Smar Solutions for
The Sugar Production
Juice Extraction Control
Juice Extraction Control
Milling Plant Controls
¾ Cane Preparation
¾ Cane Conveyors Speed and Syncronism
¾ Knives and Shredders Protection
¾ Imbibition Control
¾ Floating of Superior Roll
¾ Pol Extraction
Juice Extraction Control
Cane Reception and Preparation
Juice Extraction Control
Cane Reception and Preparation
¾ Cane Weighing. Agricultural and Industrial Control
¾ Sampling. Payment System by Pol
¾ Cane Unloading and Storage. Losses
¾ Cane Washing. Feeder Tables
¾ Cane Conveyors
¾ Levellers
¾ Knives
¾ Shredders
Juice Extraction Control
Preparing the Cane
MESA
ALIMENTADORA
ELETROIMÃ
PICADOR
DESFIBRADOR
SHUTE
DONELLY
1o TERNO
ESTEIRA
RÁPIDA
CANA
ESTEIRA METÁLICA
Shredder
Juice Extraction Control
Planta moledora
Juice Extraction Control
Planta moledora
Juice Extraction
Mills
Diffuser
Juice Extraction Control
Planta
moledora
¾ The cane juice extraction for the sugar production can be done
by mills or diffusers
¾ The mill tandem is composed generally of 4 to 7 mill units
¾ Each unit is a set of 3 rolls. Sometimes exists a fourth roll that
executes the forced feeding
¾ Its actioning is provided by steam turbines, electric motors or
hydraulic devices
Mills
Milling Plant Control
Planta moledora
Milling Plant Control
Planta moledora
Milling Plant Control
Planta moledora
Milling Plant Control
Planta moledora
Milling Plant Control
Planta moledora
Milling Plant Control
IMBIBITION
¾ The imbibition may be simple or compound
¾ The quantity of water to be added to the cane is directly
proportional to the fiber content of the cane, between 200 to
250% of fiber
¾ As the value of the fiber is a difficult parameter to establish,
generally is used 25 to 30% of the total weight of the cane
¾ The temperature is an important parameter. Never may exceed
the 65 C degrees due to the effect of dilution of wax and
dextrines
¾ There is a big commitment between the quantity of water added
to the cane to improve the extraction and the energic balance
of the total process
Imbibition
COMPOUND IMBIBITION
Planta moledora
WATER
CANE
BAGASSE
PRIMARY
JUICE
BAGASSE
POWDER
TO THE
ROTARY
FILTERS
SECONDARY
JUICE
MIXED
JUICE
ROTARY
SIEVE
PERCOLATED
JUICE
BAGASSE
Milling Plant Control
Pol Extraction
¾ The motricity of the pol extraction process is the sugar
concentration difference among the broken cells and the
imbibition juice
¾ Directly acting over the extraction as well, are the pressure of
the mills, the temperature of the imbibition water, the fiber
content, the height of the cane mattress, etc
¾ The saccharose that cannot be recovered at the mills is a direct
loss. It goes to the boilers to be burned and never more can be
recovered
Milling Plant Control
Extraction by Mills Set
80
% EXTRACTION
70
60
50
40
30
20
10
0
1
2
3
MILLS SET
4
5a6
Milling Plant Control
The Juice Extraction Operation
POL CONTENT IN FIBER
CANE
MIXED JUICE
FIRST
MILL
BAGASSE
IMBIBITION
WATER
POL CONTENT IN JUICE
LAST
MILL
Milling Plant Control
Efficiency of Pol Extraction. Comments
¾ For each 1% of strange matter that enters to the sugar process,
it’s lost 1,5 Kg of sugar by ton. of processed cane
¾ The preparation index defines the result of the preparing of the
cane to be crushed. 90% is a good index
¾ For each unit of difference between the purity of the mixed
juice and the purity of the primary juice it’s lost 2,5 Kg of sugar
by ton. of mixed juice entering at the factory
¾ The extraction at the first mill must be between 50 to 70%
¾ The humidity of the bagasse must be between 48 to 50%
¾ The pol of the bagasse at the end of the last mill must be as low
as posible. 2.0 is a good value
¾ The mills area must be an aseptic place by the use of hot water,
steam and chemical products
Milling Plant Control
Results of the Automation (1)
¾ Better energic efficiency
¾ Control over the complete process
¾ Increase of the industrial efficiency
¾ Conspicuous improvement on sugar quality (color, humidity,
filter easibility, etc)
¾ Reduction in losses and acquaintance of what are its causes
¾ Increase of the accomplishment with the technological
standards for the sugar
¾ Better condensate recovering at the heat interchanger devices
¾ Raising of the operators technical level
¾ More easibility for the maintenance tasks: the equipment are
being monitored
Milling Plant Control
Results of the Automation (2)
¾ Possibility of establishing one operation strategy for every
situation of the factory without interference among the areas
¾ Centralization of the operation. Better taking of decision
process
¾ Conspicuous increase of the real information of the process
¾ Better profit of the installed facilities
¾ Increase of the operators safety
¾ Allows the integration between the process and the laboratory
using the on-line analysis as a tool for the process operation
¾ Reduction in the energy consumption allowing one cogeneration strategy
Milling Plant Control
Results of the Automation (3)
¾ Allows the installation of one Enterprise Management System,
integrating the corporate and the process networks of the
company
¾ Increase on the capacity of the factory by the reduction in time
losses and by the increase of the industrial efficiency
Milling Plant Control
THANK YOU !!!!!!!!