SUGAR RESEARCH LIMITED

ACN 009 666 899

Sugar Research & Innovation

Confidential to E.I.D. Parry (India) Ltd

Design specification for a new 8.5 m SRI

clarifier for Nellikuppam
(E.I.D. Parry Ltd)

by

R.J. Steindl and D.W. Rackemann

August 2006

Job No. 3530

ii

IMPORTANT NOTICE

The use of this report is governed by Sugar Research

Limited’s Terms of Business. Please refer to the intellectual
property and confidentiality sections of those terms. Those
sections provide (amongst other things) that:

a. all intellectual property rights relating to the subject

matter of this report belong to Sugar Research Limited;
and

b. the contents of this report must not be disclosed to

others or used except in accordance with the Terms of
Business.
 Confidential E.I.D. Parry Ltd i

Design specification for a new 8.5 m SRI clarifier

for Nellikuppam (E.I.D. Parry Ltd)

Contents

1. Introduction...............................................................................................1
1.1 Design data ............................................................................................................2
1.2 Confidentiality of intellectual property..................................................................2

2. Specification - 8.5 m diameter clarifier ..................................................3

2.1 General...................................................................................................................3
2.2 Clarifier..................................................................................................................3
2.3 Clarifier body.........................................................................................................3
2.4 Juice feed system ...................................................................................................9
2.4.1 Feed pipe and feed chamber ....................................................................10
2.4.2 Flocculant distributor ..............................................................................12
2.4.3 Feed channel and feedwell.......................................................................12
2.4.4 Deflectors .................................................................................................13
2.5 Clear juice collection system ...............................................................................14
2.6 Scraper arrangements...........................................................................................17
2.6.1 Floor mud scraper ...................................................................................17
2.6.2 Deflector scrapers....................................................................................21
2.6.3 Perforated plate scrapers.........................................................................21
2.7 Drive ....................................................................................................................21

3. Flash tank 23

4. Juice flow control ....................................................................................25

5. pH control 28
5.1 Saccharate preparation.........................................................................................29
5.1.1 Standard scheme ......................................................................................29
5.1.2 In-line mixing system ...............................................................................32
5.2 Saccharate injection and pH control ....................................................................32
5.3 Miscellaneous ......................................................................................................36
5.4 Saccharate supply calculations ............................................................................37

6. Flocculant system....................................................................................38
6.1 Water quality........................................................................................................38
6.2 Disperser unit.......................................................................................................39
6.3 Flocculant tanks ...................................................................................................40
6.4 Flocculant pump ..................................................................................................42
ii Confidential E.I.D. Parry Ltd

6.5 Automation ..........................................................................................................42

6.6 Flocculant to juice ratio control ...........................................................................43

7. Concluding comments ............................................................................45

Appendix A List of drawings ...................................................................46

Appendix B Additional photographs of clarifier installations. ............49

List of figures
Figure 1.1 Schematic of the standard SRI clarification system showing the juice
processing stages and important control loops. ................................................. 2
Figure 2.1 Recent new generation SRI clarifier installation in Brazil. ............................... 4
Figure 2.2 Recent new generation SRI clarifier installation in Australia. .......................... 4
Figure 2.3 Photo of inspection windows and access door. Liquidation valves are
located just to the right of the photographed section......................................... 6
Figure 2.4 Illustration showing the sites requiring easy access for operation and
maintenance. ...................................................................................................... 7
Figure 2.5 Photograph of the recommended wash water system arrangement taken
inside the clarifier. ............................................................................................. 8
Figure 2.6 Photograph of a typical feed chamber viewed from above. ............................ 10
Figure 2.7 Photograph of the recommended arrangement to support the flocculant
distributor......................................................................................................... 11
Figure 2.8 Photograph of the flocculant distributor held in place by the support
arrangement. .................................................................................................... 11
Figure 2.9 Photograph of the support stiffeners for the deflector plates........................... 13
Figure 2.10 Photograph of a suitable support plate for the outer section between the
clarifier vessel and the outer wall of the feedwell. .......................................... 16
Figure 2.11 Typical support for the inner clear juice channel. Note the extension
pieces to support the full width of the channel floor. ...................................... 16
Figure 2.12 Typical mounting supports for the mud scrapers. ........................................... 19
Figure 2.13 Preferred support for the outer mud scrapers. ................................................. 19
Figure 2.14 Photograph showing how chains are used to limit the forward movement of
the floor scrapers. ........................................................................................ 2019
Figure 2.15 Photographs of two installations using modern drive systems. The motors
are typically less than 0.5 kW...................................................................... 2219
Figure 3.1 Arrangement of the flash tank and connection to the clarifier showing the
location for the control valve........................................................................... 24
Figure 4.1 Proposed scheme for juice flow control. ......................................................... 26
Figure 4.2 Schematic of the recommended controller action to achieve juice flow
control.............................................................................................................. 26
Figure 4.3 Alternative juice flow control scheme using a recycle loop of juice back to
the buffer tank.................................................................................................. 27
 Confidential E.I.D. Parry Ltd iii

Figure 5.1 Proposed arrangement for pH control. ............................................................ 28

Figure 5.2 Schematic of the standard arrangement for plant to prepare lime saccharate. 30
Figure 5.3 Illustration of the standard arrangement for plant to prepare lime
saccharate......................................................................................................... 31
Figure 6.1 Schematic of the flocculant preparation and dosing system............................ 39
Figure 6.2 Illustration of the removable screen located in the top of the flocculant
stock tank......................................................................................................... 41
Figure 6.3 General arrangement for automation of the flocculant make-up..................... 42
Figure 6.4 Recommended flocculant/juice ratio control scheme...................................... 43
Figure 6.5 In-line mixer to dilute the flocculant with water. ............................................ 44

Figure B.1 Photograph showing the perforated plate scrapers. .........................................51

Figure B.2 Photograph of the flocculant distributor T-section and flexible hose
connection........................................................................................................52
Figure B.3 Photograph showing one method of mounting the mud scrapers....................53
Figure B.4 Photograph showing an alternative method of mounting the mud scrapers....54
Figure B.5 Photograph showing location of dP sensor to measure level in the flash
tank. .................................................................................................................55
Figure B.6 Photograph showing typical piping and instrumentation for mud removal
from the mud cone...........................................................................................56

List of tables
Table 2.1 Basic dimensions for the 8.5 m clarifier vessel.................................................. 3
Table 2.2 Dimensions of the feed system........................................................................... 9
Table 2.3 The main dimensions of the clear juice removal system.................................. 14
Table 3.1 Basic dimensions for flash tank........................................................................ 23
iv Confidential E.I.D. Parry Ltd
 Confidential E.I.D. Parry Ltd 1

Design specification for a new 8.5 m SRI clarifier for

Nellikuppam (E.I.D. Parry Ltd)

1. Introduction
The SRI clarification system has evolved over several decades and is recognised as the
leading system in the cane sugar industry providing high quality clear juice. The new
generation clarifier has been designed to provide optimum conditions for removing the
maximum amount of impurities from the raw juice while producing clear juice free of
suspended solids.

