Applications of Electronic Science in Sugar industries

Applications of Electronic Science in Sugar industries

Dissertation REPORT

S.B. Jagadal KARNATAKA STATE WOMEN’S UNIVERSITY BIJAPUR 1

Chapter 1

Introduction:

The Objective behind drafting of this dissertation Report is to fulfill the

course requirement in Final Semester for successful completion of the

course.

This topic gives a major land mark to achieve & enhance the

knowledge of application of electronics in real world scenario, so our

visit to sugar factory is decided that to a leading factory world known

and best managed.

The technology used in the various stages of production in the

extraction of juice, evaporation, concentration of the juice, options for

improvement towards increasing the efficiency and reducing the cost of

sugar production as well as options to increase yield of sugar and

utilizations of bagasse as identified in sugar industry.

We visited Shree Renuka Sugars Limited factory unit-4

situated at Burlatti (Kokatnur), taluka-Athani district-Belgaum. On 22nd

june 2011. along with my classmates and our guest lecturer

G.M.Nimbal.

So as to study the electronic technology

applied in this factory and process flow steps in

manufacturing the sugar and its byproducts,

However the visit took place during the off-

season and although many aspects of sugar

factory technology were discussed at length to


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gain a clear view of the way in which extensive

application of electronic automation is applied in

the industry.

Shree Renuka Sugars Limited:

India's largest sugars refiner and ethanol producer based in Karnataka & Maharashtra, with refining capacity of 4000 tonnes/day and distillery capacity of 600 Kilo liter/day It has 21% market share in India's fuel ethanol market and has an aggressive growth plan of increasing its ethanol production capacity to 900 Kilo liter/day by Dec 2009 . It also accounts for 20% of India's international sugar trade.

The company was founded by Mr Narendra Murkumbi and his mother Mrs Vidya Murkumbi in 1998 not just dreamer but doers in their own right the company is currently 5th largest sugar producer in the world. It has significant presence in Brazil.

Shree Renuka Sugars LTD is a translational

agribusiness and bio-energy corporation. It focuses

on three businesses: viz., Sugars, Bio fuels and

Renewable energy. Several steps are usually

followed to produce sugar. As explained by The

Unit Head /The Vice president Mr. K. Suresh Babu:

these are..

Mrs Vidya

Murkumbi

chairperson,

Renuka Sugars.

Limited


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Extracting juice by pressing sugarcane Boiling the juice to obtain crystals Creating raw sugar by spinning crystals in

extractors Taking raw sugar to a refinery for the process

of filtering and washing to discard remaining non-sugar elements and color.

Crystallizing and drying sugar Packaging the ready sugar

Head of the unit Mr Suresh babu presented a

detailed overview of the fatory process flow and

Fact and figures in the production. He introduced

Mr. Udayakumar.A.Payappanvar Sr. Manager(C&I)

and Mr.Sanjay.D Head of electrical department

Mr.Udayakumar discussed regarding the electronic

instrument such as temperature sensors, weighing

machines, pressure gage, strain gage flow meter,

temperature sensors, PLCs, liquid level monitoring

controllers etc in the morning session.

The next minute Mr.Sanjay explained about

the electrical component of the factory. Factory

generates 23 M watts of power and it consumes 16

M watts only and remaining power is exported to

KEB at the cost of Rs.3/unit. They produce

electrical energy by using steam.

A home steam system consists of a boiler

with a furnace to turn water to steam, a steam

Mr .Suresh Babu Head of the Unit 4

Renuka sugars

Limited

Mr. Sanjay. .and

Mr Suresh babu

..


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engine to convert the steam energy to rotary

motion to drive a generator, and a system to re-

circulate the water once the steam has turned back

into water. During the re-circulation of the water

utilizing the exhaust steam heat (providing hot

water and heating the home itself) increases the

efficiency of the system.

