Optimum Sizing and Performance Assessment of Modified Energy Efficient Jaggery Unit for Economic Self Sufficiency of Farmers in India

The complete lockdown experienced in India since March 2020 has brought the nation’s economy to a halt, severely impacting the destitute and the most vulnerable, including farmers and migrant laborers. However, the country envisaged the vision of “Atmanirbhar Bharat Abhiyan” (Self-reliant India Movement) on May 12, 2020, that focuses on the importance of promoting local products and encourages manufacturing industries including the agricultural sector. The awareness campaign includes reforms to encourage businesses, attract investments, and strengthen production processes. Agriculture businesses are playing a major role in boosting the economy, such as Jaggery manufacturing, which is one of the most popular food processing enterprises that promotes job openings in rural India. Though, the country is the leading exporter of jaggery to the world, most of the production units, situated in remote places are designed without any scientific base and are seriously facing energy inefficiency problems. This research aims to design and develop a modified energy-efficient jaggery unit for the farmer producer groups, to achieve a “Self-reliant India”. The proposed cost effective “Energy Efficient Jaggery Unit” is self reliant to meet all the requirements of the production process,such as combined heat and power (CHP) with the generation of biofuel, termed as Tri-Generation System.


INTRODUCTION
Jaggery is one of the most popular sweeteners, manufactured by boiling sugarcane juice in a conventional open pan-furnace heating system. It is also known as "medicinal sugar", which is nutritionally equivalent to "honey" and is considered healthier than refined sugar as it primarily contains sucrose, glucose, minerals, and vitamins. The major minerals are Iron (11%), calcium (0.4%), phosphorus (0.045%), magnesium (0.08%), protein (0.25%), fat (0.05%), as well as a small amount of zinc, copper, vitamin A, and vitamin B. Jaggery is well known as a good source of energy that prevents constipation, strengthens the liver, treats flu-like symptoms, purifies blood, and avoids disorders of the bile. It also helps in relieving fatigue, relaxes muscles, nerve tissues,and vascular bundles, and keeps blood pressure and hemoglobin at a normal level. It also helps prevent anemia and boosts intestinal health . According to the Agricultural and Processed Food Products Export Development Authority (APEDA), India has recently supplied around 632,000.00 MT of jaggery at 359.USD Millions (Rs. 2659.57 Crores) and has been recognized as the leading exporter of the products to the world (APEDA 2021).
Previous research on energy optimization methods for the jaggery manufacturing process indicated that adopting uniform fuel usage over the random or batch pattern reduces specific bagasse consumption from 2.39 to 1.73 kg . Air dampers are required at the entrance of furnace air openings and flue gas passages in chimneys to improve the system efficiency (Shiralkar et al., 2013). Reversible heat pumps are used to pre-concentrate and separate cane juice from water. This method conserves thermal energy, equivalent to 15% of heat addition during evaporation (Rane et al., 2015). A computational fluid dynamic (CFD)-based simulation model is used to design and develop a fire-tube pan to replace the conventional finned flat type. It is observed that the heat transfer rate and the thermal efficiency of the manufacturing process improve considerably by replacing finned flat pans by fire tube type (Madrid et al., 2017). Solar photovoltaic-thermal (SPVT) systems are suggested for performance improvement, mainly using solar collectors for preheating sugarcane juice, input air and bagasse (Jakkamputi et al., 2016;Kulkarni et al., 2015 ).Techno-Economically sized grid-connected solar PV system 140 Kwp is suggested for semi-automatic jaggery plant located at Chakan Pune, India and relieves the farmers from use of diesel generator (DG) sets and helps in a drastic reduction of carbon emission (Hasarmani et al., 2018).Furthermore, various configurations of optimally sized renewable energy sources like solar PV-DG hybrid systems are suggested to overcome the effect of bad weather conditions on the generation of electricity for agricultural enterprises (Philip et al., 2015;Kant al., 2016;Hasarmani et al., 2019). Moreover, a Programmable logic controller is suggested for optimum generation scheduling of Solar PV-DG set that maximizes the use of solar PV system and minimizes the operational cost of jaggery units (Hasarmani et al., 2020). This research presents the design and development of an energyefficient jaggery unit, based on mass-energy balance theory, that meets not only the heat requirement of the jaggery production process but also improves bagasse utilization.

Jaggery Production Process
Jaggery production involves multiple activities, such as transportation, cutting and crushing sugarcane, open sun drying of bagasse, juice filtering, preheating, removal of scum (molasses), and packaging of the finished product. This entire process requires mechanical, electrical, and thermal energy. The conventional jaggery production process is completed at three different stages as shown in Figure 1a. In the first stage, sugarcane is crushed using a diesel engine or electric motor-driven crusher, and juice is collected in a tank. Air and sundried bagasse is supplied to the furnace for combustion through the inlet holes, and finally, flue gases are released into the environment via the chimney. In the second phase, fixed amounts of chemicals like calcium carbonate, hydrous powder, and ladyfinger mucilage are added to remove the floating scum from sugarcane juice, after which the product becomes rich in concentrated solids. In the third stage, juice is further heated from boiling to a striking point, which converts to a semisolid paste that slides on the pan. Finally, jaggery in a semisolid state is cooled, poured into molds, and packed as a final product. The mass balances of the jaggery making process are shown in Figure 1b. T. Hasarmani & R. Holmukhe / agriTECH 42 (3) 2022 xxx-xxx systems are suggested for performance improvement, mainly using solar collectors for preheating sugarcane juice, input air and bagasse (Jakkamputi et al., 2016;Kulkarni et al., 2015 ).Techno-Economically sized grid-connected solar PV system 140 Kwp is suggested for semi-automatic jaggery plant located at Chakan Pune, India and relieves the farmers from use of diesel generator (DG) sets and helps in a drastic reduction of carbon emission (Hasarmani et al., 2018).Furthermore, various configurations of optimally sized renewable energy sources like solar PV-DG hybrid systems are suggested to overcome the effect of bad weather conditions on the generation of electricity for agricultural enterprises (Philip et al., 2015;Kant al., 2016;Hasarmani et al., 2019). Moreover, a Programmable logic controller is suggested for optimum generation scheduling of Solar PV-DG set that maximizes the use of solar PV system and minimizes the operational cost of jaggery units (Hasarmani et al., 2020). This research presents the design and development of an energy-efficient jaggery unit, based on mass-energy balance theory, that meets not only the heat requirement of the jaggery production process but also improves bagasse utilization.

Jaggery Production Process
Jaggery production involves multiple activities, such as transportation, cutting and crushing sugarcane, open sun drying of bagasse, juice filtering, preheating, removal of scum (molasses), and packaging of the finished product. This entire process requires mechanical, electrical, and thermal energy. The conventional jaggery production process is completed at three different stages as shown in Figure 1a. In the first stage, sugarcane is crushed using a diesel engine or electric motor-driven crusher, and juice is collected in a tank. Air and sundried bagasse is supplied to the furnace for combustion through the inlet holes, and finally, flue gases are released into the environment via the chimney. In the second phase, fixed amounts of chemicals like calcium carbonate, hydrous powder, and ladyfinger mucilage are added to remove the floating scum from sugarcane juice, after which the product becomes rich in concentrated solids. In the third stage, juice is further heated from boiling to a striking point, which converts to a semisolid paste that slides on the pan. Finally, jaggery in a semisolid state is cooled, poured into molds, and packed as a final product. The mass balances of the jaggery making process are shown in Figure 1b.

