Vacuum Filter Description in Sugar Industry - Optimization of Sugar Loss

2/5/2020 Vacuum Filter Description in sugar industry | Optimization of Sugar Loss
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Vacuum Filter Description in sugar industry | Optimization of Sugar Loss
Vacuum Filter Operation in sugar industry | Optimization of Sugar

Loss from Filter Cake
Contents [hide]
1 Vacuum Filter Operation in sugar industry | Optimization of Sugar Loss from Filter Cake
1.1 Accessories of Rotary Vacuum Filter:
1.1.1 Mud Mixer or bagacillo mixer
1.1.2 Mud Trough & Agitator
1.1.3 Filtrate Receiving Vessel
1.1.4 Vacuum Pump & Condenser
1.1.5 Entrainment Separator
1.2 General Operational Parameters for vacuum lters:
1.3 Criteria for Ef cient Running or Optimization lter cake Pol.
1.3.1 Vacuum ( Low and High vacuum levels).
1.3.2 Bagacillo
1.3.3 Wash water temperature maintained 60 to 650C.
1.3.4 Speed of the drum: 3 to 5 min per revolution.
1.3.5 Thickness of Filter cake – 1\4” to1\2”.
1.3.6 Mud Temperature & Trough Level:
1.4 General Causes of mud trouble in Juice Clari er
1.4.1 Cane Quality
1.4.2 Mill Sanitation
1.4.3 Effect of Imbibition Water
1.4.4 Muddy Juice pH
1.4.5 Sulphited Juice Temperature
Abstract: Rotary drum vacuum filters have been widely used in sugar and a variety of
other industries for
many years. They are well suited to applications where both dewatering and washing are
required and appear to be the best of the available equipment for the treatment of cane
sugar muds. In this article discussed about vacuum filter description, its operational
parameters and also explained optimization of filter cake pol (sugar loss from vacuum
filter).
Accessories of Rotary Vacuum Filter:

Mud Mixer or bagacillo mixer.
Mud Trough
www.sugarprocesstech.com/vacuum-filter/ 1/19
Rotary Filter Drum

Two number of ltrate receivers (High vacuum and low vacuum receivers)
Vacuum Regulating valve
Filtrate pump
Vacuum pump of adequate capacity & One barometric condenser
One entrainment separator
Mud Mixer or bagacillo mixer

The mud to filters flows by gravity from the clarifier to mixer or by pump. In mixer
fitted with sttirrer, bagacillo from mill baggase carrier is fed continuously to the mixer.
The mixture of mud and bagacillo is continuously feed to the mud trough of filter. The
RPM of the mixer is around 20 to 25.
Mud Trough & Agitator

The mud and bagacillo mixture is continuously feed to mud trough from the mud
mixer. It is a semi cylindrical in shape. In order to avoid allowing the muds in the
filter tank to settle out, they are kept in movement by an agitator oscillating to and
fro, pivoted on the axis of the filter, and driven by a separate small motor.
Rotary Filter Drum
The filter drum rotates around horizontal axis is always partially submerged in the
mud trough. It is horizontal cylinder with corrugated surface. Which is covered by
fine copper or s. s. screens. The screen has 625 perforations per sq. inch. with
0.5mm dia and 23% clear opening area.
Filtrate Receiving Vessel

All segment tubes are united in trunnion valve through which filtrate withdrawal pipes
are drawn and led to filtrate connecting vessels under vacuum. One vessel for heavy
and other for light filtrate. Low vacuum maintained through control valve. Top side is
connected to vaccum pump for extraction of air and vapour to create vacuum. Bottom
side pipes are immersed in the sealing tank.
Vacuum Pump & Condenser