The realised quality of the clear juice will depend not only on the design of the clarifier but
also on:

• the juice quality which is determined by the quality of the cane supply and the standard
of hygiene within the factory; and
• the processes, process equipment and the standard of control at each stage of the juice
processing circuit from the milling tandem to the clarification station.

A schematic of the SRI clarification system is shown in figure 1.1. It is based on adding
lime saccharate to preheated juice, secondary heating to 102-104ºC, deaeration in an
atmospheric flash tank and separation of the precipitated impurities in a SRI clarifier. The
essential control loops are:

• juice flow control from the primary mixed juice tank;

• primary and secondary temperature control at the heaters;
• pH control;
• level control in the flash tank; and
• flocculant addition control.
2 Confidential E.I.D. Parry Ltd

JUICE LIC
SCREEN

2 1
FLASH
TANK
FLOCCULANT ADDITION

PRIMARY SACCHARATE
HEATERS SYRUP MILK OF LIME SRI
CLARIFIER CLEAR
JUICE

SECONDARY
HEATERS
FLOCCULANT

MIXING
SO2 FILTRATE
TANK

MIXED
JUICE DILUENT
pHC
TANK BUFFER STOCK
TANK TANK
L F
L pH MUD
FILTER
JUICE WARM JUICE
PUMP JUICE PUMP F MUD
F
FIC RC
FIC
FILTRATE

Figure 1.1 Schematic of the standard SRI clarification system showing the juice
processing stages and important control loops.

1.1 Design data

The selection of a 8.5 m clarifier and associated equipment was designed to satisfy the
following conditions nominated by E.I.D. Parry Ltd for Nellikuppam factory:
Average crushing rate 6000 tcd /22 h increasing to 7500 tcd /22h
before 2010
Raw juice 105 % on cane
Filtrate 15 % on cane
Mixed juice flow up to 410 t/h

1.2 Confidentiality of intellectual property

The intellectual property inherent in this and associated documents is owned by Sugar
Research Limited and must be protected in accordance with the terms agreed to in SRI
proposal COMD-050646-RJS dated 28th November 2005. E.I.D. Parry and Nellikuppam
staff must take all appropriate steps to protect SRI’s intellectual property. Tender
documents must include the confidentiality requirements contained in the proposal.
 Confidential E.I.D. Parry Ltd 3

2. Specification - 8.5 m diameter clarifier

2.1 General

The design of the 8.5 m diameter clarifier is based on the concepts that incorporate the New
Generation SRI Clarifier technology.

2.2 Clarifier

A full list of drawings relating to this specification is included in Appendix A.

2.3 Clarifier body

Dimensions of the body shell are given in table 2.1 and shown on drawings NKP-12-00-00,
NKP-12-05-00 and NKP-12-05-01.

Table 2.1 Basic dimensions for the 8.5 m clarifier vessel.

Item Description Dimension Value (mm)

Body Shell Diameter 8 500
Body Shell Depth 4 000
Mud cone Diameter 2 150
Inlet Pipe Diameter 450
Juice outlet pipe NB 350
Mud Outlet Pipe NB 150

The vessel walls, floor cone and mud cone must be covered externally with an appropriate
insulating material and outer protective sheeting. No insulation for the roof is required.

The ideal installation is one where the saccharate and flocculant systems are conveniently
located close to the clarifier so that the operator can access all the associated equipment and
the inspection windows on the clarifier from the same floor. Two recent installations are
shown in figures 2.1 and 2.2.
 4 Confidential E.I.D. Parry Ltd

Flash tank

Flocculant
SRI clarifier
mixing tank

Flocculant
stock tank

Figure 2.1 Recent new generation SRI clarifier installation in Brazil.

Flash tank

SRI clarifier

Flocculant
tanks

Figure 2.2 Recent new generation SRI clarifier installation in Australia.

 Confidential E.I.D. Parry Ltd 5

The clarifier should be equipped with sight glasses (complete with water wash facilities)
extending upward from the bottom of the wall to the bottom of the feedwell.

These sight glasses should project outwards from the wall to ensure that there is nothing
protruding into the clarifier that could represent potential snag sites for the rotating scraper
arrangement. During operation the mud/juice interface should be controlled to a level
approximately 200-300 mm from the bottom of the wall by adjusting the mud outflow rate.
The sight glasses are usually arranged so that the windows overlap although this is not
essential. The inspection windows are usually located adjacent to the access opening and
the liquidation pipes as illustrated in figure 2.3.

The window material must be rated to withstand 100ºC. The maximum pressure is about
40 kPag.

Easy access is each part of the clarifier and peripheral equipment is essential. The sites
where easy access is required for operation and maintenance is illustrated in figure 2.4. The
diagram is the arrangement selected at one factory. Although each factory has its own
location issues that may impact on the layout, the general principles for layout and access
are the same.

Wash water nozzles are required for each window. The internal pipes must be mounted
close to the wall. Individual valves are fitted on the outside of the clarifier. The nozzles
should be mounted so that the end of the nozzles are not more than about 40 mm from the
inside surface of the glass and should project the water down towards the glass at an angle
of about 45º. A typical wash water system is pictured in figure 2.5.
6 Confidential E.I.D. Parry Ltd

Figure 2.3 Photo of inspection windows and access door. Liquidation valves are
located just to the right of the photographed section.
(Note the large door for easy access to the inside of the clarifier and
individual valves on each water pipe)
 Confidential E.I.D. Parry Ltd 7

Figure 2.4 Illustration showing the sites requiring easy access for operation and
maintenance.
8 Confidential E.I.D. Parry Ltd

Note: water
wash pipes to
each window.

Valves are on
the outside.

Figure 2.5 Photograph of the recommended wash water system arrangement taken
inside the clarifier.

A liquidation pipe manifold and valves (150 NB) should be installed on the side wall of the
clarifier as shown in drawings NKP-12-05-00 and NKP-12-05-01. The valves should be
located close to the clarifier wall to minimise the potential for accumulation of mud in the
pipe stubs. The pipe manifold can be connected to the clear juice pipe to allow full or
partial liquidation of the juice in the clarifier to the clear juice tank.

An access door on the side of the clarifier (see drawings NKP-12-05-01 and NKP-12-05-
04) should be located near to the sight glasses and liquidation valves for convenience and to
limit the requirements for staging (see figure 2.3). There must be access to the roof to
allow inspections through the hatches on the roof of the vessel and for maintenance of the
drive system. A handrail protection system is required around the perimeter of the roof.

It is recommended that a vent pipe of 400 NB (see drawing NKP-12-05-03) and not less
than 3 m high is fitted to the roof of the clarifier near the drive system.
 Confidential E.I.D. Parry Ltd 9

A number of inspection hatches are required in the roof above the feed and clear juice
channels. Details of the inspection hatches are provided in drawings NKP-12-05-05. The
hatches will allow inspection of the clear juice, sampling of both feed and clarified juice, as
well as providing access to clean the feed channel, and perforated plates.