Mathematical Modelling of Energy Efficient Jaggery Unit
Energy optimization and scientific design of jaggery unit start with a mass-energy balance of the pan-furnace system as described in Equation 1.

Mathematical Modelling of Energy Efficient Jaggery Unit
Energy optimization and scientific design of jaggery unit start with a mass-energy balance of the pan-furnace system as described in Equation 1.
Mass balance: In steady state conditions, 2 Figure 1. Conventional jaggery making process (a), mass balance sankey diagram of jaggery unit (b)

Mathematical Modelling of Energy Efficient Jaggery Unit
Energy optimization and scientific design of jaggery unit start with a mass-energy balance of the pan-furnace system as described in Equation 1. Similarly, applying conservation of energy for inputs and outputs of pan furnace system, ℎ − ℎ = 0 Where, ℎ is the input heat supplied to jaggery unit by combustion of bagasse, Where, CVbg is calorific value of the bagasse Output heat, ℎ = ℎ + ℎ + ℎ + ℎ + ℎ + ℎ + ℎ Where, ℎ =heat required to raise sugarcane juice temperature from initial to boiling point. ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice from boiling to striking stage. ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace wall, and unburnt fuel respectively. Variables of Equation 6 are calculated using following equations, h cj = m cj * c cj (t jb − t ji ) h sm = m sm * λ h st = m jg * c jg (t st − t jb ) Similarly, h fg = m fg * c lg (t fg − t ab ) (8) h as = m as * c as (t as − t ab ) Heat loss in furnace wall takes place because of conduction, convection, and radiation as mentioned, Similarly, applying conservation of energy for inputs and outputs of pan furnace system, ℎ − ℎ = 0 Where, ℎ is the input heat supplied to jaggery unit by combustion of bagasse, Where, CVbg is calorific value of the bagasse Output heat, ℎ = ℎ + ℎ + ℎ + ℎ + ℎ + ℎ + ℎ Where, ℎ =heat required to raise sugarcane juice temperature from initial to boiling point. ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice from boiling to striking stage. ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace wall, and unburnt fuel respectively. Variables of Equation 6 are calculated using following equations, h cj = m cj * c cj (t jb − t ji ) h sm = m sm * λ h st = m jg * c jg (t st − t jb ) Similarly, h fg = m fg * c lg (t fg − t ab ) (8) h as = m as * c as (t as − t ab ) Heat loss in furnace wall takes place because of conduction, convection, and radiation as mentioned, is the input heat supplied to jaggery unit by combustion of bagasse, Where, m bg , m ar ;m fg , m as are masses of bagasse, air, flue gasses, and ash, respectively. Similarly, m cj , m cm , m jg , m sm , m st are masses of cane juice, chemicals, jaggery, floating scum, and steam.
Similarly, applying conservation of energy for inputs and outputs of pan furnace system, ℎ − ℎ = 0 Where, ℎ is the input heat supplied to jaggery unit by combustion of bagasse, Where, CVbg is calorific value of the bagasse Output heat, ℎ = ℎ + ℎ + ℎ + ℎ + ℎ + ℎ + ℎ Where, ℎ =heat required to raise sugarcane juice temperature from initial to boiling point. ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice from boiling to striking stage. ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace wall, and unburnt fuel respectively. Variables of Equation 6 are calculated using following equations, h cj = m cj * c cj (t jb − t ji ) h sm = m sm * λ h st = m jg * c jg (t st − t jb ) Similarly, h fg = m fg * c lg (t fg − t ab ) (8) h as = m as * c as (t as − t ab ) Heat loss in furnace wall takes place because of conduction, convection, and radiation as mentioned, h fw = (h fw ) cd + (h fw ) cv + (h fw ) rd (10) , m bg , m ar ;m fg , m as are masses of bagasse, air, flue gasses, and ash, respectively. rly, m cj , m cm , m jg , m sm , m st are masses of cane juice, chemicals, jaggery, floating scum, and .
rly, applying conservation of energy for inputs and outputs of pan furnace system, ℎ = 0 , ℎ is the input heat supplied to jaggery unit by combustion of bagasse, * , CVbg is calorific value of the bagasse t heat, ℎ = ℎ + ℎ + ℎ + ℎ + ℎ + ℎ + ℎ , ℎ =heat required to raise sugarcane juice temperature from initial to boiling point. heat required for conversion of water to steam. eat required to raise temperature of sugarcane juice from boiling to striking stage. , ℎ and ℎ are heat losses in flue gas, ash, furnace wall, and unburnt fuel respectively. les of Equation 6 are calculated using following equations, m cj * c cj (t jb − t ji ) m sm * λ m jg * c jg (t st − t jb ) rly, m fg * c lg (t fg − t ab ) (8) m as * c as (t as − t ab ) oss in furnace wall takes place because of conduction, convection, and radiation as mentioned, Where, = heat required to raise sugarcane juice temperature from initial to boiling point. = heat required for conversion of water to steam. = heat required to raise temperature of sugarcane juice from boiling to striking stage.
Where, m bg , m ar ;m fg , m as are masses of bagasse, air, flue gasses, and ash, respectively. Similarly, m cj , m cm , m jg , m sm , m st are masses of cane juice, chemicals, jaggery, floating scum, and steam.
Similarly, applying conservation of energy for inputs and outputs of pan furnace system, ℎ − ℎ = 0 Where, ℎ is the input heat supplied to jaggery unit by combustion of bagasse, Where, CVbg is calorific value of the bagasse Output heat, ℎ = ℎ + ℎ + ℎ + ℎ + ℎ + ℎ + ℎ Where, ℎ =heat required to raise sugarcane juice temperature from initial to boiling point. ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice from boiling to striking stage. ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace wall, and unburnt fuel respectively. Variables of Equation 6 are calculated using following equations, Similarly, h fg = m fg * c lg (t fg − t ab ) , and Where, m bg , m ar ;m fg , m as are masses of bagasse, air, flue gasses, and ash, respectively. Similarly, m cj , m cm , m jg , m sm , m st are masses of cane juice, chemicals, jaggery, floating scum, and steam.
Similarly, applying conservation of energy for inputs and outputs of pan furnace system, ℎ − ℎ = 0 Where, ℎ is the input heat supplied to jaggery unit by combustion of bagasse, Where, CVbg is calorific value of the bagasse Output heat, ℎ = ℎ + ℎ + ℎ + ℎ + ℎ + ℎ + ℎ Where, ℎ =heat required to raise sugarcane juice temperature from initial to boiling point. ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice from boiling to striking stage. ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace wall, and unburnt fuel respectively. Variables of Equation 6 are calculated using following equations, Similarly, h fg = m fg * c lg (t fg − t ab ) are heat losses in flue gas, ash, furnace wall, and unburnt fuel respectively. Variables of Equation 6 are calculated using following equations, Where, ℎ =heat required to raise sugarcane juice temperature fr ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice from b ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace wall Variables of Equation 6 are calculated using following equations, h cj = m cj * c cj (t jb − t ji ) h sm = m sm * λ h st = m jg * c jg (t st − t jb ) Similarly, h fg = m fg * c lg (t fg − t ab ) h as = m as * c as (t as − t ab ) Heat loss in furnace wall takes place because of conduction, conv h fw = (h fw ) cd + (h fw ) cv + (h fw ) rd Wheret jb , t ji and t st are boiling, initial, and striking temperatures o c jg , c cj are specific heat of jaggery and sugarcane juice in (kJ/kg Similarly, c fg , c as are specific heat of flue gas and ash in (kJ/kg K) The ideal amount of bagasse required for jaggery production proc = 20% (As per actual measure ℎ , , = Where the total mass of cane juice= mass of water+ mass of jag The heat required per kg of jaggery production by evaporating w the following Equation 12 (Shiralkar et al., 2013).
