Cane Preparation and Juice Extraction
Cane Preparation and Juice Extraction
Nov 2019 1
Outline
Cane harvesting
Cane cleaning methods (drying cleaning / wet cleaning)
Can unloading
Cane preparation (PI / POC / knives / shredder)
Juice extraction (simple balance / technical terms / milling / mill
sanitation diffusion / comparison of milling and diffusion)
Commercial cane sugar (C.C.S.)
Juice screening (DSM screen / rotating screen)
Daily report (related to this topic)
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Cane harvesting
The simplest, and probably most effective, method of reducing the
unwanted material in delivered cane is “burning” either before or after
harvesting. However, the environmental pollution from the smoke and
airborne particles is receiving increasing public resistance. Thus, the
green cane harvesting may be a more profitable practice than burning.
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Cane harvesting
Advantages of green cane harvesting to millers
fresh cane with low dextran and impurity content
degrades more slowly in storage
leads to more fuel or more biomass
Disadvantages of green cane harvesting to millers
more material to process
high fiber content leading to a greater loss of sugar in bagasse
produces more molasses as a result of the low juice purity
adversely affected the sugar color
induces more starch in the juice due to the addition of top and leaves
high milling costs
low bulk density of the cane in the transport vehicles
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P. Rein. Cane Sugar Engineering. 2nd edition. Verlag Dr. Albert Bartens KG-Berlin. 2017
Cane harvesting
Methods that are applicable in separating cane from extraneous matter (EM)
such as soil, dry and green leaves and tops are:
Cleaning with the use of a harvester
Cleaning at dry cleaning station subsequent to hand cutting the intact cane stalk
Mechanical cutting of the intact cane stalk with exclusion of the tops
Cutting of the intact stalk and cleaning with water at a receiving table
Note: type of cane cleaning methods: dry cleaning and wet cleaning
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Delgado C. Casanova Sugar processing and by-products of the sugar industry. Food and Agriculture Organization of the United Nations. 2001
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Bernhardt. Dry Cleaning of Sugarcane - A Review. Proceedings of The South African Sugar Technologists' Association - June 1994
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H.W. Bernhardt. Dry Cleaning of Sugarcane - A Review. Proceedings of The South African Sugar Technologists' Association - June 1994
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Bernhardt. Dry Cleaning of Sugarcane - A Review. Proceedings of The South African Sugar Technologists' Association - June 1994 9
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Bernhardt. Dry Cleaning of Sugarcane - A Review. Proceedings of The South African Sugar Technologists' Association - June 1994
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Bernhardt. Dry Cleaning of Sugarcane - A Review. Proceedings of The South African Sugar Technologists' Association - June 1994
Separation of sand
from removed EM
in rotary drum
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P. Rein. Cane Sugar Engineering. 2nd edition. Verlag Dr. Albert Bartens KG-Berlin. 2017
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https://www.shutterstock.com/th/search/sugar+cane+processing
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P. Rein. Cane Sugar Engineering. 2nd edition. Verlag Dr. Albert Bartens KG-Berlin. 2017
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In Thailand
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Cane unloading
Hydraulic truck damper
Cane unloader
Truck tipper
Copied from presentation slide of “ยงยุทธ ทิพยะวัฒน์. ระบบลูกหีบและการจัดการ . Sutech Consultant Co., Ltd. 2555.
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Cane unloading
Hydraulic cane unloader
Copied from presentation slide of “ยงยุทธ ทิพยะวัฒน์. ระบบลูกหีบและการจัดการ . Sutech Consultant Co., Ltd. 2555.
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Cane unloading
Side cane carrier
Tumbler or equalizer
Copied from presentation slide of “ยงยุทธ ทิพยะวัฒน์. ระบบลูกหีบและการจัดการ . Sutech Consultant Co., Ltd. 2555.