Vaccum pump create vaccum inside the system. it’s capacity is about 18 meter
cu air suction per square meter of filter area. The condenser condenses the vapour
sucked from the filtrate the pump located near treated juice receiving tank.
As per Peter Rein Approximately for 100m2 lter area required Vacuum pump capacity – 520 to 680L/sec and Condenser
cross section area- 0.48m2 required.
Entrainment Separator
Entrainment into the filter condenser is not normally a problem if the filtrate tank
cross-section area is sufficiently large, the filtrate entries directed tangentially
downwards into the tank, and the gas vent to the condenser taken from the highest
point in the tank. However, vacuum Leaks in the filtrate pump seals and tanks have
to be avoided. Some sources recommend that filtrate pipes be of corrosion-resistant
material, and that a generous head drop be
arranged between the filtrate receivers and the filtrate pumps.
Typical Analysis of Filter Drum Working :
Surface of drum is equally distributed in 24 nos. Segments having following

distribution criteria for flow flowing activites table clearly indicate that by in design.
Now the surface area is distributed for different activities. At the same time. The
retention time for each activity may be easily allocated for efficient operation.
Surface area % Vacuum

Activities Retention time Nos. Tubes Area in radius
wise Distribution
Formation of cake 16% 8” low 40 sec 4 Nos. 600
Build up of cake 16% 8” low 40 sec 4 Nos. 600
Washing of cake 33% 15” high 80 sec 8 Nos. 1200
Drying of cake 17% 15” high 40 sec 4 Nos. 600
Discharging of
18% 0” low 40 sec 4 Nos. 600
cake
Total 100% 24 no.s 3600
(https://www.sugarprocesstech.com/wp-content/uploads/2017/06/Vacuum-filters.jpg)
General Operational Parameters for vacuum filters:

The settled mud from the clarifier with 6.8 to 7.0 pH and 22 to 24 Bx contains the muddy
juice temperature above 80 O C. For better filtration temperature should be on higher
side. As viscosity of juice is inversely proportional to temperature. Low viscosity favors
the filtration.
% Pol in F.C =1.5 to 2.5
% Humidity in F.C = 70 -80
High vacuum = 350 to 450 mm of Hg
Low vacuum = 200 to 250 of Hg
Cake thickness = ¼ – ½ inch
Wash water pressure = 2.0 -2.5 kg/cm2
Wash water temperature = 60 – 75OC.
Speed rotation = 3 – 5 min. per rotation
Amount of bagacillo = 5 – 7 kg per ton of cane
Wash water % lter cake = 150% max.
F.C % cane = 3 – 5 % on cane

Example for calculation.
Taken one example for 8000TCD plant
Vacuum filter requirement:
Crushing Rate – 8000TCD (360 TCH for 22 hours)
Vacuum filter screen area requirement – 0.6 m 2 /TCH
So screen area required – 216 m 2 ( i.e for example 12Ft x 24Ft size vacuum filters 3
no.s required 3 x 84m 2 = 268m 2 )
Production of filter cake:
Production of filter cake will be 60 to 75 Kg/hr/m 2 screen area and the average is
67.5 Kg/hr/m 2 .
Total production of filter cake for 360TCH would be =216 X 67.5 =14.58 T/hr ( Filter
cake % cane is 4%)
For 268 Sq. Mtrs it would be 18 to 20 T/Hr. ( which is equivalent to our FC % cane of
4.5 to 5%)
Bagacillo Requirement:
Quantity of Bagacillo required = 6 to 8 Kg/TCH

Quantity of Bagacillo required for 360 TCH plant =360 X 7 Kg/hr =2520 Kg/hr
Bagacillo screen Area Requirement:
General Consideration value for bagacillo for 5mm hole dia screen having 65
kg/m 2 /hr.
Screen Area required for bagacillo = 2520/65 = 38.76m 2
Wash Water Requirement:
Wash water requirement for filters is 4 to 6% on cane or 150% on cake.

For 360 TCH plant, the wash water requirement would be =360X 0.06=21.6T/hr
Criteria for Efficient Running or Optimization filter cake Pol.

Vacuum (https://en.wikipedia.org/wiki/Vacuum) ( Low and High vacuum
levels).
Low vacuum: 8 to 12’’
• Function: Formation and build up of cake.

• If too low: Filter cake will either not form or will not have the necessary
consistency. when washing the cake with water under pressure from the sprays, the
filter cake will drop off the screens which affect the filter operating capacity.
• If too high: More solids goes through the heavy filtrate and screens will be
chocked.
High vacuum : 15 to 20’’
• Function : Washing and drying of cake.

