Sugar and Power Plant Process

.
PLANT TRAINING REPORT

POWER HOUSE

Power house is one where electric power is produced using fuel. The fuels used
are coal and bagasse. Fuel is fired in a closed vessel called as boiler & stem is produced
from water in it. This steam is utilized to run the turbine & electric power is produced
from alternator coupled to it.
The whole power plant can be divided in to two sections.
Boiler Section
Turbine Section
There are different systems in power plant as-
Fuel handling system for coal & bagasse.
ater!Steam flow system.
"ir flow system.
#as flow system.
"sh handling system.
$ooling system %$ooling tower&.
'ubrication oil system for turbine
(ibration indication system in turbine.
P'$!)$S!S$")" System.

*
. PLANT TRAINING REPORT
BOILER
+umber of boilers-,
-st B.-'/0
$"P"$-T12 *33 tph
P0/SS40/2567g!cm,
T/8P/0"T40/2596$
8":/2 Thermodyne
T1P/2 Top supported; Bidrum; Balanced draft; +atural circulation with pulsating
grate
--nd B.-'/0
$"P"$-T12 *<3 tph
P0/SS40/2=>7g!cm,
T/8P/0"T40/2596$
8":/2 8itsui Babcoc7 ilco?.
T1P/2 Top supported; Bidrum; Balanced draft; +atural circulation with traveling
grate.
TURBINE
-st T40B-+/
$"P"$-T12*68
0P82>3630P8
ST"#/2=
T1P/2 Bac7 pressure with bleed steam.
8":/2 Triveni
--nd T40B-+/
$"P"$-T12,<8
0P82599=0P8
ST"#/2*<

,
T1P/2 $ondensate cum -st & --nd /?traction.
8":/2 Sini +ippon
CYCLES
"T/0!ST/"8 $1$'/

<
#"S $1$'/

5
B"#"SS/ $1$'/

6
$."' $1$'/

=
"-0 $1$'/

>
BOILER FITTINGS, MOUNTINGS & ACCESSORIES.
F-TT-+#S2 These parts form boiler body & cannot be separated.
/?2 Steam drum; 8ud drum; Ban7 zone; )own comer tubes; Front header;
0are header; Side header; Boiler tubes; Top headers; 0oof tubes; Screen tubes; 0iser
tubes.

8.4+T-+#S2 These parts are mounted on boiler body & can
separated from it.
/?2 Safety valves; #auge glass; Pressure gauges; Temperature gauges;
Pressure transmitters; Temperature transmitters; Soot blowers; Blow off coc7; Stem stop
valve; non return valve; "ttemperator control valve.

"$$/SS.0-/S2 These parts are used for the proper functioning
of the boiler. These are the parts apart from boiler body.
/?2 Transfer pump; Feed tan7; Feed pump; )eairator tan7; /conomizer;
Super heater; "ir pre-heater; /SP; F) fan; S" fan; -) fan.

9
(.'(/S & 8.4+T-+#S
SL. NO. ITEM DISCRIPTION
TYPE/MODE OF
OPERATION
* ,- )rum safety valve Spring loaded
, Superheater safety valve Spring loaded
< Feed water control valve Pneumatic operated
5 Feed water isolating valve 8otorized
6 Feed water chec7 valve +0(
= ,-+os of drum safety valve Bi-color
> /lectronic level indicator $onductive type
9 Start up vent valve 8otorized
@
8ain steam valve with
integrated by-pass
8otorized
*3 "ttemperator control valve Pneumatic operated
**
"ttemperator isolating &
by-pass
8anual
*,
"ll necessary vent; drain &
isolated valve
8anual

@
TECHNICAL SPECIFICATIONS & MAKE OF
BOILER ACCESSORIES.
T0"+SF/0 P48P2
T1P/ 2$entrifugal pump%5 +os.&
'.$"T-.+2"fter 0. tan7.
8":/2 :SB pumps.
*,3m<!hr; *563 0P8; <6 mA.
8.T.02 *9.6:; *5=<0P8.
8":/2 Siemese
T0"+SF/0 P48P2 %For *33tph boiler&
T1P/ 2$entrifugal pump%< +os.&
'.$"T-.+2"fter feed tan7.
8":/2 :SB pumps.
>6m<!hr; ,@33 0P8; 93 mA.
8.T.02 =3AP; ,@330P8.
8":/2 Siemese
F//) P48P2 %For *33tph boiler&
T1P/ 28ulti tage%*< stages-< +os.&
'.$"T-.+2"fter deairator tan7.
8":/2 Sulzer.
=6m<!hr; ,@>30P8; @97g!cm,
8.T.02 ,33:; ,@960P8.
8":/2 Siemese

