HFM Plate Heat Exchanger in Sugar Industry
HFM provides top-of-the-line solutions and plate heat exchangers designed specifically for the Sugar Industry, allowing for efficient and effective operation of both traditional and modern sugar production processes.
Plate heat exchangers have been widely utilized in sugar production facilities located throughout Europe, America, South Africa, and India. These exchangers are critical for many sugar production processes, such as heating the juice, exfoliating the juice, and cooling the final molasses before they are transferred to storage tanks. Some sugar mills have begun experimenting with using plate heat exchangers to heat mixed juice with great success.
At HFM, we pride ourselves on the versatility of our products and the extensive experience of our team. Our commitment to excellence ensures that our products yield high-quality results while keeping operating costs as low as possible. Contact Us to upgrade your Plate Heat Exchanger for Sugar Production today.
Sugar Production Process Involving Plate Heat Exchanger for Sugar
1. Harvesting
2. Cleaning
3. Extraction
4. Juice Heating
5. Clarification
6. Evaporation
7. Syrup Cooling
8. Crystallization
9. Sugar Drying
10. Molasses Refining
11. Refining
12. Packaging
1. Sugar Cane and Sugar Beet Harvesting
The harvesting of sugarcane and sugar beets is a fascinating process and a critical step in the production of sugar. Sugarcane is primarily grown in tropical and subtropical regions, while sugar beets thrive in cooler, temperate climates.
Interestingly, sugarcane accounts for around 80% of the world’s sugar production, with the top producers being Brazil, India, and China. On the other hand, sugar beets account for the remaining 20% of global sugar production, with Russia, France, and the United States being the top producers.
Once the sugarcane or sugar beets are harvested, the sugar extraction process begins. The juice is extracted through crushing or slicing and then goes through a series of steps, including clarification, filtration, and evaporation, to produce raw sugar.
2. Sugar Cane and Sugar Beet Cleaning
When sugarcane or sugar beets arrive at the processing plant, they are typically covered in dirt, rocks, and other debris that may have been picked up during the harvesting process. Therefore, the first step in the processing of sugar is to remove these impurities.
The cleaning process involves various mechanical equipment such as conveyor belts, washing machines, and magnetic separators. The conveyor belts transport the sugarcane or sugar beets to the washing machines, where they are thoroughly cleaned using water and other cleaning agents. The washing machines may use different techniques to remove the impurities, such as high-pressure jets of water, scrubbers, or brushes.
After the washing process, the sugarcane or sugar beets are passed through magnetic separators to remove any metal objects that may have been picked up during the harvesting process. These separators use powerful magnets to attract and remove any metal objects.
3. Juice Extraction
Sugar production is a multi-stage process that involves several steps. Extraction is one of the critical stages that come after the harvesting of sugarcane or sugar beets. The process involves crushing the sugarcane or sugar beets to extract the juice, which is the primary raw material used for sugar production.
To extract the juice from the sugarcane or sugar beets, large machines called mills are used. These machines can crush thousands of tons of sugarcane or sugar beets each day. The sugarcane or sugar beets are fed into the mills, and the juice is extracted by crushing them. The extracted juice contains both liquid and solid particles.
To remove the solid particles from the juice, it is passed through a series of filters. The filters remove the solid particles, leaving behind a clear, translucent juice. The extracted juice is then stored in large tanks, where it is kept until further processing.
The extracted juice is rich in sucrose, the primary component of sugar. The next steps in the sugar production process involve purifying the juice to remove any impurities, concentrating the juice to increase its sugar content, and crystallizing the sugar to produce the final product.
4. Juice Heating
The clarification process is an essential step in sugar production as it removes impurities and solid particles from the juice, resulting in a clear and clean liquid that can be further processed into sugar. The heat applied to the juice during this process is crucial in achieving efficient clarification.
Heat exchangers are commonly used in the sugar industry as they offer an efficient and effective method of heating the juice. The heat exchanger consists of a series of tubes or plates that allow the juice to flow through them while hot water or steam is used to heat the juice from the outside. This creates a temperature gradient that allows heat to transfer from the hot water or steam to the juice. The use of heat exchangers also ensures that the juice is heated uniformly and at a controlled temperature to prevent over-processing or damage to the juice.
