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ISJ Feb14 Improvementsofrawsugarquality
ISJ Feb14 Improvementsofrawsugarquality
ISJ Feb14 Improvementsofrawsugarquality
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Abstract
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).
Keywords: raw sugar, raw sugar quality, raw sugar manufacturing, C-sugar affination
for A and
Three-Boiling SystemB massecuites.
with Double Purge of Hugot2 (1986) nd
magma to 88. recommends
He also mentioned that double
nd
a 2 magma purgepurity of
C-Magma nd ranging from 92 – 93 will significantly reduce ash content in raw
adjusting the purity of the 2 magma sugar and willto 88.theHe
improve alsoof thementioned
filterability melted sugar at thethat a
rd
Figure grade massecuite
1. Three-boiling scheme with double(3purge strike),
of C-magma.non-sugars which
A, B and C stages include increase
crystallization in pans andtransfer
centrifugal of co
separation of the sugar crystals from the run off molasses. G stage is the preparation of the seed for the C strike and the DP stage
includeofpreparation
crystal growth.
and second centrifugation of the first magma
Raw
Sugar
G
Final
Syrup A A Molasses B B Molasses C
Molasses
1 s t Magma
79 -81
DP Wash
2 n d Magma
Molasses DP
92 -94
62 - 66
A double purge system for Lula factory was designed and integrated into their traditional 3-
boiling
Figure scheme
2. Design andinimplementation
2012. Figureof2the
shows the
double details
purge of the
system design.
at Lula Sugar Factory
2nd Magma
Screw Conveyor
Figure 2 Design and implementation of the double purge system at Lula Sugar Factory
Even though the recycle of the double purge (DP) wash from Westfield (a sister mill) factory with a common cane supply,
molasses, in conjunction with higher magma purity alters purity operating with an unmodified three-boiling scheme.
parameters During
at the firstthestage,
2012thecrop season,
lower amounttheof double
non-sugarspurge system started continuous operation on
10/21/2012,
enhances the rate stopping
of crystalonly at liquidation
growth. The recoveryat ofthesucrose
end of the Materials and methods
season. Because of the purity (62 – 66) of the
nd
ondouble
the firstpurge
strikemolasses,
can then this stream was
be increased usually sent
by increasing the to the A molasses tank. Routine analyses of the 2
magma and
massecuite double
crystal content. purge wash streams
This produces higher Awere quality, to the Three-boiling
sugaradded lab work load.+The C magma doublefor
purity ranges purge
thesemodel
streams
lowers were defined
A molasses purity – by
andthe Audubon
lowers Sugarvolume
A molasses Institute.
at The process was closely supervised by the
the centrifuges. This, in turn, reduces the volume of massecuite A model was designed on SugarsTM software to evaluate the
managers and engineers of Lula. The raw sugar analysis results from the double purge system at Lula
produced by the second strike (B massecuite). However, if the required equipment capacities using Lula factory efficiencies for
factory were compared with those from Westfield (a sister mill) factory with a common cane supply,
double purge wash is recycled to the B strike, the volumetric flow each stage.
operating with an unmodified three-boiling scheme.
of B massecuite may increase. If this modification to the double
purge system is implemented, the performance of the B pan has Factory sampling and analysis
to Materials and methods
be closely supervised to prevent reduction of crystal content.
Effective management of the two first stages (A and B strikes) The sampling frequency at the factory was modified to include
willThree-boiling
allow control of +purity
C magma doubleflow
and volumetric purge
of Bmodel
molasses grab samples of the second magma and the double purge
preventing purity and volume increase of the C massecuite. molasses at 3 hour intervals. These samples were analyzed using
A model was designed using SugarsTM softwarethetoICUMSA evaluate the required
techniques for Brixequipment
and Apparentcapacities
Purity (International
using Lula factory
Implementation of aefficiencies
C-magma doublefor eachpurge
stage.at Commission for Uniform Methods of Sugar, 2007).
