ISJ 1388 August14 Lite

sugar INTERNATIONAL

Lite August 2014

JOURNAL

Volume CXVI Issue No. 1388

www.internationalsugarjournal.com Join ISJ in our Global Sugar Network

focus: SUGAR REFINING, COGENERATION AND FALLING FILM EVAPORATORS

FROM BASIC ENGINEERING TO FULL TURNKEY PROJECT

Sugar Plant Sugar Refinery Bioethanol Plant Cogeneration Plant Bio-based Industry

Single Point Responsibility through EPC or EPCM+® with guaranteed: Process Performances Time Schedule Budget

Contact in Brazil: [email protected] www.dsempral.com.br

Contact in Argentina: [email protected] www.dscontractors.com.ar

sugar processing and refining

> power and cogeneration > biorenewables > agricultural production

EXTRACT THE BEST FROM YOUR SUGAR CANE.

Visit us at F enasucro from Augu st 26 to

Fives Sugar Consulting: Your tailor-made access to the ultimate plant know-how. Thanks to our 200 years of expertise in sugar plant, our experts consultants will draw on our home-made CAMEIOTM Plant Manager Solution to design or optimize your cane sugar plant. Our experts are able to integrate all configurations and variables of a plant (all the flows and balances, including electricity/cogeneration), in order to simulate different scenarios for new plant projects, or improvements, expansions, energy savings in an existing plant, and to locate the optimum incomes. Rely on Fives expertise and maximize your cane plant profits.

www.fivesgroup.com

544 International Sugar Journal | August 2014

2014 29

Editorial Comment Automation systems are hackable – how good are the safeguards in the industry?

O

ne of the major noticeable changes in the sugar industry over the past decade or so has been the increase in uptake of automation systems. Not that this was necessarily forced upon the industry, rather the ready benefits in terms productivity gains and profitability accruing from installing equipment supporting various processes have been the main driver. The march of technological progress, particularly in the information communication technologies has been quite strident. Today, for example, online colorimeters provide feedback in realtime on the performance of centrifugals via quality of sugar. Defect in quality can be addressed with speed and control that was simply not possible with previous laboratory analysis. While obsolescence management is an issue that can be easily addressed, that of loss of industrial control through virus infection is a serious one. The question that goes begging is how secure are systems in place in sugar factories? It is worth looking at how Stuxnet virus was introduced to the Iranian nuclear facility at Nantaz1. Facility of this magnitude and importance clearly had substantial firewalls to check direct infiltration. In fact, it had “15 firewalls, three data diodes, and an intrusion detection system.” Cleverly, “the attackers acted indirectly by infecting soft targets with legitimate access to ground zero: contractors.” As it has transpired, both the contractors and in particular the enrichment facility, had fairly lax cybersecurity protections. “Getting the malware on the contractors’ mobile devices and USB sticks proved good enough, as sooner or later they physically carried those on-site and connected them to Natanz’s most critical systems, unchallenged by any guards.” Stuxnet attack routine was to change the speed of rotors in a centrifuge used to enrich uranium. The malware increased the speed by one third of IR-I centrifuges from 63,000 rpm to 84,600 rpm for 15 minutes. “The next consecutive run brought all centrifuges in the cascade basically to a stop (120 rpm), only to speed them up again, taking a total of 50 minutes.” The central purpose of the attack was not to destroy the centrifuges, which could have been easily replaced from stock following a mass attack, but rather “choke” them to keep the operators and engineers guessing. This strategy delayed Iranian nuclear programme by two years. One of the clever aspects of Stuxnet malware was how well it was able to manipulate the cascade protection system built by the Iranians that allows the enrichment process to keep going, even when centrifuges are breaking down. Stuxnet hid its tracks by recording “the cascade protection system’s sensor values for a period of 21 seconds. Then it replays those 21 seconds in a constant loop during the execution of the attack. In the control room, all appears to be normal, both to human operators and any software-implemented alarm routines.” The failure of operators working at the plant to notice changing sounds from increase in speed of rotors and subsequent drop in speed (from 84,600 to 120 rpm) is remarkable. While it is unlikely that a sugar plant will become a focus of dedicated attack from a highly sophisticated malware such as Stuxnet in the foreseeable future, potential vulnerability of modern sugar plants from malware cannot be ruled out. Digital sabotage is the ugly flip side of the technological advance in the sector. With consolidation in the industry, with many companies breaching the one million tonnes mark and owning more than few factories in geographically dispersed locations any weak links in the system can spread malware through local networks. It is apparent that cybersecurity measures will have to embrace unwitting introduction of malware from inexperienced and careless operators. Can any sugar plant raise its hand and say it has robust measures in place that are constantly tested and audited?

Arvind Chudasama

Reference Ralph Langner (2013) Stuxnet's secret twin. Foreign Policy http://www.foreignpolicy.com/articles/2013/11/19/stuxnets_secret_twin_iran_nukes_cyber_attack?page=full

www.internationalsugarjournal.com

3

sugar INTERNATIONAL

www.internationalsugarjournal.com

JOURNAL

2 Panel of Referees L. Jean Claude Autrey PhD, DSc, CBiol, FIBiol, Former Director, Mauritius Sugar Industry Research Institute, Mauritius. M. Asadi PhD, Former Director of Research at Monitor (now Michigan) Sugar Company, USA. L.S.M. Bento BSc, PhD, Formerly Audubon Sugar Institute, USA. L. Bichara Rocha PhD, Senior Economist, International Sugar Organisation, UK. J.C. Comstock PhD, Research Leader, USDA-ARS-SAA, Canal Point, Florida, USA.

International Sugar Journal Christchurch Court, 10-15 Newgate Street, London EC1A 7AZ, UK. Editorial: Editor: Arvind Chudasama MSc., MAgSt. (Qld), MCLIP Email: [email protected] Design and production: Snehal Sanghani Display and online advertising: Business Development Manager: Stuart Velden Direct: +44 (0)20 7017 7559 Email: [email protected] Marketing and circulation: Marketing Manager: Priyanka Adhikari Phone: +44 (20) 337 73045 Subscriptions: Phone: +44 (0)20 7017 5540 Email: [email protected]

www.internationalsugarjournal.com All technical articles have been approved by our panel of distinguished referees. Other editorial material, including abstracts, appear at the discretion of the Editor.

L. Corcodel PhD, Head of Sugar Processing and Industrials Innovations, eRcane, Reunion, France. S. Davis MSc, Head: Processing Division, Sugar Milling Research Institute, South Africa. D. Day PhD, Audubon Sugar Institute, USA. S.J. Edmé PhD, Research Geneticist, USDA-ARS Sugarcane Field Station, Florida, USA. G. Eggleston PhD, Lead Scientist, SRRC-ARS-USDA, USA. C. Garson MEngSc, BE (Mech), Bundaberg Walkers Engineering Ltd, Australia. M.A. Godshall BSc, MSc, Formerly Managing Director, SPRI, USA. D.K. Goel BEng (Mech), Executive Vice President, ISGEC John Thompson, India. M. Inkson CEng, PhD, MIChemE, FEI Director, Sugar Knowledge International, UK. P. Jackson PhD, CSIRO Plant Industry, Australia. G.L. James PhD, DIC, CBiol, FIBiol, Retired Technical Adviser - Agronomy. T. Johnson BS, MS, Chief Chemist and Manager of Quality Control, Sugarcane Growers Cooperative of Florida, USA. L. Jolly BAgricEcon(Hons), Senior Economist, International Sugar Organisation, UK. J. Joyce BEChem, MBA, Sugar Process Consultant, James Joyce & Associates, Australia. C.A. Kimbeng PhD, Asst Prof, Dept of Agronomy and Environmental Management, Louisiana State University, USA. M. Krishnamurthi PhD, Chief Executive, Sadhana Agritech Services and Consultancies Private Ltd, Bangalore, India. V. Kochergin PhD, PE Amalgamated Research LLC, USA. G.W. Leslie MSc, Entomologist, SASRI, South Africa.

ISSN 0020-8841

P. Malein BA, MA, former Head of Agriculture, Booker Tate Ltd, UK.

International Sugar Journal is published monthly by Informa UK Ltd.

J.A. Mariotti PhD, former Director, Tucumán Experiment Station, Argentina. B. Muir PhD, British Sugar, UK. H.A. Naqvi MSc, Technical Consultant, Sanghar Sugar Mills Ltd, Sanghar, Pakistan.

© 2013 Informa UK Ltd. Conditions of sale: 1. All rights reserved, no part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise without prior written permission of the Publisher. Photocopying Licence: Informa UK Ltd. does not participate in a copying agreement with any Copyright Licensing Agency. Photocopying without permission is illegal. Contact the Marketing Department to obtain a photocopying license. 2. All abstracting of the content for republication and sale must have prior permission from the Publisher. 3. The publication must not be circulated outside the staff who work at the address to which it is sent, without prior agreement with the Publisher.

D. Nixon PhD, Agriculturist, Booker Tate Ltd, UK. Y-B. Pan PhD, Research Plant Molecular Geneticist, Houma, Louisiana, USA. C. Rhoten BSc, Manager of Process Technology, The Almagamated Sugar Company, USA. M. Saska PhD, Investigador Visitante, EEAOC-Tucuman-Argentina. G. Shannon BAppSc, Extension Leader - North BSES Limited, Qld, Australia. F.M. Steele PhD, Assistant Professor of Food Microbiology, Brigham Young University, USA. P. Stevanato PhD, University of Padova, Italy. M. Suhr CEng, BS President, MS Processes Intl, LLC, USA. L M Talwar BSc Executive Director, Isgec Heavy Engineering Ltd., India. J. Torres PhD, Director Agronomy Program, CENICANA, Colombia. R.P. Viator PhD, Research Plant Physiologist, Houma, Louisiana, USA. D. Weekes BSc, CEng, MlAgrE, Senior Agricultural Engineer, Booker Tate Ltd, UK. W. Weiss Manager, Sugars International, USA. A. Wienese MScEng(Mech), Consultant, ‘Sugarwise’. M.S. Wright PhD Research Microbiologist, USDA-ARS-SRRC, USA. S. Zhang PhD, Institute of Tropical Bioscience and Biotechnology, Chinese Academy of Tropical Agricultural Sciences (CATAS), China.

4

International Sugar Journal | August 2014

C

M

Y

CM

MY

CY

CMY

K

210 x 280

centrifugation

filtration

drying

Excellence in sugar industry equipment

av Com Leopoldo Dedini 500 BR 13422-902 Piracicaba SP tel +55 19 3124 3000 fax +55 19 3124 3011 [email protected] www.mausa.com.br

alance (1000 tonnes, raw Jan/Mar value) ct/Dec ct/Dec Jan/Mar 2012 2011 2014 2013 2012 58,614 2011 2014 2013 64,678 93,492 90,889 64,678 58,614 93,492 90,889 69,330 63,325 60,478 59,304 69,330 63,325 60,478 59,304 ly 16,723 15,195 15,025 14,665 th n o M 16,723 15,195 15,025 14,665 42,721 41,455 42,188 41,467 42,721 41,455 42,188 41,467 17,121 15,522 15,522 15,493 15,493 15,646 17,121 15,646 90,889 80,157 111,314 107,744

2012 2012 96,014 96,014 21,880 21,880 14,769 14,769 41,597 41,597 13,992 13,992 77,074

Jul/Sep 2014 Jul/Sep 2013 2014 2013 92,624 88,075 92,624 88,075 32,291 31,593 32,291 31,593 15,332 16,307 15,332 16,307 46,456 45,539 46,456 45,539 17,708 17,445 17,708 17,445 76,083 72,992

2012 2012 77,074 77,074 33,308 33,308 16,386 16,386 44,606 44,606 17,485 17,485 64,678

Monthly Snapshot August‘14

Bearish sentiment continues to

World World Sugar Sugar Balance Balance

Market Overview

(mln tonnes, raw value)

(mln tonnes, raw value)