Where, ℎ =heat required to raise sugarcane juice temperature f ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice from ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace wal Variables of Equation 6 are calculated using following equations, Similarly, h fg = m fg * c lg (t fg − t ab ) h as = m as * c as (t as − t ab ) Heat loss in furnace wall takes place because of conduction, conv h fw = (h fw ) cd + (h fw ) cv + (h fw ) rd Wheret jb , t ji and t st are boiling, initial, and striking temperatures o c jg , c cj are specific heat of jaggery and sugarcane juice in (kJ/kg Similarly, c fg , c as are specific heat of flue gas and ash in (kJ/kg K The ideal amount of bagasse required for jaggery production pro = 20% (As per actual measure ℎ , , = Where the total mass of cane juice= mass of water+ mass of jag The heat required per kg of jaggery production by evaporating w the following Equation 12 (Shiralkar et al., 2013).
Where, ℎ =heat required to raise sugarcane juice temperature fr ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice from b ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace wall, Variables of Equation 6 are calculated using following equations, Similarly, h fg = m fg * c lg (t fg − t ab ) h as = m as * c as (t as − t ab ) Heat loss in furnace wall takes place because of conduction, conv h fw = (h fw ) cd + (h fw ) cv + (h fw ) rd Wheret jb , t ji and t st are boiling, initial, and striking temperatures of c jg , c cj are specific heat of jaggery and sugarcane juice in (kJ/kg Similarly, c fg , c as are specific heat of flue gas and ash in (kJ/kg K) The ideal amount of bagasse required for jaggery production proc = 20% (As per actual measurem ℎ , , = Where the total mass of cane juice= mass of water+ mass of jagg The heat required per kg of jaggery production by evaporating w the following Equation 12 (Shiralkar et al., 2013).
Where, ℎ =heat required to raise sugarcane juice temperature f ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice from ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace wal Variables of Equation 6 are calculated using following equations, Similarly, h fg = m fg * c lg (t fg − t ab ) h as = m as * c as (t as − t ab ) Heat loss in furnace wall takes place because of conduction, conv h fw = (h fw ) cd + (h fw ) cv + (h fw ) rd Wheret jb , t ji and t st are boiling, initial, and striking temperatures o c jg , c cj are specific heat of jaggery and sugarcane juice in (kJ/kg Similarly, c fg , c as are specific heat of flue gas and ash in (kJ/kg K The ideal amount of bagasse required for jaggery production pro = 20% (As per actual measure ℎ , , = Where the total mass of cane juice= mass of water+ mass of jag The heat required per kg of jaggery production by evaporating w the following Equation 12 (Shiralkar et al., 2013). Similarly, Where, ℎ =heat required to raise sugarcane juice temperature fr ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice from b ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace wall Variables of Equation 6 are calculated using following equations, Similarly, h fg = m fg * c lg (t fg − t ab ) h as = m as * c as (t as − t ab ) Heat loss in furnace wall takes place because of conduction, conv h fw = (h fw ) cd + (h fw ) cv + (h fw ) rd Wheret jb , t ji and t st are boiling, initial, and striking temperatures o c jg , c cj are specific heat of jaggery and sugarcane juice in (kJ/kg Similarly, c fg , c as are specific heat of flue gas and ash in (kJ/kg K) The ideal amount of bagasse required for jaggery production proc = 20% (As per actual measure ℎ , , = Where the total mass of cane juice= mass of water+ mass of jag The heat required per kg of jaggery production by evaporating w the following Equation 12 (Shiralkar et al., 2013).
Output heat, ℎ = ℎ + ℎ + ℎ + ℎ + ℎ + ℎ + ℎ Where, ℎ =heat required to raise sugarcane juice temperature fr ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice from b ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace wall Variables of Equation 6 are calculated using following equations, Similarly, h fg = m fg * c lg (t fg − t ab ) h as = m as * c as (t as − t ab ) Heat loss in furnace wall takes place because of conduction, conv h fw = (h fw ) cd + (h fw ) cv + (h fw ) rd Wheret jb , t ji and t st are boiling, initial, and striking temperatures o c jg , c cj are specific heat of jaggery and sugarcane juice in (kJ/kg Similarly, c fg , c as are specific heat of flue gas and ash in (kJ/kg K) The ideal amount of bagasse required for jaggery production proc = 20% (As per actual measure ℎ , , = Where the total mass of cane juice= mass of water+ mass of jag The heat required per kg of jaggery production by evaporating w the following Equation 12 (Shiralkar et al., 2013).
Heat loss in furnace wall takes place because of conduction, convection, and radiation as mentioned, Output heat, ℎ = ℎ + ℎ + ℎ + ℎ + ℎ + ℎ + ℎ Where, ℎ =heat required to raise sugarcane juice temperature fr ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice from b ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace wall Variables of Equation 6 are calculated using following equations, Similarly, h fg = m fg * c lg (t fg − t ab ) h as = m as * c as (t as − t ab ) Heat loss in furnace wall takes place because of conduction, conv h fw = (h fw ) cd + (h fw ) cv + (h fw ) rd Wheret jb , t ji and t st are boiling, initial, and striking temperatures o c jg , c cj are specific heat of jaggery and sugarcane juice in (kJ/kg Similarly, c fg , c as are specific heat of flue gas and ash in (kJ/kg K) The ideal amount of bagasse required for jaggery production proc = 20% (As per actual measure ℎ , , = Where the total mass of cane juice= mass of water+ mass of jag The heat required per kg of jaggery production by evaporating w the following Equation 12 (Shiralkar et al., 2013).
Where Where, CVbg is calorific value of the bagasse Output heat, ℎ = ℎ + ℎ + ℎ + ℎ + ℎ + ℎ + ℎ Where, ℎ =heat required to raise sugarcane juice temperature ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice from ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace wa Variables of Equation 6 are calculated using following equations, Similarly, h fg = m fg * c lg (t fg − t ab ) h as = m as * c as (t as − t ab ) Heat loss in furnace wall takes place because of conduction, con h fw = (h fw ) cd + (h fw ) cv + (h fw ) rd Wheret jb , t ji and t st are boiling, initial, and striking temperatures c jg , c cj are specific heat of jaggery and sugarcane juice in (kJ/kg Similarly, c fg , c as are specific heat of flue gas and ash in (kJ/kg K The ideal amount of bagasse required for jaggery production pro = 20% (As per actual measur ℎ , , = Where the total mass of cane juice= mass of water+ mass of jag The heat required per kg of jaggery production by evaporating the following Equation 12 (Shiralkar et al., 2013).
