CHAPTER 4

4.0 MATERIAL AND ENERGY BALANCES

4.1 Material Balance
The plant is to have a crushing capacity of 85 t/h of sugarcane. This requires a total of
367,200 t of sugarcane in a year which will produce about 14,700 t of table sugar. The
factory will grow 70% of the total tonnage of sugarcane required whiles the remaining
30% will come from out growers. The average yield of sugarcane stalk is 74 t/h (Andoh,
2016). Sugarcane must arrive at the factory within 6 hours after harvesting and this
means the planting sites must be within about a 100 km radius around the factory
(MOTI, 2016). A total 4,8962 ha of land is required to produce the required 367,200 t of
sugarcane for the plant in a year given the above yield per hectare. This represents only
0.16% of the total land available in the 100 km radius. The harvesting season is 6
months in a year. The plant will operate continuously in 6 days every week and thus 156
days in a year provided there are 26 weeks in 6 months. The plant attainment is
therefore expected to be 43%. All units in the plant will be operated 24 h/day.
Conditions used are ambient temperature taken to be 27 oC and atmospheric pressure of
1 atm unless otherwise stated.

Sugarcane
Sugarcane
Component Washed
Mass flow rate, Mass, %
Component kg/h
Mass flow rate, Mass, %
kg/h
Water
56695 Washing66.7
H2O
H
60095
69.45
2O
Component
Mass
flow
Sucrose
12835
15.1
Sucrose
12578.3
14.54
rate,
kg/h
Fibre
11560
13.6
11560
13.36
Dirt Fibre
2
H21700
O
170000
Dirt
85
0.1
Total
Organics
850
1
170000
Organics
850
0.98
Temperature
:
Inorganics
850
1
Inorganics
850
0.98
Glucose
340
0.4
Glucose
340
0.39
Fructose
170
0.2
Fructose
170
0.2
Total
85000
100
Total
86528.3
100

Washed Sugarcane
Component Mass flow rate,
kg/h
60095
H2O
Sucrose
12578.3
Fibre
11560
Dirt
85
Organics
850
Inorganics
850
Glucose
340
Fructose
170
Total
86528.3

Mass,
%
69.45
14.54
13.36
0.1
0.98
0.98
0.39
0.2
100

Mass,
%
100
100

Wash Water
Component
H2O
Dirt
Sucrose
Total
Washer (W)

Mass flow
rate, kg/h
166600
1615
256.7
168471.7

Mass,
%
98.89
0.96
0.15
100

Shredded Sugarcane
Component Mass flow rate,
kg/h
60095
H2O
Sucrose
12578.3
Fibre
11560
Dirt
85
Organics
850
Inorganics
850
Glucose
340
Fructose
170
Total
86528.3

Mass, %
69.45
14.54
13.36
0.1
0.98
0.98
0.39
0.2
100

Imbibition Water
Component
Mass flow
rate, kg/h
H2O
23120
Total
23120
Temperature : 80 OC

Shredder (S)
Shredded Sugarcane
Component Mass flow rate,
kg/h
60095
H2O
Sucrose
12578.3
Fibre
11560
Dirt
85
Organics
850
Inorganics
850
Glucose
340
Fructose
170
Total
86528.3

Mass, %
69.45
14.54
13.36
0.1
0.98
0.98
0.39
0.2
100

Mass,
%
100
100

Mixed Juice
Component
H2O
Sucrose
Dirt
Organics
Inorganics
Glucose
Fructose
Total

Mass flow rate,

kg/h
71709.9
12531.8
84.7
846.9
846.9
338.7
169.4
86528.3

Mass, %
82.87
14.48
0.1
0.98
0.98
0.39
0.2
100

Mills (M1, M2, M3, M4, M5)

Mixed Juice
Component
H2O
Sucrose
Dirt
Organics
Inorganics
Glucose
Fructose
Total

