1. Automation of Batch pan process in sugar industry
Project Members
DHANABALAN.T ( )
MUGESH KUMAR.G ( )
THIRUNAVUKKRASU.M ( )
Guide Name: Mrs.A.ShakilaBanu,M.Tech(Ph.D)
External guide: Mr.B.R.Sivakumar,Deputy Manager of instrumentation department

2. ABSTRACT
In this project, the design and implementation of the sugar boiling process in batch vacuum pans using the PIC 16F877a is proposed. With a well-designed automated system, the feed valve of the sugar cane juice and the drop valve of the batch pan are controlled automatically and the need for operators' supervision is greatly minimized and hence permits the labour cost to be reduced and optimizing the repeatability and efficiency of the process done by the system. Thus, the operator may readily and efficiently take real time action on the flow of the process permitting the latter to have an upper hand on the system as the latter may decide his own desirable set points at critical intervals during the sugar boiling process.

3. EXISTING METHOD
In the existing method the conductivity / Brix of Massecuite and level and Massecuite inside the pan are monitored continuously and feed liquor to the pan is controlled manually. There is a pan man is appointed to monitor the conductivity / Brix of Massecuite and level inside the batch pan. The feed of the sugar solution is controlled by the pan man and the dropping of sugar is also controlled by the pan man. The pan man should operate the feed valve and the drop valve according to the state of the level and conductivity in the batch pan. To maintain the quality of the Massecuite inside the Boiling Pan, the pan man should monitor the batch pan process keenly.

4. DISADVANTAGES
In the existing method the batch pan process in done manually so the human error may occur due to the carelessness of the pan man.
Manual operation of valves may affect the quality of the product.
The carelessness of the pan man will also lead to increased steam consumption during the boiling process of sugar in the batch pan.

5. PROPOSED METHOD
Our project proposes the design and implementation of the sugar boiling process in batch vacuum pans using the PIC 16F877a microcontroller. The Boiling process of Massecuite in Batch pan is very critical, So it is better to go for automation of Batch pan at least up to the extent of feed valve and drop valve control. The conductivity/ Brix of Massecuite and level inside the pan are monitored continuously and Feed of liquor to the pan and the dropping of sugar is controlled automatically by controlling the solenoid valve.

6. ADVANTAGES OF PROPOSED METHOD
In Batch pan by implementing the controller we can avoid the errors due to the carelessness of the pan man.
The quality of the product is improved.
The set point of the boiling process is also changed and maintained in this proposed method.
Uniform crystal size helps in avoiding recirculation of sugar.

7. BLOCK DIAGRAM

8. BLOCK DIAGRAM EPLANATION
In this Automation of batch pan process the block diagram consists of Microcontroller, Relay driver, LCD display, Relay, Level switch, conductivity sensor, control unit. The output of the level sensor and conductivity sensor is given to the microcontroller .The level sensor gives the output according to the level in the tank. The conductivity sensor gives the output according to the conductivity of the liquid present inside the tank. The Microcontroller is coded with the floe code for the corresponding process. According to the code written in the PIC it produce the output signal. The action of the controller is displayed in the LCD display connected with the controller. The Output of the microcontroller is given to the relay driver. The relay driver is used to drive the relay. The relay output is given to the control unit.

9. CIRCUIT DIAGRAM

10. CIRCUIT DESCRIPTION
The output of the conductivity meter is given to the pin A0. The signals from the three float switch are given to the pins A1, A2, A3. The output of the float switch is digital. These values of the conductivity meter and the float switch is processed in the controller as per the coding written in it. According to the flow code written in the controller, it produces the control signals. These control signals are taken in the pins C0 and C1. The output signal from the controller is given to the relay driver to operate the relays.

11. FLOWCHART

15. HARDWARE REQUIREMENTS
Solenoid Valve
PIC microcontroller
Relay driver
Relay
Mini float type level switch
Transformers

16. RESULT AND DISCUSSION
This project shows one practical application of automation of batch pan process. The automatic control of batch pan is tested using referance value in the Sakthi sugars limited. Due to some problem in measuring the conductivity value in the demo hardware, a variable resistance is used to show the changes in conductivity. To demonstrate the Automation of batch pan process more preciously, the methodology of using a closed tank with vacuum must be used with extra laboratory analysis.

17. THANK YOU