Chemical Process Industries

CH-211

Engr. Kamran Alam

DEPARTMETN OF CHEMICAL ENGINEERING

FACULTY OF MATERIAL & CHEMICAL ENGINEERING
GHULAM ISHAQ KHAN INSTITUTE OF ENGINEERING SCIENCES & TECHNOLOGY
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Introduction of Instructor
• Engr. Kamran Alam (Instructor)

• MS Renewable Energy Engineering (Solar Cell Materials),

• US-Pakistan Centre for Advanced studies in Energy, UETP

• Research: Efficient Solar cell Materials from Arizona State University, USA

• BSc Chemical Engineering

• University of the Engineering and Technology, Peshawar Pakistan.

• Email: kamran.alam@giki.edu.pk ; kalam3@asu.edu

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Course Content
• The topics include but are not limited to:
o Fertilizer manufacturing, like ammonia and urea
o Hydrogen and Nitrogen Production techniques
o CO2 Capturing methods
o Pulp & paper and Basic pharmaceutical industries.
o Sugar industry, Soaps & detergents production,
o Cement industry, Insecticides production
o Other chemical manufacturing units; Soda ash, Caustic soda, Chlorine,
Sulphuric acid,
o Water treatment plants, Fermentation industries, Food processing industry,
Tannery processing,
o Oil and Gas industry, Petroleum refinery
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Course Grading Criteria

Assignments/Presentations ( 2-3) = 10% Quizzes (4-6) = 20%

Midterm Exam = 30% Final Exam = 40%

Attendance as per GIKI Policy is 80% and is compulsory to appear

in final exams
 Content
 Introduction to sugar
 Applications and sources of sugar
 Classifications of sugar
 World Sugar production
 Sugar production in Pakistan
 Industrial Manufacturing process of sugar
 Refining process of sugar
 A short video of sugar manufacturing plant

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SUGAR: Introduction C12H22O11

 Organic, sweet, crystalline, short-chain, soluble carbohydrate (C, H2 & O2 )

 Essential structural component of living cells and the source of energy for all plants
and animal including humans
 For example: Photosynthesis process

Monosaccharide • Simple sugar

• e.g., Glucose, Fructose, Dextrose

Sugar
• Compound Sugar
• formed by the union of two monosaccharides with the
loss of water molecule
Disaccharide • Sucrose (table sugar) , Lactose, Maltose
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Swetness of Various Compounds

Name Type of compound Sweetness

Lactose Disaccharide 0.16

Maltose Disaccharide 0.33 – 0.45

Glucose Monosaccharide 0.74 – 0.8

Sucrose Disaccharide 1.00 (reference)

Fructose Monosaccharide 1.17 – 1.75

• Sweetness level for sugars is taken with respect to Sucrose

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Functions of Sugar
Sweetener

Preservative
S
u Tenderizer

g crystallizing agent
a
r Caramelizing agent

Fermenting agent
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Fertilizers
Types of Sugar
• Turbinado Sugar—closest to raw sugar available, only partially
refined, light brown in color, with coarse crystals and a caramel
flavor.
• Granulated Sugar—standard sugar used in the kitchen. The
crystals are white, fine and uniform in size.
 59 types of sugar is available in
markets
• Powdered Sugar—made by grinding granulated sugar through different degrees of
fine screens. Because of its tendency to lump, cornstarch is added to absorb
moisture.
• Brown Sugar— is granulated sugar with molasses added back in. It is high in
moisture and tends to clump, so it is important to store it in an airtight container.
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Sugar Types, Sources & Sugar Cane

TYPES OF SUGAR Sugar Cane Composition

Glucose
Water =70%,
Maltose
Fibrous material =10-16%,
Sucrose
Sucrose = 9.5-16%,
Lactose

Fructose
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Sugar Inversion:

o Sucrose decomposes into glucose and fructose, resulting ‘invert sugar’ (Trimoline)

o Trimoline helps to prevent crystallization & gives a smoother texture in ice creams/ ganaches

o Failure to process sugar cane within 24hr of harvesting may cause inversion

invertase
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Sugar Manufacturing & Consumption

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Pakistan Sugar Industry:

 In the manufacturing sector, Sugar Industry is the 2nd largest after textile and contributes 2%

to GDP.

 78 sugar mills operating in Pakistan

 As per world statistics Pakistan Holds,

– 5th Position in terms of area under Cane Cultivation.

– 14th position in terms of Cane Sugar Production.