The staff gave us the valuable information that all the byproducts of the factory are utilized by the factory itself and there is very less wastage. The concept of cogeneration has enhanced the value of bagasse as a main source of raw material for generation of power and increasing efficiency of operations and reducing power consumption in all areas of the Renuka Sugar Factory.

Potential for energy conservation in sugar industry is immense because of the fast developments that are taking place in the industry

This highlights the importance of energy conservation to enhance the viability of operations of sugar industry and also to prepare the industry to meet the requirements of the concept of energy Cogeneration and energy conservation.

Mr .udaya kumar

giving lecture on

electronic

instruments and

automation

Mr sanjay giving

lecture on power

generation

Mr Uddaya

kumar

Giving lecture


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Chapter 2

Overview of sugar industry:

India has been known as the original home of sugar and sugarcane. India is the second largest producer of sugarcane next to Brazil. Presently, about 4 million hectares of land is under sugarcane with an average yield of 70 tonnes per hectare. India is the largest single producer of sugar including traditional cane sugar sweeteners, khandsari and Gur equivalent to 26 million tonnes raw value followed by Brazil in the second place at 18.5 million tonnes. Even in respect of white crystal sugar, India has ranked No.1 position in 7 during last 10 years.

The sugar industry in Karnataka is also a major employer of millions of people in the state. Almost one million people are involved in the Karnataka Sugar Industry both directly and indirectly. Apart from generating employment for a huge section of the rural population, the sugar factories in the state also act as community Welfare Centers. These Welfare Centers offer scope for the foundation of educational institutions, transport facilities and hospitals.

G.M,Nimbal (Lect)

& KSWU

students

Factory Manager

Mr. Sanjay and

Mr Suresh babu .


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Sugar manufacturing process.

Sugar: Sugar (sucrose) is a carbohydrate that occurs naturally in every fruit and vegetable. It is a major product of photosynthesis, the process by which plants transform the sun's energy into food. Sugar occurs in greatest quantities in sugarcane and sugar beets from which it is separated for commercial use. The natural sugar stored in the cane stalk or beet root is separated from rest of the plant material through a process known as refining.

sugar factory process

.

The process of making sugar contain a lot of step

Mature cane is transported to factory. Stalk are thoroughly washed and cut when reached to sugar Mill. After cleansing process, a machine led by a

Mr. sanjay and

Mr suresh babu

..

Mr.Udayakumar

(centre), factory

executive & Miss

Seema Msc Student

http://www.google.co.in/search?q=sugar+factory+process&hl=en&rlz=1T4SNYN_en-GBIN436&prmd=ivns&tbm=isch&tbo=u&source=univ&sa=X&ei=zkEETvGUHdGtrAep_dibDA&ved=0CDAQsAQ


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Series of rotating knives, shreds the cane into pieces. Juicing: The shredded pieces of sugar cane travel on the conveyer belt through a series of heavy duty rollers, which extracts juice from pulp. The pulp that remains or “bagasse” is dried and used as fuel. The juice moves on through the mill to be clarified. Carbon dioxide and milk of lime are added to the liquid sugar mixture and it is heated to the boiling point, as the process of clarifying begins. As the carbon dioxide travels through the liquid it forms calcium carbonate, which attracts non-sugar debris (fats, gums, and wax) from the juice, and pulls them away from the sugar juice. The juice is then pushed through a series of filters to remove any remaining impurities.

12 CO2 + 11 H2 O = C12 H22 O11 + 12 O2

carbon dioxide + water = sucrose + oxygen

Sugar cane is a genus of tropical grasses which requires strong sunlight and abundant water for satisfactory growth The purified syrup is then concentrated to super saturation and repeatedly crystallized under vacuum to produce white refined sugar. As in a sugar mill, the sugar crystals are separated from the mother liquor by centrifuging. To produce granulated sugar, in which the individual sugar grains do not clump together, sugar must be dried.

Byproducts:

Molasses is a viscous by-product of the processing of sugarcane into sugar.

Power: the power generation of the factory is also a byproduct.

Fuel Ethanol: Dehydrated ethyl alcohol, which contains at least 99.5% ethyl content. This is used for blending in petrol.

