SYSTEM AND METHOD FOR MANUFACTURING JAGGERY

FIELD OF INVENTION

The present invention relates to a process for manufacturing of jaggery from sugar cane and the system involved therein. Particularly, the present invention is to improve the milling efficiency by providing a jaggery plant system with multiple cane handling machines, multiple rollers and other electrically/hand operated infrastructures. Specifically, the invention provides for large scale manufacturing of jaggery under the most hygienically controlled environment with no added chemicals, colours, additives and flavours. Moreover, the process for manufacturing of jaggery is fully mechanized and ensures high productivity. Advantageously, the process for manufacturing of jaggery ensures low air and sound pollution and no water pollution.

DESCRIPTION OF THE PRIOR ART

Jaggery is made from fresh sugar cane juice. It is a natural sweetener and contains Glucose, Minerals, Calcium, Vitamins, Iron, Phosphorous, Protein, Copper etc. Jaggery is a traditional accompaniment of Indian meal and is also used for preparation of various sweet dishes, instead of Sugar. Medicinal importance of jaggery is tremendous. Due to high nutritional value of the product, Ayurved has suggested jaggery as a supplement to daily food.

The traditional manufacturing is done in large pans in which all the processes like purification, heating and preparation of concentrate are done. They are less mechanized and require large manpower and also they have economic constraints. Since, jaggery making is done manually, it is more time consuming and tiresome work. Due to less heat dissipation, jaggery making becomes difficult in present days.

In the known process, the cane juice is evaporated in open pans and heated by brick furnace. An alternative available for this process is to concentrate the clarified juice into syrup and finally concentrated in vacuum pans in the presence of some chemicals like Phosphoric acid or HC1. Other existing mill designs are meant for treatment of crushed sugar cane juice on a metallic based pan and producing jaggery using multiple roller mills. The steps like loading of the juice, it's preheating, purification, boiling and concentrating the juice to obtain the jaggery are carried out in a sequential manner using gravitational force as a driving force. The concentration of the boiling juice is done by constant stirring to obtain thick concentrate which is then lifted manually over the platform or moulds to obtain the jaggery of the desired size and weights.

533/CHE/2008 disclosed an 'Automatic jaggery making machine' which increases the production rate of jaggery and decreases man power requirement. This process makes jaggery more hygienic.

767/BOM/1999 titled 'New improvements in jaggery manufacturing process and new product type of jaggery' relates to a method of improving extraction of sugarcane juice and the production of jaggery both qualitatively and quantitatively. The clarification of sugarcane juice is performed more effectively without using any hazardous chemicals.

1468/MUM/2005 titled 'Multi-roller type efficient mill design for cane sugar industry' boost up the milling efficiency to the great extent by combining five rollers in a single mill unit.

IN58395 titled 'An improved method of manufacturing jaggery continuously' relates to manufacturing of jaggery continuously of standard quality possessing improved sweetness and storage properties.

Thus it is clearly apparent from the above described cited art that there is no system which handles all the processes involved in the preparation of jaggery mechanically and economically in a single processing unit as of the present invention. The present invention avoids the problems/disadvantages noted above and overcome other problems encountered in conventional methods.

OBJECTS OF THE INVENTION

One or more of the problems of the conventional prior art may be overcome by various embodiments of the system and method of the present invention.

Accordingly it is the primary object of the present invention to provide a system and method for the manufacturing of high quality jaggery from sugar cane.

It is another object of the present invention to provide an improved extraction of sugar cane juice thereby improving the quality of sugarcane juice and the production of jaggery both qualitatively and quantitatively.

It is another object of the present invention, wherein the system for manufacturing of jaggery comprises:
cane milling plant;
juice clarification section;
filtration section;
boiling and crystallization section;
centrifugal station;
steam generating plant; and
power generating plant.

It is another object of the present invention to provide a method for manufacturing of jaggery which is economical.

It is another object of the present invention to provide a method for manufacturing of jaggery which requires less manpower.

It is another object of the present invention to provide a method for manufacturing of jaggery which is fully mechanized.

It is another object of the present invention to provide a method for manufacturing of jaggery which ensures low air and sound pollution.

It is another object of the present invention to provide a method for manufacturing of jaggery which ensures no water pollution.

It is another object of the present invention to provide a method for manufacturing of jaggery which ensures low maintenance.

It is another object of the present invention to provide a method for manufacturing of jaggery which ensures high productivity.

SUMMARY OF THE INVENTION

Thus according to the basic aspect of the present invention there is provided a system for manufacturing jaggery from sugar cane comprising:
one or more cane milling plant;
clarification plant;
evaporation and boiling plant;
crystallization station;
centrifugal station;
rotary dryers;
steam generating plant; and
power generating plant,
wherein the clarification plant is used for heating, mixing and settling of impurities like mud, and wherein the crystallization station is used for further boiling, concentrating and crystallizing the concentrated syrup.

