U.S. patent number 3,899,386 [Application Number 05/319,938] was granted by the patent office on 1975-08-12 for method for controlling vacuum pan.
This patent grant is currently assigned to Hitachi, Ltd.. Invention is credited to Shigeo Komiyama, Ichiro Matsubara, Masatake Shiraishi.
United States Patent |
3,899,386 |
Komiyama , et al. |
August 12, 1975 |
Method for controlling vacuum pan
Abstract
In a process wherein heat is exchanged between the heat
exchanger and the solution and crystals are generated and grown in
the solution, the crystal size and the inter-crystal gap length in
the solution are measured and the quantity of supply of the
material is controlled on the basis of the measurement.
Inventors: |
Komiyama; Shigeo (Katsuta,
JA), Matsubara; Ichiro (Katsuta, JA),
Shiraishi; Masatake (Koriyama, JA) |
Assignee: |
Hitachi, Ltd.
(JA)
|
Family
ID: |
11547204 |
Appl.
No.: |
05/319,938 |
Filed: |
December 29, 1972 |
Foreign Application Priority Data
|
|
|
|
|
Dec 29, 1971 [JA] |
|
|
47-3075 |
|
Current U.S.
Class: |
159/47.1; 127/16;
159/44; 23/301; 127/60; 159/45 |
Current CPC
Class: |
B01D
9/0031 (20130101); C13B 30/027 (20130101); B01D
9/0063 (20130101); B01D 9/0022 (20130101) |
Current International
Class: |
C13F
1/00 (20060101); C13F 1/02 (20060101); B01D
9/00 (20060101); B01d 001/00 (); B01j 017/00 ();
B01j 017/02 (); B01d 003/42 (); C13f 001/02 () |
Field of
Search: |
;127/15,16,58,61
;23/253A,273R,31R ;159/44,45 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Sofer; Jack
Attorney, Agent or Firm: Craig & Antonelli
Claims
I claim:
1. In a method for controlling a vacuum pan according to which heat
is exchanged between a heat exchanger and a massecuite to generate
and grow crystals in the massecuite in a batch operation, the
improvement comprising (a) measuring the inter-crystal gap length
of the crystals grown in the solution and controlling the quantity
of the supply of the solution on the basis of the measured
inter-crystal gap length to effectively grow crystals, and (b)
measuring the value of at least one other parameter indicative of
the progress of the crystal growing process, comparing the measured
inter-crystal gap length with a programmed value for the
inter-crystal gap length provided by a first program, comparing the
measured value of said other parameter with a programmed value for
said other parameter provided by a second program, automatically
preferentially selecting either said first program or said second
program for controlling said supply quantity, and controlling said
supply quantity on the basis of the deviation of the measured value
from the programmed value of the parameter corresponding to the
selected program.
2. A method for controlling a vacuum pan as claimed in claim 1,
wherein when the deviation of the measured value of at least one of
the parameters corresponding to the non-selected programs from the
corresponding programmed value exceeds a predetermined level, the
progress of the program is suspended; and when the deviation of the
measured value of the parameter corresponding to the selected
program becomes equal to a predetermined level, the control of the
supply quantity of the solution is resumed on the basis of the
selected program.
3. A method for controlling a vacuum pan as claimed in claim 1,
wherein the average diameter of the crystals grown in the solution
is used as said other parameter.
4. A method for controlling a vacuum pan as claimed in claim 1,
wherein the level the solution is used as said other parameter.
5. A method for controlling a vacuum pan as claimed in claim 1,
wherein the average diameter of the crystals grown in the solution
is used as a component for controlling the supply quantity of the
solution.
6. In a method for controlling a vacuum pan according to which heat
is exchanged between a heat exchanger and a massecuite to generate
and grow crystals in the massecuite in a bath operation, the
improvement comprising (a) measuring the crystal content of the
massecuite and controlling the supply quantity of the solution on
the basis of the measured quantity to effectively grow crystals,
and (b) measuring the value of at least one other parameter
indicative of the progress of the crystal growing process,
comparing the measured crystal content of the massecuite with a
programmed value for the crystal content of the massecuite provided
by a first program, comparing the measured value of said other
parameter with a programmed value for said other parameter provided
by a second program, automatically preferentially selecting either
said first program or said second program for controlling said
supply quantity, and controlling said supply quantity on the basis
of the deviation of the measured value from the programmed value of
the parameter corresponding to the selected program.
