Sugar Refinery Layout
The Factory Complex Layout is governed by the need of the main process requirement. In preparing the Layout, the function of each building and its relationship with each other has been kept in mind.
The building and the areas in the Refinery Complex can be broadly divided into following categories :-
1. Raw Sugar Unloading
2. Raw Sugar Store
4. Boiler House
5. Power House
7. Sugar Drying and bagging
8. Refined Sugar Warehouse
Trucks carrying Raw Sugar enters the Complex through a Gate House and to Weigh Bridge Cabin Which is provided with weigh bridges for the weighment of tare and empty trucks. Sufficient area has been provided for parking of the Vehicles. After weighment, the trucks are taken to Raw sugar unloading station.
Raw sugar is stored in bulk in a Store and having a roof slope of 30o. Two concrete retaining walls of 2.5 meters height have been provided throughout the length of house. The raw sugar store has a capacity which is equivalent to approximately three months storage. Approximately 350m long X 45 m width warehouse is capable of storing around 175000MT Raw Sugar.
Located adjacent to the Raw Sugar House is Main refinery Building having suitable size, Power Plant and Boiler will be situated near to Raw Sugar House. The layout and area of the house is such that Plant could have an easy expansion from existing MT per year to (2 X Existing) MT per year. Sufficient space should be given for empty bag store and Store keeper Office has been provided.
The sugar store is located nearer to Sugar House and has a storage capacity for about 90 days of production.
The chemicals required for the process are lime, resins, phosphoric acid, sodium chloride, etc. These are stored in the consumable store and are located on the same road as that of general store for easy unloading from trucks.
The Electrical and Engineering stores of suitable size has been provided to north of the Raw Sugar House.
Coal Storage Capacity of around 90 days has been located on the back side of Boiler House and little away from the Raw Sugar Store. Approach roads have been provided for easy access by trucks.
Molasses Tank of suitable Storage capacity for 180 days of steel construction is provided at the back of Refinery
General Administration Office is at the left of entrance road, whereas the Factory Office is located within the Refinery House.
A Canteen Building has been provided just behind the General Administration Office. A number of Toilet Blocks Have been Provided. The Factory Complex is enclosed by a compound wall. Two gates are provided, one for sugar entry and the other for remaining traffic. At the entry gate, a Time and Security Office is provided.
Water treatment and storage tanks are provided at the back.
The typical layout for standalone sugar refinery is as below : -