In another aspect of the invention there is provided a system for manufacturing jaggery from sugar cane, wherein the cane milling plant comprising:
cane handling and feeding equipment;
cane preparatory devices;
one or more mills;
one or more inter carriers;
bagasse carrier;
mill house crane gantry; and
imbibitions equipments and pumps,
wherein the bagasse carrier is a washing system,
wherein the inter carriers and bagasse carrier are driven by the electric motor with or without gear box, and
wherein the imbibitions equipments and pumps are useful for juice screening.

In yet another aspect of the present invention there is provided a system for manufacturing jaggery from sugar cane, wherein the cane handling and feeding equipment comprising: two way cane unloader;
feeder table;
cane carrier; and
cane kicker,
wherein the chain of carrier has two strands and a predetermined pitch, and
wherein the cane kicker comprises arms to control cane feeding.

In another preferred aspect of the invention there is provided a system for manufacturing jaggery from sugar cane, wherein the cane preparatory device comprising:
one or more set of cane cutter; and
one or more set of reverse cane cutter,
wherein the cane cutters have one or more knives.

In yet another preferred aspect of the invention there is provided a system for manufacturing jaggery from sugar cane, wherein the mill comprises the following assembly:
head stock;
one or more bearings;
rollers;
crown pinions;
static collars;
side caps;
trash plate and trash beam;
top scrapper assembly;
discharge scrapper assembly;
hydraulic system; and
under feed rollers.

It is another aspect of the present invention, wherein the clarification plant comprising:
mass flow meter;
multistage juice filters;
one or more juice heaters;
one or more reaction tanks;
milk of lime preparation unit;
clarifier; and
vacuum filter,
wherein the multi stage filters are used to filter suspended particles of juice, impurities, iron contents and decolorize juice using food grade granular activated carbon,
wherein the juice heaters heats the cane juice coming from the mills,
wherein the lime preparation unit includes lime slaker, lime storage tank and plunger type pumps,

wherein liming treatment is given to juice in the milk of lime preparation unit,
wherein the clarifier includes continuous type clarifier, one or more clear juice pumps and one or more muddy juice pumps,

wherein the clarifier helps for better settling of mud by further heating the juice, and
wherein the vacuum filter filters the settled mud.

It is another aspect of the present invention, wherein the evaporation and boiling plant comprising:
evaporation units;
single entry multi jet condenser;
jaggery pan;
open concentrator;
gur cooler unit; and
gur breaking and shaping unit,

wherein the evaporation unit comprises one or more evaporator bodies which helps in tripling the evaporation level, and
wherein the jaggery pan is under vacuum pressure.

In yet another preferred aspect of the invention there is provided a method of manufacturing jaggery using the above mentioned system comprising:
providing the juice by crushing the cut canes using one or more roller mills;
adding water to the cane juice (mixed juice);
heating the mixed juice in juice heater;
mixing milk of lime to mixed juice;
further heating the mixed juice in juice heaters;
storing the juice in clarifier for settling of mud;
evaporating the clear juice to a concentration of at least about 60 degree Brix using one or more evaporators;
further heating the juice in juice heaters;
collecting the concentrated syrup and pumping to the pan floor;
boiling and concentrating the syrup for crystals;
discharging the crystals with molasses (massecuite) to receiving crystallizers;
centrifuging continuously for separation of jaggery powder and molasses; and drying the powder in rotary driers,
wherein the ratio of mixed juice is 95% cane juice and 5% water,
wherein the juice is clarified without using any hazardous chemicals,
wherein exhaust/vapor is used for boiling, and
wherein the product obtained retain its natural flavor with no added chemicals, colors, additives and flavors.

It is another aspect of the present invention, wherein the vacuum created in the evaporator by turbine exhaust steam allows the juice to flow from the first to the last evaporator.

The objects, advantages and novel features of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the detailed description.

BRIEF DESCRIPTION OF THE ACCOMPANYING FLOWCHART
Figure 1: illustrates a process flow diagram for jaggery plant of the present invention.

DETAILED DESCRIPTION OF THE INVENTION WITH REFERENCE TO THE ACCOMPANYING FLOWCHART

The present invention as discussed hereinbefore relates to improving the milling efficiency by providing a jaggery plant system with multiple cane handling machines, multiple rollers and other electrically/hand operated infrastructures. The system provides for large scale manufacturing of jaggery under the most hygienically controlled environment with no added chemicals, colors, additives and flavors.

