Calculations Used in Cane-Sugar Factories PDF

Professional Sucrose Analysis & Recovery Engineering Tool

What are Calculations Used in Cane-Sugar Factories PDF?

The calculations used in cane-sugar factories pdf represent the mathematical backbone of the sugar manufacturing industry. These formulas are used by chemical engineers, factory managers, and chemists to monitor the efficiency of the milling tandem, the clarification house, and the boiling house.

From determining the Brix (the total dissolved solids) to the Pol (the apparent sucrose content), these metrics allow technicians to calculate the Purity of the juice. Understanding the calculations used in cane-sugar factories pdf is essential for optimizing the yield of commercial white or raw sugar from every ton of sugarcane harvested. Whether you are analyzing juice extraction or final molasses loss, these standard industry calculations ensure profitability and quality control.

Calculations Used in Cane-Sugar Factories PDF Formula

The core calculations revolve around the SJM formula (Deerr’s Formula) and simple mass balance equations. Here is the step-by-step mathematical derivation for primary recovery used in most factory manuals:

1. Purity Calculation: Purity = (Pol / Brix) × 100
2. Pol in Cane: Pol in Cane = Pol in Juice × [100 – (Fiber + Constant)] / 100
3. Estimated Sugar Recovery (ESR): ESR = Pol in Cane × Extraction × Boiling House Recovery (BHR)

Variable	Meaning	Unit	Typical Range
Brix	Total Soluble Solids	% Weight	12% – 22%
Pol	Apparent Sucrose	% Weight	10% – 18%
Purity	Ratio of Pol to Brix	%	75% – 92%
Fiber	Insoluble Cane Matter	%	10% – 16%
Extraction	Milling Efficiency	%	92% – 97%

Practical Examples of Calculations Used in Cane-Sugar Factories PDF

Example 1: High Purity Tropical Cane

Consider a factory processing cane with a 16.5% Brix and 14.8% Pol in mixed juice. The fiber content is 12.5% and the milling extraction is 96%. Using the calculations used in cane-sugar factories pdf standard model:

• Purity: (14.8 / 16.5) * 100 = 89.7%
• Pol in Cane: 12.5% approx.
• Estimated Recovery: Based on the high purity, the BHR would be approximately 92%, resulting in a final sugar recovery of ~11.0%.

Example 2: Low Purity Late Season Cane

In a late-season scenario, juice might show 14.0% Brix and 10.5% Pol.

• Purity: (10.5 / 14.0) * 100 = 75.0%
• Impact: Low purity signifies higher impurities, leading to more sugar being lost to molasses. The recovery would drop significantly to approximately 7.2%, emphasizing the importance of these calculations used in cane-sugar factories pdf for seasonal planning.

How to Use This Calculator

To get accurate results for your factory performance, follow these steps:

1. Input the Mixed Juice Brix obtained from your laboratory refractometer or hydrometer.
2. Enter the Mixed Juice Pol measured using a polarimeter (Lead-free clarification is recommended).
3. Provide the Cane Fiber %. This is typically determined by disintegrating the cane and washing out the soluble solids.
4. Input your Milling Extraction percentage to account for juice lost in bagasse.
5. The tool will automatically display the Estimated Sugar Recovery and intermediate purity values.

Key Factors That Affect Calculations Used in Cane-Sugar Factories PDF

• Cane Variety: Different genotypes have varying sucrose accumulation patterns and fiber structures.
• Milling Pressure: Higher hydraulic pressure on rollers increases extraction but can increase fiber in juice.
• Imbibition Water: The amount and temperature of water added during milling significantly affect extraction calculations used in cane-sugar factories pdf.
• Clarification Efficiency: Poor liming or heating can lead to sucrose inversion, reducing the final recovery.
• Evaporation Rates: Proper vacuum and steam pressure in the evaporators ensure the syrup reaches the target Brix for crystallization.
• Molasses Exhaustion: The lower the purity of final molasses, the higher the boiling house recovery.

Frequently Asked Questions (FAQ)

What is the difference between Pol and Sucrose?
Pol is the “apparent” sucrose measured by optical rotation, whereas true sucrose is measured via HPLC or double polarization to account for other optically active substances like glucose and fructose.

Why is Fiber % important in these calculations?
Fiber displaces juice in the cane. Higher fiber content means less juice is available for extraction per ton of cane.

What is a “good” milling extraction?
Modern sugar factories aim for a milling extraction between 95% and 97%. Diffuser plants often exceed 98%.

How does temperature affect Brix readings?
Brix is temperature-dependent. Readings should be corrected to 20°C using standard ICUMSA tables found in calculations used in cane-sugar factories pdf.

What is the SJM formula?
It is a formula used to calculate theoretical Boiling House Recovery: BHR = [S(J-M) / J(S-M)] * 100, where S is sugar purity, J is juice purity, and M is molasses purity.

Can purity exceed 100%?
No. Since Pol measures a component of Brix (total solids), Pol can never be higher than Brix in a pure solution.

What causes high sugar loss in bagasse?
Improper mill settings, worn-out roller groovings, or insufficient imbibition water can lead to high losses.

How often should these calculations be performed?
Factories typically perform composite sample analysis every hour and a full balance check every 24 hours.

Related Tools and Internal Resources

• Sucrose Analysis Guide – Deep dive into polarimetry and refractometry.
• Brix Correction Tables – Standard corrections for temperature and impurities.
• Milling Extraction Calculator – Advanced tool for mill tandem performance.
• Boiling House Efficiency Metrics – Analyzing pan stage and crystallization.
• Molasses Purity Optimizer – Reducing losses in the final byproduct.
• Cane Quality Assessment – Comparing variety yields and fiber impacts.