Where, CVbg is calorific value of the bagasse Output heat, ℎ = ℎ + ℎ + ℎ + ℎ + ℎ + ℎ + ℎ Where, ℎ =heat required to raise sugarcane juice temperature ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice from ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace w Variables of Equation 6 are calculated using following equation Similarly, h fg = m fg * c lg (t fg − t ab ) h as = m as * c as (t as − t ab ) Heat loss in furnace wall takes place because of conduction, co h fw = (h fw ) cd + (h fw ) cv + (h fw ) rd Wheret jb , t ji and t st are boiling, initial, and striking temperature c jg , c cj are specific heat of jaggery and sugarcane juice in (kJ/ Similarly, c fg , c as are specific heat of flue gas and ash in (kJ/kg The ideal amount of bagasse required for jaggery production p = 20% (As per actual measu ℎ , , = Where the total mass of cane juice= mass of water+ mass of j The heat required per kg of jaggery production by evaporating the following Equation 12 (Shiralkar et al., 2013). Output heat, ℎ = ℎ + ℎ + ℎ + ℎ + ℎ + ℎ + ℎ Where, ℎ =heat required to raise sugarcane juice temperatur ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice fro ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace w Variables of Equation 6 are calculated using following equation Similarly, h fg = m fg * c lg (t fg − t ab ) h as = m as * c as (t as − t ab ) Heat loss in furnace wall takes place because of conduction, co h fw = (h fw ) cd + (h fw ) cv + (h fw ) rd Wheret jb , t ji and t st are boiling, initial, and striking temperature c jg , c cj are specific heat of jaggery and sugarcane juice in (kJ/ Similarly, c fg , c as are specific heat of flue gas and ash in (kJ/kg The ideal amount of bagasse required for jaggery production p = 20% (As per actual measu ℎ , , = Where the total mass of cane juice= mass of water+ mass of The heat required per kg of jaggery production by evaporatin the following Equation 12 (Shiralkar et al., 2013). Where, CVbg is calorific value of the bagasse Output heat, ℎ = ℎ + ℎ + ℎ + ℎ + ℎ + ℎ + ℎ Where, ℎ =heat required to raise sugarcane juice temperature fr ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice from b ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace wall Variables of Equation 6 are calculated using following equations, Similarly, h fg = m fg * c lg (t fg − t ab ) h as = m as * c as (t as − t ab ) Heat loss in furnace wall takes place because of conduction, conv h fw = (h fw ) cd + (h fw ) cv + (h fw ) rd Wheret jb , t ji and t st are boiling, initial, and striking temperatures o c jg , c cj are specific heat of jaggery and sugarcane juice in (kJ/kg Similarly, c fg , c as are specific heat of flue gas and ash in (kJ/kg K) The ideal amount of bagasse required for jaggery production proc = 20% (As per actual measure ℎ , , = Where the total mass of cane juice= mass of water+ mass of jag The heat required per kg of jaggery production by evaporating w the following Equation 12 (Shiralkar et al., 2013).
Where, CVbg is calorific value of the bagasse Output heat, ℎ = ℎ + ℎ + ℎ + ℎ + ℎ + ℎ + ℎ Where, ℎ =heat required to raise sugarcane juice temperature f ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice from ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace wal Variables of Equation 6 are calculated using following equations, h cj = m cj * c cj (t jb − t ji ) h sm = m sm * λ h st = m jg * c jg (t st − t jb ) Similarly, h fg = m fg * c lg (t fg − t ab ) h as = m as * c as (t as − t ab ) Heat loss in furnace wall takes place because of conduction, conv h fw = (h fw ) cd + (h fw ) cv + (h fw ) rd Where, CVbg is calorific value of the bagasse Output heat, ℎ = ℎ + ℎ + ℎ + ℎ + ℎ + ℎ + ℎ Where, ℎ =heat required to raise sugarcane juice temperature fr ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice from b ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace wall Variables of Equation 6 are calculated using following equations, h cj = m cj * c cj (t jb − t ji ) h sm = m sm * λ h st = m jg * c jg (t st − t jb ) Similarly, h fg = m fg * c lg (t fg − t ab ) h as = m as * c as (t as − t ab ) Heat loss in furnace wall takes place because of conduction, conv h fw = (h fw ) cd + (h fw ) cv + (h fw ) rd Wheret jb , t ji and t st are boiling, initial, and striking temperatures o c jg , c cj are specific heat of jaggery and sugarcane juice in (kJ/kg Similarly, c fg , c as are specific heat of flue gas and ash in (kJ/kg K) The ideal amount of bagasse required for jaggery production proc The ideal amount of bagasse required for jaggery production process: Where, CVbg is calorific value of the bagasse Output heat, ℎ = ℎ + ℎ + ℎ + ℎ + ℎ + ℎ + ℎ Where, ℎ =heat required to raise sugarcane juice temperature fr ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice from b ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace wall Variables of Equation 6 are calculated using following equations, h cj = m cj * c cj (t jb − t ji ) h sm = m sm * λ h st = m jg * c jg (t st − t jb ) Similarly, h fg = m fg * c lg (t fg − t ab ) h as = m as * c as (t as − t ab ) Heat loss in furnace wall takes place because of conduction, conv h fw = (h fw ) cd + (h fw ) cv + (h fw ) rd Wheret jb , t ji and t st are boiling, initial, and striking temperatures o c jg , c cj are specific heat of jaggery and sugarcane juice in (kJ/kg Similarly, c fg , c as are specific heat of flue gas and ash in (kJ/kg K) The ideal amount of bagasse required for jaggery production proc Where, ℎ is the input heat supplied to jaggery unit by combustio ℎ = * Where, CVbg is calorific value of the bagasse Output heat, ℎ = ℎ + ℎ + ℎ + ℎ + ℎ + ℎ + ℎ Where, ℎ =heat required to raise sugarcane juice temperature fr ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice from b ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace wall, Variables of Equation 6 are calculated using following equations, Similarly, h fg = m fg * c lg (t fg − t ab ) h as = m as * c as (t as − t ab ) Heat loss in furnace wall takes place because of conduction, conv h fw = (h fw ) cd + (h fw ) cv + (h fw ) rd Wheret jb , t ji and t st are boiling, initial, and striking temperatures of c jg , c cj are specific heat of jaggery and sugarcane juice in (kJ/kg Similarly, c fg , c as are specific heat of flue gas and ash in (kJ/kg K) The ideal amount of bagasse required for jaggery production proc Where, ℎ is the input heat supplied to jaggery unit by combustion of bagasse, ℎ = * Where, CVbg is calorific value of the bagasse Output heat, ℎ = ℎ + ℎ + ℎ + ℎ + ℎ + ℎ + ℎ Where, ℎ =heat required to raise sugarcane juice temperature from initial to boiling point. ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice from boiling to striking stage. ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace wall, and unburnt fuel respectively. Variables of Equation 6 are calculated using following equations, h cj = m cj * c cj (t jb − t ji ) h sm = m sm * λ h st = m jg * c jg (t st − t jb ) Similarly, h fg = m fg * c lg (t fg − t ab ) (8) h as = m as * c as (t as − t ab ) Heat loss in furnace wall takes place because of conduction, convection, and radiation as mentioned, h fw = (h fw ) cd + (h fw ) cv + (h fw ) rd Wheret jb , t ji and t st are boiling, initial, and striking temperatures of sugarcane juice (°C), respectively. c jg , c cj are specific heat of jaggery and sugarcane juice in (kJ/kg K) respectively. Similarly, c fg , c as are specific heat of flue gas and ash in (kJ/kg K) respectively The ideal amount of bagasse required for jaggery production process: Where the total mass of cane juice= mass of water+ mass of jaggery (kg) The heat required per kg of jaggery production by evaporating water from the juice is calculated with the following Equation 12 (Shiralkar et al., 2013).
Where the total mass of cane juice= mass of water+ mass of jaggery (kg) The heat required per kg of jaggery production by evaporating water from the juice is calculated with the following Equation 12 (Shiralkar et al., 2013).
In this phase, the input masses of jaggery units are cane juice, chemicals like phosphoric acid, open sun-dried bagasse, and air. Similarly, output masses include fi scum, steam, ash, and flue gasses. As per mass conservation theory, equations with heating pan-furnace system are, Similarly, applying conservation of energy for inputs and outputs of pan furnace sys ℎ − ℎ = 0 Where, ℎ is the input heat supplied to jaggery unit by combustion of bagasse,