7. A method for controlling a vacuum pan as claimed in claim 6,
wherein when the deviation of the measured value of at least one of
the parameters corresponding to the non-selected programs from the
corresponding programmed value exceeds a predetermined level, the
progress of the program is suspended; and when the deviation of the
measured value of the parameter corresponding to the selected
program becomes equal to a predetermined level, the control of the
supply quantity of the solution is resumed on the basis of the
selected program.
8. A method for controlling a vacuum pan as claimed in claim 6,
wherein the level of the solution is used as said other
parameter.
9. In a method for controlling a vacuum pan according to which heat
is exchanged between a heat exchanger and a massecuite to generate
and grow crystals in the massecuite in a batch operation, the
improvement comprising (a) measuring the consistency of the
massecuite and controlling the supply quantity of the solution on
the basis of the measured quantity to effectively grow crystals,
and (b) measuring the value of at least one other parameter
indicative of the progress of the crystal growing process,
comparing the measured consistency of the solution with a
programmed value for the consistency of the solution provided by a
first program, comparing the measured value of said other parameter
with a programmed value for said other parameter provided by a
second program, automatically preferentially selecting either said
first program or said second program for controlling said supply
quantity, and controlling said supply quantity on the basis of the
deviation of the measured value from the programmed value of the
parameter corresponding to the selected program.
10. A method for controlling a vacuum pan as claimed in claim 9,
wherein when the deviation of the measured value of at least one of
the parameters corresponding to the non-selected programs from the
corresponding programmed value exceeds a predetermined level, the
progress of the program is suspended, and when the deviation of the
measured value of the parameter corresponding to the selected
program becomes equal to a predetermined level, control of the
supply quantity of the solution is resumed on the basis of the
selected program.
11. A method for controlling a vacuum pan as claimed in claim 9,
wherein the average diameter of the crystals grown in the solution
is used as said other parameter.
12. A method for controlling a vacuum pan as claimed in claim 9,
wherein the level of the solution is used as said other
parameter.
13. In a process for controlling a vacuum pan in which a raw
solution is heated to cause said raw solution to reach a
supersaturated condition, crystal seeds as nuclei are added to the
raw solution to form massecuite, and the massecuite is furthher
heated and additional raw solution or water or both are supplied to
the massecuite to thereby generate and grow crystals in the
massecuite, the improvement comprising:
1. controlling the supply of raw solution to the vacuum pan with
reference to the deviation between the signal produced by a level
control programmer and the detected level of the massecuite in the
vacuum pan,
2. after a predetermined time period or when the level of the
solution in the vacuum pan reaches a predetermined level after
addition of the seeds, preferentially controlling the supply of raw
solution and the supply of water to the vacuum pan with respect to
the deviation between the detected value of the supersaturation of
the massecuite in the vacuum pan and a signal from a consistency
control program, the preferential control of step 2 being in
preference to controlling the supply of raw solution by reference
to the deviation between the detected value of the liquid level and
the signal produced by the level control programmer, the
preferential control of step 2 being automatically selected by
means of a selector, and
3after another predetermined time period or when the level of the
massecuite in the vacuum pan reaches another predetermined level
after the addition of the seeds, preferentially controlling the
supply of raw solution and the supply of water to the vacuum pan by
reference to the deviation between the detected value of the
consistency of the massecuite and a signal from the consistency
control programmer, the preferential control of step (3) being in
preference to control by reference to the deviation of the detected
value of the liquid level of the massecuite and the signal from the
level control programmer, the preferential control of step (3 being
automatically selected by means of a selector.
14. The process according to claim 13, further comprising stopping
the progress of the programs in the liquid level controller and the
consistency controller when the detected level of the massecuite in
the vacuum pan is different from the programmed value of the liquid
level by a predetermined value, allowing heat exchange to be
carried out while controlling the supply of raw solution and water
with respect to the signals produced by said liquid level control
programmer and said consistency control programmer at the time of
the stopping of said programs, and resuming the progress of the
programs in the level control programmer and the consistency
control programmer when the level of the massecuite reaches a
predetermined level.