The roof is designed to allow unrestricted runoff of rainwater without any accumulation
behind structural support steelwork. The structural framework supporting the roof should
be kept external to minimise the corrosion effects that exist inside the body of the clarifier.

The support structure for the drive will depend on the selected drive system and this is
noted on drawing NKP-12-05-00 and NKP-12-05-02. See section 2.7 for more details on
the drive system.

2.4 Juice feed system

The feed system comprises of a single feed pipe into a feed chamber, which splits the flow
both ways into an annular feed channel. The feed channel is equipped with a perforated
sloping floor built into the top of the feedwell. Juice flowing in the feed channel enters the
feedwell through the perforations in the floor separating the feed channel and the feedwell
sections. A multiple deflector system then directs the flow of juice across the cross-section
of the clarifier. Details of the proposed feed system are shown in drawings NKP-12-06-01
and NKP-12-07-00. The main dimensions of the feed system are listed in table 2.2.

Table 2.2 Dimensions of the feed system.

Item description Dimension Value

Feed pipe Diameter 450 mm
Length (minimum) 2 000 mm
Feed chamber Breadth 900 mm
Width (level with feed channel wall) 450 mm
Height 1 500 mm
Feed channel PCD 5 430 mm
Width 300 mm
Depth (maximum) 700 mm
Depth (minimum) 300 mm
Feed holes Number of holes 231
Diameter 30 mm
Feedwell PCD 5 430 mm
Width 300 mm
Depth (including feed channel) 1 450 mm
Bottom deflector Width 450 mm
Partial deflectors (2 off) Width (each) 140 mm

The feed system should be constructed in 3CR12 or 304 stainless steel to minimise the
effects of corrosion.
 10 Confidential E.I.D. Parry Ltd

2.4.1 Feed pipe and feed chamber

The feed pipe shall be a minimum straight length of 2.0 m and shall be aligned exactly with
the radial direction of the clarifier so that the juice flow into the feed chamber is
perpendicular to the inner wall of the feed chamber.

A drain shall be fitted to the bottom floor of the feed chamber. During normal
operation this drain must remain closed.

The usual arrangement for the drain is a tapered plug with guides and an extended handle
through the roof of the clarifier as shown in figure 2.6 and NKP-12-07-02. In previous
installations a hook has been manufactured to support the handle while the plug is raised.
This type of mechanism gives the operator a visual indication of the status of the drain.

An inspection hatch is required in the roof above the feed chamber. This will facilitate
inspection of the flocculation being achieved and allow samples to be collected from the
feed chamber if required. If the hatch cover is composed of two halves then the flocculant
distributor can be mounted on a central bracket in the middle of the hatch opening. This
arrangement is illustrated in figures 2.7 and 2.8 and drawing NKP-12-05-05. The opening
must be wide enough to allow the flocculant distributor to be withdrawn easily.

Floor of feed
Channel
Flocculant
distributor

Feed pipe Drain plug

Figure 2.6 Photograph of a typical feed chamber viewed from above.

 Confidential E.I.D. Parry Ltd 11

Flexible hose for

flocculant
Each cover slides
and lifts away

Handle for drain

plug in bottom of
feed chamber

Figure 2.7 Photograph of the recommended arrangement to support the flocculant

distributor.

Slot clearance Bracket holds

should allow flocculant
easy removal distributor in place

Figure 2.8 Photograph of the flocculant distributor held in place by the support
arrangement.
12 Confidential E.I.D. Parry Ltd

2.4.2 Flocculant distributor

The flocculant distributor should be located approximately 50-150 mm above the top edge
of the wall below the opening in the feed channel wall and offset from the opening by about
150 mm. This is usually the best location for the distributor tee to ensure maximum contact
between the juice and flocculant and for best flocculation performance. Do not allow the
distributor to shift into the feed channel where it could snag the sand scraper.

The flocculant distributor should be fabricated from stainless steel tube or an alternative
thin walled pipe to minimise the weight of the distributor. The holes in the T-section shall
direct the flocculant horizontally in both directions. The position of the distributor should
be adjustable to enable the optimum location to be determined during commissioning.

The distributor should be easily removed for inspection and cleaning as required.
Screwed ends on the flocculant distributor and a long flexible hose to connect the
flocculant supply to the distributor will enable easier cleaning.

Additional details of the flocculant distributor and supports are provided in drawings NKP-
12-05-03, NKP-12-05-05 and NKP-12-07-02.

2.4.3 Feed channel and feedwell

The sloping floor of the feed channel has a total of 231 holes of 30 mm diameter of
increasing density from the feed chamber to the shallow section of the channel opposite the
feed chamber. Distribution of the holes is shown in drawing NKP-12-06-01.

The holes should be either drilled, punched or laser cut. Any of the methods are
suitable provided that the finished hole is smooth and produces square edges at the
entrance and exit.

The number of holes in the feed channel has been designed for a flow rate of 410 tonnes per
hour of juice.

The nominal juice level in the feed channel will vary along the length of the feed channel.
The operating juice level at the entrance to the feed channel should be about 235 mm below
the top of the feedwell walls at the design rate 410 tonnes per hour (average) of juice.

Two sand slots are included in the floor of the feed channel to allow sand and other settled
insolubles to pass directly to the feedwell. They are set at an angle of 30 degrees to the
feed channel as illustrated in drawing NKP-12-06-01. They must not exceed 20 mm in
width.

Two scrapers and support arms shall be provided to scrape the floor of the feed channel.
 Confidential E.I.D. Parry Ltd 13

The scraper attachments shall be arranged so that full contact is maintained

between the full length of the edge of the scraper blade and the floor of the channel at
all times.

All welded joints on surfaces that are scraped shall be ground smooth to eliminate
potential snag sites.

The feed channel scrapers shall be fitted with extended arms that allow vertical movement
within the variable depth channel. The bottom edges of the scrapers could be fitted with
nylon wear strips. The wear strips must be capable of withstanding 100oC juice throughout
their operating life. The length of the scraper support arms will need to be limited to avoid
hitting the flocculant distributor.

2.4.4 Deflectors

The multiple deflector arrangement consists of two narrow deflectors, each 140 mm wide
and positioned 200 mm below the bottom of the feedwell, plus a 450 mm wide main
deflector positioned 450 mm below the bottom of the feedwell. The three deflectors will
require stiffeners on the underside to ensure they do not sag, twist or distort. These
supports are illustrated in figure 2.9 and in drawing NKP-12-07-03. Scrapers shall be
provided to scrape the full width of each deflector. The deflector scrapers and hangers are
detailed in drawing NKP-12-09-03.

Deflector plates
Bottom of
feed well

Ribs on underside
to stiffen the
deflector plates
Hanger

Figure 2.9 Photograph of the support stiffeners for the deflector plates.
14 Confidential E.I.D. Parry Ltd

2.5 Clear juice collection system

The clear juice collection system comprises perforated plates which cover the maximum
cross-sectional area inside the clarifier and two clear juice channels to collect the overflow
clear juice for forward processing. The clear juice collection system has been designed to
allow 100 mm of juice to sit above the plate during normal operation.

