t
fs
k
1
h
o
_ _ 3
Ice thickness in ith segment and corresponding properties of the solution at the entry of the i + 1th
segment are calculated as follows.
As shown in (Fig. 4b), equation for heat transfer q
2
is
q
2
t
l
1
h
l
_ _
4
The rate equation for heat transfer q
1
is
q
1
t
0
x
k
i
t
fs
k
1
h
o
_ _ 5
From energy balance consideration, q
1
is in excess of q
2
by the amount required for the rate of ice
formation dx/dt.
q
1
q
2
q
ice
h
lat;ice
dx=dt 6
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6
Ice Growth Rate x 10
-6
(m/s)
0.15
0.20
0.25
0.30
0.35
0.40
0.45
0.50
A
v
e
r
a
g
e
D
i
s
t
r
i
b
u
t
i
o
n
C
o
e
f
f
i
c
i
e
n
t
0.15
0.20
0.25
0.30
0.35
0.40
0.45
0.50
Velocity 0.75m/s
Velocity 0.5m/s
Velocity 1m/s
Fig. 2. Eect of sucrose solution velocity and ice growth rate on average distribution coecient.
2127
Start
Input initial juice and refrigerant temperature,
freezing surface dimensions, total run time,
time steps, number of segments, juice
properties
Assume refrigerant temperature for first
time step j
Calculate mass of ice formed in i
th
segment
Calculate overall heat transfer
coefficient in segment i
Calculate heat transfer in segment i
Summation of the individual heat transfers in
segments 1 to i to calculate total heat transfer Qr
Calculate juice viscosity, density, specific
heat, freezing temperature for the new
concentration of juice in i+1
th
segment
Calculate concentration of the juice
at the end of the i
th
segment
Calculate capacity of compressor Qc
corresponding to assumed refrigerant temperature
Next time step j+1 and repeat calculations
taking into account ice thickness in the
previous time step
Is Qc=Qr
Calculate COP and energy consumption of
the compressor corresponding to the
refrigerant temperature
No
Yes
Fig. 3. Flow chart of method of analysis for calculation of energy consumption of the Freeze Concentration System.
2128
Thermal energy abstraction in sub-cooling the ice is not considered. It is negligible relative to the
latent heat of freezing requirement [5].
Mass of ice is formed in the ith segment calculated as
Dm
ice;i
q
1
q
2
Dt
j
h
lat;ice
7
Concentration of the juice entering i + 1 segment in terms of brix is calculated as
Bx
i1
1
m
juice;i
100Bx
i
100
m
ice;i
_ _
m
juice;i
m
ice;i
_
_
_
_
8
Mass ow rate of juice in the i + 1 segment is calculated as
m
juice;i1
m
juice;i
m
ice;i
9
The relation between concentration and freezing temperature is obtained from the sugarcane juice
phase diagram [6] using curve tting as
T
solution;i1
1 Bx
i1
15 0:18 10
Sugarcane juice
h
0
h
l
R
o
= 1/ h
o
q
r
t
o
t
l
R
h
= t/k
R
l
= 1/ h
l
t
o
q
r
t
l
Refrigerant
t
fs
Freezing
Surface
Sugarcane juice
Ice
h
0
t
fs
h
l
x
q
2
R
l
= 1/ h
l
t o
R
i
= x/k
t =0
R
o
= 1/ h
o
q
1
q
1
q
2
t o
t
l
t
l
R
h
= t/k
Refrigerant
Freezing
Surface
(a)
(b)
Fig. 4. Thermal circuit representations (a) bare freezing surface; (b) freezing surface with ice formation.
2129
The relation between viscosity and Bx in i + 1 segment is obtained from a graph of temperature,
concentration and viscosity [7] as
l
juice;i1
a
a b Bx
i1
c Bx
i1
2
_ _ 11
where a = 1.8214, b = 0.0337, c = 0.0002; Bx concentration of sugarcane juice (Bx).
Specic heat of sugarcane juice varies with its concentration (Bx) and temperature, it is calcu-
lated as [7]
c 1 0:6 0:0018T
juice
0:0008 100 P
_
Bx
100
4:19
_ _
12
Density of sugarcane juice in the i + 1 segment is
q
juice;i1
1:59
Bx
i1
100
100 Bx
i1
100
_ _
100 13
Velocity of the sugarcane juice in i + 1 segment is calculated by substituting the values from equa-
tions (11) and (13) in the following equations [8]:
V
gqd
2
3l
14
where
d
3Cl
q
2
g
_ _
1=3
15
This equation assumes that there is no drag force at the gas liquid interface.
