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Faculty of Engineering in South Eastern University of Sri Lanka

Hingurana Gal-Oya Sugar Factory


Gal-Oya Sugar Factory in Hingurana which is located 12km from
Ampara Siyambalanduwa road.
29/05/2013

Place:Date:Purpose of visit:Prepared by:Contacts

To get a brief idea of functions of Sri Lankan factory.


S.Jeyaram

e-mail:-

jeyaram02@gmail.com

Mobile:-

0776500043

Observation:Table 1.1- Basic process of making sugar in Gal-Oya sugar factory


Levels
Related figures
Descriptions
1. Transport by
It carries the sugarcanes to the
crane
moving plate; it can carry 10 tons at
a time. Two cranes are available at
this factory.

2. Moving plate

This chain moving plate carries the


sugarcanes to the channel. It
transfers 3 tons of sugar cans to the
channel.

3. Channel with
wheel

Channel is used to carry the


sugarcanes into the factory. The
wheel in the middle is helped to
align the sugarcanes.

Faculty of Engineering in South Eastern University of Sri Lanka


4. Chopping
wheel

Chopping wheel chops the


sugarcanes into near 1 inch in size.

5. Cruncher
(Grinder)

Crunching machine is grinding the


chopped sugarcane and collect the
molasses (nectar of sugarcane)
under this machine. Five crunching
machines are used to do this
process again and again. The first
molasses will pour into the 2nd
machine.

6. Carbide
mixer tank

Final molasses is collected in the


carbide mixer tank which can
handle 1 ton to mix the carbide
which is used to take out the mud
and other colluviums. pH is
measured at this stage. The valve
will open and send the molasses to
steam burner if the storage level
beyond 1 ton.

7. Steam
Burners

Here the molasses heating up with


high pressure (200 pound/inch).
Inside this burner some tubes used
to flow the molasses up and down.
This process helps to get the
temperature quickly. Hard water
cleaning process is happen in this
stage.

8. Rotating tank

The steam burners molasses


comes to this tank which always
rotating with small speed to filter out
the mud and colluviums which are
come out from molasses because
of carbide. After this the pure
molasses goes to another rotating
cylinder which has multiple metal
plates. The impure molasses will
clean by another machine.

Faculty of Engineering in South Eastern University of Sri Lanka


9. Metal plates
rotating cabin

Here some chemical will added to


make the molasses into pebbles
and this rotating cylinder filter out
the correct size pebbles. After this
the dry sugar which can produce by
high pressure spray will pump into
the final pipe to collect the sugar.

This factory uses the steam power to run the machines with super power steam turbines
which can produces around 2MV power. The final waste sugarcane bagasse is used as fuel
not only this but some wood also used. However Ceylon Electricity Board also provides
electricity which uses when the process is in idle mode and this power is used to start the
process also.
The unforgettable and unbearable thing is the welcoming by golden smoke from the factory
chimney.

Discussion & Conclusion:They use the sugarcane bagasse as bio fuel. The ash can be used for below purposes [1].
1) Good for fertilizers
2) Making cement already use in Brazil
3) It can give 20% more strength if it used in concrete
Yes we can use the ash for many other ways; however I cant bear the burning of bagasse
because it produces below elements.
Pollutant
PM
Uncontrolled
Controlled
Mechanical collector
Wet scrubber

Emission factor (lb./ton)b


15.6
8.4
1.4

PM-10
Controlled
Wet scrubber

1.36

CO2
NO2
Polycyclic organic matter

1560
1.2
0.001
[2]

Not only this but SO2, CO, NO and other particles also come out [3]. These are the
greenhouse gasses so in my point of view we can stop burning bagasse.

Faculty of Engineering in South Eastern University of Sri Lanka


Here I suggest some uses of sugarcane bagasse

Figure 1.1- Use as toilet paper

Figure 1.2- Use as Bio plate and packaging

Figure 1.3- Use as Bio furniture and interior designing


In the figure 1.3 we can see that the table and the table lamp both are made by sugarcane
bagasse.
I know if we use bagasse for these purposes then we will lose the 2MV but as an engineer
we have to consider the global warming first.
For Electricity we can introduce solar and wind turbines for the factory because we have
more and large sugarcane gardens around the factory we can implement these places.

Faculty of Engineering in South Eastern University of Sri Lanka

Reference List
Books
[1] Sugarcane Bagasse Ash Waste, Brittany Radke, Civil & Environmental Engineering,
University of Nevada, Las Vegas, UNICAMP, Brazil, June 5, 2012,
http://eece.wustl.edu/ContentFiles/International/2012/RadkeSugarcaneBagasseAshWasteBr
azil2012.pdf
[2] Emission Factors http://www.epa.gov/ttnchie1/ap42/ch01/final/c01s08.pdf
[3] CANE, SUGAR AND THE ENVIRONMENT, Economic & Social Develompent
Department, FAO Corporate Document Repository,
http://www.fao.org/docrep/005/X4988E/x4988e01.htm