15. In a process for controlling a vacuum pan in which a raw
solution is heated to cause said raw solution to reach a
supersaturated condition, crystal seeds as nuclei are added to the
raw solution to form massecuite, and the massecuite is further
heated and additional raw solution or water or both are supplied to
the massecuite to thereby generate and grow crystals in the
massecuite, the improvement comprising:
1. controlling the supply of raw solution to the vacuum pan with
reference to the deviation between the signal produced by a level
control programmer and the detected level of the massecuite in the
vacuum pan, and
2. after the addition of the seeds, automatically selecting by
means of a selector the deviation between the detected value of the
supersaturation of the massecuite in the vacuum pan and a signal
from a consistency control programmer in preference to the
deviation between the signal from the level control programmer and
the detected level of the massecuite in the vacuum pan for
controlling the quantity of raw solution supplied to the vacuum
pan, said consistency control programmer further controlling the
quantity of warm water supplied to the vacuum pan.
16. The process according to claim 15, further comprising stopping
the progress of the programs in the liquid level controller and the
consistency controller when the detected level of the massecuite in
the vacuum pan is different from the programmed value of the liquid
level by a predetermined value, allowing heat exchange to be
carried out while controlling the supply of raw solution and water
with respect to the signals produced by said liquid level control
programmer and said consistency control programmer at the time of
the stopping of said programs, and resuming the progress of the
programs in the level control programmer and the consistency
control programmer when the level of the massecuite reaches a
predetermined level.
17. In a process for controlling a vacuum pan in which a raw
solution is heated to cause said raw solution to reach a
supersaturated condition, crystal seeds as nuclei are added to the
raw solution to form massecuite, and the massecuite is further
heated and additional raw solution or water or both are supplied to
the massecuite to thereby generate and grow crystals in the
massecuite, the improvement comprising:
1. controlling the supply of raw solution to the vacuum pan with
reference to the deviation between the signal produced by a level
control programmer and the detected level of the massecuite in the
vacuum pan, and
2. after the addition of the seeds, automatically selecting by
means of a selector the deviation between the detected value of the
consistency of the massecuite in the vacuum pan and a signal from a
consistency control programmer in preference to the deviation
between the signal from the level control programmer and the
detected level of the massecuite in the vacuum pan for controlling
the quantity of raw solution supplied to the vacuum pan, said
consistency control programmer further controlling the quantity of
warm water supplied to the vacuum pan.
18. The process according to claim 17, further comprising stopping
the progress of the programs in the liquid level controller and the
consistency controller when the detected level of the massecuite in
the vacuum pan is different from the programmed value of the liquid
level by a predetermined value, allowing heat exchange to be
carried out while controlling the supply of raw solution and water
with respect to the signals produced by said liquid level control
programmer and said consistency control programmer at the time of
the stopping of said programs, and resuming the progress of the
programs in the level control programmer and the consistency
control programmer when the level of the massecuite reaches a
predetermined level.
19. In a method for controlling a vacuum pan in which heat is
exchanged between a heat exchanger and a raw solution to generate
and grow crystals therein, the improvement comprising measuring the
value of a first parameter indicative of the progress of the
crystal growing process, comparing the measured value of the first
parameter with a programmed value for the first parameter provided
by a first program, measuring the value of at least one other
parameter indicative of the progress of the crystal growing
process, comparing the measured value of said other parameter with
a programmed value for the other parameter provided by a second
program, automatically preferentially selecting either said first
program or said second program for controlling the supply of the
solution fed to said vacuum pan, and controlling the supply of
solution fed to said vacuum pan on the basis of the deviation of
the measured value from the programmed value of the parameter
corresponding to the selected program.
20. The process according to claim 19, wherein when the deveation
of the measured value of at least one of the parameters
corresponding to the non-selected programs from the corresponding
programmed value exceeds a predetermined level, the progress of the
programs is suspended; and when the deviation of the measured value
of the parameter corresponding to the selected program becomes
equal to a predetermined level, the control of the supply quantity
of the solution is resumed on the basis of the selected
program.
21. A method for controlling the liquid level, the amount of
solution feed and the amount of solvent feed in a batch process for
generating and growing crystals in a vacuum pan comprising
measuring the liquid level of the solution in said vacuum pan;
comparing the measured liquid level with a programmed value for the
liquid level provided by a level control programmer; measuring the
value of at least one other parameter indicative of the progress of
the crystal growing process, comparing the measured value of said
other parameter with a programmed value for said other parameter
provided by a second program, automatically preferentially
selecting said second program for controlling the amount of
solution and solvent fed to said vacuum pan after a predetermined
time period or when the liquid level in the vacuum pan reaches a
predetermined value, and controlling the amount of solution and the
amount of solvent fed to said vacuum pan on the basis of the
deviation of the measured value from the programmed value of said
other parameter.
