Cane Sugar Engineering Pdf Free Download

03 Dec, 2021 Post a Comment

... The temperature should be controlled between 30 C and 34 C, since temperatures outside this range generally will result in a low yield. For higher temperatures, other products beyond ethanol may be formed, whilst for lower temperatures, the fermentation time is extended, which provides greater opportunities for the bacteria or other organisms to ferment sugars, producing unwanted products [3,4]. ...

... Refrigeration systems based on ejectors may also be used [6]; they have some advantages as the absence of moving parts, take up little space and have low cost [4]; but, they are not energy efficient [10], they have a low COP (Coefficient of Performance) and a lower cooling capacity. ...

... For the extraction process, a dry cleaning system and mills were adopted [4]. ...

... However, practical problems have so far limited its use. One serious problem is a possibility of the combustion of dry bagasse in the flue gases dryer (Rein, 2007). Furthermore, flue gases temperature may not be high enough to be used in the flue gases dryer, or flue gases may be more efficiently used as the heating medium for other heat exchangers in the steam generation unit. ...

... The amount of excess air required for the complete combustion of bagasse depends on bagasse moisture content. According to Rein (2007), dry bagasse requires 17% of excess air ( = 0.17), and the excess air requirement of moist bagasse is given by (3) where ym is the wet-basis moisture content of bagasse; ym = xm/(1 + xm). Equation (3) is to be used for 0.4  ym  0.6. ...

... It has been found that the amount of unburned carbon depends on bagasse moisture. According to Rein (2007) Energy balance of the boiler requires that heat input is used to (1) increase the temperature of the moisture in bagasse to the saturation temperature, evaporate the water, and increase the temperature of the resulting vapor to Tg, (2) increase the temperature of dry flue gases to Tg, (3) increase the temperature of ash to Tg, and (4) evaporate feed water, and increase its temperature to Ts. Therefore, the energy balance becomes ...

Sarocha Charoenvai
Somchart Chantasiriwan

The cogeneration system in sugar factories consists of four main processes: juice extraction, evaporation, steam generation, and turbogenerator. The juice extraction process converts sugar cane into sugar juice and moist bagasse. Water content of the juice is removed in the evaporation process, and moist bagasse is used as fuel in the steam generation process. Combustion between bagasse and air in the steam generation unit produces high-pressure steam, which is used to drive the turbogenerator to produce electrical power. Steam exhausted from the turbogenerator is superheated and must be desuperheated before being used to evaporate sugar juice in the evaporation process. The standard practice is to mix the superheated steam with cooling water in the desuperheater to produce saturated steam. In this paper, an investigation is made into the improvement of the cogeneration process by replacing desuperheater with superheated steam dryer. It is found that, under the condition that the required steam flow rate for the evaporation process and the power generated by the turbogenerator are the same, the improved system with superheated steam dryer not only has higher power generation efficiency than the basic system with desuperheater but also recovers water that is lost with flue gases in the basic system.

... Lighter mud (i.e., 3–5 % mud solids) which is achieved through dilution with either water or recycling a portion of the filtrate produces a thinner filter feed of lower consistency. This enables a more even and uniform distribution of feed and cake to improve filter performance and reduce feed pipe blockages [11]. The current knowledge on sugarcane mud filtration is based on studies of the operation of RVFs under factory conditions1213141516 or laboratory studies conducted using a batch filter or similar apparatus [4, 17, 18]. ...

... Historical RVF filter area ratings of 0.5–0.8 m 2 per t/h cane were standard for milling factories with lower ratings for diffuser factories [11]. However, improved filter station capacity ratings provide 85– 100 m 2 of filter area per 1 t/h of mud solids loading Pol loss in cake at this value is expected to be around 0.3 % for wash water % cake of 200. ...

... This processing strategy is largely based on the need to improve overall factory sugar quality and recovery that results from the detrimental effects of recycling filtrate backwards to the process. Filtrate can also be added to the mud to condition the filter feed for improved filtration and reduced sugar losses [11]. Diluted filter feed can produce cakes of high porosity enabling more effective washing but typically 10–20 % filtrate is recycled in this manner. ...

Dirt collected with sugarcane is processed and separated from the juice in the sugar factory by filtration equipment for return to the cane fields. New technologies over the past decade have enabled performance improvements to be obtained for this key unit operation. Filter mud product still contains a reasonable amount of sugar and the transportation of high moisture mud product has considerable cost. Australia's traditional approach has been to use Rotary Vacuum Filters for processing and separating mud and other impurities from juice, but in recent years there has been interest in reducing sugar losses and transportation costs through utilisation of new technologies such as Horizontal Bed Filters, Vacuum Belt Press Filters, Membrane Press Filters and Centrifuges. Increasingly, these alternative equipment are being installed in new factories. This chapter describes the general principles of mud filtration theory and mud conditioning followed by a  Corresponding author: T. detailed description and review of the various filtration technologies and analysis of the relative merits associated with the equipment.

... In the manufacture of raw sugar, evaporation is an important unit operation in which exhaust steam from the turbine is used to evaporate water from sugar juice to increase its concentration. Since evaporation is the major user of steam in a sugar factory, efficient use of steam is necessary and the multiple-effect evaporator is always used in the sugar factory to increase juice concentration from 13–16% to 65–70% (Rein, 2007 ). The multiple-effect evaporator can be operated in co-current mode, countercurrent mode, or mixed mode. ...

... Because multiple-effect evaporators used in the sugar industry rarely have more than five effects (Rein, 2007), it is assumed that there are five effects in the evaporator under consideration as shown in Figure 1. In the development of a model of the multiple-effect evaporator, it is assumed that the system is at steady state, all vapors are saturated, sugar juice is at boiling point, the boiling point of sugar juice is the saturated vapor temperature plus the boiling temperature rise due to the concentration of dissolved solids in juice and hydrostatic head, and there is no loss of vapor pressure between the two effects. ...

... Note that the assumption leading to Equation (7) is that a horizontal-tube evaporator is used. If either a Robert or falling film evaporator is used, there will be no effect on rise in boiling temperature due to hydrostatic head (Rein, 2007). Equations (7) and (8) form a nonlinear equation for T f as a function of p, H, and x. ...

Somchart Chantasiriwan

The multiple-effect evaporator is commonly used in the sugar industry. The final effect of the evaporator operates under a vacuum, which is created by the mixing of cooling water and vapor in a condenser. The complete analysis of the multiple-effect evaporator must take into account the interaction between the evaporator and the condenser. To date, coupled models of evaporator and condenser remain unavailable. Although most studies pertaining to multiple-effect evaporators assume that the final vapor pressure leaving the last effect is given, in fact it depends on the operating conditions of the condenser. This article aims at investigating the interaction between multiple-effect evaporator and direct-contact condenser. Coupled models of multiple-effect evaporator and direct-contact condenser are developed. Nonlinear equations resulting from the models are solved by an iterative procedure. Simulation results of a test case indicate quantitatively how the concentration of sugar juice at the exit of the evaporator varies with the cooling water flow rate and temperature.

... Although the co-current mode does not yield the highest steam economy, it is used in some industries including the sugar industry. Advantages of this mode in the sugar industry includes low temperature in the last-effect vessel, which minimizes color formation and sucrose degradation losses, and favorable pressure profile for the solution, which allows it to flow through the evaporator without pumping requirement (Rein, 2007). Another factor that affects the performance of the multipleeffect evaporator, in general, and the steam economy, in particular, is the distribution of surface area among the vessels of the evaporator . ...

... The model of multiple-effect evaporator illustrated inFig. 1 is more simplified than previous models. Despite its simplicity, it resembles actual arrangements used in the sugar industry (Rein, 2007). The development of the multiple-effect evaporator in this paper follows the approached taken by Chantasiriwan (2015). ...

... However, they found that fouling in the second-effect vessels was negligible. Unlike results from Jorge et al. (2010), operational data of industrial multiple-effect evaporators have indicated that fouling occurs mostly in the last-effect vessel of the multiple-effect evaporator (Rein, 2007). Fouling in the first effect is kept small by reducing the amount of suspended solids in sugar juice. ...

