There are two types of systems of open pan boiling process in India. North India and Gujarat (Here), multi pan boiling system is used. In Maharashtra and south India, single pan boiling system is used.
In multi span system, generally there are 4 pans, 1.8 mt dia and thickness of spherical bottom plate is 30mm, 25mm, 20mm and 16mmor 12 mm. So very thick plates are used. Plus such heavy plates are shaped spherical little bit, not flat bottom. Fresh juice is poured in the first pan of minimum thickness, say 16mm, then after boiling considerably, juice is transferred in second pan of 20mm thick bottom, then from there, concentrated juice is transferred in third pan of 25mm thick bottom and lastly it is transferred in to last pan of 30mm thick bottom where final jaggery is vigorously heated and then transferred to cooling pan. All 4 pans are arranged in line and underneath furnace gives heat of bagasse firing maximum to 4th pan, then flue gases travel under 3rd pan, then under second pan and then under first pan and then goes to chimney.
In a single pan system, one there is only one boiling pan of at least 3 mt dia with flat bottom of hardly 3 mm thick. After preparing jaggery , it is transferred to cooling pan and new juice is taken in the same pan. it takes about 2 hours to prepare jaggery in this batch type process.
There is a lot of confusion about which system is better, single pan or multi pan. Both systems have their strong advocates. But I have come to conclusion that single pan is far cheaper, simpler and jaggery quality is same in both systems. So to employ multi pan is sheer wastage of money.
So I have offered you single pan system.
for producing free energy from the waste heat going to chimney, i have thought out 2 different boiler designs. One is to put water tube mono tube coil boiler in the chimney which must give you steam to drive steam engine to run sugarcane crusher. In this system, continuous supply of dry steam may become problem. expert and experienced boiler engineer having good experience in mono tube boiler is required. There is no storage of steam and no storage of water. Fresh water is continuously supplied which must deliver continuous supply of steam. This is too difficult. So 2 separate drums of water and steam must be connected before and after coil ends. Then also, it will be difficult to maintain balance.
Another system is to install a Babcock & Wilcox type boiler of bundle of inclined straight tubes all parallel and connect them by headers in underground trench of flue gases from furnace to chimney. This boiler is somewhat similar to Babcock & Wilcox boilers widely used in power houses. The main header of steam drum will remain above the ground level and two pipes will connect the boiler remaining under ground in the trench. This boiler will be easier to operate by common people. So I have offered it to you. However if you are interested in chimney coil mono tube boiler, i can supply the coil also.