 19 distilleries producing Ethanol with production capacity of +400,000 tones/yr

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Zero Waste Industry:
Sugar Cane
Belongs to grass family.
Bamboo-like stalk, grows to the height of
3 to 5 m.
Contains 11 – 15 % sucrose.
Failure to process sugar cane within 24hr
of harvesting may cause sucrose losses to
glucose and fructose due to inversion.
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Sugar Manufacturing Process:

1- Harvesting of Cane 6- Evaporation

2- Transport & Handling 7- Crystallization

3- Cutting & Shredding 8- Centrifugation

4- Extraction of Juice 9- Drying and Packing

5- Clarification & Filtration 10- Refining of Brown Sugar

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Sugar Manufacturing Process:

Milling Clarification Filtration Evaporation

Crystallization
Crushing

Centrifugal
Washing separation

Transportation to Storage
Sugar Industry Harvesting
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Sugar Manufacturing Process:

1. Harvesting of Sugar Cane 2. Transportation & Handling
MANNUAL: canes are harvested by the help
 Animal driven carts
of manpower/ labor.
 Trolleys
MECHANICAL: canes are harvested
 Trucks
by the machine (harvester)
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Sugar Manufacturing Process:

3. Material Handling & Storage 4. Washing
 Stored in cane yards  Agitator washing with strong and warm jets, &
 Carried from cane yard to feeding area by brushes are used to remove mud or debris
Cranes, Conveyer belt, Carry, Huge before entering the crushers.
suction truck……
 Shredder 20
• large powerful hammer-mill that
Sugar Manufacturing Process: shreds the cane into a fibrous
material.
• The cane stalk containing the
5. Cutting, Chopping & Shredding sugar juice is ruptured but no juice
is extracted.
Cutting operation is the first operation in industry.

 Cutters are mechanical equipment to cut canes into desired size.

 Cutter operated by electric motor shaft pulley & belt arrangement & consist no. of
cutting blades to cut the cane.

 Shredder is used to remove leaves and undesired solid particles from cane.

Cutting Shredding
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6. Juice Extraction (Tandem Milling)

 The shredded cane is fed through a series of crushers that exerts heavy pressure to
extract the sugar rich juice, which is then pumped away for further processing.
 The remaining fibrous material is called bagasse.
 Water/weak juices may also added to soft the cane and extract further juice.
 About 93 – 95 % juice is extracted from the cane

Tandem Mill?
• Rolling Mill where rolling is done in one pass while In a
traditional rolling mill rolling is done in several passes.
• There are several stands (>=2→18) and reductions
take place successively.
• Rollers are attach each other in triangle shape
93 – 95 % juice
 7. Juice Processing

Screening to remove the floating impurities.

Activated Carbon. (Odour and colour removal)
Phosphoric acid may be added for further Calcium phosphate: as
clarification and cleaning. flocculent. Lime: as
Lime is added to: Coagulant, precipitant of
 Coagulate the part of colloidal matter. impurities & pH controller,
 Precipitate the impurities. SO2: as bleaching agent,

 and to Control the PH. Heating: Increase solubility

(Lime in slight excess over that theoretically requirement is added to
precipitate all the unconsumed phosphates).
 Classifiers / Continuous Settlers / Thickeners
The obtained juice is then
heated with high-pressure steam
and then it is allowed to enter
the gravitational settling tank.
In CS, juice travels at very low
superficial velocity so that the
solids settle out and clear juice
exits.
To recover the sugar from
settled-out muds, Continuous
rotary-drum vacuum filters are
used.
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Sugar Manufacturing Process:
7. Filtration (Juice Processing)

 Clarified mud from the clarifier further filtered in

• Mud from clarifier still
rotary filter.
contain some residual
 rotary filter consist a rotary drum & vacuum
juice
atmosphere in its center.
• Filtered to extract
 Mud & sludge are stick on the periphery of rotating
residual juice in vacuum
drum by the action of suction. Solid cake removes
Rotary Press mud Filters
from the drum by doctor blade.

 Settled-out mud contains 1-4 % of the weight of cane charged and used as manure.
Continuous Rotary Drum VacuumFilters
Settled-out mud contains 1 to 4 % of the weight
of cane charged and is used as manure.
The settled out mud can optionally be washed by
using water flow for further separation of any
remaining amount of sugar content.
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Sugar Manufacturing Process:
 Conc---15ᴼ → 65ᴼ
8. Evaporation (Juice Processing)  ~85% →~40% water

 Juice from Clarifiers / Settlers contains ~85 % water. • Two types of evaporators
 It is then evaporated by steam to obtain thick supersaturated – Single effect
evaporators
solution (~40 % water, pale-yellow juice).
– Multiple effect
 1 liter steam to evaporate 4 liter juice evaporators

Pressure decreasing
effect evaporator
Triple/quadruple

85 ᴼC 55 ᴼC
110ᴼC

vacuum

1st effect 2nd effect 3rd effect

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Sugar Manufacturing Process:
 Brix: 65ᴼ → 75ᴼ at 60 ᴼC
9. Crystallization (Juice Processing)  ~40 % →~10 % water

 Thick juice is evaporated to supersaturation to get

purest form of substance.

 Carried out in single effect high-vacuum boiling pans

 Addition of nucleate (Seeding)

 By the addition of thick juice and controlled

1. Nucleation
evaporation, the crystals are grown to desired size 2. Initiation
stages of
and shape. crystallization 3. Elongation (growth)

 The object of the process is usually the recovery of

the solute (crystals) from the solvent.
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Sugar Manufacturing Process:  Massecuite, Molasses, sugar
9. Crystallization (Juice Processing) pulp

• The mixture of syrup and crystals (massecuite, mother liquor) is pumped into the crystallizer for

further heating in vacuum pans to vaporize remaining vapors.

