85TH SOUTH AFRICA SUGAR TECHNOLOGISTS’ ASSOCIATION

CONFERENCE

International Conference on:

‘New Role for the World Sugar Economy in a changed Political

and Economic Environment’

Pyramisa Isis Island HotelAswan, Egypt.

10th-13th November, 2012

Increase production rate and solve bottle necks in Phosphatation and Carbonatation – Clarification types of Sugar Refineries with the use of high performance adsorbents

INTRODUCTION

This paper reviews the Value added to the production stream of Sugar Refineries and Mills with the application of the CarboUA high quality adsorbents.

We are presenting four case study with reference to some Refineries where these CarboUA adsorbents are used . We also have application in the Raw mills

Value added are: Increased productivity, Improved quality of final products, Chemical reduction, energy saving, water saving, increase in return on Investment etc..

CASE STUDY No 1

Sugar Refinery in Colombia

Phosphatation Type Refinery Attached Refinery to Mill Production: 900 Ton/day Raw sugar feed: 400 – 500 IU

Process Conditions:

Figure 1:PROCESS FLOW DIAGRAM

Melter Phosphatation Clarifier

Back Boiling SystemLiquor : syrup ratio 60:40

Press Filters

Melt Liquor400 – 500 IU

Final Liquor200 – 250 IU Refined

Sugar

Pan strike configurationFine Liquor 60 : Syrup 40

Figure 2: PROCESS FLOW DIAGRAM

Melter Phosphatation Clarifier

Back Boiling Systemliquor:syrup ratio 50:50

Press Filters

Melt Liquor400 – 500 IU

Final Liquor100 – 150 IU

RefinedSugar

High Performance Adsorbent 250 ppm at Melter

Lower final color enabled better exhaustion of recycled syrups. More sugar production / Less run-off to raw house

Pan strike configuration:Fine Liquor 50 : Syrup 50

SUMMARIZED FINDINGS

Process MethodColor (UI)

Melted Liquor Final Liquor % Removal

Phosphatation Only 363 203 44

Enhanced Phosphatation 408 143 65

Color removal after was improved by + 21% enabling to produce better quality of sugar and improved plant yield .

Lower final liquor enabled to reduce the centrifugal washing time to produce less syrups and more refined sugar per day.

Table 1: Color Profile – Color Removal Comparison.

Table 2: SUMMARIZED FINDINGS

ProcessSugar

Turbidity (IU)

Sugar Ashes

(%)

Sugar Potential Floc

Phosphatation Only

12 IU 0.004 0.019

Enhanced Phosphatation

8 IU 0.0025 0.014

33% less turbidity 25% less ashes 26% less potential floc

Table 3: SUMMARIZED FINDINGS

Enhanced Phosphatation generates optimization of the chemicals in Clarification:

Less chemicals in clarification and MORE color removal

Chemical Reduction

PROCESS Phosphoric Acid Flocculant Decolorant Filter Aid ppm ppm ppm ppm

Normal Phosphatation 578 10 153 1561

Enhanced Phosphatation 488 7 71 1161

% Reduction 15,6 30 54 25,6

Chart 1: SUMMARIZED FINDINGSTemplas 50/50 - Sirope/Licor

0

100

200

300

400

May-09 Jun-09 Jul-09 Ago-09 Sep-09 Oct-09 Nov-09 Dic-09 Ene-10 Feb-10 Mar-10 Abr-10 May-10

# Tem

plas

Increase Number of strikes with Fine Liquor 50 : Syrup 50 42% reduction in syrups to raw house. Daily refined production increased by + 6%.

Nº

of

Str

ike

s 5

0:5

0

Adsorbent Application

PIX 1: ILUSTRATIVE IMAGE

Refinery Color Profile with Patent Pending High

Performance Adsorbent

Refinery Color Profile withOUT enhanced

phosphatation

CASE STUDY No 2

Sugar Refinery in Africa

Phosphatation Type Refinery Stand Alone Refinery Production: + 3000 Ton/day Raw sugar feed: 600 – 800 IU

Process Conditions:

Figure 3:PROCESS FLOW DIAGRAM

Straight Boiling System

R1 to R3

Melter Phosphatation Clarifier

I.E.R.Problem: R4 rejected

as the high color generated composite is out of specification

Problem: Recycled syrup used like back boiling in strike 3

Raw Sugar: 600 – 700 IU

Final Liquor: 220 – 280 IU

Proposed Objectives :

To produce the 4th strike (Avoiding the 3rd strike back boiling) and reduce energy consumption

To Produce more sugar per day for same energy Improve Phosphatation clarifier performance To meet ALL Quality specifications of the most

strict costumers (Such as bottlers) Alternative to by-pass IER system

Proposed Solution

Figure 4: PROCESS FLOW DIAGRAM

Straight Boiling System

R1 to R4

Melter Phosphatation Clarifier

I.E.R.

