METHOD FOR THE PROGRAMME CONTROL OF THE CRYSTALLIZATION IN A VACUUM VESSEL

Abstract: In the field of automatic boiling in a pan in which the consistency of massecuite is controlled in accordance with a program, intermittent boiling is employed as an effective way of improving boiling time and the quality of boiled products by supplying an appropriate amount of water or a solution into the pan to loosen the consistency each time it has reached a set value. This invention provides a novel concept in connection with the procedure for establishing the programed value of consistency. The concept includes two curves defining the upper and lower limits, respectively, of an allowable range of consistency within which the consi­ stency of massecuite is maintained, whereby the product of high quality is obtained safely within a minimum of time.

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention : This invention relates to a method of programing the consistency of massecuite of the kind defined by the precharacterizing features of claims 1 and 4, respectively. 2. Description of the Prior Art : A vacuum boiling apparatus is shown by way of example in FIGURE 1. It comprises a parallel side pan 1 having a calandria type heating area 2. The solution F (e.g., syrup) to be boiled is supplied into the bottom of the pan 1 through a solution control valve 3. Heating steam S is supplied to the heating area 2 through a control valve 4 to heat and concentrate the solution by vaporization. The solution continues to be supplied until a concentration enabling crystallization is reached. Then, a seed is added from a feeder 5 through a valve 6 to form appropriate nuclear grains. While the interior of the pan is watched, water or the solution is supplied to avoid the bonding of the nuclear grains and the formation of undesirable nuclear grains (false grains), so that the concentration of the solution and the growing of crystals may be continued. If crystals grow to a certain extent, false grains are less likely to form, as the crystals occupy a certain volume in a unit volume of massecuite (a mixture of solution and crystals) and are located relatively close to one another. The solution is further concentrated to facilitate the growth of crystals. The solution is added to increase its volume in the pan to a certain level, and when a predetermined crystal size has been obtained, the massecuite 7 is discharged through a discharge valve 8. The massecuite is separated by a centrifugal separator into the crystals and the solution. The solution is recycled for boiling. In order to control the concentration of the massecuite appropriately during boiling, it is possible to supply the pan 1 with water W or solution F through a water control valve 9 or the solution control valve 3. It is possible to watch the interior of the pan 1 through peep windows 10. Steam is drawn out from the pan 1 into a condenser 11 by a vacuum pump 13 which is connected to the condenser 11 through a valve 12. The condenser 11 is cooled by cooling water W which is supplied through a valve 14. While various methods have been proposed for controlling the pan, it has become usual to employ an intermittent boiling method which increases the consistency of massecuite in accordance with a program and thereby realizes the stability of operation, as disclosed in Japanese Laid-Open Patent Specification No. 41248/1977 which method is in line with the method mentioned in the preambles of claims 1 and 4. A signal e m indicating the consistency of massecuite is transmitted from a consistency meter 15, such as a rheometer, to the control portion 161 of a sequence control system 16. The system 16 also includes a program setter 162 for feeding a set value e s of consistency to the control portion 161, and a valve actuator 163 for opening or closing the solution control valve 3 or the water control valve 9 in accordance with the output of the control portion 161. A level gage for determining the level of the massecuite 7 in the pan, a pressure control device for maintaining an appropriate vacuum degree in the pan, etc. are also provided, though not shown in FIGURE 1. A conventional method for the program control of the boiling operation is shown in FIGURE 7. Part (A) shows the changes in the measured value e m and set value e s of consistency in a specific area of the crystal growing process in which the solution is boiled, and part (B) shows the operation of the solution control valve 3. At time t₁ when the measured value e m has increased to the level m₁ of the set value e s , the solution is supplied to loosen the consistency of massecuite. The next level m₂ of the set value e s is higher than the level m₁ by ▵m. When the value e m has increased to the level m₂, the solution is supplied again at time t₂. The same is repeated at t₃, t₄, ... . A broken line C obtained by connecting the peak values of e m defines an ideal limit curve for the program control of consistency. If the consistency of massecuite is controlled in accordance with curve C, it is possible to complete a batch of operation in a minimum of time, while