Somchart Chantasiriwan

Multiple-effect evaporator is used to increase the concentration of a solution in a series of pressure vessels. If the total surface area of the evaporator is fixed, the performance of the evaporator is affected by the distribution of surface area among vessels. Previous studies have been concerned with optimization of surface area distribution with the assumption that no fouling occurs. The present study considers a more realistic case when the last-effect vessel is subjected to fouling. The model of multiple-effect evaporator yields a system of nonlinear equations. Specified parameters are pressures and juice concentrations at inlet and outlet of the evaporator. The solution obtained from an iterative procedure is used to compute two objective functions, which are maximized at different optimum surface area distributions. Given a known rate of fouling, it is shown quantitatively how much the area of the last-effect vessel must be increased relative to the areas of the other vessels in order to achieve the maximum overall steam economy or the maximum amount of input to the evaporator.

... One part is treated for ethanol production, while the other is treated for sugar production. The difference is that the treatment for sugar production begins with the screening and the sulphitation process in order to remove some colour components of juice [33]. After that commonly there are the same treatments used for ethanol production: heating, liming, decantation , and mud filtration. ...

... For this case, without consider the heat integration, vapour bleedings of first effect are used for heating in juice treatment and for heating the vacuum pans in crystallization step. The syrup obtained in concentration step is sent to the crystallization process, which is accomplished in vacuum pans, in order to maintain low temperatures in massecuite [33], which has high content of soluble solids. In this way, problems of sucrose inversion can be avoided. ...

... Moreover it was necessary to create a subroutine in Fortran from empirical correlations [36] and link it to the simulator in order to calculate specific enthalpies for these solutions. It was performed because the sugarcane juice is a complex mixture of water, sucrose and impurities [33]. Finally, for ethanol mixtures in the distillation and dehydration steps, the UNIQUAC model was selected because according to the literature data [4] this model represents appropriately the behaviour of this mixture. ...

The sugarcane industry represents one of the most important economic activities in Brazil producing sugar and ethanol for the internal and external markets. There are also plants dedicated only to ethanol production. The aim of this study is to accomplish a joint assessment to evaluate the reduction of process steam demand and water usage obtained through heat integration and an exergy analysis to quantify the reduction in irreversibility generation owing to heat integration procedure. Two configurations of plant were analysed Case I – all sugarcane juice is destined to produce ethanol without sugar production and Case II – distribution of 50%/50% of total recoverable sugars in sugar and ethanol production. Simulations in ASPEN PLUS® software were performed in order to evaluate the mass and energy balances and heat integration using the Pinch Method was applied in order to minimize the utilities consumption. The results showed that heat integration promoted a reduction in steam consumption of 35% approximately, while the reduction in water consumption (water collecting requirement) was 24 and 13% in comparison to the conventional cases without heat integration.

... The sugar is obtained from sugarcane through four main steps: the juice extraction in mills or diffusers; then the juice following for the treatment in order to remove impurities such as sand and bagasse debris and adjust the pH of the sugarcane juice [4] [5]. The next step is the concentration of the treated sugarcane juice by heating to remove water and the final one is the drying [4] [5]. ...

... It is important to highlight that these types of sugar are naturally darker than crystal and refined due to their processes. In this case is not correct associate low quality to these products because, in this case, this color is due to the color compounds of sugarcane [4] [6] [16] [31]. Color is an important attribute because can influence final aspects of sugar application, mainly in the color of the food and the sweetness perception. ...

Brazil is the largest producer of sugarcane and its derivatives in the world, and one of the largest consumers of sugarcane derivatives. Sugar places a position of great prominence in Brazilian feed, either by direct consumption or as a component of industrialized products, from increasing consumption in the country. Sugar samples taken from local market were analyzed as the quality of table sugar consumed in the state of São Paulo (Brazil). The analysis of the parameters and basic attributes of characterization of sugar was according to the methodology developed by ICUMSA (2005; 2011) and ICUMSA modified by Copersucar (2002). Samples of sugar from this region showed that medium-low quality. It can be observed in fundamental aspects such as purity and insoluble residues, which were below the standard. In addition, it should be noted the difficulty of obtaining information about the limit values for each attribute, by virtue of Legislation not be assertive to the product and, also, the scientific studies have not been unified to present the specifics for each type of sugar.

... Multiple-effect evaporator consists of a number of pressure vessels operating at decreasing pressures. It is designed to be most efficient when incoming juice is at a saturation temperature (Rein, 2007). If the temperature is lower, part of the heating surface designed for evaporation operation will have to be used to preheat the juice to the saturation temperature. ...

... If the temperature is lower, part of the heating surface designed for evaporation operation will have to be used to preheat the juice to the saturation temperature. Preheating is more efficiently carried out in a separate heat exchanger, known as juice heater (Rein, 2007). Like multiple- effect evaporator, juice heater requires a supply of steam, of which condensation releases thermal energy that is used to raise juice temperature. ...

... However, the required steam does not have to be high-pressure steam. Low-pressure steam can be bled from vessels of the multiple-effect evaporator for this purpose (Rein, 2007). It should be noted using bled vapor to preheat the solution is also found to increase the energy efficiency of the evaporation process in the pulp and paper industry (Khanam and Mohanty, 2010;Jyoti and Khanam, 2014). ...

Somchart Chantasiriwan

A multiple-effect evaporator is used to evaporate water from sugar juice in a series of pressure vessels. Steam is used for evaporation in the first vessel, and vapor from all vessels except the last one is used for evaporation in subsequent vessels. In order for evaporator surfaces to be used efficiently, juice entering the evaporator should be at the saturation temperature. Therefore, incoming juice with a low temperature must be heated in a juice heater. The heating medium in the juice heater is vapor bled from the evaporator. It is apparent that the multiple-effect evaporator and the juice heater interact through mass and energy balances. Previous investigations have focused on only the multiple-effect evaporator, and paid little attention to the juice heater. This paper presents the model of the interaction between the multiple-effect evaporator and the juice heater. The model is used to investigate how variations of surfaces in the evaporator and the juice heater affect the two performance parameters of the system, which are the amount of sugar juice processed by the system and the ratio of the amount of water evaporated from sugar juice in the evaporator to the amount of high-pressure steam required by the evaporator.

... Así, un sistema de cogeneración quedará constituido por un conjunto de equipos colaborando funcionalmente para satisfacer de modo eficiente las demandas de calor y trabajo que se le solicitan. (Rein, 2006) (Hugot, 1986) Normalmente los sistemas de cogeneración se diseñan de modo que sean capaces de satisfacer la demanda térmica del consumidor ya que en la mayor parte de los casos resulta inviable la compraventa de este tipo de energía a un agente económico externo. Si también las necesidades de trabajo quedan justamente satisfechas por el sistema de cogeneración prescindiéndose del apoyo Capítulo I. Los esquemas térmicos de los centrales azucareros. ...

... (De Boeck., 2011)( Almazan del Olmo, 2012) (Mihael, 2010) Los ciclos de cogeneración para las plantas de azúcar y alcohol actuales, se restringen por el estado de vapor que requiere el proceso, en el sistema de generación de electricidad se usan turbinas de vapor a contrapresión con eficiencias isotrópicas que pueden variar entre 60-83 %, que garantizan un vapor para el proceso, típicamente de 137,3 kPa (1,40 kgf/cm 2 ) con una temperatura un poco superior a la región de vapor saturado. ( Amaya, 2014) (De Boeck, 2011) (Rein, 2006) (Hugot, 1988) En Colombia los sistemas de cogeneración actuales del sector azucarero, generan vapor de alta a 2 079 kPa (21,2 kgf/cm 2 ) dando una Generación de Vapor Capítulo I. Los esquemas térmicos de los centrales azucareros. Estado actual y tendencias de mejora. ...

... Según (Victoria, 2009) este indicador se comporta en el intervalo del 35 -48 %. De manera general este indicador autores lo reflejan entre un 40 y 60 % pero, el consumo de vapor en el proceso según (Rein, 2006) (Hugot, 1986) se encuentra en un 35 %. ...