The juice is heated to temperatures of up to 200°F (93°C) during the clarification process. At this temperature, the impurities and solid particles in the juice are destabilized and agglomerate, making them easier to remove. The heat also helps to break down enzymes and microorganisms that could potentially interfere with the sugar production process. The clarified juice is then ready for further processing, which includes boiling and evaporation to remove water and concentrate the sugar solution.
5. Juice Clarification
The clarification process is an essential step in sugar production as it removes impurities and solid particles from the juice, resulting in a clear and clean liquid that can be further processed into sugar. The heat applied to the juice during this process is crucial in achieving efficient clarification.
Heat exchangers are commonly used in the sugar industry as they offer an efficient and effective method of heating the juice. The heat exchanger consists of a series of tubes or plates that allow the juice to flow through them while hot water or steam is used to heat the juice from the outside. This creates a temperature gradient that allows heat to transfer from the hot water or steam to the juice. The use of heat exchangers also ensures that the juice is heated uniformly and at a controlled temperature to prevent over-processing or damage to the juice.
The juice is heated to temperatures of up to 200°F (93°C) during the clarification process. At this temperature, the impurities and solid particles in the juice are destabilized and agglomerate, making them easier to remove. The heat also helps to break down enzymes and microorganisms that could potentially interfere with the sugar production process. The clarified juice is then ready for further processing, which includes boiling and evaporation to remove water and concentrate the sugar solution.
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6. Juice Evaporation
When fruit juices are extracted, they are often not clear and contain impurities such as suspended solids, fibers, and pectin. To make the juice clear and stable, it is chemically treated and then concentrated by evaporation.
The process of evaporation is done using multiple-effect evaporators. These evaporators use heat exchangers which transfer heat from one fluid to another without mixing them. In this case, the heat exchangers transfer heat from the steam generated in one evaporator to the juice in the next evaporator.
The steam is generated in the first evaporator by boiling the juice under reduced pressure, which lowers the boiling point of the liquid. The steam is then directed to the next evaporator, where it transfers its heat to the juice in the heat exchanger, causing the juice to boil and evaporate, which further concentrates the juice.
The heat exchangers used in this process are typically of the shell-and-tube or plate-and-frame type. Shell-and-tube heat exchangers consist of a series of tubes that are enclosed in a larger shell. The fluid to be heated or cooled flows through the tubes, while the other fluid flows through the shell. In plate-and-frame heat exchangers, the fluids flow between a series of thin plates that are stacked together.
As the steam is transferred from one evaporator to the next, it loses its heat and condenses back into liquid form. The latent heat of condensation, which is the energy released when the steam condenses, is transferred to the juice, which causes it to boil and evaporate. The steam is then collected and reused in the process, making it more energy efficient.
Overall, the use of multiple-effect evaporators and heat exchangers is an effective way to concentrate fruit juices by evaporation while minimizing energy consumption.
7. Syrup Cooling
Once the juice extracted from sugar cane or beet is evaporated to produce a concentrated syrup, the syrup is then cooled down before it proceeds to the crystallization process. The cooling process is necessary to achieve the optimal temperature range for the next stage of the sugar-making process.
The syrup is cooled down using a sugar production heat exchanger, which is a device that can transfer heat from one fluid to another. Water or chilled brine is circulated through the heat exchanger, and the syrup flows on the other side of the heat exchanger. The chilled fluid absorbs the heat from the syrup, which in turn cools down the syrup to the desired temperature.
8. Syrup Crystallization
After the concentrated syrup is cooled down to the desired temperature, it is then boiled in vacuum pans to start the crystallization process. The vacuum pans are large vessels that are capable of withstanding high temperatures and low pressure, and they allow for efficient boiling of the syrup.
As the syrup boils, the water content is evaporated, which causes the concentration of sugar to increase. The heat from the boiling process causes the sugar molecules to come together and form crystals. At this stage, the syrup is referred to as massecuite.
To ensure that the crystal growth is controlled and consistent, heat exchangers are used to cool the syrup. The heat exchangers can be designed to control the rate of crystal growth by adjusting the cooling rate of the syrup. This ensures that the crystals grow to the desired size and form a consistent product.
9. Sugar Drying
After the sugar crystals have grown to the desired size, they need to be dried to remove any remaining moisture before packaging. The drying process is typically done using a series of rotating drums that employ hot air to remove the moisture from the sugar crystals.