22. The method according to claim 21, wherein said other parameter
is the consistency of the solution.
23. The method according to claim 21, wherein said other parameter
is the degree of supersaturation when the crystal growing process
is in an unstable phase, and further wherein said other parameter
is the consistency of the solution when the crystal growing process
is in a stable phase.
24. The method according to claim 21 wherein said other parameter
is the supersaturation of said solution.
25. The process according to claim 24, further comprising
determining the value of the supersaturation of said solution by
comparing the boiling point of said solution with the temperature
in said vacuum pan.
26. The method according to claim 25, wherein the pressure in said
vacuum pan is measured and the value of the temperature in said
vacuum pan is determined by means of a pressure/temperature
transducer.
Description
BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
The present invention relates to a method for controlling a vacuum
pan used in the sugar manufacturing process.
2. DESCRIPTION OF THE PRIOR ART
The sugar manufacturing process consists of continuous process at
the anterior stages and batch process at the posterior stages, both
processes being intricately combined. Among the individual
processes, the boiling process to cause the crystallization of
sugar is the most difficult to automate.
The boiling process is performed in a vacuum pan and has been
practiced for many years. Many attempts to automate the boiling
process were made in vain due to the batch process which has
complicated characteristics. And experienced staff usually operated
the vacuum pan and the associated devices. There have been only a
few successful cases, which were accompanied by some restrictions
so that no definite method for automatically operating the vacuum
pan has been established before now.
SUMMARY OF THE INVENTION
One object of the present invention is to provide a method for
automatically operating the vacuum pan without the difficulties
encountered by the conventional automatic operation.
Another object of the present invention is to provide a method for
controlling the vacuum pan according to which crystal growth is
stably performed without the formation of false grains and the
resolution of crystals taking place after seeding.
An additional object of the present invention is to provide a
method for controlling the vacuum pan according to which the stable
range in crystal growth is enlarged.
A further object of the present invention is to provide a method
for controlling the vacuum pan according to which crystals are
stably grown even if there is a disturbance owing to, for example,
a change in the sort of supplied solution.
According to the present invention which has been made to attain
such objects as described above, the quantity of supply of the
solution is controlled by a signal obtained by comparing the
reference signal from a programmer with more than two independent
signals representative of the level of the solution in the vacuum
pan, the inter-crystal gap length (or crystal content or
consistency) or the average diameter of crystals instead of the
level.
Moreover, the quantity of supply of the solution is controlled by
comparing the reference signal with the preferentially selected one
of the independent signals.
Further, the supply of the solution is controlled on the basis of
the preferentially selected one of the components (detecting
signals) concerning the control of the supply. The control is
temporarily held when the deviation of any non-selected component
from the reference signal exceeds a predetermined level and the
supply is controlled on the basis of each selected component when
the deviation of the selected component becomes equal to a
predetermined level.
The present invention will be more clearly understood when the
following description of the specification is read along with the
attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a system for controlling the vacuum
pan, embodying the present invention.
FIG. 2 is a graphical representation of the variations with time of
variables important in the process of crystal growth.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The conventional method of controlling the vacuum pan will be
described here with the aid of FIG. 1 of the attached drawings. In
FIG. 1, parts within an enclosure 50 by the long-and-two-short-dash
line is a means first proposed by the inventors claiming the
patentability of this application and the other parts or elements
are familiar to those skilled in the art. And the conventional
vacuum pan was run according to the following steps of
procedure.
1. Vacuuming
At first, an open valve 2 provided in a vacuum pan 1 in FIG. 1 is
closed while the main vacuum valve 4 and the cooling-water valve 5
of a barometric condenser 6 communicating via a pipe 3 with the
vacuum pan 1 are opened. As a result of these operations, vapor in
the vacuum pan 1 is conducted into the barometric condenser 6 and
condensed there into water by means of cooling water. The condensed
water is evacuated and non-condensed vapor is ejected from the
vacuum vessel by means of a vacuum pump (not shown). By this
process the reduction of pressure in the vacuum pan 1 takes
place.
2. Liquorfeed
When the pressure in the vacuum pan 1 reaches a predetermined value
(about 400 mmHg Abs), the sugar solution, almost condensed up to
saturation through the previous step, is sucked from a pan tank
(not shown) through a pipe 7 and a valve 8 associated therewith
into the vacuum pan 1. The valve 8 is closed as soon as the upper
surface of the solution rises a little above a heat exchanger 9 in
the pan 1.
