Continuous improvement in cane raw sugar … · Continuous improvement in cane raw sugar decolorisation technology François ROUSSET NOVASEP PROCESS BSST meeting Nov 2010

Continuous improvement in cane raw sugar decolorisation technology

François ROUSSETNOVASEP PROCESS

BSST meeting Nov 2010

Novasep Process Novasep Synthesis

3

Novasep Process MarketsNovasep Process Markets

Biopharma FunctionalIngredients Bio-Industries

Food Ingredients g

Blood FractionationmAbsRecombinant ProteinsV i

Sugar StarchMilk

PolyphenolsAnthocyanesFOS

VitaminsAntibioticsOrganic Acids

VaccinesCell Therapy

Sweeteners Aminoacids

Decolorization of Raw Cane Sugar syrupDecolorization of Raw Cane Sugar syrup

Decolorization is one of theRaw Cane Sugar Decolorization is one of the critical steps in raw cane sugar refining R d l f filt dAFFINATION

Raw Cane Sugar

LOW GRADE BOILING Reduce color of filtered syrup

from 500-1200 Icumsa to 100-300 Icumsa in order to crystallize white refined

AFFINATION

REMELT

BOILING

Refinery crystallize white refined sugar at 25-45 Icumsa (R1+R2+R3 refined sugar)70 90% color reduction

EPURATION

Refinerymolasses

70-90% color reductionDECOLORIZATION Must remove color :

HIGH GRADE BOILING

• Initially present in canne : Polyphenols

• Developped during the refinery process : Caramel, Melanoidins, Hexose Degradation

Refined Sugar

Caramel, Melanoidins, Hexose Degradation Products


Decolorization is one of the critical Decolorization is one of the critical steps in raw cane sugar refining

Reduce color of filtered syrup from 500 1200 I t 100 300 I500-1200 Icumsa to 100-300 Icumsa in order to crystallize white refined sugar at 25-45 Icumsa (R1+R2+R3 refined sugar)(R1+R2+R3 refined sugar)

70-90% color reduction

Must remove color :

• Initially present in canne : Polyphenolsy p yp

• Developped during the refinery process : Caramel, Melanoidins, Hexose Degradation ProductsProducts


3 industrial technologies are used for I t f 2000 t fi d3 industrial technologies are used for decolorization of raw cane sugar syrup in sugar refineries: Bone char

Inventory for 2000 tons refined sugar per day

I t ll d 3 Activated carbon

• powdered carbon + filtration for small capacities

2000

Installed m3

p• Fixed-bed granular carbon

columns for large capacities• Pulse-bed granular carbon 1600

1000

1500

systems• External thermal reactivation /

onsite thermal reactivation

600 900

500

Bone char GAC IX Ion-exchange resins

Only ion-exchange resins systems are Capex and Opex competitive for smallest

BV/h 0,05 - 0,1 0,25 - 0,5 1- 4

Capex and Opex competitive for smallest to largest refinery capacities


Capex/Opex for 2000 tons refined sugar/day

C i ME O i E /t

6

Capex in MEuros Opex in Euros/ton sugar

5,6456

,5,2

2,823

1,8 1,301

Bone char GAC/Kiln IX/VAP/NFBone char 1600 m3

GAC/Kiln 600 m3

IX/VAP/NF 90 m3


Decolorization of Raw Cane Sugar syrup

Novasep Process combined refining capacities :

Decolorization of Raw Cane Sugar syrup

p g p

Novasep Process SAS - Sugar decolorization systems Combined installed capacity in tons refined sugar /day

35 000

40 000

25 000

30 000

10 000

15 000

20 000

0

5 000

10 000

2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0

1972

1973

1974

1975

1976

1977

1978

1979

1980

198

1982

1983

1984

1985

1986

1987

1988

1989

1990

199

1992

1993

1994

1995

1996

1997

1998

1999

2000

200

2002

2003

2004

2005

2006

2007

2008

2009

2010

Year


Success driven by continued innovation in the ion exchange decolorization Success driven by continued innovation in the ion-exchange decolorization process :