Stocks

Stocks 85 80

Ending Stocks Consumption Ending Stocks Production Consumption

80

Production

85

Prod/Cons

Prod/Cons 190

190 180

180 170

75

170 160

75 70

160 150

70 65

150 140

65 60

130 140

2013/142013/14

2012/132012/13

2011/122011/12

World production estimates of cane and beet

2010/112010/11

2009/102009/10

2008/092008/09

2007/082007/08

Source: FO Licht F.O. Licht

2006/072006/07

55

2005/062005/06

60 55 2004/052004/05

end up with before F.O.a ld on to

August

2003/042003/04

Union Union fell fell 13/14 13/14 –– 0.4 0.4 uidance but uidance but a year ago. a year ago. is currently is currently n has theren has thered earlier in earlier in dd of tenders the dties of and tenders aties sugar andinto the upply so a sugarisinto fallenisthat upply so nnes out of fallen that ota (totaling nnes2013/14 out of ota (totaling d as nobody end 2013/14 up with dldason nobody to a

Apr/Jun 2012 2014 Apr/Jun 2013 2012 111,314 2014 107,744 2013 80,157 80,157 111,314 107,744 56,410 25,362 24,370 56,410 ot 24,370 apsh25,362 Sn 13,290 14,459 15,508 13,290 14,459 15,508 40,460 43,542 42,683 40,460 43,542 42,683 13,384 14,970 14,970 16,865 13,384 16,865 96,014 92,624 88,075

120 130

120

from Brazil and Central America

Over the past three months, sugar while October prices have been in thethe range USc 16.5 ended at 17.8 -18.5/lb as global surplus continues to $465.20/tonne while the Oc decline on thewas back of reduced output. According to the latest estimate from FO Licht, world sugar production in 2013/14 is at 181.1 mln tonnes, compared with According 184.6 mln tonnes last year. In to theirIndia latest Meteorologic reports Czarnikow and Rabobank look to earlynotes June, and expects below a 2014/15 - the former a rebound in beet sugar production from 35.1 million impact of36.3 Elmtrv, Niňo weather phen tonnes raw value (mtrv) to while cane sugar production is forecast to decline from 148.8 mtrv to 147.9 mtrv. Both Cazarnikow and Rabobank indicate By0.5the week of June, 11 deficits of some mln second and 0.9 mtrv next year, respectively.

This was practically unchanged

Brazil – drought has had impact in

World production estimates ofatcane beet on the year to nearly 2.6 mln the sugar had already the andtonnes F.O. Lichtbeen concluded the current season some regionsmillion of yearin to 5.439 tonnes com ere not protime and the results were known. on high beet yields and sugar con- Sao Paulo, the main sugar producing before F.O. duct crystal Russia's 2013/14 beet sugar output tent, which represents an upward state. Czarnikow puts 2014/15 sugar output, 4.838 billion litres compa the sugar had already been concluded at the tonnes on the year to nearly 2.6 mln ed for fuel declined to 4.8 mln tonnes from 5.1 revision of our February estimate of production at 32.9 mtrv compared with ere not propro- time resultswhile were Ukraine known. on sugar mln aand yeartheearlier, 2.4 high mln. beet yields and sugar con- 34.3 mtrv in 2013/14. duct crystal Russia's 2013/14 beet sugar output tent, which represents an upward differs from produced only 1.4 mln tonnes of onal Sugar and Sweetener Report Source: Czarnikow India – with the cyclical production now Source: Czarnikow Withofcurrent campaign in Mexic ed forsugar fuel declined to 4.8 mln tonnes from revision bloc's sugar in 2013/14 compared with 5.1 the Africa of our February estimate of becoming a feature the past, over 26 EU statisprevious year's 2.3 while mln. Ukraine Surplus sugar pro- mln a year earlier, 2.4 mln. mtrv sugar was produced in 2013/14, but there have stocks in the country World reach 5.891 million tonnes com African sugar production is now Sugar by Regions havetonnes been Production rediffers from produced only 1.4 mln of which Czarnikow forecasts may increase y adjustments seen up at 12.1 mln tonnes in Russia and duced sharply and area for 2014/15 Oct/Sep (1,000 raw value) to 27.9 mtrv next year. This maybe, bloc's sugar in 2013/14 compared with the tonnes, Africa cast. sugar from 11.3 mln in2009/10 2012/13 - as Rabobank suggests due to Indian edEU from our has recovered 2012/13 2013/14 2011/12 2010/11 statisprevious year'ssomewhat. 2.3 2013/14 mln. Turkey's Surplus an 15,892 upward revision of government extending the subsidy of EU production rose 16,804 17,445 representing 19,062sugar campaigns sugar by 0.2 mln African production17,518 is now China’s campaign ended in May stocks in the country have tonnes 24,776 from our 26,463 previous INR 3.33/kg (USD Europe 27,132been re28,676 47,000 30,942 54/tonne) for exports seen up at 12.1 mln tonnes in Russia and duced for 2014/15 Africasharply and area12,074 11,267 forecast. 10,356 10,336 10,178 of up to 4 mtrvwhite sugar over the next ion is forecast value, uptwo 1.9% from last y from 11.3 mln in 2012/13 N.recovered & C. America somewhat. 22,439 23,709 2013/14 18,860 18,856 ed from our Turkey's The 20,490 y-o-y increase is mainly driven- years until September 2014, at the same World Sugarhas Balance onnes year-onSouth America 46,322 48,701 representing 43,024 an 46,216 48,721 of upward revision by a recovery in South Africa as well time increasingrose import4.9% duty onto sugar campaigns sugar production by 0.2 mln ich is (1,000 0.6 mlntonnes, t/Sep raw value) rose 68,619 12,571,700 tonnes Asia 67,217 66,293 47,000 tonnes 61,388 from our 51,109 previous from 15% to 40%. capacity guidance.2012/13 The 3/14 2011/12 2010/11 4,615 2009/105,028 as Oceania 3,820 expansion 3,949 in Ethiopia 3,700 and ost exclusively forecast. output declined 91.9 64,677.7 58,614.3 56,970.0 Total 181,200 60,363.3 184,597 Sudan. 174,925 165,525 159,027 China – 2013/14 sugar production wassharply to 746,3 ected output in Balance It be increase pointed isthat sugardriven pro- 13.8 mtrv. It could have been more if Note: May not add165,524.5 due to roundings159,026.7 00.1 184,596.8 174,924.6 Themay y-o-y mainly World Sugar tonnes), 63,202.8 with duction in theinsouthern hemisphere 02.2 59,640.6 59,612.7 62,357.3 by a recovery South Africa as well it wasn’t for the beet sugar production Source: Licht consecutive t/Sep (1,000 raw value) for the FO fifth season Elsewhere, production in Indonesia ,77.4 India, andtonnes, 172,408.9 168,117.9 162,443.3 162,027.4 producers of the continent (suchand as being down byAccording 31% at 811,000 totonnes FO Licht, sugar pr as capacity expansion in Ethiopia though the 2013/14 crop was the is now seen up at 3.1 mln tonnes in 3/14 2012/13 2011/12 2010/11 2009/10 within striking 34.1 67,076.6 60,383.9 61,049.7 62,749.9 South Africa, Swaziland, Zimbabwe, raw value. Czarnikow forecasts 2014/15 Indian swing cycle suspended over the last few years Sudan.from 2.8 mln a year ago due since 2009/10. us projections. higher than last 91.9 64,677.7 smallest 58,614.3 56,970.0 60,363.3 2013/14 82.7 72,991.9 64,677.7 58,614.3 56,970.0 Zambia etc.) on an Oct/Sep basis cuts production to decline further to 13.2 year (26.3 millio China's production rose to It conducive for thesugar local prod our 184,596.8 sugar maytwo be weather pointed that 00.1 174,924.6 sugar 165,524.5 159,026.7 across local crop years. In the mtrv, but consumption is estimated to persists, farme payment arrears to 14.559,612.7 mln tonnes in 2014 crushin (ofthe which all produced by India 96.7for 63,202.8 9,672.2 slightly 9,400.1 6,497.8 7,198.6 duction southern hemisphere 02.2 59,640.6 62,357.3 grow by 4% to 17.6 mtrv. continent's top producer South Afrifrom 14.2 4.09 mln the year end of September belongs to our than others. n tonnes172,408.9 from 1.84 5.53 2013/14 5.68 4.74 the 77.4 168,117.9 162,443.3 162,027.4 producers of the continent as ca, forbalance example, local (such 2013/14 Source: Czarnikow before, with output415.9 falling short341.9 of 2013/14 year).the Production in ing season4,291.0 has Indonesia – 2014/15 sugar production 68.5 5,674.6 34.1 67,076.6 our 60,383.9 61,049.7 62,749.9 South Africa, Swaziland, Zimbabwe, crushing season lasted from April is estimated to be 2.6 mtrv with no previous by just 0.2 mln most 1.84 all states. 2.55 3.49 forecast0.26 0.21 the Philippines is now seen higher 82.7for the72,991.9 64,677.7 56,970.0 2013 January 2014, which Zambia etc.) onwith an Oct/Sep basis cuts significant expansion The 2014/15 While 58,614.3 the in to February the of final totalonly on mills in acreage. (Nov/Oct) sugar ou 3.33 42.34 tonnes.38.47 36.08area under 35.16 than the sugar produced from October 1, Government is expected to issue import cultivation was down slightly, better estimated 2.4 crop mln tonnes me of the mills across twoat local years. In the tonnes, up by 6.3% from last ye 96.7 9,672.2 9,400.1 6,497.8 7,198.6 allowed for the increase in 2013 onwards belongs to the councompared withtop 2.3producer mln three months in August90.8 8,314.2 weather 6,063.4 1,644.3 -3,393.3 continent's South Afri- licenses to refiners amounting 3.2 mtrv. 110 million tonnes cane. Export is ago still somewhat below the 1.84 5.53 production. 5.68 Production 4.09in 2014/154.74 try's output for the of this h is the reason ca, but for example, thepurpose local 2013/14 Thailand – a record 12.1 mtrv sugar likely5,674.6 to be lower as the industry is nearly 2.5 mln tonnes produced in dings; unrecorded disappearance r theconsumption country 68.5 4,291.0excluding 415.9 341.9 8 million tonnes last year. crushing season lasted from April was producedfrom in 2013/14. This is likely and cane price t.1.84 While Indian 2.55 operating 3.49in the red 0.26 0.21 2012/13. 2013 to January 2014, of which only to increase to 12.8 mtrv in 2014/15 have piled up, which together alling 3.33 modestly 42.34 arrears38.47 36.08 35.16 Compared with with falling cane prices Czarnikow 2014 F.O.Licht GmbH enticed Oceania since reaching the sugar produced from October 1, 313according to Czarnikow. In Queensland, Australia, unsea Source:

rice and cassava, sugarcane continues campaign has delayed harvestin to be a profitable crop for farmers. Thailand produced 11.6 mln tonnes eded domestic try's output for left the unchanged purpose ofat this – consumptionOceania exceeding has production been of2014/15 sugar inbalance 2013/14,sheet just fractionally the fourth the first week EU – 2014/15 sugar production is of June. dings; consumption excluding disappearance February’s 4.6 mln tonnes, which below unrecorded our February forecast of 11.7 2013/14. Also, forecast at 17.7 mtrv, up by almost 5% would be down somewhat from 5.0 mln and up considerably from the be expected to on last year as producers battle for mln last year. previous year’s 10.3 mln tonnes. It is Consumption in industria evel as farmers market share ahead of the abolitiongrowth of Australia's sugar production is 2014 F.O.Licht 313quotas in 2017.developing countries is 2%, not self-understood that GmbH this volume ne despite the seen falling to 4.4 mln tonnes in represented a new record as crushing ancial situation 2013/14 from 4.8 mln a year earlier. US – Sugar production anticipated to where issugar consumption grow was aided by dry conditions and high as cane prices Harvesting in Australia has started decline 5.5% to 7.7 mtrv compared with sugar content. Farmers have been mpared to other gradually from 4.7% in 2013 to earlier in June, with large-scale last year. sticking to cane due to high cane herefore likely processing taking place from July growth is projected to drop fract prices aided by government sops. exceeding 2014/15 balance sheet – consumption production ent in 2014/15 onwards to October before Source: Czarnikow production volumes drop off Source: Czarnikow significantly up to the end of the rld Sugar Consumption calendar year. The number for (mln tonnes, raw value) 2013/14 therefore includes the tail 6 International Sugar Journal | August 2014 end of last year's crush and the better part of the current 2014 crush, which

farmers to switch to– consumption other crops. 2011/12, 8,314.2 the Source: Czarnikow 2013sugar onwards belongs to the coun2014/15 balance sheet exceeding 90.8 6,063.4 1,644.3 -3,393.3 Theproduction production estimate for

sugar INTERNATIONAL

Sugar Industry News

JOURNAL

For the latest sugar industry news visit www.internationalsugarjournal.com

Thailand – Khonburi sugar to spend US$133.3 million on sugar and ethanol plant

T

hailand’s Khonburi Sugar (KBS) will spend 4.3 billion baht (US$133.3 million) this year and next to expand sugar production capacity and build an ethanol plant Nakhon Ratchasima province.

a Smart Eye Colobserver ®

MCC3000

Pan Microscope

Color Analyzer

Monitor Crystallization in real-time* Follow crystal growth in the pan Improve crystallization process Measure crystal sizes (from 4 µm) Keep video records of the process Trigger out-of-specification alarms Acquire valuable statistical information

Track Sugar Production in real-time Manage your sugar color and quality Record video sequences on events Optimize centrifugal washing time Detect out-of-specification sugar Increase productivity and profitability Reduce water and power consumption

www.iteca.fr - [email protected] phone: +33 (0) 442 977 700

*Performance limitations differ from one application to the other, depending on the type of pan, the type of massecuite, the type and density of crystals and seeds quantity.

www.internationalsugarjournal.com

7

Sugar Industry News

Austrian researchers produce erythritol from straw

R

esearchers at the Vienna’s University of Technology have been successful in producing the sugar alcohol erythritol from cereal straw and mould fungi Trichoderma reesei. Up until now, erythritol could only be produced with the help of special kinds of yeast in highly concentrated molasses.