Reinier Jiménez Borges

Esta investigación presenta un estudio sobre las potencialidades de mejoras en el proceso tecnológico de los centrales de la provincia de Cienfuegos, con el fin de poder evaluar alternativas para lograr el incremento en la entrega de energía eléctrica al Sistema Electroenergético Nacional. En el primer capítulo se presentan las características de los sistemas de cogeneración más utilizados en la industria, así como la evolución de los esquemas termoenergéticos de los centrales azucareros para cada salto de mejoras, las tendencias en la entrega a partir de la cogeneración y la proyección de nuestro país en el perfeccionamiento de la industria azucarera. En el segundo capítulo se describen los cinco esquemas termoenergéticos actuales así como el sistema Termoazúcar (STA 4.1) para evaluar un caso base en cada uno de ellos y poder determinar las oportunidades de mejoras a partir del análisis de indicadores operacionales. En el tercer capítulo se implementan las medidas propuestas en los casos mejorados, concluyéndose que los cambios en el proceso tecnológico en los centrales favorecen un incremento de un 12 a un 38 % del bagazo sobrante para cada central, es decir un sobrante total de 823 t/d de bagazo respectivamente 192 t/d más que para los casos bases, así como la cantidad de energía vendida para estos de 195 320,5 kWh/d, con un incremento de 22 382,8 kWh/d más que para los casos bases. En el cuarto capítulo a partir del análisis económico para los casos mejorados con las propuestas implementadas permitió una ganancia en conjunto de 348 624 258,56 CUP/zafra, además del incremento en los excedentes de energía a la red nacional donde los ingresos obtenidos fueron de 3 722 545,44 CUP/zafra.

... The ratio between the two quantities is in the range of 2.0-2.2 (Reid & Rein, 1983;Rein, 2007). In this article, the ratio of 2.0 is assumed, yielding the relation Sugar juice that enters the evaporation process comes from a juice extraction process using sugar milling machinery. ...

... If no heat loss occurs between the outlet of the juice extraction process and the inlet of the juice heater, T h,4 5 30 8C. The temperature of sugar juice leaving the juice heater (T h,0 ) is assumed to be 103 8C (Rein, 2007). The sugar juice is also assumed to be saturated, which means that the juice pressure is above the atmospheric pressure. ...

... the sugar juice enthalpy in effect i, and d i1 is the Kronecker delta function (d i1 5 1 if i 5 1, and d i1 5 0 if i 6 ¼ 1). It is assumed that a fraction E of heat is lost in each effect.Rein (2007) suggests that E 5 0.015. Mass balance and energy balances of the flash tanks yield the following expression for vapor mass flow rate from each flash tank (i 5 1-4): ...

Somchart Chantasiriwan

The sugar juice evaporation process consists of juice heater, evaporator, and crystallizer. The juice heater increases the temperature of diluted sugar juice from the ambient temperature to the boiling point. The evaporator removes most water content of diluted sugar juice. The crystallizer removes the remaining water content, yielding raw sugar as the final product. Since both the juice heater and the crystallizer require vapor bled from the evaporator, there are interactions between the three components. A model of interactions between the three components of the sugar juice evaporation process is presented in this paper. The model yields a system of nonlinear equations that, under some specified assumptions and conditions, consists of only two free parameters. This implies that there is a unique distribution of a given total juice heater surface when vapor is bled from the first two effects of the evaporator. In contrast, if vapor is bled from the first three or four effects, there are many possible surface distributions. It is shown that there is an optimum surface distribution when vapor is bled from either the first three or four effects of the evaporator that minimizes the steam economy. The optimum four‐effect vapor bleeding arrangement results in the largest steam economy. However, the two‐effect vapor bleeding arrangement produces a larger mass flow rate of processed sugar juice than either three‐effect vapor bleeding arrangement or four‐effect vapor bleeding arrangement. Practical applications This paper presents a mathematical model of a sugar juice evaporation process. Although one specific process design is under consideration, the model can easily be adjusted for a different process design. This model will be useful for analysis and optimization of the process. One optimization problem mentioned in the paper is the optimum allocation of a fixed total surface among the four heat exchangers of the juice heater, which is used to increase juice temperature to the boiling point before entering the quintuple‐effect evaporator. It is found that there are two different optimum surface allocations corresponding to the maximum rate of processed juice and the minimum amount of steam required by the process. Results of this paper should provide a guideline to a process designer in selecting the juice heater that will both satisfy the required heating duty and yield the optimum performance.

... However, practical problems have so far limited the use of this method. One serious problem is a possibility of the combustion of dry bagasse in the flue gases dryer (Rein, 2007). Furthermore, the temperature of flue gases may not be high enough to be used in the flue gas dryer, or flue gases may be more efficiently used as the heating medium for other heat exchangers. ...

... Inputs to the juice extraction process are 100 t/h of sugar cane and 42 t/h of water. According to Rein (2007), the composition of sugar cane is 15% fiber, 16% dissolved solids, and 69% water. It may be assumed that there is no fiber in the extracted juice and all dissolved solids in sugar cane is transferred to the juice. ...

... , and x S are mass fractions of C, H, O, and S, respectively, in dry bagasse. According to Rein (2007), the typical composition of dry bagasse is 45.92% C, 43.89% O, 5.67% H, 0.31% N, 0.04% S, and 4.17% A. In order to determine the lower heating value of bagasse, the amount of water resulting from the combustion of 1 kg of dry bagasse must be known. Since the complete combustion of 1 kg of dry bagasse produces 9x H kg of water, the lower heating value of dry bagasse is ...

Somchart Chantasiriwan
Sarocha Charoenvai

The cogeneration system in sugar factory uses bagasse with high moisture content as the fuel for the boiler, which results in low boiler efficiency. The system also produces superheated steam, which is extracted from the turbine, and mixed with cooling water to produce saturated steam required by the evaporation system. The potential use superheated steam to reduce bagasse moisture content is ignored in the standard practice of the sugar factory. In this article, an investigation is made into the improvement of the cogeneration system by using superheated steam dryer to reduce the moisture content of bagasse. Mathematical models are developed for the typical system without superheated steam dryer and the improved system with superheated steam dryer. They are then used to compare the performances of both systems. It is found that, under the condition that the required steam flow rate for the evaporation process and the power output are the same, the improved system requires less bagasse consumption, and has larger energy utilization factor. In addition, water that would be lost with flue gases in the typical system is recovered in the improved system.

... Usually, the low color in crystal sugar means that its value will be high (Clarke & Godshall, 1988). There are four color-causing agents in cane sugar processes: plant pigments (chlorophylls, xanthophylls and anthocyanins), Maillard's reaction, caramelization and alkaline fructose degradation products (Rein, 2007). In general, the sugarcane color is related to enzymatic reactions with phenolic compounds naturally in sugarcane (Nguyen & Doherty, 2012). ...

... In Brazilian sugarcane mills (world's largest producer of sugar), sulfitation is the technique widely used for color reduction during the white crystal sugar manufacturing, even though it has many operational limitations, such as environmental problems (for example, atmospheric pollution and acid rain), workplace security, difficulty of process adjustment and sulfur residues in sugar above European, Canadian and North American market legislation. In this way, there are barriers to commercialization of Brazilian crystal white sugar, then Brazil has been exporting basically VHP sugar (very high polarization), which is a raw sugar with low added value (Hugot, 1986;Morilla, Alves, & Aguiar, 2015;Morilla, Alves, & Aguiar, 2016;Rein, 2007). Our group has been evaluating some alternative techniques to replace sulfur as clarifying agent in the sugarcane juice process, like ozone (Sartori, Angolini, et al., 2017), hydrogen peroxide Sartori, Galaverna, et al., 2017) and ionizing radiation (Lima et al., 2016). ...

... Cathode generates metallic ion and anode releases hydrogen gas (H 2 ) which assists the flocculation. Consequently, Chen (2004), Holt, Barton, Wark, and Mitchel (2002), Rein (2007) reported that impurities (non-sugars components, like proteins, ashes, pectins, bagacillo (very small bagasse), waxes and others) were decanted and floated. ...