Details of the clear juice removal system are shown in drawings NKP-12-06-00, NKP-12-
06-01 and NKP-12-07-00 to NKP-12-07-02. Dimensions of the main components are
given in table 2.3.

Table 2.3 The main dimensions of the clear juice removal system.

Item description Dimension Value

Inner perforated plate Inside diameter 760 mm
Outside diameter* 3 474 mm
Number of 12 mm dia holes 255
Middle perforated plate Inside diameter* 3 806 mm
Outside diameter* 5 114 mm
Number of 12 mm dia holes 251
Outer perforated plate Inside diameter* 6 111 mm
Outside diameter 8 444 mm
Number of 12 mm dia holes 760
Inner CJ channel PCD 3 640 mm
Width (inside) 150 mm
Depth (minimum) 200 mm
Depth (maximum) 450 mm
Outer CJ channel PCD 5 920 mm
Width (inside) 175 mm
Depth (minimum) 200 mm
Depth (maximum) 550 mm
*
Note: This is an approximate dimension assuming 6 mm plate.

The perforated plate and juice channels should be constructed in 3CR12 or other suitable
stainless steel to minimise the effects of corrosion.

The perforated plate shall be positioned 370 mm below the top of the feed channel and 770
mm below the top of the clarifier wall. The hole layout should provide for a uniform hole
density across each plate section. There is a vertical baffle around the outside of the outer
plate. This baffle has a nominal 20 mm gap to to the clarifier wall. This allows for
variations in the ‘roundness’ of the clarifier shell. There should be no holes within 50 mm
of the clear juice channels and no holes within 25 mm of the vertical baffles near the outer
clarifier wall and around the shaft. A number of 10 mm diameter holes should be
positioned in the vertical baffle both near the outer clarifier wall and around the shaft.
These holes will ensure that clear juice does not stagnate but slowly circulate through the
space without interfering with the intended flow path of the bulk of the juice.
 Confidential E.I.D. Parry Ltd 15

The number of holes for each plate specified in table 2.3 is the optimum for the
design flow rate. When fabricated, the final number of holes in each plate must be
within ±1% of the specified number.

The hole pattern is based on an equilateral triangle with the side dimension as shown in
NKP-12-06-01. When laying out the hole pattern for fabrication, the centre of the clarifier
should be used as the origin.

Adequate support shall be provided to ensure that the clear juice channels and the
perforated plates can never move. The usual support arrangement is illustrated in figures
2.10 and 2.11 and in drawing NKP-12-07-03.

The height from the plate to the overflow edges of the clear juice channels determines the
operating height of juice that exists above the plate. The inner and outer overflow edges of
each clear juice channel are to be trimmed on site after hydraulic level tests once the plates
and channels are fixed in position. There is no requirement for the perforated plates to be
perfectly horizontal. However, they should be flat to allow the scrapers to maintain full
length contact with the plates.

The critical feature of the design is the uniformity of the overflow edge of each
wall of the clear juice channel. The variation along each edge shall not exceed ±1 mm.
During the hydraulic test, the water should overflow each edge uniformly along the
full length of each edge.

The perforated plate shall be attached to the walls of the clear juice channels as well as to
the inner wall of the feedwell. The seal should be sufficient to prevent juice bypassing the
perforated plate. Separate baffles are attached to the inner plate adjacent to the main shaft
and to the outer edge of the outer plate adjacent to the wall of the clarifier. These measures
will ensure that all juice passes through the perforated plate.

All burrs at hole edges are to be removed to ensure smooth top and bottom plate
surfaces. The insides of the holes must also be free of burrs.
 16 Confidential E.I.D. Parry Ltd

Outer clear
juice plate

Support for
outer clear
juice channel

Radial
support

Wall of
clarifier

Figure 2.10 Photograph of a suitable support plate for the outer section between the
clarifier vessel and the outer wall of the feedwell.

Inner
supports

Note support
Clear juice
Inner wall of across full width
pipe
feed well of channel

Figure 2.11 Typical support for the inner clear juice channel. Note the extension
pieces to support the full width of the channel floor.
 Confidential E.I.D. Parry Ltd 17

The deepest section of the clear juice channels and the exit pipe for the clear juice pipe are
shown at 90º to the feed inlet (see drawing NKP-12-07-00). The clear juice channels and
pipe can be rotated to suit the site arrangements. The clear juice pipe should be positioned
so that it does not interfere with the feed channel floor and does not extend below the
bottom edge of the feedwell.

The best indication of clarification performance is turbidity of the clear juice. Installation
of a turbidity meter is recommended.

2.6 Scraper arrangements

The following scrapers, which are detailed in drawings NKP-12-09-00 to NKP-12-09-05

are required to be fitted:

Description No. required

Floor mud scraper arms (off main shaft) 4
Pivoted floor mud scrapers 16
Mud boot wall scrapers 2
Scrapers for deflector plates 4
Sand scrapers for feed channel 2
Inner clear juice plate scrapers 2
Middle clear juice plate scrapers 2

Below the normal operating level of juice there should be no flat horizontal surfaces that
are not scraped.

2.6.1 Floor mud scraper

The scraper arrangement for the floor cone has been designed to provide four blades on
each arm, each of approximately 875 mm nominal length as illustrated in drawings NKP-
12-09-00 and NKP-12-09-04. This length will need to be verified once the method of
attachment to the support arms has been determined.

There should be a nominal 150 to 200 mm overlap of the scraped path between
the leading and trailing ends of following scrapers. The trailing ends of the two inner
scrapers should overlap the mud cone by 50 to 100 mm.

The outer scrapers (labelled A in drawing NKP-12-09-00) should have a nominal clearance
to the side wall of 25-40 mm. This should apply for any position of swing of the blade.
The blade thickness has been nominated as 16 mm.

To simplify installation of the floor scrapers, the following procedure is recommended. It

involves in situ assembly of individual components, working from the scrapers back to the
fixed lugs on the support arms.
18 Confidential E.I.D. Parry Ltd

Scribe out sufficient of the concentric annuli traced out by the leading and trailing
edges of each blade to enable the blades to be tack welded to the cone in the correct
location under the appropriate arm. The angle between the blade and the arm
should be 50°. Also, the blade should hang back at about 10-15° to the vertical.

The hangers can be cut to the correct length and attached. Finally, the lugs on the
main arm are attached. The line joining the pivot points on each blade should be
parallel to the cone bottom. Stainless steel bolts and nuts are recommended for
attaching the hangers to the lugs. The edges of some scrapers trimmed to suit the
profile of the floor cone.

