Performance Evaluation of Sugar Cane Milling Plant and Optimization of Process Parameters: A Case of Wonji-Shoa Sugar Factory
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Date
2019-06
Authors
Journal Title
Journal ISSN
Volume Title
Publisher
Addis Ababa University
Abstract
Performance assessment of WSSF and setting targets for the relatively inefficient mills to improve
the
efficiency
and
productivity
is
crucial.
This
study,
focus
on
performance
evaluation
of
milling plant
and
optimization
of
its
process
parameters.
The
milling
plant
(WSSF)
performances
have
been
evaluated
in
terms
of
its
Brix
juice
extracted
at
all
mill
sets
(5
sets).
The
performance
of
each
mill
was
monitored
by
drawing
juice
Brix
curves.
From
the
Brix
curve,
the
second
mill
front
roller Brix curve overlays the back roller Brix curve this was not appropriate hence, improvement
for
delivery
mill
setting
was
desired.
However,
the
reverse
curve
showed
acceptable
result.
The
juice
and
bagasse
sample
analysis
for
each
mill
set
were
analyzed
then
maximum
loss
areas
were identified and the process optimization were done. The Brix free water for WSSF
were done and found to be averagely 30.63 % on cane fiber. The statistical analysis were done
by design expert software (6.08, version) of central composite design. The study were done by
varying the effect of hydraulic pressure and imbibition water flow on the last mill for the response
variables
of
pol
and
moisture
%
of
final
bagasse.
The
experimental
design
combination
were
held
by
inserting
the
lowest
and
highest
values
of
hydraulic
pressure
and
quantity
of
imbibition
water flow rate for the last mill. The optimal results of pol and moisture % of bagasse
were between 1.63 - 1.88% and 50.47 - 51.31% respectively, with the respective hydraulic pressure
and
quantity
of
imbibition
water
application
of
195
-
200
kg/cm
2
3
and 71.3 - 72 m
/hr. The
pol and Brix extraction trends were done for how each and individual mills can perform well for
a given milling season. The existing milling plant flow diagram were modified by recycling the
primary juice Cush-Cush prior to the first mill and secondary juice Cush-Cush to the second mill.
Using the optimum values of application of hydraulic pressure and quantity of imbibition water
flow rate on the last mill, drawing juice Brix curve, Brix free water on cane fiber and recycling
of respective Cush – Cush to recommended point and the optimum output of pol and moisture
content of last mill bagasse which can be taken as a positive outcome to bring efficiency improvement,
product
maximization,
for
energy
saving,
cost
reduction
and
increased
profitability
to
WSSF in
particular
and
all
other
sugar
factories
as
general.
Description
Keywords
Extraction, Imbibition, Hydraulic Pressure, Moisture, Pol, Optimization, Bagasse, Milling Loss, Milling Efficiency