Initially, evaporator temperature is assumed. For the rst time step, the heat transfer from juice
to refrigerant, that is q
r
is calculated for each of the segments taking in to consideration corre-
sponding properties of the juice in the respective segment. Compressor cooling capacity q
c
at
the assumed evaporator temperature and sum of the individual heat transfers in all the segments
are equated. If they do not converge, new evaporator temperature is assumed and above men-
tioned calculation is repeated to get evaporator temperature. Similar procedure is repeated for
the next time step. Resistance due to the ice formed in the previous time step in the corresponding
segments is taken in to consideration in the next time step. Compressor capacity and COP is cal-
culated for every time step using vapor compression cycle simulation program for R 22 refrigerant
with condenser temperature of 10 C and compressor isentropic eciency: 0.8.
5. Electrical energy consumption of the FCS
Compressor of the FCS is selected based on the nominal capacity and evaporator temperature.
Nominal cooling capacity is calculated for the specications of the unit at Rahu Pimpalgaon.
Water to be separated from the 400 kg/h juice to concentrate it from 20 to 40 Brix is
m
water
m
juice
1 Bx
j
=Bx
f
200 kg=h 16
2130
Thus, concentrated juice (syrup) ow rate at the exit of the FCS is 200 kg/h. In FCS, juice is
cooled from 1 C at 20 Bx to 5 C corresponding to 40 Bx is. Total load is
Q
tot
; Q
sensible;FCS
Q
latent;FCS
m
Juice;20 Bx
h
Juice;20 Bx;1
C
m
Syrup;40 Bx
h
Syrup;40 Bx;5
C
_ _ _ _
m
water
h
lat;ice
3 18:6 21:6 kW
Heat gain from ambient into the ice separated is, assumed to be 10% of the latent heat load, which
is 1.8 kW. Thus, nominal cooling capacity of the FCS is 23.4 kW. Assuming minimum approach
of 3 C, initial evaporator temperature is xed at 8 C. Results were computed using the above
discussed model.
5.1. Results and discussion
Results are shown in Fig. 5, the evaporator temperature decreases through out the ice building
process. As ice thickness on the freezing surface increases, overall heat transfer coecient de-
creases because of increased ice resistance. This results in reduction of the evaporator temperature
and pressure leading to reduced cooling eect and power consumption. However, reduction in
cooling eect is much more than the reduction in power consumption leading to reduction in
the COP.
It can be seen that at 7 mm ice thickness, COP of the system is around 8. This COP value does
not take into account eect of mismatch of condenser and evaporator duties. The COP is based on
the assumption that the total heat in the condenser is rejected for melting ice only. In practice,
condenser can reject a part of the total heat (equivalent to the latent load) at 10 C for ice melting.
0 15 30 45 60 75 90 105 125 135
Time (minutes)
-15
-14
-13
-12
-11
-10
-9
-8
-7
E
v
a
p
o
r
a
t
o
r
T
e
m
p
e
r
a
t
u
r
e
o
C
7.
.
5
8.
.
0
8.
.
5
9.
.
0
9.
.
5
10.
.
0
10.
.
5
C
o
e
f
f
i
c
i
e
n
t
o
f
P
e
r
f
o
r
m
a
n
c
e
0
1
2
3
4
5
6
7
8
I
c
e
T
h
i
c
k
n
e
s
s
(
m
m
)
20
21
22
23
24
25
26
27
28
C
o
m
p
r
e
s
s
o
r
C
a
p
a
c
i
t
y
(
k
W
)
Evaporator Temperature
Coefficient of Performance
Compressor Capacity
Ice Thickness
Fig. 5. Eect of time varying ice thickness on the compressor performance.
2131
Excess heat, contributed by compressor power input and leakages has to be rejected to heat sink
at ambient temperature. Eect of this heat rejection on the COP is analyzed in the following
section.
Fig. 6 illustrates the cooling loads and eect of delivery of excess heat to the sink at ambient
temperature on net COP. Thus, 23.4 kW heat has to be pumped to a higher temperature. Out
of this, part of the heat (16.5 kW) is pumped at 10 C for ice melting. Since cooling COP of
the FCS is 8, power input for pumping 16.5 kW heat is 16.5/8 = 2.1 kWe. Thus, total heat deliv-
ered for ice melting is 16.5 + 2.1 = 18.6 kW which is equal to the latent load.