The sugar crystals are fed into the drum dryers, where they are tumbled and exposed to hot air. The hot air circulates through the drum, and the crystals are dried as they tumble in the hot air. The moisture content is monitored throughout the drying process, and the drying time is adjusted as necessary to achieve the desired moisture level.
The drying process can take several hours, depending on the type of sugar and the desired moisture content. Once the sugar is dried to the appropriate level, it is ready for packaging. The packaged sugar can then be distributed to retailers, wholesalers, and other consumers.
Overall, the drying of the sugar crystals is a critical step in the sugar-making process. It ensures that the sugar is free from excess moisture, which can affect its quality and shelf life. The use of rotating drum dryers and hot air is an efficient and effective way to dry the sugar crystals, and it is widely used in the sugar industry.
10. Molasses Refining
During the crystallization process of sugar, a thick and dark syrup called molasses is produced as a byproduct. Molasses contains residual sugar, minerals, and other impurities that can be further processed to extract additional sugar. The process of extracting sugar from molasses is called molasses refining.
The first step in the molasses refining process is to dilute the molasses with water and filter it to remove any solid particles. The resulting liquid is then heated to evaporate the water and concentrate the sugar. This process of evaporating water from the liquid is similar to the one used in sugar crystallization.
Once the molasses has been concentrated, it is mixed with lime and heated again to remove any impurities. This process is called sulfitation, and it helps to improve the color of the final product. The molasses is then sent to the crystallization process again to extract any remaining sugar.
The molasses refining process results in various types of molasses, each with different sugar content and color. The final molasses product is usually used as a sweetener, a flavor enhancer, or a source of minerals and vitamins in food and feed. Molasses can also be used in the production of ethanol and other chemicals.
In summary, molasses is a byproduct of sugar production that can be further processed to extract additional sugar. The molasses refining process involves dilution, filtration, evaporation, lime mixing, and sulfitation. The resulting molasses can be used in various applications, such as food, feed, ethanol, and chemicals.
11. Raw Sugar Refining
Raw sugar, also known as turbinado sugar, is a minimally processed type of sugar that still contains some of the natural molasses and impurities found in sugarcane. To make it suitable for use in various food products, raw sugar may undergo further processing to remove these impurities and create a more uniform product.
The refining process typically starts by dissolving the raw sugar in water and passing it through a series of filters and ion exchange resins to remove any remaining impurities. This results in a clear liquid that is then heated and evaporated to concentrate the sugar. The concentrated sugar solution is then seeded with sugar crystals to encourage further crystallization.
As the sugar crystals grow, they trap any remaining impurities, which are removed by a process called clarification. The clarified sugar syrup is then filtered and bleached to produce white sugar, which is the most commonly used type of sugar in the food industry.
The refining process can be further customized to produce different types of sugar, such as brown sugar, which is made by mixing refined white sugar with molasses, or specialty sugars like demerara and muscovado, which are partially refined to retain some of the natural molasses and flavor compounds found in raw sugar.
12. Sugar Packaging
Once the sugar crystals have been dried and cooled to room temperature, they are typically packaged into bags, boxes, or other containers for distribution to consumers. The packaging process is an important step in ensuring the sugar remains fresh and free from contaminants during transport and storage.
The packaging material used for sugar depends on the type of sugar being packaged and the intended use. Granulated sugar, which is the most common type of sugar used in households, is typically packaged in paper or plastic bags. The bags are usually printed with the brand name, nutritional information, and other important details.
Powdered sugar, also known as confectioner’s sugar, is a fine powder that is commonly used in baking and pastry-making. It is usually packaged in boxes or canisters with a sifter on top to make it easy to sprinkle onto food. The packaging for powdered sugar is usually designed to prevent the powder from clumping and to keep it fresh.
Other types of sugar, such as brown sugar, may be packaged in resealable bags or containers to help keep them fresh and prevent clumping. Some specialty sugars, such as muscovado sugar or demerara sugar, may be packaged in decorative bags or tins to appeal to consumers who are looking for unique and high-quality products.
In conclusion, sugar production is a complex process that involves multiple steps, from harvesting the crop to producing the final refined sugar product. Heat exchangers play a critical role in sugar production, as they allow for the efficient transfer of heat between process fluids, which helps to reduce energy consumption and improve the overall efficiency of the process.