Arms should extend from the main support arms at appropriate angles to allow the blades to
form an angle of 50º with the radial direction. These arms should be fabricated from square
hollow section and the ends blanked. The scraper blades should also hang back at an angle
of 10-15º to the vertical. The bottom edges of the scrapers should also be fitted with nylon
wear strips. The wear strips must be capable of withstanding 100oC juice throughout their
operating life. Typical mounting supports for the mud scrapers are illustrated in
figure 2.12.

It should be noted that the blades should be hung under the arms to achieve satisfactory
coverage of the cone surface. The coverage falls off as the scraper is hung behind the arm
and in this position it may not be possible to achieve any overlap on the trailing edge of the
inner scrapers.

The blades must be allowed to swing up and away from the floor cone during
periods when the mud density is high.

The two outer scrapers (labelled A in drawing NKP-12-09-00) require a different hanging
arrangement to enable them to lift clear of the body wall and avoid catching on any surfaces
protruding from the wall. The following procedure is recommended.

Scribe out sufficient of the concentric circles traced out by the trailing edge of each
blade. Tack weld each blade to the floor cone at 50° to the main arm. Allow the
25-40 mm clearance between the leading edge of the blade and the wall and
sufficient overlap on the trailing edge. Ensure that the leading edge of the blade is
located behind the centre line of the main arm. The blades should be hung back at
10-15° to the vertical plane.

Attach two short lugs to the main arm. The lugs should be parallel. The centre line
of pivot points is 130 mm below the centre of the arm and parallel to the cone. The
hangers can be measured and cut. Using stainless steel bolts and nuts, bolt the
hangers firmly to the lugs and swing out to contact the blade. The hangers can be
welded to the blades. Some bending of the ends of the hangers is required to
facilitate attachment. Cross-bracing of the hangers may be desirable. The leading
edges of the scrapers should be trimmed to suit the floor cone profile.
 Confidential E.I.D. Parry Ltd 19

Note wear strip

on bottom of
mild steel blades

Figure 2.12 Typical mounting supports for the mud scrapers.

The preferred arrangement for the outer scraper is illustrated in figure 2.13. This
arrangement has the pivot axis parallel to the shaft so that the blade will swing parallel to
the wall. Other methods for attaching the mud scrapers are illustrated in figures B.3 and
B.4 in Appendix B.

Outer scrapers

Figure 2.13 Preferred support for the outer mud scrapers.

20 Confidential E.I.D. Parry Ltd

Some mills have fitted chains to the back of the floor scrapers to prevent them from
swinging forward and potentially jamming onto the floor cone as they try to swing back.
The other end of each chain is attached to the scraper arms at convenient locations (see
figure 2.14).

Figure 2.14 Photograph showing how chains are used to limit the forward
movement of the floor scrapers.
 Confidential E.I.D. Parry Ltd 21

2.6.2 Deflector scrapers

Two scrapers are required for each deflector. Details are provided in drawing NKP-12-09-
03. The ends of the scrapers should not contact the support plates holding the deflectors.

2.6.3 Perforated plate scrapers

Scrapers are required for the inner and middle perforated plates. Details are provided in
drawing NKP-12-09-01. These should only be light weight as the purpose is to keep in
suspension any mud particles that pass through the perforated plates. This will prevent any
accumulation on the top of the plates.

It is not possible to provide similar scrapers for the outer perforated plate.

If there is any unevenness in the plate surfaces, chains should be used to scrap the plates.

2.7 Drive

The scraper arrangement should rotate at four revolutions per hour (4 r/h).

The drive mechanism should include a shear pin or other shear or torque limiting device to
prevent damage being sustained by the scraping equipment in the unlikely event of
restricted scraper system movement. The drag forces imposed on the scraper system are
negligible. The risk is that part of the scraper equipment will snag on an edge or projection
inside the clarifier causing damage. It is usual to limit the drive torque to be less than what
can be safely accommodated by the 250 NB shaft carrying the scrapers.

The current trend is to use a Brevini or Sumitomo gear drive. Illustrations are provided in
figure 2.15.
22 Confidential E.I.D. Parry Ltd

Figure 2.15 Photographs of two installations using modern drive systems. The
motors are typically less than 0.5 kW.
 Confidential E.I.D. Parry Ltd 23

3. Flash tank
The purpose of the flash tank is to take juice at 102–105oC (normally 103oC) and flash the
juice back to 100oC to expel the air, which would otherwise prevent the insoluble solids
from settling when the juice is transferred to the clarifier. Poor air removal will cause
insoluble solids, particularly fibre, to float to the surface in the clarifier and carryover with
the clear juice. The result will be processing difficulties and lower quality sugar.

Successful operation of the SRI clarifier depends on the feed being properly deaerated in
the flash tank. It is essential that there is no excessive freefall of the juice either in the flash
tank or in the feed piping to the clarifier and there should be no opportunity to entrain air
into the juice feed.

The recommended arrangement is to position the flash tank at a higher level than
the clarifier and control the flow to the clarifier using a level control loop on the flash
tank with the controller output manipulating a valve on the juice feed pipe just prior
to the expansion to the 450 NB pipe into the feed chamber of the clarifier.

For ideal operation, the operating level of the juice in the flash tank must be
maintained at a point within 20 mm below the splash plate. The level sensor (usually
a differential pressure transducer) should be flush mounted onto the bottom cone
about 500 mm above the pipe connection. There should be no pipe section where sand
or mud can build up inside the pipe and disrupt the level measurement (see figure B.5
of Appendix B). The arrangement of the flash tank and feed to the clarifier is
illustrated in figure 3.1.

The cone of the flash tank should be positioned at the minimum height above the clarifier
that will allow a short 150-200 mm piece of pipe plus a 90° bend and the appropriate length
of horizontal feed pipe to the clarifier.

Details of the flash tank are given in drawings NKP-12-13-00 to NKP-12-13-05a and the
basic dimensions are given in table 3.1.

Table 3.1 Basic dimensions for flash tank.

Item description Dimension Value

Body shell Diameter 3 600 mm
Body shell Depth 1 800 mm
Bottom cone Angle 45o
Feed pipe NB 250
Orifice (6000 tcd) ID 183 mm
Orifice (≥7000 tcd) ID 198 mm
Splash plate Diameter 1 200 mm
Outlet pipe NB 300
24 Confidential E.I.D. Parry Ltd

The splash plate should be constructed from stainless steel, 3CR12 or other suitable hard
wearing material.

Keep this
section short

Figure 3.1 Arrangement of the flash tank and connection to the clarifier showing
the location for the control valve.

The juice pipe from the flash tank to the clarifier must include a drain line, (not shown in
figure 3.1).

The 250 NB feed pipe should extend from the final heaters to the flash tank. There should
not be any expansion or reduction in the pipe size or installation of pipe fittings (such as
magnetic flow meters or valves) that would create a pressure drop and encourage partial
flashing of the juice before entering the flash tank. An orifice plate with an internal
diameter of 183 mm is added to the end of the feed pipe in the flash tank initially. When
the crushing rate approaches 7000 tcd, the orifice should be increased to 198 mm (see
drawings NKP-12-13-04 and NKP-12-13-05).