Lula Factory (Belle Rose, Louisiana) Raw sugar was sampled and analyzed every 3 hours at two
Factory sampling and analysis factories (Lula & Westfield) for polarization and moisture according
A double purge system for Lula factory was designed and to ICUMSA methodology. A daily composite sample of raw sugar
integrated intoThe sampling
their traditionalfrequency at theinfactory
3-boiling scheme was 2justfrom
2012. Figure modified to include
both factories wasgrab samples
analyzed of the
by the second
Westfield Lab. The
magma and the double
shows the details of the design. purge molasses at 3 hour intervals. These samples were analyzed using the
composite raw sugar samples were analyzed mostly according
During the 2012 crop season, the double purge system started to a refinery protocol defined by the Sugar No. 16 contract (ICE,
continuous operation on 10/21/2012, stopping only at liquidation 2008). The most relevant analyses were: polarization, moisture,
at the end of the season. Because of the purity (62 – 66) of the ash, grain size, whole and affined raw color (modified ICUMSA
double purge molasses, this stream was usually sent to the A
3 4 – 1978), dextran (MAU), and starch (ICUMSA GS1-17 - 2005).
molasses tank. Routine analyses of the 2nd magma and double
purge wash streams were added to the lab work load. The purity Factory color profile
ranges for these streams were defined by the Audubon Sugar
Institute. The process was closely supervised by the managers A series of grab samples were taken from the feed and output
and engineers of Lula. The raw sugar analysis results from the of each crystallization stage for color analysis (modified ICUMSA
double purge system at Lula factory were compared with those GS1/3-7 (2002) 8.5 pH raw sugar solution).
The model for the double purge system of C magma, blending the double purge molasses with B
molasses is shown in Figure 3. The model is specific for Lula factory as the material flow rates depend on
exhaustion levels, which are determined by installed capacity. The model was created using the average
parameter valuesfrom
Figure 3. Section fordouble-purge
the 2012 season
model – for this. mill.
Sugars Centrifuge 2640 produces the C sugar to prepare the first magma and
TM
centrifuge 2670 produces the double purge sugar to prepare the 2 magma. Optional blending of double purge molasses to A, B
nd
molasses or to syrup
Figure 3 Section
Results double-purge model – SugarsTM. Centrifuge 2640 produces the C sugar to prepare
and fromTable 2. Boiling house flow-rates and percentage of variation for three boiling scheme and without (3B)
the first magma and centrifuge
discussion 2670 produces the double purge sugar to prepare the 2nd magma. Optional
and with double purge of C-magma (3B+DP) for syrup at different purities and constant volumetric and
blending of double purge
solids molasses
input to A, B molasses or to syrup
The model for
MATERIAL UNITS 82 SYRUP PURITY 86 SYRUP PURITY 90 SYRUP PURITY
the doubleSimulations
purge of the 3 boiling scheme with and without double purge of C-magma were run for the
same
systemvolumetric
of C magma,rate of syrup input, for the 3B
same3B+DP
amount of refractometric
∆ (%) 3B 3B+DP
solids
∆ (%)
(65
3B
Brix) and for∆ 3(%)
3B+DP
blending the double
different syrup purities (82, 86 CUMT/TC
A MASS
and 90). Other
0.071
parameters
0.076 6.6
were0.090
fixed 0.095
according5.9
to the year-to-date
0.108 0.111
values
2.0
purge molasses with B MASS CUMT/TC 0.085 0.076 -10.5 0.065 0.058 -10.7 0.046 0.040 -11.3
ofBthe factory report.
molasses is shown
Brix and Purity of the raw sugar produced was fixed at 99.7 and 99.3 respectively.
C MASS CUMT/TC 0.047 0.051
The
in expected
Figure 3. flow-rates
The according to the simulations are9.2shown 0.036 0.040
in Table 2. 9.6
Flow-rate 0.026 0.029
depends 9.4
strongly on
A MASS T.SOL/TC 0.098 0.104 6.5 0.124 0.131 5.9 0.149 0.152 2.0
model is specific
B MASS T.SOL/TC 0.120 0.107 - 10.5 0.092 0.082 - 10.6 0.064 0.057 - 11.2
for Lula factory
C MASS T.SOL/TC 0.069 0.075
4 9.1 0.053 0.058 9.7 0.039 0.042 9.4
as the material
flow rates depend A MOL T.SOL/TC 0.047 0.048 3.2 0.050 0.053 7.3 0.053 0.053 0.3
on exhaustion B MOL T.SOL/TC 0.066 0.059 - 10.5 0.050 0.045 - 10.6 0.035 0.031 - 11.2
levels, which are MAG1 T.SOL/TC 0.025 0.030 22.3 0.019 0.024 23.0 0.014 0.018 22.1
determined by MAG2 T.SOL/TC n.a. 0.017 n.a. n.a. 0.014 n.a. n.a. 0.010 n.a.
installed capacity.