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Cane unloading
Sand separation system : Sand kicker
leveler
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Cane preparation
Cane preparation
Measurement of cane preparation
Bulk density : measured by
compressing a sample of prepared
cane at a set pressure for a given
time, finer particle sizes give a higher
bulk density. This method requires a 6.8 kg, 5 min, 103 kPa gauge
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P. Rein. Cane Sugar Engineering. 2nd edition. Verlag Dr. Albert Bartens KG-Berlin. 2017
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Cane preparation
Measurement of cane preparation
Preparation Index (PI) : the degree of finesse or percent of open cells,
when cane prepared its density increases from 200 kg/m3 to 400 kg/m3
wDS ,T
PI 100
wDS , D
Good juice extraction
PI involves tumbling a sample of 500 g of is achieved if PI is
prepared cane in 3,000 g of water for 30 min above 90
and measuring the brix of the extract (wDS,T).
This is compared with the extract in a wet
disintegrator in which the same ratio of cane to
water is used (333 g and 2,000 g respectively)
(wDS,D).
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P. Rein. Cane Sugar Engineering. 2nd edition. Verlag Dr. Albert Bartens KG-Berlin. 2017
Cane preparation
Measurement of cane preparation
Pol in open cell (POC)
POC involves tumbling a sample
100wS ,T mW , D
of 1,000 g cane in 10,000 g of
wS , D mC , D water for 10 minutes. In the
POC disintegrator 2,000 g cane is
mW , D wS ,T w disintegrated in 6,000 g water.
1 1 1.25 F ,C
This assumes 25% brix-free
mC , D wS , D 100 water on fiber in cane wF,C.
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P. Rein. Cane Sugar Engineering. 2nd edition. Verlag Dr. Albert Bartens KG-Berlin. 2017
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Cane preparation
Cane preparation equipment
Knives : used to cut the cane into small pieces, leaving a high
proportion of unruptured cells. (PI 70-75%)
Leveler : used on the main cane carrier in an attempt to
obtain a uniform height of cane fed to the knives or shredder,
steadies the load on the subsequent preparation equipment
and helps to reduce the incidence of choking.
Cane knife set : usually consist of one or two rotating knife sets
preceded by a leveler for whole stalk cane.
https://slideplayer.com/slide/10839415/ https://www.indiamart.com/proddetail/cane-leveler-9094096155.html
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https://www.indiamart.com/proddetail/cane-leveler-12931201212.html https://www.indiamart.com/proddetail/swing-type-cane-cutter-9094075248.html
https://www.ssab.com/company/newsroom/media-archive/2015/11/09/10/00/wear-resistant-
knives-from-f%C3%A1cil-system-named-finalist-for-2015-swedish-steel-prize
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38 – 76 mm
152 - 356 mm
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P. Rein. Cane Sugar Engineering. 2nd edition. Verlag Dr. Albert Bartens KG-Berlin. 2017
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P. Rein. Cane Sugar Engineering. 2nd edition. Verlag Dr. Albert Bartens KG-Berlin. 2017
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P. Rein. Cane Sugar Engineering. 2nd edition. Verlag Dr. Albert Bartens KG-Berlin. 2017
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Cane preparation
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Cane preparation
Cane after knife #2
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Sugarcane. Milling manual. Philippine Sugar Millers Association Inc. Volume 1. 2005
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Juice extraction
Methods of juice extraction
Milling : squeeze the cane between successive pairs of roll, to express
as much as possible of juice (free water, sucrose, nonsucrose) from
insoluble fiber. With in this sequence, water called “imbibition” is
added -normally in front of the last mill- and the juice expressed is
applied in counter flow to the cane.
