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
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
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
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.
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
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 10 10 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
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 1 2 2 2 CHAPTER TWO 2.0 LITERATURE REVIEW 2.1 History of Sugar 3 4 Ix
2.2 Types of Sugar 6 2.3 Uses of sugar 8 2.4 Sugat:canc 8 2.4.1 Cane agriculture 9 204.2 Cane agronomy 10 2.4.3' Cane management 11 2.4.3 New cane developments 12 2.5 Sugar Beet 13 2.6 Process Routes for the Production of Sugar 14 2.6.1 I>roduction of sugar from sugarcane 14 2.6.2 Production of sugar from sugar beet. 15 2.7 Detailed Description of the Selected Technology 2.7.1 Extraction 2.7.2 Clarification and Evaporation 2.7.3 Crystallization 2.7.4 Centrifuging 18 19 20 21 23 ClIAI'TER TIlItEI!: 3.0 Material Dalance 29 3.1 I"eed Stock (sugar cane) Compositions 29 3.2 Material Balance arowld each of the Unit Operations Equipments 30 x
CHAPTER FOUR 4.0 Energy Balances 4.1 Thermodynamics Properties 4.1.1 Heat Capacity Coefficients of the Components 4.1.2 Heat of Formation of the Components 4.2 Formulation of Energy Balance Equation 4.2.1 Energy Balances Calculations CHAPTER FIVE 5.0 Process Flow Diagram CHAPTER SIX 81 81 81 81 82 83 111 6.0 Equipment Design 112 6.1 Design of Crusher 113 6.2 Sizing ofthe Clarifier Tank 115 6.3: Evaporator Design 118 6.4 Crystallizer Design 124 6.5 Sizing of the Affination Tank 127 6.5 Equipment Design of Adsorption Column. 129 6.5.1 Design Specification 129 6.7 Design of dryer 132 CHAPTER SEVEN 7.0 Equipment Optimization 136 7.1 Equipment Optimization: Storage Tank 136 7.2 Optimization of the Converter using the Principle of Minimizing 136 CHAPTER EIGHT 8.0 Quality Control and Safety 8.1 Waste generation 8.1.1 Wastewater 141 141 141 xi
8.1..2 Solid wastes 8.1.3 Air pollutants 8.2 Economic usage of water 8.3 Safety 143 144 144 146 CHAI'TER NIN}: 9.0 PROCESS CONTROL AND INSTRUMENTATION 9.1 Product Quality 9.2 Product Quantity 147 148 149 9.3 I)iant Safety 149 9.4 tvlanual or Automatic Control 150 9.5 Control System 150. CHAPTER TKN 10.0 Environmental Acceptability 154 10.1 Definition of the problem 154 10.2 Identification of possible pollutants 10.3 Effects of the pollutants 10.3.1 Effects of carbon dioxide 155 157 157 10.3.2 Effects of carbon monoxide 10.3.3 Effects of nitrogen oxides 157 157 )(ii
10.3.4 Effects of hydrocarbons 158 10.3.5 Effects of particulate matters 158 10.4 Pollution treatment and prevention strategies 158 CHAPTER ELEVJ!:N 11.0 Start up and Shut down Procedure 159 11.1 Start up procedures 159 11.2 Shut down procedure 11.2.1 Emergency shutdown of plant 160 160 11.2.4 Start up afler emergency shut down 161 CHAPTER TWELVJ~ 12.0 Site tor Plant Location 12.1 Factors.Considered for Site and Plant Location 162 162 12.1.1 Location, with respect to the marketing area 12.1.2 Raw materials 12.1.2 Transport 12.1.4 Availability oflabour 12.1.5 Utilities (services) 12.1.6 Environmental impact, and effluent disposal 162 163 163 163 163 165 12.1.7 Local community considerations 12.1.8 Availability of suitable Jand (site considerati~ns) 165 165 xiii