This work analyzed the use of electrocoagulation as substitute for sugarcane clarification process using sulfitation. It was evaluated technological parameters (Icumsa color and turbidity), phenolic compounds content and CIELAB color parameters. Four kinetics of reduction color from sugarcane juice were carried out. The essays were divided according to the voltage applied: 35, 45, 55 and 65 V (also based on previous tests). Higher voltage treatments achieved greater reduction of Icumsa color, turbidity and total phenolic compounds. However, none of treatments impacted simple phenolic content analyzed in this work. Tristimulus analysis presented some pattern that went beyond technological analysis, including that 65 V essay changed the pigmentation of sugarcane juice and had an early stabilization on chroma. This kind of results could be useful for industry, once they could correlate quality with different color parameters and finally improve the clarification in general with finer settings of technique according to different situations.

... This work deals with an industrial Robert type evaporation train with four effects [20]. Figure 1 shows a simplified flowchart of the process and Figure 2 presents a simplified scheme of each evaporator. ...

... The global heat transfer coefficient (U) was modeled according to Equation (6), which includes effects for the sugar content and temperature of the juice [20]. The digital twin uses this equation as a reference with some corrections induced by the brix difference between the calculated and the reference values, for purposes of real time adaptation of the model performance. ...

... As desired brix values for each tank are defined by the operation crew, these values were used as references for calculation of the initial conditions and for corrections performed by the numerical state observer (Equation (7)). The specific gravity and thermodynamic properties of the juice were calculated as described by Llano-Restrepo (2005) [22], Rein (2016) [20] and Hugot (1986) [23], considering effects of sugar content, sugar purity and temperature. The thermodynamic properties of vapor streams, such as specific weight and enthalpies, were calculated as described by Smith et al. (2001) [24]. ...

Digital twins are rigorous mathematical models that can be used to represent the operation of real systems. This connection allows for deeper understanding of the actual states of the analyzed system through estimation of variables that are difficult to measure otherwise. In this context, the present manuscript describes the successful implementation of a digital twin to represent a four-stage multi-effect evaporation train from an industrial sugar-cane processing unit. Particularly, the complex phenomenological effects, including the coupling between thermodynamic and fluid dynamic effects, and the low level of instrumentation in the plant constitute major challenges for adequate process operation. For this reason, dynamic mass and energy balances were developed, implemented and validated with actual industrial data, in order to provide process information for decision-making in real time. For example, the digital twin was able to indicate failure of process sensors and to provide estimates for the affected variables in real time, improving the robustness of the operation and constituting an important tool for process monitoring.

... El proceso de producción de azúcar de caña es uno de los principales consumidores de agua y productor de aguas residuales (Rein, 2007;Rein et al., 2011;Urbaniec y Klemeš, 2008). En la mayoría de los países productores de azúcar, el tema del manejo del agua en esta industria es un punto crítico ( González et al., 2011). ...

... Para ello se tienen en cuenta los circuitos cerrados. En cada uno de dichos circuitos se producen pérdidas, en este trabajo solo se consideraron los circuitos que se muestran en la tabla 2 (Rein, 2007). ...

... Para las nuevas condiciones este valor es de 0,22 m 3 /t caña , lo que representa una disminución de 37% aproximadamente respecto a las restricciones iniciales. Este resultado concuerda con Rein (2007), el cual plantea que para una fábrica de azúcar con una adecuado manejo de condensados la cantidad de efluente oscila entre 0,2 m 3 /t caña y 0,3 m 3 /t caña . ...

One of the main process industries in Cuba is that of the sugarcane. Among the characteristics of this industry is the high demand of water in its processes. In this work a study of water integration was carried out from the different operations of the production process of raw sugar, in order to reduce the fresh water consumption. The compound curves of sources and demands were built, which allowed the determination of the minimum water requirement of the network (1587,84 m³/d), as well as the amount of effluent generated (0,35 m³/t cane).The distribution scheme of fresh water and water reuse among different operations were obtained from the nearest neighbor algorithm. From considering new quality constrains was possible to eliminate the external water consumption, as well as to reduce the amount of effluent in a 37% in relation to the initial constrains.

... Commercial harvesting of green sugarcane is becoming more widespread (Environment Directorate 2011), particularly in those growing regions where power generation from trash is economic and/or concern over the environmental impact of burning of sugarcane has resulted in legislative change. Whilst the decision to burn sugarcane has impacts upon subsequent sugarcane processing and sugar production (Rein 2007), the use of burnt sugarcane obviously has a profound impact on the availability of trash and tops for animal feed applications. ...

... The dry matter content of tops is highly variable and depends on the season and whether the tops have been freshly harvested (Rein 2007) or, as is often the case, air-dried prior to use in animal feed trials (Table 1.2). Chemical composition of tops is also variable (Table 1.2) but average compositions can be determined. ...

Mark D Harrison

This chapter provides an overview of how sugarcane crop residues, the products of sugarcane processing, and the products of raw sugar production are being used to support animal production and describes technologies available to enhance them for this purpose. It focuses only on whole sugarcane, tops and trash, bagasse, sugarcane juice, and molasses. Processing sugarcane residues to enhance their value in animal feed includes ensilage/microbial conditioning; chemical conditioning; and physical processing, such as baling, pelletization, depithing; and pretreatment. While a range of both physical and chemical changes occur during pretreatment, effective pretreatment of plant biomass is dependent upon achieving significant lignin solubilization, lignin modification, hemicellulose solubilization, defibrillation, particle size reduction, or combinations thereof. The challenges are to make these technologies readily available to farmers, apply emerging biomass-processing technologies to enhance the value of sugarcane for animal feed, and develop new technologies to enhance the economics of animal weight.

... The HTC in a Robert evaporator is known to be a function of juice brix and juice temperature (Peacock, 2007); however, an optimum liquid level corresponding to a maximum HTC is known to exist and is associated with the point at which the tubes are fully wetted (Watson, 1986). The importance of the liquid level to achieve optimum heat transfer has been widely reported (Guo et al., 1983; Peacock, 2007; Broadfoot and Dunn, 2007) as well as the importance of juice velocity in the form of recirculation (Guo et al., 1983; Bosnjak, 1969; Rein, 2007 ). However, no conclusive equations exist for the design of a semi-sealed downtake with particular reference to the size and positioning of the off-take cone. ...

... The semi-sealed down-take design, as shown in Figure 1, allows optimum heat transfer to be achieved (Rein, 2007), where the diameter of the down-take itself is recommended to be between one-eighth to one-quarter of the vessel diameter (Hugot,1972). Careful positioning of the off-take cone within the down-take enables a minimum liquid level to be maintained, and thus ensures the constant wetting of the tubes. ...

Shaista Shah
Steve Peacock

Research has shown that a higher fluid velocity, as a result of increased recirculation, results in improved Robert evaporator performance. Although no conclusive correlation for the optimum recirculation rate can be found in literature, extensive experimental data was made available. With the aid of a digitising program, data was extracted from existing graphs and was mathematically manipulated to yield a number of correlations. The first set of correlations allow the minimum recirculation rate and liquid level to be predicted for juice of up to 65 brix, corresponding to various temperature driving forces and the optimum heat transfer coefficient. The prediction of the juice velocity as a function of temperature driving force allows a second correlation between the Reynold number and the Grashof number to be developed, presenting the results in terms of dimensionless numbers which can be easily interpreted in terms of heat transfer theory. The correlations developed will assist in the design of semi-sealed down-takes to ensure adequate recirculation and a sufficient liquid level within the Robert evaporator to optimise heat transfer.

... In the case of billeted cane, mechanically harvested, it can be fed directly into a shredder without any additional cutting. For cane juice extraction, there are many studies comparing milling and diffuser [30,35,36]. The main advantage of a diffuser over mill is the greater extraction of sugar; however, a diffuser uses more imbibition water and steam than a mill. ...

... For this, lime Ca(OH) is added, which is the most widespread process used. For refineries that produce sugar in addition to ethanol, processes such as sulfitation, phosphatation, and carbonation [36] are also used, aiming to lower the color and turbidity. After the pH adjustment, the juice is sent to a clarifier to settle the insoluble part of the juice. ...