Australia – Demise of the marketing body QSL in sight as Wilmar, MSF and COFCO decide to go it alone

T

he Australian unit of Chinese agribusiness COFCO Corp which owns Tully Sugar has joined Wilmar and MSF to stop selling sugar through the industry-owned marketing body Queensland Sugar Limited (QSL) from 2017.

British Sugar actively encouraging female engineering graduates to join the company

W

omen engineering graduates recently got the chance to learn about opportunities in the beet sugar industry at an event organised by British Sugar.

8

International Sugar Journal | August 2014

     

France - 2014/15   beet yield hitting fresh record

WORLD  LEADERS  IN  CANE  SUGAR   TECHNOLOGY  

F

rench sugar beet yields this year could be among the highest on record thanks to timely spring rains, which boosted most seedlings in early growth stages, Yves Belegaud, director for the country's top sugar maker Tereos told Reuters.

Ethiopia - Seven new sugar factories to start production in 2015

E

thiopia expects seven of the 10 sugar factories the government plans to develop in the first phase of the Growth and Transformation Plan (GTP) to start operating by end of 2015, according to the country’s sugar body reports UKRAgroConsult.

 

BWEL  HAS  A  WIDE  VARIETY  OF  PRODUCTS   AND  SERVICES  AVAILABLE   • • • • • • •

Turn-­‐key  project  up  to  complete  Cane  Sugar   Factories   Cane  Preparation  and  Milling  Equipment   Process  House  Equipment     Co-­‐generation  Projects     Quality  Spare  Parts  and  Mill  Rollers   Steel/Iron/Bronze  Castings   Visit  our  website  for  more  information    

 

www.bundabergwalkers.com.au   PO  Box  12,  Bundaberg,  Qld  4670  Australia   Works:  Gavin  Street,  Bundaberg,  Qld  4670  Australia   Phone:        +61  7  4150  8700   Fax:  

+61  7  4150  8711  

   Email:  [email protected]   www.internationalsugarjournal.com

9

Sugar Industry News

'Land grabbing' has the potential to expand cane production by 148%

C

rops grown on "land-grabbed" areas in developing countries could have the potential to feed an extra 100 million people worldwide, a new study has shown.

Vietnam - 2013/14 sugar output seen at 1.59 mln t

T

he 2013/2014 campaign in Vietnam has ended, with output reaching 1.7 mln tonnes of sugar, white value, including 1.59 mln from cane and the rest from refining raw sugar, the Vietnam Economic Times reported.

Russia - Sucden plans U$100 mln investment to expand beet sugar output

S 10

ucden plans to invest $100 mln expanding its Russian sugar beet production to meet growing demand, its local country chief, Etienne Pelletier, told Bloomberg.

International Sugar Journal | August 2014

Born to find out

Sucrolyser It‘s about the combination 4 Automated analysis of raw, intermediate and final products in sugar manufacturing 4 For: Sugar content (%Pol), dry substance (°Brix), apparent purity 4 Analysis of strongly colored samples 4 Compliant with ICUMSA, OIML and Australian Standard K157 4 Results for both sugar content (°Z) and apparent purity due to the combination of MCP polarimeter and Abbemat refractometer

ISJ_Sucrolyzer_.indd 1

Anton Paar® GmbH [email protected] www.anton-paar.com

14.07.14 14:49

Fiji – Prison inmates exploited to harvest sugar cane

I

nmates from the Fiji Corrections Service were used during the last cane campaign. They earned about FJD$200,000 (US$109,000) from harvesting sugar cane last year, according to the Fiji Times online.

www.internationalsugarjournal.com

11

Sugar Industry News

Dominican Republic - San Pedro cogen plant to be operational by Sep 2015

N

ational Energy Commission (CNE) director Enrique Ramírez and technicians recently inspected the construction of the San Pedro Bio Energy biomassfired power plant, which will be the country's biggest such facility, with the capacity to produce 30 MW from bagasse, according to local press reports.

Pakistan - Mills fail to export quota

P

akistan's sugar mills have failed to export the whole quota of 250,000 tonnes of sugar permitted by the federal government in the stipulated period of almost one month from May to June, as 110,000 tonnes of sugar is still lying in warehouses meant for export, according to local press reports.

Uganda - 2014/15 sugar output forecast to rise 13%

U

gandan sugar production is projected to hit a record high this year, on the back of expansion in acreage and mill capacity, the Uganda Sugar Manufactures Association said.

United Kingdom - Coca - Cola to launch stevia - sweetened soda in September

C

oca-Cola aims to battle falling fizzy drinks sales in mature markets with stevia-sweetened soda that will have its European launch in the UK, the FT reported.

12

International Sugar Journal | August 2014

Bangladesh Sugar output rises 20% in 2013/14

B

angladesh's sugar output in 2013/14 rose 20% from a year ago at a time when the state procurement agency is struggling with huge stocks of unsold sweetener amid rising raw sugar imports by private refiners, Reuters reported.

Spain - Acor and ED&F Man form Iberlíquidos to market molasses and sugar by-products

S

ugar producer Acor and ED&F Man announced in late April the formation of a joint venture, Iberlíquidos SL, to market molasses and other sugar by-products, along with other liquid raw materials, under the trademark "Sugar Plus".

www.internationalsugarjournal.com

13

worked in the AB Mauri division o Foods (ABF), latterly as VP Northe general management and finan

Steve will ensure that Germains f customers and ensure the appro market requirements.

People and Places

Steve Moon – Germain’s new Managing Director Steve  Moon  –  Germain’s  new  Managing  Director  

Steve Moon

 

Steve Moon joined Germains as Managing Director/CEO in May 2014 from British Sugar where he was Commercial and Supply Chain Director. Prior to this role Steve worked in the AB Mauri division of Germains’ parent company, Associated British Foods (ABF), latterly as VP Northern Europe. Previous to ABF, Steve undertook various general management and finance roles with Unilever. Steve will ensure that Germains focus on delivering the best solutions for their customers and ensure the appropriate strategies are in place to address future market requirements. Alan du-Rieu also recently joined Germains. He is the Commercial Manager. He comes with extensive Alan du-Rieu experience in Asia which includes stint with Syngenta.

Steve Moon joined Germains as Managing Director/CEO in May 2014 from British Sugar where he was Commercial and Supply Chain Director. Prior to this role Steve worked in the AB Mauri division of Germains’ parent company, Associated British Foods (ABF), latterly as VP Northern Europe. Previous to ABF, Steve undertook various general management and finance roles with Unilever.

(Please crop the picture to includ

Steve will ensure that Germains focus on delivering the best solutions for their customers and ensure the appropriate strategies are in place to address future market requirements.

Alan du-Rieu also recently joined comes with extensive experience  

(Please crop the picture to include only Alan – in the centre) Alan du-Rieu also recently joined Germains. He is the Commercial Manager. He comes with extensive experience in Asia which includes stint with Syngenta.  

14

International Sugar Journal | August 2014

www.internationalsugarjournal.com

15

Obituary

Obituary – Desmond Leighton (1927-2014)

Desmond Leighton (1927-2014) Desmond Leighton passed away peacefully on the 27th June 2014 aged 86 years. He had spent the majority of his working life as editor of this journal. Desmond was born in Seaton Delaval near Newcastle in 1927, but 3 years later his parents moved to west London to start a new life. Desmond worked hard at school, determined to carve out a good education despite the onset of the Second World War. After leaving school, he committed to getting himself a degree although circumstances dictated that he do so by going to night school while also working full time. Desmond obtained a BSc in Chemistry from the University of London and went on to become a Fellow of the Royal Institute of Chemistry. It was while working in industrial chemical research at Park Davies Laboratories that he met Valerie Parker, whom he married in 1949. In 1951 Desmond joined the staff of the International Sugar Journal, whose offices in those days were in Central London, close to the site of the Great Fire. By 1957 Desmond had became ISJ’s editor, a post he held until his retirement in 1992, by which time he had also acquired an ownership interest. By then the ISJ had moved, first to High Wycombe and then in the mid 1980’s to Port Talbot in South Wales. The publication had a small but long-serving and loyal staff led by Desmond, whose expertise regarding the sugar industry was matched by his impressive linguistic abilities; during his more than 40 years with the ISJ he became fluent in French, German, Spanish and Italian,passed and hadaway a working knowledgeon of the Portuguese. Desmond to attend international conferences Desmond Leighton peacefully 27th June 2014 travelled aged 86widely years. He had connected with the sugar industry and regularly visited many of the major sugar producing countries to stay abreast of spent the majority of his lifeinnovation as editor of this journal. operational and working technological in the industry. This information would then find its way into the features and editorial pages of the ISJ, to ensure its readers were up to date and well informed. Keen to pass on his knowledge to younger generations, Desmond also wrote a book entitled “Sugar” which was published as part of the World Resources Desmond was born in Seaton Delaval near Newcastle in 1927, but 3 years later his Series in 1977. very many friends within the sugar industry. He remained in touch with a good number of them parents movedDesmond to westmade London to start a new life. Desmond worked hard at school, even following his retirement and relocation to the warmer climate of the south of France. Since his passing many have how amuch theyeducation enjoyed his despite company the and his dry sense of humour. was wellWar. liked and respected in the determined commented to carve out good onset of the SecondHeWorld industry, by friends and colleagues who describe him as having been an ‘old fashioned gentleman’; unfailingly polite and After leaving school, he hewas committed getting himself a degree although circumstances considerate, completely to reliable, honest and kind. Desmond lost his wife Valerie in 2011, after 62 happy years of marriage, but he is survived by his four children, five dictated thatgrandchildren he do so by going to night school while also working full time. Desmond and two great granddaughters. He will be sadly missed by all his family and friends. his life Desmond numerous charities but was especially keen on the obtained a BSc[Throughout in Chemistry from thesupported University of London andhe went on to become a work of Barnardo’s. A donations page has been set up at www.justgiving.com/desmondleighton.]

