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Application Note914DNS2018
1 www.springres.com
Application Note914DNS
Density Measurement for Sugar & Alcohol Industry
Application Note914DNS2018
2 www.springres.com
SummaryDensity Meter for Sugar & Alcohol Industry. ..............................................................................................................................................3
1. Mill Tandem, Brix Measurement. ................................................................................................................................................................3
1.1 The Primary Juice. .....................................................................................................................................................................................4
1.2 The Secondary Juice. ...............................................................................................................................................................................4
2. Decanters, Mud Concentration. .................................................................................................................................................................5
3. Evaporators, Brix Measurement. ................................................................................................................................................................6
3.1 Brix measurement at the Pre-Evaporator. .........................................................................................................................................6
3.2 Brix measurement between Evaporators. ........................................................................................................................................6
4. Vacuum Pan, Brix Measurement.................................................................................................................................................................7
5. Must control, Brix Measurement. ...............................................................................................................................................................8
6. Fermentation Tank, Brix Measurement. ...................................................................................................................................................9
7. Anhydrous Alcohol, Grade Measurement. ..............................................................................................................................................9
8. Hydrous Alcohol, Grade Measurement. ...................................................................................................................................................10
Application Note914DNS2018
3 www.springres.com
Density Meter for Sugar & Alcohol Industry.The Springfield Density Meter model 914DNS will read the differential pressure of a pair of sensing diaphragms fixed
into a vertical column, given the distance between these sensors, the density of the oil fill and the local gravity, the
914DNS will calculate the Specific Density leading to the measurement of Brix, alcohol concentration and other
optional density units; the preferred unity scale for this industry is Brix.
Sugar & Alcohol manufacturing process is all about density. Given the raw product sugar cane, the processing plant
will extract the juice (Mill Tandem), filter (Decanters), reduce to syrup (Evaporators) and force the sugar crystallization
(Vacuum Pans). In every step of these processes density measurement and control will bring a major result in sugar
quality and energy efficiency of the processing plant.
For the alcohol production, the processing plant will get the juices from the mills and or the syrup from the
Evaporators, will make an ideal fermentation mix (Fermenting Tanks), filter the batch and extract the alcohol from the
fermented mixture (Distillery Columns), here too density control is extremely important.
An average Sugar & Alcohol plant can have from 20 to 30 points requiring density measurement, each point will
have its particular constraints, such as measurement range, product temperature, sampling method, static pressure,
turbulences, embedded bubbles, embedded debris, corrosion levels, installation issues, operator access, and control
strategy as well. The following chapters will address and explain many of these constraints, suggesting solutions to
optimize the performance of the 914DNS to measure density at every point of the process plant.
1. Mill Tandem, Brix Measurement.
Fig. 1. - Mill Tandem
Most Mill Tandems will have at least 4 sets of mills, so the sugar cane will be pushed from one into the next for further
crushing to remove nearly all the juices from the mass. The first set of mill will extract the Primary Juice, the following
sets will extract the Secondary Juice, these juices are handled separately until they reach the Decanter area for
clarification.
Application Note914DNS2018
4 www.springres.com
1.1 The Primary Juice.
The Primary Juice is extracted from the first Mill, it will represent nearly 50% of all juices to be processed by the plant,
so the first mill has a tremendous extraction rate.
The Brix measurement of the Primary Juice will indicate the quality of the sugar cane and also will specify the
parameters for the next process, this product density will measure up to 20 Brix.
The 914DNS must be installed into a sampling vase designed to eliminate turbulences and air bubbles, the drawing
914DNS-1250 will indicate minimum requirements for this sampling vase. This technique will assure near real time
Brix indication.
1.2 The Secondary Juice.
The Tandems downstream will have an intricate system of juice recirculation
The Secondary Juice is extracted from the second Mill, it will the reminder of all sugars to be processed by the plant,
the sequent Mills, third, fourth, fifth, …., have theirs extractions connected in Tandem, output fifth-> input fourth,
output fourth-> input third, ….., and so on, the last Mill will be embedded with hot water to maximize the extraction.
The water amount is critical, too much will increase the energy requirement on the evaporation and distillery, too
little will waist too much sugar carried out by the fiber mass that will be used to fuel the steam boilers.
The Brix measure of the Secondary Juice will indicate the quantity of water necessary for the last Mill, and also will
specify the parameters for the next process, this product density will measure up to 20 Brix.