Excess heat (6.9 kW) is pumped to 36 C in the water cooled condenser. Cooling COP of 3.7 is
calculated for this condensing temperature using vapor cycle simulation program. Power input for
pumping 6.9 kW heat to 36 C sink is 6.9/3.7 = 1.9 kWe. Thus, total heat delivered at 36 C is
6.9 + 1.9 = 8.8 kW.
The net COP is calculated as
COP
net
Q
R;ice
Q
R;sink
P
Total
18:6 8:8
1:9 2:1
6:8 17
Electrical energy consumption is
P
e;FCS
Q
cooling
COP
net
23:4
6:8
3:44 kW h 18
Since unit works for 10 h in a day, total electrical energy consumption of the FCS to concentrate
juice from 20 to 40 Bx for the day is 34.4 kW h.
Sensible heat load
3 kW
c
Latent heat load
18.6 kW
c
at -10
o
C
Total cooling load
23.4 kW
Freeze Concentration System
Heat rejection to heat sink
Heat leakage
1.8 kW
Heat rejection for ice melting
COPc = 8
Power Input
2.1 kWe
18.6 kW
at 10
o
C
16.5 kW
8.8 kW
at 36
o
C
COPc = 3.7
6.9 kW
Power Input
1.9 kWe
Net COP = (8.8 + 18.6)/(1.9 + 2.1)
= 6.85
Fig. 6. Eect of excess heat rejection on COP.
2132
6. Bagasse consumption for the concentrated juice boiling
It is required to evaporate 100 kg/h water at a striking temperature of 118 C from (200 kg/h)
concentrated juice coming from the FCS. Vapor generated in the boiling pan at 118 C is used to
heat the concentrated juice at the exit of the FCS. With an approach of 6 C, the concentrated
juice is heated from 112 C before entering the boiling pan.The juice is heated from 112 to
118 C in the boiling pan. Total heat load in the boiling pan is
Q
T;heat
m
w
h
fg
m
Syrup
c T
f
T
i
@ 99:5
C
m
w;e
h
fg
@ 113:5
C
216:6 kW 24
7.1. Sensible heat loss in ue gas
Ratio excess air weight to weight of air theoretically necessary is calculated as [7]:
c
0:871 w
4:451 wm 0:0561 w
25
Assuming CO
2
content per unit volume of ue gas to be 0.13, from Eq. (25)
m 1:52
Suarcane Juice at 20Bx,
400 kg/h, 30
o
C
Vapor
100
o
C,150kg/h
Syrup
90
o
C,400kg/h , 20 Bx
Syrup
109
o
C,250kg/h , 32 Bx
Vapor
113.5
o
C,150kg/h
Jaggery paste
118
o
C,100kg/h , 80 Bx
Stage I
Stage II
Stage III
Sensible heat
Sensible heat + Latent Heat
Sensible heat + Latent Heat
Fig. 7. Temperature ranges for heat load calculations.
2134
Heat loss is
Q
f
1 w 1:4m 0:13 0:5 T 4:18 m
bagasse;con
125:5 kW 26
Other losses include unburnt and radiation loss. Unburnt loss is assumed to be 10% of the total
heat input. The result of the energy balance is indicated in Fig. 8(a).
8. Comparison of the FCS integrated jaggery making with the conventional process
Fig. 8 shows that, bagasse consumption in FCS integrated process is 41.2 kg/h as against
175 kg/h in conventional process. Saving in bagasse is
175 41:2 133:8 kg=h
Energy Input 415.3 kW
h
Bagasse Consumption 175 kg/h
Loss in Flue Gas
125.5 kW
Juice Evaporation
216.6 kW
Other Loss
73.2 kW
(a)
Freeze Concentration
System (FCS)
Sugarcane Juice
400 kg/h
27
o
C
20 Bx
Ice Water
200 kg/h
0
o
C
Electrical Energy Input 34.4 kWe
Loss in Flue Gas
28.7 kW
Other Loss
9.5 kW
Energy Input 103 kW
h
Bagasse Consumption 41.2 kg/h
Boiling Pan
112
o
C
Concentrated Juice
200 kg/h
1
o
C
40 Bx
64.8 kW
Jaggery Paste
100 kg/h
Water Vapor
100 kg/h
118
o
C
Condensate
100 kg/h
118
o
C,
(b)
Fig. 8. Comparison of energy consumption of the Freeze Concentration System integrated jaggery making and
conventional process.
