEVJ!:N 11.0 Start up and Shut down Procedure Start up procedures Shut down procedure Emergency shutdown of plant Start up afler emergency shut down 161 CHAPTER TWELVJ~ 12.0 Site tor Plant Location 12.1 Factors.Considered for Site and Plant Location Location, with respect to the marketing area Raw materials Transport Availability oflabour Utilities (services) Environmental impact, and effluent disposal Local community considerations Availability of suitable Jand (site considerati~ns) xiii