Fellow of the Royal Institute of Chemistry. It was while working in industrial chemical

research at Park Davies Laboratories that he met Valerie Parker, whom he married in 1949. In 1951 Desmond joined the staff of the International Sugar Journal, whose offices in those days were in Central London, close to the site of the Great Fire. By 1957 Desmond had became ISJ’s editor, a post he held until his retirement in 1992, by which time he had also acquired an ownership interest. By then the ISJ had moved, first to High Wycombe

16

International Sugar Journal | August 2014

Providing innovative thinking Fornecendo ideias inovadoras and quality, cost efficient e soluções de alta qualidade e solutions. baixo custo. Sugar:

#3(&%"6A3)@8'-$B

6-'%(2B

!"#$%&$'()*"+,&--)-("."/'&0)1),)$2"#$34)'0 !"Project Structuring and Funding !"5'0)(-"."6-()-''%)-( !"Project Delivery !"Operations Management

!"C94'%-"D'*=-9,9(2 !"Proven Performance !"Design Flexibility !"6-'%(2"6EE)*)'-$ !">,91&,"#3@@,2

!"L9M('-'%&$)9!"Feasibility Studies !"Biofuel Distilleries !"Consulting Services

Açúcar:

6A3)@&8'-$90"@&%&"F;G*&%B

6-'%()&B

! +,&-'7&8'-$9"60$%&$:()*9"'"60$3490" de Viabilidade !"60$%3$3%&;,91&,

!"L9('%&;99.2  Pol)  to  produce  refined  sugar   of  an  average  25  colour  (ICUMSA).  The  process  (refer  Figure  1)  includes  affination,  melting,   Phosphatation  clarification,  filtration,  ion  exchange,  crystallisation,  centrifugation  and   drying.     Figure 1. Unit Operations at MHS Refinery

Introduction

 

The Manildra Harwood Sugars   (MHS) Refinery was commissioned in 1989. It is attached to the raw sugar   mill at Harwood Island and has a melt capacity of 260,000 tpa at a melt rate   of 34tph. The refinery processes very high pol Raw Sugar (>99.2 Pol) to   produce refined sugar of an average 25 colour (ICUMSA). The process   (refer Figure 1) includes affination,   melting, Phosphatation clarification, filtration, ion exchange, crystallisation,   centrifugation and drying.

Affination  

Raw  Sugar  99.2Pol,   1600  ICU  

Affined  Sugar   800  ICU  

Melting  

Melt  Liquor    

Phosphatation  

Clarified  Liquor  600  ICU  

Clarified  Liquor    

Filtration  

Filtered  Liquor  600  ICU  

Filtered  Liquor    

Ion  Exchange  

Fine  Liquor  200  ICU  

 

Continuous Improvement and   MHS  

In 2010 the management at MHS Refinery decided to introduce the   concept of continuous improvement (CI) into the business. This process was  

Crystallization  

Centrifugation  

Figure  1  –  Unit  Operations  at  MHS  Refinery  

32

International Sugar Journal | August   2014

Drying  

Refined  Sugar  25  ICU  

Mike 25/6/

Comment 8235  hours  a refineries  pro

It’s in Our Nature

to improve all facets across the business with the intention of gaining savings and productivity improvements. The concept of continuous improvement is associated with teaching new problem solving skills. Companies such as Toyota have used the CI process which has transformed its workplaces to a more satisfying environment; which in turn has increased the morale and the productivity of the workforce (McBride). Similar outcomes were anticipated at MHS. Three pilot projects were identified at the initial stage and a further four projects at the second stage. ‘Best Practices at Centrifuge Station’ was part of the second stage of projects.

The CI Project Refined sugar pan yield is a critical key performance indicator in a sugar refinery. The yield is largely influenced by the performance at the centrifuges and at the pan stage. Any reduction of the performance at the centrifuges will see a lower pan yield and additional expenditure on steam and electricity due to higher recycle streams. The refined sugar pan yield is calculated on a weekly basis by dividing the total refined sugar produced by the number of pans produced for the week. Refined sugar pan yield prior to the CI project was averaging 24.5t of sugar per strike (50t of massecuite); this equated to 53.3% in terms of yield (dry solids basis). The aim was to increase this up to 25.5t of sugar per strike or 55.4% in terms of yield. This is a 2.1% increase.

Innovative and efficient centrifugal separation technology from GEA Westfalia Separator Group for the production of bioethanol and sugar.

GEA Westfalia Separator Group GmbH Werner-Habig-Straße 1, 59302 Oelde, Germany Phone: +49 2522 77-0, Fax: +49 2522 77-1794 [email protected], www.gea.com

engineering for a better world www.internationalsugarjournal.com

33

RR-03-010

GEA Mechanical Equipment

Challenges and potential solutions for storage of large quantities of bagasse for power generation*

BS Purchase, S Rosettenstein and DV Bezuidenhoudt

Bosch Projects, PO Box 2009, Durban, 4000, South Africa

Contact author:

[email protected] | [email protected] | [email protected]

Abstract Prolonged storage of large quantities of bagasse for off-season power generation presents challenges different from those associated with small-scale storage or large-scale, wet storage for pulp and paper production. The challenges include loss of fuel value, spontaneous combustion, bagasse handling and a variety of health and environmental impacts. Experiences with these challenges in Australia and Brazil are reviewed and suggestions made for alternative storage methods. Theoretical requirements for good storage are outlined. The possible special requirement of pasteurised bagasse from diffusers is highlighted.

Keywords: bagasse, storage, power generation, bagassosis, combustion, diffuser bagasse

Introduction The increased demand for renewable energy has created opportunities for selling energy derived from bagasse. The simplest route to such energy is combustion accompanied by steam and electricity generation. For commercial success, it is important that the expensive capital equipment is used throughout the year despite the seasonal production of bagasse. This dictates that bagasse be stored for use during off-crop, or that an alternative fuel be used during off-crop. In most cases it is not viable to use an alternative fuel, therefore storage of large quantities of bagasse is a requirement. Very large quantities (>100 000 t) may be involved in cases where an optimised (high pressure) power generation unit draws surplus bagasse from a number of surrounding factories. The storage of large quantities of bagasse presents challenges that are not faced by the existing small-scale, short-term storage systems that are operated by factories for use during start-ups and short stoppages. It might be assumed that experience with large-scale storage systems has been developed in countries like Mauritius and India, where off-crop power generation takes place. In these countries, however, most of the mill-based generation systems form an integral part of the national power supply, so they are sized to burn all the bagasse as it is produced and to then use coal during off-crop. There is thus no need to store bagasse. Knowledge based on large-scale storage at pulp and paper factories is of limited value because the bagasse is stored in a

34

International Sugar Journal | August 2014

water-saturated state. The storage system delivers bagasse that is too wet for combustion. The trend towards power generation from bagasse has been accompanied by progress in developing other large-scale uses for the material, e.g. ethanol production (www. betarenewables.com) and bagasse-to-fuel via small-scale Fischer-Tropsch technology (www.oxfordcatalysts.com). Most of these other uses require minimum water in the bagasse and maximum preservation of the fuel components. They add to the need for effective nonsaturated storage techniques. This paper highlights the new challenges and gives perspectives on storage systems and their potential for large-scale application.

www.internationalsugarjournal.com

35

Falling-film evaporator plant for a cane sugar factory: Presentation of the concept and operating results* Contact author:

A. Lehnberger1, F. Brahim1 and S.S. Mallikarjun2

BMA Braunschweigische Maschinenbauanstalt AG, Germany 2 Indian Cane Power Ltd, India 1

[email protected] | [email protected]

Abstract In the cane sugar industry, Robert evaporators are generally considered the preferred evaporator design because of the issues associated with the scaling of heating surfaces. An evaporator set concept has been developed in collaboration with a supplier to utilise falling-film evaporators in the cane sugar industry in order to benefit from the numerous advantages of this technology. In 2011, a new 5-effect evaporator set composed entirely of falling-film evaporators was designed, supplied and commissioned for the Indian Cane Power Limited (ICPL), Uttur, a sugar cane factory located in the State of Karnataka, India. The design targets for this evaporator plant were smooth operation of falling-film evaporators in the cane sugar industry, considerable reduction of the steam consumption of the sugar factory and clear increase of power export to the local power supply network. The supplier BMA accompanied this project with the preparation of mass and energy balances, process flow diagrams and process layout concepts. BMA also assisted with commissioning and chemical cleaning of the plant.

Keywords: falling film evaporator, scaling, cleaning, non-condensables

Introduction Nowadays, cane sugar factories are not only companies that produce sugar from sugarcane, but are increasingly also defining themselves as sellers of by-products. One such by-product is the cogeneration and sale of surplus electricity The cane sugar factory of Indian Cane Power Ltd (ICPL) in the federal state of Karnataka derives considerable economic benefits from feeding electrical power into the local grid, and the company is attempting to increase their co-generation proceeds by employing new technologies in sugar production and gaining surplus electricity from bagasse. In order to increase their power yield, ICPL is trying to minimise the specific steam consumption in the sugar production process. In ICPL’s original concept to increase cogeneration, the evaporation plant was equipped with Robert and falling-film evaporators, and used continuously operating vacuum pans in the sugar house. Since the new concept proved to be promising, the capacity was, as a second step, increased with a new 5-effect evaporation plant in 2011. The evaporation plant now entirely consists of falling-film evaporators, and the steam requirements for sugar

36

International Sugar Journal | August 2014

production have been further reduced by shifting the bleedings down to later evaporation effect and increasing the thick juice brix. Falling-film evaporators allow advanced steam-saving concepts to be implemented for sugar production. This publication shares the experience and results of a full evaporator set with falling film evaporators in a cane sugar factory with particular view to scaling and non-condensable gases, which both have a distinct heat transfer reducing effect in falling-film evaporators.

B* P

Massecuite * Magmas * Molasses *

Preferred solution worldwilde

240 t/h 180 t/h

New KX90

300 t/h

New KB90

New KMC90

360 t/h

150 t/h 120 t/h 60 t/h 40 t/h

Massecuite - Magmas

Cold molasses

X 120

X 90

X 60

X 40

X 20

X 10

B 240

B 120

B 90

B 60

B 20

B 40

B 10

B6

MC 240

MC 120

MC 90

MC 60

MC 20

MC 40

MC 6

15 t/h

MC 10

30 t/h

Process molasses

BROQUET PUMPS - 15 rue Jean Poulmarch - 95100 Argenteuil - France - www.broquetpumps.com www.internationalsugarjournal.com 37

How to manage sugarcane in the field and factory following damaging freezes*

B. Legendre1, G. Eggleston2, H. Birkett1, M. Mrini3, M. Zehuaf3, S. Chabaa3, M. Assarrar3 and H. Mounir3

Audubon Sugar Institute, Louisiana State University Agricultural Center, St. Gabriel, Louisiana, USA 2 SRRC-USDA-ARS, New Orleans, Louisiana, USA 3 Sucreries Raffineries De Cannes (SURAC), Morocco 1

Contact author:

[email protected]

Abstract Exposure of sugarcane to damaging frosts occurs in approximately 25% of the sugarcane producing countries world-wide. A series of damaging freezes, –2.6, –3.3 and –2.1 °C, occurred in Morocco on 4, 5 and 13 February 2012, respectively, only 2 weeks after the commencement of the harvest season. Furthermore, the sugarcane had not reached maturity with factory sugar recovery yields under 8.0%. The use of pH (litmus) paper in the field is considered a good indicator of possible deterioration of the juice when the pH is 5.0 or less, and can be used to define the level of topping to remove the deteriorated portion of the stalk prior to milling. In all, thirty fields of the three leading varieties, CP 70-321, CP 66-346, and L 62-96, were inspected. Only 13% of the fields had a juice pH of 5.0 or less which was generally limited to the uppermost internodes. The worst damage occurred in fields with cane yields of < 40 t/ha, regardless of variety, and which had received no irrigation water and were harvested after June 2011, the previous year. Concentrations of mannitol and/or dextran in the juice are much more reliable indicators of sugarcane Leuconostoc deterioration. Because of high levels of brown leaves (>10%) in delivered cane, there were high levels of polysaccharide found in the juice that contributed to the measurement of high haze dextran levels; however, the absence of mannitol confirmed little or no deterioration had occurred from the growth of Leuconostoc. The key to success in reducing significant losses through deterioration when freezes occur are good management and close cooperation between growers and processors. Final recommendations on how to manage a freeze in both the field and factory are described.