3. Concentration
The steam valve 10 of the heat exchanger 9 is opened so that the
heating of the solution in the pan is initiated. In order to
prevent the heat exchanger 9 from appearing above the solution of
sugar due to the reduction in volume of the solution owing to the
steam heating, a supply valve through which additional sugar
solution is supplied into the vacuum pan is so controlled as to
maintain the surface of the solution at a constant level. The
inside of the pan 1 is kept at a pressure of 50 to 150 mmHg Abs and
at temperatures from 50.degree. to 60.degree.C.
4. Seeding
When the sugar solution is so far condensed till it reaches a
supersaturated condition, crystal nuclei (seeds) are added to the
solution through a valve 12.
There are other methods of producing crystals, such as
I. Natural seeding in which condensation is performed to excess so
as to form natural crystals, and
II. Shock seeding in which inhalation of air with or without a
small amount of seeds is used to form crystals by means of external
shock.
However, it is difficult with the above methods to form a desired
number of crystals. Therefore, according to the method preferred at
present, there are added to the solution seeds equal in number to
crystals desired to be formed. Moreover, instead of shock seeding,
a method has been proposed in which seeds in the form of alcoholic
slurry are mixed into the sugar solution in an air-tight
condition.
The present invention can be applied to any one of the above
described method.
5. Crystal growth
In the vacuum pan wherein the operation of seeding has been
completed, the surface area of any crystal is very small in
comparison with the speed of vaporization of the solvent and the
crystallization speed is slow so that either the formation of false
grains or the resolution of crystals once formed takes place.
Therefore, the growth of crystals is very unstable. In order to
improve the stability of crystallization, the following processes
may be recommended.
1. To decrease the quantity of steam fed to the heat exchanger and
to limit the speed of solvent vaporization. In this case, however,
with a vacuum pan having no stirrer therein, the vaporization speed
can not be rendered slower than a limit attainable with a vacuum
pan having a stirrer.
2. To supply hot water through a valve 13 corresponding to the
difference between the speed of vaporization of solvent and that of
crystallization.
3. To decrease cooling water so as to increase the pressure within
the vacuum pan. As a result, the speed of vaporization is
suppressed, the temperature of the solution rises, and the degree
of supersaturation is leveled down, so that the speed of
crystallization decreases.
When the unstable phase just after seeding shifts to the rather
stable phase of crystal growth, the above described processes are
cancelled and the sugar solution is supplied again. Crystals of
sugar grow gradually and the volume of massecuite (a slurry
composed of crystals and molasses) also increases gradually.
In this stage, the surface area of any crystal increases,
self-equilibrium is established and a quite stable condition is
reached. Namely, as the surface area of each crystal increases, the
speed of crystallization of sugar is accelerated. The
crystallization speed depends on the degree of supersaturation; the
speed is quickened with the rising of the degree of supersaturation
and slows down with the fall thereof. Thus, the change in
crystallization speed tends to decrease that in the degree of
supersaturation. However, care must be taken of at this stage since
adhesion, twinning and conglomeration of crystals are easily
caused.
6. Boiling-down
When the diameter of each crystal reaches a predetermined
dimension, the supply of sugar solution is stopped. Then, heating
is continued to perform the boiling-down. This step is necessary to
make the solution have such a fluidity as is suitable for the
centrifugal separation as the next step and to increase the rate of
crystallization.
If a desired consistency is reached, the valve 10 of the heat
exchanger 9 is closed and the valve 2 is opened to reduce the
pressure in the vacuum pan 1.
7. Discharge
The discharge valve 14 of the vacuum pan 1 is opened and the
massecuite is discharged to be treated by the next separation
process. The massecuite is then divided through centrifugal
separation into crystals and molasses. Thereafter, the separated
crystals are passed through a dryer and a cooler and stored in
silos or sugar bins and the sugar is packed and sent to the
market.
8. Washing of the pan
A washing steam valve 15 and a washing water valve 16 are opened
and the inside of the vacuum pan 1 is cleaned with steam and hot
water. Thus the vacuum pan 1 is prepared for the following boiling
step.