According to the present invention, the system for manufacturing of jaggery comprises:
a) cane milling plant;
b) clarification plant;
c) evaporation and boiling plant;
d) steam generating plant; and
e) power generating plant

a) The cane milling plant comprises:
cane handling and feeding equipment;
cane preparatory devices;
one or more mills;
one or more inter carriers;
bagasse carrier;
mill house crane gantry; and
imbibitions equipments and pumps.

The cane handling and feeding equipment further comprises:
Cane un loader: 1 set of 5 ton capacity electrically operated ceiling type two way cane un loader having a span of 13 meter.

Feeder table: 1 set of feeder table of 6 meter x 6 meter size.

Cane carrier: one cane carrier of 533 (21") mm wide, 8 meter of horizontal length and 8 meter of inclination length is driven by reduction gear at 10-30 meter/min apron speed enclosed with 15 hp motor. The chain of carrier has two strands and a pitch of 110 mm. The cane carrier is completed in all respect and suitable to 400 TCD capacities.

Cane kicker: Cane kicker of 533 mm wide having arms to control cane feeding is driven by reduction gear at 50 -70 rpm and is enclosed with 5 hp electric motor.

The cane preparatory device comprises one or more set of cane cutter and one or more set of reverse cane cutter. The cane cutters have one or more knives, driven by a pulley which is attached to 40 hp electric motor at 600 rpm and 650 rpm respectively. Both of cutter sets is completed in all respect. The reverse cane cutter comprises one set of cane cutter having one or more knives driven by pulley attached to 50 hp electric motor at 700 rpm.

In accordance with another aspect, one or more roller mills (16" x 24") with under feed rollers and donnally chutes suitable to 400 TCD capacities comprises of head stock, one or more bearings, rollers, crown pinions, static collars, side caps, trash plate and trash beam, top scrapper assembly, discharge scrapper assembly, foundation bolts, hydraulic system, and under feed rollers. One or more rake type inter carriers, driven by 3 hp 1400 rpm is enclosed with reduction gear box 30:1, linear speed 25 meter/min. Inter carrier is completed in all respect and suitable to 400 TCD capacity. One mainbagasse carrier of single trough design 356 mm wide and of suitable length suits the boiler. It is able to carry 6 ton of bagasse per hr. and is driven by 5 hp TEFC electric motor through gear box to have linear speed 25 met/min. The mill house crane gantry is electrically/hand operated over head crane mill house having one 5 ton SWL capacity.

The imbibitions equipments and pumps include:

Juice screening: One number DSM screen of 1.4 square meter filtration area for mixed juice.
Juice tanks and pumps:
2 numbers of whirler tanks with conical bottom of 750 m diameter and 1000 mm height.
1 number of whirler tanks with conical bottom of 1000 m diameter and 1000 mm height.
2 numbers of pumps of 6 m3/hr against 10 m head driven by 5 hp electric motor.
1 number of pumps for mixed juice screening having 20 m3/hr cap against 10 m head and driven by 7.5 hp motor.

b) The clarification plant comprises:

1. Mass flow meter:

(a) one set mass flow meter, is capable of measuring 20 m3/hr.

(b) one number mixed juice pump of 20 m3/hr against 30 m head.

2. Multi stage juice filters:

(a) Mechanical filter: 1 Set. This filter is in three stages and is made of mild steel structural frame using stainless steel sieves of three different sizes.

(b) Filter 1: 1 Number. This filter is used to filter suspended particles of juice upto 300-400 microns. This is made of M.S. and coated inside by acid proof paints.

(c) Filter 2: 1 Number. This filter is used to filter suspended particles of juice upto 200 microns. This is made of M.S., coated inside by acid proof paints using silts as filter media meter.

(d) Filter 3: 1 Number. This filter is used to filter impurities and iron contents of juice up to 100 microns. This is made of M.S. and coated inside by acid proof paints.

(e) Filter 4: 2 Numbers. These filters are used to filter and decolorize juice using food grade granular activated carbon. This is made of M.S. and coated inside by acid proof paints.

(f) Micro filters 5: 2 Numbers. Micro filters are used to filter suspended particles of juice if remained in previous filters. This is made of M.S., coated inside by acid proof paints using p.p. candles as filter media meter.

3. Juice heaters: 2 Numbers and have the following specifications:

Type : Direct contact
Size : 500 O.D. x 4000 Lg.
Material : M.S.
Plate thickness:
Shell plate thk. : 6 mm
Baffle plate thk : 5 mm
Cover plate thk : 6 mm
Bottom cone plate : 6 mm
Connections:
size of Juice inlet/outlet : 100 NB/100 NB
size of steam entry : 80 NB

4. Reaction tank: 5 Numbers.

(a) Type: Continuous type

Size: 1000 mm diameter x 1500 mm height.
Arrangements: motorized stirrer, chemical dosing equipments and all accessories.