The specific type of heat exchanger used in each step of the process depends on factors such as the temperature and pressure of the fluids involved, the flow rate of the fluids, and the desired heat transfer rate.
Case Study of HFM Plate Heat Exchanger for Sugar Prodcution
1. Clear Juice Heating
Case Study 1: Dalton Sugar Mill, South Africa
In sugar production, plate heat exchangers are used in several stages of the process to heat the clear juice. The type of heat exchanger used depends on various factors, such as the temperature and pressure of the fluids, the flow rate of the fluids, and the desired heat transfer rate. The Dalton Sugar Mill uses plate heat exchangers with 44 plates, each having a heating area of 0.79 m2. The clear juice flow rate is 130t/h, and it is heated from 92°C to 104°C using steam with a saturation temperature of 111°C. The heat transfer coefficient is 3400W/m2.K, and the pressure drop of the clear juice through the heat exchanger is 76 kPa.
The actual temperature difference is still small, and the heat transfer coefficient is also higher. After five weeks of continuous operation, the juice heater is turned on, and some sludge deposition is observed inside. However, the black film on the plate surface is easy to wash away with water.
Case Study 2: German Nande Sugar Factory
The German Nande Sugar Factory uses four plate heat exchangers to heat the clear juice before it enters the evaporation tank. The flow rate of beet juice is 600t/h, and the juice vapour of the 1~4 effect evaporation tank is used as the heat source. The temperature reached by each stage is heated, and it is only 3°C lower than the juice vapour temperature. Finally, the temperature reaches 127°C.
Case Study 3: Guangzhou Huaqiao Sugar Factory
The Guangzhou Huaqiao Sugar Factory (carbonic acid method) uses a plate heat exchanger with 50 plates, each having a heating area of 0.79m2. The clear juice flow rate is 117t/h, and it is heated from 68.7°C to 100.7°C using the first juice steam. The steam inlet temperature is 114.2°C, the drainage temperature is 108.4°C, and the heat transfer coefficient K is 4010W/m2.K. The pressure drop of the clear juice through the heat exchanger is 36 kPa. The outlet water temperature is about 6°C lower than the inlet steam temperature, and there is little water in the tank. After more than ten days of continuous use, most of the sheet’s surface is still as smooth as new.
Case Study 4: Shunde Sugar Factory
The Shunde Sugar Factory (sulfuric acid) uses a plate heat exchanger with a plate area of 1.07 m2 for the third stage heating of the clear juice. The average cane juice flow rate is 254t/h, and the waste steam with a temperature of 129130°C is used to heat the juice. The juice temperature before heating is 106108°C, and the temperature after heating is 120126°C. The heat transfer coefficient is 24003900 W/m2.K.
Case Study 5: Guangdong Zhujiang Ganhua Plant
The Guangdong Zhujiang Ganhua Plant uses a plate heat exchanger with a heat transfer area of 35m2 for the first-grade heating of the clear juice. The juice temperature is only 2 to 4°C lower than the steam temperature after heating. After 15 days, the temperature difference is 4 to 6°C, and the heating temperature is higher than the 60 m2 tube heater used. Its heat transfer coefficient is 2700~4000W/m2.K.
2. Mixed Juice Heating
Case Study 1: Dalton Sugar Mill in South Africa
The Dalton Sugar Mill in South Africa uses a plate heat exchanger to heat the mixed juice. The plate heat exchanger has 50 pieces and is cleaned once a week. The cane juice flow ranges from 103 to 130t/h, and it is heated from 72 to 76°C to 94 to 97°C using waste steam saturation temperature of 109 to 111°C. The heat transfer coefficient is between 2900 and 3380W/m2.K, and the pressure drop of the cane juice is 0.05-0.1 MPa.
When the machine is shut down, the interior is deposited by sediment and sugarcane, and there is a thin layer of scale on the board surface, but less than the tube heater. Each work shift is “backwashed”, and some of the sediment can be washed away. However, it is preferable to remove the fibrous impurities in the cane juice by sieving.
