INDUSTRIAL ATTACHMENT REPORT

KAKRAO TECHNICAL AND VOCATIONAL

COLLEGE

DEPARTMENT: ELECTRICAL
COURSE: ELECTRICAL AND ELECTRONIC
ENGINEERING
NAME: ABUOR ALPHAS OKOTH
REG; 21S/DEE/0286

PERIOD OF ATTACHMENT:

5TH SEPTEMBER TO 5TH NOVEMBER 2022

SUPERVISOR:KEN OMOLLO

DECLARATION
I Abuor Alphas Okoth declare that this is my original work done and prepared by
myself in support of my industry supervisor and has not been reported in any
other university for any award.

Signature…………………………….. Date…………………………..

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Reg No: 21S/DEE/0286

DEDICATION
I dedicate this work to God for his protection throughout my attachment period,
and the gift of life He has granted me. I also dedicate to my dear parents, siblings
and friends for the support and encouragement. Finally I dedicate to all my
lectures and the whole of faculty of science. God bless all.

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ACKNOWLEDGEMENT
I thank the Lord God Almighty for the divine protection, guidance and opportunity
of a memorial an fruitful period at Sony Sugar Company, secondly may I extend
my heartfelt gratitude to my family members for their support both financially
and for pieces of advice they granted me with.
I also owe so much thank you and gratitude to South Nyanza Sugar Company as a
whole for their unfailing support and for giving me the chance to undertake my
industrial attachment at their place. I express my gratitude to the Quality
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 Assurance Department at large who despite of their duties they agreed to lead my
supervised training to a success. I also express my gratitude to my supervisor Ken
Omollo for his guidance positive remarks and relevant suggestions and pieces of
advice he gave me. God bless you all.
I would like to say thank you to Electrical and electronic engineering Department
and a big thank you to my assessor Mr Denish who came to supervise my
attachment work and made it a success. May God bless you.

ABSTRACT
Industrial attachment is of importance as it exposes the student to real works. The student
applies the information obtained in class to the field. This report contains the information
obtained during my two months of industrial attachment at Sony Sugar Company. The report
covers different areas in the factory department where different operations take place. It
contains company brief introduction, location, vision, mission, core values and activities it deals
with. The section that I passed through and the skills learned in each section. It also highlights
the relevance of the attachment challenges faced during the attachment exercise, problems in

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the company and solutions given to the at least one of the problems and finally
recommendations and conclusions.

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TABLE OF CONTENTS

Contents
DECLARATION............................................................................................................2
DEDICATION...............................................................................................................3
ACKNOWLEDGEMENT...............................................................................................4
ABSTRACT..................................................................................................................5
CHAPTER ONE........................................................................................................9
INTRODUCTION.........................................................................................................9
1.0 Background information..................................................................................9
1.1 Vision................................................................................................................9
1.2 Mission...........................................................................................................10
1.3 Core values.....................................................................................................10
1.4 Occupational health and safety act..........................................................10
1.5 Objectives of the attachment.........................................................................12
1.6 Challenges......................................................................................................12
1.7 Significance of the report...............................................................................12
CHAPTER TWO.........................................................................................................13
2.0 WEIGHBRIDGE...................................................................................................13
2.1Token office.....................................................................................................13
2.1.1 Weighbridge................................................................................................13
2.1.2 Ticketing office............................................................................................14
2.2 CANEYARD.........................................................................................................14
2.2.1 Cane handling..............................................................................................15
Equipment’s.............................................................................................................15
2.2.3 Components of feed tables.........................................................................15
2.2.4 Care and maintenance................................................................................15
2.2.5 Challenges...................................................................................................16

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2.3 MILLS AND PRE-MILLS.......................................................................................16
2.3.1 Pre-mills.......................................................................................................16
2.3.2 Components of main cane carrier...............................................................16
2.3.3 Mills................................................................................................................17
2.3.4 Components and functions.........................................................................17
2.3.5 Major operation at the mill section............................................................17
2.3.6 Turbines.......................................................................................................18
2.3.7 care and maintenance.................................................................................18
2.3.8 Flow diagram of milling..............................................................................19
2.4 BOILERS..............................................................................................................19
2.4.1 Steam generation........................................................................................19
2.4.2 Customers of steam....................................................................................21
2.4.3 Equipment’s.................................................................................................21
2.4.5 Care and maintenance................................................................................21
2.5 POWER HOUSE..................................................................................................22
2.5.1 Process of steam conversion.......................................................................22
.2 Factors that keep electric generators in good condition......................................22
2.5.3 Types of steams...........................................................................................23
2.5.4 Care and maintenance................................................................................23
CHAPTER THREE.......................................................................................................24
PROCESS HOUSE......................................................................................................24
3.0 JUICE TREATMENT.............................................................................................24
3.1 Equipment and their functions......................................................................24
3.1.1 Juice Clarification.........................................................................................25
3.1.2 Filtration......................................................................................................26
3.1.3Accessories of rotary vacuum filters............................................................27
3.1.4 Evaporation.................................................................................................27

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 3.1.5 Syrup clarification........................................................................................28
3.2 SUGAR HOUSE...................................................................................................28
3.2.1 Factors to consider when designing a pan..................................................29
3.2.2 Pan accessories...........................................................................................29
3.2.3Pan parameters............................................................................................29
3.2.4 Major equipment at the pan.......................................................................30
3.2.5 Terminologies used at the pan station.......................................................30
3.2.7A massecuite boiling....................................................................................31
3.3.8 Flow diagram of juice treatment processes................................................33
3.2.9 Crystallization..............................................................................................34
3.3 CENTRIFUGATION..............................................................................................35
3.4 SUGAR DRYING AND GRADING.........................................................................37
3.5 SUGAR BAGGING AND PACKAGING..................................................................38
3.6 WAREHOUSE......................................................................................................38
CHAPTER FOUR........................................................................................................39
4.0 LABORATORY.....................................................................................................39
4.1 WATER TREATMENT..........................................................................................43
4.1.1 Raw water tank...........................................................................................43
4.1.2 Chemical treatment....................................................................................43
WASTE WATER TREATMENT...................................................................................45
CHAPTER FIVE..........................................................................................................47
5.1CONCLUTION...................................................................................................47
5.2Recommendations..........................................................................................47