1978 : downflow → upflow syrup decolorizers 1983 : double-cell upflow compact decolorizers 1996 : regenerant brine recovery from effluent by NF (first industrial g y y (

system worldwide, after pilot trials by SMRI, Tongaat, Applexion) 1997 : preconcentration of dilute regeneration effluent by atmospheric

concentration (procédé Lorant)concentration (procédé Lorant) 2004 : development of pre-engineered solutions for customers projects

• 9 capacities• Decolo• Decolo• Decolo + NF• Decolo + VAP + NF• Efficient toolbox = many solutions for all refinery projects• Efficient toolbox = many solutions for all refinery projects


PFD-1

22-102 PR01.01 1/1

ION-EXCHANGE DECOLORIZATION

FS Filtered SyrupPDS Pre-decolorized SyrupDS Decolorized syrupSW Sweet on/off WaterHW Hot regeneration waterRW Recovered Water

FRREV DATE DESIGN CHECK

RM0 20/01/2006

MX175

C120A C120B C120C

DSPDS PDS PDS

PTPTPT

PIPIPI

Applexion SAS

PFD-3: HCl 33%

PFD-2: NaCl 9%

F125

FILTERED SYRUP

PT

TT

FT FT FT

TT TTPT

PT PT

PTPT

PFD-2:EFFLUENTS

P155

F165

T150T140P105T100 T160

HE115

F110 T130

steam

condensate

FS HWPT

LT LT LT

SC

FIC

SC

LT

PT

HWTIC

SWDS

LT

RW

FIC

e 22-102 PR01.03

0 20/01/2006 RM

1/1

BRINE PREPARATION/EFFLUENTS

PFD-3REV DATE DESIGN CHECK

FRApplexion SAS Kg NaCl /tS 10xm3 Water /tS 10xm3 Effluent/t S

F340MX310

T320PFD-1: HCl 33%

COLD WATER

NaOH 50%

DECANTER

PT

AIR 3 bar

SANDFILTERHCl 33%

TO COLUMNS IF ACID DEPOLLUTION

FIC

PFD-2: NaCl 25%

678

Kg NaCl /tS 10xm3 Water /tS 10xm3 Effluent/t S

optionalT370P375 T360 P365 P305 P325P335 B345

LT

NaOH 50%

NaOH 50%

SC SC

FICLT

SC

LT

HCl33%

HCl 33%

SC

NaOHHCl PFD-2:EFFLUENTS

WASTEDISPOSAL

SALT

NF PERMEATE 2

3456

T300

P355

T350

LT

NEUTRAL BRINE 300 g/lPREPARATION TANK

LT pHT

EFFLUENTS NEUTRALIZATION TANK

012

Decolo


PFD-1

22-102 PR01.01 1/1


E 22-101 PR01.05

FR

PFD-2REV DATE CHECK

20/01/2006DESIGN

0 RM1 24/08/2006 RM2 15/12/2008 FR

1/1

BRINE NF RECOVERY

Applexion SAS



RM0 20/01/2006

MX175

C120A C120B C120C

DSPDS PDS PDS

PTPTPT

PIPIPI

Applexion SAS

PFD-3: HCl 33%

PFD-2: NaCl 9%NF skid

CSB Concentrated Spent BrineNFR NF RetentateNFP NF Permeate

MEMBRANES

NF260

2 15/12/2008 FR

NF PERMEATE FIC

FICNF RETENTATE

PFD-1: NaCl 9%

CIP WATER

FIC

CT

F125

FILTERED SYRUP

PT

TT

FT FT FT

TT TTPT

PT PT

PTPT

PFD-2:EFFLUENTS

T230

P265 P266

U75 U115

P235

F240

HE245

MX295

P250

P255LIC

TIC

SC PICPT

PIT

PR

FICNF RETENTATE

CT

PFD-1: EFFLUENTS

PFD-3: EFFLUENTS

