VERTICAL CONTINUOUS PAN AUTOMATION BASED ON YUTECH FLUID-DENSITY-BRIX ANALYZER CUM CONTROL SYSTEM AND MOTORIZED FLUID-DENSITY SENSOR

VERTICAL CONTINUOUS PAN AUTOMATION ADVANTAGES:

MAINTAINED SEED-TO-SYRUP RATIO AT ALL TIMES, ENSURES CONSTANT GOOD QUALITY PRODUCT
ACCURATE FLUID-DENSITY- BRIX SENSING IN EACH COMPARTMENT ENSURES MAINTAINED BRIX THROUGHOUT THE CHAMBER AT ALL TIMES
MAINTAINED BRIX ENSURES VERY LITTLE OR NO ADDITION OF WATER THUS INCREASING EFFICIENCY
STEPWISE INCREASE IN BRIX OF THE MATERIAL IN EACH CHAMBER IS ACHIEVED EFFICIENTLY TILL THE FINAL DISCHARGE
VACUUM CONTROL AND MAINTAINED VALUE WITH TEMPERATURES MAINTAIN EQUILIBRIUM IN THE ENTIRE PROCESS
VFD SPEED CONTROL AS PER PAN CHAMBER LEVEL ENSURES PROPER MIXING OF MATERIAL THROUGHOUT THE CHAMBER
SYNCHRONIZATION BETWEEN THE PRECEDING AND NEXT CHAMBER IS MAINTAINED
SEMI-AUTOMIC / AUTOMATIC DROP CONTROL IN ABNORMAL CONDITIONS IS CONTROLLED AND THERE IS NO LOSS OF MATERIAL OR TIME
ENSURED LOWER LOSSES AND VERY HIGH PROFITABILTY

VERTICAL CONTINUOUS PAN AUTOMATION:

SEED / MAGMA AND SYRUP / MOLASSES FLOW SENSING
SEED OR MAGMA FLOW CONTROL WITH RESPECT TO MOLASSES OR LIQUOR FLOW ENSURES MAINTAINED MOLASSES-TO-SEED RATIO
FLUID-DENSITY-BRIX SENSING AND SYRUP / MOLASSES INTAKE CONTROL
AUTO WATER INTAKE IN THE CHAMBER IF PROCESS CONDITIONS DEMAND IT WITH RESPECT TO FLUID- DENSITY-BRIX
HEATING STEAM / VAPOUR CONTROL WITH RESPECT TO FLUID-DENSITY-BRIX
VFD SPEED CONTROL AS PER PAN CHAMBER LEVEL
TEMPERATURE SENSING THROUGHOUT THE PAN CHAMBER TO ENSURE UNIFORM TEMPERATURE INSIDE THE CHAMBER
SEMI-AUTOMIC / AUTOMATIC DROP CONTROL IN ABNORMAL CONDITIONS
STANDALONE SYSTEM FOR PAN CHAMBER FLUID-DENSITY- BRIX CONTROL AND COMMUNICATION WITH MAIN VCP PLC / DCS SYSTEM

YUTECH approaches Vertical Continuous Pan Automation from the Process Point of View, not a typical Automation Perspective.

We aim to achieve maximum throughput in the same Batch Time by properly controlling process parameters to improve process dynamics, resulting in consistent maximum capacity production, with the best possible grain size and sugar quality. The following Procedures are performed in a Controlled Manner:

Seed / Magma Flow Control with respect to Syrup / Molasses Flow as a Ratio Control.
Auto Feeding of Syrup to each Compartment based on Fluid Consistency-Brix Sensing to maintain / build Preset Brix.
Auto Selection of Syrup (or Molasses) or Water depending on Consistency-Brix.
Steam Control wrt Consistency-Brix.
Callendria Vapour / Heating Steam Pressure Control.
Overall, Pan Vacuum Control by Condenser Automation.
- Please check our Condenser Automation Presentation
Massecuite Overflow Control wrt Compartment Consistency-Brix.
Massecuite Bottom Drain Control wrt Consistency-Brix into next Compartment or Abnormal Conditions
Bypass next Compartment and send material to another compartment wrt Level / other abnormal condition of next Compartment
Wash Water and Wash Steam Intake after Material Discharge
Intake of Fresh Material from Previous or Earlier Compartment and repeat procedure
Seed or Magma Flow Control with respect to Molasses or Liquor Flow:
- Molasses and Seed Flowmeters sense Flow.
- Ratio Controller delivers exact Flow of Seed wrt Molasses Quantity by Controlling Seed / Magma Pump VFD.
Individual Compartment Brix Control by Auto Feeding Molasses or Water into each Compartment:
- Fluid-Density-Brix Sensing of each Compartment by YUTECH Fluid-Density-Brix Analyzer
- Control of Molasses Intake Valve w.r.t., Consistency-Brix Set Point, and Process Value in a PID Mode
- Addition of Water when required as per Process Dynamics.

BASIC SCIENCE BEHIND FLUID-DENSITY-BRIX:

Fluid-Density: the Density of a particular Fluid.
Density: is defined as" Mass per unit volume", which means it is the Mass contained in a fixed volume. It is denoted by "p" which is a Greek Letter called "Rho".
Density can be derived using the formula "p = m/v" where p is the Fuild-Density, m is the Mass and V is Volume. The unit to measure Fluid- Density is kg/m3 (Kilogram per cubic meter).
Brix: the measurement in percentage by weight of sucrose in pure water solution.
Online Direct measurement of Brix in a Process Fluid is difficult, so indirect methods are used.
The most popular ways of measuring Brix are:
- Hygrometric and Refractometric (Lab Methods).
- High-Frequency or Radio-Frequency Conductivity type Brix Sensing.
- Microwave Type Brix Sensing.
- Fluid-Density Type Brix Sensing.
While Conductivity or Microwave methods are very successful in measuring Brix of "B and C" Massecuite in CVP, Brix of Sugar Melt, and Brix in a Molasses Conditioner unit, they cannot measure Brix of "A" Massecuite as we measure the Fluid's electrical quality which is variable.
Fluid-Density Measurement using a Motorized Stirring Sensor proves very successful as it directly measures the Fluid's mechanical quality of Fluid irrespective of its electrical characteristics. Thus measured Fluid-Density Value is further processed in the Fluid-Density- Brix Equation, to derive Fluid-Density-Brix.

Salient Feature:

Fluid-Density Type Brix Analyzer System targets sensing the Fluid-Density of Liquids, Slurries, or Syrups like Sugar Massecuite, Sugar Syrup, Sugar Melt, Liquors, and Molasses.
The Motorized Fluid-Density Sensor is specially designed to be inserted in a vessel to stir the Fluid Media and Measure its Fluid-Density which can be expressed in simple terms as the Tightness or Thinness of a Fluid Media. It can also be informally referred to as the Consistency of the Fluid and is a Mechanical Property of a Fluid which in Liquids is directly proportional to its Viscosity.
Motorized Sensor's torque and power which is required to stir the Fluid varies with varying Fluid-Density.
The Motorized Fluid-Density Sensor's Power Consumption is directly proportional to the Fluid's Density.
The variation in the Motorized Fluid-Density Sensor's Power Consumption is sensed by the Fluid-Density Type Brix Analyzer's highly accurate Sensing Circuitry, this deviation is further processed to Derive the Raw Fluid-Density Value.

We are Manufacturer, Supplier, Exporter of Fluid-Density Sensor, Analyzer Sensing the Fluid Density of Liquids, Slurries, or Syrups like Sugar Massecuite, Sugar Syrup, Sugar Melt, Liquors and Molasses, India.