... According to Rein (2007), there are other heating requirements in sugar manufacturing process such as maceration, juice clarification, and sugar drying. Vapor bleeding for these purposes is assumed to be much less that for juice heating and crystallization. ...

... The assumed values of total heating surface areas for a typical installation are A = 15,000 m 2 and A h = 2,500 m 2 (Rein, 2007 In the A 4 -optimized evaporator surface area distribution, there are three free parameters (A 1 , A 2 , and A 3 ). Figure 3 shows the variation of SE with A 3 for A 1 = 2,600 m 2 and A 2 = 2,600, 2,700, 2,800, and 2,900 m 2 . ...

Somchart Chantasiriwan

The conversion of diluted sugar juice into raw sugar and molasses requires thermal energy for evaporating the water content in sugar juice. The supply of thermal energy is saturated steam at around 200 kPa. The efficiency of energy use by the process is determined from the amount of saturated steam to process a given amount of sugar juice. It depends on heating surfaces of the juice heater and the evaporator. This article investigates the improvement in energy efficiency of the sugar juice evaporation process that has five evaporator effects by distributing fixed heating surface areas of the evaporator and the juice heater optimally. It is shown that there exists the optimum distribution of heating surfaces that results in the maximum energy efficiency for a specified sugar juice flow rate. Practical applications A mathematical model of quintuple‐effect evaporator in sugar juice evaporation process is presented in this paper. The proposed model should be useful for the design and analysis of the process. The article also presents an example of the application of the proposed model in determining the optimum distribution of fixed total heating surface areas that results in the maximum energy efficiency. The method presented in this article can be used by a process designer to determine the optimum distributions of evaporator and juice heater surface areas when total heating surface areas and sugar juice flow rate are given.

... However, various product and process parameters, such as crystal growth rate, nature and concentration of the impurities, are possibly affecting the final product quality (Ferreira, Faria, & Rocha, 2009;Godshall, Vercelotti, & Triche, 2002;Lionnet, 1998aLionnet, , 1998bMantovani, Vaccari, Sgualdino, Aquilano, & Rubbo, 1986a, 1986bRein, 2007;Van der Poel, 2000). Much work concerning the processes of impurity inclusions has been reported. ...

The systematic study presented addresses the need to understand the co-crystallization of beet and cane material better. This is important because of the sugar market liberalization in 2017. Here the effect of crystal growth velocity on final sugar quality is investigated. Comparing three different thermal setups, studying different cane and beet mixtures color inclusion into sucrose crystals was analyzed. Within one thermal setup supersaturation was practically constant. Almost exclusively the time necessary to complete the crystallization at 50% solids level changed. Particle size and distribution remained unchanged. Hence, only the growth velocity varied. Growth rate appears to influence color inclusion less than mixing of beet and cane syrups. In cane syrups the relative color inclusion is the highest and most sensitive to growth velocities. Admixing only 33% of beet syrup, already changes this pattern dramatically and the color transfer factor is more than halved. This effect of beet material is most prominent for the mechanism liquid inclusion but also significant for co-crystallization of colorants. This observation is possibly due to the different nature of the colorants originating from beet and cane. The findings provide a framework to optimize the space-time yield under consideration of highest sugar quality to manufacturers.

... There are three major brands of the raw sugar; low polarization abbreviated as (LP) with Pol < 99%, very high polarization (VHP) with Pol 99.3%, and very very high polarization (VVHP) with Pol about 99.65% [5]. ...

... Color is a generic term used to encompass the wide variety of components that contribute to the pigmentation of sugar, and it is measured as the total effect of all colored compounds on the absorbance of light (Rein 2007). Most of these components display complex structures and are not easy to quantify. ...

Ozone as an alternative process for the clarification of sugarcane juice has been studied because it presents as an advantage the mineralization of organic compounds that cause color in the crystal sugar. No residues harmful to humans were found after ozonation in contrast to the sulphitation process traditionally used. In this work, the degradation by ozonation of flavonoids and phenolic acids were studied using two compounds: rutin and caffeic acid. Ozonation was efficient and was monitored by liquid chromatography, UV scanning and direct infusion electrospray ionization mass spectrometry. From the collected data, degradation mechanisms and potential mineralization of rutin and caffeic acid after ozonation were proposed.

... Sugarcane cleaning, preparation and juice extraction The cleaning system is used to remove field soil, rocks and rubbish that came with the sugarcane. After cleaning, sugarcane is prepared using rotary knives and shredders, in order to reduce the size of the pieces, as well as to rupture the sugar-bearing cells in the cane to facilitate the extraction of the sugar process [11]. The juice extraction separates the sucrose-containing juice from the bagasse. ...

... The sucrose solubility depends on the dry substance (brix), temperature and non-sugar composition. Solubility curves for different supersaturation levels y p are given in Figure 1 ( Rein, 2007). In order to start crystallisation y p needs to be >1. ...

Boris Morgenroth
H. Max
M. Mogalle
H. Singh Bola

In many sugar plants batch pans are still operated manually. The pan station is usually the largest vapour consumer of the plant and therefore its impact on the energy demand is high. Experience with pan automation system installations in Brazil, India and Pakistan has been gained in the last couple of years and results are presented. Pans operated manually usually require 2-5 t water per strike depending for example on pan size, feed brix and other parameters. The steam demand for this water addition is typically within a range of 2 to 16% exhaust steam on cane for the raw house pans and, if present, even larger for the refinery pans. The targets of modern pan automation systems are good crystal quality, capacity maximisation, smooth operation and low water/steam consumption. In general, it is possible to operate batch pans with no water addition at all. Apart from the control of single pans, it is also important to interlock the pans and optimise the speed in relation to the feed tank storage volumes, thus reducing vapour flow fluctuations in the plant. Modern pan automation systems allow a considerable reduction of the steam demand by eliminating, or at least reducing, the water additions. Another important aspect apart from the technical requirements is to overcome old operational habits that often cause drawbacks in practice.

... El proceso de producción de azúcar de caña es uno de los principales consumidores de agua y productor de aguas residuales [59][60][61]. En la mayoría de los países productores de azúcar, el tema del manejo del agua en la industria azucarera es un punto crítico. Las regulaciones ambientales obligan a la reducción en el consumo de agua y el vertimiento de aguas residuales. ...

... Lyle (1957) provided data on specific heat for 0 ≤ t ≤ 100 C (R 2 = 0.999). Data on thermal conductivity for 0 ≤ t ≤ 80 C were obtained from Rein (2007) and maximum FIGURE 4 Relative electrical permittivity and loss factor of some samples as a function of temperature for frequencies of 915 and 2,450 MHz temperature was extrapolated to 90 C (R 2 = 0.999). The adjusted correlations are (t: C, ρ Sp : kg/m 3 , Cp Sp : J/kg.K, k Sp : W/K.m): ...

A model food based on aqueous solutions of sucrose and sodium chloride is proposed for studying the microwave‐assisted pasteurization of fruit juices and nectars. Relative electrical permittivity, dielectric loss factor, and electrical conductivity of solutions with sucrose up to 40.0 g/100 mL and sodium chloride up to 1.6 g/100 mL were experimentally determined and successfully correlated with concentrations and temperature (from 10 to 90 °C). By adjusting the concentrations of the solutes, it was possible to satisfactorily match the dielectric behavior of 12 examples of products. Thermophysical and flow properties of the model food (density, specific heat, thermal conductivity, and viscosity) could be estimated from literature data, which is useful for process simulation. Practical applications Continuous flow microwave heating is an emerging technology with a potential to be used in the thermal processing of liquid foods. Model foods are important to study heating patterns, test prototypes, test process control, or tuning strategies, to be used as sterilization solutions, or carrier of chemical, biological, or enzymatic markers. The model food proposed here can match dielectric properties of fruit juices or nectars.

... High energy consumption in distillation is due to the low ethanol concentration of wine in the distillation feed, thus a slight increase in final ethanol concentration of wine can considerably reduce the steam requirements in distillation. According to [3,10,11], the amount of steam 1 used in distillation per litre of dehydrated ethanol is in the range of 1.8e3 kg/l. This consumption is equivalent to 50e60% of thermal energy in the overall ethanol process without energy integration [10,12]. ...