The 914DNS must be installed into a sampling vase designed to eliminate turbulences and air bubbles, the drawing
914DNS-1250 will indicate minimum requirements for this sampling vase. This technique will assure near real time
Brix indication.
Application Note914DNS2018
5 www.springres.com
2. Decanters, Mud Concentration.
Fig. 2. - Decanters
The main purpose of a decanter is to filter the Primary and Secondary Juices, in order to remove most debris such as
sand, fibers and micro-fibers left from the Mill Tandem. At the bottom of the decanters there will be accumulation
a layer of solids namely Mud. Such Mud will contain high quantity of juices that can’t be lost. To optimize this juice
recovery, it is necessary to know the concentration of the Mud to trim in the treatment process. Here the scale of
measure is from 800 to 1300 Kg/m3.
The Mud product has high viscosity, high contents of sand, organic fibers and other debris that make it very abrasive.
The sampling vase must reduce the speed of the Mud and minimize the erosion of the sensing diaphragms. It is also
important good access to the Transmitter for cleaning and inspection.
The 914DNS must be installed into a sampling vase designed to ensure a low speed of the Mud to minimize the
effects of abrasion, the drawing 914DNS-1951 will indicate minimum requirements for this sampling vase. This
technique will assure adequate measurement of this concentration.
Application Note914DNS2018
6 www.springres.com
3. Evaporators, Brix Measurement.
Fig. 3. - Evaporators
The main purpose of the Evaporators is to remove water from the Juices, creating a dense syrup for immediate
use downstream, or stored for later use. They are composed of a battery of at least 4 stages, the first is named Pre-
Evaporator, the following are second, third and fourth stage. The evaporation process requires massive amounts of
energy, adequate density control will assure energy savings, product quality and smooth operation of the plant.
3.1 Brix measurement at the Pre-Evaporator.
The Pre-Evaporator is the most dynamic of all effects, it will take the raw juice and remove around 50% of the water
contained. It requires massive amounts of energy and operate at temperatures around 120C. The steam generated
by this process, namely vegetable steam, will provide energy to the following evaporation stages, therefore the
operation of the Pre-Evaporator is extremely important.
The Pre-Evaporator will output syrup up to 40 Brix, the set value is user defined.
The 914DNS must be installed into a sampling vase designed to ensure a low temperature of the syrup with cooling
arrangements, the drawing 914DNS-1952 will indicate minimum requirements for this sampling vase. This technique
will assure adequate measurement of this Brix without thermal failures.
Beware the Density Transmitter will require cooling the syrup collected from the Pre-Evaporator, the sampling pipe
itself can cool the syrup to acceptable levels. For instance, the fixture can be installed at the bottom level of the
evaporator and the pipe column itself will offer great cooling features.
3.2 Brix measurement between Evaporators.
The output of the Pre-Evaporator will feed the second stage and so on, each stage will remove more water from the
syrup to the limit allowed by the process, up to 80 Brix. The Brix increase between stages is user defined, depend
upon observations and experience with the process.
The 914DNS must be installed into a sampling vase designed to ensure a low temperature of the syrup with cooling
Application Note914DNS2018
7 www.springres.com
arrangements, the drawing 914DNS-1952 will indicate minimum requirements for this sampling vase. This technique
will assure adequate measurement of the Brix without thermal failures.
The resulting syrup from one effect is fed into the next by gravity plus normal process suction, at the last effect there
are syrup pumps to push it into the next processing equipment or reservoirs. These pumps can drain all syrup from
the sampling vase causing measurement disruption, in this case we recommend connecting the outlet of the vase
into the inlet of the last effect.
4. Vacuum Pan, Brix Measurement.
Fig. 4. - Vacuum Pan
The main purpose of the Vacuum Pan is to remove all the water and promoting the crystal formation, from start
to end there are many different phases requiring unique control strategy. During this transformation process, the
density is measured by very dedicated micro-wave reflectometry covering all aspects of the transformations within
the sugar syrup.
To obtain an optimum product at the output is necessary operator experience, a good control strategy for each
phase of the process, energy and start the whole process with syrup at optimum conditions. The starting syrup is a
mixture of the products from the Evaporators, water plus the residual sugars from the centrifuges, these products are
mixed into a pre-set density ranging from 50 to 90 Brix, then pre-heated, and fed into the Vacuum Pan.
The 914DNS can be installed directly inside the syrup mixing tank, the drawing 914DNS-1952 will indicate minimum
requirements for this installation. This technique will assure adequate measurement of the Brix with minimum
failures.