Case Study 2: Foreign Sulfite Process Sugar Factory
A foreign sulfite process sugar factory uses a wide flow channel plate heat exchanger to heat mixed juice and sulfur smoked juice using the third effect evaporation juice steam. The juice pressure used is very low, only 40kPa absolute pressure. The steam temperature is 75°C. The heat transfer coefficient reaches 2090-2440W/m2.K, and its heating area is less than half of the tube type. The factory can run continuously for 30 days.
Case Study 3: Beet Sugar Factories in Poland
Two beet sugar factories in Poland, processing over 2,000 tons of beet per day, use a wide-gap plate heat exchanger. They use the juice vapor of the boiling sugar can (temperature about 60°C) to heat the exudation juice. The temperature is raised to about 50°C at about 30°C. Ash is added and heated again to about 88°C with steam and third juice.
It works well and can be used continuously for one season. After shutdown, it can be sprayed with high-pressure water to remove all deposits on the surface of the sheet. It utilizes a large number of low-temperature heat sources to significantly reduce the sugar mill’s fuel consumption. The wide-gap plate heat exchanger can use low-temperature juice steam with vacuum as a heat source to heat the low-temperature cane juice, which has greater energy-saving value.
3. Molasses Cooling
Molasses is a byproduct of sugar production and is commonly used as a feed ingredient for livestock. However, molasses must be cooled before entering storage tanks to prevent its deterioration. Cooling molasses is challenging because of its high viscosity and poor heat transfer properties. In this case study, we examine two locations where plate heat exchangers were used to cool molasses.
Case Study 1: Gladhow and Sezela Sugar Mill, South Africa
The Gladhow Sugar Mill and the Sezela Sugar Mill in South Africa used plate heat exchangers to cool molasses. The molasses flowed through the device in a single pass, while cooling water passed in five passes. The heat exchangers used a plate size of 1556 × 416 mm, with 96 and 160 plates, respectively. The heat transfer area was 50 and 83 m2, respectively, and the processed molasses amounts were 11.5 and 12.6 t/h, respectively.
The temperature of the molasses was cooled from 59.8°C to 42.8°C and from 62.1°C to 36.7°C. The inlet and outlet temperatures of the cooling water were 30.2°C and 36.3°C, respectively, and 23.3°C and 46°C, respectively. The cooling water consumption was 13.8 and 6.1 t/h, respectively. The heat transfer coefficients were 96.3 and 112 W/m2.K, respectively. The heat exchanger required washing once a month with water.
Case Study 2: Bingera Sugar Factory, Australia
The Bingera Sugar Factory in Australia used a plate heat exchanger manufactured by GEA in Germany to cool molasses. The model used was B12, with 149 V-shaped corrugated plates measuring 1400×400 mm and a heat exchange area of 67.6 m2. The molasses and water flowed in a one-way direction, with the actual amount of molasses ranging from 10 to 15 t/h.
The temperature of the molasses was reduced from 57-62°C to about 37°C, while the temperature of the cold water used was 32-35°C. The amount of water was automatically adjusted according to the temperature and was 1.5 to 3 times that of molasses. The heat transfer coefficient ranged from 200 to 550 W/m2.K, and the pressure drop of molasses was 50-150 kPa.
The heat exchanger was in regular operation throughout the season, with inspection and cleaning performed in the middle. The stainless steel sheet used (model 316SS) showed no visible corrosion. The cold water used required cleaning. Lower temperature river water was tried, but soft deposits formed between the plates, which affected heat transfer.
Overall, plate heat exchangers were effective in cooling molasses in both South Africa and Australia. The design and operating parameters of the heat exchangers varied between locations but demonstrated that plate heat exchangers can be an efficient and reliable solution for cooling molasses.
Transform Your Sugar Production with HFM Plate Heat Exchangers
As an experienced player in this field, HFM offers high-quality plate heat exchangers that can meet the diverse needs of the sugar industry.
Our plate heat exchangers are designed to handle high temperatures and pressures while providing efficient heat transfer, reducing energy consumption and operating costs. We offer a wide range of plate heat exchangers for sugar production applications, including mixed juice heating, molasses cooling, and more. To know more about what we can do, visit HFM Youtube Channel to get more HFM Plate Heat Exchanger industrial application.
At HFM, we pride ourselves on providing top-notch customer service and technical support to ensure that our clients are completely satisfied with their plate heat exchanger solutions. Contact Us today to learn more about our plate heat exchangers and how we can help optimize your sugar production process.