Diffusion : a process in which dissolved molecules in solutions of
different concentration will diffuse due to a concentration gradient until
equilibrium is reached.
i. Bagasse diffusion – where there is pre-extraction of juice in a single
mill prior to lixiviation (leaching).
ii. Cane diffusion – where there is no pre-extraction of juice before
lixiviation (leaching) process
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W. Legendre. Preparation and Milling. Handout of 35th International Raw Cane Sugar Manufactures’ Institute. May 29 – June 8, 2019. Nicholls State University. Thibodaux. Louisiana. USA
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Cane Bagasse
S/K M1 M2 M3 M4 M5
Milling tandem : a number of individual mill, which can have three, four, five
of six compression rollers, arranged in series
Imbibition : the process that used to dilute the juice remaining in the cane
bagasse blanket after each extraction. Water added is called
imbibition water. The norms used of imbibition have risen over
the years from 200 – 350% on fiber at 85oC.
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A.V. Delgado, C. A. Casanova. Sugar processing and by-products of the sugar industry. FAO. 2001.
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http://www.sugarprocesstech.com/terminology-sugar-clarification/ 39
W.A.Bizzo, P.C. Lenço, D.J. Carvalho, J.P.S. Veiga. Renewable and Sustainable Energy Reviews 2014; 29 : 589.
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In the diagram, Mi is the total feed into mill i, Ji is the juice extracted from mill i
and Bi is the cane/bagasse exiting from mill i. The juice from mills 1 and 2
(Jl and J2) is passed through screens to remove fiber that has been extracted with
the juice. The screened mixed juice is sent onwards to the factory as raw juice.
The fiber removed is returned with some remaining juice as “cush cush”.
“Cush cush” is the stream of wet bagasse or bagacillo separated from raw juice
by the juice screens.
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P. Rein. Cane Sugar Engineering. 2nd edition. Verlag Dr. Albert Bartens KG-Berlin. 2017
Three roller mill : it was the backbone of the cane sugar industry during
the 20th century with mill tandems comprised of three to seven 3-roll
mills, often preceded by one, two or even three 2-roll crushers.
It faces the feeding problem.
Compression
Pusher roll
region
Top roll
Feed Delivery
roll roll
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Milling configuration
Four roller mill : the fourth roll is an
Compaction
underfeed roll with a cast iron shell, and only
grooved like a conventional roll. Compression
region
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P. Rein. Cane Sugar Engineering. Verlag Dr. Albert Bartens KG-Berlin. 2007
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W. Legendre. Preparation and Milling. Handout of 35th International Raw Cane Sugar Manufactures’ Institute. May 29 – June 8, 2019. Nicholls State University. Thibodaux. Louisiana. USA 45
O.P. Thaval. Modelling the flow of cane constituents through the milling process of a raw sugar factory. Master thesis of Queensland University of Technology. 2012.
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P. Rein. Cane Sugar Engineering. 2nd edition. Verlag Dr. Albert Bartens KG-Berlin. 2017
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http://www.usipl.com/product-detail/sugar-cane-mill
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R.E. King. Cane preparation and juice extraction. Handout of 35 th International Raw Cane Sugar Manufactures’ Institute. May 29 – June 8, 2019. Nicholls State University. Thibodaux. Louisiana. USA
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Sugarcane. Milling manual. Philippine Sugar Millers Association Inc. Volume 1. 2005
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Sugarcane. Milling manual. Philippine Sugar Millers Association Inc. Volume 1. 2005
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Sugarcane. Milling manual. Philippine Sugar Millers Association Inc. Volume 1. 2005
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P. Rein. Cane Sugar Engineering. 2nd edition. Verlag Dr. Albert Bartens KG-Berlin. 2017
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P. Rein. Cane Sugar Engineering. 2nd edition. Verlag Dr. Albert Bartens KG-Berlin. 2017
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C
cN 1 0.04 Pf n D 2 L
112,320 f
C capacity of mill (t cane/h)
c coefficient of preparation: 1.15 @ 70% – 85% open cells; 1.25 @ 85% – 90% open cells;
1.30 @ 91% – 92% open cells
N rpm of mill
Pf number of mills with pressure feed rollers
n number of rollers, including the pressure feed rollers in the tandem, factoring in thr rigidity of the feed
rollers, example, 5 tandems of 3 roller and 2 pressure feeders, thus n = (5)(3) + 5(2)(rigidity)
and rigidity factor: 0.5-for light duty pressure feeders
0.75-for medium duty pressure feeder roll (with underfeed roll)
1.0-for heavy duty pressure feeder roll
D diameter of roll (inch)
L length of roll (inch)
f fiber % cane
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P. Rein. Cane Sugar Engineering. 2nd edition. Verlag Dr. Albert Bartens KG-Berlin. 2017 / Sugarcane. Milling manual. Philippine Sugar Millers Association Inc. Volume 1. 2005
RPM C H N D 2 L
Mill capacity
112,320 f
RPM mill speed (7)
C coefficient of cane preparation (1.25)
H milling hour (23.75)
N number pf mill roller
D diameter of mill roller (inch)
L length of mill roller (inch)
f fiber in cane (0,125)
Note :