Bagasse: A fibrous residue obtained after the crushing and extraction of juice from sugarcane used as fuel in boilers.

http://en.wikipedia.org/wiki/Granulated_sugar


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Schematic diagrams of process measurement and control

Process flow snaps Juice purification process


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Lime milk preparation

Operator Panel


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Process overview 1

Process overview 2

Sugar drying and cooling


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Electrical power generation


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A-centrifugal

Batch pan-B


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Chapter 3

Application of electronic science in sugar industry.

Process control application:

Renuka sugar factory utilizes maximum number of electronic instruments and technology compared to other sugar industry. It use different kinds of temperature sensors electronic weighing meters Pressure gauges etc, plc’s are used and well adapted in the factory to a range of automation task. We have seen a number of PC’s which are interfaced with industrial I/O hardware using “soft PLCs” while executing programs within a version of commercial operating systems adapted for process control needs. LCs may include logic for single-variable feedback analog control loop, a "proportional, integral, derivative" or “PID controller”.

Distributed Control Systems (DCSs) are

custom designed processors as controllers used to control manufacturing processes such as oil refining, petrochemicals, central station power generation, fertilizers, pharmaceuticals, food and beverage manufacturing, and papermaking. DCSs are connected to sensors and actuators. Local communication is handled by a control network with transmission over twisted pair, coaxial, or fiber optic cable. A server and/or applications processor may be included in the system for extra computational, data collection, and

Shree Renuka

Sugars Limited

Instrumentation

department

inside factory ,in

front of the

factory


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reporting capability. The DCS largely came about due to the increased availability of microcomputers and the proliferation of microprocessors in the world of process control. Computers had already been applied to process automation for some time in the form of both Direct Digital Control (DDC) and Set Point Control. Panel board display is done using DCS. To control industrial system SCADA (supervisory control and data acquisition) is used in computer systems l industrial, infrastructure, or facility-based processes, industrial process include those of manufacturing, production, power production, fabrication, and refining, and may run in continuous, batch, repetitive, or discrete modes.

Human machine interface (HMI): HMI is the

apparatus which presents process data to a

human operator, and through which the human

operator controls the process. The HMI system

usually presents the information to the operating

personnel graphically, in the form of a mimic

diagram. This means that the operator can see a

schematic representation of the plant being

controlled. For example, a picture of a pump

connected to a pipe can show the operator that

the pump is running and how much fluid it is

pumping through the pipe at the moment.

M.Sc student in

power house

,explanation by

Mr.Udayakumar

Computer systems in

power house I/O

device SCADA

performance


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Programmable logic controller: A programmable logic controller (PLC) or programmable controller is a digital computer used for automation of electromechanical processes, such as control of machinery on factory assembly lines, amusement rides, or lighting fixtures. PLCs are used in many industries and machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in battery-backed or non-volatile memory. A PLC is an example of a hard real time system since output results must be produced in response to input conditions within a bounded time, otherwise unintended operation will result.

Control panel with PLC (grey elements in the center). The unit consists of separate elements, from left to right; power supply, controller, relay units

Contol panel and plc

and cards showing

,explaing by

Mr.Udayakumar

Computer systems in

power house I/O

device on arrays of

almira

http://en.wikipedia.org/wiki/Digital_computer

http://en.wikipedia.org/wiki/Automation

http://en.wikipedia.org/wiki/Electromechanical

http://en.wikipedia.org/wiki/Assembly_line

http://en.wikipedia.org/wiki/Non-volatile_memory

http://en.wikipedia.org/wiki/Non-volatile_memory

http://en.wikipedia.org/wiki/Real-time_computing

http://en.wikipedia.org/wiki/Power_supply

http://en.wikipedia.org/wiki/Relay

http://en.wikipedia.org/wiki/File:Siemens_Simatic_S7-416-3.jpg

http://en.wikipedia.org/wiki/File:PLC_Control_Panel.png


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PID controller: A proportional–integral–