High Performance Adsorbent

350 ppm at Melter

Raw Sugar: 600 – 700 IU

Final Liquor: 120 – 180 IU

Result: R4 accepted. Elimination of the 3rd strike back boiling

Production Increase Steam (Energy) Saving

Table 4:SUMMARIZED FINDINGS

Process Method

Fine Liquor Colour (IU)

R1 – R4 Sugar Colours (IU)

Phosphatation Then IER

220-280 IU

R1: 25R2: 50

R3: 100R4: N/A

Phosphatation WITH Adsorbent,

Then IER120-180 IU

R1: 12R2: 25R3: 38R4: 75

Easily enabled R4 as a white sugar boiling,Increasing daily yield by 2.1% on average.

Table 5:SUMMARIZED FINDINGS

Process MethodPolymer

Decolourant (ppm)Phosphoric Acid

(ppm)

Phosphatation Only

300ppm 450ppm

Phosphatation WITH Adsorbent

125ppm 250ppm

Enhanced Phosphatation generates optimization of the chemicals in Clarification:

Less chemicals used in clarification & MORE color removal

SUMMARIZED FINDINGS

Results

Achieved 4th strike ALL the time

Plant production yield increase by + 2%

Improvement in final sugar quality. From a typical blended color of 60 – 80 IU to 30 – 45 IU

Steam (Energy) savings to avoid the 3rd strike back boiling

CASE STUDY No 3

Sugar Refinery in Middle East

Carbonatation Type Refinery Stand Alone Refinery Production: 3.000+ Ton/day Raw sugar feed: 900 – 1300 IU

Process Conditions:

Figure 5: PROCESS FLOW DIAGRAM

Saturators

Limed Juice

1st Filtration 2nd Filtration

G.A.C.

Straight Boiling System

R1 to R4

Flow Rate: 235 m3/h Liquor Bx: 55 - 58º Filtered Color: 750 IU RSO: 3300 Ton/day

Proposed Objectives

Increasing Sugar throughput (Increasing Brix and process flow rate through the filters)

Improve Carbonatation Performance to obtain lower final liquor color for improved plant yield

To meet ALL Quality specifications of the most strict costumers (Such as bottlers)

Proposed Solution

PROCESS FLOW DIAGRAM

Saturators

Limed Juice

G.A.C.

Straight Boiling System

R1 to R4

Flow Rate: 260 m3/h Liquor Bx: 61º Filtered Color: 525 IU RSO: 3700 Ton/day

Adsorbent added at Carbonated Liquor Tank

1st Filtration 2nd Filtration

Table 6: SUMMARIZED FINDINGS

Enhanced Carbonatation produces lower filtered carbonated liquor color

Adsorption of contaminant, starch, dextrin, allows better filtration rate

Process Method Fine Liquor Daily INCREASEColour (after

GAC)Refined Sugar

OutputCarbonatation

Only 225 - 250 IU ---Enhanced

Carbonation 125 - 150 IU 12% increase

Table 7: SUMMARIZED FINDINGS

Process MethodProcess Flow

RateLiquor

ConcentrationFiltered Liquor Average RSO

(m3/hr) ºBrix Colour (IU) (Tons/day)Carbonatation

Only 235 ~ 55 775 3300Enhanced

Carbonatation 260 ~ 61 525 3700

Process MethodFuel Oil Steam Water

(kg/ton RSO) (Tons/Tons RSO) (kg/ton RSO)

Carbonatation Only 84 1.13 620Enhanced Carbonatation 68 0.84 440

SUMMARIZED FINDINGS

Results

Maximizing daily production capacity by 12% within the constraints of the existing vacuum pan and centrifugal capacity

Reduced centrifugal wash time to 2/1 seconds on R-1, compared to 3/2 seconds on R-1 with the normal Carbonatation process