2135
Thus, bagasse saving for 1000 kg jaggery production in 10 h is 1338 kg.
8.1. Initial cost
The FCS consists of two latent heat exchangers, a sensible heat exchanger, multi way valve and
controls. A boiling pan of juice holding capacity 500 kg is used to further concentrate the juice
from the FCS. The initial cost of FCS and boiling pan is about Rs. 2 Lakh. Conventional jaggery
making unit essentially consists of a furnace, chimney and a boiling pan of juice holding capacity
1000 kg. Cost of the complete unit including construction of the chimney and furnace is about 2
Lakh.
8.2. Jaggery quality
The boiling pan in the proposed unit is half the capacity of the conventional jaggery making
unit. Reduced size of the boiling pan facilitates proper stirring of the juice. This reduces localized
hot spots. Further, time for which juice is exposed to high temperature reduces because 50% of the
concentration is carried out in the FCS. This reduces caramelisation and improves jaggery color
and quality.
9. Techno economics
As indicated in the results of the experiments, loss of sucrose is 4%. During 10 h working,
2000 kg ice is separated. Loss of sucrose in this ice is (2000 0.04) 80 kg. It is assumed that
80 kg jaggery forms out of 80 kg sucrose loss in ice. Considering rate of jaggery as Rs. 3 per
kg realized by the farmer [10], Rs. 240 is the loss due to sucrose inclusion.
9.1. Net savings
Saved bagasse can be sold to various industries like sugar factory, paper and pulp industry at
the rate in the range of Rs. 0.60 to Rs. 1.2 per kg [10]. Considering an average value of Rs. 0.9 per
kg, revenue generated per day by sell of the 1338 kg saved bagasse is Rs. 1204.2.
Electrical energy consumption of the FCS for 1000 kg jaggery production is 34.4 kW h. Con-
sidering electricity rate of Rs. 5/kW h (in Maharashtra), electricity cost is Rs. 172.
Net saving per day is Revenue generated by the sell of bagasse
Electricity cost of the FCS
cost of the sucrose lost in inclusion
Rs: 1204 Rs: 172 Rs: 240 Rs: 792 per day
Simple pay back period of the system is about 252 days.
2136
10. Conclusion
A heat pump based Freeze Concentration System is proposed to concentrate sugarcane juice
from 20 to 40 Brix in a jaggery making process to save bagasse and enhance jaggery quality. Eect
of operating parameters on ADC is studied through experiments. Use of heat pump facilitates
rejection of a major part of the condenser heat at about 10 C while melting the ice. COP of
the FCS is estimated as 6.8 using mathematical model and considering heat losses and mismatch
of evaporator and condenser duty. Comparison of the conventional and FCS integrated jaggery
making process is presented. FCS integrated process results in better quality jaggery by reducing
hot spots and caramelisation due to reduced size of the boiling pan. Bagasse saving of 1338 kg per
day or for 1000 kg jaggery can be achieved.
Acknowledgements
The authors would like to acknowledge the help and support oered by Dr. J.P. Patil, Director,
Regional Sugarcane and Jaggery Research Station, Kolhapur, Dr. B.S. Patil (Kolhapur) and Mr.
Hanumant Shinde from Rahu Pimpalgaon.
References
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an experimental study, Journal of Food Engineering 38 (1998) 113.
[3] P. Chen, X.D. Chen, W.F. Kevin, An experimental study on the spatial uniformity of solute inclusion in ice
formed from falling lm ows on a sub-cooled surface, Journal of Food Engineering 39 (1999) 101105.
[4] A.L. London, R.A. Seban, Rate of ice formation, ASME Transactions 65 (1016) (1943) 771778.
[5] S.I. Finer, A.C. Cleland, S.J. Lovatt, Simple mathematical model for predicting the transient behaviour of an ice-
bank system, International Journal of Refrigeration 16 (1993) 312320.
[6] A.G. Patil, Freeze concentration: an attractive alternative, International Sugar Journal 95 (1993) 349355.
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[8] R.H. Perry, Perrys Chemical Engineers Handbook, seventh ed., McGraw-Hill, New York, 1997, pp. 642.
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juice, Energy Conversion and Management 45 (2004) 171179.
[10] Personal communication with Mr Hanumant Shinde, jaggery unit owner at Rahu Pimpalgaon.
2137