derivative controller (PID controller) is a generic control loop feedback mechanism (controller) widely used in sugar industrial control system– a PID is the most commonly used feedback

controller. A PID controller calculates an "error" value as the difference between a measured process variable and a desired set point. The controller attempts to minimize the error by adjusting the process control inputs. The PID controller calculation (algorithm)

involves three separate constant parameters, and is accordingly sometimes called three-term control: the proportional the integral and derivative values, denoted P, I, and D. heuristically these values can be interpreted in terms of time: P depends on the present error, I on the accumulation of past errors, and D is a prediction of future errors, based on current rate of change. The weighted sum of these three actions is used to adjust the process via a control element such as the position of a control valve or the power supply of a heating element.

Practically all PID controllers made today are based

Inside factory

photoes

Inside the factory


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on microprocessors. This has given opportunities to provide additional features like automatic tuning, gain scheduling, and continuous adaptation. Difference Between and PLC and DCS

PLC DCS

Initial costs Lower Higher

Configuration More challenging More pre-configured

Migration Difficult Possible

Overall Costs Tends to be lower but must calculate in programming costs

to have same features

Tends to be higher particularly if you do not need all included

features

Support More readily supported system-house or by third parties

Usually supported by manufacturer

Standards Traditionally engineered for maximum integratability

Typically engineered to work best with devices from same

manufacturer

CPU memory capacity

Limited More

Reliability From device simplicity From component compatibility

Redundancy Available Available & built in some dcs

On-line configuration and

programming

More complex Yes,can be configured on line

Hotswap I/O No Yes

Troubleshooting Straightforward with simple PLC configurations; but can be

challenging in complex control configurations

Multiple intelligent units hence easy to troubleshoot

Interface to ERP/MIS/IT

Yes, but limitations.* Yes

Traditionally for Discrete and batch production with less I/O's

Suitable for continuous production and for higher I/O's

Scada Interface Available with limited features More features with many tools and liabrary functions


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Chapter 4

Process Control Equipments and Measurements

Sacchariometer: A sacchariometer is a hydrometer used for determining the amount of sugar in a solution It consists of a large weighted glass bulb with a thin stem rising from the top with calibrated markings. The sugar level can be determined by reading the value where the surface of the liquid crosses the scale. It works by the principle of buoyancy. A solution with higher sugar content is denser, causing the bulb to float higher. Less sugar results in a lower density and a lower floating bulb. Degrees Brix (symbol °Bx) sugar content of an aqueous solution the °Bx has traditionally been used in the wine, sugar, fruit juice, honey and other industries.

Figure Automatic Saccharimeter

Purity: The percentage of sucrose in

total solids is a sugar product.

MSc student in power house

,explaination by

Mr.Udayakumar

Computer systems in power

house I/O device SCADA

performance


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Density and concentration measurement:

The density measuring system is used for non-

contacting, continuous density measurement of

liquids or bulk materials in pipes and vessels. It is

easily installed on existing pipelines without

process downtime. Therefore a subsequent

installation is possible without problems. The

measurement is reliable and unaffected by color,

temperature, pressure or chemical properties of

the measurement product. The density system

provides high levels of operational safety and

requires virtually no maintenance, even under

extreme environmental conditions.

Microwave

measuring

device

Infrared

thermometer

The density and

concentration

measuring system

Density meter

http://bertholdtechn.en.ec21.com/Density_and_Concentration_Measurement--4243436_4243704.html

http://www.rudolphresearch.com/density_meters/index.php


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Moisture Measurement:

Using the microwave measuring systems technology

concentration, dry substance, moisture and water content can be measured during the ongoing process in a wide variety of sugar products.

Neutron Moisture Measurement

For the continuous determination of moisture in bulk solids, the neutron moisture measurement gives a representative moisture signal in sugar and bagasse.

