DESIGN OF A SUGAR REFINING DRYING UNIT OF 300 TONS PER

ANNUM SUGAR PLANT FROM SUGARCANE

A FINAL YEAR DESIGN PROJECT

PRESENTED BY
IGBOKE EZE IGBOKE UNDER DR. M.T ISA

15TH OCTOBER, 2015

OUTLINE
INTRODUCTION
LITERATURE
PROCESS SELLECTION
MATERIAL AND ENERGY BALANCE
DETAILED EQUIPMENTS DESIGN
PLANT LAYOUT
PROCESS CONTROL
ENVIRONMENTAL MANAGEMENT AND SAFETY
ECONOMIC ANALYSIS AND PROJECT EVALUATION
START-UP AND SHUT-DOWN PROCEDURE
CONCLUSION

INTRODUCTION
Sugar is the generalized name for sweet shortchain, soluble carbohydrates, many of which
are used in food. They are carbohydrates,
composed of carbon, hydrogen and oxygen.
Sugar production from sugarcane uses several
unit processes that generally begin with the
cane
crushing,
milling,
clarification,
evaporation, crystallization, centrifugation,
separation, drying, storage and packaging for
final delivery. Drying is among the most
important unit operation in sugar production
as such integral concern will be given to the
design and operation of suitable drying
equipment.

INTRODUCTION CONTD
1.1 PROBLEM STATEMENT
Nigeria depends solely on importation of raw brown
sugar from Brazil and some other part of the world
The clumping of sugar caused by poor drying has
become a problem of common concern in Nigeria
hence the need for the design of effective drying
equipment.
1.2 AIM AND OBJECTIVE
The aim of this design project is to design a dryer that
has the capacity to dry 300 tons per annum of refined
sugar produced from sugar cane.

INTRODUCTION CONTD
1.3 JUSTIFICATION
The design and construction of sugar plant will
contribute to increase in internally generated revenue
thereby contributing to national economy.
1.4 SCOPE
The scope of this project is to use empirical
formulation and analysis to design the structural,
mechanical and electrical principles of a dryer
including the cost and economic effect.

LITERATURE REVIEW
Economic sources of sugar are sugarcane and sugar
beet
Sugarcane is a tropical plant; it has no adaptation to
survive freezing and it is dependent on abundant
sunlight for healthy growth.
Sugar beet, Beta vulgaris, is a temperate zone plant
grown largely in the northern hemisphere.
Classes of sugar are: simple sugar (Glucose, fructose
and galactose) and disaccharides (Sucrose, maltose,
lactose ).
Uses of sugar are: domestic, pharmaceutical, food and
beverages industries e.t.c

LITERATURE CONTD
Sugar manufacturing processes from sugarcane are:
Milling, Clarification, Evaporation, Crystallization,
Centrifugation and Drying.
Drying of materials whether solids, liquids or slurries
to improve storage life or reduce transportation costs
is one of the oldest and most commonly used unit
operations.

PROCESS SELECTION
Process selection is a technique employed by design
engineers in choosing the best process among
possible alternative processes.
Criteria for process selection are
Choice of production method and,
Choice of drying technique

MATERIAL AND ENERGY BALANCE

Material balances are the basis of process design. A
material balance taken over the complete process will
determine the quantities of raw materials required and
products produced.
Table 1: Material Balance parameters
S/N

Material Balance

parameters

1.

Plant attainment

92%

2.

Working days in a year

336days

3.

Quantity of sugar to be produced

in a year

300tons

4.

Percentage of sucrose in sugarcane 14%

5.

Quantity of sugarcane to be processed in

year

2,142.857tons

6.