Application Note914DNS2018
8 www.springres.com
5. Must control, Brix Measurement.
Fig. 5. - Must control
The alcohol production will start with the preparation of Must, it is a mixture of syrups from the Evaporators and
remainders of the Vacuum Pans, plus pure Juice from the Mill Tandems, and if absolutely necessary, water. The final
Must need to have a pre-defined Brix measure, then it will feed the Fermentation tanks.
This process will happen in a Must mixing tank and the output is pumped into the Fermentation tank, we
recommend taking a sample of the output to feed the sampling vase for real time measurement. The installation of
the vase should be near the mixing tank, so we recommend the output of the vase to feed back the same tank, the
flow rate can be adjusted by the shut-off valves.
The 914DNS must be installed into a sampling vase designed to eliminate turbulences and air bubbles, the drawing
914DNS-1250 will indicate minimum requirements for this sampling vase. This technique will assure near real time
Brix indication.
Application Note914DNS2018
9 www.springres.com
6. Fermentation Tank, Brix Measurement.
Fig. 6. - Fermentation Tank
The Fermentation process happen inside tanks, it will take the Must and the ferment and left for several hours until
the bacteria transform all sugars into alcohol. The Brix measurement is extremely important to indicate when batch is
finished, once finished the fermented product should move to the next process as fast as possible minimizing losses
due to alcohol evaporation.
914DNS must be installed directly into side walls of the Fermentation tanks, there is no special installation
requirements other than utilizing the Density Meter for side installation. This technique will assure near real time Brix
indication, from start to end of the process.
7. Anhydrous Alcohol, Grade Measurement.
Fig. 7. - Anhydrous Alcohol
Application Note914DNS2018
10 www.springres.com
This alcohol is product of the distillation process, the temperature will change from case to case but always above the
20C reference temperature. We recommend sampling the alcohol directly from the output of the distillery column
and cooling it down to as close as possible to room temperature, preferably keeping it at constant value to optimize
the measurement accuracies. The Grade measure is important for controlling the distillation process.
The 914DNS must be installed into a sampling vase designed to eliminate turbulences and air bubbles, the drawing
914DNS-1250 will indicate minimum requirements for this sampling vase. This technique will assure near real time
Grade indication.
8. Hydrous Alcohol, Grade Measurement.
Fig. 8. - Hydrous Alcohol
This alcohol is product of the distillation process, the temperature will change from case to case but always above the
20C reference temperature. We recommend sampling the alcohol directly from the output of the distillery column
and cooling it down to as close as possible to room temperature, preferably keeping it at constant value to optimize
the measurement accuracies. The Grade measure is important for controlling the distillation process.
The 914DNS must be installed into a sampling vase designed to eliminate turbulences and air bubbles, the drawing
914DNS-1250 will indicate minimum requirements for this sampling vase. This technique will assure near real time
Grade indication.
Brix Density Transm
itter
Shut-off valves
8" Sampling vase
Inlet
Outlet
2198" SC
H 10Pm
ax 150 psi
BB
Flange 4" 150 psi
129 246 500
1.5" SCH 10
200
875
104
B-B
Inlet ratings:Pm
ax: 150 psiTm
ax: 65CQ
max: 300 l/m
Outlet ratings:
Pmax: 150 psi
Tmax: 65C
Qm
ax: 300 l/m
General requirem
ents:
a) System m
ust be rinsed w
ith clean water for 10 m
inutes every 12 hours.b)Prod
uct flow m
ust be constant without bubles &
turbulence.c) Prod
uct temperature m
ust be kept constant and below
65C.
d) Instrum
ent must have easy acess for m
aintenance and calibrations.
e) Am
bient temperatue w
ithin limitis of hum
an confort.f) D
rain all pressure before attempt to rem
ove the instrument.
g) Observe m
aximum
pressures and tem
perature recomend
ed.
h) Use clean water for calibraiton, prefereable at w
orking temperature.
Inlet FlowResponse tim
e35 l/m
in60 sec
70 l/min
15 sec140 l/m
in8 sec
300 l/min
4 sec
DRA
WN
CHK'D
APPV
'D
MFG
Q.A
UNLESS O
THERWISE SPEC
IFIED:
DIM
ENSIO
NS A
RE IN M
ILLIMETERS
SURFAC
E FINISH:
TOLERA
NC
ES: LIN
EAR:
AN
GULA
R:
FINISH:
DEBUR A
ND
BREA
K SHARP
EDG
ES
NA
ME
SIGN
ATURE
DA
TE
MA
TERIAL:
DO
NO
T SCA
LE DRA
WIN
GREVISIO
N
TITLE:
DW
G N
O.