(b) 2 numbers sulphated juice pumps of 20 m3/ hr, 50 m, head is provided.

(c) one number air compressor of 60 m3/hr at 1 kg/cm2 g pressure.

5. Milk of lime preparation unit:

(a) one number lime slacker capable of slaking of about 120 kg lime per hour.

(b) one number milk of lime storage tank of 20 h.l. capacity.

(c)Two number plunger type pump of 1 m3/hr capacity against 10 m head.

6. Clarifier:

(a) one continuous type clarifier of 4000 mm diameter with one compartment.

(b) two numbers clear juice pumps of 20 m3/hr capacity against 30 m head.

(c) one number muddy juice pump of 3 m3/hr capacity against 10 m head.

7. Vacuum filter: one set rotary type vacuum filter of 6'x6' size, having nominal filtration area 9 square meters.

c) The evaporation and boiling plant of the present invention comprises:

(a) Evaporation units: Triple effect evaporator set

All body vapour cell type:
Conventional (tubes - 45mm OD, 1.2 mm thickness 2 M long, S.S.) 1st body 2nd body 3rd body
Heating surface area :125sqm. 125 sq.m. 75 sq.m.
Tube Size : 45 O.D. x 18 SWG x 2000 Lg.
No. of tubes : 468 468 280
Diameter of shell : 1350 mm 1350 mm 1100 mm
Size of steam/vapor entry : 200 mm 200 mm 200 mm
Size of condensate outlet : 50 mm
Size of vapor outlet to next body : 200 mm 200 mm 500 mm
SizeofNOXgasses : 25mmx2nos.
Plate thickness:
Shell plate : 10 mm
Tube plate : 20 mm
Calendria shell plate : 10 mm
Bottom cone : 12 mm
Top cone : 10 mm
Save all plate : 8 mm

(b) Single entry multi jet condenser: One number for third evaporator body.
Material of construction : Stainless steel
Shell thickness : 6 mm
Conical thickness : 6 mm
Diameter of shell : 500 mm
Injection water inlet : 150 mm
Size of tail pipe throat : 150 mm
Condenser is completed in all respect and be suitable for third body of evaporator.

(c) Jaggery pan (under vacuum) : 2 numbers
Heating surface area : 15 sq m
No. of body : 2 numbers
Tube Size : 63.5 O.D. x 18 SWG x 750 Lg.
No. of tubes : 110
Type of down take : central down take
Size of steam entry :200 mm
Size of condensate outlet : 40 mm
Size of vapor outlet : 3 50 mm
SizeofNOXgasses : 25 mm x 2 numbers
Plate thickness:
Shell plate : 10 mm
Tube plate : 25 mm
Calendria shell plate :10 mm
Bottom cone : 12 mm
Top cone : 10 mm
Save all plate : 8 mm

(d) Single entry multi jet condenser : two numbers for jaggery pan.
Material of construction : Stainless steel
Shell thickness : 6 mm
Conical thickness : 6 mm
Diameter of shell : 400 mm
Injection water inlet : 125 mm
Size of tail pipe throat :125 mm
Condenser is completed in all respect and be suitable for third body of evaporator.

(e) open concentrator - : two numbers
Heating surface area :10sqm
No. of body : 2 numbers
Tube Size : 45 O.D. x 18 SWG x 600 Lg.
No. of tubes : 132
Type of down take : central down take

Size of steam entry : 80 mm
Size of condensate outlet : 40 mm
Size of NOX gasses : 25 mm x 2 numbers
Plate thickness:
Shell plate : 10 mm
Tube plate : 25 mm
Calendria shell plate :10 mm
Bottom cone :10 mm

(f) Gur cooler unit: 5 Numbers.
Gur cooler is used to cool gur without crystallization of sugar using water as cooling
mediameter.

(g) Gur breakrtting/shaping unit: 2 Numbers.
Gur is given a proper shape of definite weight by this machine.

d) The steam generating plant comprises one water tube boiler of 10 tons per hour capacity, boiler headers, super heater, furnace, induced draft fan, drive for induced draft fan for boiler, forced draft fan, blow down arrangements, soot blow equipment, economizer, air pre-heater, fly ash arrester, chimney, boiler feed water tank, boiler feed water pump and boiler feed water treatment plant.
Water tube boiler shall satisfy the following conditions:

i) M.C.R. (maximum continuous rating evaporation): 10 tones per hour

ii) Peak generation : 110% of M.C.R. for half an hour

iii) Pressure at super heater outlet : 32 kg/sq cm.

iv) Temperature at super heater outlet : 360° C +/- 5° C at M.C.R.

v) Feed water temperature : 85° C

vi) Excess air % theoretical air : not exceeding 35%

vii) Temperature of gasses at outlet : 170° C

viii) Efficiency: minimum 68% 2% on GCV of bagasse having 50% moisture with bagasse as fuel, determined as per IS code.

ix) Fuel: bagasse with 50% moistureboiler is designed for a pressure of 32 kg/sq cm g at super heater outlet with a temperature control through heat exchanger to be provided to maintain automatically the temperature of steam at super heater outlet at 370° c +/- 5°.

