Control of the Crystallization Process in Batch Pans
The challenge
In sugar production, crystallization is one of the most critical stages: it defines both the quality of the product and the efficiency of the process. However, this phase depends on complex variables such as supersaturation, temperature, viscosity, and purity of the mother liquor.
Manual operation, even with experienced personnel, generated uncertainty, and a generational change was also looming with the arrival of younger but inexperienced staff. This posed risks to sugar quality, directly impacting the mill's productivity.
The solution
Advanced control system for sugar crystallization, based on supersaturation control and volumetric control of the tanks.
With the integration of tank #4, the final stage for advanced crystallization control in the sugar manufacturing area was completed. The integration of field instrumentation, industrial communication network, and advanced visualization platform was completed.
Components supplied:
- ControlLogix PAC controller.
- Remote panels for digital and analog I/O with Ethernet/IP interface..
- Brix, level, pressure, and temperature transmitters.
- Soft starter panels for motor control.
- Mixers
- FactoryTalk visualization platform with intuitive graphic displays for real-time operation and monitoring.
Engineering and execution services:
- Basic and detailed engineering (PI&D, electrical diagrams, panel and interlock design).
- PAC programming and control logic development.
- HMI and operator station design and configuration.
- Factory and site acceptance testing, calibration, and system commissioning.
- Training for operation and maintenance personnel.
The benefits
Maintain sugar quality and control over desired productivity with greater independence from staff experience.
- Advanced supersaturation control, ensuring uniform sugar quality.
- Increased productivity, with better grain size distribution and improved molasses exhaustion.
- Stable and reliable operation, reducing variability.
- Real-time information for quick and informed decision-making.
- Scalable and future-proof system, with modular architecture and redundant power supplies.
Impact on the plant
Increased productivity, quality, and efficiency of the crystallization process, less sugar recirculation, and reduced sucrose losses.
The modernization of the crystallization system allowed the sugar mill to increase productivity, improve performance, and ensure higher quality sugar in each batch. In addition, the operation went from being dependent on the operator's experience to an automated, standardized, and safe process.
2022 No.4 Batch PAN Control System