SCA
LE:1:10SHEET 1 O
F 1
A4
WEIG
HT:
Springfield
Research
Corp.
914DN
S-1250
Density M
eter application note:Sam
ple vase for juices and syrups, Range from
0 to 70 Brix
Inled of the box, M
ud pum
pedfrom
Decanters
Outlet of the box, M
ud to
treatment &
vacuum filters
Mud
inspection & sam
pling at the inlet sid
e of the box
pre existing m
ud inspection box
type open top
Density Transm
itterassem
bled at corner
Mud
level barrierto be installed
1000min
2501/4" steel plate
45° BB
Density Transm
itterassem
bled w
ith sensing diaphram
s d
irected to the corner
150mud flow
30512" SC
H 5M
ud Inlet
30512" SC
H 5M
ud O
utlet
6m
udbarrier
1000min
110mud imersion
500mud column
B-B
Sensing diaphragm
facing the cornerto m
inimize d
amages &
erosion
DRA
WN
CHK'D
APPV
'D
MFG
Q.A
UNLESS O
THERWISE SPEC
IFIED:
DIM
ENSIO
NS A
RE IN M
ILLIMETERS
SURFAC
E FINISH:
TOLERA
NC
ES: LIN
EAR:
AN
GULA
R:
FINISH:
DEBUR A
ND
BREA
K SHARP
EDG
ES
NA
ME
SIGN
ATURE
DA
TE
MA
TERIAL:
DO
NO
T SCA
LE DRA
WIN
GREVISIO
N
TITLE:
DW
G N
O.
SCA
LE:1:20SHEET 1 O
F 1
A4
WEIG
HT:
Springfield
Research
Corp.
914DN
S-1251
Density m
eter application note:M
ud inspection & control area
Instalation at pre-existing box
874
2198" SC
H 10Pm
ax 150 psi AA
flange 4" 150psi
Density Transm
itter
8" vaseTm
ax 75C
1.5" SCH 10
Top Inlet
1.5" SCH 10
Bot Outlet
shut-off valves
drain valve
water valve
sifon
flange 4" 150 psi
128 246 500
874
120
114
75
A-A
top mirror
From top m
irror,Syrup coolantm
ay be required
drain
water
To syrup INPUT
General requirem
ents:
a) System m
ust be rinsed w
ith clean water for 10 m
inutes every 12 hours.b)Prod
uct flow m
ust be constant.c) Prod
uct temperature m
ust be kept constant and below
75C.
d) Instrum
ent must have easy acess for m
aintenance and calibrations.
e) Am
bient temperatue w
ithin limitis of hum
an confort.f) D
rain all pressure before attempting to rem
ove the instrument.
g) Observe m
aximum
pressures and tem
perature recomend
ed.
h) Use clean water for calibration, prefereable at w
orking temperature.
DRA
WN
CHK'D
APPV
'D
MFG
Q.A
UNLESS O
THERWISE SPEC
IFIED:
DIM
ENSIO
NS A
RE IN M
ILLIMETERS
SURFAC
E FINISH:
TOLERA
NC
ES: LIN
EAR:
AN
GULA
R:
FINISH:
DEBUR A
ND
BREA
K SHARP
EDG
ES
NA
ME
SIGN
ATURE
DA
TE
MA
TERIAL:
DO
NO
T SCA
LE DRA
WIN
GREVISIO
N
TITLE:
DW
G N
O.
SCA
LE:1:20SHEET 1 O
F 1
A4
WEIG
HT:
Springfield
Research
Corp.
914DN
S-1252
Density M
eter application note:Evaporators: Sam
pling vase Range from
0 to 70 Brix
Springfield Research reserves the right to make changes to design and functionality of any product without notice. Springfield Research does not assume any liability arising out of the application or use of any product. Springfield Research logo is registered trademarks of Springfield Research.HART is a registered trademark of the HART Communication Foundation.© 2017 Springfield Research Corp. All rights reserved
Springfield Research Corporation3350 NW 22nd Terrace Suite 500 • Pompano Beach, FL USA 33069Tel: +1 (954) 657.8849 • Fax: +1 (954) 657.8895 • [email protected] • www.springres.com
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