The construction of boiler is such that, it is provided with minimum, one steam drum and one mud drum, both of fusion welded construction. The drum is provided with suitable dishes ends, man hole, doors fitted with cross bars, studs and nuts at each end. The steam drum of boiler is to be provided with suitable internals to promote circulation and ensure high steam purity. The heating surface of boiler is determined with reference to main bank of boiler tubes, front wall and roof, rear wall and side wall tubes. The boiler headers are constructed in accordance with the I.B.R. / I.S.O. specifications with flange ends to promote cleaning and inspection. The super heater is capable of super heating total steam generated by the boiler to a final steam temperature 370 deg C +/- 50° C at M.C.R. and complete with interconnected pipelines between the boilers and super heaters, mountings such as safety valves, drain / air vent valves, pressure gauges etc. as per I.B.R. / I.S.O. The tube elements of super heater would be constructed from seamless alloy steel tubes of appropriate specifications. The tube elements of the super heater are expanded to the steam drum at one end and butt welded /expanded to the outlet manifold at the other end. The inlet header provided is connected by means of suitable number of tubes to the steam drum. The super heater manifold is fabricated from solid drawn seam less pipes. The manifold is supplied complete with branches for main stream take off, safety valve, air release connection etc. A thermo well in the outlet manifold be provided to measure the temperature of superheated steam. The furnace is to burn bagasse with 50% moisture and is designed to give maximum continuous rating with bagasse firing only even when furnace chamber is being cleaned. The boiler is provided with spreader stoker type damping grate type furnace with all accessories.

The ash hoppers are provided below each furnace and the boiler height is adjusted such that manually operated trolley can be placed below the ash hopper for quick removal of ash. The rotary feeders coupled to variable speed drive are provided for regulating the quantity of bagasse to the furnace. The feeders shall have speed variation and maximum speed not to exceed 25 rpm. The induced draft fan is designed for a minimum discharge capacity of 25% higher than the theoretical flue gas quantity corresponding to 35% excess air and 170° C flue gas temperature at M.C.R. and head 30% higher than required at rated M.C.R. Renewable hard face wear pads on blades are incorporated in the impeller. Induced draft fan is complete with drive etc. and fan rated should not be more than 750 rpm. The blades of the fan rotor are fabricated out of minimum 5 mm thick MS plate. The induced draft fan is driven by a squirrel cage TEFC A.C. motor complete with accessory.

The forced draft fan is designed for a minimum discharge capacity of 25% higher than the theoretical air required at 35% excess air at M.C.R. and head 30% higher than required at rated M.C.R. Variable inlet vane controlled dampers in the suction end of the F.D fan is provided. Forced draft fan is complete with drive motor, starter etc. The blades of the fan rotor are fabricated out of minimum 5 mm thick MS plate. Continuous blow down equipment as per I.B.R. / I.S.O. complete with all piping. M.S fabricated tank to act blow down pit within 5 meters outside the boiler house.

The steam operated hand controlled soot blowing equipment is provided with one or more soot blowers for boiler at appropriate places to cover back of boiler tubes. An additional soot blower shall also be provided for the economizer. The boiler is provided with economizer of suitable heating surface area. Economizer is complete with tubes, economizer coils, support, dampers, and thermo wells for measuring inlet and outlet water temperature, casing and ducting, soot blower, lagging etc. to be provided. The economizer is designed in accordance with the requirement of I.B.R. / I.S.O. The air heater of suitable heating surface to heat the air by flue gasses is required for combustion for boiler. The air heater is complete in all respects with ERW tubes, tube plates, support, dampers, casing and ducting etc. Entry of cold air is distributed properly over the length of air heater to avoid condensation of moisture. It is designed for double pass for air with cross counter current flow. The air heater and economizer are designed so as to give final flue gas temperature within 170° C.

The fly ash arrester is of multi cyclone type having vertical cyclones of hard cast alloy which is installed on the suction side of induced draft fan and be completed with rotary air lock valve with drive.

MATERIAL OF CONSTRUCTION AND GENERAL INSTRUCTION:

The boiler is manufactured in accordance with the requirements of Indian boiler rules and regulations / I.S.O.

