INNOVATIVE APPROACH TO RAW CANE JUICE FILTRATION

BY

MR. CHANDRAPAL DIXIT

Shalini Impex

F-102, 1st Floor, Airport Avenue,

Opp. Hotel Airport, Harni Road

Vadodara – 390 022. (India)

Tel : 0265-6543984

Email : dixit@shaliniimpex.com

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OVERVIEW 1. Currently Sugar Cane Processing plants are using DSM & Rotary

screens for filtration of bagacillo from extracted mill juice - Mixed Juice

2. Amount of fine bagacillo in Mixed Juice ranges between 5-7 grams / liter of juice on dry solids basis.

3. These bagacillo particles passing along with mixed juice after screening (Rotary/DSM screen) results in many difficulties such as,

• Color liberation during heating.

• Increase settling period in clarification and processing of sugar,

• High Mud volume,

• High Chemical consumption,

• High Color formation and

• Sugar loss due to inversion. 2

THOUGHTS TO REMOVE CONSTRAINTS Based on the Difficulties / Constraints of Juice Clarification, Studies made on,

1. Removal of maximum possible bagacillo particles from Cold Mixed juice.

2. To aim for highest efficiency of Juice treatment with mild Clarification.

3. To have filtration with specially designed concept, which will be Maintenance free and with minimum Power Consumption.

4. To arrange for the placement of equipment at mill itself to reduce further handling of bagasse from equipment.

5. Continuous research & development program of two years ended in designing the equipment which can handle the whole quantity of juice without any retention /on line separation of the particles.

6. It has commercially operated at SHREE KHEDUT SAHAKARI KHAND UDYOG MANDLI LTD,

PANDVAI (KOSAMBA) GUJARAT ,INDIA Sugar mill during 2014-15 Crushing season and separated bagacillo up to 32 microns at optimum Capacity of Plant.

7. Continued with different pore size membrane for future process in order to eliminate the filters and clarifiers from sugar industry .

NOTE : OUR EQUIPMENT AND DESIGN IS PATENTED ALREADY.

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KEY PERFORMANCE OF NEW DESIGN IN BAGACILLO SEPARATION

1. DSM & Rotary screening with various sizes to remove the bagasse from juice but could not find complete solution. The reasons being the clogging of screens and finally capacity reduction.

2. Major problem is media selection for filtration of cold juice with desired capacity.

3. After two years of research, trial runs in India and other countries, We find no clogging membrane at optimum particle separation of 32 micron.

4. The membrane manufactured with different procedures and Special treatment in order to make abrasion resistant and to avoid effect of PH of juice .

5. During running the equipment, quantity of Water/Steam used for washing filters is only for 1 minute (two times in 24 hrs). Each wash hardly consumed 160 liters of water on each cycle, controlled by timer and strainer for foreign Particles.

6. There is no retention time on line filtration. It retains 90% of the fibers on filter cloth & it is absolute filtration.

7. Particles measured on 5 micron filter paper is 0.50 grams on dry solid basis max.

8. This has helped and allowed us to produce white sugar without Sulfur. 4

• It is expected and proved that innovative filtration system will explore ways to enhance recovery, improve the quality of final product, reduced energy consumption in the manufacturing of Plantation White sugar.

• Major Constraints in juice clarification are cane variety, Soil & growing conditions, Weather conditions, Seasonal and Periodic fluctuations in Manufacturing process it self.

• The Conventional Liming-Sulphitation process does not remove complete colloidal matter and dissolved impurities hence advances a turbid, dark brown – Yellow color to the clarified juice.

• This high color sugar compares unfavorably with refined sugar in the international market and we are loosing international market.

• Further there are concerns regarding the high sulfur content in Plantation White sugar.

• White sugar without sulphitation will create great impacts in international sugar market and edge to the Indian sugar .

CURRENT CONDITIONS IN SUGAR INDUSTRY

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EFFECT OF BAGACILLO DURING CLARIFICATION

Bagasse is the substance in juice which is insoluble in water & mainly it is a fibrous material which is consisting of,

• Cellulose

• Hemi cellulose

• Lignin

• High Colour generates by bagasse after heating with juice due to presence of coloring compound.

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RAW JUICE FILTER DURING MANUFACTURING. STAGE

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RAW JUICE FILTER DURING INSTALLATION STAGE

RAW JUICE FILTER DURING OPERATION STAGE

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MECHANICAL ASPECTS OF FILTER

• Size of filter Model No- SIM-2500,SIM-5000, SIM -7500

• Drive – 3.7 KW with frequency control

• Rotary drum revolutions per minute - 4

• Particle size retained on membrane- above 32 micron.

• Material Of Construction - All liquid contact parts are made in SS 304 & Membrane in SS 316 L

• Construction of Scraper & Sealing arrangement (Food grade).

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OPERATING PRINCIPLES

• The innovative Raw juice filter is working on principle of Centripetal force and Hydrostatic pressure.

• Due to escape velocity through narrow outlet, a draught is created in the internal juice escaping pipe.

• Due to above, fibers are forced to stick on membrane.

• Level of juice in the trough plays vital role for the filter capacity.

• Size of the fibers in juice should not be bigger than 1mm for optimum capacity.

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1. High reduction in fine bagacillo going with filtered juice. 2. Sparkling clear sugar cane juice results in superior Sugar color. 3. Shorter retention time in clarifier, mostly online clarifier. 4. Shorter juice boiling time and faster crystal growth rate

increases productivity. 5. Greater sugar recovery with less sugar loss in molasses. 6. Easy to integrate, installed scale up with limited space

requirement. 7. Easy to operate system with semiskilled Operator & with

minimum maintenance required. 8. Scaling reduced due to partial liming and low temperature. 9. Less equipment required for capacity expansion of the sugar

plant.

10. No consumables required for operation.

PRIME BENEFITS OF RAW JUICE FILTER

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PROCESS FLOW DIAGRAM

SUGAR CANE WEIGHMENT

CANE PREPARATION JUICE EXTRACTION IN

MILLS

DCM JUICE SCREENING

INNOVATIVE RAW JUICE FILTER OF 32

MICRON FILTRATION

RAW JUICE COLD DEFECATION AND

HEATING TO 900C

ONLINE CLARIFIER

CLEAR JUICE

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AVERAGE ANALYSIS DATA DURING CAMPAIGN 2015

THANKS FOR PATIENT

HEARING.

QUESTIONS ? PLEASE

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