18-09-2014, 03:31 PM
THE PANIPAT CO-OPERATIVE
SUGAR MILLS
THE PANIPAT.docx (Size: 873.53 KB / Downloads: 21)
INTRODUCTION
The Panipat Co-operative Sugar Mills Ltd. Panipat, Haryana was established in the year 1956 and started its first commercial production on 22-03-1957 with double carbonate –double sulphitation process having a crushing capacity of 1200 TCD.
The plant was supplied by M/s Skoda Ltd. Czechovakia. The plant was expanded to 1400TCD in the year 1964-65 by adding one mill. During this period, the profits were good which can be attributed to low cost of inputs and better price realisation of sugar.
The mill was further expanded to 1800TCD in the year 1975-76. The expansion was done by M/s E. E. Engineering, Bareilly. The manufacturing process changed to double sulphitation from carbonation- double sulphitation in the year 1996-97 without changing the crushing capacity.
The highest crushing in a season has 3,37,992 lac tonns of cane and 3,33,300 bags of sugar in the season 1991-92.
The highest recovery percent cane has been 10.11% during the year 2003-04.
BOILERS
There are four boilers in plant out of which three are of Skoda type boilers and one is Taxmaco make boiler. They are fulfil same purpose i.e. production of steam. The three Skoda boilers are setup by a Czechoslovakian company and Taxmaco is by an Indian company. These boilers were setup during 1976.
Skoda type:-
Construction:- It is a water tube , externally fired, horizontal boiler; its furnace is of step grate type. The evaporate capacity is 24 ton/hr water tubes in the boiler are inclined at some angle so as to have maximum coefficient of heat transfer. There are total 308tubes in it, 14 per column. Tubes are seamless and each of 4inch o.d.
BOILING HAUSE
The juice is collected from all 6 mills and mill no. 1&2 is pumped to DSM screen with help of chokeless pump. The juice is filterd and transferred to juice weighment tank for weighing the juice.
The weighing is necessary to calculate the efficiency of the plant is knowing how much sugar is produced by much juice.
From receiving tank juice is pumped to juice heater through centrifugal pump as greater quantity of juice has to br pumped at smaller heights.
Construction:-
It is a cylindrical vessel, which is divided into four chambers or compartments. In the center of clarifier there is pipeline for juice inlet for various compartments
Working:-
When all the compartments are full of juice then the muddy juice settles at the bottom of each compartment and overflowing from each compartment collects the clear juice and muddy juice is collected from the bottom of each compartment. The clear juice is sent to juice heater and muddy juice from clarifier is sent to vacuum filter where the remaining is extracted before the baggase is disposed
PAN
It is a cylindrical vessel in which tubes are installed vertically through two horizontal plates. A large diameter tube is also presented between the centres of horizontal plates, which are used to transfer the products from pan to crystallizer.
In pan syrup and 33% minute grains are fed and heated. The sugar content in the syrup starts depositing on the minute grains present in the pan.
Therefore some crystals are formed in the pan itself then these grains and the liquid present in the pans is drawn in the crystallizer through central pipe of large diameter. The liquid present in the pan is known as mascutte, it is a mixture of grains of sugar and molasses.
VACUUM FILTER
Universal heavy engineering company installed it. The size of vacuum filter is 8 *16 inch. The filtering area is 402sq.ft. the filtering is made of stainless steel.
The juice to be filtered by the screen is sucked in due to vacuum present inside the pipes of small diameters and mud or waste remains stuck to the screen, which is removed with the help of scrappers. Then this filtered juice is sent juice heater.
After juice heating by heater it goes to vapour cell or evaporator.
HISTORY OF “SUGAR”
India has been known as the original home of sugar and sugar cane. Indianmythology supports the above fact as it contains some legends showing the origin of sugar cane. The growth the sugar industry is full of tales of adventure and conquest. Itreceived attention of the builders of different Empires from time to time.About 800 B.C. sugar cane was perhaps taken eastward, i.e. China, where it foundsuitable soil for development. About 327 B.C. when Alexander the great, invaded Indiahe and his soldiers were the First Europeans to see sugar cane in India. On their returnwestward they took sugar cane to Europe, but it was about 700 A.D. that it is was actuallycultivated there. It was between the fourth and sixth centuries that the art of making sugar was discovered in India. The cane was cut into pieces and crushed by a heavy weight andthe juice thus obtained was boiled and stirred until solids formed. These solids being of uneven shapes and sizes were called “Sarkara”, the Sanskrit term for gravel. The modernword “Sugar” is a derivative of the word “Sarkara”. The larger solids were called Khandfrom which the word Candy has been derived.The Chinese Emperor, Tsai-Hang sent a mission to Bihar in about 600 A.D. toascertain and study the art of sugar manufacture. From India the knowledge of sugar making went over to Persia. It would thus be seen that India has been the original homeof sugar cane as also sugar manufacture.
RAW MATERIALS PROCESSED
1.Carbohydrates present in many plants having more or less sweet taste are calledas Sugar. The primary sugar, glucose, is a product of photosynthesis and occurs inall green plants. In most plants, the sugars occur as a mixture that cannot readily be separated into the components. In the sap of some plants, the sugar mixturesare condensed into syrup. Juices of sugar cane and sugar beet are rich in puresucrose, although beet sugar is generally much less sweet than cane sugar. Thesetwo sugar crops are the main sources of the commercial sucrose