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 CHAPTER ONE

INTRODUCTION
1.0 Background information
It was established in 1976 under the companies Act Cap 486 of the laws of Kenya and commissioned in
1979. The company premise and sugarcane nucleus estate sit on an area covering 2492 hectares without-
growers cane area of 15500 hectares. The company serves over 25,000 cane farmers in ten districts within the
cane growing zone at Homabay, Gucha, Trans Mara, Kuria Migori, Uriri, Rongo, Kisii south Ndhiwa and
AwendoThe company contribute significantly to the realization of Kenya’s vision 2030 through sugar
production whose current capacity stands at 2500 TCD.Government is the main stakeholder of the company
owing 98.8%, centum investment co. (ICDC) 0.717%, industrial development bank (IDB) 0.28% and Mehta
group 0.21%.The company is managed by the MD assisted by the managers of different departments for
example : factory manager, agriculture manager, human resource manager ,finance manager and marketing
manager.

1.1 Vision
To be a leading world class manufacturer of preferred sugar and associated production.

1.2 Mission
Sustainable production of sugarcane, manufacture and market of quality and associated products of the
delight of customer.

1.3 Core values

Customer first

Integrity

Sustainability

Professionalism

Entrepreneurship

Safety

Timeliness

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 1.4 Occupational health and safety act
Sony is committed to provide a work environment devoid at risk to health and safety of its employees,
contractor, visitors and other personnel within its premises in all aspects of our business. It does this by:

 Ensuring compliance with all applicable loss, regulation and any other statutory requirements on
matters of health and safety in places.
 Identify and prevent any potential risk to health and safety at the workplace and where possible
mitigate any hazard.
 Create awareness on individual obligation to all persons working under the control of the
company through provision of occupation health and safety information.
 Provide adequate and appropriate personnel protective equipment and put in place engineering
control to prevent injury and ill health at the place of work.
 Ensure that health and safety rules and procedures are in place implemented and routinely
monitored and evaluated.
 Establish mechanism for investigation and follow up all health and safety incidents to avoid
recurrence.
 Periodically reviews the occupation health and safety policy to ensure that it remains relevant to
be appropriate to the company
. The audits carried out include: environmental audit, safety and health audit, noise level. thermal,
air quality, waste water, hazardous substance, fire safety, risk assessment, plant inspection, and
medical examination among others. The environmental, health and safety aspects identified forms
the basis for the development of environmental health and safety management plan for
implementation and continual review. It also forms part of the company strategic plan on
addressing potential impact to the organization.
To this end the company has successfully implemented and reserved substantial number of
aspects and significant impacts as identified in the audits. These include; establishment of
oxidation ponds to improve on waste water quality, safe handling of used oil, reduction in
accidents and incidents, procurement of new and modern fire engine, creating awareness on
environment health and safety, adequate ablution blocs and provision of wholesome water.

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 The location of this company was influenced by the factors

 Ample land for premise construction

 Presence of sufficient water from river Sare.
 Enough manpower from the surrounding community.
 Availability of enough sugarcane. (Raw material)
 Enough capital

1.5 Objectives of the attachment

 To provide opportunities for student to put into practice the knowledge and skills gained in class
to real life working environments.
 To facilitate fulfillment of a diploma course
 To familiarize with the environment of your profession
 To create rapport with the future employers after completion of studies
 To test readiness to take a place in the work situation.
 To gain an appreciation of the atmosphere and environment of one professionalism and
to develop feelings towards the profession
 To extend experience, develop opinions and enhance self-confidence.

1.6 Challenges
 Lack safety elements like boots and helmet which resulted to delay in beginning the attachment as
I went to look for those vital elements.

1.7 Significance of the report

It serves to summarize the activities I engaged in, the skills learnt and the challenges faced and most
importantly recommendations which I believe if are considered may benefit the company, community and
country and large. Finally, the report may be used as a reference and whoever is willing to be employed by the
company

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 CHAPTER TWO

2.0 WEIGHBRIDGE
2.1Token office
It is a place where tokens cards are issued to the drivers. The driver hands in the delivery note which
contains the driver’s number, drivers name, the number of delivery notes are checked and entered into the
system and all the verification codes entered. After entering the details, he verifies the information with the
driver and then placed on the reader. after activation the ticket is issued to the driver.

2.1.1 Weighbridge
The purpose of the weighbridge is to account for the cane entering the factory. The process of cane
weighing is automated and smart weighing system is one of the most preferred way of accurate cane weighing.
Tractors are placed on the platform where the tractor data is accessed by use of the token card which must be
inserted in a machine at the weighing office. The gross weight is taken by the system after which the driver
proceeds to offload the cane at the cane yard. The tractor has to pass again at the weighbridge to tare of. The
tare weight is the weight of the empty tractor. The tare weight is subtracted from gross weight to obtain the net
weight that is used to pay farmers. Token holder takes the details of the tractor. To maintain the weighbridge,
monthly calibration is done using dead weights totaling to ten tones. A big lorry is also used to check the status
variation of the bridge. Once in a year the bridges are checked by KEBS. Stagnant water is also removed at the
platform to ensure the bridge is efficient for use

2.1.2 Ticketing office.

The computer operator gives print out of sugarcane weigh slip in four copies

White ticket-out growers account

Blue ticket-farmers

Yellow ticket-transporters

White-finance office

The ticket bears date and time received, gross, net and tare weights, cane grower’s distribution number
and name, and vehicles name.

Cane is weighed at the weighbridge for the following purposes

1. For purpose of paying farmers based on tons delivered
2. For contractors payment which include transporters and cane cutters.

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 3. For effective control of factory operations and planning.
4. For purpose of planning in agriculture department.

2.2 CANEYARD
This is a place where cane is temporarily stored awaiting milling process. The cane yard is divided into
three sides, the northern side, the southern side and the A and B slope. Once cane arrive at the yard the process
of offloading begins. This can be done manually by manpower or hydro-unloaders. There are two types of
hydro-unloaders

1.Direct hydro-unloader-offloads cane directly from the truck onto the feed tables when the processing is
on course.