*3
AP ).S-+# P48P2 %For *33tph boiler&
T1P/ 2Piston pump%, +os.&
8":/2 8etachem dosing pump.
<3ltr!hr; 937g!cm,
8.T.02 *AP;*5*30P8.
8":/2 $romton #reaves
'P ).S-+# P48P2 %For *33tph boiler&
T1P/ 2Piston pump%, +os.&
8":/2 8etachem dosing pump.
<3ltr!hr; 67g!cm,
8.T.02 3.<>:; *<930P8.
8":/2 Siemese
F) F"+2 ,+os %For *33tph boiler&
8":/2 Power ma? -ndia ltd.
,=m<!sec; *553 0P8; ,<3mm$.
8.T.02*<6AP
8":/2Siemense.
S" F"+2 ,+os %For *33tph boiler&
8":/2
8.T.02
8":/2Siemense.

**
-) F"+2 ,+os %For *33tph boiler&
8":/2
8.T.02
8":/2Siemense
B"#"S )048 F//)/02 * T0PF %> +os.& %For *33tph boiler&
8.T.02 >.6AP; *5530P8.
8":/2 Siemense.
#/"0 B.B2
#B002 5,>2*
B"#"S F//)/02 * T0PF %> +os.& %For *33tph boiler&
T1P/2 Screw type
8.T.02 <.>:; *5530P8.
8":/2 Siemense.
#/"0 B.B2
#B002 ,=.6,2*
8":/2 Top gear transmission ltd.
P4'S"T-+# #0"T/2 %For *<3tph boiler&
P./0 $1'-+)/0S2 5+os.
.0:-+# P0/SS40/2 937g!cm,
.-' T"+: $"P"$-T12 ,33ltr.

*,
0.T"01 #0"T/ %For *<3tph boiler&
8.T.02 >6AP; *5530P8 %,+os.&.
8":/2 Bharat biClee ltd.
#/"0 B.B2
#B002 ,3332*
8":/2 "''0.1).
B"#"S )048 F//)/02 , T0PF %6 +os.& %For *<3tph boiler&
8.T.02 6AP; *5530P8.
8":/2 Siemense.
$."' F//)/02 %5 +os.& %For *<3tph boiler&
T1P/2 )rag chain type.
$"P"$-T12 6.6TPA
8":/2 Duality conveying system ltd.
8.T.02 6AP; *5530P8.
8":/2 "BB.
#/"0 B.B2
#B002 *,62*
8":/2 PB/#'.
$..'-+# "-0 F"+%,+os.& %For *<3tph boiler&
8.T.02 5AP; *5530P8.

*<
POWER PLANT COOLING TOWER PUMPS & MOTORS.
$.+)/+S.0 P48P.
T1P/2 $entrifugal pump%5 +os.&
8":/2 8ather & platt pump ltd.
*933m<!hr; *553 0P8; 53 mA.
8.T.02 ,*6AP; *5530P8.
8":/2 $romton #reaves.
"4B-''"01 $..'-+# P48P.
T1P/2 $entrifugal pump%, +os.&
8":/2 8ather & platt pump ltd.
=33m<!hr; *553 0P8; 53 mA.
8.T.02 ,*6AP; *5530P8.
8":/2 $romton #reaves.

*5
PRDS (Pressure Reu!"#$ Desu%er&e'("#$ s(e')*
Se!("+#.
From this valve steam pressure & temperature can be maintained at desired value.
+umber of P0)S- 5
-st2- =>7g!cm, to 567g!cm,%For *6 8 turbine&
--nd2- 567g!cm, to >7g!cm,%For distillary&
---rd2- 567g!cm, to *.67g!cm,%For process&
-(th2- 567g!cm, to >7g!cm,%For distillary&

*6
BOILER OPERATION
ST"0T-+# .F B.-'/0
-.pen all the vent valves.
-8aintain steam drum level 63E
-8aintain feed tan7 level @3E.
-Start the sto7er firing.
-Start -); F); S" Fan.
-Slowly increase the firing.
-"fter reaching the design pressure close all the vent valves.

