1. Bryan Picou James Roberts Advisor: Dr. Junkun Ma ET 493 Instructor : Dr. Cris Koutsougeras

2.  Refinery is in Arabi, La  Produce 8 million pounds of sugar per day on average  It is the third largest sugar refinery in the world

4.  Steam is one of the most expensive resources for a refinery Take the current operation of the evaporators and make it more efficient Take the current operation of the melters and eliminate the steam

5.  Evaporator uses steam in a vacuum to heat the sugar liquor and lower its density  Left over vapors from this process is what we are trying to optimize

6.  Takes the raw sugar and uses steam to melt this sugar into a liquid.  It uses direct steam injection  Vapors from evaporator will be rerouted to power the melter

9.  Based upon 8 million pound melt rate  8 % scrap rate  Sugar going into melters assuming 70 Brix

11.  Q = C p of Sugar at 70 Bx* Mass of Sugar * Δ Temperature  C p = 0.65 BTU/lb F  Mass of Sugar at 70 Bx and 8 % scrap rate = 478,800 lb/hr  T i = 130 FT f = 170 F  Δ T = 40 F  Q = 12,448,800 BTU/hr

12.  Q = Mass of Steam * Latent Heat of Steam  Latent Heat of Steam = 976.6  Mass of the Steam = 18,100 lb/hr  Q = -17,676,460 BTU/hr

14.  Q steam = Q sugar  Mass of Steam * Latent Heat of Steam = C p of Sugar * Mass of Sugar * Δ Temperature  Rearranging:  Mass Steam = (C p of Sugar * Mass of Sugar * Δ temperature)/Latent Heat of Steam

15.  Mass of Steam = (0.65 * 478,800 * 40)/976.6  Mass of Steam = 12,747.08 lb/hr

16.  Q = C p of Steam * Mass of Steam * Δ Temperature  C p = 0.45 BTU/lb F  Mass of Steam = 5,353 lb/hr  T i = 188.5 FT f = 170 F  Q = -44,563.045 BTU/hr

17.  Q = Mass of Steam * Latent Heat of Steam  Latent Heat of Steam = 976.6  Mass of the Steam = 12,747 lb/hr  Q = -12,448,800 BTU/hr

18.  Q steam without phase change + Q steam with phase change  Q total = -12,493,363 BTU/hr

19.  Volumetric Flow Rate = Velocity * Area  Velocity = Volumetric Flow Rate/Area  Volumetric Flow Rate of Steam = 18,100 * 47.344 = 856,926.4 ft 3 /hr  Area of 16 in pipe = 1.396 ft 2  Velocity = 856,929.4 ft 3 /hr / 1.369 ft 2 = 170.56 ft/s

20.  Mass of Sugar = (Mass of Steam being condensed * Latent Heat of Steam) / Latent Heat of Sugar  Enthalpy of Sugar at 70 Bx and at 188.5 F = 82.47 BTU/lb  Mass of Sugar = 150,949.436 lb/hr

21.  Volumetric Flow Rate = Velocity * Area  Velocity = Volumetric Flow Rate/Area  Volumetric Flow Rate of Sugar = 150,949.436 * (1/92.2) = 1637.196 ft 3 /hr  Area of 4 in pipe = 0.0872 ft 2  Velocity = 5.214 ft/s

22.  Head Loss = friction factor * (Length/Diameter) * (Velocity 2 / 2*gravity)  H L = 0.015 * (377.95 ft/ 1.33 ft)*((170.567 ft/s) 2 / (2*32.2 ft/s 2 ))  H L = 1920.83 ft

23.  Bernoulli’s Equation:  P 1 + Z 1 + V 1 2 - H L = P 2 + Z 2 + V 2 2 Υ 2g Υ 2g  Rearranged  P 2 = [(P 1 / Υ )-H L * Υ ]  P 2 = [(8 * 144) – (1920.83 * 0.0193)]  P 2 = 7.743 psi

24.  λ = Volume of Melter / Volumetric Flow Rate  Volume of Melter = 329.867 ft 3  Volumetric Flow Rate = 2168.675 ft 3 /hr  λ = 9.13 min

26.  λ = Volume of Melter / Volumetric Flow Rate  Volume of Melter = 400.553 ft 3  Volumetric Flow Rate = 2168.675 ft 3 /hr  λ = 11.082 min

27.  Sketch of future operation (Nov)  Energy of vapors (Nov)  Vapor Flow Rate (Nov)  Energy Required to melt sugar (Nov)  Residence time of melters (Dec)  Design new melter (Dec) Designing the new melters based on energy requirements and availability  Design condenser (Dec) Flow Rates, Pressure and Temperature Differences Energy Transfer

28.  Design Vapor and liquor Pipeline (Dec) Determine pipe size Stress Analysis Material Selection Minimize Energy Loss  Design Heat Exchangers (Feb) Size of Heat Exchangers Materials of Heat Exchangers Energy Transfer

29.  Design Pipeline Support Structure (Feb) Deflection Stress Analysis on Structure Distance between supports Material Selection  COMSOL (March) Pipeline stress analysis Structural Support Stress Analysis Pipeline Deflection Beam Deflection

30.  Design New System Layout (March) ACAD Sketch Instruments Selection Space Requirements  Control Sequence (April) Safety Ladder Logic (PLC)

31.  Cost Analysis (April) Yearly savings from cutting down steam consumption  Project Cost (April) Cost of New Materials and Machines Cost of a Contractor installing all Materials and Machines

32.  Sketch of Future Operation  Energy Required to Melt Sugar  Residence Time  Design Melters  Design Sugar Liquor Pipeline  Design Structural Support System  COMSOL  Design New System Layout  Control Sequence

33.  Sketch of Future Operation  Energy of Vapors  Vapor Flow Rate  Design Condenser  Design Vapor pipeline  Design Heat Exchanger  COMSOL  Design New System Layout  Cost Analysis, Project Cost Analysis

34.  Domino Sugar Corporation  Cane Sugar Refining Handbook  www.sugartech.co.za