2. indirect hydro-unloaded -offloads the cane at a steel wall.

2.2.1 Cane handling

It is done by pilling of the cane at the cane yard. This is done based on the status of the cane e.g. burned
cane and green cane. Also done according to the date they were harvested. Cane sorting is the arrangement of
cane at the yard based on the status of the cane i.e. date they were cut, removal of cane trashes and removal of
foreign material from cane

Equipment’s
 Hydro-unloaders-are hydraulic machines which operate by hooking at the grooves on the tractor
side lifting the database bar with the cane and then pouring it into the feed tables or steel wall.
 Cane stackers -are heavy vehicles meant to push and lift the cane on the. ground to the feed
tables or to the cane yard for storage
 Overhead crane-serves to move stored cane from the yard to the feed tables or pile the cane at the
cane yard. There, are two types of crane in this company, Morris and Garlic crane
 Feed tables-it feeds the cane on the auxiliary cane carrier. There are two types of feed tables,
southern and northern feed tables. Feeding of the cane on the table can be done by hydro-
unloaders, cane stackers and overhead crane

2.2.3 Components of feed tables

Cane kicker -controls the flow of cane on the table to auxiliary cane carrier

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 Drag chains-drag cane to auxiliary can Driv chains-run the drag chain on the motor
Motors -drive the hydraulic pump
Auxiliary cane carrier-transports the cane from the table to cutters

2.2.4 Care and maintenance

Weekly maintenance is carried out on equipment’s
Repair of worn out parts
Greasing and oiling of movable parts of the machine
Being cautious when handling machines
In case of any breakdown the operation is stopped and the breakdown is worked on

2.2.5 Challenges
Breakdown of machines
Burned cane and immature cane leads to low production
Foreign materials in the operation i.e. stones or piece of metal may lead to breakdown of the machines
Miscoordination by the operator

2.3 MILLS AND PRE-MILLS

2.3.1 Pre-mills
All units in pre -mills are driven by motor coupled to gearbox

Cutters-cane preparation begins at the cutters chamber. Its main work is .to cut the cane into smaller
chamber pieces and discharges the cut cane to the fibrizer. Its revolution per minute is 588 rpm

Fibrizer-chops the cane to fibers and discharges the fiber to the mcc through the anvil.it has got harmers
and tips and rotates in a clockwise direction with 591 rpm

Main cane carrier-it’s a rubber conveyor which transports the cane fibers to the mills.

2.3.2 Components of main cane carrier

Mcc kicker-levelizes the cane fiber which goes to the mills

Electric magnet-traps any ferromagnetic material which might be inside the fiber

Belt weigher-weighs the cane fiber which passes through the mcc

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 2.3.3 Mills
Mills are principally used for juice extraction.it receives the cane fiber from the mcc via a chute which
directs it into the mill number one. Milling section has four mills three are driven by steam and one is driven by
electric motor with each having four rollers driven by steam.

2.3.4 Components and functions.

 Top roller-it is the top most roller which drives all other rollers with the help of rope coupling
gearbox from the turbines
 Force feed roller-forces the fiber to the feed roller expression at hole.
 Feed roller-once the fiber is directed by force feed roller it initiates the grooves which ensures that
juice drain through and fibers is cleared by the scraper
 Discharge roller-discharges the already squeezed juice to the boot of the intercarrier
 Top scraper-clears the fiber at the top roller for efficient extraction of juice
 Bottom scraper-clears the fiber off the grooves of the discharge roller for the efficient extraction
of juice
 Trash plate -keeps the fibers passing through the mills under pressure and prevents fiber from
falling between the bottom roller

2.3.5 Major operation at the mill section

Imbibition water system is done to ensure maximum extraction of juice from the fibers
and can be done by either using imbibition water or imbibition juice
Hydraulic system-the top roller should always be maintained at the position of mill setting to

ensure maximum extraction of. juice, thus if the fiber goes to the milling the top roller relatively
displaced hydraulic oil is therefore used to pressure off between the required pressure on top cap

Mill setting-is very important for maximum extraction of juice and varies from mill one to mill four
depending on the amount of fiber. Feed setting is between the top roller and feed roller
mill sanitation- is hot washing of the mill section-this is done and steaming out the bottom of the rollers
then raise temperature hence not favorable for the growth of bacteria which
otherwise cause inversion of sucrose to simple sugars

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 2.3.6 Turbines
The mills are powered by live steam from the boilers hence the steam power plant
The steam is obtained from burning the bagasse in the boiler to heat water and channeled to the mills
Live steam has safety valve to discharge heavy steam and the strainer filters steam and drain the wet steam from
destroying the mills The steam hits the movable blades of the rotor through the angle then to the fixed blade
Live steam comes at ahigh temperature at 20 bars hence the cooling system of the turbine oil and is
pumped by mechanical pumps or motor through the oil filter and then to coolers where water is used to cool oil
in the perforations and on the sides
Turbines have hydraulic governor controlled by hydraulic oil, pneumatically controlled by the instrument
air compressed.
The turbine runs at 6000rpm therefore it undergoes a series of reduction gear boxes till it drives the roller
which runs at 4rpm

2.3.7 Care and maintenance

Lubrication of all movable parts
Replacement of worn out parts
Weekly maintenance is carried out on the equipment’s
Hot water is used to kill bacteria from the mills and conveyors
Cooling water is used to kill parts of the equipment’s
Being cautious when handling machine

2.3.8 Flow diagram of milling

Imbibition juice

Mill 1 Mill 2
prepared Mill 3 Mill 4

cane

imbibition water

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 2.4 BOILERS
Boiler is an enclosed vessel that is extensively used to produce steam under high temperatures this
company has two boilers used for steam generation

There are two types of boilers;

Water tube boilers also called high pressure boiler- are the ones applied in this company. Here water
passes through the tubes and fires surrounds the tube tank
Fire tube boilers are also called low pressure boilers, in this type of boiler fire passes through the
numerous tubes from the furnace and water surrounds the tube tank-