ST.PP-+# .F B.-'/0

*=
-Stop the firing.
-Stop S" fan.
-Stop F) fan.
-Stop -) fan.
-8aintain 63E water level in steam drum.
-.pen airvent slowly.

B"$: -+ B.-'/0
0easons-
-Feeding of wet bagas; Faming of superheater coil.
--) draft less.
-F) draft more.
--mproper damper opening.
-+T/08")-"T/ & $.+T-+4.4S B'. ).+.
-ntermediate blow down.
-t is given to mud drum. -f T)S hardness of mud drum increases or the water level in
steam drum increases then it is opened & blow down.
$ontinuous blow down.
-t is given to steam drum. " continuous crac7 remains open at 63E level of steam drum.
Sludge; oil content in water is removed from this crac7 continuously.
These lines are ne?t connected to silencer drum.

*>
RO PLANT
Plant capacityG63m<!hr

*9

B.-'/0 "T/0 P"0"8/T/0S T. B/ 8"+T"-+/)
PARTICULARS FEED BOILER CONDENSATE

*@
(PPM* WATER
WATER
WATER
PH 9.6-@.6 @.6-*3.6 @-@.6
T+(', &'r#ess 3 3 3.3,
TDS ,.6 ,63 -
C ',-',"#"(. - >3 -
P ',-',"#"(. - ,3 -
C+,+ur $lear $lear $lear
Ir+# 3.3, - 3.3,-3.36
O", C+#(e#( 3 3 3
C&,+r"e 3 3.6 3.3,
P&+s%&'(e - <3-53 *6

PROCESS/BOILING HOUSE

,3
Fuice from the mill house is pumped to boiling section where the sucrose contains is
e?tracted by different processes on it.
There are two processes carried out here
-. /?traction of sugar from Cuice.
--. /?traction of sugar from raw sugar. %0efinery Section&
The whole boiling house can be divided as2-
$larification
/vaporation
Pan boiling
$entrifugal
Sugar drying
#odown
PurityG Pole!Bri?
CLARIFICATION/

,*
E0APORATION/

,,
$lear Cuice from clarifier is pumped to Falling Film /vaporator %FF/& bodies. The Cuice is
pumped to the top of a body by circulation pump & it is made to circulate in FF/ bodies.
Aere the heat e?change ta7es place between Cuice & steam. The Cuice is brought in
indirect contact with steam. The Cuice flows in tube side & steam flows in shell side.
"fter getting heated the syrup formed is pump to the pan section by syrup pump.
+umber of FF/ bodies2 *3 %9 remains online during process&
Aeating surface area2 <633m,
-nlet bri? of Cuice2 *6
.utput syrup bri?2 =9.>
The vapors condensate is collected in cigar & this water is used in ne?t process and mill
for spraying as hot water.
PAN BOILING/

,<
Syrup from evaporation section is boiled in pan section. The syrup is made to flow
through the pipes & steam is supplied from the shell side. Sugar powder is added as seed.
(acuum is created in pan by condensing the vapor formed in condenser.
There are two types of pans.
Batch pan
$ontinuous pan.

B"T$A P"+
+umber of pan2 *,
hite sugar pan2 < %8S material&
$apacity2 93tons!hr
0efinery sugar pan2 @ %SS material&
$apacity2 >3tons!hr
+umber of tubes2 *,,3
-nner dia2 @9mm
.uter dia2 *3,mm
'ength2 **33mm
(acuum2 9H
$.+T-+4.4S P"+2
+umber of pan2 5 %";B;$;)& %* stand by&
" & ) $apacity2 *36tons!hr
B & $ $apacity2 96tons!hr
+umber of compartments2*,
-nner dia2 @9mm
.uter dia2 *3,mm
'ength2 *<33mm
(acuum2 ,6H

