Zuckerindustrie最新文献

{"title":"Process optimization and reduction of production costs in modern beet sugar manufacturing","authors":"Arash Bagherzadeh, Quido Smejkal, Uwe Freißlich, Joachim Pfauntsch, Sandra Gruden, Steve Howe","doi":"10.36961/si30577","DOIUrl":"https://doi.org/10.36961/si30577","url":null,"abstract":"Exploding fuel prices and increasing costs for emission certificates motivate sugar manufacturers to invest in new processes to reduce production costs. A critical part of the optimization is, without any doubt, the reduction of steam consumption of the factory, and the minimization of carbon footprint. Technological development projects in the EU and worldwide deal mostly with the i) reduction of steam/electricity consumption and ii) environmentally motivated projects. Environmental protection represents a strong driving force for the optimization and technological development in the sugar branch. The paper summarizes the experience of a long-term development project in two of the best EU beet factories. Unlike conventional sugar factories, one of these plants is already equipped with vapor recompression, thus, suits the trend of using power in sugar manufacture. Some challenging technological improvements have been realized between 2009 and 2022. The experience with optimizing process technology and reducing manufacturing costs is described in detail. Two modification packages are presented in simplified form based on engineering tools used for the optimization tasks. Selected projects are structured in terms of investment costs, from moderate and mid-term improvements to strategic investment. The payback and return on investment play a dominant role in this paper. The most challenging issue is how to reduce the overall energy requirement for the process, concurrently to identify the right technology significantly lowering CO2-emissions, in a financially viable way.","PeriodicalId":24046,"journal":{"name":"Zuckerindustrie","volume":"228 2","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135116415","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Utilization of bagasse as a soil amendment in sugarcane production on mineral soils in Florida","authors":"Jehangir Bhadha, Nan Xu, Naba Amgain, Abul Rabbany, Stewart Swanson","doi":"10.36961/si30578","DOIUrl":"https://doi.org/10.36961/si30578","url":null,"abstract":"A 4-year study tested the feasibility of using bagasse as a soil amendment in sugarcane production on a commercial field with mineral soil in Florida. The experiment was established as a completely randomized design trial with three rates of fresh bagasse applications: approximately 5 cm of bagasse, 10 cm of bagasse, and 10 cm of bagasse + nitrogen (N), which are equivalent to 85 t ha–1, 170 t ha–1, and 170 t ha–1 + 336 kg ha–1 ammonium nitrate, respectively. A control (no bagasse and no N added) was also included. As each treatment and the control had three replicates, there were 12 plots (6.5 ha each in size) totaling over 77 ha. The high pH of the soils is a result of years of mixing underlying limestone (calcium carbonate) bedrock with the topsoil. Overall results indicate that bagasse application positively affected the accumulation of soil organic matter during a short-term period, resulting in higher water-holding capacity and lower bulk density. The high rate of bagasse application had a positive effect on N accumulation, extractable phosphorus (P) and potassium (K) contents during the short term. One single application of bagasse significantly increased the first-year sugarcane biomass and sugar yield by approximately 23%. An overall higher application rate of bagasse (10 cm) was recommended as it showed significantly positive effects on soil health indicators and had a longer effect on increasing sugarcane biomass and sugar yield. There is potential to incorporate bagasse into commercial sugarcane production grown on mineral soils in Florida.","PeriodicalId":24046,"journal":{"name":"Zuckerindustrie","volume":"228 5","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135116414","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Reducing boiler maintenance costs with improved materials for air-heater tubes","authors":"Anthony Mann, Floren Plaza, Nazmul Alam, Kelly Ryan","doi":"10.36961/si30576","DOIUrl":"https://doi.org/10.36961/si30576","url":null,"abstract":"Corrosion of boiler air-heater tubes costs the industry several million dollars each year in repairs, reduced boiler steam output and reduced boiler efficiency. There have been many cases where the reduced boiler steam output caused by leaking air-heater tubes has reduced factory crushing rates and electricity export. Corrosion of air-heater tubes can, in many cases, be minimised by improving the gas and air flow distributions with turning vanes and ductwork redesign, but in nearly all cases, there are some tubes on