Transcript Business World Map Template

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
Figure 1:PROCESS FLOW DIAGRAM
Back Boiling System
Liquor : syrup ratio 60:40
Melter
Phosphatation
Clarifier
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
High Performance Adsorbent
250 ppm at Melter
Melter
Melt Liquor
400 – 500 IU
Phosphatation
Clarifier
Pan strike configuration:
Fine Liquor 50 : Syrup 50
Back Boiling System
liquor:syrup ratio 50:50
Press
Filters
Final Liquor
100 – 150 IU
Lower final color enabled better exhaustion of
recycled syrups.
More sugar production / Less run-off to raw
house
Refined
Sugar
SUMMARIZED FINDINGS
Table 1: Color Profile – Color Removal Comparison.
Color (UI)
Process Method
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 2: SUMMARIZED FINDINGS
Process
Sugar
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
Chemical Reduction
PROCESS
Normal
Phosphatation
Enhanced
Phosphatation
% Reduction
Phosphoric Acid
Flocculant
Decolorant
Filter Aid
ppm
ppm
ppm
ppm
578
10
153
1561
488
7
71
1161
15,6
30
54
25,6
Enhanced Phosphatation generates optimization of the
chemicals in Clarification:
Less chemicals in clarification and MORE color removal
Chart 1: SUMMARIZED FINDINGS
50:50
Nº of
# Strikes
Templas
Templas 50/50 - Sirope/Licor
400
300
200
Adsorbent
Application
100
0
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
Increase Number of strikes with Fine Liquor 50 : Syrup 50
42% reduction in syrups to raw house.
Daily refined production increased by + 6%.
PIX 1: ILUSTRATIVE IMAGE
Refinery Color Profile
withOUT enhanced
phosphatation
Refinery Color Profile with
Patent Pending High
Performance Adsorbent
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
Raw Sugar: 600 – 700 IU
Melter
Phosphatation
Clarifier
Final Liquor:
220 – 280 IU
Straight Boiling System
Problem: R4 rejected
as the high color
generated composite is
out of specification
I.E.R
.
R1 to R3
Problem: Recycled syrup used like back
boiling in strike 3
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
Raw Sugar: 600 – 700 IU
Melter
Phosphatation
Clarifier
Final Liquor:
120 – 180 IU
Straight Boiling System
High Performance
Adsorbent
350 ppm at Melter
I.E.R
.
Result: R4 accepted.
Elimination of the 3rd strike back boiling
R1 to R4
Production Increase
Steam (Energy) Saving
Table 4:SUMMARIZED FINDINGS
Process
Method
Fine Liquor
Colour (IU)
Phosphatation
Then IER
220-280 IU
Phosphatation
WITH Adsorbent,
Then IER
120-180 IU
R1 – R4 Sugar
Colours (IU)
R1: 25
R2: 50
R3: 100
R4: N/A
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
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
1st Filtration
2nd Filtration
Limed
Juice
Straight Boiling System
Flow Rate: 235 m3/h
Liquor Bx: 55 - 58º
Filtered Color: 750 IU
RSO: 3300 Ton/day
R1 to R4
G.A.C
.
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
1st Filtration
2nd Filtration
Limed
Juice
Adsorbent added at
Carbonated Liquor Tank
Straight Boiling System
Flow Rate: 260 m3/h
Liquor Bx: 61º
Filtered Color: 525 IU
RSO: 3700 Ton/day
R1 to R4
G.A.C
.
Table 6: SUMMARIZED FINDINGS
Process Method
Carbonatation
Only
Enhanced
Carbonation
Fine Liquor
Colour (after
GAC)
Daily INCREASE
Refined Sugar
Output
225 - 250 IU
---
125 - 150 IU
12% increase
Enhanced Carbonatation produces lower filtered
carbonated liquor color
Adsorption of contaminant, starch, dextrin, allows better
filtration rate
Table 7: SUMMARIZED FINDINGS
Process Flow
Rate
Liquor
Concentration
Filtered
Liquor
Average RSO
(m3/hr)
ºBrix
Colour (IU)
(Tons/day)
Carbonatation
Only
235
~ 55
775
3300
Enhanced
Carbonatation
260
~ 61
525
3700
Process Method
Process Method
Carbonatation Only
Enhanced Carbonatation
Fuel Oil
Steam
Water
(kg/ton RSO)
(Tons/Tons RSO)
(kg/ton RSO)
84
68
1.13
0.84
620
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
D.B.F. or Press filtration is required for
better implementation of 2 stages method
By-pass
Phosphatation
Clarifier
Melter
Clarified
Liquor
High Performance
Adsorbent added at
Melter/Raw sugar conveyor
AND at the Outlet Clarifier
D.B.F.
I.E.R.
Final
Liquor
Table 8: SUMMARIZED FINDINGS
Process Method
Liquor Color AFTER
I.E.R.
Liquor Colour AFTER
Evaporator
Normal Clarification +
I.E.R.
170 – 230 IU
220 - 280 IU
Process Method
Liquor 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 + 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
Benefits of using High Performance Adsorbents
 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
SPECIAL SECTION
Energy Saving & Carbon Footprint
BENEFITS FOR SUGAR REFINERY
 Demonstrating market leadership
 Delivering cost savings through reduced energy
and resource consumed
 Increasing Brand Value and Market Share
 Providing consumer and stakeholder satisfaction
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