| SPRAY CONTINUOUS PAN (SCP ®) |
| (Evaporative Crystallizer / Vertical Continuous Vacuum Pan) |
Crystallization consumes major portion of heat energy in a Sugar Manufacturing Process. The Continuous Pans were introduced in 1970’s for a variety of massecuite and sugar quality. Their introduction resulted in reduced steam demand and fluctuation apart from reduction of number of equipments in the plant. However, massecuite produced from these pans is always considered inferior to Batch Pans in terms of sugar quality and exhaustion of molasses.
Spray Continuous Pan ( SCP ® ) is the latest development for optimizing evaporative crystallization of sugar solutions. ( SCP ® ) is designed to achieve highest level of energy efficiency without any compromise on the process parameters. Multi-chambered mechanically stirred vertical continuous pan has several advantages over horizontal continuous pans due to its flexibility.
SPRAY CONTINUOUS PAN ( SCP® ) DISTINCT FEATURES( SCP ® ) can be manufactured in 4, 6, 8 or 9 chambers as per the requirement of customer. In 8 chamber ( SCP ® ), one chamber can be used as a graining pan. Additional seed crystallizer can be incorporated in 9 chamber design. The capacity of 4 chamber pan can be enhanced by adding chambers over the tower.
- Suitable for all types of massecuites (Raw, Refined, A, B and C).
- Operates with low pressure vapours of 200 mbar – 500 mbar.
- Vertically arranged 4 or more superimposed crystallization chambers for uniform crystal size.
- Essential wetted parts in stainless steel to reduce colour additions.
- Specially designed Mechanical Circulator for a homogenous massecuite & uniform crystal size.
- Compact size with self supporting structure.
- Mechanically sealed bottom mounted circulator eliminating air leakages.
- Honeycomb calandria for improved circulation.
- Consistent Final Product Quality. Minimum Coefficient of Variation (C.V.) [28-30].
- Liquor handling from 50 – 85% concentration due to vigorous circulation.
- Sugar yield of Pan – 55% - 60% with 90-91% brix.
- On-line cleaning by isolation of individual chambers without reducing its capacity.
- Fully automated intelligent system for precise operation.
- Brix analysis using microwave technology.
- Vertical outdoor installation in compact self supporting structure.
- Possibility of including seed pan and receiving crystallizer within the tower (optional).
- Chambers can operate on both bottom or overflow discharge.
- Modular chamber pre-fitted with instruments to reduce erection time.
- Most economical sugar crystallization system.
- FASTEST DELIVERY (4-6 weeks).
- PATENTED TECHNOLOGY *
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| Pan Capacity Chart |
| Diameter of Pan |
Volume per chamber |
Heating surface per chamber |
Total volume |
| 4 Chamber SCP |
6 Chamber SCP |
8 Chamber SCP |
9 Chamber SCP |
| mm |
m³ |
m² |
m³ |
m³ |
m³ |
m³ |
| 3450 |
15 - 18 |
150 - 175 |
60 - 72 |
90 - 108 |
120 - 144 |
135 - 162 |
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PROCESS ADVANTAGES:
Suitable for all massecuite types: As distinguished from other continuous pans, ( SCP ® ) is ........ [More >>]
Suitable for all massecuite types: As distinguished from other continuous pans, ( SCP® ) is suitable for all types of massecuites viz. A, B, C, Raw, Refined, etc. In cane and beet sugar refinery, SCP™ can be used for both recovery house (raw sugar) as well as for refining operation.
Better massecuite quality: SCP can have 5 - 9 chambers. Increased numbers of chambers are optimized to ensure better massecuite quality with minimal coefficient of variation and least colour. Uniform residence time for seeds, mechanical circulation, proper super saturation control and gradual brix increase in each chamber results in least crystal size variation.
Improved sugar recovery: Better exhaustion and higher crystal content of the mother liquor due to efficient circulation in the pan results in maximum extraction of sugar and thus low purity molasses.
Improved evaporation and crystallization rates with low temperature / pressure vapours: Honeycomb calandria design and efficient mechanical agitator improves circulation, evaporation and crystallisation rate. This also reduces incrustation, colour, conglomerates & uneven heating.
Continuous operation with online cleaning: ( SCP® ) has facility to bypass any chamber for cleaning without reducing its capacity. Online cleaning results in continuous operation & 100% availability with better productivity & quality.
Lesser hydrostatic effect: Effect of hyrdrostatic head is largely negated through efficient mechanical circulation and use of honeycomb calandria with optimum tube length.
Provision of seed pan with uniform seeding: A provision of seed pan can also be made in ( SCP® ). A separate flexible control for seed pan can be made helping in uniform seed sizing and feeding.
Availability for all process ranges: ( SCP® ) is available for all process ranges with customized parameters involved, depending upon the requirement.
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STEAM & POWER ECONOMY / ENERGY EFFICIENCY:
Steam economy: All conventional batch pans usually operate with vapours ........ [More >>]
Steam economy: All conventional batch pans usually operate with vapours of 100 -110 deg C bled from 1st or 2nd effect of the evaporator train. But SCP can operate with vapours of 300mbar – 500mbar (~85 deg C) vapour bled from 3rd or 4th effect of evaporator train. Capability to operate with low temperature vapours ensures process steam economy.