Reference numeral 17 designates an orifice; 18 a
pressure-difference detector to detect the pressures of steam
before and after the orifice 18; 19 an arithmetic unit to measure
the flow rate of steam on the basis of Bernoulli's theorem in
response to the output of the detector 18; and 20 a programmer for
the quantity of steam flow. A signal from the programmer 20 is
applied through a selector 21 to a steam flow controller 22 and the
aperture of the valve 10 is controlled in response to the deviation
of the output of the arithmetic unit 19 from the reference signal
of the programmer 20. A pressure detector 23 measures the absolute
pressure in the vacuum pan 1, a temperature measuring element 24
measures the boiling point of the sugar solution in the vacuum pan,
and a pressure-temperature transducer 25 obtains from the absolute
pressure in the pan the corresponding temperature in accordance
with the pressure-temperature characteristic of the solvent (water
in this case). A supersaturation detector 26 receives the outputs
of the element 24 and the transducer 25 to obtain the degree of
supersaturation. A cooling water controller 27 receives the output
signal of the pressure detector 23 to control the cooling water
valve 5. An electromagnetic flow meter 28 delivers an output
proportional to the flow rate of sugar solution to be applied to an
arithmetic unit 29, the output signal of which, representative of
the flow rate of sugar solution, is applied to a sugar-solution
supply controller 30.
Now, the principle of the present invention will be described. By
maintaining the degree of supersaturation of the sugar solution in
the vacuum pan at values of from 1.00 to 1.25, i.e. at a
quasi-stable condition, during seeding, crystals can be stably
grown from added nuclei. The degree of supersaturation indicates
the condition of the crystals growth during the time from the step
of seeding to the middle point of the step of crystal growth.
After the middle point, the consistency of the solution is the most
important indication of the occasion for boiling-down because of
the following reasons.
1. During that time, the level of the solution rises and the
consistency becomes smaller, so that the speed of the circulation
of the massecuite slows down. The decrease in the circulation speed
causes the degradation of the heat transfer capacity of the heat
exchanger and therefore the time of boiling down is prolonged and
the quantity of solvent vaporization decreases in a vacuum pan
using natural convection with the result that the circulation is
further decelerated. Moreover, the decrease in the circulation
speed tends to cause the adhesion, twinning and conglomeration of
crystals.
2. If, however, the crystal content is diminished, the circulation
speed of massecuite increases while the inter-crystal gaps increase
to leave more room for the formation of false grains. Thus, the
uniformity of the diameters of produced crystals is adversely
affected. The experiment has it that the gap should be diminished
gradually during the step of boiling-down up to about 0.2 mm in the
end.
However, the gaps between the crystals are not constant and
1. during seeding that quantity of sugar solution enough for the
heat exchanger to be completely immersed in the solution which is
needed in the step of condensation, determines the gap length. The
gap length is usually larger than in the end of the seeding step so
that it must be gradually lessened to a required value.
2. When the diameter of each crystal is smaller, the formation of
the false grains tends to be suppressed even if the crystal content
is small. Moreover, since the speed of crystal growth can be
increased too, crystals can be produced at a high rate of
circulation. Therefore, the above described matters have to be
taken into consideration in order to grow crystals under an optimal
condition.
FIG. 2 gives the summary of the foregoing consideration, which
shows an optimal model of crystal growth. The model has been
obtained as follows. It has been proved that it simulates a
practical process of sugar boiling with a high accuracy.
It is here assumed that the crystal is a cube. And it follows
that
Q = N(a + g).sup.3 (1)
where Q is the total volume of the massecuite in the pan, N the
number of the total crystals, a the length of each edge of each
crystal, and g the inter-crystal gap length. The ratio .PHI. of the
net volume of the total crystals to the total volume is expressed
by the formula ##EQU1## where .PHI. is the crystal content.
The crystal content cannot be determined by direct measurement but
it is well known that it can be indirectly measured by means of a
consistency meter. Namely, the consistency can be given by the
expression ##EQU2## where x is the consistency, x.sub.o the reading
on the consistency meter when .PHI. = 0, k .sub.1 and k.sub.2
constants. It is known empirically that the size of each crystal
and the total volume can be expressed respectively by linear
expression whose value increases with time, and the inter-crystal
gap length is optimal as in the model shown in FIG. 2 so that the
model can be obtained by substituting quantities from the curves in
FIG. 2 into the above mentioned formulae.
From the above description, it can be deduced that
1 The variations of two variables with time must be independently
specified so as to determine the condition in the vacuum pan.