Mass flow rate,

kg/h
71709.9
12531.8
84.7
846.9
846.9
338.7
169.4
86528.3

Bagasse
Mass, %

Component

82.87
14.48
0.1
0.98
0.98
0.39
0.2
100

H2O
Sucrose
Fibre
Dirt
Organics
Inorganics
Glucose
Fructose
Total

Mass flow rate,

kg/h
11505.1
46.5
11560
0.3
3.1
3.1
1.3
0.6
23120

Mass, %
49.763
0.201
50
0.001
0.013
0.013
0.006
0.003
100

Mixed Juice
Mixed Juice
Component Mass flow rate, Mass, %
Component Mass flow rate, Mass, %
kg/h
71709.9
82.95
H2Okg/h
71709.9
82.95
H2O
Sucrose
12531.8
14.50
Sucrose
12531.8
14.50
Organics
846.9
0.98
Organics
846.9
0.98
Inorganics
846.9
0.98
Inorganics
846.9
0.98
Glucose
338.7
0.39
Glucose
338.7
0.39
Fructose
169.4
0.2
Fructose
169.4
0.2
Total
86443.6
100
Total
86443.6
100

Screen

Mixed Juice

Sulphur Gas Mixture

Componen Mass flow rate,
t
kg/h
SO2
63.76
O2
31.88
N2
211.64
Total
307.28

Dirt
Mass flow rate, kg/h
84.7
84.7

Mass, %
20.76
10.38
68.86
100
5

Sulphitation Tower

H2O
Sucrose
Organics
Inorganics
Glucose
Fructose
Total

Component Mass flow rate, Component

Mass, %
Mass, %
Mass flow rate, kg/h
Dirt
kg/h
71709.9
H2O
Total82.95
71709.9
82.95
Sucrose
12531.8
14.50
12531.8
14.50
Organics
846.9
0.98
846.9
0.98
Inorganics
846.9
0.98
846.9
0.98
Glucose
338.7
0.39
338.7
0.39
Fructose
169.4
0.2
169.4
0.2
Total
86443.6
100
86443.6
100
Mixed Juice Tank

Component

Mixed Juice

Mass, %
100
100

Sulphur Gas Mixture

Componen Mass flow
Mass, %
t
rate, kg/h
SO2
0.42
0.17
Mixed Juice
O2
31.88
13.07
Component Mass flow rate,N Mass, % 211.64
86.76
2
kg/h
100
71709.9 Total 82.89 243.94
H2O
Sucrose
12531.8
14.49
Organics
846.9
0.98
Inorganics
846.9
0.98
SO2
63.34
0,07
Glucose
338.7
0.39
Fructose
169.4
0.20
Total
86506.94
100

Mixed Juice

Milk of Lime

Milk of Lime

CaO

Mass flow
rate, kg/h
55.3

13.33

Componen
t
CaO

H2O

359.5

86.67

H2O

359.5

86.67

Total

414.8

100

Total

414.8

100

Component

Mass, %

Mixing Tank

H2O
Sucrose
Organics
Inorganics
SO2
Glucose
Fructose
Total

Mass flow rate, Mass, %

kg/h
Milk of Lime
71709.9
82.89
12531.8 Mass flow
14.49 Mass, %
Component
846.9 rate, kg/h
0.98
CaO 846.9 55.3 0.98 13.33
H2O 63.34 359.5 0,07 86.67
338.7
0.39
Total
414.8
100
169.4
0.20
86506.94
100

Lime Tank

Component

Mass flow
rate, kg/h
55.3

Mass, %
13.33

Mixed Juice
Component
H2O
Sucrose
Organics
Inorganics
SO2
Ca(OH)2
Glucose
Fructose
Total

Mass flow rate,

kg/h
71709.9
12531.8
846.9
846.9
63.34
414.8
338.7
169.4
86921.74

Mass, %
82.50
14.42
0.97
0.97
0.07
0.48
0.39
0.19
100