,5
.(/0(-/ .F 8"T/0-"' F'.2

,6

CENTRIFUGALS/

,=
This is the section where sugar is cured%0ecovered& from the mother liIuor%masecute&.
The masecute is charged in centrifugal & sugar is separated from heavy & light molasses
due to centrifugal action.
The sugar is separated in bas7et having two meshes.
or7ing screen
Supporting screen.
$/+T0-F4#"'S 4S/) F.0 )-FF/0/+T 8"SS/$4T/S.
" centrifugal- = +os.
B centrifugal- 6 +os. Thyssen :rupp made
$ centrifugal- , +os.
0* centrifugal- < +os.
0, centrifugal- , +os. Five$ail-:$P made
0< centrifugal- , +os.
$apacity2 *>63:g!cycle
+umber of cycles2 *9-,3
0P82 **33

,>
.0:-+# .F F-(/$"-'-:$P $/+T0-F4#"' %B"T$A
T1P/&
P'.4#A 4+-T %=30P8 )40"T-.+&
*. Aood lifting up.
,. Scraper in %Plough rotation&
<. Scraper down.
5. Scraper up.
6. Scraper out%Plough rotation&
=. Aood down.
$A"0#-+# T-8/ %*63 0P8 )40"T-.+&
>.8T$ %8asecute Thic7ness $ontroller liver& -n- .+
9. 'ower valve is open.
@. 4pper valve open%8asecute charging start&
*3. "fter masecute charging 8T$ cutoff.
**. 4pper valve closed.
*,. $hute wash-Five seconds %SA *33$-*63$&
*<. 'ower valve closed.
SP-++-+# T8/.
*5. 533-=330P8 first wash %<-5 sec&.
*6.933-@330P8 second wash. %,-<Sec&
*=. 8a?imum 0P8 spinning %*3630P8&
*>. Bas7et wash before charging masecute %*3-*6sec&.

,9
SUGAR DRYING AND GODOWN.
Sugar from the centrifugal section is brought to dryer through screw conveyor.
)01/02
+o of )ryers2 <
Fluidized Bed )ryer2 ,
0otary dryer2 *
Sugar from the dryer is send to grader through buc7et elevator.
#0")/02
$apacity2 <6 tons!hr %5 +os.&
From grader the different size sugar is stored in different silo. The sugar is collected
through chute in to bags.
The bags are carried through the belt conveyor in to the godown for storage.

,@

<3
REFINARY PROCESS.

<*
SUGAR LAB
A!("1"("es (&'( 're %er2+r)e
$hec7ing of Sugar & 0aw sugar
8oisture
$olor
So, content
$hec7ing of 8i?ed Cuice & Pure Cuice.
Purity
Bri?
Sucrose
ater content from sugar cane to final sugar.
$hec7ing of Bagasse
Pole
8oisture
I#s(ru)e#(s use
Bri?ometer - Bri? $hec7ing
PA meter J PA chec7ing
/.$.; T.).S. analyzer.
Photo sucrose scan2 Transferancy
$onical flas7s; Burettes; pipettes etc.

<,
MILLING
8illing is the section where cane is crushed & made in ruptured form for the
ma?imum e?traction of Cuice. The bagasse formed send to boilers & Cuice e?tracted send
to boiling house.
The eIuipments used here are $rane; Feeder table; $ane carrier; $hopper;
'eveler; Fibreriser; Belt conveyor; 8ill; -nter ra7e carrier; Bagasse elevator through
which cane handling ta7es place & operation on cane is carried out.
)ifferent capacity motors of different power & rpm; #ear bo? with reIuired
gear reduction ratio are used.
$ompound imbibition; Aot water spray system; 'ubrication oil supply for
bearings; Aydraulic system to maintain the gap between the rollers; ater circulation
system to identify bearing temperature is used.
By pass pumps to pump the Cuice; 0otary screen to filter the Cuice & to put the
bagasse again in to inter ra7e carrier are used.
Finally the Cuice is collected in to 0aw Cuice tan7 and it is pumped to boiling house.

