Reconstruction of sugar factories
Ingehim proposes reconstructing the diffusion section of the sugar factory to increase its feed capacity. The reconstruction involves replacing the existing apparatus with a continuous diffusion pulsating extractor (DPA) capable of processing 1,000 to 6,000 tons per day. Detailed characteristics of the DPA are provided in the Presentation and the Article.
Schematic diagram of the reconstructed diffusion section of a sugar factory using DPA.
1 – diffusion pulsating apparatus (DPA); 2 – chips scalder; 3 – chips heater; 4 – pulse creation subsystem; 5 – pulp-press section; 6 – juice heater; 7 – destructed chips catcher; 8 – belt conveyor; 9 – juice accumulator
The fundamental difference between the proposed apparatus and traditional mechanical devices (such as column, rotary, or screw apparatuses) lies in the patented method of transporting beet chips (cossettes) through the apparatus without the use of energy-intensive transport mechanisms. This performance is achieved through the apparatus’s design and dimensions, as well as the parameters of the pulsation effect generated by an external pulse creation system. Enhanced efficiency is ensured by a higher degree of extraction of target components, resulting from countercurrent and non-stationary diffusion and heat exchange processes, optimal utilization of the apparatus’s working volume, reduction of oxidative and bacteriological activity, minimal sensitivity to chip length and structural condition (such as putrefaction or freezing), and improvements in the purity and clarity of the diffusion juice, among other benefits.
Comparative characteristics of diffusion apparatuses processing 6,000 tons of sugar beets per day
|
Parameter name |
Diffusion apparatus type | |||
|
DPA Pulsating apparatus |
CDA Apparatus manufactured by BMA company |
RDA Rotary apparatus |
DS Screw apparatus |
|
| Aparatus type | column | column | rotary | double screw |
| Positioning | vertical | vertical | horizontal | at inclination |
| Chips transportation method | by pulsations | mechanical | mechanical | mechanical |
| Internal transporting elements | none | hollow shaft, counter blades | rotation of entire apparatus | double screw, counter blades |
| Sugar beet capacity, t/day | 6000 | 6000 | 6000 | 6000 |
| Beet chip characteristics, m/100g | 6-16 | 8-12 | 14-16 | 13-15 |
| Additional chips crushing during operation | none | significant | insignificant | significant |
| Volume utilization factor | 0.9-0.95 | 0.65-0.7 | 0.4-0.45 | 0.55-0.6 |
| Air contact zone size | absent | minimum | maximum | medium |
| Diffusion time, min | 65-80 | 76-80 | 65-70 | 60-65 |
| Working zone diameter, m | 6 | 8 | 6 | 8 – 9 (equival.) |
| Working zone length, m | 15 | 20 | 43.5 | 35 |
|
Overall dimensions, m Height Length Width |
20 8 8 |
25 9 9 |
15 43.5 12 |
13.4 8.8 34.5 |
| Total power consumption, kW | 90 | 120 | 175 | 320 |
| Apparatus weight, t | 180 | 300 | > 300 | >300 |
The use of DPA will significantly reduce capital costs by 30 to 50%, decrease energy consumption by 1.3 to 3 times, and lower operating costs, production floor space, and labor inputs. Additionally, it will enhance the energy efficiency and profitability of the diffusion section.
To accurately assess the scale of reconstruction and its potential economic impact, it is essential to conduct a technology audit of the diffusion section of the sugar factory.
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