SUMMARIZED FINDINGS

Results

Substantial improvements in flow rate (9.6 % more flow rate) and increase melt Brix (~ 3 - 6º) were achieved with Enhanced Carbonatation Process

19% decrease in fuel oil consumption 25% decrease in steam consumption 29% decrease in water consumption achieved

ILUSTRATIVE IMAGE

1st and 2nd Filtered Carbonated liquor

withOUT adsorbent

1st and 2nd Filtered Carbonated liquor WITH

Adsorbent

CASE STUDY No 4

Two Stages Method

Phosphatation Type Refinery Stand Alone Refinery Production: + 3000 Ton/day Raw sugar feed: 600 – 700 IU

Process Conditions:

Proposed Objectives

By-pass the I.E.R. system maintaining the fine liquor quality (or improving the quality of the same)

To meet ALL Quality specifications of the most strict costumers (Such as bottlers)

Proposed Solution

Figure 7: PROCESS FLOW DIAGRAM

Melter

Phosphatation Clarifier

I.E.R.

By-pass

Clarified Liquor

Final Liquor

D.B.F.

High Performance Adsorbent added at

Melter/Raw sugar conveyor AND at the Outlet Clarifier

D.B.F. or Press filtration is required for better implementation of 2 stages method

Table 8: SUMMARIZED FINDINGS

Process MethodLiquor Color AFTER

I.E.R.Liquor Colour AFTER

Evaporator

Normal Clarification + I.E.R.

170 – 230 IU 220 - 280 IU

Process MethodLiquor Color AFTER

I.E.R.Liquor Colour AFTER

Evaporator

Adsorbent at Two Stages Method

120 – 160 IU 150 - 190 IU

Two stage method removed more color compounds and color precursors that enabled a reduction in color

increase at evaporators

SUMMARIZED FINDINGS

Results

100% by-passed the I.E.R. successfully: therefore cost saving in energy and processing!

Lower fine liquor color range. From 220 – 280 IU to 150 – 190 IU with two stages method

Lower evaporated Fine Liquor demonstrating capacity to remove higher amount of color precursors

Pix 4: ILUSTRATIVE IMAGE

Liquor after NORMAL Process

Clarification + IERLiquor after

CarboUA

2 STAGES METHOD

OUR APPROACH

The technical crew of the Sugar Plant explains their technology and bottle necks to the CarboUA crew .

The objectives are set by the technical crew of the Sugar Plant and CarboUA technical crew.

Laboratory test is conducted to select best product and finally a Plant test is done for 2 weeks.

What is new in CarboUA?

We are happy to introduce to you our latest product line that are all Carbon free and whitish in appearance and gives better in performance.

We also have a new product line for application in the Pans to remove impurities.

We also have some latest array of products used in treating the juice in the Mills.

New products already tried in Zambia and BUA with excellent performance.

SPECIAL SECTIONEnergy Saving & Carbon Footprint

Our Process & Products assist the companies to reduce/optimize its energy consumption.

In addition to generate economic benefits, it is also contributing to the improvement of the carbon footprint measurements

Process committed with reduction of carbon footprints!

SPECIAL SECTIONEnergy Saving & Carbon Footprint

Reduce your organization’s greenhouse gas emissions and help mitigate global warming or destructive climate change

Implement systems ahead of emerging regulations for your organization and maximize production rate

Benefits of using High Performance Adsorbents

SPECIAL SECTIONEnergy Saving & Carbon Footprint

Demonstrating market leadership

Delivering cost savings through reduced energy and resource consumed

Increasing Brand Value and Market Share

Providing consumer and stakeholder satisfaction

BENEFITS FOR SUGAR REFINERY

GENERAL CONCLUSIONS

The use of high performance process aids have shown to significantly enhance Carbonatation and Phosphatation Refinery process in terms of improved colour / impurity removal, reduce operation cost and reduce energy consumption

In Carbonatation type Refineries is also possible to increase production rate by flow rate and brix increases.

GENERAL CONCLUSIONS

These benefits (better quality of final liquors) can enable an increase in daily refined sugar output (RSO) even with the constraints of existing process equipment, as well as reduce energy consumption per ton RSO.

Instead of installing an additional process/stage for color removal, it is now possible to implement the high performance adsorbent technology with little or NO capital investment in new equipment

Thank you for your attention !

www.carboua.com