Sucrose lost per hour

47.5kg/hr

Table 2: Material balance calculated

from the drying unit
S/N

Material balance evaluated

parameters

Moisture to be removed

0.03307kg

Weight of sugar to be produced

37.2126kg/hr

Overall yield of sugar based on the 11.89%

cane used

Weight of air entering the dryer

0.8408kg/hr

Density of thee air entering the

dryer

1.12kg/m3

ENERGY BALANCE
In process design, energy balances are made to
determine the energy requirement of the process.
Enthalpy equation
Cp is given in terms of heat capacity coefficients as
2
On integration, the enthalpy balance equation become
3

Table 3: Specific heat capacity coefficients

Component

Sucrose

8.704

17.476*10-1

-8.524*10-4

21.575*10-8

Water

18.296

47.212*10-2

-133.88*10-5

1314.2*10-9

Reducing

29.13

-0.134*10-2

0.972*10-5

-4.335*10-9

sugar
Impurities

121

Lime

38.90

(http://www.engineeringtoolbox.com/specific heat
capacity)

Table 4. Enthalpy results for the drying

COMPONENTS
ENTHALPY IN
ENTHALPY OUT
unit
(KJ/hr)

(KJ/hr)

(stream 18)

(stream 19)

Water
Water

14.8709
14.8709

00

Sucrose
Sucrose
Reducing sugar
Reducing sugar
Impurities
Impurities
Lime

0
0
0
0
0
0
0

0
0
0
0
0
0
0

Lime
Total

00

Total
Heat load

-14.8709kJ/hr

DETAILED EQUIPMENT DESIGN

Detailed design of rotary drum drier, screw conveyor
and air heater and specifications are discussed below
Table 5:List of feed to the Dryer
S/N

Feed

Values

Water in the feed

0.3307kg/hr

Dry solid in the feed

37.2126kg/hr

Water removed by the dryer

0.1984kg/hr

Water content in the product

0.13228kg/hr

DETAILED EQUIPMENT DESIGN CONTD

Table 5.1 Condition of inlet air into the dryer
S/N
1

Ambient temperature of air

300C

Relative humidity of the air (R.H)

10%

Weight bulb temperature air at RH 220C

Humidity ratio of the air at RH

0.002kgwater/kg dry
air

The heated air temperature into

the dryer

1560C

The air entering the dryer

0.8408kg/hr

DETAILED EQUIPMENT DESIGN CONTD

Rotary dryer design equations

Diameter of the drier

Length of the drier

Flight Design
Number of flights in the drier = 3 x D

(5.5)
Overall heat transfer coefficient

 DETAILED EQUIPMENT DESIGN CONTD

Speed of rotation of the drier
Revolutions per minute = Peripheral Speed/Diameter.
Radial height of the Flight
The radial height of the flight is taken as 1/8th of the
diameter of the drier
MECHANICAL DESIGN EQUATIONS
Thickness of the drier shell
ts

DETAILED EQUIPMENT DESIGN CONTD

Thickness of insulation of the dryer
Q =
(5.9)
The torque at each end of the drier is given by
(5.15)
Stress sharing around the circumference due to the applied
torque T is

 DETAILED EQUIPMENT DESIGN CONTD

ELECTRICAL DESIGN EQUATIONS FOR
ROTARY DRIER

Power to drive the Drier

Power (5.17)

DETAILED EQUIPMENT DESIGN CONTD

Table 5.2 Drier Parameters
Parameters

Values

Wet bulb temperature of inlet air

1800F

Air required to dry the moist sugar crystal

0.300

Preheating period of air temperature

21.940F

Heating period of air temperature

94.120F

Evaporating period of air temperature

79.860F

Mean temperature difference

67.880F

NTU

1.75

Drier diameter (D)

0.184m

Drier overall heat transfer coefficient

66.0566Btu/hr.ft30F

Drier length (Z)

1.07m

Z/D

5.81

Drier speed of rotation

4.9

Number of flight in the drier

2.0

DETAILED EQUIPMENT DESIGN CONTD

Table 5.3 Mechanical drier design parameters
Parameter

Values

Drier shell thickness

Thickness
Thickness of
of the
the drier
drier insulation
insulation

mm

Tensile
Tensile stress
stress exerted
exerted by
by the
the load
load on
on the
the dryer
dryer