1. Mill capacity increase 5% when installed one set of H.D. PF.
2. Mill capacity increase 7.5% when installed two or more sets of H.D.PF.
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Sutech Consultant Co., Ltd.
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bT bF
Back roller juice extraction 100
bB bF
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60
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= (13.5/100)690 = 93.2
= (16.87/100)690 = 116.4
= (14/100)690 = 96.6
= 116.4-96.6 = 19.8
= (69.63/100)690 = 480.5
= 116.4+480.5 = 596.9
= (93.2/690)100 = 13.5
= (116.4/690)100 = 16.87
= (96.6/690)100 = 14
= (19.8/690)100 = 2.87
= (480.5/690)100 = 69.63
= 13.5 + 16.87 + 69.63 = 100
= (96.6/116.4)100 = 83
61
=X
= (0.3/100) X = 0.003X
= (22.57100) X = 0.2257X
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= (0.3/100)388.1 = 1.2
= (22.57/100)388.1 = 87.6
= (76/100)96.6 = 73.4
= 87.6-73.4 = 14.2
= 480.5-[(60/100) (690-388.1)] = 299.3
= 87.6 + 299.3 = 386.9
= (1.2/388.1)100 = 0.30
= (87.6/388.1)100 = 22.57
= (73.4/388.1)100 = 18.92
= (14.2/388.1)100 = 3.66
= (299.3/388.1)100 = 77.13
= 0.3 + 22.57 + 77.13 = 100
= (73.4/87.6)100 = 83.8
63
= (92/301.9)100 = 30.47
= (28.8/301.9)100 = 9.53
= (23.2/301.9)100 = 7.68
= (5.6/301.9)100 = 1.85
= (181.1/301.9)100 = 60.0
= 30.47 + 9.53 + 60.0 = 100
= (23.2/28.8)100 = 80.56
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W. Legendre. Preparation and Milling. Handout of 35 th International Raw Cane Sugar Manufactures’ Institute. May 29 – June 8, 2019. Nicholls State University. Thibodaux. Louisiana. USA
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F. Beyen. Clarification. Handout of 35th International Raw Cane Sugar Manufactures’ Institute. May 29 – June 8, 2019. Nicholls State University. Thibodaux. Louisiana. USA
Milling tandem
juice pans conveyers
chains & belts drives
splash guards juice troughs
DSM screens : inspect the back sides
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F. Beyen. Clarification. Handout of 35th International Raw Cane Sugar Manufactures’ Institute. May 29 – June 8, 2019. Nicholls State University. Thibodaux. Louisiana. USA
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F. Beyen. Clarification. Handout of 35th International Raw Cane Sugar Manufactures’ Institute. May 29 – June 8, 2019. Nicholls State University. Thibodaux. Louisiana. USA
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F. Beyen. Clarification. Handout of 35th International Raw Cane Sugar Manufactures’ Institute. May 29 – June 8, 2019. Nicholls State University. Thibodaux. Louisiana. USA
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F. Beyen. Clarification. Handout of 35th International Raw Cane Sugar Manufactures’ Institute. May 29 – June 8, 2019. Nicholls State University. Thibodaux. Louisiana. USA
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F. Beyen. Clarification. Handout of 35th International Raw Cane Sugar Manufactures’ Institute. May 29 – June 8, 2019. Nicholls State University. Thibodaux. Louisiana. USA
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F. Beyen. Clarification. Handout of 35th International Raw Cane Sugar Manufactures’ Institute. May 29 – June 8, 2019. Nicholls State University. Thibodaux. Louisiana. USA
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F. Beyen. Clarification. Handout of 35th International Raw Cane Sugar Manufactures’ Institute. May 29 – June 8, 2019. Nicholls State University. Thibodaux. Louisiana. USA
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F. Beyen. Clarification. Handout of 35th International Raw Cane Sugar Manufactures’ Institute. May 29 – June 8, 2019. Nicholls State University. Thibodaux. Louisiana. USA
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F. Beyen. Clarification. Handout of 35th International Raw Cane Sugar Manufactures’ Institute. May 29 – June 8, 2019. Nicholls State University. Thibodaux. Louisiana. USA
