85 th south africa sugar technologists’ association conference international conference on: ‘new...
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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