DP MOL T.SOL/TC n.a. 0.013 n.a. n.a. 0.010 n.a. n.a. 0.008 n.a.
The model was
created using the
average parameter values for the 2012 season for this mill. (Brix). The massecuite flows are reported in cubic meter per
Simulations of the 3 boiling scheme with and without double ton of cane and in tons of solids per ton of cane (Metric Units).
purge of C-magma were run for the same volumetric rate of syrup Molasses and magma were reported in tons of solids per ton of
input, for the same amount of refractometric solids (65 Brix) and cane. An important observation from these simulations is that
for 3 different syrup purities (82, 86 and 90). Other parameters the volumetric rate of these materials can fluctuate between 40
were fixed according to the year-to-date values of the factory to 60 %, from low purity to high purity, while double purge for a
report. Brix and Purity of the raw sugar produced was fixed at determined purity only changes massecuites flow-rate +/-10%.
99.7 and 99.3 respectively. The expected flow-rates according Figure 4 shows the effect of syrup purity on massecuites flow-
to the simulations are shown in Table 2. Flow-rate depends rate. This information is important considering the installed
strongly on the molasses dilution or massecuites tightening capacity of the factory. When syrup purity is low (~82) the low
www.internationalsugarjournal.com 45
B MASS T.SOL/TC 0.120 0.107 - 10.5 0.092 0.082 - 10.6 0.064 0.057 - 11.2
C MASS T.SOL/TC 0.069 0.075 9.1 0.053 0.058 9.7 0.039 0.042 9.4
A MOL of raw
Improvements sugar quality0.047
T.SOL/TC 0.048
using double 3.2 0.050 0.053 7.3 0.053 0.053 0.3
purge of C-magma
B MOL T.SOL/TC 0.066 0.059 - 10.5 0.050 0.045 - 10.6 0.035 0.031 - 11.2
MAG1 T.SOL/TC 0.025 0.030 22.3 0.019 0.024 23.0 0.014 0.018 22.1
Figure 4.MAG2 T.SOL/TC
Massecuite flow-rates as a function of 0.017
syrup purity 0.014purge target apparent purities
Figure 5. Double 0.010 (2nd magma,
respect to cane for the traditional 3 – boiling scheme
DP MOL T.SOL/TC 0.013and for 1st magma and double purge molasses)
0.010 0.008
3 – boiling with double purge of C magma (Metric and British
units)
Figure 5 Double purge molasses target purities (2nd magma, 1st magma and double purge m
Figure 6 compares raw sugar produced by double purge of C-magma at Lula com
sugar produced by Westfield without double purge. The level of improvement of whole co
factory for a polarization of 99.2 °Z was ~ 40%. Affined color, which is related to the colo
the core of the crystal, reduced ~15% at the same polarization.
Figure 5 Double purge molasses target purities (2
Figure
Figure46.Massecuite
Raw sugar colorflow-rates as a function of syrup purity
(Wf): respect toColor,
caneb)for theColor
traditional
(modified 3 – boiling
a) Whole Color
comparison between Lula (Lu) and
scheme and for 3 – boiling with double purge of C magma Figure
Westfield
b) Affined
a) Whole
(Metric 6and Color
Affined
British units)
ICUMSA 4 – 1978)
a) Whole Color
compares raw sugar produced by
b) Affined Color
sugar produced by Westfield without double purg
Figure 5 shows the average daily purities of the magmas and double purge (DP) molasses. They
factory
fluctuated around the expected values (DP molasses forMagma
~63, 1st a polarization
~80 and 2of
nd 99.2 °Z was ~ 40%. A
Magma ~93). Spikes of
the core of the crystal, reduced ~15%
low purities wash molasses probably were caused by leaks of final molasses into the first at the
magma same
in the
first set of centrifuges (4 SW 4630 –Wf
basket 1170 mm, 2000 rpm and screen 0.06 mm).