maintaining the high quality of crystals. The ideal curve C can, however, be maintained only when various parameters, including the amount of steam in the pan, its vacuum degree and the purity of the solution, are maintained at appropriate levels. It is difficult to maintain any such ideal pattern of control if, for example, the amount of the steam S in the pan or its vacuum degree has greatly changed. For example, if the amount of steam has been reduced abnormally after time t₄, a long time is required for the value e m of consistency to reach the set value m₅, and if the same pattern of control is continued, the value of consistency changes to e' m . A curve C' obtained by connecting the peak values of e' m has a lower gradient than curve C and largely deviates therefrom. If boiling is continued under these circumstances, a drastically prolonged time is required for a batch of operation and it is difficult to obtain crystals of good quality, as false grains are likely to form. An abnormal increase in the amount of steam after time t₄ gives rise to a phenomenon contrary to what has hereinabove been described. The value of consistency changes to e'' m . A curve C'' obtained by joining the peak values of e'' m has a higher gradient than curve C and largely deviates therefrom. A batch of operation is completed abnormally rapidly resulting in the production of defective products containing a large amount of false grains. SUMMARY OF THE INVENTION In connection with the program control of consistency, it is generally advisable to establish an ideal curve (upper limit curve) obtained by joining the peak values of consistency for enabling operation within a minimum time without the formation of false grains and a permissible limit curve (lower limit curve) taking any possible changes in parameters into account and having a lower gradient than the ideal curve. It is necessary to determine the speed of crystallization in relation to the speed at which solute molecules form germs. Therefore, in order to grow crystals without the formation of false grains, it is necessary to supply the solution or water to destroy the germs appropriately before new false grains grow from the germs. This is one of the characteristics of intermittent boiling. The following formula is known as giving the number of the germs: where n c : number of the germs which grow in a unit time; m: mass of a solute molecule; π: constant; k: constant; T: absolute temperature; x c : distance between peak values (points c) of gravity between solute molecules; N: number of solute molecules per unit volume; v : average velocity of movement of solute and solvent molecules; A: constant of about 0.4; C: upper limit of speed at which molecules are caught by crystals; E c : gravity at distance x c in the interaction of grains. As is obvious from this formula, if the number of solute molecules (purity) N is given, the number of the germs growing per unit time and hence the speed of crystal precipitation and growth are proportional to N². Therefore, there exists a speed of crystallization specific to a particular kind of sugar (depending on the crystal size and the solution) when ideal conditions covering the apparatus, the amounts of solution and steam, and other utilities exist. This speed of crystal growth under ideal conditions is expressed by an upper limit curve for consistency if a sensor (consistency meter) is used for detecting the ratio of crystallization and the factors dictating the growth of crystals from the solution (its concentration, supersaturation, etc.). As a matter of fact, however, it is necessary to adjust the boiling time in view of changes in the purity of the solution, the amount of steam, etc. This adjustment can be realized in accordance with a program in which the set values are maintained at specific levels. In the event the solution is low in purity, or the amount of steam is reduced, it is necessary to set at higher levels the factors dictating the growth of crystals which are detected by the consistency meter. These values define a lower limit curve for consistency. If the concepts of these upper (ideal) and lower (permissible) limit curves are introduced into the program control of consistency, it is possible to cope adequately with any variation resulting in the limit curves from disorder in the surrounding conditions or the correlation between the speeds of crystal growth in massecuite and its concentration and thereby realize the stabilized control of the boiling operation. It is an object of this invention to solve the drawbacks of the conventional method for the stepwise program control of consistency and provide a control method which does not cause any substantial deviation from an ideal limit curve even if any disorder may develop in the surrounding conditions. This object is attained by the characterizing features of claim 1. Both, the upper and lower limit curves advantageously may be determined using the formula given above for the germ growth. It is another object of this invention to provide a method of the defined in the preamble of claim 4. which method employs