COOLING WATER

PT

HW

LSH

LSL

PSH

CT

P155

F165

T150T140P105T100 T160

HE115

F110 T130

steam

condensate

FS HWPT

LT LT LT

SC

FIC

SC

LT

PT

HWTIC

SWDS

LT

RW

FIC

e 22-102 PR01.03

0 20/01/2006 RM

1/1




optional

optionalP270T220 P225 HE290T275 P285P276 T280

LT

NFP

LTTIC

steam

condensate

NFR

LT

NF PERMEATE 2

CSB

CT

SC FIC

HW PFD-3: NaCl 25%NF PERMEATE1

LSL

F340MX310

T320PFD-1: HCl 33%

COLD WATER

NaOH 50%

DECANTER

PT

AIR 3 bar

SANDFILTERHCl 33%


FIC

PFD-2: NaCl 25%

678



LT

NaOH 50%

NaOH 50%

SC SC

FICLT

SC

LT

HCl33%

HCl 33%

SC


WASTEDISPOSAL

SALT

NF PERMEATE 2

3456

T300

P355

T350

LT


LT pHT


012

Decolo NF


PFD-1

22-102 PR01.01 1/1


E 22-102 PR01.05

FR

PFD-2REV DATE CHECK

20/01/2006DESIGN

0 RM1 03/04/2007 RM FR

1/1

BRINE NF RECOVERY

Applexion SAS



RM0 20/01/2006

MX175

C120A C120B C120C

DSPDS PDS PDS

PTPTPT

PIPIPI

Applexion SAS

PFD-3: HCl 33%

PFD-2: NaCl 9%

CSB Concentrated Spent BrineNFR NF RetentateNFP NF Permeate

MEMBRANES

NF260NF PERMEATE FIC

FICNF RETENTATE

PFD-1: NaCl 9%

CIP WATER

FIC

CT

F125

FILTERED SYRUP

PT

TT

FT FT FT

TT TTPT

PT PT

PTPT

PFD-2:EFFLUENTS

AC215

T230

P265 P266

U75 U115

P235

F240

HE245

MX295

P250

P255LIC

TIC

SC PICPT

PIT

PR

CT

PFD-1: EFFLUENTS

PFD-3: EFFLUENTS

COOLING WATER

PT

CTHW

PFD-3: NaCl 25%

PI

PSH

P155

F165

T150T140P105T100 T160

HE115

F110 T130

steam

condensate

FS HWPT

LT LT LT

SC

FIC

SC

LT

PT

HWTIC

SWDS

LT

RW

FIC

e 22-102 PR01.03

0 20/01/2006 RM

1/1




optional

optionalT200 P205 HE210 P270T220

F226

P225 HE290T275 P285P276 T280

LT

NFP

LTTIC

steam

condensate

NF PERMEATE 2

CSB

CT

SC FIC

NF PERMEATE 1

LT

CTWARM WATER

TIC

DSB NFR

LT

LSLPT

F340MX310

T320PFD-1: HCl 33%

COLD WATER

NaOH 50%

DECANTER

PT

AIR 3 bar

SANDFILTERHCl 33%


FIC

PFD-2: NaCl 25%

678



LT

NaOH 50%

NaOH 50%

SC SC

FICLT

SC

LT

HCl33%

HCl 33%

SC


WASTEDISPOSAL

SALT

NF PERMEATE 2

3456

T300

P355

T350

LT


LT pHT


012

Decolo NF VAP/NF


S d i b ti d ti d h d Success driven by continued cooperation and shared process improvement with major Refiners in this industry:

1978 : First complete replacement of bone char decolorization system with Generale Sucrière in Marseilles

1995-1997 : First NF brine recovery process with Generale Sucrière in Marseilles

1989-2005 : Bone char replacement project at Lantic Sugar 1989-2005 : Bone char replacement project at Lantic Sugar in Montreal 2000 tons sugar/day