Wf
a) Whole Color
Lu Lu
5
Wf
Figure 6 Raw sugar color comparison between Lula (Lu) and Westfield (Wf): Lu a) Whol
grade station requires increased capacity to keep up with the
Affined Color
boiling house, (modified
and when ICUMSA
the purity is high (~90) the high4grade
– 1978)
Table 3. Comparison of raw sugar parameters (weighted-
average) between Lula and Westfield
station is compromised.
Table 3 shows the weighted average of sugar quality
Parameter
Figure 5 shows the average daily purities of the magmas
and double purge (DP) molasses. They fluctuated around the
Unit
parameters,
Lula
evaluated
Westfield %∆
after a
continuous operation of double purge of C-magma Polarization (10/23/12-11/26/12).
expected values (DP molasses ~63, 1st Magma ~80 and 2nd °Z 99.3 99.1 Conductivity
-0.2 ash
for Lula raw sugar compared to those for Westfield.
Magma ~93). Spikes of low purities wash molasses probably
Whole Color
Reducing
CU
sugars,2923
1552
starch or47
dextran di
Figure
were caused by leaks of final molasses into the first magma in
improvement with the double purge of C-magma. 6
Affined Color
the first set of centrifuges (4 SW 4630 – basket 1170 mm, 2000
Raw sugar
CU
color
1026
comparison
1289 20
between Lu
rpm and screen 0.06 mm). Affined Color (modified
Ash (Conduct.) % 0.07 ICUMSA0.15 457– 1978)
Table 3 Comparison of raw sugar parameters (weighted-average) between Lula and Westf
Figure 6 shows raw sugar produced by double purge of
Reducing
C-magma at Lula compared with sugar produced by Westfield
Sugars % 0.15 0.17
Parameter
Starch
Unit
without double purge. The level of improvement of whole color TableLula3ppm
shows188Westfield
the weighted
187 average
%∆ of su
continuous operation of double purge of C-magm
Dextran
at Lula factory for a polarization of 99.2 °Z was ~ 40%. Affined
MAU 31 26
Table 5. Boiling house color profile (modified ICUMSA GS1/3- 1989. 100-103.
7 (2002) 8.5 pH raw sugar solution) Rein, P. 2007. Cane sugar engineering, Berlin, Bartens.
Van Der Poel, P. W., Schiweck, H. M., Schwartz, T. K. & Foundation, B.
Material A Strike B Strike C Strike
S. D. 1998. Sugar Technology: Beet and Cane Sugar Manufacture, Verlag
Dr Albert Bartens KG.
Feed 22,590 48,590 76,220
Van Hengel, A. Modified Boiling System for Better Sugar Quality.
Seed 20,640 21,020 70,770 In: SASTA, ed. Fifty-seventh Annual Congress of the South African
Massecuite 19,680 38,940 73,190 Sugar Technologists' Association, June 6-9 1983 Durban and Mount
Sugar 740 1,270 42,060 Edgecombe.
Double Purge 10,620 Wright, P. G. The Modelling of Crystallisation Schemes in a Raw Sugar
Magma Factory. 1996. Australian Society of Sugar Cane Technologists, 324-333.
Conclusions
A comparison of results obtained during the 2012 season for
two Louisiana factories, processing cane from the same sources,
showed that the double purge system improved raw sugar color
approximately on ~50% (1,500 compared to 3,000 CU at pH
8.5). The ash content reduced ~ 60% and the affined color was
reduced ~20%. Other impurities in raw sugar were not changed
by use of this modified boiling scheme. There was no detectable
effect on factory performance even though grinding rates were
higher than previous seasons. There is still room for improvement
on factory performance of Lula but the experience learnt on
2012 has given guidance to enhancing future performance using
double purge of C-magma.
www.internationalsugarjournal.com 47
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