• If too low: The washing and drying the cake would be deficient. This would results
in filter cake with high sucrose.
• If too high: Filtrate would be more cloudy and there would be a tendency for the
screens and suction tube to clog.
Bagacillo
Bagacillo Act as a filtering medium and increase the porosity of cake. Hence
bagacillo should be uniform in size and is adequate quantity. Bagacillo quantity will
depend on the texture or density of mud. If the mud is too diluted it will be necessary
to apply more bagacillo and vice versa.
a) Normally the quantity of bagacillo is from 6 to 8 Kg per ton of cane crushed.
b) Excess of bagacillo reduce the operating capacity of the filter. Adversely affect the
exhaustion the filter cake and increase the polarization and sugar losses.
c) Lower bagacillo quantities reduces the filtering action. The filtrates are a lot of
more cloudy and it may cause clogging of the screens and suctions tube due to the
greater amount of solids that pass with the juice. The action of the scrapper is also
affected which does not clean the screens.
Washing of Cake
a) Remove the sugar from the cake by displacement principal.
b) Quantity of wash water 150% on filter cake and wash water pressure of around 3
Kg/cm 2 .
c) Part of soluble impurities are picked up during the washing. Resulting is a drop in
purity of the juice reaching the filter and the clear filtrate leaving it. This drop is
generally of the order of 2-4 units.
Wash water temperature maintained 60 to 650C.

a) To achieve an efficient exhaustion of the sucrose & less Wax in the filtrates.
b) If temp is high: Extract a larger amount of undesirable impurities, more wax will
enter in the process, affecting the filter ability and quality of commercial sugar.
c) If temp is low : Desugarisation the filter cake is not achieved,results higher pol in
filter cake.
Speed of the drum: 3 to 5 min per revolution.

a) If bagacillo application constant.
b) If too slow: The filter cake is too thick which would result in higher pol.The mud
volume should be increased ,reduce the capacity.
c) If too high :exhaustion and washing should not be proper.
Thickness of Filter cake – 1\4” to1\2”.

a) If too much:- the exhausting of the sucrose in the mud is less ,the pol in mud will
be higher and sugar losses will be greater .
b) If too thin :operating capacity of the filter is adversely affected more.cloudy

filtrate, risk of clogging in the screens and suction tubes.
Mud Temperature & Trough Level:

80-85 0 C after the addition of the bagacillo. Below that temp there is a risk of waxes
blocking the gauge.
If trough level is higher, the cake should be thin.
If trough level is lower, the cake should be thick.
General Causes of mud trouble in Juice Clarifier

Low vacuum & unsatisfactory working of lters.
Lower P2O5 content in juice
Faulty addition of occulent dosage
Poor mill sanitation
Excessive staling of cane
Over matured or deteriorated cane
Diseased cane
Poor quality lime
Higher brix of mixed juice
Cane Quality
a) The cane quality is first important aspect while discussing the mud settling rate.
b) The cane shall be free from all extraneous matter as far as possible. In some
sugar mills, cane quality is given prime importance and cane received is almost free
from extraneous matter. In such situation definitely the mud settling rate is always
good.
c) In case of flood affected cane may also lead to higher mud level in clarifier. A
cane washing laundry as being practiced in number of countries where mechanical
harvesting is practiced may be helpful for maintaining lower mud level in clarifier.
d) The cane washing is helpful for removal of mud, sand and other extraneous matter
which decreases.
e) The cane shall be fresh as far as possible. The cane staling time shall not be
more than 48 hours. Considering the recovery, the cane staling shall not be more
than 24 hours.
f) The stale cane is increases microbial products such as dextran in cane juice.
These products are not settled easily in clarifier and increase the turbidity as well as
colloids in clear juice.
Mill Sanitation (https://www.sugarprocesstech.com/terminology-sugar-

clari cation/)
a) At mills, the growth of microbes shall be controlled well. It is generally observed
that the microbes grow well at various corners and surrounding of mill station as the
cane juice is excellent medium for growth of microbes.
b) Leconostock mesenteriods at dead pockets of mill juice gutters, cane carrier

chains, mill inter carrier chains etc.
c) Advisable to have permanent steam washing arrangement for chains of cane

carrier and mill inter carriers.
d) Washing of mill surrounding and dead pockets of juice gutters shall be made twice
in a shift so as to resist the microbial growth and to reduce microbial growth products
in extracted juice.
e) DSM screens or rotary juice screens are also one of the important station for
growth of microbes and shall be paid due attention for cleaning and washing.
E ect of Imbibition Water