Namely, in this embodiment, the speed of crystal growth and the
rate of increase in volume of massecuite have to be prescribed.
Both the speed and the rate can be independently determined.
2 The change in consistency with time is generally considered to
vary linearly but in fact it varies non-linearly. The reason is
that the boiling of sugar solution is performed with non-uniform
inter-crystal gap length.
As described in the previous embodiment, two independent programs
are necessary to specify the condition in the vacuum pan. It is
theoretically preferable to control in program the average size of
crystals and the crystal content. The crystal content, as described
above, is related to the inter-crystal gap length and can be
controlled according to the gap length and the average size by
directly measuring the gap using an industrial television system or
pattern recognition system. Here, the average diameter of crystals
and the crystal content are controlled with the level and the
consistency of sugar solution in the vacuum pan. This will be
explained by reference to FIG. 1, in which are shown a level
detector 31 for detecting the level of the sugar solution in the
pan, a consistency meter 32, a transducer 33 for obtaining the
consistency of the solution from the output of the consistency
meter 32, a programmer 34 for controlling the level of the
solution, and a programmer 35 for controlling the consistency of
the solution.
In addition, the present invention has the following features,
which were devised to increase the range of stability.
1. The vacuum pan forms a part of the mutually interrelated,
complicated systems and therefore the control system is given
priority. Usually, the quantity of sugar solution supply is
controlled by the programmer 34 related to the level of the
solution in the vacuum pan and the level controller is actuated
according to the deviation of the output of the level detector 31
from the reference signal from the programmer 34 to operate the
sugar-solution supply controller 30 through the level
controller.
However, if the output of the transducer 33 is smaller than the
reference value of the programmer 35 during the time when the
degree of supersaturation or the consistency is a better indication
of control after seeding, respectively, then the signal from the
programmer 35 is selected by means of the selector 37 prior to the
signal from the programmer 34 so as to control the quantity of
supply of sugar solution. Thus, there is provided a control system
almost free from disturbances and with ease of programming by
employing the method in which the control of consistency has
priority to that of the level of the solution. The control of
consistency consists of control to provide additional sugar
solution successively, control to dilute the solution in the vacuum
pan and control to continue boiling the solution with the program
stopped for a moment. And by performing any one of these control
operations can be controlled the inter-crystal gap length under an
optimal condition. In FIG. 1 are further shown a supersaturation
controller 38, a consistency controller 39 which delivers an output
according to the deviation of the output of the transducer 33 from
the output of the programmer 35, and a switch 40 selectively
switched over when the consistency is a better indication of
control than the degree of supersaturation after seeding. The
programmer 35 controls the hot water valve 13.
2. Moreover, according to the present invention, when the level of
the solution is deviated from the range defined by the used
program, the progress of the program is temporarily interrupted. At
this time, the solution is supplied to the pan in accordance with
the programmed value of the supersaturation or consistency.
Thereafter, the program of the level control program is resumed
when the level of the massecuite is gradually restored and reaches
the predetermined programmed value. This method of control is
especially effective in the case where the program of consistency
control can no longer be continued since the concentration of the
sugar solution to be supplied is too thick to render control of
consistency prior to the control of the level of the solution. For
the consistency, control can be resumed when the condition suitable
for consistency control is reached again by vaporizing the water of
the solution with the level of the solution kept constant.
With the conventional non-automatic vacuum pan 1.5 .times. 1 to 2
man-hours for control for soft sugar, 1.5 .times. 2 to 4 man-hours
for fine granulated sugar and 1.5 .times. 6 to 10 man-hours for
remelted sugar were required so as to produce sugar from a solution
having a purity of 90 to 100 %. On the other hand, using the
automatic control method according to the present invention, a 0.5
.times. 1 to 9 man-hours can complete the whole process of boiling.
It is quite natural to decrease the amount of labor where automatic
operation is employed, but the reason for reducing the running time
is probably as follows. The boiling process is performed nearly at
the upper limit of the speed of crystal growth and therefore
continuous control at a constant rate is very easy with an
automatic operation while the control is stepwise with manual
operation with the result that the accuracy of control is degraded
to prolong the time of operation.
As described above, with a vacuum pan according to the present
invention, all the requirements for automatic operation can be
satisfied and the labor of the supervisor can be decreased to a
great extent. The present invention can be applied to such
processes involving crystallization as the productions of some
drugs and of sodium glutamate.
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