58mm
58mm
2
1.399KN/m
1.399KN/m2

Centrifugal force acting on the elemental 16.04N/ m2

length of the drier
Thermal stress exerted on the drier

162.45MN/ m2K

Sheering
Sheering force
force at
at any
any point
point of
of the
the drier
drier

2
1.399KN/m
1.399KN/m2

Torque at each end of the drier

-1
Torque at each end of the drier
Stress sharing around the circumference of the 1000N/ m22
Stress sharing around the circumference of the 1000N/ m
drier due to the applied torque
drier due to the applied torque

DETAILED EQUIPMENT DESIGN CONTD

Table 5.4: Electrical design parameters of the drier
Parameters

Values

Power require to drive the drier

10.17KW

Power require by the blower

13.98KW

Power require by the exhaust fan

17.84KW

Total power required by the drying unit

41.99KW

 DETAILED EQUIPMENT DESIGN CONTD

Screw conveyor design equations
(5.22)
(5.24)
Power consumption by the conveyor
P = 0.8D2L
(5.25)
Conveyor surface area
(5.26)

DETAILED EQUIPMENT DESIGN CONTD

Table 5.5 Screw conveyor specification
Parameter

Specification

Conveyor surface area

0.7780in2

Pipe outer diameter

4 inch

Pipe inside diameter

3.5inch

Pipe thickness

0.5inch

Length

254inch

Flight thickness

7/16inch

Power required

0.725kw

 DETAILED EQUIPMENT DESIGN CONTD

SHELL AND TUBE HEAT EXCHANGER DESIGN

EQUATIONS

(5.27)
is the log mean temperature difference.

(5.28)
(5.29)
(5.30)

The number of tubes is calculated from

(5.31)

DETAILED EQUIPMENT DESIGN CONTD

Table 5.6 Shell and heat exchanger parameter
Parameter

Specification

Exchanger type

Shell and tube

Heat transfer area

5.73m2

Length of heat exchanger

1.12m

Number of tubes

60

Tube ID

0.0212m

Tube OD

0.0254m

Shell ID

0.3048m

Number of passes

Pitch type

Square

GENERAL OVERVIEW OF EQUIPMENT LAYOUT

The economic construction and efficient operation of

the process units will depend on how well the plant and
equipment specified on the process flow diagram were
laid out. The principal factors to be considered include:
Economic consideration: both initial fabrication and
operating cost
Process requirements
Convenience for operation
Convenience for maintenance
Safety
Future expansion
Modular construction

GENERAL OVERVIEW OF EQUIPMENT LAYOUT

Table 6.1 Summary of process equipment and
dimension
Equipment

Diameter(m)

Height(m)

Dryer

0.184

1.71

Screw conveyor

0.373

6.451

Heat exchanger/furnace

0.0212

1.12

Total

0.5782

9.281

Length occupied by the unit

11.8592

Maximum possible breath

8.451

Plant layout area

124.98 m2

GENERAL OVERVIEW OF EQUIPMENT LAYOUT

Figure 1: Layout models of the sugar drying unit both the 3D

drawing using AUTO CAD

GENERAL OVERVIEW OF EQUIPMENT LAYOUT

CONTD

Figure 2: 2D drawing of the equipment layout using

AUTO CAD

PROCESS CONTROL AND INSTRUMENTATION

The control of equipment in any plant is to help achieve
and maintain process operating conditions at the desired
values, to ensure product quality, process safety and
safety of personnel.
INCENTIVE OF A CHEMICAL PROCESS CONTROL
Safety
Process variables which include pressures, temperatures,
and concentration
Dangerous situations are detected as they develop and to
provide alarms and automatic Shut-down systems.
Production Specification
Environmental Regulations etc.

PROCESS CONTROL AND INSTRUMENTATION

Figure 3: The overall process control for the refined sugar drying
unit in sugar production plant.