2.4.1 Steam generation

A boiler incorporates a furnace in order to burn bagasse and generate heat which is transferred to water to
make steam.
This steam is then superheated and passed under high pressure to turbines and other process equipment’s.
The boiler has four sections put in place for steam generation;
Water system-there must be a permanent source of water especially for water tube boilers
In this company water is supplied by river Sare then pumped to the water treatment plant
Boiler water is pumped to the Dm plant for further treatment then to the deaerator which is then pumped
to the steam drum via the economizer
Fuel system -the boiler require fuel which liberate heat to turn water into steam
Water tube boilers takes high quantity of fuel compare to fire tube boilers, the main source of fuel in this
company is bagasse obtained from extraction section which is conveyed to the boilers through bagasse elevator
which then discharges bagasse. to the main bagasse carrier
At the mbc the feeder chutes are connected which directs the bagasse to the boiler furnace for
commercial use
Excess bagasse goes to the bagasse store where it comes back to the boiler through a back-feed elevator.
Back feed helps the boilers in supplementing any shortage of fuel from the mills and to sustain the boiler when
there is no milling
Draught system-each boiler is served by three fans namely forced draught fan (FD) fan, secondary air
(SA) fan and the induced draught (ID) fan

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 Force draught fan -brings in positive draught to the boiler furnace to facilitate measure of fuel and air and
also makes the fuel to burn in suspension.
Secondary air fan -spreads the fuel inside the furnace causing the mixture of air and fuel to be even and
burn in suspension.
Induced draught fan -eliminates the product of combustion to the atmosphere
through chimney
Steam system -steam formation starts from the steam drum where heat is supplied and the water inside
absorbs the heat to turn water into saturated steam which is directed to superheated chambers for drying
and further heating
. when the working temperature and pressure has been attained the steam is supplied to the steam bank by
opening the main steam valve slowly.

2.4.2 Customers of steam

There are sections that fully depend on steam from boilers;

Powerhouse
Powerplant turbines (mills)
Process house for process heating


2.4.3 Equipment’s

 Boiler tubes -carry water that is heated to produce steam

 Deaerator-removes dissolved gases from boiler feed water
 Super heaters -convert the wet steam generated by the boiler to dry steam
 Economizer -pre heats the feed water
 Steam drum -contain cyclone, scrappers, circulating baffles which aid in separation of steam from
water
 Feed water pump-transports water into the boiler using high pressure
 Fans i.e. force draught fan, induced draught fan and secondary fan
 Carriers -e.g. main bagasse carrier

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 Ash conveyors

2.4.5 Care and maintenance

Cleaning of the boiler house

Weekly maintenance must be carried out as planned
All steam and water leakages must be sorted
Water to the boilers must be treated to the standards
Dumping and short blowing must be done as per the routine
Gauge glasses must be flashed in at least once per shift
Avoiding frequent venting

2.5 POWER HOUSE

This subsection is concerned with generation of electricity which is then supplied to the factory and
estate. It also deals with steam distribution to various sections i.e. process house

2.5.1 Process of steam conversion

Steam is converted from mechanical energy to kinetic energy then to electrical energy

Steam from the boilers is released to the powerhouse where the steam turbines convert the high-pressure
steam to mechanical steam

. During this process a steam first encounters a set of stationary blades called nozzles that guide steam
towards the next set of blades.

Steam then encounters asset of moving blades called rotor blades which are connected to turbine shaft

. when the rotor blades move, they rotate the turbine shaft to produce kinetic energy.an electric generator
is then used to convert the rotating turbine shaft kinetic energy to electricity.

.2 Factors that keep electric generators in good condition

Good quality of steam

Clear lubrication oil

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 Enough cooling water for bearing

2.5.3 Types of steams

Live steam-it is a high-pressure steam which comes directly from boilers. This steam is used to drive the
mill turbines and alternators which produce electricity to drive all the motors in the factory and also provides
light, reduced live steam pressure is used in the factory for heating or steaming out pipes

Exhaust steam-used for evaporation, clear juice heating and secondary mixed juice heating

2.5.4 Care and maintenance

Weekly maintenance

Annual maintenan

CHAPTER THREE

PROCESS HOUSE

3.0 JUICE TREATMENT

The purpose of juice treatment is to remove impurities from the juice. Some of the key operations at the
juice treatment are:

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 Receiving and weighing raw juice from the screened juice tank hourly
 Heating the raw juice
 Liming the raw juice at the lime station
 Clarification by chemical addition and settling
 Evaporation of clear juice
 Filtration of mud at the mud filters

Requirements for effective treatment of juice are:

Proper conditions for effective treatment of juice which include-temperature and PH

Necessary chemicals used for treatment e.g. phosphoric acid, lime, and flocculant

3.1 Equipment and their functions

Weighing scale- used to weigh the raw juice that comes to production site for processing
Raw juice tank- receive the raw juice that has been weighed
Primary heaters- heats the raw juice at a temperature of about 65-70 ℃ it helps to kill natural enzymes
in the juice which would otherwise breakdown the sucrose. The juice temperature rises by use of steam in
a jacket and juice flows in the tubes. Pre heaters have chambers that house the heat exchanger which have
baffles to ensure that the steam flows through the tubes that have juice. Primary heaters get the exhaust
steam from the turbines and its strength raised by injecting live steam to increase its efficiency
Secondary heaters- uses the principle of heat exchange that is inside the jacket, the steam is transferred
to the juice and its temperature raised to about 100-110℃ and its PH is 6.8-7.0. Secondary heating helps
to complete the reaction of calcium hydroxide. It also helps in expelling the dissolved gases in the juice,
and important in coagulation of finely suspended matter.
Lime station- entails addition of lime to raise the PH to about 6.8-7.0 that will help in reducing acidity of
the raw juice therefore preventing inversion of sucrose.
Flash tank- receives juice from the secondary heaters and slows its speed to ensure steady flow of juice
to the clarifier and avoid turbulence in the clarifier, it also removes the non- condensable gases that may
cause disturbance in the clarifier

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 3.1.1 Juice Clarification
Clarification is done to remove impurities from the juice. The process depends on the formation of a
precipitate throughout the bulk of juice. This precipitate encloses impurities when it forms and entraps more
impurities as it compacts and settles. Some chemicals necessary for juice clarification are: phosphoric acid-
which is important in raw juice defecation. It is added when there is minimal amount of phosphates in cane.