ℎ = *
Where, CVbg is calorific value of the bagasse Output heat, ℎ = ℎ + ℎ + ℎ + ℎ + ℎ + ℎ + ℎ Where, ℎ =heat required to raise sugarcane juice temperature from initial to boilin ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice from boiling to striking s ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace wall, and unburnt fuel Variables of Equation 6 are calculated using following equations, h cj = m cj * c cj (t jb − t ji ) h sm = m sm * λ h st = m jg * c jg (t st − t jb ) Similarly, h fg = m fg * c lg (t fg − t ab ) h as = m as * c as (t as − t ab )

Heat loss in furnace wall takes place because of conduction, convection, and radiat h fw = (h fw ) cd + (h fw ) cv + (h fw ) rd
Wheret jb , t ji and t st are boiling, initial, and striking temperatures of sugarcane juice c jg , c cj are specific heat of jaggery and sugarcane juice in (kJ/kg K) respectively. Similarly, c fg , c as are specific heat of flue gas and ash in (kJ/kg K) respectively The ideal amount of bagasse required for jaggery production process: Where, c p = specific heat capacity of water=4.186 (kJ/kg K) λ = latent heat of evaporation of water=2270 kJ/kg t st = Juice striking temperature=118 (°C) t ji = Juice initial temperature=30 (°C).