Keywords: freeze deterioration, Leuconostoc bacteria, mannitol, dextran, brown leaves

Introduction The exposure of sugarcane to damaging freezes occurs in approximately 25% of the sugarcane producing countries worldwide. The frequent winter freezes in the sugarcane area of the state of Louisiana in the United States forced the industry to adapt to a short growing season (about 7 months) and a short milling season (about 3 months). This is generally not the case in Morocco where damaging freezes are rare with the harvest season commencing in January and ending in July/August. The nature and extent of damage to sugarcane by a freeze depends on the intensity and duration of the freeze, and the

38

International Sugar Journal | August 2014

weather condition after the freeze can control and accelerate deterioration (Table 1). Varietal differences often determine the rate of deterioration following a freeze (Irvine and Legendre, 1985). Lower topping removes soured, freeze-damaged tissue and improves sugar quality since high acidity and dextran are not found in the undamaged part of the stalk. There is also a strong varietal response for sugar quality after cane is frozen (Irvine and Legendre, 1985). Furthermore, when all the tissues of varieties are completely frozen, the varietal differences may last two or more weeks after the freeze.

World Champion results. Let hops take you to the top. BetaTec‘s smart sustainable alternative to synthetic chemicals and antibiotics will make it easy to maximise profitability and minimise losses. Our naturally-derived hop products for controlling bacteria and accelerating fermentation come with full on-site support to offer you cost efficient, tailor-made solutions.

Bahnhofstr. 20 • 91126 Schwabach • Germany Phone: +49 (0)9122 87 301-0 • Fax: +49 (0)9122 87 301-30 [email protected] • www.betatec.eu

www.internationalsugarjournal.com

39

3 ISRMAX Sugar Asia 2014 rd rd

(Sugar Expo & International Conference)

Conference Title - Integrated Approach to Sustainable Development of Sugar Industry

29-31 August 2014

IMPACT Exhibition and Convention Center, Bangkok, Thailand

IMPACT

Reasons to Attend

Who Should Attend

 A comprehensive exhibition on agriculture, sugar, co-generation and Ethanol industries-chemicals, machineries, spare parts, process control equipment etc.  Listening to industry leaders & experts.  Interfacing with technology providers.  Exposure to emerging technologies & new ideas for production, processing and value addition.  B2B event providing opportunity to meet serious business partners with one to one interactions.  Opportunity to interact with the who’s who of the sugar industry.  Developing contacts & exploring business opportunities.

 Sugar, Co-generation, Alcohol &

Organizers Pixie Consulting Solutions Ltd.

INDIA

MUANG THONG THANI

THAILAND

www.isrmaxasia.net 40 International Sugar Journal | August 2014 facebook.com/ISRMAXAsia

Ethanol manufacturers.

 CEO’s, Heads of Engineering, Process

& Agriculture departments. institutions, R&D Professionals.  Professionals in sugar engineering technology & agriculture.  Consultants working for the sugar & allied industries.  Local equipment manufacturers for possible tie-ups & joint ventures.  Associations of sugar & allied industry.  Government organizations, policy makers.  Banks & financial institutions  Merchants &traders.  Overseas manufacturers.  Research

For Further Information on Opportunities of Participation as Sponsor/Exhibitor/Delegate or Visitor Please Contact

Ashish Agnihotri Mobile: +91 9991705001 | Email: [email protected]

www.internationalsugarjournal.com

41

The Crompion LLT Clarifier: A Sweet Solution As the world's sugar producers patiently await to see what the global market has in store for their year's labors, many are looking to the future for more efficient, cheaper ways to operate successful and profitable businesses. The global sugar industry recently received an answer thanks to next generation technology that will sweeten the taste of the world sugar market - The Crompion Louisiana Low As the world's sugar producers patiently await to see what the global market has in store for their year's labors, many are looking to the future for more efficient, cheaper ways to operate successful and profitable businesses. The global sugar industry recently received an answer thanks to next generation technology that will sweeten the taste of the world sugar market - The Crompion Louisiana Low Turbulence (LLT) Clarifier.

temperature. This provides more degassing area compared to an external flash tank of equivalent capacity, and a smaller footprint than an external flash tank of comparable capacity, while simultaneously reducing the possibility of air entrainment. The second patent-pending design pertains to the fluid distributors, or Turbulence Reduction Devices (TRDs), which significantly reduce fluid velocity and eliminate turbulent eddies inside the clarifier, enhancing the clarification operation. As a result, superior juice quality can be obtained at much shorter residence time.

Crompion International is a Louisiana-based, globally operational leader in providing specialty stainless solutions and consulting services to a broad range of industries - including Themanufacturer second patent-pending design pertains to the fluid distributors, or Turbulence sugar. As the world's leading and distributor of Reduction Devices significantly reduce fluid velocity and Cromgard high-performance stainless steel products,(TRDs), Crompion which As a consequence of these two clarifier design additions, the eliminate International prides itselfturbulent not only on selling specialty products, Crompion LLT Clarifier provides shorter retentionoperation. time, reduces As a res eddies inside the clarifier, enhancing the clarification but on understanding how sugar producers use these products. sucrose losses and provides juice of high quality compared to superior juice quality can be obtained at much shorter residence time. other clarifier available in the industry. In addition, the Crompion In order to improve customer efficiency and productivity, LLT Clarifier is built with Cromgard Specialty Stainless Steel, through two patented technologies developed with strategic which increasesdesign abrasion resistance and reduces corrosion, LLT Clarif As a consequence of these two clarifier additions, the Crompion partners, Crompion International has developed products that leading to less maintenance needs. provides shorter retention time, reduces sucrose losses and provides juice of high are dramatically evolving the sugar industry - The Crompion LLT quality compared to other clarifier available in the industry. In addition, the Cromp Clarifier and the Crompion LLT Filtrate Juice Clarifier. A top and side view of the Crompion LLT Clarifier can be LLT Clarifier is built with Cromgard observedSpecialty in figure 1. Stainless Steel, which increases abr resistance and reduces corrosion, leading to less maintenance needs. In conjunction with the Louisiana State University (LSU) AgCenter's Audubon Sugar Institute and global sugar industry The Crompion LLT Clarifier reduces juice turbidity at a retention specialists, Crompion International has developed these new time of 30 minutes or lower. Industrial trials in which the A top and side view of the Crompion LLT Clarifier can be observed in figure 1. types of low-residence time clarifiers for the clarification of cane juice.

Figure 1. The Crompion LLT Clarifier

The first is the Flash Trough, built into the LLT clarifier and providing more degassing area compared to an external flash tank of equivalent capacity. In the clarification process, a flash tank is often employed to remove the non-condensable gases and ensure a constant temperature of the juice. The flashing operation is very important in order to achieve proper clarification of the juice; however, in many factories it is overlooked, reducing the clarifier’s performance (e.g. excessive presence of bagacillo and increased turbidity in the clear juice). The Crompion Flash Trough guarantees proper removal of all the non-condensable gases entrained in the juice that can affect the operation and will send the juice to Journal the clarifier at a constant International Sugar | August 2014 42

Figure 1: The Crompion LLT Clarifier.

Figure 2. Layout of the TRD inside the Clarifier.

is shown in Table 1. Compared to the SRT, the Crompion LLT Clarifier can save approximately $43,282 per every million tons of cane milled, this value triples when the Crompion LLT is compared to the Graver Type clarifier, saving up to $129,847 per every million tons of cane.

Table 1. Inversion estimations in different types of clarifiers LLT Price of Sugar (¢/lb)

SRT Type

Graver Type

21

Residence Time (min)

30

60

120

Sugar Inverted (g/100 g Sucrose)

0.04

0.09

0.18

Juice Purity (%)

85

85

85

Total Sucrose Lost (metric ton/ million TC)

93.5

187

373.9

Total Losses ($/Million TC) 43,281 86,563 173,127 Crompion LLT Clarifier was run side-by-side with alternative Figure 2: Layout of the TRD inside the Clarifier. Total Gain ($/Million TC) 43,282 129,847 clarifier designs validate these results. The majority of clarifiers still in use today have a retention span in the range of one to In addition, another application of the LLT Clarifier is Filtrate two hours. Some of the new “best technology” clarifiers range LLT Clarifier's residence timetests results in less sucroseClarification. destruction Filtrate Clarification has many benefits: reduction of betweenshorter 45-60 minutes. Commercial have demonstrated sucrose inversion by avoiding recirculation, which is detrimental thatresidence the Crompiontime LLT Clarifier design outperforms the ation. With at a minimum of 30 minutes, it is estimated the process; increase in clarification capacity of the main conventional designs in terms of turbidityclarifier levels. y saved on sugar loss from a traditional could pay fortothe clarifier by 15 to 20%; and reduction of invert sugars, which can Clarifier The in just over a year. Because of the shorter residencelead time, heat to additional color generation in the factory. Crompion LLT Clarifier operating principle consists of a o reduced, which results in energy uniform pathway for the juice inlet,savings. which evenly distributes the For this reason, the company has also introduced the Crompion juice to several end-points uniformly positioned around the cross LLT Filtrate Juice Clarifier, which was designed to produce a sectional area of the clarifier. After this, the juice reaches the mpion LLT Clarifier uses less steel, and the capital outlay of the new residence time in clear juice of approximately 8-10 minutes, a end-point of the pipe where a patented Turbulence Reduction mated to be significantly less than that of alternative conventional designs. significantly lower residence time than that of many clarifiers Device is installed to reduce the turbulent eddies present in the ard designs availablethefor mills of(figure different sizes. Additionalcurrently long-term operating in the industry (45 to 120 min). The results juiceare by dissipating momentum 2). obtained e realized by using Crompion International's high-performing, cost- during the initial trials have shown the removal of The Crompion LLT Clarifier's shorter residence time results in gard Specialty Stainless Steel to build the new Crompion LLTapproximately clarifier. 95% of suspended solids. less sucrose destruction and color formation. With residence Utilizing the Crompion LLT Clarification technology to achieve time at a minimum of 30 minutes, it is estimated that the money nce of thesaved Crompion Clarifier has been lowclarifiers residence times, the Crompion LLT Filtrate Juice Clarifier on sugarLLT loss from a traditional clarifier compared could pay for to the other operating principle consists of a uniform pathway for the juice Crompion LLT Clarifier in just over a year. Because of the shorter na conditions, which are characterized by high mud content in cane that inlet, which evenly distributes the juice to several end-points residence time, heat losses are also reduced, which results in h as 15%. The typical residence time achieved in a Crompion LLT Clarifier positioned around a cross-sectional area of the clarifier. The energy savings. en 25-30 minutes, compared to the Graver and Dorr type clarifiers, which juice then reaches the end-point of the pipe where the TRD is installed to reduce the turbulent eddies present in the juice by Themore new Crompion LLT time Clarifier uses the less Crompion steel, and the LLT capitalClarifier. 350-400% retention than dissipating of the new is estimated to be significantly less 30 and ompared outlay to a SRT typedesign clarifier that can range between 60 the momentum. than that of alternative conventional designs. Several standard rompion designs LLT clarifier has between 50 and 100% less retention time. Filtrate juice, which accounts for roughly 15 to 20% of the mixed are available for mills of different sizes. Additional longjuice produced in a raw sugar factory, is typically recirculated term savings may be realized by using Crompion International's longer the retention times in the clarifier, the higher the inversion of through the original clarifier. This recirculation is detrimental high-performing, cost-efficient Cromgard Specialty Stainless stimation Steel of the sugar generated to the process and leads to a reduced clarification capacity; to build the inversion new Crompion LLT clarifier.in each of the previously higher sucrose losses, caused by inversion or microbial activity; ifiers is shown in Table 1. Compared to the SRT, the Crompion LLT as well as color generation and increased turbidity, due to the The performance of the Crompion LLT Clarifier has been ave approximately $43,282 per every million tons of cane milled, this recirculation of very fine particles. compared to other clarifiers under Louisiana conditions, which are characterized by high mud content in cane that can be as In addition, the Filtrate Juice Clarifier also uses the same builthigh as 15%. The typical residence time achieved in a Crompion in flash trough as the Crompion LLT Clarifier for enhanced LLT Clarifier ranges between 25-30 minutes, compared to the degassing of juice. Graver and Dorr type clarifiers, which have between 350-400% more retention time than the Crompion LLT Clarifier. Additionally, The Crompion LLT Clarifier technology will undoubtedly benefit compared to a SRT type clarifier that can range between 30 sugar mills due to its ability to provide savings as a result of and 60 minutes, the Crompion LLT clarifier has between 50 and both sugar loss reduction and reduced energy usage, the lowest 100% less retention time. cost design made of high performance Cromgard Stainless Steel Moreover, the longer the retention times in the clarifier, the and the lowest turbidity juice and residence time to reach the higher the inversion of sucrose. An estimation of the sugar global sugar market. inversion generated in each of the previously discussed clarifiers

www.internationalsugarjournal.com

43

Falling film evaporators in cane industry Alexandre Mesmacque | Fives, France Email: [email protected]

www.fivesgroup.com

Figure 1. Main components of the falling film evaporator

Introduction The falling film evaporator has been widely used in the beet sugar industry for more than 30 years. This technology has been adapted and optimized for cane sugar factories addressing the increased risks of incrustation of the juice distribution system and heating surface due to an increased scaling propensity of cane juice. The developments carried out by Fives on falling film evaporator permitted the elimination of these problems. Falling film evaporators are characterized by the simplicity of installation and maintenance. The absence of a hydrostatic head means that for the same thermal power, lower ΔTs are possible, especially for intermediate and last effects of the evaporator station. Thus, reconfigurations of the bleedings may be possible, achieving lower steam consumptions than can be obtained with different evaporator technologies.