The boiler is provided with a steel supporting structure from rolled steel section and designed with adequate strength of loads imposed by the boiler and associated equipments.

The boiler is completed with necessary tubes, manifolds, integral pipe works, mounting and fittings, with valves, gauges, high and low water alarm, maintenance tools consisting of expander, mandrills, ratchets, two grease guns and a set of spanner, water gauges, chemical injection valves etc. The integral pipe work shall consist of blow off bends, high and low pressure drains, water gauge piping, water and steam connections to the feed water regulator, feed pipe work from feed control valve to economizer inlet manifold, feed pipe work from economizer outlet manifold to the boiler steam drum, pressure gauge piping, soot blower steam supply pipe works, safety valves, escape pipe work etc.

Boiler is provided with the three element type automatic feed water regulator of the thermostatic / pneumatic controller type which should respond to momentary fluctuations in steam demand upto +/- 5% of the rated M.C.R. of the boiler. One hand operated control valve of cast steel (located such that operator can see water level in gauge glass) capable of passing the required amount of water shall also be provided. The boiler shall have two water gauge glasses at top drum independently connected.
Necessary mild steel ducting of 4 mm thick plate in case of air duct and 6 mm thick in case of gas duct with stiffeners is provided comprising of cold air ducting's extending between the F.D. fan discharge and air inlet of air heater, hot air ducting's from the air heater outlet to underground duct and branches there from to the furnace through the blowers, flue gas ducting's connecting boiler with its accessories to the chimney.
Chimney: One mild steel chimney of 1.0 meter diameter at top and 35 meter height along with ladder with guard etc. suitable for boiler of 10 tons per hour capacity for ultimate capacity of 300 TCD is provided.

Boiler feed water tank: One cylindrical closed mild steel tank is provided of 60 HL capacity for ultimate capacity of 400 TCD with inlet connections for condensates, cold water, chemical dosing arrangements, outlet connections, for transfer pumps, over flow leading to feed water storage tanks, air vent etc. is supported on steel structure. The chemical dosing equipment shall consist of two chemical injection pumps, two mixing tanks, each of 100 liters capacity and each with stirrer and complete with piping and fittings. Bottom of the tank shall not be less than 7 meters height from the transfer pumps suction. Access ladder and platform around the tank is provided. A water level alarm is provided in the feed tank.

Two transfer pumps (one as stand by) each of 20 m3 per hour capacity and suitable head to pump water from boiler feed water tank to de-aerator to maintain 4 kg /cm2 g pressure at the nozzles of de-aerator is provided.

Boiler feed water pump: Two pumps (one as stand by) of 8 m3 per hour capacity against head not less than 420 m.

Boiler feed water treatment plant: A suitable feed water treatment plant of 3.5 tones/hr capacity is installed to suit the water requirement of the high pressure boiler.

The storage tank 200 H.L. capacities are installed to store the treated water from the treatment plant. One pump of 10 m3 per hour capacity and of about 20 meters head is provided to pump the water from treated water storage tank to feed water tank.

e) Power generating plant comprises of:

One turbo alternator of (1000 KW at 0.8 power factor) with synchronizing panel (a) 1000 KW turbo set is suitable of developing momentarily 1000 KW at 0.9 power factor even when both the over load valves of the turbine are closed.
The steam turbine is designed for operation for the following ranges of steam parameter.
Inlet steam parameter-
Maximum : 34 kg/ cm2 g
Normal : 32 kg/ cm2 g
Minimum : 27 kg/ cm g
Inlet steam temperature-
Maximum : 3950 C
Normal : 3700 C
Minimum : 3400 C
Exhaust steam pressure-
Maximum : 1.25 kg/ cm2 g
Normal : 1.0 kg/cm2 g
Minimum : 0.7 kg/ cm2 g

The turbine is capable of developing 1000 KW when steam pressure at inlet stop valve is 27 kg/ cm g and temperature is 3450°C and both over load valves are open. The specific steam consumption at its rated speed and on normal steam operating parameter should not exceed 8.0kgs/KW/hour, while delivering 1000 KW.
The turbine is coupled to a suitable enclosed reduction gear box of hardened and ground/ nitrided gears designed to transmit 1000KW continuously at turbine rated speed and ambient temperature of 450°C with a service factor not less than 1.5. The gear box is coupled to alternator through suitable coupling, capable of transmitting 1000 KW continuously. The gear box is designed as per relevant standard. Necessary cooling arrangement for the gear box is provided.