High temperature imbibition water (max. 70 0 C) is also helpful for reducing microbial
population as well as microbial products in the extracted juice. At the same time the
high temperature water will help in extracting more sugar. Higher % of imbibition
water is useful for reducing mud level by reducing the brix % of clear juice.
Muddy Juice pH
a) It is general opinion that bacterial activity is reduced at higher temperature. But
recently it has been established that some thermophillic bacteria continue their
activity even at 100 o C.
b) If muddy juice remains stagnant for long time in clarifier then such incidents are
noticed. The drop in pH below 6.5 of muddy juice is the indication of microbial
activity. In such case, the muddy juice becomes highly viscous and filter cake
porosity decrease to a great extent.
c) To combat such problem it is beneficial to increase muddy juice pH above 8.0 and
to process of all muddy juice with in minimum time possible.
d) This should be done immediately either by reducing crushing rate or in extreme

cases by mill stoppage.
Sulphited Juice Temperature

a) The temperature of sulphited juice before flash tank should be 102 0 C plus.
b) It is observed that in some factories the mud trouble is a result of lower

temperature of sulphited juice due to scaled juice heaters or short circuiting of
sulphited juice and raw juice. The short circuiting of juice is either due to faulty
double beat valves or bent juice heater lids.
Summery :
Author : Sudheer Godavarthi , KCP SUGAR & INDUSTRIES CORPORATION LIMITED
Short Description : Accessories of Rotary Vacuum Filter and its operation in sugar
industry | Criteria for Efficient Running or Optimization of filter cake sugar Loss |
General Causes of mud trouble in Juice Clarifier
(https://www.sugarprocesstech.com/wp-
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17 thoughts on “Vacuum Filter Description in sugar industry |

Optimization of Sugar Loss”
Reply
Suryakant Takawane (June 26, 2017 - 6:36 am)
Nice
Reply
Awanish kumar (July 21, 2017 - 10:15 am)
Sir please confirm press mud density, generated from RVF.

Reply
*Raghvendra Srivastava (August 14, 2017 - 1:47 am)
I want on line calculation

Reply
siva alluri (http://www.sugarprocesstech.com) (August 17, 2017 - 3:56 pm)
thank you sir

In next revision of this article we will provide online calculator
Reply
A P Bhatt (August 21, 2017 - 5:53 pm)
.785Dia*Dia*velocity= Valume flow rate

Reply
MAHESH R (October 17, 2017 - 6:42 am)
It’s super
Reply
siva alluri (http://www.sugarprocesstech.com) (October 19, 2017 - 12:02 pm)
Thank you
Reply
Neeraj kumar rajput (October 19, 2017 - 7:07 am)
Sir what is the angle of mud trough please reply

Answer a short period
Reply
siva alluri (http://www.sugarprocesstech.com) (October 19, 2017 - 12:22 pm)
Mud trough angle depend upon vacuum filter drum dia. According to drum dia trough
dia will be provided.
Reply
Ikenna Iheanacho (October 21, 2017 - 3:21 am)
Illuminating piece. thank you

Reply
BAHMED (March 8, 2018 - 11:48 am)
I can have the analysis of the turbid filtrate liquid and the nature of the solids, their
size and their content? Thank you
Reply
siva alluri (http://www.sugarprocesstech.com) (March 8, 2018 - 3:18 pm)
The “www.sugarprocesstech.com” invites to all sugar technologists to share your

knowledge, achievements in your working organization and new developments and
technologies in sugar industry and its concerned units. It is very much helpful to show
your identity to the world at the same time it will helpful to another technologist to
enhance their insight and enhance great execution in there working.
[email protected] (mailto:[email protected])
Reply
Salman (April 2, 2018 - 6:04 am)
I want to know for angular distribution of hi, low and no zone of rotary vacuum filter.
Reply
siva alluri (https://www.sugarprocesstech.com) (April 6, 2018 - 1:40 pm)
Read this article to know the angle distribution

https://www.sugarprocesstech.com/rotary-vacuum-filter/
(https://www.sugarprocesstech.com/rotary-vacuum-filter/)
Reply
Deshraj singh (June 9, 2018 - 1:55 pm)
Thanks
Reply
siva alluri (http://www.sugarprocesstech.com) (June 13, 2018 - 5:35 pm)
Thank you Mr.Deshraj singh