<<

<5
TECHNICAL SPECIFICATION OF MILL
E3UIPMENTS/
o $0"+/
$"P"$-12 *, tons %=+os.&
F4+$T-.+2 To lift the cane bundles of 6-9 ton & to put in feeder table.
8.T.0 0"T-+#
o F//)/0 T"B'/
"0/"2 5,m, %5 +os.&
8.T.0 0"T-+#2 ,3AP
F4+$T-.+2 To feed cane in to cane carrier at an uniform rate by the action of drag chain
which is driven by sproc7et running at <rpm driven by motor through gear bo?. -t is
manually operated.
o $"+/ $"00-/0
'/+#TA2 >3m
8.T.0 0"T-+#2 *,6AP
F4+$T-.+2 To carry cane at reIuired speed. -t is driven by plane chain. -t is
automatically operated.
o $A.PP/0 %, +os.&
)-"8/T/02 *=33mm
+48B/0 .F B'")/S2 *6B 5G=3
8.T.0 0"T-+#2 <33AP
F4+$T-.+'2 Sugar canes are chopped in to pieces here. -t is driven at ,63rpm.

<6
o '/(/'/0
)-"8/T/02 *933mm
+48B/0 .F B'")/S2 9B *3G93
8.T.0 0"T-+#2 633AP
F4+$T-.+2 Aere sugar cane is formed in still small pieces & leveled.
o F-B0/0-S/0 %,+os.&
S-+# )-"8/T/02 ,333mm
+48B/0 .F B'")/S2 *> B 9G*<=
8.T.0 0"T-+#2 ,533AP
"+(-' P'"T/2 -t covers the hammer of fibreriser. The clearance between the tip of
hammer & anvil plate can be varied by bolting arrangement. The varies from **3mm to
=6mm at centre to *3mm at end.
F4+$T-.+2 $hopped pieces of sugar cane are ruptured in small pieces here. -t is run at
>63rpm. The preparative inde? is maintained between 95-99.
o B/'T $.+(/1.0
8.T.0 0"T-+#2 *,3AP
F4+$T-.+2 To carry cane from fibreriser to first mill.
o ).++/' $A4T/2
F4+$T-.+2 To hold the bagasse under pressure on the top of a mill.

<=
o P0/SS40/ $A4T/2
F4+$T-.+2 To carry bagasse under pressure between top roller. The pressure is
maintained by adCusting the trashplate provided with bolting arrangement.
o 8/SA$A"0T :+-F/2
F4+$T-.+2 To clear bagasse from the groves of the roller.
o -+T/0 0":/ $"00-/0
+48B/0 .F 0":/S2 5,
8.T.0 0"T-+#2 =3AP
"+#'/ .F /'/("T-.+2 56
$/+T0/ T. $/+T0/ )-ST"+$/ .F T.P 0.''/02 *5m

<>
4UICE FLOW SYSTEM/
$ompound imbibition system is used. The actual flow of Cuice is as shown in F"$ #+.
Aot water %93$& spray is made before the last mill. Primary Cuice is collected in first mill
tan7 & secondary Cuice is collected in second mill tan7. -t is pumped to rotary screen to
filter it. Finally the mi?ed Cuice is collected in raw Cuice tan7.
P48PS 4S/)2
T1P/2 $/+T0-F4#"' %,+os - Bypass&
$"P"$-T12 5,6m<!hr; 53AP motor %.n -
st
; --
nd
& ---
rd
mill&
,,6m<!hr;=3AP motor %.n -(
th
& (
th
mill&
0.T"01 S$0//+2
SP//)2 <60P8 %, +os.&
8.T.0 0"T-+#2 *3AP
F4+)T-.+2 T. filter the Cuice & put the bagasse in to conveyor. -t is given "ngular
draft.

<9

<@
MILL MOTION/

8.T.02 ) $ Type. %:irlos7ar&
0"T-+#2 *333AP; **330P8
#/"0 B.B2
#B002 632*
P-+-.+ & 8"ST/0 A//'.
0/)4$T-.+ 0"T-.2 62*

53
P-+-.+ T//TAS2 ,>
#/"0 B.B T//TAS2 *<*
$.4P'-+# 4S/)2 0ope type
)0-(/S2 $hain drive
#ear drive
0.''/0 S-K/2 5,H%)& B 95H%'&.

5*
HYDRAULIC SYSTEM

+48B/0 .F $1'-+)/0S2 9
P0/SS40/ .+2 0.''/0 -
st
; 2 *93:g!cm,

0.''/0 --
nd
2 *@3:g!cm,
0.''/0 ---
rd
2 ,33:g!cm,
0.''/0 -(
th
2 ,,6:g!cm,
0.''/0 (
th
2 :g!cm,
F4+$T-.+2 To maintain the gap.

