Improving the thermal efficiency of a jaggery production module using a fire-tube heat exchanger

Jaggery is a product obtained after heating and evaporation processes have been applied to sugar cane juice via the addition of thermal energy, followed by the crystallisation process through mechanical agitation. At present, jaggery production uses furnaces and pans that are designed empirically based on trial and error procedures, which results in low ranges of thermal efficiency operation. To rectify these deficiencies, this study proposes the use of fire-tube pans to increase heat transfer from the flue gases to the sugar cane juice. With the aim of increasing the thermal efficiency of a jaggery installation, a computational fluid dynamic (CFD)-based model was used as a numerical tool to design a fire-tube pan that would replace the existing finned flat pan. For this purpose, the original configuration of the jaggery furnace was simulated via a pre-validated CFD model in order to calculate its current thermal performance. Then, the newly-designed fire-tube pan was virtually replaced in the jaggery furnace with the aim of numerically estimating the thermal performance at the same operating conditions. A comparison of both simulations highlighted the growth of the heat transfer rate at around 105% in the heating/evaporation processes when the fire-tube pan replaced the original finned flat pan. This enhancement impacted the jaggery production installation, whereby the thermal efficiency of the installation increased from 31.4% to 42.8%.