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Last mill
2.5-10 ppm
2.5-10 ppm
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F. Beyen. Clarification. Handout of 35th International Raw Cane Sugar Manufactures’ Institute. May 29 – June 8, 2019. Nicholls State University. Thibodaux. Louisiana. USA
(i) (ii)
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https://www.dsengineers.com/images/brochures/DSEC_Sugar_Cane_Diffusion_-_2018_web.pdf
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Cane Bagasse
K S Diffuser DM
Diffusion
K – knives juice
S – shredder Delgado and Casanova. Sugar processing and by-
DM – dewatering mills products of the sugar Industry. FAO. 2001
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A.V. Delgado, C. A. Casanova. Sugar processing and by-products of the sugar industry. FAO. 2001.
Stage trays
Dewatering
mills
III IV V VI VII VIII IX X XI
Raw Press
juice water
There are usually 12–16 sections in a diffuser. The most dilute juice removed from section
12 is returned to the top of section 11 to dilute the material lying in this section. The slightly
richer (i.e higher brix) juice leaving section 11 is returned to dilute the material lying in
section 10, and so on. The greater the number of sections (or stages) the better the sucrose
extraction achieved for a given throughput.
80
Rein. Proceedings of The South African Sugar Technologists' Association - June 1995
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Cane Bagasse
K S 1M Diffuser DM
K – knives
S – shredder Diffusion
M1 – number of mills
DM – dewatering mills
juice Delgado and Casanova. Sugar processing and by-
products of the sugar Industry. FAO. 2001
82
https://www.dsengineers.com/images/brochures/DSEC_Sugar_Cane_Diffusion_-_2018_web.pdf
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84
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Adjustable sprays
Press water return
Press water drum
Chain and slats
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Copied from presentation slide of Tongaat cane diffusers
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P. Rein. Cane Sugar Engineering. 2nd edition. Verlag Dr. Albert Bartens KG-Berlin. 2017
mPW
mB wDS , B wF , B wW , DB / 100 wW , DB wW , B
100 w DS , PW wSo , PW wDS , PW wSo , PW wW , DB / 100 wW , DB
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P. Rein. Cane Sugar Engineering. 2nd edition. Verlag Dr. Albert Bartens KG-Berlin. 2017
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18.5
1,101.6 276
378.1 24.2
402.3
378.1 1,101.6 256.5
9.9 256.5
89
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P. Rein. Cane Sugar Engineering. 2nd edition. Verlag Dr. Albert Bartens KG-Berlin. 2017
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P. Rein. Cane Sugar Engineering. 2nd edition. Verlag Dr. Albert Bartens KG-Berlin. 2017
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P. Rein. Milling or diffusion-which should you choose?. Sugar Journal. January 2015
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P. Rein. Milling or diffusion-which should you choose?. Sugar Journal. January 2015
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P. Rein. Cane Sugar Engineering. 2nd edition. Verlag Dr. Albert Bartens KG-Berlin. 2017
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P. Rein. Cane Sugar Engineering. 2nd edition. Verlag Dr. Albert Bartens KG-Berlin. 2017
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http://kanchanapisek.or.th/kp6/sub/book/book.php?book=5&chap=3&page=t5-3-infodetail16.html 97
http://www.foodnetworksolution.com/wiki/word/3591/commercial-cane-sugar
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Juice screening
The juice from the extraction plant contains a significant quantity of
small pieces of bagasse (cush) and organic mater, which can lead to blockages
in equipment like heaters.