Flocculant- induce flocculation of particles of precipitate forming heavy and dense flocs that settles more
rapidly to make clear juice. Lime reacts with phosphates in the in the cane juice to form first a very fine
amorphous calcium phosphate which is insoluble

3Ca (OH)2+2 H3PO4- Ca3(PO4)2+6H2O

During this reaction and under the action of heat and increase in PH, the other non-sugars are precipitated
out of solution. After the juice has mixed well with lime and passed through a reaction box where flocculant is
dosed, it is then passed to the central pipe in the clarifier, a form of separator where juice and mud are
separated. Flocculant inoculates all the solid materials and settles it down to the mud boot in all the four
chambers. The mud boot is linked to the reciprocating pumps to all chambers while the chambers overflows
juice through the top of the vessel and let to the clear juice tank. The clear juice has a PH of 6.8-7.0, its golden
brown with a temperature of about 99-100℃

Conditions leading to good clarification

 Optimum phosphate content of juice

 Enough lime to ensure adequate precipitation

Juice pH temperature

 Pre-Limed juice 6.0-6.6 70-85C

 Limed juice 7.5-8.5 100-105
 Clear juice 6.8-7.2 95-98
 The clear juice color should be yellow green and sparkling clear free of suspended solids
 Filter cake pol. 3.0%
 Filter cake moisture 70-72

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  Filtered juice pH 7.5-8.0


3.1.2 Filtration
The mud from the mud boot is drawn to the mud mixer where bagaccilo is added to aid infiltration for it
increases the porosity of mud. It also helps in maximum recovery of sucrose and helps in prevention of
blockage of sieves by the mud. The mixture of bagaccilo and mud is then taken to the trough which is
continuously mixed by the camshaft to avoid compaction as the vacuum filters picks at a loss vacuum as it
rotates to high vacuum where the juice is sucked to the capillary tubes as filtrate and the suction breaks and mud
falls to conveyor to the mud pin. The filtrate is taken back to lime station for processing. The vacuum is created
in the condenser where the vapor comes from the mud which is sucked plus diverge. Sony sugar uses two
vacuum filters the Paxman filter and the Jord filter. The mud is used as fertilizer.

3.1.3Accessories of rotary vacuum filters

 Mud mixer -mixing of mud from the clarifier bagaccilo
 Mud trough and agitator -the mixture of mud and bagaccilo is fed continuously into the
trough. They are kept in motion by an agitator oscillating to and fro pivoted on the access of the filters and are
driven by a separate small motor.
 Rotary filter drum- it rotates in horizontal axis and is partially submerged in the mud
trough.
 Filtrate tank- receives the juice sucked from mud for reprocessing
 Filter wash-washes all the sugar in mud to avoid loss of sucrose


3.1.4 Evaporation
Clear juice from the clarifier is concentrated in the evaporators and the brix should not exceed 65%, so
that the false grains may be dissolved when the syrup is fed into the vacuum pans. In this company there are
five evaporators namely: 1A, 1B, 2,3,4 each has its own brix. The main aim of evaporation is to boil off water
from the clear juice increasing its brix from about 18 -65%. Water is evaporated up to 80% to achieve the syrup,
the multiple effect evaporators which are steam economy by boiling juice in the evaporator 1A and 1B under
pressure then its vapor is used to evaporate juice in evaporator 2 under partial pressure. Some if its vapor is

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withdrawn to heat the vacuum pan boilers and the secondary heaters when necessary. Vapor at evaporator 2
heats the third evaporator for a given stream and some is taken to heat the primary heaters. The last evaporator
operates under vacuum to reduce the boiling point of the syrup. Vacuum is created by use of vapor from
evaporator 4 move to the condenser into the cold water via the pipes and on sudden cooling it creates sucking
effect to enable continuous flow of vapor and materials in the evaporator. The evaporator utilizes the exhaust
steam and vapor circulating in the calindria where the juice fills the tubes to a third and evaporates to the body
space and vapor moves to the subsequent evaporator. Condensate from the first and the second evaporators of
each stream is called pure condensate and is taken for steam generation at the boilers. Condensates from the
third and fourth evaporators is called sweet water condensates and is stored in sweet water tanks from where it
is used for various industrial tasks like imbibition.

3.1.5 Syrup clarification

The syrup is heated at the syrup heaters to increase its temperature to about 75 ℃ thus killing the micro
organisms before it is moved to the reaction box where the final treatment of juice is done. The flocculant is
added flowing by gravity to the clarifier. The clarifier has a central pipe with a scraper and arms which scrapes
the impurities to drain to the raw juice tank. The scraper is run by motor, the juice is dense hence settles while
the impurities floats with the help of compressed air which increases the buoyancy of the particles.

3.2 SUGAR HOUSE

A pan is device designed to produce and develop satisfactory sugar crystals from syrup or molasses fed
to it gradually and in a control evaporation in as many steps as may be required to reduce the purity of the syrup
until it attains the purity of the final molasses and maximize the amount of pol recovered in the raw sugar. To
recover maximum sugar from syrup three massecuite boiling systems is adopted, A & B are high grade
massecuite while C is a low grade massecuite. Mother liquor from A massecuite curing will serve as a feeding
material for B massecuite boiling and the mother liquor obtained from B massecuite curing serves as feed
material for C massecuite boiling. The kind of pans used in this company are of the batch type and are six in
number.
Vacuum pan design
 Dome-for recovery of pan entrainments through the vapor line
 Body -carries and holds materials being boiled

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 Saucer -provide room for circulation of materials below the calandria.
 Calandria- steam exchange jacket comprising of tubes trough which materials is heated

3.2.1 Factors to consider when designing a pan

 Quick and uniform distribution of feed and steam
 Efficient withdrawal of condensates and non-condensable gases

3.2.2 Pan accessories

Syrup valve, A &B molasses valves and water valve – for feeding materials in the pan
Cut over valve- for cutting and transferring materials from one pan to another vessel
Discharge valve-for striking down the massecuite
Vacuum breaker -to break the vacuum
Overhead steam valve -for washing the pan after striking materials and for creation of vacuum
Steam valve-admits steam to the pan
Proof stick -for checking samples
Sight glass- for clear observation of material level in the pan
Graduated scale- to show the volume of the boiling material
Save all- maintain entrainment minimal

