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Sugar Milling Research Institute, Durban, South Africa
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Proceedings
22nd International Symposium
Mauritius – february 2015
AVH Association – 22nd Symposium – Mauritius, February 2015
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Abstract
The Sugar Milling Research Institute sugar-ethanol-cogeneration
NPC in Durban, South Africa, is biorefinery was chosen for the
undertaking broad techno-economic starting scenario.
modelling of the sugarcane
In the presented study we report on
biorefinery as a basis for selecting
products and processes with the a MATLAB® model of the sugar mill
highest potential for successful only, putting special emphasis on
implementation. Although most of the method of boiling house
the fundamental processing steps modelling. A flowchart illustration of
involved in bio-refining are well the Weiss model of massecuite
known, there is a need for a centrifuging along with a matrix
methodology capable of evaluating representation of the respective
the integrated processes to identify mass and energy balances are
the optimal set of products and the discussed in detail. The results of
best route for producing them. The MATLAB® simulations for the entire
approach adopted at SMRI is a case mill have been compared with those
study modelling of pre-selected obtained for the same mill
plant configurations involving mass configuration using SUGARS™
and energy balances of individual software.
units constituting the biorefinery. A
INTRODUCTION
The Biorefinery Techno-Economic integrate them into the Biorefinery
Modelling (BRTEM) project model. The first phase of the BRTEM
undertaken by the Sugar Milling project involves a biorefinery
Research Institute NPC (SMRI) in configuration consisting of a sugar
Durban intends to develop a generic mill, an ethanol plant, and a
techno-economic model of potential cogeneration plant (see Figure 1).
sugarcane biorefinery processes that However, the presented paper
can be used as a basis for selecting discusses the calculation
research projects with the highest methodology and shows selected
potential. The intention is to model simulation results for the sugar mill
individual plant units separately and only. The sugar mill is in a sense
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AVH Association – 22nd Symposium – Mauritius, February 2015
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(1 wwat
MAG MAG
) Fwat wwat
MAG MAG
( Fsuc Fnsuc
MAG
Fcry
MAG
)0
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AVH Association – 22nd Symposium – Mauritius, February 2015
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MASC
Fsuc Fcry
MASC
Q MASC
100 MASC
Fsuc Fnsuc
MASC
Fcry
MASC
Hence, given the stream purity, a linear expression in flow rates results again:
PANA
Fsuc
where PANA
SWimpure PANA
,
Fwat
S * (t PANA )
PANA
( SWimpure ) sat SC ( SWpure
PANA
) sat SC ,
100 S * (t PANA )
PANA
Fnsuc
NSW PANA
, non-sucrose to water ratio,
Fwat
After combining all these equations, one can arrive at a nonlinear relationship
of the form:
PANA Fwat
PANA
Fsuc
PANA
PANA Fnsuc
PANA
0
where coefficients PANA and PANA depend on flow rates and temperature as
follows:
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AVH Association – 22nd Symposium – Mauritius, February 2015
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S * (t PANA )
PANA SS PANA a
100 S * (t PANA )
S * (t PANA ) Fnsuc
PANA
PANA SS PANA b (1 b ) exp c PANA
100 S * (t PANA ) Fwat
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AVH Association – 22nd Symposium – Mauritius, February 2015
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Molasses streams
Finally:
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AVH Association – 22nd Symposium – Mauritius, February 2015
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Sugar streams
WW
Fsug (1 Pw) RF MAS
SUG
Fwat (1 Pl ) Fwat
MAS
Fsug
WW
else
SUG
Fcry (1 Z ) Fcry
MAS
SUG
rmelt 0
end
SUG
Fsuc (1 Pl ) Fsuc
MAS
rmelt
SUG
SUG
Fnsuc (1 Pl ) Fnsuc
MAS
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AVH Association – 22nd Symposium – Mauritius, February 2015
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Figure 2. The order of calculation used in the method of successive substitutions as implemented in the sugar mill modelling
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Figure 3. Typical South African boiling-house configuration with a three-boiling partial remelt scheme
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Fk
i
in ( k )
Fi out 0
Mixer
Hk
in ( k )
H out 0
Fi out ( k ) k Fi in 0 ,
k
k 1
Distributor
H
k
out ( k )
H 0in
Fi out ( k ) ik ( xk , Tk ) Fi in 0
Separator
H
k
out ( k )
H in 0
Mi
Fi in i X A FAin Fi out 0
Reactor ( A ) M A
H in H out
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AVH Association – 22nd Symposium – Mauritius, February 2015
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Table 2. List of independent variables involved in mass balance equations of the boiling house
rMOLA, rMOLB, rMOLC (crystal melting rate in A-, B-, C-molasses streams) 3
rSUGA, rSUGB, rSUGC (crystal melting rate in A-, B-, C-sugar streams) 3
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Table 3. List of governing equations for the boiling house mass balancing
Syrup distributor mass balances: 3
“A” pan mass balances: 4
“A” crystalliser mass balances: 4
“A” centrifuge mass balances: 12
A-molasses distributor mass balances: 4
“B” pan mass balances: 4
“B” crystalliser mass balances: 4
“B” centrifuge mass balances: 12
B-molasses distributor mass balances: 4
B-sugar distributor mass balances: 4
“C” pan mass balances: 4
“C” crystalliser mass balances: 4
“C” centrifuge mass balances: 12
C-molasses distributor mass balances: 4
C-sugar distributor mass balances: 4
Remelter mass balances: 4
Mingler mass balances: 4
Magma distributor mass balances: 4
Syrup distribution conditions: 8
“A” pan exit conditions:
supersaturation 1
dry substance 1
“B” pan exit conditions:
supersaturation 1
dry substance 1
“C” pan exit conditions:
supersaturation 1
dry substance 1
“A” crystalliser exit condition:
supersaturation 1
“B” crystalliser exit condition:
supersaturation 1
“C” crystalliser exit condition:
supersaturation 1
purity 1
A-molasses distribution: 8
B-molasses distribution: 4
B-sugar distribution: 8
C-molasses distribution: 4
C-sugar distribution: 4
Mingler exit condition:
saturation 1
water content in magma 1
Magma distribution: 8
B-sugar distribution condition: 1
Remelter exit conditions:
remelt brix 1
remelt temperature 1
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