The juice coming from a milling tandem can contain over 3 kg insoluble
solids/100 kg raw juice, but is usually about half that value.
Raw juice from diffusers has much less bagasse in it, due to the filtering
action of the diffuser and in a number of diffuser mills screens are
dispensed with altogether. This is a common practice in South Africa
where suspended solids are less than 0.1 kg/100 kg raw diffuser juice.
Note:
Coarse dispersoids that have to be removed are cush-cush and sand & silt
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P. Rein. Cane Sugar Engineering. 2nd edition. Verlag Dr. Albert Bartens KG-Berlin. 2017
Juice screening
Types of screen
DSM screens or “ski jump”
A stationary screen developed by
Dorr-Oliver called DSM (Dutch State
Mines).
Juice is carefully fed from a weir to
the top surface of the concave screen
and passes through the curved static
screen while the bagasse particles are
retained on the screen and slide down
to be discharged at the bottom by
gravity. The screens come in sections
between 0.6 and 1.6 m wide and the
arc of the screen on the frame usually
encloses an angle of 45o.
Sugarcane. Milling manual. Philippine Sugar Millers Association Inc. Volume 1. 2005
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F. Beyen. Clarification. Handout of 35th International Raw Cane Sugar Manufactures’ Institute. May 29 – June 8, 2019. Nicholls State University. Thibodaux. Louisiana. USA
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Juice screening
Types of screen
DSM screens or “ski jump”
A capacity of 400 gpm per meter width of screen is conservative.
Washing with hot water or steam once per shift keeps screens clean.
https://www.wirescreen.org/window-screen/dsmscreen.html
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F. Beyen. Clarification. Handout of 35th International Raw Cane Sugar Manufactures’ Institute. May 29 – June 8, 2019. Nicholls State University. Thibodaux. Louisiana. USA
Juice screening
Types of screen
Rotating screen
It is installed above the milling train to facilitate the return of the
extraneous matter back to the tandem.
Juice is introduced from a head box, falling almost tangentially onto the
screen in a direction opposite to the direction of rotation of the screen. This
arrangement results in minimal blocking of the screen and gives high
throughputs and screening efficiency.
The screen is arranged in a truncated conical cylinder in a horizontal axis,
which encourages the juice to spread over the whole length of the screen
when the small end tends to choke up. The large end is fully open, and
delivers into a small compartment where the fine bagasse is deposited .
An area of about 0.1 m2 of metallic cloth per ton cane per hour should be
provided.
Sugarcane. Milling manual. Philippine Sugar Millers Association Inc. Volume 1. 2005
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F. Beyen. Clarification. Handout of 35th International Raw Cane Sugar Manufactures’ Institute. May 29 – June 8, 2019. Nicholls State University. Thibodaux. Louisiana. USA
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Juice screening
Wedge screen
http://www.liquidfiltersystem.com/wedge%20screen.htm
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F. Beyen. Clarification. Handout of 35th International Raw Cane Sugar Manufactures’ Institute. May 29 – June 8, 2019. Nicholls State University. Thibodaux. Louisiana. USA
Juice screening
Sutech design
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106
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https://www.youtube.com/watch?v=g3wybPWf9I0
https://www.youtube.com/watch?v=RY8GWTHsBTY
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