practical means for the approximate establishment of curves defining the upper and lower limits of an allowable range of consistency. This object is attained by the characterizing features of claim 4, by defining the lower limit of an allowable range of consistency to be approximately a straight line having a gradient which is determined by a very simple algorithm. BRIEF DESCRIPTION OF THE DRAWINGS FIGURE 1 is a diagrammatic view of a boiling apparatus including a crystallizing pan; FIGURE 2 is a graphical representation of a method embodying this invention; FIGURE 3 is a graphical representation of another embodiment of this invention; FIGURE 4 is a graphical representation of still another embodiment of this invention; FIGURE 5 is a graphical representation of a further embodiment of this invention; FIGURE 6 is a graphical representation of a still further embodiment of this invention; and FIGURE 7 is a graphical representation of a conventional method for the program control of the boiling operation. DESCRIPTION OF THE PREFERRED EMBODIMENTS A method embodying this invention is shown in FIGURE 2. The measured value e m of consistency is shown by way of example as having reached the level m₁ of a set value e s at time t₁. The measured value e m has a peak P₁. The inventors of this invention know from their experience of actual operation that no single curve is sufficient to define the consistency of massecuite, but that there exists a specific range in which the peak value of consistency changes from one point to another. This range is shown as a region R defined by and between two curves both starting from the point P₁, i.e., a curve C₁ defining the upper limit of the range (upper limit curve) and a curve C₂ defining its lower limit (lower limit curve). We have found that strictly speaking, there exist a pair of optimum upper and lower limit curves starting from each peak. Accordingly, it is possible to maintain the measured value e m of consistency within the allowable range R throughout the boiling operation by reading out of a memory two programed curves starting from a particular level of the set value of massecuite consistency and increasing the set value to another level in accordance with those curves so that another peak of the value e m may be maintained within the range R. The program control of the set value e s will now be described in detail. If the value of e m reaches at P₁ the value e s1 (consistency level m₁) set for a particular cycle of boiling operation, two curves C₁ and C₂ starting from point P₁ (time t₁; consistency level m₁) are defined as shown by broken lines in FIGURE 2. The set value of consistency for another cycle of boiling operation is defined by a curve e s21 coinciding with curve C₁ as shown by a one-dot chain line and representing a proportional increase in consistency with the lapse of time. When the set value has been increased to a specific degree from point P₁ as shown at ▵m, or when a specific length of time has passed as shown at t, it is maintained at a constant level m₂ of consistency after point Q₂₁ on curve e s21 as shown by a horizontal line e s22 . With the lapse of further time, line e s22 meets the lower limit curve C₂ at point Q₂₂, and the set value is thereafter defined by a curve e s23 coinciding with curve C₂ and increases in proportion to time. The values of ▵m and ▵t, which determine points Q₂₁ and Q₂₂, are so selected based on experience that the point at which the value of e m is expected to reach another peak P₂ may fall on the line e s22 between points Q₂₁ and Q₂₂. The program is established to define a pair of limit curves starting from each peak of the value e m substantially as hereinabove described. It enables the achievement of the results of program control comparable to those obtained in accordance with any conventional control curve, since all of the peaks P₁, P₂, ... of the value e m fall within the respective ranges R unless there is any disorder in the parameters dictating the boiling operation in the pan. The shift of the peak value of consistency from P₁ to P₂ is equivalent to the shift from m₁ to m₂ in FIGURE 7. If there occurs any disorder to any of the parameters governing the boiling operation, it is possible that the peak P₂ may appear earlier than at point Q₂₁ and not fall on the horizontal line e s22 . The consistency is, however, so programed as to increase in proportion to time along the curve e s21 which coincides with curve C₁, and which represents smaller values than m₂. Therefore, the value e m and hence the peak P₂ thereof are kept from rising above the upper limit defined by curve C₁. If the peak P₂ does not fall on line e s22 , but appears later than at point Q 22 , the value e m is kept from falling below the lower limit defined by curve C₂ above point Q₂₂ and the peak P₂ is correspondingly increased, since the consistency is so programed as to increase in proportion to time along the curve e s23 which coincides with curve C₂, and which represents larger values than m₂ at Q₂₂. Insofar as even in case any disorder occurs to any of the parameters, the peak of the