... The quantity produced is usually in the range of 30–45 kg per ton of cane. Fermentable sugars (i.e., sucrose, fructose and glucose) content allows the production of ethanol, usually between 240 and 280 liters per ton of molasses[15]. Assuming a yield of 260 liters of ethanol per ton of molasses and the price of molasses at US$ 100 per ton, the feedstock cost of ethanol would be US$ 0.38 L −1. Parity between ethanol and gasoline, based on the energy content, is achieved at an ethanol price of US$ 0.65 L −1. ...

World sugar production has consistently overrun demand in the past five years. Moreover, in 2017 the European Sugar Regime will expire, ending the quota system and preferential sugar prices, largely affecting small producers, particularly in Africa. Diversification emerges as an option for sugar-oriented mills. Two evident alternatives are ethanol and electricity production that allow better use of molasses and cane fibers, respectively. Molasses is the cheapest feedstock for ethanol production, while the cane fibers-in the form of bagasse-are readily available at the mill. The transition from sugar to sugar, ethanol and electricity may require substantial investment capital, yet our results show that significant progress can start at relatively small cost. In this work, we use simulations to explore the impact of ethanol and electricity production in an existing sugar mill in Mozambique. In spite of the large amounts of energy obtained from ambitious scenarios, such as Ethanol-2 and Ethanol/EE, molasses-based ethanol (Ethanol-1 scenario) seems more attractive in economical and infrastructural terms. High opportunity costs for molasses, low oil prices and enabling institutional conditions, such as mandatory blending mandates, to promote bioenergy remain a challenge.

... Measurements and analyses were undertaken comparing the performance of the lamella clarifier with that of the existing clarifiers, run in parallel. The important parameter in judging syrup clarification is turbidity (Rein 2007). Turbidity removal should be above 80 %, and it is difficult to judge performance using other parameters because the differences are small. ...

A new design for syrup and juice clarifiers is presented. The design takes advantage of the considerably improved performance of clarifiers incorporating lamella plates, and the reasons for the improvement are outlined. CFD work done to simulate the performance is summarised. This design enables the residence time to be dramatically reduced and the simplified design leads to cheaper and better clarifiers. Practical experience with factory scale units is described, confirming the good flow characteristics. The results of preliminary test work on a factory syrup clarifier are presented, which is also shown to operate efficiently as a phosphatation clarifier. In addition the performance of a full-scale juice clarifier has been evaluated and compared with the performance of a conventional clarifier. This work confirms the considerable advantages which this type of design provides, in realising substantial reductions in residence time, capital costs and operating costs

... Kadar abu biomassa biasanya memiliki konsentrasi logam alkali lebih tinggi seperti kalium (K), klorin (Cl), dan silikon (Si), serta memiliki variasi kadar air yang tinggi dan kandungan sulfur yang lebih rendah. Perbedaan fitur bahan bakar biomassa dan kadar abu tidak hanya berpengaruh pada pembakaran, tetapi juga secara signifikan mengubah potensi perilaku kadar abu untuk membentuk deposit pada suhu dibawah ruang bakar dapur boiler dan akan meleleh di atas boiler grate (Rein, 2016). ...

Saptyaji Harnowo
Yunaidi Yunaidi

Operasional boiler di sebagian besar pabrik gula saat ini banyak yang mengalami kekurangan pasokan bahan bakar ampas tebu karena penurunan kapasitas giling. Kondisi ini menimbulkan masalah terhadap kontinuitas pasokan energi uap dan listrik di pabrik gula, sehingga untuk mengatasi masalah tersebut banyak dilakukan dengan penambahan bahan bakar alternatif dengan model pembakaran bersama (co-firing). Penelitian ini mencoba melakukan kajian model pembakaran bersama ampas tebu dengan sekam padi dan cangkang kelapa sawit berbasis persentase berat bahan bakar. Penelitian dilakukan berdasarkan data operasional boiler di pabrik gula Trangkil saat musim giling tahun 2020. Data yang dikumpulkan meliputi tekanan, kapasitas, dan temperatur uap, serta temperatur air masuk boiler dan temperatur gas buang. Analisis bahan bakar yang dilakukan adalah uji proksimat dan ultimat. Perhitungan dan simulasi pemakaian bahan bakar, kebutuhan volume furnace, efisiensi, dan rugi-rugi boiler dilakukan menggunakan bantuan analisis software Firecad WTPB. Hasil penelitian menunjukkan bahwa co-firing dapat menaikkan efisiensi boiler, menurunkan rugi-rugi boiler, menurunkan pemakaian bahan bakar dan kebutuhan volume furnace, serta menurunkan kecepatan gas buang di sekitar pipa-pipa uap utama. Mitigasi risiko harus dilakukan karena sistem ini dapat meningkatkan temperatur furnace, yang dapat meningkatkan potensi slagging dan fouling sehingga mengganggu kinerja boiler saat musim giling.

... Selebihnya 87 gram adalah air dan zat terlarut bukan gula (Rein, 2007). ...

... La industria de la caña de azúcar es una de las principales actividades productivas en la economía cubana, posición que ha alcanzado por las posibilidades de obtención de una diversidad de productos a partir de su fraccionamiento. Del procesamiento de la caña de azúcar se pueden obtener varios productos principales e intermedios, Rein (2007), entre los que se encuentran el azúcar, mieles, bagazo, alcohol, biogás, levadura torula y otros derivados de alto valor agregado. Se debe sumar a estos productos la electricidad que en los últimos años se ha presentado como un nuevo producto a través del que la industria azucarera puede aumentar sus ingresos. ...

In this work, the stages of losses and lower exergetic efficiency are determined when the sugar production process is integrated with others for the production of products such as biogas, torula yeast and electricity. The study is carried out in three scenarios of integrated processes for obtaining the indicated products. A sugar factory in which sugar and electricity are produced is considered as the base scenario and from this; a second scenario is inferred in which alcohol is produced from the molasses of the sugar process and biogas from the vinasse of the alcohol distillation process. Finally, a third scenario is exergetically evaluated in which sugar, electricity, biogas and alcohol are produced, but this last one from juices and molasses of the sugar process. For the exergetic analysis the integrated scheme was divided into 8 subsystems. From the analysis of results, the major subsystems that generate irreversibilities are: cogeneration (64.36-65.98%), juice extraction (8.85-9.85%), crystallization and cooking, (8.48 -9.02%), fermentation (4.12-4.94%) and distillation (2.74-3.2%). Improvements are proposed to minimize irreversibilities, including the thermal integration of processes, technological modifications in the fermentation process and the introduction of more efficient equipment for the generation of electricity. The exergetic efficiency is between 78.95-81.10%, obtaining greater exergetic efficiency in the scheme of joint operation to produce sugar, alcohol and biogas.

... Alternativas de mejoras para el CB Alternativa 1(A1): Disminuir la humedad del bagazo hasta el 47% empleando una maza del tipo "Lotus" en el último molino [Rein, 2007]. ...

... Since then, more efficient cogeneration systems have been introduced in the sugarcane sector, with steam cycles operating at 65 bar and 480 C, and energy efficiency has been sought by sugarcane mills; steam consumption has been steadily reduced for improved electricity generation or production of higher bagasse surplus. Steam consumption of most sugar mills is around 500 kg steam per ton of cane, and the minimum steam consumption based on the current technology can range from 340 to 350 kg of steam per ton of cane, if intensive energy integration is implemented ( Rein, 2007). Along with energy integration, the process can be optimized replacing energy-intensive unit operations like azeotropic distillation by efficient processes, such as adsorption on molecular sieves. ...

This chapter addresses the economic feasibility of conventional sugar mills producing ethanol, sugar, and electricity, and their projected future configurations, comprised of biorefineries producing sugar, first and second generation ethanol, and electricity, among other products. Existing sugar mills in Brazil, their technologies, products, and coproducts are first described, followed by our perspectives concerning the future sugarcane biorefinery in the new energy scenario in Brazil, which includes technologies to efficiently convert lignocellulosic biomass to electricity and chemicals, including ethanol. Many biorefinery configurations can be deployed, and techno-economic analysis can indicate the directions new biorefinery design should take. In this chapter, an overview of methodologies used for techno-economic analyses, and selected studies of biorefinery analyses are discussed, in order to offer a background on the competition between electricity and second generation biofuels from sugarcane.