the cold air side of air-heaters that are still susceptible to dew-point corrosion. Using improved tube materials in parts of boiler air-heaters that are susceptible to dew-point corrosion will significantly extend air-heater life. Available materials and coatings were reviewed, and laboratory- and factory-scale trials, metal temperature measurements, dew-point calculations and a financial analysis-based ranking of commercially available tube materials were undertaken. S-TEN 1 had a similar corrosion performance to SS304 stainless steel. Both the S-TEN 1 and SS304 stainless steel tubes had significantly greater resistance to dew-point corrosion than the carbon-steel tubes typically used in the air-heaters of Australian sugar factory boilers. The good performance of S-TEN 1 in this project is not consistent with the poor performance of S-TEN 1 (no better than carbon-steel) in earlier trials carried out by Isis Mill. The conditions experienced by the trial tubes in this project were not as severe as those experienced by the tubes in the earlier Isis Mill trials, and this appears to be the main reason for the current improved performance of the S-TEN 1 tubes. This requires further investigation.","PeriodicalId":24046,"journal":{"name":"Zuckerindustrie","volume":"228 6","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135116413","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Controlled-release urea for use in sugarcane ratoons","authors":"Raffaella Rossetto, Heitor Cantarella, N.P. Ramos, Marcos Guimarães de Andrade Landell","doi":"10.36961/si30507","DOIUrl":"https://doi.org/10.36961/si30507","url":null,"abstract":"Urea is the main solid N fertilizer used worldwide. Among its advantages are the high nutrient content, ease of handling and application, and low cost. Urea is subject to high losses through NH3 volatilization if surface-applied on soils. Therefore, ammonium nitrate is the preferred N source, especially in the ratoon cycles. Urea treated with the urease inhibitor NBPT and controlled-release fertilizers are options to replace ammonium nitrate. Controlled-release urea (CRU) is produced by coating the urea granules with resin or synthetic polymers so that the urea in the nucleus is not in contact with soil moisture. This study aimed to test CRU in sugarcane ratoons compared with ammonium nitrate (AN) and urea treated with urease inhibitor (UR-NBPT) at three rates: 60, 120 and 180 kg ha–1. Efficiency was also compared with two control treatments, the N control and the NPK control. Two field experiments were established and conducted in 2020 and 2021 in Sao Paulo state, Brazil. Sugarcane yield was evaluated in both experiments. N losses as NH3 volatilized were measured in the first experiment. All sources were equally efficient in promoting increases in sugarcane ratoon yield in both experiments. The relative yield obtained with N fertilizers and the control without N showed yield increases in the first experiment of 40, 54 and 68% for 60, 120 and 180 kg N ha–1 as AN, respectively; 29, 61 and 61% for 60, 120 and 180 kg N ha–1 as urea-NBPT, respectively; and 32, 62 and 67% for 60, 120 and 180 kg N ha–1 as CRU, respectively. Yields were higher in the second experiment, but increases in yield were lower compared to the first. Increases of 7, 10 and 16% for AN in three doses, 5, 12, 15% for UR-NBPT and 7, 9 and 14% for CRU were observed, respectively. N losses as NH3 volatilized were relatively low; CRU fertilizer showed good protection against NH3 losses by volatilization, protecting urea for about 30 days. This protection, however, did not affect yield. NH3 losses reached 13% of the N applied in the treatment with urea (about 16 kg N ha–1), 11% for Urea-NBPT (about 13 kg N ha–1) and 9% for CRU (about 11 kg N ha–1). Analyzing the results of both experiments CRU did not show an advantage in efficiency compared to AN and Urea-NBPT.","PeriodicalId":24046,"journal":{"name":"Zuckerindustrie","volume":"26 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135368272","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Clarification upsets and ion exchange resin symptoms due to design","authors":"Patrick L. Coterillo","doi":"10.36961/si30505","DOIUrl":"https://doi.org/10.36961/si30505","url":null,"abstract":"Abstract: Ion exchange resin (IER) decolorization columns face challenges because of upstream process upsets and certain design choices. Some of these challenges have been caused by excessive amounts of calcium carbonate carried over from press filtration to the IER columns. As a result, the columns experience sudden impacts on performance, which causes a premature shutdown or retention of the calcium carbonate, degrading resin performance over time. In addition, the refinery suffers in terms of overall throughput due to pressure drop in the IER columns or reduced decolorization and higher amount wash