value e m is so corrected as to fall on the horizontal line e s22 and maintained at least on the upper or lower limit curve as hereinabove set forth, it is possible to maintain the value e m of consistency within the allowable range R throughout each cycle of boiling operation and thereby improve greatly any serious variation in boiling time and the production of defective products which have hitherto been unavoidable. According to this invention, it is necessary to establish two limit curves starting from each peak of the value e m and a somewhat complicated algorithm is required for establishing those curves, depending on the position of the peak. They are, however, relatively easy to establish if a control apparatus including a computer is employed to combine empirical data on the curves with a modified algorithm based on the shift of the peak. An embodiment of this invention which can simplify the algorithm is shown in FIGURE 3. This method can effectively be employed to establish a program without affecting the advantages of this invention. The area in which boiling is carried out is appropriately divided into a plurality of regions. The initial value of massecuite consistency in a particular region is shown at m₁, and its final value at m n . If the consistency of massecuite reaches m₁ at time t₁, there are established two straight lines D₁ and D₂ starting from the peak P₁ defined by t₁ and m₁, and defining an allowable range R therebetween. The set value after time t₁ is given by a one-dot chain line e s21 coinciding with the upper limit line D₁ until it increases by ▵m to m₂. The value increasing along line e s21 reaches m₂ at point Q₂₁ and is thereafter maintained at m₂ as shown by a horizontal line e s22 . Line e s22 meets the lower limit line D₂ at point Q₂₂ and the value is thereafter given by a straight line e s23 coinciding with line D₂. The next program is set when the peak P₂ of the value e m has fallen on any of lines e s21 to e s23 at time t₂. There are established an upper limit line D'₁ and a lower limit line D'₂ extending from the peak P₂ defined by t₂ and m₂ in parallel to the upper and lower limit lines D₁ and D₂, respectively. The set value after t₂ is given by a two-dot chain line e s31 coinciding with the upper limit line D'₁ until it increases by m from m₂ to m₃. The value reaches m₃ at point Q₃₁ and is maintained at m₃ as shown by a horizontal line e s32 . The line e s32 meets the lower limit line D'₂ at point Q₃₂ and the set value is thereafter given by a line e s33 coinciding with the lower limit line D'₂. The foregoing procedure is repeated whenever the value e m has reached the set value, so that each peak of the value e m may be maintained within the range R until the consistency of massecuite reaches the level m n . The same procedure is repeated for establishing two lines for the program control of consistency in the next region. According to the method shown in FIGURE 3, all of the set values e s are programed in accordance with straight lines, i.e., two limit lines for each region which start from the peak. Therefore, it is possible to program the set value of consistency at each level by a very simple algorithm. Another embodiment of this invention is shown in FIGURE 4, and characterized by a still simpler algorithm. The area in which boiling is carried out is appropriately divided into a plurality of regions, and the initial value of massecuite consistency in a particular region is shown at m₁, and its final value at m n , as is the case with the method shown in FIGURE 3. If the measured value of consistency reaches m₁ at time t₁, an upper limit curve or line D₁ is established as starting from the peak P₁ defined by t₁ and m₁. The set value after time t₁ is given by a one-dot chain line e s21 coinciding with the upper limit curve or line D₁ until it increases by ▵m to m₂. The value reaches m₂ at point Q₂₁ and is thereafter maintained at m₂ as shown by a horizontal line e s22 . The length of time from P₁ to Q₂₁ is shown as ▵t. According to a first feature of the method shown in FIGURE 4, the constant value represented by the horizontal line e s22 is maintained for a specific length of time t₀. Therefore, the time at which point Q₂₂ appears with the lapse of time t₀ after point Q₂₁ is expressed as t₁+▵t+t₀. A second feature of the method shown in FIGURE 4 resides in the procedure for establishing the lower limit curves D₂, D₂', ... The first lower limit curve D₂ is defined by a straight line extending from point P₁ to Q₂₂ and has a gradient expressed as ▵m/(▵t + t₀). The line e s23 is so established as to extend from the line as hereinabove defined. The program for the next cycle of operation is so set as to start at the peak P₂ which appears at time t₂ when the measured value e m of consistency falls on any of lines e s21 to e s23 . The program for each further cycle is set in accordance with the upper and lower limit lines which are based on either a specific increment ▵m in consistency over the peak, or a specific length of time ▵t which has passed after the peak. The method shown in FIGURE 4 is based on a specific