The alternator is suitable for developing continuously 1000 KW at 0.8 power factor) 3 phase, 4 wire, 50 cycles/ sec at a normal voltage of 400-440 volts and shall conform to IS: 4722-1968 specifications. The alternator is suitable for developing continuously 1000 KW even when the power factor is 0.9. The alternator is complete with exciter, base frame, couplings, water cooled radiator-inter-connecting cabling etc. The alternator is provided with two bearings (one at each end).

(b) Electrical distribution system: The electrical distribution system shall include:

The electrical bus bar trunking, connecting the alternator with the alternator breaking panel
i. Main distribution board in the power house
ii. Auxiliary panel
iii. Main and sub lightning distribution boards
iv. Motor control centers
v. All electrical motors
vi. Starters and switches for all electrical motors
vii. Power factor improving capacitors
viii. All power lightening and control electrical cables
ix. Earthing system
x. Electrical erection material etc.

Further the system includes:

F. 1-PRDS, PIPING, LAGGING

1 set- Pressure reducing and De-super heating unit

One number automatic PRD station pressure of steam from 32 kg/ cm2g to 1.5 kg/ cm2g pressure with suitable de-superheating arrangement. The reduced de-superheated steam is connected to a receiver with two branches to supply steam to centrifugals, S02 burners, molasses, clarification equipments, boiling house, etc. and a second branch along with pressure pumps, pressure controllers, steam flow meter, steam pressure recorder and by-pass arrangement, to maintain a steady pressure of 1.0-1.5 kg/ cm2g in the receiver of exhaust steam by exhaust from turbine or by injection steam from 5-6 kg/ cm2g. The capacity of the PRD station is suitable for 400 TCD Plant.

1. Necessary Piping and Lagging: Piping, valves and fittings for all equipment in the Boiling House as per Terminal Points for non-gravity flow Jaggery Plant of 300 TCD capacity. Lagging of glass wool, for all heat exchange equipment, exhaust and vapor pipelines, clarifier, evaporator bodies are provided.

2. Juice /syrup/water tanks -
raw juice tank - 1250 mm diameter x 1250 height x 4 mm thickness x 1 no.
clear juice tank - 1500 mm diameter x 1250 height x 4 mm thickness x 1 no.
syrup juice tank - 1250 mm diameter x 1250 height x 4 mm thickness x 2 nos.
thick syrup juice tank - 1250 mm diameter x 1250 height x 4 mm thickness x 2 nos.
condensate receiving tank -1000 mm diameter x 1500 height x 5 mm thickness x 2 nos. cold/hot water over head tank - 1750 mm diameter x 1500 height x 4 mm thickness x 2 nos.

3. Pumps, valves, inter connecting pipelines and fittings within gur plant for above said machineries.

4. Electrical motors, cables starters, within gur plant for above said machineries.

5. Steel structure, within gur plant for above said machineries.

JAGGERY POWDER PLANT MACHINERY:

Jaggery powder plant machinery is provided with 60 tons capacity crusher machinery, one drier machine, motors, pumps and spares.

Reference is now invited to accompanying figure 1 that illustrates a process flow diagram for jaggery plant of the present invention. The method of preparing high quality jaggery is explained hereunder:

The cane is cut into pieces by cane cutters. The cut canes are crushed using three roller mills, where the juice is extracted. To get sucrose or extraction, hot water is spread on Bagasse, (sort of washing system) about 20 to 25% on cane, and then water is added and the cane juice which is called, as mixed juice is collected at first mill. The mixed juice % on cane is around 95%. Cane juice coming from the mills is heated in juice heater from 30° C to 65° C. This 65° C juice is taken to liming vessel where milk of lime is or mixed to juice for 6 to 8 minutes, i.e, liming treatment is given to juice. This juice is further heated from 65° C to 103° C, in juice heaters, heating upto 103° C helps for better setting of mud, in juice clarifier. Clarifier is a circular bigger tank, in which juice is kept for 3 hours in stand steal position where the mud settles down. Clear juice is taken from the upper portion of tank to process. Settled mud is taken out/filtered with the help of rotary vacuum filter. The mud can be used as manure in field.

The clear juice is then evaporated using four evaporators. Clear juice from the clarifier is taken, again heated to 115° C to 120°C, in juice heater and fed to 1st body of Evaporators. Turbine exhaust steam is given to 1st body and last body is connected to condenser for condensation and creation of vacuum. Juice flow takes place from 1st body to 4th last body. With concentration and is leaves at 60 Bx, called syrup. The syrup is collected at ground level and pumped to the pan floor. Two syrup concentration pans, working under vacuum are installed. The syrup is further boiled, and concentrated. After concentration very fine, crystals are developed, and these developed crystals with molasses, called massecuite, is discharged to receiving crystallizers. About 3 hours are required, for formation of fine jaggery powder. The exhaust/vapour is used for boiling. Massecuite is fed to continue centrifuge, for the separation of jaggery powder and molasses. This molasses is again re-circulated for further recovery of powder. Jaggery powder coming from centrifugal machines is dried in rotary dryers and after screening the same is bagged, in different sizes, to suit market.