• Crystallizer is a horizontal agitated tank provided with cooling coils.

• The first grade molasses is obtained by first evaporation in VACUUM PAN. It is called sugar pulp.
 CENTRIFUGATION

• Separate sugar from molasses

• Centrifuge operates at 1500-1800 rpm
• Molasses pass through perforations
• Sugar crystals are washed with hot water
• Raw sugar and molasses
 high quality raw sugar with light brown color.
 Blackstrap molasses.
 Raw sugar and molasses (Products)
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Sugar Manufacturing Process:
 Brix: 65ᴼ → 75ᴼ at 60 ᴼC
10. Centrifugation (Juice Processing)  ~40% →~10% water

Before centrifugation After centrifugation

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Sugar Manufacturing Process:
11. Drying, Screening & Packing (Juice Processing)

 The moisture content in sugar after leaving centrifuge which varies b/w 0.5-2 % needed to reduced
about 0.05% for safe storage.
 Sugar is tumbled through large cylindrical dryers where sugar is contacted normally in cross flow
with hot air and Moisture will migrate from the sugar to the air.

 SCREENING: sugar crystals are separate in the form of over, under & desired size.

 PACKING: final process where screened crystals are packed in different size of bags.
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Sugar Manufacturing Process:
Final Product
 Raw sugar, that contains about 97.8 % sucrose is then delivered further to sugar refinery. Where

more refined sugar is produced having white color (table sugar).

 By product: Molasses: thick, dark black colored liquor

• used as a source of carbohydrates, animal feed & for citric acid preparation etc.
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Fertilizers
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Sugar Refining Process

 Sugar Refining Steps

 Affinition
 Carbonation
 Filtration
 Decolourization
 Evaporation and Crystallization
 Drying

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1- Affination
o Affination is a process in which raw sugar crystals are treated with a warm, heavy
syrup (60-800 brix), to remove adherent film/remaining of molasses.
o Affination is performed in U-mixer, melter & Mingler
o In the U-mixer, raw sugar is stirred with a measured amount of water
o This operation does not remove the impurities from the raw sugar crystals.
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2- CARBONATION
o Dissolved sugar is now reacted with milk of lime (CaO) and Carbon Dioxide

(CO2) under controlled pH and temperature to form a calcium carbonate

(CaCO3) precipitate.

3- Filtration
o Carbonated liquor (solution) is pumped through a series of leaf filters which
retain the calcium precipitate in the filter and discharge a clear but colored
sugar solution.
o Resulting liquor is filtered and sent to the decolorization process
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3- Decolorization
 After the removal of insoluble impurities still soluble coloring matter is to be
removed.

 Soluble impurities are removed by percolation through

1. Bone-char

2. Activated carbon

3. Ion ionization method

 3- Decolorization (Percolation through activated Carbon)

—Coarse carbon granules can be used in beds for adsorption purposes.

—Revivification can be done by roasting at high temperature of about 1000 oC.

—Activated carbon is normally preferred due to longer operating cycle, but it can not

remove inorganics.

—Used for small installations & seasonal batches.

—Micro-porous structure with high surface area available for adsorption purposes.
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3- Decolorization (Percolation through bone-char)

 Percolation is carried out at 82 0C and clear white syrup is obtained.

 When bone-char losses its decolorizing ability, it can be revivified by heating it to

0
400-500 C in vertical pipes.

 It has advantage over CO2 percolation as it also removes inorganic impurities.

 Primarily used for filtration and decolorization.

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4- Evaporation & Crystallization

 Evaporation: Sugar syrup evaporated up to super saturation by evaporating water
from the fine liquor in specially designed equipment to concentrate the sugar solution
into a stream known as thick liquor.

 Crystallization: Thick liquor is transferred to boiling vessels known as pans where

under controlled vacuum the liquor is boiled at low temperature to further
concentrate the solution. As water evaporates and the liquor concentrates, sugar
crystals begin to form, their growth being controlled by careful adjustment of the
boiling conditions.

 Centrifugation to obtain refined sugar crystals

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5- Drying & Storage

 Bucket elevator on conveyer

 Hot air for drying

 Sieving
—Fine, medium and bold grains

 Storage in go downs
—Cool, dry, moisture and odor free
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6- Packaging

• Containers opaque, airtight, moisture/odor proof

• Glass canning jars or cans for liquid sugars

 RAW & REFINED SUGAR
• Raw sugar
— Obtained directly from sugar cane juice without refining

— Most natural sugar

— Brown in color due to molasses

• Refined sugar
— Have white luster and transparent

— Bleached to remove color and other impurities

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FACTORS AFFECTING SUGAR STORAGE

—Temperature

—Moisture

—Quality of sugar

—Light

—Grain size and distribution

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 Energy Economy In The Sugar Manufacturing Process
— Bagasse can be used to generate steam. Steam can be used for

electricity generation thus save consumption of fuel.

— Bagasse is also used as raw material for paper industries as fertilizer

and cattle feed.

— The final mother liquor; molasses is used for the production of ethyl

alcohol by fermentation process.

— Press mud is used as phosphatic fertilizer in farms. 46

THANK YOU

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