5,
OIL SUPPLY SYSTEM/

'ubrication oil is supplied to Cournal bearings to reduce the friction & to maintain
bearing temperature.
.-' 4S/)2 india survo oil 96

5<
WORK SHOP/MANTAINANCE
P"0TS TA"T "0/ 8"$A-+/)2 0otary shafts; Split plate; Bush;
:ey; +ipple; Feeding table shaft.
8"$A-+S -+ .0:SA.P2
'athe *2 5ft Bed length %Penther 8ade&
'athe ,2 *3ft Bed length %Batala 8ade&
'athe <2 *,ft Bed length %Batala 8ade&
'athe 52 To 0egrovig roller%Shantaram made&
8illing 8achine2 %Batala 8ade&
)rilling 8achine *2 Aeavy duty- ,H $apacity
)rilling 8achine ,2 Small- ,6mm $apacity
Aac7saw 8achine2 Bar cutting purpose
Shaping machine2 To ma7e :ey way.
#rinding 8achine

55
DISTILLERY
MAIN PRODUCTS & CAPACITY
/?port Duality 0ectified spirit %/D0S&
=6 :'P)
/thanol
=3 :'P)
/?tra +eutral "lcohol %/+"&
=6 :'P)
Spent ash
*,3 :'P)
BROAD CLASSIFICATION OF PROCESS
Fermentation plant
)istillation plant

56
FERMENTATION
$"P"$-T1
8olases Tan7 2- 69*6 8T- < +os.
$ulture (essel-- 2- *33 ltr.
$ulture (essel--- 2- *333 ltr.
Fermentation tan7 - 2- >63m
<
Fermentation tan7 -- 2- 563m
<
Fermentation tan7 --- 2- 563m
<
ash holding Tan7 2- ,33m
<
1east "ctivation Tan7 2- *33m
<

5=

5>
DISTILLATION
/+" P'"+T
=- $olumns
"nalyzer
Pre-rectifier
0ectifier
/?tractive )istillation
0ecovery $olumn
Polishing $olumn
/D0S P'"+T
5- $olumns
"nalyzer
0ectifier
Aeads $olumn
0ecovery $olumn

59
/BP.0T D4"'-T1 0/$T-F-/) SP-0-T $.'48+S
SL.
NO.
DISCRIPTION
COL.
ANALYSER/
DEGASSER
COL.
RECTIFIER
COL.
HEADS COL.
RECO0ARY/
F.O. COL.
5
)ia.
%mm&
,*33!*533 *>33 933 =33
6 8...$. SS-<35 SS-<35 SS-<35 SS-<35
7 +o. .f Plates ,3L6 >, <3 =3
8 Type of plate Sieve Sieve Bubble Bubble
9
Plate Spacing
%mm&
>63 <33 ,33 ,63
:
Thic7ness
%Shell!Plate&
%mm&
>!< 6!< ,!*.6 ,!*.6

5@
SL.
NO
.
DISCRIP;
TION
COL.
ANALYSER/
DEGASSER
COL.
PRE;
RECTIFIER
COL.
E.D.
COL.
RECTIFI
;ER
COL.
POLISHI
;NG
COL.
RECO0A
;RY/ F.O.
COL.
5
)ia.
%mm&
,*33!*533 ,*33 *633 *>33 **63 933
6 8...$. SS-<35 SS-<35
SS-
<35
53SS!<,$
4
$4 )/-$4
7
+o. .f
Plates
,3L6 >, =6 >, =3 63
8
Type of
plate
Sieve Sieve Sieve Sieve Sieve Bubble
9
Plate
Spacing
%mm&
>63 <33 <33 <33 ,63 ,63
:
Thic7ness
%Shell!Plate&
%mm&
>!< =!< 5!, 6!< ,.,!, ,!*.6
/BT0" +/4T0"' "'$.A.' $.'48+S

63
SP/+T "SA $.'48+S

6*
SL.
NO
.
DISCRIPTION
COL.
CAL;
I
CAL;
II
CAL;
III
P;
COND
S;
COND
.
0;
SEP
BAL.
TANK
5
)ia.
%mm&
*6>3 *6>3 *6>3 *6*6 693 *533 ,*33
6
.'ength
%mm&
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Sugar and Power Plant Process

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