1990-2009 : Cosumar in Casablanca 3000 tons sugar/day 2000-2009 : Cevital in Bejaia 5000 tons sugar/day


Presentations from many team members at professional hibiti d i d t tiexhibitions and industry meetings:

2000 CANE SUGAR REFINING HANDBOOK Dr Chi-Chou 2nd Edition - John Wiley & Sons CHAPTER 10 : ION-EXCHANGE RESIN PROCESS FOR COLOR ANDCHAPTER 10 : ION-EXCHANGE RESIN PROCESS FOR COLOR AND ASH REMOVAL Denis Bourée/François Rousset

SIT 2001 ION-EXCHANGE DECOLORATION : A FLEXIBLE WAY TO

MODERNIZATION AND CAPACITY EXTENSIONMODERNIZATION AND CAPACITY EXTENSION Jean de Lataillade/François Rousset SIT 2004 DECOLORIZATION OF REFINERY LIQUORS : A TECHNICAL AND ECONOMIC COMPARISON BETWEEN THE DIFFERENT SYSTEMS

USING ACTIVATED CARBON OR RESINSUSING ACTIVATED CARBON OR RESINS. Francis Gula/Dominique Paillat SIT 2006 NEW DEVELOPMENTS FOR THE REDUCTION OF THE

CHEMICAL CONSUMPTIONS AND THE PRODUCTION OF EFFLUENTS IN MODERN ION EXCHANGE DECOLORATIONEFFLUENTS IN MODERN ION-EXCHANGE DECOLORATION SYSTEMS FOR THE SUGAR REFINERY

Xavier Lancrenon/François Rousset SIT 2007 PROGRESSIVE REPLACEMENT OF BONE CHAR

DECOLORIZATION BY AN ION-EXCHANGE RESIN SYSTEM AT LANTIC MONTREAL

Francis Gula/Xavier Lancrenon/François Rousset BEST PAPER AWARD SIT 2007


SIT 2008 NEW TECHNOLOGIES USED IN MINIMIZING WASTE WATER IN SUGAR FACTORIES AND REFINERIES

Xavier Lancrenon IAA 2004 DES PROCEDES D’ECHANGE D’IONS RESPECTUEUX DE

L’ENVIRONNEMENT : MYTHE OU REALITE Francis Gula/Dominique Paillat IAA 2008 NOUVELLES TECHNOLOGIES UTILISEES POUR REDUIRE LA

PRODUCTION D’EFFLUENTS DES SYSTEMES D’ECHANGE D’IONSDANS L’INDUSTRIE SUCRIERE

Xavier Lancrenon IAA 1980 DECOLORATION DU SIROP DE REFONTE DE SUCRE DE CANNE AIAA 1980 DECOLORATION DU SIROP DE REFONTE DE SUCRE DE CANNE A

LA RAFFINERIE DE MARSEILLE Raymond Celle/Daniel Hervé 1997 DESALINATION 113 – NF BRINE RECOVERY FROM REFINERY

DECOLORIZATION EFFLUENTDECOLORIZATION EFFLUENTStéphanie Cartier/Marc-André Théoleyre/Martine Decloux

SPRI 1999 RESIN DECOLORIZATION OF HIGH COLOR SYRUPS THANKS TO REGENERATION RECOVERY

François Rousset François Rousset


? Next steps ?

Further innovation for greener process smaller Opex: Further innovation for greener process, smaller Opex: Decolo/VAP/NF/RO ?

Projects for joint production of refined sugar and liquid sucrose/medium invert syrup in cane sugar refineries

More new refinery projects in large sugar consumption areas for domestic market, or for re-export in EU market

Decolorization needs for co-refining of cane raw sugar in beet sugar factories

Documents

Continuous improvement in cane raw sugar … · Continuous improvement in cane raw sugar decolorisation technology François ROUSSET NOVASEP PROCESS BSST meeting Nov 2010