3.2.3Pan parameters
Temperature of the pan-65-68℃
Vacuum-20-23InHg
Vapor -0.5-0.75bars
Calindria temperature-105-110℃

3.2.4 Major equipment at the pan

 Vacuum pan- for crystallization of sugar
 Crystallizers-to store massecuite awaiting separation at centrifuge
 Stirrer -to allow uniformity by mixing materials at the crystallizer

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  Receivers-to contain semi solid materials used at the pan station
 Boxes -storage of liquid materials used at the pan station
 Condenser-for vacuum creation

3.2.5 Terminologies used at the pan station

 Syrup- concentrated juice with 65% brix
 Massecuite-mixture of crystals and mother liquor
 Brix-percentage of soluble solids in juice
 Purity-measure of amount sucrose and purity of sucrose found in sugar
 Footing-material drawn into the pan for starting a pan
 Graining-introduction of fine sugar particles unto the boiling material
 Feeding -introduction of the boiling house material
 Cutting- dividing of total pan content into two and transferring to another vessel
 Seeding-introducing slurry to start crystallization
 Striking-dropping massecuite into crystallizers
Conglomerates-two or more crystals grown together during pan boiling

3.2.7A massecuite boiling

. Allow the crystals to harden then wash with syrup to remove unwanted crystals that cannot grow. feed
the pan with syrup and water till you get the wanted crystals

Shocking method-draw in syrup and boil to a desired consistent then add the sugar dust
Slurry method-draw in 250-350 ml of slurry into the pan at a point of supersaturation below that at
which the shock will be added and the result is that the slurry added mainly become the nuclei which develop
into grains

2.-Babooning method -draw in syrup up to 15m3, boil to the desired consistence and add B magma
od-draw magma into the pan, wash with water and syrup, develop then harden the crystals

B massecuite boiling

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 Draw syrup into the pan up to a volume of 15m3 and allow the crystals to harden concentrate then add
500mL of slurry. wash with water and syrup then allow them to come close. open A molasses bit by bit and
feed the pan to a volume of 31m3”2B grain”. Divide the 2Bgrain into two, the pan remains with 16m3 of the
sampler and the receiver will have 15m3 of the sample. Add A molasses to 2B at the pan to a volume of 31m3
brix then strike

How to create vacuum in pan

 Close the discharge door or vacuum breaker and any other pan inlets or outlets
 Pre heat the pan by opening the overhead steam valve
 Close the steaming out valve
 Open injection water into the condenser
Uses of vacuum
 Feeds the pan by exerting suction force
 Enhances circulation of materials in the pan
 Lowers the boiling point of liquor thus reducing boiling time

3.3.8 Flow diagram of juice treatment processes

Table
of

A-Massecuite

Centrifugal separation

A-sugar
A-molasses

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 B-Massecuite

B-Molasses

C-Massecuite

C-molasses
C-melt
3.2.9 Crystallization
It is the process that takes place in vacuum pans which boil the syrup at low temperature under partial
vacuum. When the syrup concentrates some seeding are added which causes the development and growth of
sugar crystals .when the crystals reach the desired size the process is stopped and the outcome is called
massecuite.crystalization also involve exposure of massecuite striked from pans to crystallizer to allow them
cool, this facilitate further exhaustion of sucrose through further crystal development
Types of crystallizers
Air cooled horizontal crystallizer -striking of massecuite is done at a temperature of about 60 ℃ .air
cooling will decrease the temperature to about 45-50℃ .during cooling solubility of any remaining
sucrose in the mother liquor decreases hence attaining supersaturation zone and going into the developed
crystals. This occurs in all pans and facilitate further extraction of sucrose from the mother liquor.
Water cooled vertical crystallizers-this occurs mainly in c pans to facilitate maximum extraction of
sucrose and prevent its loss through the final molasses
Factors affecting sugar crystallization
 Temperature
 Supersaturation
 Vacuum

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  Purity of mother liquor
 viscosity

3.3 CENTRIFUGATION
Once the mother liquor has been exhausted to the practical limit for the strike concerned, it is separated
by a centrifugal force in a centrifugal machine. Centrifugal machine consists of a spindle with a perforated steel
wall connected to it. Spindle and the baskets are driven by electric motor and rotated inside a housing. A screen
is inserted into the inside of the basket along its inner circumference. This screen keeps off the crystals but the
mother liquor is able to pass slots and goes on through perforations in the basket then flows down the housing
walls. There are two types of centrifugal machines:

batch centrifugal for A curing

continuous centrifugal for B&C curing

Batch centrifugal
Massecuite from the crystallizer is released into the centrifuge via massecuite header and pugmill.it is
then charged onto the basket from the top and build up against the screen until the wall of certain thickness is
formed. The centrifuge rotates rather slowly at this stage (100 rpm) as it is very important that the massecuite is
spread evenly over the surface ot the screen to prevent imbalance. When the basket has been loaded with the
massecuite the machine accelerates to high speed (2000rpm) and the molasses is separated. hot water, steam or
both is sprayed on the inside of the sugar walls and it washes away the residue of molasses from the crystals.
Spinning continues for a while to remove as much of the wash water as possible. Brake is put into auction
which slows down the baskets , the discharge valve open and the sugar is removed by means of a plough which
is lowered into the basket .while ploughing the machines rotates very slowly when then sugar has been removed
the discharge valve is closed again and the basket can take the next load.
Continuous centrifugal
These centrifugal have a cone shaped baskets belt driven from underneath by a motor mounted upside
down alongside the machine. Massecuite via the pugmill is continuously fed into the center of the cone
and it is accelerated in a cylindrical cup.by centrifugal force it slides up the cone in a layer of even
decreasing thickness. Molasses is separated from crystals and escapes through the perforations of the
screen into the molasses compartment from where it flows by gravity to the discharge valve. Crystals are

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 kept back by moving screen and move up till they reach the rim and are discharged into the stationary
outer housing where they drop down into a conveyor the high force which the crystals contact the wall
causes damage to the crystals.
Molasses removal is more efficient when:
 time for spinning at high speed is longer
 The size of the crystal is uniform
 Crystals are bigger
 Viscosity of the molasses is low
 Thickness of the massecuite wall is small

