Presentation on theme: "85 TH SOUTH AFRICA SUGAR TECHNOLOGISTS’ ASSOCIATION CONFERENCE International Conference on: ‘New Role for the World Sugar Economy in a changed Political."— Presentation transcript:
85 TH 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 Hotel Aswan, 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 MelterPhosphatation Clarifier Back Boiling System Liquor : syrup ratio 60:40 Press Filters Melt Liquor 400 – 500 IU Final Liquor 200 – 250 IU Refined Sugar Pan strike configuration Fine Liquor 60 : Syrup 40
Figure 2: PROCESS FLOW DIAGRAM MelterPhosphatation Clarifier Back Boiling System liquor:syrup ratio 50:50 Press Filters Melt Liquor 400 – 500 IU Final Liquor 100 – 150 IU Refined Sugar 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 Method Color (UI) Melted LiquorFinal Liquor% Removal Phosphatation Only 36320344 Enhanced Phosphatation 40814365 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 Process Sugar Turbidity (IU) Sugar Ashes (%) Sugar Potential Floc Phosphatation Only 12 IU0.0040.019 Enhanced Phosphatation 8 IU0.00250.014 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 AcidFlocculantDecolorantFilter Aid ppm Normal Phosphatation 578101531561 Enhanced Phosphatation 4887711161 % Reduction 15,6305425,6
Chart 1: SUMMARIZED FINDINGS 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 Strikes 50:50 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 MelterPhosphatation 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 MelterPhosphatation 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 3 rd 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: 25 R2: 50 R3: 100 R4: N/A Phosphatation WITH Adsorbent, Then IER 120-180 IU R1: 12 R2: 25 R3: 38 R4: 75 Easily enabled R4 as a white sugar boiling, Increasing daily yield by 2.1% on average.
Table 5:SUMMARIZED FINDINGS Process Method Polymer Decolourant (ppm) Phosphoric Acid (ppm) Phosphatation Only 300ppm450ppm Phosphatation WITH Adsorbent 125ppm250ppm 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 LiquorDaily INCREASE Colour (after GAC) Refined Sugar Output Carbonatation Only 225 - 250 IU--- Enhanced Carbonation 125 - 150 IU12% increase
Table 7: SUMMARIZED FINDINGS Process Method Process Flow Rate Liquor Concentration Filtered LiquorAverage RSO (m 3 /hr) ºBrixColour (IU)(Tons/day) Carbonatation Only 235~ 557753300 Enhanced Carbonatation 260~ 615253700 Process Method Fuel OilSteamWater (kg/ton RSO)(Tons/Tons RSO)(kg/ton RSO) Carbonatation Only 841.13620 Enhanced Carbonatation 680.84440
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 1 st and 2 nd Filtered Carbonated liquor withOUT adsorbent 1 st and 2 nd 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 Method Liquor Color AFTER I.E.R. Liquor Colour AFTER Evaporator Normal Clarification + I.E.R. 170 – 230 IU220 - 280 IU Process Method Liquor Color AFTER I.E.R. Liquor Colour AFTER Evaporator Adsorbent at Two Stages Method 120 – 160 IU150 - 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 + IER Liquor 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 SECTION Energy 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 SECTION Energy 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 SECTION Energy 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