Power economy: Due to centralized unit & use of planetary drives in circulators & other units, overall power consumption for SCP is quite less. The installed power for complete unit is around 250 - 275 kW.
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DESIGN ADVANTAGES:
Compact modular single tower design with increased number of chambers: Innovatively designed ( SCP ® ) ........
[More >>]
Compact modular single tower design with increased number of chambers: Innovatively designed SCP has 8 or more evaporative crystallization chambers in a single tower of around 35 metres. Overhead hot water or syrup or seed tanks are optionally available. Provision of in-built seed pan available.
Honeycomb calandria:Inclusion of honeycomb design in the heating chest leaves no space for settling of sugar. It also improves circulation rate due to reduced friction.
Complete instrumentation: ( SCP® ) is packed with instruments, valves and control system from quality oriented companies. SED has developed precise control intelligent software for smooth operation and performance analysis which can be monitored online. Software is made self intelligent to take decision without manual intervention.
Stainless steel wetted parts:
All essential wetted parts inside the chambers of SCP in direct contact with massecuite / sugar solutions are either made of or lined with stainless steel. Use of stainless steel reduces color formation and improves equipment / component life.
Light gauge self-supported structure:
It has light gauge steel structure for platform and stairs. Stairs are supported on the tower itself. No extra staircase tower is required.
Vertical outdoor installation: No building / shed or extra steel structure is required. Self supporting structure decreases structure/building & civil work/housing cost. Less floor area is required due to standard vertical tower construction. |
Click on image to enlarge |
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CONTROL ADVANTAGES:
The control scheme of a continuous pan is quite different from a batch type pan........ [More >>]
The control scheme of a continuous pan is quite different from a batch type pan. ( SCP® ) has all essential instrumentation that gives flawless performance.
1. Ease of operation.
2. Integration with any third party control system / DCS via MODBUS.
3. Process parameters control in each chamber made the whole system highly efficient.
4. Provision for flow, temperature, pressure, level & brix / consistency control for each chamber.
5. Fail safe / fall back provisions through software / hardware in case of error / failure.
6. Faster and accurate remedial action control. Inbuilt alarms & historic trends provision.
7. Auto cleaning / rinsing cycle of valves & sensors minimizes the shutdowns.
8. Seed / Syrup ratio automatically defined & ensures least crystal variation.
9. Effect of Boiling Point Elevation (BPE) is reduced in later chambers / calandrias by having individual control in steam & vapor pressure control hence achieving constant boiling process.
10. Use of remote I/O’s for each chamber to avoid cables & wires facilitating easy operation. |
Click on image to enlarge |
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OPERATIONAL ADVANTAGES:
Continuous operation with no stoppages........ [More >>]
1. Continuous operation with no stoppages.
2. Fully automated intelligent system resulting in less skilled man power requirement.
3. Fast remedial action conserving product quality, saving process time & money.
4. Internal buffer capacity and continuous operation reduce massecuite storage requirements.
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INSTALLATION ADVANTAGES:
( SCP® ) can be installed in a cluster to reduce vapour piping and foundation cost........ [More >>]
( SCP® ) can be installed in a cluster to reduce vapour piping and foundation cost.
FEATURES OF ( SCP® ) IN CLUSTERS:
1. Centralized station.
2. Central steam / vapours header (Composite Header*).
3. Less footprint.
4. Common structure / platform.
5. Common lift arrangement can be provided (optional).
6. Less piping work.
7. Common accessories like oil circulation, condensate pumping, circulator flushing etc.
8. Central Vacuum System.
* Patent Pending. |
Click on image to enlarge |
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SCP FAQ's
What is the CV of Spray Continuous Pan ( SCP ® )? ........
[More >>]
Q1: What is the CV of Spray Continuous Pan ( SCP ® )?
Reply: 28-30
Q2: What is the Sugar yield of this Pan?
Reply: 55%-60% with 91% brix.
Q3: What is the difference between ( SCP ® ) and other Vertical Continuous Pans?
Reply:
- Number of chambers in ( SCP® ) can be upto 9 as compared to 4 or 5 in conventional Vertical Continuous Pans in the same height.
- ( SCP® ) has dedicated bottom mounted mechanical circulator in each chamber as compared to top mounted mechanical circulators in conventional Vertical Continuous Pans.
- ( SCP® ) has honeycomb calandria for improved circulation avoiding incrustation.
- ( SCP® ) work efficiently on A ,B,C massecuite, Refine Sugar, Raw Sugar whereas conventional Vertical Continuous Pans are basically designed for low purity massecuites.
- ( SCP® ) has fastest delivery time of only 4-6 weeks as compared to conventional Vertical Continuous Pans with almost 15-18 months.
Q4: Where is ( SCP ® ) installed?
Reply: Poland, Indonesia, Sakthi Sugars (India), JMSIL (India) etc.
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