Juice  distribution  system   (buse)  

Incondensable  gases  extraction   Protecting  skirt   Tubes  bundle  

Droplet  separator  

‘’Flash’’  and  juice  circulation  box   Juice  outlet  to  next  effect  

Design features of Cail & Fletcher falling film evaporator Figure 1 gives a schematic illustration of the falling film evaporator used in the cane sugar industry. The main parts constituting the evaporator are: • Upper section: juice distribution system • Central section: Tubes bundle, • Bottom section: Juice collection box and droplet separator

Juice  outlet  to  juice  pump  

                                         Figure  1:  Main  components  of  the  falling  film  evaporator Figure 2. Steam distribution in calandria

The Fives Cail calandria is equipped with a steam inlet located approximately halfway down bundle. In the steam input area, a skirt girdles all the tubes of the calandria with a height

metres. This skirt and the calandria are positioned off-center from the external shell, to

homogeneous distribution of the steam around the periphery of the calandria (Figure 2

arrangement produces a low mean velocity of steam entering the peripheral tubes with a v the range of 1.5 to 2 m/s, producing no mechanical stress on the tubes due to vibration, Central removal of incondensable gases

Off-centered tubes bundle

The Cail & Fletcher

44

International Sugar Journal | August 2014 Steam  inlet  

Central  removal  o

calandria is equipped Figure 3. Juice distribution system (schematic Figure 4. Juice distribution plate under with a steam inlet view) distribution tank located approximately halfway down the   tube bundle. In the steam input area, a skirt girdles all the tubes of the calandria with a height of 2 to 3 metres. This skirt and the calandria are positioned offcenter from the external shell, to allow a homogeneous distribution of the steam around the periphery of the calandria (Figure 2). This arrangement produces a low mean velocity of steam entering the peripheral tubes with a velocity in the range of 1.5 to 2 m/s, producing no mechanical stress on the tubes due to Figure  3  :  Juice  distribution  system  (schematic  view)            Figure  4  :  Juice  distribution  plate  under  distribution  tank     vibration, to the top of the evaporator and then distributed in three stages. Incondensable gases are extracted along a single central pipe, Stage 1: The juice supply is distributed by a star shaped feed drilled vertically along its length. This design permits efficient around thethe central vertical (seediscs, Figure 3). Each branch sweeping of the incondensable periphery through Stage 3: gases The from juicetheflows through thesesystem orifices onto centre of inlet small which have been of the star has a horizontal length which then bends at 90 degrees the tube bundle to the central pipe., arranged into a continuous plate as seen in Figures 4 and 5. The juice overflows the circumference of discharging onto a disc thus avoiding a direct fall into the tank. small disc onto the ligament of the The tubepurpose plate from overflows uniformly down Juice distributioneach system of thiswhere devicethe is tojuice distribute the juice evenly and at the a low rate as to cause minimal disturbances on the free surface of inner wall of the tubes. The main inherent technical issue associated with falling juice which is established in the upper distribution tank. film evaporators is the need for uniform juice flow along the Stage 2: The juice then flows through orifices located in the Figure 5 shows the measured distribution of wetting rate per tube. The Figure shows a normal tubes. It is critical that the entire heating surface is always fully of Figure distribution wetting5.rates with 80% of the tubes a wetting rate equal to the average wetting Distribution of juice in tubes in having Fives evaporators wetted with juice in order to avoid rate ± the relative standard deviation of approximately 30%. burning or caramelizing of the sucrose on the tube inner wall. Any dry sections could also result in failure in the tubes due to localized tube hot spots. Thus, a homogenous and sufficient juice feeding rate is required to ensure the correct wetting of each tube. For cane applications a good wetting rate is between 1000 and 1400 L/h per metre of circumferential length of tube. The entering juice (clarified juice or from the previous effect stage) is ‘’flashed’’ in the bottom part of the evaporator in order to avoid disrupting the feeding and distribution of juice which is 4     pumped to the upper part of the       evaporator. The juice is pumped     ISJ  2014   from the bottom of the evaporator

 

www.internationalsugarjournal.com

45

 

base of the tank. The number, size and position of these orifices are nominated in order to maintain a level within the distribution header, as well as to ensure an even and uniform distribution of juice through each opening. Stage 3: The juice flows through these orifices onto the centre of small discs, which have been arranged into a continuous plate as seen in figures 4 and 5. The juice overflows the circumference of each small disc onto the ligament of the tube plate from where the juice overflows uniformly down the inner wall of the tubes. Figure 5 shows the measured distribution of wetting rate per tube. The Figure shows a normal distribution of wetting rates with 80% of the tubes having a wetting rate equal to the average wetting rate ± the relative standard deviation of approximately 30%. This specific juice distribution system, described above, which has been developed following trials on a pilot experiment by Fives in collaboration with ONERA, has been patented.

Incondensable gases extraction Steam entering the calandria contains small amounts of incondensable gases (inerts), mainly air, ammonia, and carbon dioxide. As steam condenses, these gases tend to accumulate in the calandria unless removed. The presence of incondensable gases may affect thermal exchange between steam and juice in two ways: • The heat exchange coefficient between the steam and the tube outer surface is reduced. • The partial pressure of gases increases causing the partial pressure of the vapor to decrease and the saturated steam temperature to reduce, thus reducing the temperature difference across the heating surface. The extraction of incondensable gases developed by Fives, illustrated in figure 6, consists of a vertical pipe situated centrally with drilled holes along its length. The design of the system of extraction of incondensable gases, combined with efficient sweeping of the tube bundle by the steam flow achieves a maximum extraction of incondensable gases. Fives recommends a vapour/gas removal rate through the incondensable gas pipe of no less than 2.5% of the heating steam flow. Studies carried out by Fives in 2007 and 2008 [4] at the Le Gol site demonstrated the consequences of inadequate steam

sweeping. The global heat transfer coefficient may be reduced by 3.5% to 7% with a steam sweeping flow that is 50% less than the Fives recommendations.

Droplets separator A droplet separator is used to separate the juice droplets from the vapour. This type of separator, as illustrated in figure 7, is based on the establishment of a horizontal vapour flow through a set of vertical curved profiles (baffles). Inertia forces act upon the transported droplets as they are subjected to directional flow changes in the baffle vanes. This diverts the droplets from the original gas flow causing them to come into contact with one of surfaces of the separator (profiles) where they meet to form a film. This type of separator is more efficient than a centrifugal separator and is less prone to encrustation. The separator is cleaned by water sprays which are applied at timed intervals. To ensure an optimum operation of the droplets separator, the vapour flow must be uniform over the whole surface of the droplet separator. The design of Cail & Fletcher evaporator allows for an even distribution of vapour flow entering the droplets separator, with low dispersion around average velocities. The distribution of vapour flow as predicted by CFD modeling is shown in figure 7.

Figure 7. Distribution of inlet vapour flow in the droplets separator as predicted by CFD modeling

Figure 6. Extraction of incondensable gases

Residence time, sugar losses and juice coloration Morgenroth [1] illustrates, for a given effect, the total juice residence time in a falling film evaporator station is significantly less than the juice residence time in a set comprising the Robert evaporator type. Clear juice coloration is between 300 to 500% within Robert evaporator stations, in comparison with 10% to 20% with falling film evaporator stations, as per Morgenroth observes [1].

Heat exchange coefficient and steam consumption Figure 8 shows schematically the change in temperature required to achieve the flow of heat from steam to juice. The heat transfer coefficient h between the inside of the tube

46

International Sugar Journal | August 2014

ge coefficient and steam consumption

s schematically the change in temperature required to achieve the flow of heat from Figure 8. Temperature profile along the steam heating medium, flow condensing film, tube wall, flow juice film and finally bulk juice flow

Heating  steam  

   

Flowing  condensates  film   ruisselant  

Flowing  juice  film  

 

 

Table 1 presents the heat exchange coefficients from literature [2], for different technologies of evaporators for effects 1 and 2. Global heat transfer coefficient data for the different evaporator types operating in the beet industry were provided by Baloh [3]. These data are plotted in Figure 9. Also shown in this figure are data for four installations of the Fives falling film evaporators in the cane industry. The data suggests that the falling film evaporators will achieve similar heat transfer coefficients in the cane industry as for the beet industry. The good thermal performances obtained at Le Gol and Bois Rouge permitted both factories to extend their evaporation station to 6 effects. Steam consumptions at Le Gol site has since then been significantly reduced. Thus, with an average steam (2.7 bar abs and 150°C) consumption of 367 kg/t cane during season 2007 with the average steam consumption for previous seasons being 410 kg/t cane, resulting in an average of 10% steam savings.

wall and the boiling juice is the coefficient which

erature  plimits rofile   long   the  steam   heating  m flow  condensing  film,  tube  wall,  flow  juice  film   theaheat transfer in the evaporation of edium,   Figure 9. Heat transfer coefficients for different evaporator technologies cane juice. and  finally  bulk  juice  flow.

Global  heat  transfer  coefficient  (W/(m².°K)  

The studies carried out on the most recent installations of falling film evaporators supplied by Fives, which are installed in 1st sfer coefficient h between the inside of the tube wall and 2nd effects, have assessed the global ch limits heat thetransfer heat coefficients. transfer in the evaporation of cane juice.

A.Baloh measurements: 1 : Evaporator type Roberts and the boiling juice is the 2 : Evaporator type Kestner 3 : Falling film evaporator

arried out on the most recent installations of falling film evaporators supplied by Fives The global heat transfer coefficient Hg, as illustrated st in Figurend8, includes the thermal

Fives  Cail  trials  :  

installed in 1 and effects, assessed the global heat transfer coefficients. conduction heat 2transfer throughhave the tube wall and the scale on the heating surface, and the thermal convection heat transfer on the juice and steam sides. The global heat transfer coefficient is calculated according to the following formula :

7            

Hg = Φ/ (S.ΔT)

FUEL  (Mauritius  Island)  

Gardel  (Guadeloup    island)   Equipav  (Brazil)  

  ISJ  2014    

Le  Gol  (Reunion    i sland)  

With: Φ : Heat exchanged in W Φ = Latent enthalpy of inlet steam – Enthalpy of condensates - Losses Dry  substance  content  (%)   S : Heating surface in m², calculated on internal diameter of the tubes Figure  9  :  Heat  transfer  coefficients  for  different  evaporator  technologies   ΔT : Difference of temperature between heating steam and Falling film evaporator cleaning outlet juice in °K.