The neutron moisture measurement is based on the principle that fast neutrons are slowed down (or moderated) through their collision with hydrogen nuclei. Thus, a cloud of slow neutrons is created around a source of fast neutrons coming from an americium/beryllium source, while the concentration of slow or thermal neutrons depends only on the hydrogen content in the measuring volume. The Nuclear measurement will not change the products being measured. The measurement is independent of High temperature High pressure or vacuum Volatile and biohazard material Corrosive material pH value and color of the product


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The level measurement system: is used for the non-contacting, continuous measurement of liquids and bulk materials in reactors, vessels and bunkers. Chemical and physical properties of the product do not affect the measurement.

The level measurement is adapted to the

specific geometry of the vessel. The evaluation unit

incorporates state of the art microprocessor

technique with 32-bit processor for high computing

performance and high accuracy together with most

simple operation. The software is tailor-made to the

measuring principle.

Figure 1 level suitch

level meter level switch

MSc student in

instrumentation

department

explaination by

Mr.Udayakumar

Observing instrument

in instrumentation

department

Flow meter


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Magnetic flow meter

Ball valve

Magnetic flow meter:

Principle of operation:Electromagnetic flow meter is based on faraday’s law of electromagnetic induction. In a electromagnetic flow meter, magnetic field is generated by a set of coils. As the conductive liquid passes through the electromagnetic field, an electric voltage is induced in the liquid, which is directly proportional to its velocity. This induced voltage perpendicular to both the liquid flow direction and the

electromagnetic field direction. The voltage sensed by the electrode is further processed by the transmitter to give standardized output signal or displayed in appropriate engineering units on LED display. This meter is more suitable to those fluids which present difficulties in handling, Fluids such as effluents, slurries, pulps, brines & other highly corrosive liquids, acids bases, wash, fermenter-molasses etc.

The meter offers no resistance to flow hence the pressure drop is almost negligible. The measurement being based on Faraday’s law of electromagnetic induction is independent of viscosity, density, pressure & temperature of flowing medium.


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Magnetic Flow Meter Diagram (insertion probe)


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Pressure gauge & Differential pressure gauge

Pressure gauge: Elastic elements when subjected to pressure get

deformed. This deformation when measured gives an indication of the

applied pressure. These elements may be in the form of Diaphragm,

Bourdan Tube, Capsules, Bellows, Helical Tube. Etc. These deformations

can be measured by

mechanical means It is an

instrument for measuring the

condition of a fluid (liquid or

gas) that is specified by the

force that the fluid would

exert, when at rest, on a unit

area, such as pounds per

square inch or Newton’s per

square centimeter.

BOURDEN TYPE PRESSURE GAUGE: These types of pressure gauges are

mainly using in power plant, sugare industry, refineries and other

Industrial Process Applications. It ranges from 1 kg/cm² to 2000 kg/cm²


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Temperature Sensors &Gauges:

Different types of temperature sensors are

used in Sugar factory among them are Infrared

thermometers, laser thermometers, bimetallic strip

Temperature gauges bolometer, gardon gauge, heat

Flux sensors etc

Bimetal & Mercury Temperature Gauges:

Temperature in process material can goes up

to 1000deg.C. or more for certain applications.

Suitable sensors for high temperature or ambient

conditions are used in sugar mill. A sensor is a

device which receives and responds to a signal.

Integral type flow

meter

Remote type Flow m eter

Thermocouple sensor

for high temperature

measurement

Temperature guage

Remote type Flow m eter and pressure

guages in

intromentation

department


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Microwave measuring technology for the sugar

industry:

The microwaves used for measuring systems in the sugar industry typically have frequencies of approximately 2.5 GHz and are not very powerful.

The components of a product stream are polarized at varying strengths during microwave transmission through the product, resulting in the microwave signal losing speed and energy. The

speed reduction brings about a phase shift in the signal, and the weakening of the energy affects an attenuation of the microwave If

free charge carriers or polar materials like water molecules are present in the product, this effect is disproportionately increased. The water influence on the signal is around 40-times greater than the influence of other components such as sugar. Hence, it is clear how selectively sensitive the measurement is to water concentration.