Design of Energy Efficient Jaggery Unit
Mathematical modeling of conventional jaggery unit of various losses was estimated in the production process. During the detailed site survey, two conventional jaggery units of both 24 TCD crushing capacity were studied, first in Maharashtra (MH) and second in Karnataka (KA) states in India.The Chimney of the first unit was taller than the second, causing more input airflow due to increased draft and consequently decreased the inner temperature of the furnace, leading to lesser heat transfer to the juice pan and lower thermal efficiency in the range of 50 to 60%. However, the lesser height of the chimney in the second unit caused a lower draft, which resulted in inefficient combustion of fuel (bagasse), and ultimately larger amount is left unburnt, causing lower thermal efficiency in the range of 45 to 55%. Based on these critical findings during the site survey, the scientifically based study (13) However, CV bg =16, 000 kJ/kg (Shiralkar, et al., 2013) Therefore, ideal amount of bagasse per kg of jaggery =
However, CVbg =16, 000 kJ/kg (Shiralkar, et al., 2013) Therefore, ideal amount of bagasse per kg of jaggery = Similarly, applying conservation of energy for inputs and outputs of pan furnace system, ℎ − ℎ = 0 (4) Where, ℎ is the input heat supplied to jaggery unit by combustion of bagasse, Where, CVbg is calorific value of the bagasse Output heat, ℎ = ℎ + ℎ + ℎ + ℎ + ℎ + ℎ + ℎ Where, ℎ =heat required to raise sugarcane juice temperature from initial to boiling point. ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice from boiling to striking stage. ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace wall, and unburnt fuel respectively. Variables of Equation 6 are calculated using following equations, h cj = m cj * c cj (t jb − t ji ) h sm = m sm * λ h st = m jg * c jg (t st − t jb ) Similarly, h fg = m fg * c lg (t fg − t ab ) (8) h as = m as * c as (t as − t ab ) Similarly, applying conservation of energy for inputs and outputs of pan furnace system, ℎ − ℎ = 0 (4) Where, ℎ is the input heat supplied to jaggery unit by combustion of bagasse, Where, CVbg is calorific value of the bagasse Output heat, ℎ = ℎ + ℎ + ℎ + ℎ + ℎ + ℎ + ℎ Where, ℎ =heat required to raise sugarcane juice temperature from initial to boiling point. ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice from boiling to striking stage. ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace wall, and unburnt fuel respectively. Variables of Equation 6 are calculated using following equations, h cj = m cj * c cj (t jb − t ji ) h sm = m sm * λ h st = m jg * c jg (t st − t jb ) Similarly, h fg = m fg * c lg (t fg − t ab ) (8) h as = m as * c as (t as − t ab ) Similarly, applying conservation of energy for inputs and outputs of pan furnace system, ℎ − ℎ = 0 (4) Where, ℎ is the input heat supplied to jaggery unit by combustion of bagasse, Where, CVbg is calorific value of the bagasse Output heat, ℎ = ℎ + ℎ + ℎ + ℎ + ℎ + ℎ + ℎ Where, ℎ =heat required to raise sugarcane juice temperature from initial to boiling point. ℎ = heat required for conversion of water to steam. ℎ = heat required to raise temperature of sugarcane juice from boiling to striking stage. ℎ , ℎ , ℎ and ℎ are heat losses in flue gas, ash, furnace wall, and unburnt fuel respectively. Variables of Equation 6 are calculated using following equations, h cj = m cj * c cj (t jb − t ji ) h sm = m sm * λ h st = m jg * c jg (t st − t jb ) Similarly, h fg = m fg * c lg (t fg − t ab ) (8) h as = m as * c as (t as − t ab ) (9) = heat required to raise sugarcane juice temperature from initial to boiling point. = heat required for conversion of water to steam. = heat required to raise temperature of sugarcane juice from boiling to striking stage.
Where h= Chimney height, ΣΔPf=frictional pressure loss, and ρ a and ρ fg are air and flue gas densities.
.186(100 − 30) + 4 * 2270] + [1 * 2(118 − 30)] = 10428 / } (13) 0 kJ/kg (Shiralkar, et al., 2013) t of bagasse per kg of jaggery = (14) =10428/16000=0.65kg. as per Equation 8 calculated. ΔP = ℎ * * (ρa − ρfg) − ΣΔPf (15) ight, ΣΔPf=frictional pressure loss, and ρa and ρfg are air and flue gas densities. himney, = √2 * [ℎ * * ( − ) − ]/ (16) loss, ΔPf = 2 * * * ρ * v 2 /D (17) r duct, D= diameter of duct, v= velocity of flue gas, ρ=density of flue gas icient Jaggery Unit modeling of conventional jaggery unit of various losses was estimated in the uring the detailed site survey, two conventional jaggery units of both 24 TCD e studied, first in Maharashtra (MH) and second in Karnataka (KA) states in the first unit was taller than the second, causing more input airflow due to sequently decreased the inner temperature of the furnace, leading to lesser heat n and lower thermal efficiency in the range of 50 to 60%. However, the lesser in the second unit caused a lower draft, which resulted in inefficient combustion ultimately larger amount is left unburnt, causing lower thermal efficiency in the sed on these critical findings during the site survey, the scientifically based study g toward optimum sizing and energy improvement of jaggery units. As per tical modeling, modified energy efficient jaggery unit of 24 TCD is designed and er producer group located at Post-Maindargi, District-Solapur, Maharashtra (MH), re 2a. In this method, the main stress is given towards optimum sizing of panystem that minimizes the losses and improves fuel combustion during jaggery e heat recovered from various losses is used for hot air supply to the furnace shown in Figure 2b. Therefore, cautious efforts are made to improve the thermal tional units, which led to bagasse saving. A furnace with thick firebricks rather brick significantly reduces heat loss. Similarly, cast iron fire grates were provided furnace for proposer mixing of fuel (bagasse) and combustion air. During ired into the furnace, falls on these grates and burns by combining with hot air nings and that entering from the bottom openings of the fire grates. Fire grates atic drop of ash in to the bottom trays that are collected periodically. Similarly, a circular cross-section and is designed per outcomes of mathematical modeling xperiences. Sliding dampers made of mild steel [M.S] plates inserted into the ooth flow of exhaust gases with the sufficient draft.Using a heavy-duty sugarcane ry gearbox (Kiran, crushing capacity-1200 kg/hr, Rajkot, India) has caused juice efficiently from 65% of the conventional drive system to 70%, with additional ansmission losses. This is due to direct shaft mounting, lesser operation and e-free, reduced space, and foundation expenses.
.186(100 − 30) + 4 * 2270] + [1 * 2(118 − 30)] = 10428 / } (13) 0 kJ/kg (Shiralkar, et al., 2013) t of bagasse per kg of jaggery = (14) =10428/16000=0.65kg. as per Equation 8 calculated. ΔP = ℎ * * (ρa − ρfg) − ΣΔPf (15) ight, ΣΔPf=frictional pressure loss, and ρa and ρfg are air and flue gas densities. himney, = √2 * [ℎ * * ( − ) − ]/ (16) loss, ΔPf = 2 * * * ρ * v 2 /D (17) r duct, D= diameter of duct, v= velocity of flue gas, ρ=density of flue gas icient Jaggery Unit odeling of conventional jaggery unit of various losses was estimated in the ring the detailed site survey, two conventional jaggery units of both 24 TCD studied, first in Maharashtra (MH) and second in Karnataka (KA) states in the first unit was taller than the second, causing more input airflow due to sequently decreased the inner temperature of the furnace, leading to lesser heat n and lower thermal efficiency in the range of 50 to 60%. However, the lesser in the second unit caused a lower draft, which resulted in inefficient combustion ultimately larger amount is left unburnt, causing lower thermal efficiency in the sed on these critical findings during the site survey, the scientifically based study g toward optimum sizing and energy improvement of jaggery units. As per ical modeling, modified energy efficient jaggery unit of 24 TCD is designed and er producer group located at Post-Maindargi, District-Solapur, Maharashtra (MH), re 2a. In this method, the main stress is given towards optimum sizing of panystem that minimizes the losses and improves fuel combustion during jaggery e heat recovered from various losses is used for hot air supply to the furnace shown in Figure 2b. Therefore, cautious efforts are made to improve the thermal tional units, which led to bagasse saving. A furnace with thick firebricks rather brick significantly reduces heat loss. Similarly, cast iron fire grates were provided furnace for proposer mixing of fuel (bagasse) and combustion air. During red into the furnace, falls on these grates and burns by combining with hot air nings and that entering from the bottom openings of the fire grates. Fire grates atic drop of ash in to the bottom trays that are collected periodically. Similarly, a circular cross-section and is designed per outcomes of mathematical modeling xperiences. Sliding dampers made of mild steel [M.S] plates inserted into the ooth flow of exhaust gases with the sufficient draft.Using a heavy-duty sugarcane y gearbox (Kiran, crushing capacity-1200 kg/hr, Rajkot, India) has caused juice efficiently from 65% of the conventional drive system to 70%, with additional nsmission losses. This is due to direct shaft mounting, lesser operation and e-free, reduced space, and foundation expenses.
Where, L = length of air duct D = diameter of duct v = velocity of flue gas ρ = density of flue gas

Design of Energy Efficient Jaggery Unit
Mathematical modeling of conventional jaggery unit of various losses was estimated in the production process. During the detailed site survey, two conventional jaggery units of both 24 TCD crushing capacity were studied, first in Maharashtra (MH) and second in Karnataka (KA) states in India.The Chimney of the first unit was taller than the second, causing more input airflow due to increased draft and consequently decreased the inner temperature of the furnace, leading to lesser heat transfer to the juice pan and lower thermal efficiency in the range of 50 to 60%. However, the lesser height of the chimney in the second unit caused a lower draft, which resulted in inefficient combustion of fuel (bagasse), and ultimately larger amount is left unburnt, causing lower thermal efficiency in the range of 45 to 55%. Based on these critical findings during the site survey, the scientifically based study was conducted, aiming toward optimum sizing and energy improvement of jaggery units. As per outcomes of mathematical modeling, modified energy efficient jaggery unit of 24 TCD is designed and developed for the farmer producer group located at Post-Maindargi, District-Solapur, Maharashtra (MH), India, as shown in Figure 2a. In this method, the main stress is given towards optimum sizing of pan-furnace and chimney system that minimizes the losses and improves fuel combustion during jaggery production process. The heat recovered from various losses is used for hot air supply to the furnace and bagasse drying, as shown in Figure 2b. Therefore, cautious efforts are made to improve the thermal performance of conventional units, which led to bagasse saving. A furnace with thick firebricks rather than a simple masonry brick significantly reduces heat loss. Similarly, cast iron fire grates were provided at the bottom of the furnace for proposer mixing of fuel (bagasse) and combustion air. During combustion, bagasse fired into the furnace, falls on these grates and burns by combining with hot air from the front wall openings and that entering from the bottom openings of the fire grates. Fire grates also facilitate the automatic drop of ash in to the bottom trays that are collected periodically. Similarly, a modified chimney has a circular cross-section and is designed per outcomes of mathematical modeling results and practical experiences. Sliding dampers made of mild steel [M.S] plates inserted into the chimney help in the smooth flow of exhaust gases with the sufficient draft. Using a heavy-duty sugarcane crusher with a planetary gearbox (Kiran, crushing capacity-1200 kg/hr, Rajkot, India) has caused juice extraction to improve efficiently T. Hasarmani & R. Holmukhe / agriTECH 42 (3) 2022 xxx-xxx The main dimensions of various components of heating systems are detailed in Table 1.
from 65% of the conventional drive system to 70%, with additional advantages of zero transmission losses. This is due to direct shaft mounting, lesser operation and maintenance cost, noise-free, reduced space, and foundation expenses. The main dimensions of various components of heating systems are detailed in Table 1.

