Beet sugar factory heat balances at processing rate 12,000-ton sugar beet/day, it relies on sugar boiling's types and vapors distribution. Thin juice brix 17% is concentrated to 73.4%t through heating with turbine's exhaust steam of 2.8 bar abs in a five evaporator effects, the steam and juice flowing in co-current flow. Evaporated vapors from all effects are used for heating juices & run offs and sugar boiling processes while the condensates are used as hot water source for beet wash, juice extraction/purification, and sugar house processes.  

Evaporation heat balances showing that running sugar boiling by 3rd and 4th vapors, the steam consumption is low "24.5%OB", and 3rd vapor pressure is high "1.55 bar abs". While running sugar boiling by only 3rd vapor, the steam consumption is raised to 26.5%OB and 3rd vapor pressure is dropped to 1.36 bar abs as result of the raise in BPE "2.61 C" and brix "54.93%"of 3rd effect juice.

Good vapors bleeding and distribution enhances the energy saving and economic sugar production.   

Beet juice extraction is a complex process governed by several key factors. From the acidic conditions to the control of residence time and tower speed, each element plays a crucial role in ensuring optimal results. The continuous countercurrent method employed in this process is meticulously designed to extract raw juice efficiently.

The journey of sliced beet cossettes begins in the Cossette mixer, where they are heated with a large quantity of recirculated hot juice to 72 degrees. As the juice/cossettes mixture moves into the extraction tower, a series of intricate steps take place. Acidic pressed pulp water and fresh hot water are introduced midway up the tower to aid in sucrose diffusion from beet cells. Simultaneously, the tower facilitates the separation of hot wet beet pulp, directing it out of the tower to the pulp press.

Control over raw juice purity and sugar loss in beet cossettes is maintained through careful monitoring of juice pH, tower temperature, residence time, added press water/freshwater quantity, and pulp roughness. Gypsum addition at the entrance of the cossettes into the mixer serves to adapt and optimize the process for maximum efficiency. 

Carbonatation process plays a crucial role in the purification of beet juice and decolorization of cane refining liquor. Achieving a 35% elimination of non-sugar in beet juice leads to a significant 3:4 purity points increase, while a 55% decolorization of cane refining sugar liquors is achievable through the carbonation process.

During the two-stage process, the first stage involves injecting a maximum amount of CO2 gas at high pressure into hot limed juice. This facilitates the absorption of non-sugars and impurities by the resulting CaCO3 carbonated mud, which is then separated from the clarified juice through sedimentation clarifiers. In the second stage, excess lime salts are removed through over carbonatation, leading to the attainment of the required final alkalinity and pH levels.

Moreover, the second carbonated juice undergoes fine and safety filtration stages, resulting in thin juice. For beet juice, the thin juice is further processed through IXR decalcification for juice softening, ensuring optimal heat transfer of evaporators and vacuum pans. The soft juice's alkalinity is reduced to 0.005%, enhancing its purity. 

Steam and energy consumption can be effectively reduced by running vacuum pans at lower vacuum pressure levels. For instance, the steam consumption of R1 vacuum pan decreases from 0.45 to 0.43 T steam/T sugar when operating at vacuum 0.15 bar abs, compared to 0.22 bar abs. Similarly, Beet A vacuum pan shows a decrease from 0.49 to 0.47 T steam/T sugar at the same vacuum levels. This approach not only lowers steam consumption but also allows for working with low-pressure steam/vapors, achieving the desired sugar quality while minimizing color formation.

Moreover, when calculating massecuite viscosity in vacuum pan operations, it is crucial to consider a 65% decrease from the calculated value to adjust for practical operation conditions, where thinning properties are not taken into account.

Efficient use of vacuum pans at lower pressure levels presents a practical solution for reducing steam consumption, maintaining product quality, and optimizing energy efficiency in sugar processing operations.

Pan/Centrifugal yield of Beet C massecuite shows the yield after vertical cooling crystallizers (52.25% mass) where after C-pan it is 33: 35%

Pan/Centrifugal yield diagram shows efficiency of crystal washing in centrifuges and its effect on syrup recirculation, expected sucrose to final molasses loss, and the quality of obtained sugar product.