The following are summary of the target parameter for boiling house materials;

MASSECUITE BRIX PURITY

A 90-93 86-88
B 94-95 74-76
C 96-98 58-62


MOLASSES BRIX PURITY

A 78-80 72-74
B 80-82 54-56
C 84-86 35-37

MAGMA BRIX PURITY

B 92-94 88-92
C - 85-86
C-MELT 60-65 85-86
SYRUP 60-68 86-88


Maintenance
Check the plough and sugar
screw for wear and accordingly

3.4 SUGAR DRYING AND GRADING

Sugar discharged from A centrifugal is hot and wet and has to be dried before storage and packing.it is
dried to reduce microbial activities and to prevent caking wet bucket elevator transports the sugar from the

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conveyor onto the drier via a conveyor. The drier consists of a rotary drum through which the sugar passes in
counter current with hot and cold air. The heated air is injected at the front end of the drier and the cold air is
brought at the exit point which is then sucked out by the ID fan the hot air gives latent heat of evaporation of
moisture on the crystals while the cold air cools the heated crystals sugar, dust is blown from sugar and
directed to the cyclone for remelting.Dry sugar exits the drier through the chute which directs it to the vibrating
screen for lumps removal which is then directed to the Melter through the chute while the dried sugar is
conveyed to the sugar bins
Care and maintenance
Thorough cleaning of the dried is done during maintenance
Clear the air filters
Clean the vibrating screen for stuck sugar crystals

3.5 SUGAR BAGGING AND PACKAGING

Bagging is done separately in 50Kg and 25Kg bags .it has its own bins and its storage done in large scale
packaging goes on as long as the sugar is in the bins. the process is automated to pack 2Kg ,1Kg,1/2Kg, and
1/4Kg depending on the market demand. The amount of sugar bagged and packed is accounted for by keeping
records of the number and weight of the outgoing packed and bagged units

3.6 WAREHOUSE
It is a part of the building where bagged and packed sugar, are received protected against all types of
hazards and they await distribution

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 CHAPTER FOUR

4.0 LABORATORY
The laboratory is the heart of quality control and assurance in the factory. The laboratory staffs perform
the following task:

Sampling
Analysis of various products and raw materials a
Reagent preparation
Generation of lab reports

Sampling and sampling methods

Correct sampling methods of different products at different stages of manufacture are carried out for
effective plant control. The method of sampling depends on the nature of the particular product. There are two
sampling lines in this company water line and the juice line which can be sampled by the following methods

Continuous sampling- samples is collected hourly and it includes all juices, prepared cane, raw and
treated syrup, filtrate, filter cake, A, B&C molasses, boiler water and condensates
Composite sampling -includes final molasses, massecuite-magma, sugar
Spot sampling -sampling of all the entrainments
Analysis

Boiler water and condensates

Boiler water is analyzed to determine the pH and total dissolved solids while the condensate is analyzed
to determine the pH and sugar traces. this analysis is done using naphthol indicator and concentrated Sulphuric
acid

Entrainments

Samples from the pans, syrup line, mud drain, mill drain, east west and north mill drain are analyzed to
determine brix, while those obtained from the sugar house and factory effluent are analyzed for pH and brix’
those from the spray bond is analyzed for temperature and ph.

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 Juices

First expressed juice, last expressed juice, mixed juice, clear juice and filtrate are analyzed to determine
its pH and calculate its purity. while for limed juice only the pH is determined.

Procedure

Sampling, measure the brix and pH add two spatulas full of lead acetate and filter, measure the pol and
calculate purity.

Purity= (pol corrected /brix) × 100

Syrup

Sampling, measure the pH and brix, weigh 65g into a 250 mL volumetric flask and top up to the mark,
pour into a measuring cylinder and add two spatulas full of lead acetate then filter and measure the pol

Purity =(pol/brix) × 100

A&B molasses and massecuite

Measure ratio 1:1, weigh 65g of the sample into a 250 mL volumetric flask and measure the brix of the
remaining solution top up to the mark using water. And transfer into a beaker and add two spatulas full of lead
acetate then filter and find the pol

Purity= (pol× 2/ brix ×2)× 100

Final molasses

Measure ratio 1:1, weigh 78g in 500mL volumetric flask and top up to the mark using water, measure
brix of the remaining sample. Transfer into the beaker and add two spatulas full of lead acetate and filter in a
1oomL volumetric flask to the mark. Measure 10mL of acetic acid in 10mL measuring cylinder and top up with
water then add to the mixture and find pol

Purity= (pol×3.67 brix) × 100

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 Sugar color

Weigh 30g of sugar sample in conical flask add 70mL of water and swirl until it dissolves, adjust the pH
to 7 and filter using a Buchner funnel, measure the brix at then find the absorbance at 420nm

Color= (absorbance ×1000)÷(corrected brix÷100)×cell length)

Sugar pol

Weigh 26g of sugar in 100mL volumetric flask add water to about 60% and shake to dissolve

Add 1mL of lead solution then add water to about 80%. leave it to settle for 15 minutes then add three
drops of diethyl ether, filter then find pol

Sugar moisture

Rake weight of the petri dish measure 20g of sugar in a dish. Put in oven for three hours

Moisture= (weight loss/weight of sugar)×100

Insoluble in sugar

Weigh 100g of sugar in 100 mL beaker. add 199mL of hot water filtered at 45℃ by membrane filter. Stir
until it dissolves and take the weight of the membrane filter. Filter and dry in oven for one hour

Insoluble= weight of the solid in mg×1000/weight of the sample

Water hardness
Measure 100mL of the sample add 2mL of Erichrome T black indicator and add 10 mL of ammonium
solution. Titrate with 0.01M EDTA multiply the reading by 10

Alkalinity of boiler water

Measure 10Ml of the sample, add barium chloride and add two drops of phenolphthalein indicator and
titrate against 50% con sulfuric acid