Reply
Aseem Kumar (http://Know) (December 20, 2019 - 7:24 am)
Hello Sir, Lekh padkar achcha laga, But I need Everyone , start to Cane yard ,
Deficater , quard, Magma mixer , Raw sugar ,Raw pan, MCS/SCS, Refinery , Refinery
pan se Suger FBD , tak ki jankari chahiye, Prosses oprate system with pictures
please send me,
Thank you.
WhatsApp:-. 07457876717
or email :-
[email protected] (mailto:[email protected])
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Vacuum Filter Description in Sugar Industry - Optimization of Sugar Loss

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2/5/2020 Vacuum Filter Description in sugar industry | Optimization of Sugar Loss

Vacuum Filter Description in sugar industry | Optimization of Sugar Loss

Vacuum Filter Operation in sugar industry | Optimization of Sugar

Accessories of Rotary Vacuum Filter:

Rotary Filter Drum

Mud Mixer or bagacillo mixer

Mud Trough & Agitator

Rotary Filter Drum

Filtrate Receiving Vessel

Vacuum Pump & Condenser

Typical Analysis of Filter Drum Working :

Surface of drum is equally distributed in 24 nos. Segments having following

Surface area % Vacuum

General Operational Parameters for vacuum filters:

F.C % cane = 3 – 5 % on cane

Taken one example for 8000TCD plant

Vacuum filter requirement:

Crushing Rate – 8000TCD (360 TCH for 22 hours)

Vacuum filter screen area requirement – 0.6 m 2 /TCH

Production of filter cake:

Quantity of Bagacillo required = 6 to 8 Kg/TCH

Bagacillo screen Area Requirement:

Screen Area required for bagacillo = 2520/65 = 38.76m 2

Wash Water Requirement:

Wash water requirement for filters is 4 to 6% on cane or 150% on cake.

Criteria for Efficient Running or Optimization filter cake Pol.

• Function: Formation and build up of cake.

High vacuum : 15 to 20’’

• Function : Washing and drying of cake.

a) Normally the quantity of bagacillo is from 6 to 8 Kg per ton of cane crushed.

a) Remove the sugar from the cake by displacement principal.

Wash water temperature maintained 60 to 650C.

Speed of the drum: 3 to 5 min per revolution.

c) If too high :exhaustion and washing should not be proper.

Thickness of Filter cake – 1\4” to1\2”.

b) If too thin :operating capacity of the filter is adversely affected more.cloudy

Mud Temperature & Trough Level:

If trough level is higher, the cake should be thin.

If trough level is lower, the cake should be thick.

General Causes of mud trouble in Juice Clarifier

Mill Sanitation (https://www.sugarprocesstech.com/terminology-sugar-

b) Leconostock mesenteriods at dead pockets of mill juice gutters, cane carrier

c) Advisable to have permanent steam washing arrangement for chains of cane

E ect of Imbibition Water

d) This should be done immediately either by reducing crushing rate or in extreme

Sulphited Juice Temperature

b) It is observed that in some factories the mud trouble is a result of lower

Author : Sudheer Godavarthi , KCP SUGAR & INDUSTRIES CORPORATION LIMITED

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 Categories: Clari cation (https://www.sugarprocesstech.com/category/clari cation/), Clari er

(https://www.sugarprocesstech.com/category/clari cation/clari er/), Mud Filters

(https://www.sugarprocesstech.com/category/clari cation/mud- lters/) | / 17 Responses / by siva alluri

Carbonation Process Sugar Factory Melt Clarification

Flow...  Calculations in Clari cation

17 thoughts on “Vacuum Filter Description in sugar industry |

Sir please confirm press mud density, generated from RVF.

.785DiaDiavelocity= Valume flow rate