A Regression Model for Estimating Sugar Crystal Size in a Fed-batch Vacuum Evaporative Crystalliser (original) (raw)

Predictive Model for Post-Seeding Super-Saturation of Sugar Massecuite in a Fed-Batch Evaporative Crystalliser

ETP International Journal of Food Engineering

The conflicting reports on the performances of the online probes for super-saturation of sugar massecuite necessitate the application of soft-sensor to complement or replace them. Unfortunately, the available sugar crystallisation models which are theoretical and semiempirical in nature are not in the form which can be directly utilised as soft sensor for real time estimation of the massecuite super-saturation. Therefore, in this study, easyto-measure online variables that can be correlated with the super-saturation were identified and used to develop a regression model for online estimation of the supersaturation value of sugar massecuite after seeding. The post-seeding regression model gave coefficient of determination and maximum relative error of 0.994 and 4.7%, respectively. It is therefore concluded that the resulting model has the potential of being used for real time estimation of post-seeding super-saturation of sugar massecuite, as opposed to the existing complex fundamental and semi-empirical sugar crystallisation models. 

Empirical modelling of vacuum pans for a sugar mill crystallisation stage

2005

Empirical models of vacuum pans are important to understanding the interactions between the pans and upstream and downstream stations, and stock tanks. This paper describes the development of empirical vacuum pan models for crystallisation operations in raw sugar processing. Vacuum pan production rates and steam usage models are used to define the rate at which each pan takes feed material during the different phases of the pan's operation. The rate of consumption of the feed materials for an individual pan is a function of the massecuite level and phase of the pan, steam rate, vacuum and the brix and purity of the liquor/molasses.

On-line multivariate statistical monitoring of a fed-batch sugar crystallisation process

Elsevier eBooks, 2004

The paper describes statistical process control tools that have been applied for the online monitoring of an industrial fed-batch sugar crystallisation process. The process is characterised by distinct operating phases during operation and the presence of strong non-linear, dynamic relationships between the variables. Process performance is controlled manually by operators based on their experience. The success of each batch is determined at the end of the batch run through off-line crystal size distribution measurements. The development and application of a monitoring tool based on the online frequent process measurements could be of significant benefit, since it could realise early detection of operational changes, process faults and hence a reduction in the number of off-specification batches.

Fed-Batch Sucrose Crystallization Model for the B Massecuite Vacuum Pan, Solution by Deterministic and Heuristic Methods

Processes, 2020

Fed-batch crystallization is a crucial step for sugar production. In order to relate parameters that are difficult to measure (average diameter of the crystals and total mass formed) to other easier to measure parameters (volume, temperature, and concentration), a model was developed for a B massecuite vacuum pan composed of mass and energy balances together with empirical relations that describe the crystal development inside equipment. The generated system of ordinary differential equations (ODE) had eight parameters which were adjusted through minimization of relative differences between the model results and experimental data. It was solved through the function fmincon, available in MATLABTM, which is a deterministic and gradient-based optimization method. The objective of this paper is to improve the model obtained and, for this purpose, two metaheuristic functions were used: genetic algorithm and particle swarm. To compare the results, the convergence time of each algorithm wa...

On-line monitoring of a sugar crystallization process

Computers & Chemical Engineering, 2005

The present paper reports a comparative evaluation of four multivariate statistical process control (SPC) techniques for the on-line monitoring of an industrial sugar crystallization process. The process itself is challenging since it is carried out in multiple phases and there exists strong non-linear and dynamic effects between the variables. The methods investigated include classical on-line univariate statistical process control, batch dynamic principal component analysis (BDPCA), moving window principal component analysis (MWPCA), batch observation level analysis (BOL) and time-varying state space modelling (TVSS). The study is focused on issues of on-line detection of changes in crystallization process operation, the early warning of process malfunctions and potential production failures; problems that have not been directly addressed by existing statistical monitoring schemes. The results obtained demonstrate the superior performance of the TVSS approach to successfully detect abnormal events and periods of bad operation early enough to allow bad batches and related losses in amounts of recycled sucrose to be significantly reduced.

Steady state modeling and simulation of an industrial sugar continuous crystallizer

Computers & Chemical Engineering, 2001

The profile of supersaturation along a continuous crystallizer of sugar factories, is the decisive factor that determines the performance of this apparatus. In order to control this profile, a mathematical model was developed taking into account the main physicochemical phenomena involved in crystallization process. The model is based on flow pattern, which was assumed and validated against plant measurements using a tracer test. The steady state mathematical model developed describes the most important aspects of the crystallizer behavior in each compartment: supersaturation, crystal size distribution and flow rate of the product crystals. The model can also describe the undesirable behavior such as dissolution and nucleation. Validation of the developed model was performed using industrial data. A parametric sensitivity study confirmed that the syrup supply distribution is the main variable that should be manipulated to achieve good performance for the crystallizer.

Full Paper Modeling of Sugar Crystallization through Knowledge Integration

2010

This paper reports on the comparison of three modeling approaches that were applied to a fed batch evaporative sugar crystallization process. They are termed white box, black box, and grey box modeling strategies, which reflects the level of physical transparency and understanding of the model. White box models represent the traditional modeling approach, based on modeling by first principles. The black box models rely on recorded process data and knowledge collected during the normal process operation. Among various tools in this group artificial neural networks (ANN) approach is adopted in this paper. The grey box model is obtained from a combination of first principles modeling, based on mass, energy and population balances, with an ANN to approximate three kinetic parameters ± crystal growth rate, nucleation rate and the agglomeration kernel. The results have shown that the hybrid modeling approach outperformed the other aforementioned modeling strategies. 1

Modeling of Sugar Crystallization through Knowledge Integration

Engineering in Life Sciences, 2003

This paper reports on the comparison of three modeling approaches that were applied to a fed batch evaporative sugar crystallization process. They are termed white box, black box, and grey box modeling strategies, which reflects the level of physical transparency and understanding of the model. White box models represent the traditional modeling approach, based on modeling by first principles. The black box models rely on recorded process data and knowledge collected during the normal process operation. Among various tools in this group artificial neural networks (ANN) approach is adopted in this paper. The grey box model is obtained from a combination of first principles modeling, based on mass, energy and population balances, with an ANN to approximate three kinetic parameters ± crystal growth rate, nucleation rate and the agglomeration kernel. The results have shown that the hybrid modeling approach outperformed the other aforementioned modeling strategies.

Soft-sensor for industrial sugar crystallization: On-line mass of crystals, concentration and purity measurement

Control Engineering Practice, 2010

This paper deals with the design of a model-based soft-sensor to improve the process monitoring and control in industrial sugar crystallization. This soft-sensor is based on an original model dedicated to the last stage of crystallization, avoiding the solving of the population balance. Additional information like the mass of crystals in the solution, the concentration of dissolved sucrose and the purity are relevant to improve the manufacturing process. As these physicochemical properties are not measurable on-line, a model based soft-sensor is developed. The effectiveness of the soft sensor is demonstrated using real plant data from an industrial crystallization process.