... Alternativas de mejoras para el CB Alternativa 1(A1): Disminuir la humedad del bagazo hasta el 47% empleando una maza del tipo "Lotus" en el último molino [6]. Alternativa 2 (A2): Modificar A1 a partir de los resultados del AP: calentar la meladura con la corriente de vinaza y flemaza proveniente de la destilería; calentar el jugo mixto mediante un calentador jugocondensados; aumentar el área de transferencia del cuarto vaso de 2 000 m 2 a 4 000 m 2 ; emplear como medio de calentamiento vapor proveniente del cuarto y tercer vaso en el calentador primario y secundario respectivamente. ...

ABSTRACT In this work alternatives to increase the thermal energy efficiency of a bioelectric factory were analyzed. The evaluation of the thermal energy system was carried out using STA v4.1 and Aspen Pinch v11.1. The results showed a bagasse deficit due to the high consumption of exhaust steam in the process. Pinch analysis (PA) allowed verifying energetic reserves in the system. Based on process simulation and PA results three improvement alternatives were proposed. The 3 rd alternative allows exhaust vapor consumption in the process; the possibility to store 23,6 kg bagasse/t milled cane and the increment of the electricity sold. KEY WORDS: bioelectric, simulation, pinch analysis

In the work the thermal diagram of the sugar mill factory Elpidio Gómez belonging to the Cienfuegos Province is studied. Process flow graph and information flow were made for their posterior simulation in the software Termoazucar (STA 4.1). With the help of the reference software, the simulation of the study allowed to determine the improvement opportunities which this thermal scheme provides. Their implementation in the simulation of an improved case provided knowledge on the possibility of increment of sold electricity to the Electro-energetic National System (ENS)for the studied sugar mill factory, which is 12% maintaining for this case a similar grounding level.

Luz Stella Polanco
Vadim Kochergin
Stephen Savoie
Gregory Carline

Double purge or affination of C - magma offers an opportunity to improve color of Raw Sugar by reducing the recycle of final molasses to the first crystallization stage. The system can be implemented in a traditional three-boiling scheme with minor process changes. It requires the addition of a second centrifugation after an initial centrifugation of C - massecuite. Little or no water is applied to the first centrifugation to obtain 79 - 81 magma purity. In a second centrifugation, the magma is affined, producing 92 - 94 magma purity. The wash molasses - 62 to 66 purity, can be blended with either the A or B molasses. The high purity magma becomes the footing for A and B massecuites. Results obtained during the 2012 season from two Louisiana factories, processing cane from the same sources, showed that a double purge system improved the raw sugar color about 50% (1,400 CU compared to 3,000 CU, as measured by the modified ICUMSA method 4 - 1978).

Somchart Chantasiriwan
Sarocha Charoenvai

Superheated steam drying has previously been shown to improve the performance of the cogeneration system in sugar factory because it can reduce bagasse moisture content, which increases the efficiency of the steam generation unit, and recover water that would be lost with flue gases. The performance of this system depends on the degree of superheat in the extracted superheated steam, which is the difference between the superheated steam temperature and the saturated steam temperature at the same pressure. In this paper, an investigation is made into the use of parabolic trough solar collector to increase the temperature of superheated steam for drying bagasse. A case study under consideration is that of a system that processes 100 t/h of sugar cane. The pressure and temperature of steam generated from the steam generation unit are, respectively, 4.5 MPa and 440 °C. This system requires 42 t/h of water in the juice extraction unit. The outputs of the unit are 112 t/h of diluted sugar juice and 30 t/h of moist bagasse. The amount of saturated steam at 200 kPa required for the evaporation unit is 37.3 t/h. If 6 MW is generated by the steam turbine, a system with only superheated steam dryer consumes 2.325 kg/s of dry bagasse consumption and recovers 0.282 kg/s of water. If the solar direct beam irradiation is 500 W/m², the integration of the parabolic trough solar collector with the aperture area of 1000 m² results in the reduction of dry bagasse consumption by 0.027 kg/s or 283 ton/year compared with the system without parabolic trough solar collector. Furthermore, 0.089 kg/s of more water is recovered. The simple payback period for this system is 6.36 years.

High-biomass sweet sorghum is considered a promising energy crop suitable for the production of energy, first- and second-generation biofuels and biobased chemicals. Processing in a typical sugar cane mill or dedicated sorghum mill is challenged by the presence of trash (leaves and panicles). The separation of leaves and panicles could generate additional value streams, and the reduction of trash is considered beneficial for juice extraction and juice quality. A two-stage trash removal system for the separation of leaves, and panicles was designed and tested. The pneumatic leaf separation stage allowed the removal of up to 56% of leaves in a single pass and the second stage, a novel rotating-disk separator, demonstrated the feasibility of the panicle separation. The basic design parameters were optimized for both systems, and the impact of trash removal tested on Ceres® Inc. "Durasweet" sorghum in 2015 and 2016. Trash removal from the feedstock allowed practically identical recovery (97.3–99.9%) of soluble solids, while up to 19.1% less feedstock with significantly less fiber (82.6% of original feedstock) was processed.

Proteins, waxes, lipids, minerals, colloids, and pigments are known as nonsugars in sugarcanes and their precipitation has been associated with ICUMSA color reduction. This work aimed to evaluate the effect of three hydrogen peroxide doses (1,000; 5,000; and 10,000 mg/L), after 1 hr, on the ICUMSA color, turbidity, and total soluble solids (Brix) and by gas chromatography‐mass spectrometry the composition of the chemical compounds presents in precipitates formed by the action of hydrogen peroxide and in the sugarcane wax was identified. Reductions occurred in ICUMSA color for the three doses (39.7%, 48.3%, and 60.7%, respectively) and in the Brix (63.9%, 65.2%, and 67.1%, respectively). For turbidity, the dosage of 1,000 mg/L showed an increase (3.7%), while the others reduced (7.3% and 13.3%, respectively). By gas chromatography‐mass spectrometry, 32 compounds were identified, 10 of them were present in all the samples and the major class components were hydrocarbons and fatty acids. In this work, we studied the potential application of hydrogen peroxide as an alternative of the sulfitation process, which it has been associated with health disturbs.

The present investigation was carried out in Khuzestan province of Iran to evaluate the effects of chemical ripeners on the advancement of cane maturity (var. CP57-614) during incline phase. Three chemicals viz. Ethephon (2-Chloroethyl phosphoric acid), Glyphosate, and Fitomas M (a growth regulator) were applied as foliar spray on the crop using a small aircraft. The result showed that application of glyphosate increased brix, pol%, fiber, and recoverable sugar; however, its application reduced cane length and invert sugars and also showed marginal decline in the cane yield. The improvement in cane quality was more pronounced compared to the reduction in cane yield. Ethephon application had no impact on cane tonnage, and showed marginal improvement in pol per cent (3.3 %) and recoverable sugar (3.4 %) compared to untreated control. Fitomas-M had no effect on cane tonnage; on the contrary, it showed decline in pol%. Based on the large-scale trials done in Khuzestan province, it was demonstrated that 0.5 l ha−1 of glyphosate increased recoverable sugar to the extent of 10.60 % indicating that this treatment was most suitable for increasing sucrose content during incline period of crop maturity or early stages of harvest.

Chetan Sharma
Vikas Kumar

Sugar industry is one of the most important agro-industries in India. Cane Sugar Industry has an important role in the Indian economy as well as in the foreign exchange earnings. Since cane consists of about 70-75% water, cane sugar mill processes more water than sugar. All the water entering a mill must also leave it in one form or another. So why the sugar industry is a major water user and wastewater producer. Water is most essential but scarce resource in developing countries. Recycling of condensate, segregation of high strength and low strength effluent, proper operation of ETP (Effluent Treatment Plant), etc. leads to a well maintained water managements in the sugar industry and leads to reduction in the requirement of fresh water. In this study we quantified the volume of the main water and wastewater in a sugar manufacturing process followed by the suggestion regarding the reutilization of the waste water.