A safety overflow pipe is required in the flash tank at not lower than 300 mm above the
nominal operating level. The actual location will depend on site details and the need to
reclaim any juice overflow. The load limits of the supporting structure must allow for the
extra volume of juice.
 Confidential E.I.D. Parry Ltd 25

4. Juice flow control

It is most important to maintain good juice flow control. The concepts discussed here apply
equally to the mixed juice tank prior to the juice heaters and to any intermediate buffer
tank. A steady flow of juice will provide significant benefits for downstream processes
including pH control, juice heating and temperature control, flash tank operation, flow
control to the clarifier and regulation of flocculant addition to the clarifier feed. In
particular, good performance of the clarifier depends on a steady flow of juice. Sudden
variations in feed rate can disrupt the settling trajectories of the mud flocs. Short term
variations of more than 4% per minute should be eliminated.

The basic scheme to achieve juice flow control is illustrated in figure 4.1. The essential
components are a buffer tank to provide a maximum capacity of about 8-10 minutes of
juice production, a level transmitter fitted to the buffer tank, a flow controller, a juice pump
fitted with a variable frequency drive and a flow meter to monitor the juice flow. This juice
flow signal can also be used as input to a ratio controller to regulate the rate of flocculant
addition to the juice feed to the clarifier.

The incoming feed flow should be directed tangential to the buffer tank. The location of the
feed pipe should be at a position approximately 50-60% of the tank wall height.

Although the level in the buffer tank is being measured, the objective is not to control the
juice level in the tank to a narrow range of operation. The juice level in the tank must be
allowed to vary to absorb the variations in juice flow from the milling tandem. At a
controlled pumping rate from the tank, changes in the juice inflow will be reflected as level
changes in the tank. The control action on the flow controller should slowly modulate the
pumping rate to prevent the tank from over-flowing or emptying.

The types of control action that provide the desired insensitive control include a wide
proportional band and gap action control. An appropriate controller response to changes in
tank level is illustrated in figure 4.2.

An alternative scheme to achieve juice flow control is illustrated in figure 4.3. This scheme
allows for a portion of the juice to be recycled back to the buffer tank and allows a fixed
flow rate of juice to proceed to the juice heaters. However this scheme assumes that the
variation in inflow is small.
26 Confidential E.I.D. Parry Ltd

Figure 4.1 Proposed scheme for juice flow control.

100
OUTPUT SIGNAL FROM CONTROLLER(%)

80

60

40

20

0
0 20 40 60 80 100
BUFFER TANK LEVEL (%)

Figure 4.2 Schematic of the recommended controller action to achieve juice flow
control.
 Confidential E.I.D. Parry Ltd 27

Figure 4.3 Alternative juice flow control scheme using a recycle loop of juice back to
the buffer tank.
28 Confidential E.I.D. Parry Ltd

5. pH control
For good clarification performance and downstream factory efficiency, tight control of the
pH of the juice is essential. Achieving good pH control depends on the processes leading
up to the addition of lime or saccharate, as much as the control of the addition of the lime or
saccharate to achieve and maintain the pH set point. Good pH control and a high standard
of clarification require that the following conditions apply:
• Consistent flow and temperature of the juice at the point where the lime is added;
• Use of saccharate to control the juice pH rather than milk of lime;
• Addition of saccharate to juice at 70-80°C rather than to cold or hot juice;
• A pH set point that will provide the clearest juice (usually in the range 7.5-7.8 for non-
sulphited juice and 7.2-7.4 for sulphited juice);
• Immediate and effective mixing of the saccharate into the juice at the addition point;
and
• A short delay time between when the saccharate is added and where the pH
measurement of the juice is made.

The proposed system is illustrated in figure 5.1. The preferred dosing point would be
between the primary and secondary heaters.

Figure 5.1 Proposed arrangement for pH control.

 Confidential E.I.D. Parry Ltd 29

To obtain ideal pH control it is essential that the variables to be controlled are limited as far
as possible to the variation in lime demand only. Process variables that could adversely
impact on the standard of pH control include:
• Juice flow rate;
• Juice temperature;
• Milk of lime strength; and
• Proportion of syrup in the saccharate.

Although it is not possible to completely eliminate fluctuations in juice flow and saccharate
concentration, the degree to which the ideal condition can be approached largely determines
the effectiveness of pH control.

5.1 Saccharate preparation

Two options are offered for saccharate preparation. They are:

a. The standard scheme involving two small header tanks and a mixing tank; and

b. An in-line mixing system that avoids buffer capacity to eliminate alkaline

degradation of reducing sugars to organic acids and colour compounds.

5.1.1 Standard scheme

The standard scheme for preparing saccharate is illustrated in figures 5.2 and 5.3. It is
based on supplying milk of lime and syrup in approximately equal quantities into a well-
mixed tank. It is proposed to install two constant head tanks, to be located above the
saccharate mixing tank.

A saccharate mixing tank of working volume of about 1.9 m3 is proposed, complete with
the following:

• A high efficiency mixer;

• Two level sensors set 200 mm apart or a single capacitance probe of suitable length;
and
• An ON/OFF controller to open the make-up valves to supply syrup and milk of lime
into the top of the draught tube in the mixing tank.

To simplify the arrangement to provide for equal volumes of milk of lime and syrup, it will
be necessary to maintain the concentration of the milk of lime to about 11 baumè. This
concentration should be based on the available calcium oxide in the lime and not on the
total amount of lime powder added in each batch.
30 Confidential E.I.D. Parry Ltd

Figure 5.2 Schematic of the standard arrangement for plant to prepare lime
saccharate.
 Confidential E.I.D. Parry Ltd 31

Surplus lime Lime Syrup

returned to
stock tank

Mixing
tank

Saccharate
pumps

Figure 5.3 Illustration of the standard arrangement for plant to prepare lime
saccharate.
32 Confidential E.I.D. Parry Ltd

The tank outlet to the dosing pump is located at the top of the conical bottom. A valve is
located at the base of the cone to drain settled solids at appropriate intervals. The mixing
tank should provide sufficient saccharate for five minutes of operation.

The level sensors can be either contactless conductivity/capacitance probes or float

switches.

A guaranteed supply of syrup is required. Each head tank should hold a minimum of
0.2 m3 of milk of lime or syrup. This will ensure that sufficient volume is available each
time the make-up valves open. The pipes feeding the draught tube should be sufficiently
large to allow the fill volume to drain into the mixing tank within 30 seconds.

The pipe supplying milk of lime to the head tank should extend to within 50 mm of the
bottom of the tank. This will assist to keep the undissolved lime in suspension.

An overflow pipe of 50 NB is required on the mixing tank to direct excess liquid and froth
into a drain.

The pump should be a positive displacement type with a variable frequency input to
achieve variable speed. A number of factories are using a Bredel Hose Pump for this duty.
However, a progressing cavity pump (see figure 5.5) may also be used.