The good thermal performances obtained at Le Gol and Bois Rouge permitted both factories to extend

evaporators permit an efficient andhas safe since chemical The results obtained for the evaporation global heat exchange their stationcoefficient to 6 effects. Falling Steamfilmconsumptions at Le Gol site then been and/or mechanical cleaning. for the falling film evaporators ranged from 2800 to more than significantly reduced. Thus, with2.an average steam (2.7 barsystem abs and 150°C)onconsumption The same distribution described figures 3 and 4ofis 367 kg/ t 3000 W/m².°K when the evaporator is clean, for effects 1 and used to distribute the caustic soda for chemical cleaning. cane during season 2007 with the average steam consumption forsolution previous seasons being 410 kg/t This provides uniform distribution of the caustic soda across the cane, resulting an average of 10% steam savings. Table 1. Global heat exchange coefficientinW/(m².K) heating surface and consequently achieves effective cleaning of tubes. Type evaporator* 1st effet 2nd effet Falling2800-2500 film evaporator cleaning The installation of automatic valves allows for safe cleaning Robert * 1800-3000 operation. Automation of cleaning eliminates the risk of error Kestner * 2900 2100 relatedand to manual manipulation of isolating valves.cleaning. Falling film evaporators permit an efficient safe chemical and/or mechanical Falling film (plates)* 2600-3000 The mechanical cleaning is carried out by high pressure water The same described onbars; figures 3 and 4 after is used to distribute the caustic soda Falling film (tubes) 2800distribution - >3000 >system 2600 jet (800 Hydrojet type) opening of the manholes for *Rein (2007) and lifting of distribution tank.of the caustic soda across the solution for chemical cleaning. Thisaccess provides uniform distribution The design of evaporators allows the operators accessibility to

heating surface and consequently achieves effective cleaning of tubes.

The installation of automatic valves allows for safe cleaning operation. Automation of cleaning www.internationalsugarjournal.com eliminates the risk of error related to manual manipulation of isolating valves.

47

The mechanical cleaning is carried out by high pressurewater jet (800 bars; Hydrojet type) after

the tubes and the time required to clean one tube will not exceed References 30 seconds. [1] Boris Morgenroth, Darren Jayatilaka and Gary Punter (1997) : In all the cases, the periodicity of chemical and mechanical Development of plate evaporator technology, the market place and the cleanings will have to be optimized. As a matter of fact, it may choice for the sugar engineer. EuroTech Link 97, British Sugar not be easy to implement mechanical cleaning during the course [2] Rein, P. (2007): Cane sugar engineering, Verlag Dr. Albert Bartens, of the campaign, as it requires to stop the evaporator for a longer Berlin, p. 293 time than chemical cleaning, [3] Baloh, A. (1991): Energiewirtschaft in der Zuckerindustrie, Berlin, Verlag The ease of cleaning is an important asset of the falling film Dr. Albert Bartens, p. 283- 287 evaporator. [4] J.Coustel and G.Journet (2009): Falling-film evaporator performance Trials performed on falling film evaporators show the global results from two Reunion Island factories – ZuckerIndustrie, 134 (4): :225heat exchange coefficients is about 3000 to 3500 W/m².K when 228 the evaporator is clean and this reduces progressively during Trials performed on falling film evaporators show the global heat exchange coefficients is about 3000 operation. After 7 days, the evaporator is chemically cleaned to3500and W/m².K when the evaporator is clean reduces the initial performance is restored. Figureand 10 this presents the progressively during operation. After 7 of the heat transfer coefficient on a 14 weeks trial. days, progression the evaporator is chemically cleaned and the initial performance is restored. Figure 10   presents The data show that the cleaning of the evaporator is very effective the progression heat transfer and there is of no the cumulative effect ofcoefficient encrustation.on a 14 weeks trial. The data show that the cleaning of

the evaporator is very effective and there is no cumulative effect of encrustation. Figure 10. Heat exchange coefficient data for a 14 week period – Le Gol

Global  heat  exchange  coefficient  (W/m².°K)   Coefficient d'Echange (W/m2.°C)

5000 4500 4000 3500 3000 2500

Average  Brix  brix =  27.7%   moyen = 27,7 % Average  Δ T  delta_T =  5.2°C  moyen = 5,2 °C Average   evaporation  moyen rate  =  2=8.4   kg/h.m²   taux d'évaporation 28,4 kg/h.m2

2000 1500 1000 500 0 0

7

14

21

28

35

42 49 56 63 70 time  ((jour) days)   Durée Operation   d'Exploitation

77

84

91

98

105

Figure  10  :  Heat  exchange  coefficient  data  for  a  14  week  period  –  Le  Gol  

Conclusions of falling film evaporator installation Conclusions of falling film evaporator installation

Developments carried out by Fives on falling film evaporators in the cane industry have overcome the problems related to Developments carried out by Fives Cail on falling in the cane industry have overcome high thermal sensitivity of the concentrated cane film juiceevaporators and the high propensity of sensitivity the distribution system and the problems relatedfor to encrustation high thermal of the concentrated cane juice and the high propensity heating surface. Numerous evaporators installed by Fives in for encrustation of the distribution system and heating surface. Numerous evaporators installed by Brazil, Guadeloup Island and Mauritius Island demonstrate easy Fives operation Cail in and Brazil, Guadeloup and Mauritius Island demonstrate easy operation and maintenance, and Island good thermal performance. Through operation with smaller temperature differences in the maintenance, and good thermal performance. Through operation with smaller temperature differences falling film evaporators changes to the configurations of the sets in the have falling filmpossible, evaporators changes to the configurations of the sets have been possible, resulting in been resulting in reduced steam consumptions, substantial in factorysubstantial incomes andincreases reductions in reduced steam increases consumptions, in the factory incomes and reductions in the environmental footprints.

environmental footprints.

48

International Sugar Journal | August 2014

Factory modeling with a view of improving energy efficiency and predicting sugar colour www.dsengineers.com [email protected]

Sébastien Schellen – Process Engineer at De Smet Engineers & Contractors (DSEC) - Belgium

DSEC presents an innovative predictive model for the optimization of complete sugar processes which has been validated in beet and cane sugar factories as well as in raw sugar refineries. The model proposes a novel follow-up of the sugar colour and purity throughout the process based on physical equations as opposed to arbitrary ratios. It provides therefore more accurate performance predictions in terms of product quality and utilities consumption. It allows an in-depth audit of existing factories so as to identify possible process bottlenecks as well as potential energy efficiency increases. One of the major interests of this model based on Matlab / Simulink® software is its capability to simulate the complete plant in one integrated calculation tool considering also the cogeneration and plant utilities. Thanks to its friendly presentation, similar to a process flow diagram, the model gives an easy overview on all streams’ physical data and provides the basis of design for all key equipments. By simulating different technological solutions, DSEC is able to propose reliable technical and economical analysis leading to profitable investment decisions.

Not a simple Heat and Mass balance Any sugar technologist is able to compute a Heat and Mass balance for his sugar plant by using home-made calculation spreadsheets or licensed commercial software (e.g. Sugars™, SugarSoft™ …). Even if these solutions of sugar process modeling are very widespread, they present some limitations in matching the high accuracy objectives set by De Smet Engineers & Contractors (DSEC), world class provider of Engineering, Procurement and Construction services in the agro-industry: 1. While spreadsheets are commonly used for simple calculations related to a part of a factory, they are quickly limited to compute more complex, iterative simulations that are particularly important to model the numerous recirculation streams at all stages of the sugar production such as mud recirculation at juice purification, run-offs recirculation in the crystallization step, remelt syrup recirculation to the beginning of the production line,.... 2. When using licensed software, we are guided by the proposed pre-established unit operations and have no flexibility on process modeling or on the calculations done internally. 3. Mostly based on empirical parameters and arbitrary ratios, licensed software is generally a useful tool in an existing plant in order to easily adapt production values and utility requirement in function of actual plant throughput and feedstock characteristics. Unfortunately, this cannot be applied to new projects or process innovation because a plant concept has first to be defined and an accurate prediction of the plant performances is needed. DSEC model is based on physical parameters that provide full reliability. 4. One of the main disadvantages of licensed software is their opacity and restriction to understand the foundation of the simulation: code is inaccessible and equipments are black boxes. Being liable towards his clients for process performances

achievement, DSEC cannot rely on such readymade solutions and must enter into the basements of the code and the parameters of all equipment. Due to these major limitations, DSEC decided to develop its own predictive model for the optimization of the integrated sugar process (cane, beet and raw sugar) so as to be in a position to propose technical solutions fully adapted to its customer’s specific projects. 1. Equipments basic design: our model is able to give all key data for the equipments design. It also allows the optimization of the equipment in order to get the best compromise between OPEX and CAPEX. 2. Performance guarantees: the complete integration of the process line and utilities into one integrated calculation will give a reliable view of the performances of the plant. Built on physical formulations validated in operational factories, the model will give a perfect view of the plant performances and consumptions. Moreover, it is able to give a unique follow-up of the sugar colour across the process which is essential for the production of refined sugar as well as high-valued coloured special sugars. 3. Process innovation: the big advantage of the model is the possibility to simulate original concepts and propose the best process solution for the project. 4. Energy savings: by simulating the complete plant during in-depth audit of the facility, all levels of energy are studied and optimized to identify the most profitable investments. 5. Plant revamping: with its flexibility, the model can assist in choosing between several technological solutions in case of a site revamping considering increase of capacity, equipment substitution and energy efficiency improvement.

Model architecture The model’s architecture is based on Matlab / Simulink® software. Simulink® is an interface commonly used in several domains of simulation, especially those which need block diagrams representations. While Simulink® offers numerous pre-programmed block libraries; it also allows a complete customization of such blocks. This option has been used to model each unitary operation of sugar factories and refineries. Thanks to its integration with Matlab®, the calculation software, DSEC has developed complex numerical methods to reach the model convergence, incorporating physical computations as well as a clear method of programming the streams and the unit operations throughout the complete process. To build a complete Heat, Colour and Mass Balance for a sugar plant, customized Simulink® blocks representing the equipments with arrows representing the process streams (Figure 1) are interconnected so that they can interact. At every step of the simulation, each unitary operation will receive information from different sources: 1. The mass flows and the process properties of the inlet streams

www.internationalsugarjournal.com

49

(e.g. the dry substance content of a sugar Figure 1. The model’s architecture showing the arrangements of blocks solution, the volume fraction of a certain representing unitary operations (e.g. Crystallisation Pan R1) and arrows gas or the flow, the alkalinity of a limed describing streams’ properties. solution …). 2. The targeted value for the outlet streams (e.g. a certain steam flow that is required by another process unit). 3. The design values of the equipment. Those are chosen to be as physical as possible in order to avoid the use of arbitrary ratios. They can be changed by the user of the simulation (e.g. the speed of a discontinuous centrifugal, the guaranteed filter cake dry substance in a mud filter, the desired brix at the outlet of a melter). 4. The process functions. The model uses reliable process functions based on scientific literature and on DSEC’s experimental formulations validated in sugar plants during operation. A full definition of main products of the sugar factory is given for all the process units. (e.g. enthalpy, viscosity, boiling point elevation, colour, heat transfer coefficient, solubility, LHV, volumic/mass fraction of gases, alkalinity, …). model starting from 1000 IU standard liquor. By considering a 5. The global parameters of the simulation. Our software allows colour profile for the crystal instead of a mean determined by preus to adapt, inter alia, the communication language and the established ratios, our model is able to deal with more complex number of iterations used to reach the model convergence. process features with the purpose of optimizing the client’s project. With this information, each unitary operation calls for a Matlab® function which computes the properties of the outlet and inlet flows In this simple example, the centrifugation will affect the extern and also basis of design for the main equipments (surface of heat layers of the crystals which contain the higher concentration of exchangers and evaporators, sugar pan volume, electrical power of coloured molecules. The result of our model will be significantly a turbine generating set …). Further to several iterations the model more precise that any other simulation. converges to the solution corresponding to the expected Mass, Colour and Heat Balance of the plant. Figure 2. Crystal colour profile starting from a 1000 IU

A predictive model of the end sugar colour

standard liquor.

The innovation of DSEC’s model is its capability to follow the colour and the purity of sugar solutions (juice, syrups, runoffs, liquors …) and sugar crystal throughout the process. While traditional commercial software uses arbitrary ratios to define colour and purity, it is essential for DSEC to consider precise and in-plant validated equations of crystallization and centrifugation operations to guarantee the end-sugar colour, opening the way to mastering and optimizing the heart of the process, especially in raw sugar refineries.