ENVIRONMENTAL MANAGEMENT AND SAFETY

PROCESS SAFETY
The process must operate safely at design conditions.
Suitable provisions must be made to cope with unsafe
deviations from design conditions.
Safe start-up and shut-down procedures must be
established and complied with.
HAZARDS OF SUGAR DRYING
Air Pollutants
Noise and Dust

ENVIRONMENTAL MANAGEMENT AND SAFETY

Safety and Control

Automatic control system should be employed in the plant
especially for the process control instruments. In any case of
accident, control can be carried out directly from the control
room.
Equipment , process lines, steam lines and steam tracing lines
whose surfaces are usually hot should be lagged to prevent
steam loss and skin burns
The use of personal safety equipment such as protective
goggles, gloves, clothing, helmet and respiratory devices
should be diligently observed.
Fire safety department should be provided in the event of fire
outbreak and or explosions and safety should be the utmost in
everybodys mind.

ECONOMIC ANALYSIS AND PROJECT EVALUATION

Sugar production plants are built to make profit, and an
estimate of the investment required and the cost of
production are needed before the profitability of a
project can be assessed.
PRODUCTION COSTS
As regards to production cost, there are three (3) major
concerns
manufacturing or acquisition costs (production costs)
operation and maintenance costs (running costs)
capital costs

ECONOMIC ANALYSIS AND PROJECT

EVALUATION CONTD
EQUIPMENT COSTING
Table 9.1Summary of the various equipments and their
purchase costs
Equipment

Cost ()

Dryer

99,500

Screw Conveyor

1,472,600

Shell and tube heat exchanger

39,300

Centrifugal blower

238,800

Furnace

1,233,800

Total

3,084,000

ECONOMIC ANALYSIS AND PROJECT

EVALUATION CONTD
Table 9.2: Raw materials/ Utilities
Raw

Unit

material/Utilit

Unit

Unit

Price(#)

year

200

1,87,500

per Total Cost

Source

y
Sugarcane

Stalk

37,500,000

Commercial
market

Electricity

Total

Mw/h

15.2

1591.088

24,184.5376

37,524,184.54

www.nercng.or
g

ECONOMIC ANALYSIS AND PROJECT EVALUATION

CONTD
Table 9.3: Summary of data evaluated
S/N

Evaluated parameter

Amount ()

Fixed capital cost

13,415,400

Working Capital (WC)

2,414,772

Total capital investment

15,830,172

Fixed Cost

670,770

Total investment

11,666,772

Annual operating cost (AOC)

38,865,724.54

Annual Production Cost (APC)

54,412,032.36

Cost of sugar

398,000/ton

Annual sales revenue

119,400,000 per year.

10

Profit before Tax (PBT)

64,987,967.64

11

Profit after Tax (PAT)

39,216,088.58

12

Pay Back Period (PBP)

1.78years (21.32 months)

13

Return on Investment (ROI)

336%

START-UP AND SHUT-DOWN PROCEDURE

START UP PROCEDURE
All valves are put in manual position.
All installed equipment in the various units is ensured to
be intact.
All control valves are tested to ensure safety.
All lines are tested to ensure that they are free and no
leakages.
SHUT DOWN PROCEDURE
All unit personnel of the plant are notified of the
shutdown.
The control mechanism is set to shut down mode and
pumping of products to waste is initiated.
All valves should be turned to manual position.

CONCLUSION
At the end of the project design work, the following
conclusions were drawn;
Sugar crystals will be produced from the sugarcane
Material and energy balances were carried out across the plant
equipment and it shows that the power requirement of the
plant is and the total power require by the dryer is and that of
the drying unit is 41.99KW.
The equipment design was also carried out for only the drying
unit of the plant, specifying the materials of construction.
The detailed economic analysis of the unit shows that the
capital investment was 15,830,172 profits after tax was
39,216,088.58 with a payback period of 1.78years i.e.
approximately 21.32months and a return rate of 336%
respectively.

RECOMMENDATION
The design parameters should be simulated to know
whether the design is feasible

Proper maintenance should be put into consideration in

other to increase the life span of the equipment's

Government should put more interest in the indigenous

sugar production plant in other to reduce the level of
importation of raw brown sugar.