The correlation between water content and dry substance enables a very precise measurement of the concentration, brix and density in all stages of sugar production.

In measuring the dry substance of magma, the microwave measurement technique accounts for the dry substance of the crystals in a similar manner to

Microwave

measuring

device in the

factory

The density and

concentration

measuring system

http://bertholdtechn.en.ec21.com/Density_and_Concentration_Measurement--4243436_4243704.html


Dissertation REPORT


the dry substance of the solution. For calibration, the microwave signals (phase and attenuation) are referenced to the laboratory analyzed value of the sample. If crystals are present in the sample, these must be initially dissolved (by dilution) and the total solids content of the solution determined. Thus, the microwave system always measures the actual dry substance content, regardless of whether the sugar is in solution or partially crystallized.

This results in a simple calibration process as well as a high reliability for use in crystallization. Calibration samples can be taken evenly spread over the entire crystallization process, regardless of whether the sugar is in solution or in the magma phase. Two samples are sufficient to determine the calibration equation, which is mostly linear.

PH measurement:

During carbonation, the pH must be high enough to remove lime in the form of calcium carbonate (limestone). But if the pH becomes too high in the first carbonation then the calcium will actually complex with the sucrose and negatively affect yields.

The pH sensor is inserted directly into the process extraction house.

The high pH prevents the sugar from becoming starch or reverting to non-sucrose forms. Organic acids are changed into salts for later removal by precipitation. Foreign matter is kept in suspension for removal by filtration. To prevent scale buildup in subsequent stages, the mill must remove the excess

Instruments

The calibration of

measuring system


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lime via carbonation. One way to improve pH control is to

connect the fresh water flow as the main disturbance

variable with the output value of the pH controller

(13). As a result, a specific acid quantity is added to a

specific volume of water, to achieve a defined ratio.

The pH controller then influences the process by only

changing the acid quantity. The continuously

measured values (pH and Brix degree in the middle of

the extraction tower, Brix degree of press water) allow

for continuous monitoring of the extraction value and

early recognition of disturbances.

Machineries In the

factory

Flow meter


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Sugar Mill Accessories: Industrial Automation Systems, Process Control

Instruments, Temperature Sensors, Thermocouples,

Temperature Scanners, Recorders, Digital

Temperature Indicators, Controller, Scanners,

Automation Systems, Instrumentation Panels, Data

Acquisition System, Switches, Proximity Switches,

Safety Switches, PID Controller, Electronic Instrument

for sugar Industry, Counters, Preset Counter, Timers,

Sequential Timers, Programmable Counter,

Controllers, Signal Transmitters, Signal Isolator, Signal

Converter, Industrial Control Switches, Drives (A/C,

D/C ), Variable Frequency Drive, Level Controllers,

Indicators, Level Switches, Float Switches, RF

Capacitance level instruments, Microprocessor based

Instruments, Microprocessor Temperature Systems,

Microprocessor Length Counter, Photo Electric

Sensor, Photo Sensor, Switch Mode Power Supply,

CVT, UPS, Servo Stabilizers, SCADA System, PLCs

Packing & Packaging Machines

Meter board display

Simulation of process

flow and monitoring

using SCADA software


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Conclusion: This dissertation report is a sincere effort to give the overview of

electronic Technology applied in the process of automation of sugar factory, and gives a brief account of electronics instruments in the process flow of sugar production and explanations of sugar factory accessories which we have seen during the visit to Renuka Sugar Factory.

This report contains, the principles of operation of the different electronic devices, measuring instruments and circuits. These have been discussed in brief and a set of simulated demonstration using process flow diagrams are included wherever possible for the understanding of concepts of sugar production.

This dissertation visit testifies that everything learned in theory during this course is applied in the real life situation.

The theory gives the fundamentals of a subject, to see how these Fundamentals put in practice is a good experience for us by this visit to sugar factory.

Applications of Electronic Science in Sugar industries

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