5.1.2 In-line mixing system

The system is illustrated in figure 5.4 and is based on the following characteristics:

• Positive displacement pumps of similar capacity fitted with variable frequency drives
supplying milk of lime and evaporator syrup to an in-line static mixer;

• A mixing column; and

• An additional control loop to ratio the syrup supply to the milk of lime flow.

Flow meters could be added to each flow stream but they are not essential.

Duplication of the pumps is recommended. Figure 5.5 illustrates an installation using

progressing cavity pumps for each flow stream and a mixing column is shown in figure 5.6.
A suitable static mixer element is shown in figure 5.7. Guaranteed supplies of milk of lime
and syrup are required.

5.2 Saccharate injection and pH control

The saccharate should be injected into the juice pipe within 1.0 m of the inlet of the pump.
The injection pipe should reach to the centre line of the juice pipe as illustrated in
figure 5.8.
 Confidential E.I.D. Parry Ltd 33

Figure 5.4 In-line mixing system.

Milk of
lime
supply

Syrup
supply

Figure 5.5 Installation using progressing cavity pumps for each flow stream.
 34 Confidential E.I.D. Parry Ltd

Mixing column

Inlet

pH electrode
for limed
mixed juice

Saccharate
sample line

Outlet

Figure 5.6 A mixing column installed as part of the in-line saccharate preparation
system.
 Confidential E.I.D. Parry Ltd 35

Figure 5.7 A suitable static mixer element.

Figure 5.8 Recommended arrangement for saccharate injection into the juice.

The sample line to the pH electrode pot must be short to ensure a fast response. The
maximum response time of the control loop should be no greater than 15 seconds. The
sample line should draw off limed juice from the juice pipe between the juice pump and the
heaters. An example of an electrode pot is given in figure 5.9. The final dimensions of the
pot will depend on the type of electrode holder in use.

There should be no restrictions to flow in the sample line from the juice pipe to the pH
electrode pot. This requires the use of long radius bends and full bore ball valves. It is
suggested that the sample line be DN15 pipe.
36 Confidential E.I.D. Parry Ltd

Figure 5.9 Details of a typical electrode pot for pH measurement of the limed juice.

5.3 Miscellaneous

Other issues that should be considered include:

• An alternative source for syrup should be included for use during mill start-up periods.
The usual alternative source is the syrup storage tank on the pan stage. Other options
include using clarified juice or straight milk of lime until syrup becomes available. If
milk of lime is used then it will be necessary to reduce the pH set point to allow for the
slower response time in dissolving the lime into the juice.
• The supply piping and valves used for the milk of lime should be sized to ensure that
undissolved solids remain in suspension and are not allowed to settle or accumulate in
the pipes. This will require a flow velocity of greater than 1.3 m/s.
• Polythene or PVC pipes could be used for the milk of lime circuits. This would allow
them to be replaced at appropriate intervals at little cost when the build up of lime scale
inside the pipes restrict flow.

Do not oversize the pumps. Tight pH control becomes very difficult if pumps with
excess capacity are used.
 Confidential E.I.D. Parry Ltd 37

5.4 Saccharate supply calculations

Cane rate 340 t/h (7,500 tcd /22h)

Lime consumption 0.2 % on cane
Available CaO in lime supply 67%
Concentration of milk of lime (MoL) 11 Bé
Syrup Purity 81
Brix 65
Density 1280 kg/m3

Milk of Lime flow rate 6.44 m3/h

Syrup flow rate 4.73 m3/h
Total saccharate flow rate 11.17 m3/h

Equipment design – Option 1 – Batch mixing

Mixing tank volume 1.9 m3
Header tank volumes 0.2 m3

Equipment design – Option 2 – In-line mixing

MoL pump duty (average) 6.44 m3/h
Syrup pump duty (average) 4.73 m3/h
Mixing column height 3.5 m
diameter 0.200 m
Centre feed tube diameter 0.051 m
38 Confidential E.I.D. Parry Ltd

6. Flocculant system
It is standard practice to construct the flocculant tanks in either stainless steel or suitable
plastic. This eliminates the potential contact between flocculant molecules and iron, which
can quickly degrade the flocculant. The tanks detailed in drawings NKP-12-14-00 and
NKP-12-15-00 are sized to provide at least 8 hours supply of 0.2% concentration to satisfy
a flocculant demand equivalent to 4 ppm on juice. It is expected that flocculant usage
should be lower at about 2-3 ppm and this means that each batch should be sufficient for a
longer period of time. Details of the expected flows are:

Design parameters:
Stock concentration: 0.2%
Batch supply time: Depends on juice rate
Diluted concentration at clarifier: 0.04%

Powder (per batch): 11.2 kg

Working volumes:
Mixing tank: 5.6 m3
Stock tank: 5.9 m3

Flow rates:
Juice 1.0 ppm 1.5 ppm 2.0 ppm 2.5 ppm 3.0 ppm
rate, Floc, Water, Floc, Water, Floc, Water, Floc, Water, Floc, Water,
m3/h L/h L/h L/h L/h L/h L/h L/h L/h L/h L/h
200 100 400 150 600 200 800 250 1000 300 1200
240 120 480 180 720 240 960 300 1200 360 1440
280 140 560 210 840 280 1120 350 1400 420 1680
320 160 640 240 960 320 1280 400 1600 480 1920
360 180 720 270 1080 360 1440 450 1800 540 2160
400 200 800 300 1200 400 1600 500 2000 600 2400

A schematic flow diagram highlighting the piping and valve arrangement for a flocculant
preparation and dosing system is shown in figure 6.1. The system consists of a mixing tank
located above a stock tank from which the flocculant solution is pumped via a variable
speed progressing cavity pump (e.g. Mono pump) to the clarifier. The top tank is fitted
with a powder disperser unit and a slow speed stirrer. No agitation is necessary for the
stock tank. There should be no dilution of the flocculant in the stock tank.

A minimum of four hours of mixing should be allowed before the flocculant solution is
dropped to the stock tank. A mixing time of two hours should be considered as the absolute
minimum mixing time and should only be adopted as an emergency procedure.

6.1 Water quality

The water supply used to prepare the flocculant solution must be:
 Confidential E.I.D. Parry Ltd 39

• good quality (cooled condensate is best);

• pH greater than 8 (adjust using caustic soda);
• low hardness; and
• less than 50ºC.

6.2 Disperser unit

It is essential that all the flocculant powder is wetted before reaching the water in the
mixing tank to prevent the formation of large lumps or 'oysters' of flocculant, which are
difficult to dissolve fully, and can block pipes and screens.

Suitable disperser units consist of a funnel hopper and a variable aperture arrangement
designed to ensure wetted individual particles of flocculant powder. Flocculant suppliers
can usually supply a suitable eductor that will wet the powder as it is feeding into the
mixing tank.

Figure 6.1 Schematic of the flocculant preparation and dosing system.