increment ▵m in consistency. The consistency increases by ▵m from m₂ to m₃ at point Q₃₁ on the upper limit curve or line D₁ starting from peak P₂. The straight line e s31 extending from P₂ to Q₃₁ defines the second upper limit line D₁'. The length of time required for the consistency to increase from P₂ to Q₃₁ is expressed as ▵t'. The set value after point Q₃₁ is maintained constant for the same length of time t₀ along a horizontal line e s32 as along the horizontal line e s22 . The line e s32 meets at point Q₃₂ the lower limit line D₂' which is defined by a straight line extending from P₂ to Q₃₂. A line e s33 extends from point Q₃₂. In case the method is based on the lapse of a specific length of time t, point Q₃₁ appears on the upper limit curve or line D₁ with the lapse of time t after peak P₂. In this case, the increase ▵m' in consistency from m₂ to m₃ is greater than ▵m, and the upper limit line set for each cycle of operation is closer to D₁. Therefore, it is possible to decrease the number of the regions into which the whole process for boiling from the beginning to completion of crystallization is divided. The horizontal and lower limit lines are established in the same way as when they are based on ▵m. According to the method shown in FIGURE 4, it is possible to establish the upper and lower limit lines by a very simple algorithm as according to the method shown in FIGURE 3. A still simpler procedure for establishing the lower limit lines is shown in FIGURE 5, while the procedure shown in FIGURE 4 is repeated for establishing the upper limit line D₁. The method of FIGURE 5 is characterized by a lower limit line which is defined by a straight line D₂ extending below line D₁ and representing a specific difference m₀ therefrom. While the lines e s21 , e s22 and e s23 starting from point P₁ and the lines e s31 , e s32 and e s33 starting from point P₂ are established in accordance with exactly the same procedure as those shown in FIGURE 4, only the upper limit line is established as starting from each peak, and the lower limit line D₂ is not varied. According to the method shown in FIGURE 5, as well as that shown in FIGURE 4, point Q₃₁ is that point on the upper limit curve or line D₁ at which the consistency m₃ which is ▵m higher than m₂ at point P₂ is obtained. It is, however, possible to select that point on D₁ which is reached with the lapse of time ▵t after P₂. In this case, if the consistency increases by ▵m' from m₂ to m₃, ▵m' is greater than ▵m, and the upper limit line D₁' is closer to D₁. Therefore, it is possible to decrease the number of the regions into which the whole boiling process from the beginning to completion of crystallization is divided. The horizontal and lower limit lines are established in the same way as is shown in FIGURE 5. According to the method shown in FIGURE 5, the lower limit line D₂ is finalized as initially defined and does not vary. Therefore, it can be established by a still simpler algorithm. While FIGURES 3 to 5 have been described as showing a method for programing consistency only in a particular portion of the boiling area, FIGURE 6 shows the program control of consistency over the whole boiling area which is divided into a plurality of regions T₁, T₂, ... and T n . As is obvious from FIGURE 6, the upper limit curves or lines y₁ to y n for the regions T₁ to T n , respectively, are defined by a combination of curves or lines which gradually increase in gradient. As is obvious from the foregoing description, the method of this invention provides the following advantages; (1) It is possible to decrease drastically the possibility of abnormal change in boiling time and defective production that might otherwise result from a great deviation, from the limit curves, of the curve joining the peak values of massecuite consistency in the event any variation has developed in any of the parameters, such as the amount of steam or pressure in the pan, or the purity of the solution. Should any disorder develop in any such parameter, it is often unavoidable to finish a particular batch of operation without the production of defective products, since even a highly experienced operator often finds it difficult to switch the setting of consistency from automatic to manual and restore the correct limit curves. According to the method of this invention, however, the curves defining the set value of consistency are automatically corrected so as to fall within the allowable range to prevent any defective production unless the disorder in the parameters is fatal. Therefore, the method of this invention is easy to carry out even by an unskilled operator and drastically mitigates the mental burden which the job of watching the operation of a pan has hitherto imposed on even a highly skilled person. (2) The method of this invention can be carried out by employing a simplified procedure as shown in FIGURES 3 to 5. The stability of operation is ensured only if a program is set by two lines for each particular region. As no complicated programing is required, the method of this invention can be carried out by an inexpensive apparatus.