Measurements and Equipments
During detailed measurements, the fixed amount of sugarcane of 24 tons was crushed per day (TCD) at a per batch rate of 1.2 tons per hour. The masses of sugarcane, extracted juice, wet and dry bagasse were measured using digital industrial heavy-duty weighing machine (iScale,Kanpur,India). Similarly, the total batch time of jaggery process, Brix content in the juice, temperature at several points, moisture, and calorific value of bagasse were also measured. The soluble solid content in sugarcane juice that plays a vital role in calculating the amount of jaggery produced per ton was measured by a digital hand refractometer (Genex, Erma, 0-32 Brix, Japan). The moisture content in bagasse was calculated by actual measurement of weight loss, by putting fixed amount of bagasse in a thermostatic controlled hot air oven (Labline, HOS-6 ,50-250 °C, accuracy ± 0.5 °C, Kochi, India) for 5 hours at 105 °C. The compositions in flue gasses (C, H, O Contents) were measured by using thermo-gravimetric analyzer (TGA) (Perkin Elmer, TGA8000, 20-1200 °C, Thane, India). Thecalorific value of bagasse that remained almost constant at various locations of jaggery units was measured with bomb calorimeter (V-Tech, VT-05, 0-10 °C, Coimbatore, India).

RESULT AND DISCUSSION
The energy-efficient unit, capable of crushing 24 tons (100%) sugarcane per day, was designed and developed for farmer producer group. Per day mass balances of production process are shown in Figure  1b. The average working hours of the plant during the production process (September to February) were 20 hrs/day. Therefore sugarcane crushed per hour was 1.2 ton. The total mass of wet bagasse produced per day with 50% moisture content (as measured in lab) was 7.2 ton (30%). Where as the mass of dry bagasse with 6% moisture content (as measured in lab) produced after drying in bagasse drier was 6 ton (25%). Because of effective utilization, the heat lost in an enclosed bagasse drier as against open sun drying was reduced. The amount of dry bagasse produced in an energy efficient jaggery unit increased from 4.8 ton (20%) conventional to 6 ton (25%). The use of highly efficient sugarcane crusher with planetary gear box produced more amount of juice and final jaggery of 16.8 ton (70%) and 3.36 ton (14%), respectively. This was in contrast with thecorresponding lower produced values of 15.6 ton (65%) and 2.88 (12%) respectively for similar capacity. In this way, the energy efficient unit produced additional 0.48 ton of jaggery and 1.2 ton of dry bagasse per day, that earned extra revenue for farmers with other benefits of lower operational and maintenance cost. With the proposed technology, the entire operation that involves, sugarcane crushing, bagasse handling, juice extraction (filtering, boiling, removal of molasses), and jaggery processing (cooling and packaging) requires only 10 skilled workers because of the eliminated manpower.

Total Batch Time
The duration of each batch of the production process depends on several factors like efficiency of pan-furnace heating system, brix content in sugarcane juice, bagasse feeding rate, skill and experience of labours etc. The duration measured at site, varying between 150 min to 100 min is shown in Figure 3. Jaggery is manufactured in two shifts of 10 hours each (first shift working hours is 4:00 AM to 2:00 PM, the second is 2:00 PM to 12:00 PM). During each shift, 5 batches of jaggery productions are completed. Generally, the first batch takes more time compared to the second, because it is cold-started after a gap of 4 hours (from 12:00 AM to 4:00 AM). Due to uniform fuel feeding and efficient heating practices, the duration for subsequent batches also reduces (at lower rate as compared to the first batch) as efficient heating system retains more heat and avoids loss of temperature in furnace walls, ducts, and chimney.
6 gery unit increased from 4.8 ton (20%) conventional to 6 ton (25%). The use of highly garcane crusher with planetary gear box produced more amount of juice and final jaggery (70%) and 3.36 ton (14%), respectively. This was in contrast with thecorresponding lower alues of 15.6 ton (65%) and 2.88 (12%) respectively for similar capacity. In this way, the cient unit produced additional 0.48 ton of jaggery and 1.2 ton of dry bagasse per day, that ra revenue for farmers with other benefits of lower operational and maintenance cost. With ed technology, the entire operation that involves, sugarcane crushing, bagasse handling, tion (filtering, boiling, removal of molasses), and jaggery processing (cooling and packaging) ly 10 skilled workers because of the eliminated manpower.
h Time duration of each batch of the production process depends on several factors like efficiency ace heating system, brix content in sugarcane juice, bagasse feeding rate, skill and of labours etc. The duration measured at site, varying between 150 min to 100 min is shown Jaggery is manufactured in two shifts of 10 hours each (first shift working hours is 4:00 AM , the second is 2:00 PM to 12:00 PM). During each shift, 5 batches of jaggery productions ted. Generally, the first batch takes more time compared to the second, because it is coldr a gap of 4 hours (from 12:00 AM to 4:00 AM). Due to uniform fuel feeding and efficient ctices, the duration for subsequent batches also reduces (at lower rate as compared to the as efficient heating system retains more heat and avoids loss of temperature in furnace , and chimney. ariation in batch time with respect to the number quirements of Heating System rmal energy required for the production process depends on several factors like inlet e of sugarcane juice, air supplied to furnace, and design of heating system etc. Analytical are done to determine thermal energy required at various stages of the production process tion 1 to 9. The energy required or generated at different jaggery manufacturing stages are The variation in sensible heat required for water removal from juice with varying initial e is shown in Figure 4. 6 jaggery unit increased from 4.8 ton (20%) conventional to 6 ton (25%). The use of highly sugarcane crusher with planetary gear box produced more amount of juice and final jaggery ton (70%) and 3.36 ton (14%), respectively. This was in contrast with thecorresponding lower d values of 15.6 ton (65%) and 2.88 (12%) respectively for similar capacity. In this way, the efficient unit produced additional 0.48 ton of jaggery and 1.2 ton of dry bagasse per day, that extra revenue for farmers with other benefits of lower operational and maintenance cost. With osed technology, the entire operation that involves, sugarcane crushing, bagasse handling, raction (filtering, boiling, removal of molasses), and jaggery processing (cooling and packaging) only 10 skilled workers because of the eliminated manpower.

atch Time
The duration of each batch of the production process depends on several factors like efficiency furnace heating system, brix content in sugarcane juice, bagasse feeding rate, skill and ce of labours etc. The duration measured at site, varying between 150 min to 100 min is shown 3. Jaggery is manufactured in two shifts of 10 hours each (first shift working hours is 4:00 AM PM, the second is 2:00 PM to 12:00 PM). During each shift, 5 batches of jaggery productions pleted. Generally, the first batch takes more time compared to the second, because it is coldafter a gap of 4 hours (from 12:00 AM to 4:00 AM). Due to uniform fuel feeding and efficient practices, the duration for subsequent batches also reduces (at lower rate as compared to the ch) as efficient heating system retains more heat and avoids loss of temperature in furnace cts, and chimney.
. Variation in batch time with respect to the number

Requirements of Heating System
Thermal energy required for the production process depends on several factors like inlet ture of sugarcane juice, air supplied to furnace, and design of heating system etc. Analytical ons are done to determine thermal energy required at various stages of the production process quation 1 to 9. The energy required or generated at different jaggery manufacturing stages are d. The variation in sensible heat required for water removal from juice with varying initial ture is shown in Figure 4.