While the invention has been described herein with reference to specific embodiments, it is recognized by those skilled in the art that variations are possible without departing from the spirit and scope of the invention, and that it is intended to cover all changes and modifications of the invention disclosed herein for the purposes of illustration which do not constitute departure from the spirit and scope of the invention.

WE CLAIM:
1. A system for manufacturing jaggery from sugar cane comprising:
one or more cane milling plant;
clarification plant;
evaporation and boiling plant;
crystallization station;
centrifugal station*,
rotary dryers;
steam generating plant; and
power generating plant,
wherein the clarification plant is used for heating, mixing and settling of impurities like mud, and
wherein the crystallization station is used for further boiling, concentrating and crystallizing the concentrated syrup.

2. The system as claimed in claim 1, wherein the cane milling plant comprising:
cane handling and feeding equipment;
cane preparatory devices;
one or more mills;
one or more inter carriers;
bagasse carrier;
mill house crane gantry; and
imbibitions equipments and pumps,
wherein the bagasse carrier is a washing system,
wherein the inter carriers and bagasse carrier are driven by the electric motor with or without gear box, and
wherein the imbibitions equipments and pumps are useful for juice screening.

3. The system as claimed in claim 2, wherein the cane handling and feeding equipment comprising:
two way cane unloader; feeder table; cane carrier; and
cane kicker,
wherein the chain of carrier has two strands and a predetermined pitch, and
wherein the cane kicker comprises arms to control cane feeding.

4. The system as claimed in claim 2, wherein the cane preparatory device comprising:
one or more set of cane cutter; and
one or more set of reverse cane cutter,
wherein the cane cutters have one or more knives.

5. The system as claimed in claim 2, wherein the mill comprises the following assembly:
head stock;
one or more bearings;
rollers;
crown pinions;
static collars;
side caps;
trash plate and trash beam;
top scrapper assembly;
discharge scrapper assembly;
hydraulic system; and
under feed rollers.

6. The system as claimed in claim 1, wherein the clarification plant comprising:
mass flow meter;
multistage juice filters;
one or more juice heaters;
one or more reaction tanks;
milk of lime preparation unit;
clarifier; and
vacuum filter,
wherein the multi stage filters are used to filter suspended particles of juice, impurities, iron contents and decolorize juice using food grade granular activated carbon,
wherein the juice heaters heats the cane juice coming from the mills,
wherein the lime preparation unit includes lime slaker, lime storage tank and plunger type pumps,
wherein liming treatment is given to juice in the milk of lime preparation unit,
wherein the clarifier includes continuous type clarifier, one or more clear juice pumps and one or more muddy juice pumps,
wherein the clarifier helps for better settling of mud by further heating the juice, and
wherein the vacuum filter filters the settled mud.

7. The system as claimed in claim 1, wherein the evaporation and boiling plant comprising:
evaporation units;
single entry multi jet condenser;
jaggery pan;
open concentrator;
gur cooler unit; and
gur breaking and shaping unit,
wherein the evaporation unit comprises one or more evaporator bodies which helps in tripling the evaporation level, and
wherein the jaggery pan is under vacuum pressure.

8. A method of manufacturing jaggery using the system as claimed in anyone of claims 1 to 7 comprising:
providing the juice by crushing the cut canes using one or more roller mills;
adding water to the cane juice (mixed juice);
heating the mixed juice in juice heater;
mixing milk of lime to mixed juice;
further heating the mixed juice in juice heaters;
storing the juice in clarifier for settling of mud;
evaporating the clear juice to a concentration of at least about 60 degree Brix using one or more evaporators;
further heating the juice in juice heaters;
collecting the concentrated syrup and pumping to the pan floor;
boiling and concentrating the syrup for crystals;
discharging the crystals with molasses (massecuite) to receiving crystallizers;
centrifuging continuously for separation of jaggery powder and molasses; and
drying the powder in rotary driers,
wherein the ratio of mixed juice is 95% cane juice and 5% water,
wherein the juice is clarified without using any hazardous chemicals,
wherein exhaust/vapor is used for boiling, and
wherein the product obtained retain its natural flavor with no added chemicals, colors, additives and flavors.

9. The method as claimed in claim 8, wherein the vacuum created in the evaporator by turbine exhaust steam allows the juice to flow from the first to the last evaporator.

10. A system and method for manufacturing jaggery from sugar cane substantially as herein described and illustrated with reference to the accompanying figure.