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1.6 MB pdf - Thermal Energy Systems
Continuous improvement in cane raw sugar decolorisation technology François ROUSSET NOVASEP PROCESS BSST meeting Nov 2010 Novasep Process Novasep Synthesis 3 Novasep Process Markets Biopharma Blood Fractionation mAbs Recombinant Proteins V i Vaccines Cell Therapy Food Ingredients Sugar Starch Milk Functional Ingredients g Polyphenols Anthocyanes FOS Sweeteners Bio-Industries Vitamins Antibiotics Organic Acids Aminoacids Decolorization of Raw Cane Sugar syrup Raw Cane Sugar AFFINATION REMELT EPURATION LOW GRADE BOILING Refinery molasses DECOLORIZATION HIGH GRADE BOILING Refined Sugar Decolorization is one of the critical steps in raw cane sugar refining R d Reduce color l off filtered filt d syrup from 500-1200 Icumsa to 100300 Icumsa in order to crystallize white refined sugar at 25-45 Icumsa (R1+R2+R3 refined sugar) 70 90% color reduction 70-90% Must remove color : • Initially present in canne : Polyphenols • Developped during the refinery process : Caramel, Melanoidins, Hexose Degradation Products Decolorization of Raw Cane Sugar syrup Decolorization is one of the critical steps in raw cane sugar refining Reduce color of filtered syrup from 500 1200 IIcumsa tto 100 500-1200 100-300 300 IIcumsa in order to crystallize white refined sugar at 25-45 Icumsa (R1+R2+R3 refined sugar) 70-90% color reduction Must remove color : • Initially yp present in canne : Polyphenols yp • Developped during the refinery process : Caramel, Melanoidins, Hexose Degradation Products Decolorization of Raw Cane Sugar syrup 3 industrial technologies are used for decolorization of raw cane sugar syrup in sugar refineries: IInventory t for f 2000 ttons refined fi d sugar per day Bone char Activated carbon I t ll d m33 Installed • powdered carbon + filtration for small capacities p • Fixed-bed granular carbon columns for large capacities • Pulse-bed granular carbon systems • External thermal reactivation / onsite thermal reactivation Ion-exchange resins Only ion-exchange resins systems are Capex and Opex competitive for smallest to largest refinery capacities 2000 1500 1000 500 0 BV/h 1600 600 Bone char 0,05 - 0,1 GAC 0,25 - 0,5 90 IX 1- 4 Decolorization of Raw Cane Sugar syrup Capex/Opex for 2000 tons refined sugar/day C Capex iin MEuros ME 6 5 4 3 2 1 0 O Opex in i Euros/ton E /t sugar 5,6 , 5,2 2,8 1,8 Bone char 1600 m3 GAC/Kiln 600 m3 1,3 IX/VAP/NF 90 m3 Decolorization of Raw Cane Sugar syrup Decolorization of Raw Cane Sugar syrup Novasep p Process combined refining g capacities p : Novasep Process SAS - Sugar decolorization systems Combined installed capacity in tons refined sugar /day 40 000 35 000 30 000 25 000 20 000 15 000 10 000 0 1972 2 1973 3 1974 4 1975 5 1976 6 1977 7 1978 8 1979 9 1980 0 1981 2 1982 1983 3 1984 4 1985 5 1986 6 1987 7 1988 8 1989 9 1990 0 1991 2 1992 1993 3 1994 4 1995 5 1996 6 1997 7 1998 8 1999 9 2000 0 2001 2 2002 2003 3 2004 4 2005 5 2006 6 2007 7 2008 8 2009 9 2010 0 5 000 Year Decolorization of Raw Cane Sugar syrup Success driven by continued innovation in the ion ion-exchange exchange decolorization process : 1978 : downflow → upflow syrup decolorizers 1983 : double-cell upflow compact decolorizers 1996 : regenerant g brine recovery y from effluent by y NF ((first industrial system worldwide, after pilot trials by SMRI, Tongaat, Applexion) 1997 : preconcentration of dilute regeneration effluent by atmospheric concentration (procédé Lorant) 2004 : development of pre-engineered solutions for customers projects • • • • • 9 capacities Decolo Decolo + NF Decolo + VAP + NF Efficient