Energy Requirements of Heating System
Thermal energy required for the production process depends on several factors like inlet temperature of sugarcane juice, air supplied to furnace, and design of heating system etc. Analytical calculations are done to determine thermal energy required at various stages of the production process as per Equation 1 to 9. The energy required or generated at different jaggery manufacturing stages are calculated. The variation in sensible heat required for water removal from juice with varying initial temperature is shown in Figure 4.
T. Hasarmani & R. Holmukhe / agriTECH 42 (3) 2022 xxx-xxx 6 aggery unit increased from 4.8 ton (20%) conventional to 6 ton (25%). The use of highly ugarcane crusher with planetary gear box produced more amount of juice and final jaggery n (70%) and 3.36 ton (14%), respectively. This was in contrast with thecorresponding lower values of 15.6 ton (65%) and 2.88 (12%) respectively for similar capacity. In this way, the ficient unit produced additional 0.48 ton of jaggery and 1.2 ton of dry bagasse per day, that tra revenue for farmers with other benefits of lower operational and maintenance cost. With sed technology, the entire operation that involves, sugarcane crushing, bagasse handling, ction (filtering, boiling, removal of molasses), and jaggery processing (cooling and packaging) nly 10 skilled workers because of the eliminated manpower.
tch Time he duration of each batch of the production process depends on several factors like efficiency rnace heating system, brix content in sugarcane juice, bagasse feeding rate, skill and e of labours etc. The duration measured at site, varying between 150 min to 100 min is shown 3. Jaggery is manufactured in two shifts of 10 hours each (first shift working hours is 4:00 AM M, the second is 2:00 PM to 12:00 PM). During each shift, 5 batches of jaggery productions leted. Generally, the first batch takes more time compared to the second, because it is coldter a gap of 4 hours (from 12:00 AM to 4:00 AM). Due to uniform fuel feeding and efficient ractices, the duration for subsequent batches also reduces (at lower rate as compared to the ) as efficient heating system retains more heat and avoids loss of temperature in furnace ts, and chimney.
Variation in batch time with respect to the number equirements of Heating System hermal energy required for the production process depends on several factors like inlet re of sugarcane juice, air supplied to furnace, and design of heating system etc. Analytical ns are done to determine thermal energy required at various stages of the production process uation 1 to 9. The energy required or generated at different jaggery manufacturing stages are . The variation in sensible heat required for water removal from juice with varying initial re is shown in Figure 4. The value of sensible heat (h cj ) decreases from 1180 kJ/kg to 380 kJ/kg jaggery with rising (t ji ) from 30 °C to 80 °C. This indicated that, by preheating sugarcane juice using waste heat recovery, substantial amount of temperature required is saved, consequently, fuel needed to prepare the jaggery. Variation in heat lost in flue gas (hfg) with varying ambient air temperature (tab) is calculated using Equation 8 and shown in Figure 5. It is shown that, by supplying preheated air to furnace, huge amount of waste heat is saved, that helps in drastic reduction in green house gas (GHG) emission.  The value of sensible heat (hcj) decreases from 1180 kJ/kg to 380 kJ/kg jaggery with rising from 30 °C to 80 °C. This indicated that, by preheating sugarcane juice using waste heat reco substantial amount of temperature required is saved, consequently, fuel needed to prepare the jagg Variation in heat lost in flue gas (hfg) with varying ambient air temperature (tab) is calculated u Equation 8 and shown in Figure 5. It is shown that, by supplying preheated air to furnace, huge am of waste heat is saved, that helps in drastic reduction in green house gas (GHG) emission. The amount of change in bagasse and sensible heat saved during the initial stage of jag processing with raising sugarcane juice temperature is shown in Figure 6. As per Equation 14, the value of bagasse required per kg of jaggery production is 0.65 Kg. However, in conventional u because of illogical construction of pan-furnace heating system and non uniform fuel feeding pract bagasse consumption per kg jaggery production is in the range of 1.5 to 1.75 kg. This consume entire dry bagasse produced during the production process. In the novel technology, dry bag produced per kg of jaggery production is 1.78 kg (as shown in mass balance Sankey diagram). meeting the total heat requirement of the production process, the amount of bagasse saved, incre from 0.847 to 0.920 kg/kgjag preparation. The field survey and actual measurements performed commissioning of the novel technology at farmer's site showed that, approximately 50% of dry bag was saved. Therefore, the proposed jaggery unit of 24 TCD is capable of saving around 540 ton o bagasse in 6 month, which gives extra revenue to farmers. The amount of heat saved from bag increases from 1.355 to 1.472 kJ/kgjag with the raising juice temperature from 30 °C to 75 °C. The amount of change in bagasse and sensible heat saved during the initial stage of jaggery processing with raising sugarcane juice temperature is shown in Figure 6. As per Equation 14, the ideal value of bagasse required per kg of jaggery production is 0.65 Kg. However, in conventional units, because of illogical construction of pan-furnace heating system and non uniform fuel feeding practices, bagasse consumption per kg jaggery production is in the range of 1.5 to 1.75 kg. This consumes the entire dry bagasse produced during the production process. In the novel technology, dry bagasse produced per kg of jaggery production is 1.78 kg (as shown in mass balance Sankey diagram). After meeting the total heat requirement of the production process, the amount of bagasse saved, increases from 0.847 to 0.920 kg/kgjag preparation. The field survey and actual measurements performed after commissioning of the novel technology at farmer's site showed that, approximately 50% of dry bagasse was saved. Therefore, the proposed jaggery unit of 24 TCD is capable of saving around 540 ton of dry bagasse in 6 month, which gives extra revenue to farmers. The amount of heat saved from bagasse increases from 1.355 to 1.472 kJ/kgjag with the raising juice temperature from 30 °C to 75 °C.

CONCLUSION
Design based modifications in conventional jaggery unit plays major role in improving thermal efficiency of the manufacturing process. In this study, the heat wasted at variouSs stages of the production process, like via flue gases, ash, and walls, are used for preheating of sugarcane cane juice, bagasse and air supplied to the furnace. The thermal efficiency of the investigated jaggery unit raised upto 75% compared to the conventional units ranging from 45 to 60%. By scientific design, approximately 50% of dry bagasse is saved, which is used as alternative fuel, raw product for paper and pulp as well as in biofuel industry. The saved dry bagasse during manufacturing, generates extra revenue to the farmers. Further research is recommended on design and development of affordable solar PV-DG-Battery hybrid system to meet the needs of energy efficient jaggery units, that make them self-reliant.   Figure 6. Bagasse and sensible heat saved with raising inlet juice temperature during jaggery processing