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 Preparation index
Weigh 500g of fiber from the fibrizer then add 3000mL of water put in a tumbler and run for 30 minutes
then measure the brix. weigh 333g of fiber add 2000mL of water put in wet disintegrator for 20 minutes then
find the brix of the juice
PI= (tumbler brix/disintegrator brix)× 100
Calculations of BOD
Measure 50mL of distilled water, 10mL potassium permanganate solution, 10mL of conc. sulfuric acid.
10 ml of the effluent in a conical flask and leave it for one hour. Add 10 mL of potassium iodide solution add
two drops of starch indicator and titrate against sodium thiosulfate solution. carry out a blank experiment
OA value=(x-y)× 10 ^6×Q)/(X×P) where
Q=quantity of MnO4 used
P=quantity of effluent taken
X= titer reading for the blank
Y=titer reading for the sample

4.1 WATER TREATMENT

Sony sugar Company obtains its water from river Sare. This natural water source contains some
particulate suspended in it forming colloids that make it unsuitable for its intended applications.
Water treatment make water suitable for its application water from the river is pumped into the water
treatment plant where it undergoes various treatment processes to make it suitable for industrial use.

4.1.1 Raw water tank

This tank acts as storage tank for water from the river awaiting treatment. It also serves as a
sedimentation tank since some of the suspended solids settle while the water awaits treatment
4.1.2 Chemical treatment
Refers to dosing of chemicals to the raw water. The raw water is dozed with Aluminum sulphate and
calcium hydroxide to aid in coagulation and flocculation.
Coagulation
Is the process where a coagulant is added to water to help form tiny sticky particles (floc) which attract
dirt particles. The combined weight of the dirt and coagulant become heavy enough to sink to the bottom during
sedimentation. Also4 acts as the coagulant in the process.

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 Flocculation
Is the reversal formation of aggregates which the particles are not in physical contact. Flocculants are
normally high molecular weight material which trap particles and settle together.
It’s the growth of large floc. This occurs and allows sedimentation of particles.
Al₂(SO4) + 3Ca (OH)₂ 2Al(OH)₃+ 3CaSO₄

Sedimentation
Is the tendency for particles in suspension to settle out of the fluid in which they are entrained and come
to rest against a barrier. At Sony sugar, this process is carried in decanter which basically is a sedimentation
tank with residence time of 3 hours. The settled particles are withdrawn and disposed off while the clarified
water is taken for filtration. Sedimentation tank is wide to ensure proper aeration and removal of odor.
Filtration
Is the process of removing solids from a fluid by passing it through a porous medium, coarse and fine
medium. At Sony Sugar Company, sand filters are used for filtration which further purify the clarified water.
At this stage the filtered water is ready for use in factory for cooling lubricating oil for turbine bearings
and bearings of mill rollers as well as those of feed water pumps.
Water intended for drinking is further taken for chlorination.
Chlorination
Water chlorination is the processes of adding the element chlorine for disinfection to purify it for human
consumption.
Chlorine is an effective disinfectant since it kills disease causing microorganism such as bacteria, viruses
and protozoans that commonly grow in water supply reservoirs and on the walls of storage tanks. The
disinfected water is the supplied for drinking in the factory, surrounding community and the company estate
Water softening
Is the removal of calcium, magnesium and other metal cations that causes water hardness.
Filtered water intended for use as make –up water in boiler feed water is further softened for removal of
water hardness. Temporary water hardness caused by bicarbonates of calcium and magnesium.
The calcium and magnesium ions that cause hardness also scales the boiler tubes thus reducing their heat
transfer coefficient.
Water softening is done using an ion exchange device to reduce the hardness by replacing the calcium
and magnesium ions with sodium ions. Ion exchange resins are organic polymers containing anioinic functional
group to which the di-cations bind more strongly than the mono cations. (Na⁺)

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 WASTE WATER TREATMENT
There are various sources of wastewater generating in a sugar industry. The quantity of the effluent
depends on the size of the factory.
Waste water treatment is by use of aerobic lagoon systems and cooling tower.

Aerobic Lagoon Systems

Lagoons are pond-like bodies of water designed to receive, hold and treat wastewater for a predetermined
period of time. To prevent leaks to underground water. They are line with clay or artificial liner.
The Oxygen in the aerobic zone makes conditions favorable for aerobic bacteria. Both aerobic and
anaerobic bacteria are very important to waste water treatment.
Oil Trap
Waste water is passed through to remove oil
Reserve pond
They are two ponds used as hold up ponds for water whose oil has been removed.
They function to allow natural aeration for odor removal and sedimentation of suspended particles.
Weir
This is a barrier designed to alter water flow characteristics. It’s used to determine flow rate
Sedimentation pond
Ensures a great percentage of suspended solids from the waste water settle. Also helps in aerationing.
Primary Pond
They are two ponds and are provisions for mechanical aeration of water to speed up oxygen supply and
odor removal
Secondary Pond
For natural aeration.
Final Pond
There is addition of bacteria which treat waste water by converting it into other substances.
Aerobic bacteria convert organic wastes into carbon dioxide, ammonia and phosphates which in turn are
used by the algae as feed. Water from the final pond is deemed harmless and is then discharged back to the
river.

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CHAPTER FIVE

5.1CONCLUTION
Much was gained from my attachment period at Sony Sugar Company. It is a good place for
students to undertake their attachment for effective practical learning.
5.2Recommendations
Problems encountered at the boilers include;
 High temperatures around the boiler area. This makes the personnel on duty uncomfortable and a
lot of heat is lost.
 This can be remedied by properly lagging all the steam pipes and the boiler body
 High intensity of noise, especially when the steam pressure is high, leading to bleeding some
steam to the atmosphere from the safety valves. This is a short-term problem that can be solved
by generating manageable levels of steam or venting it into the ground.
 Air pollution by bagasse. During windy periods, a lot of bagasse is blown and suspended
on the air from conveyer belts and storage sites. This problem can be solved by
enclosing the bagasse on the storage yard and the conveyer belts well from the wind.
 The laboratory apparatus for molasses sampling should be improved instead of using blue band
bottles which can cause contamination from other samples that had been analyzed earlier.
 Also the laboratory glass apparatus which are in poor cleaning condition can be improved by
regular washing after analysis or just supplying new apparatus at the laboratory.

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