Crystallization In the model, crystal colour and purity is decomposed into numerous layers from its center to its periphery. During crystallization, we compute the crystal properties at each time step on all its layers from its appearance and we follow its growth by considering the main physicals phenomena’s of the crystallization process: • a part of the colour and impurities of the mother liquor is transferred to the crystal, • final tightening of the vacuum pan is foreseen and will have a serious impact on the crystal properties, • crystallization time and temperature will provoke an increase of coloured molecules and affect the process. Figure 2 shows one sugar cane crystal colour profile from our

50

International Sugar Journal | August 2014

Moreover, having a follow-up of the crystal colour and purity will offer the possibility to simulate other process tricks such as the multi-stage syrups injection during the crystallization. By differentiating liquors and run-offs on colour and purity, the model is able to select the best syrup to be used in order to achieve the desired sugar crystal. Figure 3 shows the impact of selecting the right timing, quantity and syrup properties to inject during the crystallization. If we consider two different sugar solutions of 1000 IU and 3000 IU we see that the crystal profile won’t be the same as if we start to feed the vacuum pan with 1000 IU solution or with 3000 IU solution. For both cases, the quantity of coloured

2. Centrifugal and operational parameters • Basket inner diameter • Initial massecuite cake layer • Centrifugal cycle (speed and time) • Syrup separation • Different types of washing are possible (syrup, water, steam…) • Basket cleaning • Venting losses are estimated Thanks to this, it is possible to analyze the consequences of changing a parameter so as to optimize the centrifugation of any plant by selecting the best time for syrup separation, by choosing the best way of washing (water, syrup) and by optimizing the centrifugal cycle. One is often surprised by the potential gain of quality and energy efficiency that can be achieved by optimizing Figure 3. Crystal colour profiles starting with the same a centrifugation Figure 5 shows the evolution of sugar colour Figure 3. liquors Crystalbut colour profiles starting with theinsame standard liquors butline. injected standard injected into the vacuum pan a inside the centrifugal during the cycle, demonstrating the influence into the vacuum different timing. pan in a different timing. of some physical parameters on the final colour e.g: centrifugal speed, timing for washing. molecules injected is the same, but the resulting sugar crystal profile is completely different. In the same way, if we now look at a mix of both solutions to get a 2000 IU solution, this third case will be identified as being different from the two others with our model while it would appear as totally identical for any other model which does not compute the colour profile. Another process figure which is simulated in DSEC’s model thanks to crystal profile is pan seeding: each crystal formed during crystallization will conserve its profile throughout the simulation. That means that we are able to keep the crystal history and use it for pan seeding. Figure 4 shows different kind of crystal profiles depending on the type and volume of seeding. We see on this graph that the colour profile of the seed is conserved in the final sugar.

Figure 5. Evolution of a typical sugar colour in a discontinuous centrifu Figure 5. Evolution of a typical sugar colour in a during a cycle. discontinuous centrifugal basket during a cycle.

Another process figure which is simulated in DSEC’s model thanks to crystal profile is Figure 4. Different crystal colour profile showing the pan seeding: each crystal formed during crystallization will conserve its profile influence of the history of the crystal through the model. In throughout the simulation. That means that we are able to keep the crystal history case of seeding with a crystal formed in another strike, the and use it for pan seeding. Figure 4 shows different kind of crystal profiles depending initial profile is kept. has been validated and as well as in Thiscolour model has been in beet andcane canefactories factories as on the type and volume of seeding. We see on this graphThis that model the profile of validated the in beet refineries for several years. DSEC has taken part in many projects des well as in sugar refineries for several years. DSEC has taken part seed is conserved in the final sugar. advised many factories for reshaping their decolourization process. in many projects design and have advised many factories for Figure 4. Different crystal colour profile showing the influence of the history of the reshaping their decolourization process. Only a flexible and trustable predictive model (figure 6) can ensure the crystal through the model. In case of seeding with a crystal formed strike, Onlyina another flexible and trustable predictive model (figure 6) can process optimization project in order to provide reliable performance g the initial profile is kept. ensure the best possible process optimization project in order the to end-sugar specification, energy, water and consumption provide reliable performance guarantees on chemicals the end-sugar requirements. specification, energy, water and chemicals consumptions and

utilities requirements. Figure 6. DSEC’s model overview of a complete plant showing the inte process and utilities units of the factory. Figure 6. DSEC’s model overview of a complete plant showing the integration of all process and utilities units of the factory.

Centrifugation ToCentrifugation model the centrifugation DSEC once again base its equations on physical parameters: To model the centrifugation DSEC once again base its equations 1. Massecuite properties on physical parameters: • Temperature, viscosity, % of crystal, colour… 1. Massecuite properties • Size of sugar crystals (MA/CV) • Temperature, viscosity, % of crystal, colour… 2. Centrifugal and operational parameters • Size sugar crystals (MA/CV) • ofBasket inner diameter • • •

Initial massecuite cake layer Centrifugal cycle (speed and time) Syrup separation

www.internationalsugarjournal.com

51

For the latest updates visit: www.internationalsugarjournal.com

Meetings Calendar

20-22 August 2014

9-11 September 2014

Pietermaritzburg, South Africa Contact: [email protected] www.sasta.co.za/

Contact: Stephen Ashiotis Email: [email protected] www.sugarethanolafrica.com

South African Sugar Technologists' Association 86th Annual Congress

Sugar & Ethanol Africa Durban, South Africa

26-28 August 2014 20th Asia International Sugar Conference, Indonesia Yogyakarta Indonesia

Tel: +65 6508 2401 Email: [email protected] http://aiscsugar.com/

29-31 August 2014

3rd ISRMAX Sugar Asia 2014 Bangkok, Thailand Contact: Ashish Agnihotri Mobile: +91 9991705001 Email: [email protected] www.isrmaxasia.net

7th European Forum for Industrial Biotechnology and the Biobased Economy 2014 Reims, France Contact: Hayley Marsden Email: [email protected] Tel: +44(0)1372 802000

www.efibforum.com/home.aspx

3-6 November 2014 F.O. Licht’s World Ethanol and Biofuels 2014 Budapest, Hungary Contact: +44 (0)20 3377 3658, Email [email protected]

31 August - 3 September 2014

www.worldethanolandbiofuel.com

SPRI 2014 Conference: Sustainability in the International Sweetener Industry: The Role of Research and Innovation Ribeirao Preto, Brazil

25-26 November 2014

Email: [email protected] www.spriinc.org

9-11 September 2014 73rd Annual Convention of The Sugar Technologists Association of India Bengaluru, India Contact: Amit Khatter Tel: +91 11 64645069 - 72 Email: [email protected] [email protected]

www.staionline.org

52

30 September - 2 October 2014

International Sugar Journal | August 2014

23nd Int Sugar Organization seminar Sugar and Ethanol: Fresh Options London, UK Contact: Birgit Myrie Tel: +44 (0)207 513 1144 Email: [email protected]

www.isosugar.org

Not currently an ISJ subscriber? Why subscribe to ISJ?

The complete value chain from sugarcane and beet production right through to sugar processing and sugar refining PLUS the latest developments in the biofuels and biobased sectors

How you will benefit from an ISJ subscription: • The latest in-depth news, analysis and intelligence from your industry in one place • Reliable information that could improve your efficiency and save your company money • React quickest with the latest issue available online at www.internationalsugarjournal.com

The World’s Leading Sugar Industry Magazine • Cane sugar manufacturing • Beet sugar manufacturing • Sugar refining • Equipment and machinery • Alternative sweeteners • Biofuels • Cogeneration

• Nutrition and health • Environmental issues • Food and non-food uses of sugar • By-products - molasses, alcohol and vinasse • Economics, trade and legislation

subscribe... 3 easy ways to subscribe... International Sugar International SugarJournal Journalone oneyear yearsub: sub: UK£620 £600 Europe Europe €770 €750 Rest Rest of of World World US$955 UK US $979 To enquire about advertising in ISJ, please contact [email protected] or call +44 (20) 701 77559

orderonline, online,please please visit visit 1. 1. ToToorder https://store.agra-net.com/isj.html www.internationalsugarjournal.com CalPriyanka l Alex CasAdhikari t on +44 (on 20) +44 7017(20) 7506337 7 73045 2. 2. Call [email protected] [email protected] 3. 3. OrOremail FREEsample sample copy copy forfora aFREE

www.internationalsugarjournal.com

From time to time we may wish to send you information and offers about Informa plc products and services. If you do not wish to receive this information, please tick the following box. In some circumstances we may wish to pass on your details to carefully selected 3rd parties, in order for them to send you relevant information and offers. If you would like us to pass on your details in this way, please tick the following box. Data Protection: Personal Data supplied is subject to the Data Protection Act 1998. The personal information shown on this form, and/or provided by you, will be held on a database and may be shared with companies in the Informa Group in the UK and internationally. It may be used to keep you, or any additional names provided by you, up to date with developments in your industry. If you have any questions about Informa’s use of your data please write to the Database Manager, PO Box 461, West Byfleet, KT14 9BN. Tel: +44 (0)20 7017 5239 Fax: +44 (0) 20 7017 6241 or email [email protected]

Annual d 2n

Book by 8 August 2014 and save up to $1,200

9-11 September 2014

Hilton Hotel, Durban, South Africa

Expert insights into sugar and ethanol developments, demand and new business opportunities across Africa An outstanding line-up of sugar and ethanol producers across Africa and international industry experts including: Larry Riddle Commercial Director Illovo Sugar Limited South Africa Michael Dwyer Director, Global Policy Analysis Division U.S. Department of Agriculture (USDA) Rosemary Mkok CEO Kenya Sugar Board Farhan Nakhooda Projects Director Kakira Sugar Ltd Uganda Lindsay Jolly Senior Economist International Sugar Organization

Kokeb Ketsela Senior Statistician, Planning and Project Division, Ethiopian Sugar Corporation

Bernard Odote Chairman and Chief Executive Officer House of Procurement Group, Kenya

Imameleng Mothebe Director : Agro Processing Industrial Development Division - Department of Trade & Industry South Africa

Geraldine Kutas Head of International Affairs UNICA

Alf Stevens Secretary, Ethanol Producers Association of Southern Africa (EPASA) Penalto Miguel CEO SILVAPEN GROUP Brazil

Plus

BIOFUEL BLENDING MANDATES Identify new business as the biofuel potential is unlocked in South Africa and across the region

TRADE AND PRODUCTION STRATEGY Hear first-hand the strategic plans from the continent’s leading producers

Gold Sponsor:

Associate Sponsor:

Peter Starling Managing Director NCP Alcohols South Africa

Low de Vries Renewable Energy Engineer Analyst Tongaat Hulett South Africa

Farid Mohamed Managing Director Lion’s Head Kenya

GLOBAL EXPERT INSIGHTS Get the latest on policy, trade and technology from global industry leaders

Shi-Zhong Li Executive Director MOST-USDA Joint Research Center for Biofuels, China

Josef Modl Executive Vice President Vogelbusch GmbH Austria

Jonas Strömberg Director Sustainable Solutions Scania, Sweden

PAN AFRICAN TURNOUT Meet sugar and ethanol producers from across Africa as a range of trading and investment opportunities are opening up

CONFERENCE CHAIRS:

Stuart Rayner Principal Engineer Ford Motor Company South Africa

Suresh Kumar Executive Vice President, Africa and Execution PRAJ

FOCUSING ON:

Rob Vierhout Secretary General ePURE

Burger Pretorius Group Export Marketing Manager – Ethanol Illovo Sugar South Africa Kerry O’Donoghue Programme Director Partners for EuroAfrican Green Energy (PANGEA)

ETHANOL PRODUCTION TECHNOLOGY FORUM TUESDAY 9TH SEPTEMBER

Providing you with the information and contacts you need to maximise production efficiency, implement new technologies and manage cost and financial demands for an ethanol business.

Supported by:

W: www.sugarethanolafrica.com E: [email protected] T: +44 (0) 20 3377 3658 @worldethanol

F.O. Licht’s Biofuels and Ethanol Exchange

process engineering • plant layout • architecture • structural design • electrical / C&I engineering

Your reliable partner for engineering solutions

IPRO Industrieprojekt GmbH Braunschweig, Germany www.internationalsugarjournal.com www.ipro-bs.de

55