Claims: A method of controlling the consistency of massecuite obtained from a starting material having a specific number of solute molecules per unit volume in a batch process during automatic boiling in a pan using a rheometer for measuring the consistency, said method comprising the steps of supplying water or syrup solution to said pan each time the consistency measured by said rheometer has increased to one of a plurality of peak values corresponding to succeeding consistency set values in order to loosen the consistency of massecuite before the next higher value of consistency is reached, each consistency set value following to a preceeding one being higher than said preceeding set value, characterized by the steps of reading out of a memory two programmed curves defining the upper and lower limits, respectively, of a range of massecuite consistency in which the peak value of consistency reached at a set value changes to the following peak value upon supplying said water or syrup solution, increasing said set value in accordance with said curve defining the upper limit, holding said set value constant when it has been increased to a specific degree or when a specific length of time has passed, and increasing said set value in accordance with said curve defining the lower limit after a straight line representing said held value has crossed said curve defining the lower limit, whereby said set value is varied in a programmed pattern. The method according to claim 1, wherein each of said curves is defined by a straight line. The method according to claim 1, wherein each of said curves is established by an algorithm of emperically available curves modified based on said curves and variation in the peak values of said consistency. A method of controlling the consistency of massecuite obtained from a starting material having a specific number of solute molecules per unit volume in a batch process during automatic boiling in a pan using a rheometer for measuring the consistency, said method comprising the steps of supplying water or syrup solution to said pan each time the consistency measured by said rheometer has increased to one of a plurality of peak values corresponding to succeeding consistency set values in order to loosen the consistency of massecuite before the next higher value of consistency is reached, each consistency set value following to a preceeding one being higher than said preceeding set value, characterized by the steps of reading out of a memory a programmed curve defining the upper limit of a range of massecuite consistency in which the peak value of consistency reached at a set value changes to the following peak value upon supplying said water or syrup solution, starting from a point at which the consistency has reached a set value, increasing said set value in accordance with said curve defining the upper limit, holding said set value constant when it has been increased to a specific degree or when a specific length of time has passed, and increasing said set value in accordance with a line defining the lower limit of said range after said value has been held for a constant period of time, said line being defined by a straight line extending from said point to that point at which said constant period of time has passed, said set value being varied in a programmed pattern. The method according to claim 1 or 2, wherein the curve defining the lower limit extends below the curve defining the upper limit and represents a constant difference in said value of consistency therefrom.

Inventors: CHIGUSA, TAKEHIKO YOKOGAWA HOKUSHIN ELECTRIC CORP., FUKUSHIMA, KAZUNORI ENSUIKO SUGAR REFINING CO. LTD, HASHIMOTO, HITOSHI ENSUIKO SUGAR REFINING CO., LTD, KAWAMURA, TSUNENORI ENSUIKO SUGAR REFINING CO. LTD, KUROKAWA, KIYOUMI ENSUIKO SUGAR REFINING CO., LTD., MIYAZAKI, MASAKATSU ENSUIKO SUGAR REFINING CO. LTD
Applicants: ENSUIKO SUGAR REFINING COMPANY, LIMITED, YOKOGAWA ELECTRIC CORPORATION
Application year: 1985
Main classification: C13F1
IPC codes: C13F1, C13G1