A technological innovation is presented that minimizes the sugarcane juice reabsorption during the milling cycle, increasing its juice extraction: the XM mill roll. The innovation is based on the Lotus mill roll, but is not built on steel, but rather on cast iron, similar to the conventional shells. The innovation consists of implementing drains directing flow towards the inner part of the mill rolls in order to rapidly separate the bagasse juice during the milling cycle. Hundreds or thousands of nozzles are placed at the root of the mill rolls teeth to capture the liquid and direct it internally towards wide longitudinal drains that channel the juice through the exit sides, ending in the juice collecting tray. In an initial phase, internal drains were built on the top roll since it has the greatest contact area with the juice, achieving a significant reduction of the bagasse moisture at the exit of the last mill and increasing sucrose extraction in the first mill. Later on, the other mill rolls were built (feed roll, discharge roll, fourth roll) with internal drains increasing, or at least, maintaining good indicators through time. We have achieved, in Colombia, extractions up to 75% using mill rolls with internal drains in the four rolls of the first mill, and bagasse moisture between 45% and 50%, with internal drains only in the top roll of the last mill. We register a special case of a drying mill installed in Ecuador in which the bagasse exits the diffuser with approximate moisture of 80% and when passing through the mill, obtained moisture of less than 50% using internal drains in the feed roll and the top roll. Other indirect benefits are: possibility of increasing water imbibition; improving and stabilizing boiler operation; having a bagasse surplus; reducing pollution by lowering fossil fuel consumption; possibly increasing milling capacity; and achieving positive tandem indicators using only 5 mills.

Sugarcane bagasse is a vast lignocellulosic byproduct generated in the industry with ~50% humidity (1 kg dry matter associated with 1 kg water). Although the presence of water brings deleterious consequences for combustion, storage and sugar extraction, the location of water in fresh bagasse remains unknown. In this work, we use synchrotron X-ray microtomography for non-invasive 3D imaging of fresh bagasse particles, which allows the visualization of intraparticle water. The sclerified fiber cells in the sheaths surrounding xylem vessels are often found full of water. We suggest this can be juice preserved from the native stalks as many sclerified fibers seem to keep their structural integrity despite the mechanical action during sugarcane crushing. The microtomograms of fresh bagasse also shows mineral particles adhered to biomass surfaces, with adhesion presumably favored by the presence of water. In summary, this work unveils the location of water in fresh bagasse, solving an old mystery of sugarcane technology.

In this study, we discuss the difference regarding thermo-economic and environmental (water intake) aspects between two methods of biomass hydrolysis. A thermo-economic model was developed using Aspen Plus® and MATLAB software in order to analyze the energy efficiency, as well as, the economic impact of the hydrolysis process integrated into a traditional ethanol production process from sugarcane. The study aimed at comparing the enzymatic route for sugarcane bagasse ethanol production with the supercritical water-based one. The use of supercritical water hydrolysis (SCWH) process showed promising results, being the process energetically self-sufficient when considering pumping of liquid streams with biomass content of 20% and the decompression of the steam separated after SCWH with a turbine, in order to produce electricity. In terms of economics, the biorefinery concept using enzymatic route presented the highest production costs due to the higher total investment cost and the cost for the raw materials, which is 14% higher than the biorefinery with SCWH, giving a payback time for the investments of 7.5 years, meanwhile 6.2 for the SCWH route. Also better results were obtained for water intake for the SCWH option, being lower than the maximum permitted for a new investment on the Brazilian sugarcane sector.

Abstract Wonji Shoa Sugar Factory (WSSF) is one of the top sugar factories in Ethiopia which produces sugar and electricity from sugarcane using three critical plants: mill plants, sugar processing plant, and a cogenerating power plant. Among three plants, the mill plant is the most important plant used to crush the cane for separating sugar juice from bagasse. In this plant, Fibrizer hammer device is used for cruising sugarcane. The Fibrizer performs the major share in milling process for fibrizing the chopped cane after set of cane knives using rotating knives. Most of the times, WSSF is facing breakages of Fibrizer hammer by which losses incurring to the factory. The main aim of the paper is to analyze the failure causes of existing Fibrizer hammer with respect to design and modify the necessary changes in design for Fibrizer hammer at WSSF. By which, get high preparation index (PI) and optimize in power consumption and cost. In addition, hardness of the existing Fibrizer hammer was tested to know the mechanical strength. For modification of existing Fibrizer hammer: comparison was made in terms of design, and load along with harmonic simulation analyses performed using finite element analysis. The results from finite element analysis revealed that the modified Fibrizer hammer having minimum deformation, minimum shear stress, and more centrifugal force has a relation to achieve better preparation index. Keywords Fibrizer hammer Harmonic analysis Preparation index (PI) FEM Wonji Shoa Sugar Factory

Bioethanol production from molasses has advantages in greenhouse gas emissions because of its energy acquisition from bagasse. However, the improvement of bioethanol productivity is challenging; while each elemental technology option can be greatly improved, the trade-offs between the production of raw sugar and bioethanol are complex. This issue should be addressed through the optimization of the whole system, including both agricultural and industrial processes. In this study, we constructed a model of combined raw sugar and bioethanol production from sugarcane considering agricultural and industrial technology options. Data were acquired through a detailed investigation of actual sugar mills. Case studies on the redesign of combined raw sugar and bioethanol production demonstrated that the simultaneous implementation of both technology options increases production of food, materials, and energy from plant-derived renewable resources, thus demonstrating the effectiveness of the interdisciplinary approach.

Gustavo Henrique Gravatim Costa
Sandro Ciaramello
Jorge Wilson Giachini
Raul Andres Martinez Uribe

The harvest of sweet sorghum has been studied in several countries because it increases the costs. However, it could decrease the quality of raw material destined to ethanol production. Therefore, the goal of this study was to analyse the quality of the raw material coming from two different sorghum cutting types and at different processing times. At 120 days after sowing, the harvest was carried out manually, the sorghum being chopped into 20-cm billets, and a portion of the stalks were shredded in a forage chopper, resulting in particles of 2–3 cm in diameter. The broth was extracted through a hydraulic press at 0, 6, 12 and 24 h after cutting and characterized. We concluded that the billets was the most suitable for the sorghum, since there was less deterioration of the plant in relation to the cut into forage form and the plant processing must occur within 6 h for the best possible use of the material.

Selective fermentation of reducing sugars in mixed saccharides is an emerging key technology for productivity enhancement utilizing high-yielding sugarcane cultivars in cane sugar mills coproducing sugar, ethanol and electricity. In this paper, a sophisticated analysis on the heat exchanger networks for inlet and outlet of selective fermentation is performed. As a key constraining parameter, the effect of availability of hot/cold heats at cane sugar mills on energy use, investment efficiency and process complexity were examined. The results demonstrated that no additional fuels are needed for implementing selective fermentation into cane sugar mills by utilizing bagasse as fuel. The heat exchanging between process streams should be incorporated to save main steam and initial cost for temperature control for selective fermentation. Cold heat acquisition has a high impact on the final decision in the choice of precooling and heating units.

Reinier Jiménez Borges

Krzysztof Ptasinski

Bioethanol can be classified either as a first- or second-generation biofuel depending on the feedstock used. The first-generation bioethanol is at present produced commercially from edible crops such as sugarcane or grains using biochemical methods. The second-generation ethanol can be produced from lignocellulosic biomass (wood or grasses) using biochemical or thermochemical methods. This chapter deals with biochemical methods of ethanol production from edible and lignocellulosic biomass. It presents an overview of biochemical methods of ethanol production. The chapter also presents an exergy analysis of the second-generation lignocellulosic ethanol. It describes the alternative ethanol production processes, including fossil ethanol from mineral oil and renewable ethanol via water electrolysis. The chapter provides a short overview of energy balances, environmental aspects, and production costs of ethanol for the major ethanol feedstocks. Environmental concerns about global climate change are one of the major drives in the replacement of fossil fuels by biofuels.

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Source: https://www.researchgate.net/publication/311674659_Cane_Sugar_Engineering_2nd_Edition

Nidia Tornquist

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