40 Confidential E.I.D. Parry Ltd

6.3 Flocculant tanks

The tanks should be constructed of plastic, 3CR12, 304 SS or other suitable stainless steel.
All pipelines carrying flocculant should preferably be stainless steel or polythene. The
recommended stirrer arrangement has two paddle arms attached to a 50 mm shaft. Each
paddle arm has four blades set at 45º and arranged so that flocculant solution is circulated
up the walls and down the centre of the tank. The recommended speed of the stirrer is 10-
15 r/min.

The mixing tank should be positioned so that the top of the tank is easily accessible to
operators. The mixing tank should be located directly above the stock tank. The flocculant
solution that is dropped to the stock tank should first pass through a removable sieve (see
figure 6.2) with an aperture of about 4 to 6 mm. The purpose is to remove any lumps of
undissolved flocculant and prevent blockages downstream, particularly in the flocculant
distributor.
 Confidential E.I.D. Parry Ltd 41

Removable
screen

Transfer
pipe from
mixing tank

Ultrasonic
level sensor

Figure 6.2 Illustration of the removable screen located in the top of the flocculant
stock tank.
42 Confidential E.I.D. Parry Ltd

6.4 Flocculant pump

The most suitable pump for flocculant is a progressing cavity pump operating at slow
speeds with a variable frequency drive. The Dresser Mono pump is used exclusively in
Australian factories. A second pump should be installed as a standby unit.

6.5 Automation

The system is automated by providing level sensors and valves as shown in figure 6.3.
Sequencing is arranged so that when the stock tank is empty as indicated by L4, the mixing
tank dumps flocculant to the stock tank via valve C. To ensure the mixing tank drains
completely, a timer should be included so that valve C remains open for about five minutes
after the level sensor indicates that the tank is empty. With an interlock to ensure that valve
C is closed, the tank then fills with water via valve B to L2, when the water supply valve
should close and a light in a convenient panel indicates that the system is ready for
flocculant to be added. The operator is required to start the water flow through the
disperser by opening valve A and then adding the correct weight of flocculant to the
hopper. L1 indicates when the tank is full and closes valve A.

Figure 6.3 General arrangement for automation of the flocculant make-up.

 Confidential E.I.D. Parry Ltd 43

The level L2 should be located so that the baffles are immersed in the water by about
25-50 mm when the water flow stops. Adequate depth should then be available so that the
flocculant can be added with a generous safety margin before the water level reaches
position L1.

A system involving single ultrasonic level sensors on each tank that are linked to a process
controller is the most economical arrangement to provide an automated fill/transfer
sequence.

6.6 Flocculant to juice ratio control

The flocculant flow rate is based on a pre-set ratio to the secondary juice flow rate. This
scheme enables a constant ratio of flocculant to juice to be maintained so that when the
juice flow increases with a corresponding increase in upflow juice velocity in the clarifier,
satisfactory settling rates can be maintained. Also, flocculant over-dosing under low flow
conditions is avoided.

The recommended flocculant control scheme is shown in figure 6.4. This involves
measurement of stock flocculant flow with a small bore magnetic flowmeter and
comparison with the signal from the flowmeter on the juice flow with a ratio controller.
The output from the controller should vary the speed of the progressing cavity pump
through a variable frequency drive.

TO CLARIFIER

Figure 6.4 Recommended flocculant/juice ratio control scheme.

44 Confidential E.I.D. Parry Ltd

Water should be used to dilute the flocculant to 0.03-0.05% before the flocculant is injected
into the clarifier feed. The amount of dilution water added to the flocculant flow can be set
manually for the average flocculant flow rate. A suitable design for an in-line mixer is
given in figure 6.5. A proprietary in-line mixer can be used provided that the shear rate
imposed on the flocculant solution is no greater than might be expected from the design in
figure 6.5.

Diluting the flocculant in the stock tank should be avoided as this can reduce the useful life
of the flocculant. This is particularly important if the water to be used for dilution is of
poor quality or has a pH below 8.0.

ELEVATION

VIEW A-A

Figure 6.5 In-line mixer to dilute the flocculant with water.

 Confidential E.I.D. Parry Ltd 45

7. Concluding comments
The following aspects need to be determined on-site prior to fabrication:

• The alignment of the feed and clear juice piping relative to the proposed flash tank
and ESJ tank.
• The location of the liquidation valves, sight glasses, access door and the provision
of walkways and platforms on the clarifier. This should also include the provision
of guard rails around the periphery of the roof of the clarifier.
• The positioning and orientation of the mud outlet pipe and mud drain pipe at the
bottom of the clarifier.
• The location of inspection hatches in the roof of the clarifier to allow access to the
feed chamber and channels as well as a system to prevent injuries associated with
lifting the hatch covers or sustaining superficial burns from the vapours released
when the hatch covers are removed.
46 Confidential E.I.D. Parry Ltd

Appendix A List of drawings

Confidential E.I.D. Parry Ltd 47
48 Confidential E.I.D. Parry Ltd
 Confidential E.I.D. Parry Ltd 49

Appendix B Additional photographs of clarifier installations.

50 Confidential E.I.D. Parry Ltd
 Confidential E.I.D. Parry Ltd 51

Perforated plate scrapers and roof support

Main shaft

Feed channel

Clear juice
channel

Figure B.1 Photograph showing the perforated plate scrapers.

52 Confidential E.I.D. Parry Ltd

Flocculant distributor
Two distributors are required. One is cleaned and ready for use while the other is being
used. The distributor should be easily removed from the clarifier for cleaning. Screwed
end caps are required on the ends.

Flexible hose
connection

Screwed
end caps

Figure B.2 Photograph of the flocculant distributor T-section and flexible hose
connection.
 Confidential E.I.D. Parry Ltd 53

Mounts for floor scrapers

Arms should extend from the main support arms at appropriate angles to allow the blades to
form an angle of 50º with the radial direction. These arms should be fabricated from square
hollow section. All tube sections should have blanked ends.

The scraper blades should also hang back at an angle of 10-15º to the vertical.

Deflector plates. Support arm for

deflector scrapers.

Main scraper
support arm.

Blanked ends.

Pivot and
Hanger.

Figure B.3 Photograph showing one method of mounting the mud scrapers.

Note: Avoid any flat horizontal surfaces where mud can accumulate.
54 Confidential E.I.D. Parry Ltd

Flat plate and pivots

hang vertically.

Note: Hangers lay back at

an angle of 10-15o.

Figure B.4 Photograph showing an alternative method of mounting the mud

scrapers.
 Confidential E.I.D. Parry Ltd 55

Flash tank
The level sensor should be mounted so that the diaphragm is flush with the cone. This will
prevent mud from building up on the surface or in a pipe between the cone and the
diaphragm.

If a pipe spacer and valve is used then water must be provided to flush the pipe at
intervals not exceeding 8 hours.

Cone of
Pressure flash tank
sensor

Figure B.5 Photograph showing location of dP sensor to measure level in the flash
tank.
56 Confidential E.I.D. Parry Ltd

Mud pipe

Manual valve. Control valve.

Water flush
Drain.
pipes.

Figure B.6 Photograph showing typical piping and instrumentation for mud
removal from the mud cone.