syrup in the centrifuges. Fiber glass nozzles installed in the columns have been replaced with stainless steel nozzles. Pros and cons of the replacement are discussed, which resulted in a much longer service life of the nozzles.","PeriodicalId":24046,"journal":{"name":"Zuckerindustrie","volume":"90 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135368271","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"The new dimple tube – a technology to improve evaporating crystallizer performance","authors":"Darius Bezuidenhoudt, Meethan Gokool, Steve Rosettenstein, Murray Stevens","doi":"10.36961/si30504","DOIUrl":"https://doi.org/10.36961/si30504","url":null,"abstract":"A common requirement in existing and expanding factories is for them to increase the crystallisation/evaporating crystallizer (vacuum pan) capacity; this is often not feasible due to the significant investment required to install new vessels, reallocate the existing vessels, and the necessary additional ancillary services. An innovative evaporating crystallizer tube has been developed, tested, trialled and commercialised; it provides an alternative solution for increasing the capacity at a significantly lower investment compared to the market equivalents. The dimple tube technology has been developed over four years, from an initial concept through to its commercialisation, and it has been through a series of analyses, alterations, tests and trials. These analyses included Computational Fluid Dynamics (CFD) to predict flow and performance characteristics, Finite Element Analysis (FEA) to analyse the direct and fatigue stresses, pressure testing, non-destructive testing, in-service trials and laboratory testing. Manufacturing equipment and systems have been designed, developed and implemented as part of the commercialisation process to ensure the reliable and repeatable production of the technology, which has been taken from a concept through to a commercially available and value-adding product. The outcome is a new tube technology that increases the heating surface area of an existing vessel by approximately 15%. The performance benefits of the additional heating surface area are as expected, but in addition to this, the increased turbulence significantly affects the heat transfer coefficients, resulting in a further increase in the evaporation rate and an increase in the throughput. The trial operation in a vessel without stirrer has shown no drawbacks or compromises to the existing operations. Retrofitting the existing vessels is as simple as retubing the evaporating crystallizer. Extensive development and testing have led to a new patent-pending tube technology that significantly impacts on the performance of heat exchangers, particularly evaporating crystallizers. The benefits are attained at a significantly lower cost and lead time than competing technologies or options currently available on the market.","PeriodicalId":24046,"journal":{"name":"Zuckerindustrie","volume":"42 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135368273","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Preliminary study of the impacts of constituents of sugarcane juice on sucrose degradation and pH drop during evaporation","authors":"Chalani Marasinghege, William O.S. Doherty, John Bartley, Darryn Rackemann","doi":"10.36961/si30506","DOIUrl":"https://doi.org/10.36961/si30506","url":null,"abstract":"During sugar-manufacturing processes such as evaporation, loss of sucrose can occur due to acid-catalysed hydrolysis to glucose and fructose, a reaction that is exponential with temperature. This reaction is also affected by pH, dry substance (rds) content and residence time, as well as the nonsucrose composition. Sugarcane juice contains many nonsucrose substances extracted from the cane plant during processing, including invert sugars, minerals, organic acids, proteins, amino acids, phenolics, flavonoids and polysaccharides. Representative chemicals reflecting these nonsucrose substances were spiked into synthetic sucrose solutions to determine how specific classes of nonsucrose substances impact sucrose degradation under thermal conditions. Invert sugars, flavonoids and minerals had a catalytic effect on sucrose degradation that was accompanied by a higher juice pH drop. Organic acids minimised sucrose degradation slightly due to a buffering effect. Other juice constituents showed minimal impact. Studies on the catalytic activity of minerals showed that catalytic activity increased in the order of Na+ < K+ < Mg2+ < Ca2+. During thermal processing, juice constituents are involved in complex interactions, so further research is necessary to better elucidate these interactions.","PeriodicalId":24046,"journal":{"name":"Zuckerindustrie","volume":"80 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135368274","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}