toolbox = many solutions for all refinery projects Decolorization of Raw Cane Sugar syrup 1/1 22-102 PR01.01 ION-EXCHANGE DECOLORIZATION REV 0 Applexion SAS PT FS PDS DS SW HW RW Filtered Syrup Pre-decolorized Syrup Decolorized syrup Sweet on/off Water Hot regeneration water Recovered Water PT PFD-1 DATE DESIGN CHECK 20/01/2006 RM FR PT PFD-2: NaCl 9% C120A C120B C120C PFD-3: HCl 33% PDS PI PDS PI PT PDS PI PT TT MX175 PT TT TT PT PT FT DS PT FT FT FILTERED SYRUP F125 PFD-2: EFFLUENTS F165 TIC FIC FS SC DS HE115 LT SW P105 condensate F110 LT T130 PT RW LT T100 HW FIC steam PT HW SC LT LT T140 T160 P155 T150 e 22-102 PR01.03 1/1 BRINE PREPARATION/EFFLUENTS REV 0 Applexion SAS PFD-3 DATE DESIGN CHECK FR 20/01/2006 RM FIC COLD WATER AIR 3 bar PT T320 TO COLUMNS IF ACID DEPOLLUTION MX310 HCl 33% DECANTER 6 5 SAND FILTER F340 NaOH 50% LT FIC SC HCl 33% NaOH 50% LT P375 SC SC SC LT T370 T360 P365 P305 P335 optional P325 B345 WASTE DISPOSAL HCl NaOH PFD-2: EFFLUENTS SALT NF PERMEATE 2 LT LT pHT P355 T300 NEUTRAL BRINE 300 g/l PREPARATION TANK T350 10xm3 Water /tS 8 7 PFD-2: NaCl 25% PFD-1: HCl 33% Kg NaCl /tS EFFLUENTS NEUTRALIZATION TANK 4 3 2 1 0 Decolo 10xm3 Effluent/t S Decolorization of Raw Cane Sugar syrup E 1/1 22-101 PR01.05 BRINE NF RECOVERY 1/1 22-102 PR01.01 ION-EXCHANGE DECOLORIZATION REV 0 Applexion SAS REV 0 1 2 Applexion SAS PFD-1 DATE DESIGN CHECK 20/01/2006 RM FR PFD-2 DATE DESIGN CHECK 20/01/2006 RM FR 24/08/2006 RM 15/12/2008 FR PFD-1: NaCl 9% PT FS PDS DS SW HW RW Filtered Syrup Pre-decolorized Syrup Decolorized syrup Sweet on/off Water Hot regeneration water Recovered Water PT PT PFD-2: NaCl 9% C120A C120B NF PERMEATE PDS PI PDS PI DS MX175 CSB NFR NFP Concentrated Spent Brine NF Retentate NF Permeate MEMBRANES FIC CT PT PT FIC NF260 PFD-3: HCl 33% PDS PI NF skid CIP WATER C120C FIC NF RETENTATE PT PIT TT TT COOLING WATER TT PT PT FT TIC PT FT FT P265 P266 PSH LSH FILTERED SYRUP R LIC F125 U75 CT P PT LSL U115 PT SC F240 PIC P255 T230 PFD-1: EFFLUENTS PFD-2: EFFLUENTS P235 HE245 P250 PFD-3: EFFLUENTS MX295 HW F165 TIC PFD-3: NaCl 25% NF PERMEATE1 HW NF PERMEATE 2 FIC steam PT FS SC DS HE115 SW steam PT RW HW SC optional CSB LT T100 P105 condensate F110 LT T130 LT LT T140 T160 P155 NFP NFR LSL LT CT FIC SC FIC LT LT TIC LT T150 T220 e 22-102 PR01.03 1/1 P225 P270 optional T275 P276 T280 P285 HE290 condensate BRINE PREPARATION/EFFLUENTS REV 0 Applexion SAS PFD-3 DATE DESIGN CHECK FR 20/01/2006 RM FIC COLD WATER AIR 3 bar PT T320 TO COLUMNS IF ACID DEPOLLUTION MX310 HCl 33% DECANTER 6 5 SAND FILTER F340 NaOH 50% LT FIC SC HCl 33% NaOH 50% LT P375 SC SC SC LT T370 T360 P365 P305 P335 optional P325 B345 WASTE DISPOSAL HCl NaOH PFD-2: EFFLUENTS SALT NF PERMEATE 2 LT LT pHT P355 T300 NEUTRAL BRINE 300 g/l PREPARATION TANK T350 10xm3 Water /tS 8 7 PFD-2: NaCl 25% PFD-1: HCl 33% Kg NaCl /tS EFFLUENTS NEUTRALIZATION TANK 4 3 2 1 0 Decolo NF 10xm3 Effluent/t S Decolorization of Raw Cane Sugar syrup E 1/1 22-102 PR01.05 BRINE NF RECOVERY Applexion SAS 1/1 22-102 PR01.01 REV 0 1 ION-EXCHANGE DECOLORIZATION REV 0 Applexion SAS PFD-2 DATE DESIGN CHECK 20/01/2006 RM FR 03/04/2007 RM FR PFD-1 DATE DESIGN CHECK 20/01/2006 RM FR PFD-1: NaCl 9% PT FS PDS DS SW HW RW Filtered Syrup Pre-decolorized Syrup Decolorized syrup Sweet on/off Water Hot regeneration water Recovered Water PT CIP WATER PT PFD-2: NaCl 9% NF PERMEATE C120A C120B NF260 PFD-3: HCl 33% PDS PI FIC C120C PDS PI PDS PI DS CSB NFR NFP Concentrated Spent Brine NF Retentate NF Permeate MEMBRANES FIC MX175 CT PT PT FIC NF RETENTATE PI PT PIT COOLING WATER TT TT TT PT TIC PT FT PT FT AC215 FT P265 P266 PSH FILTERED SYRUP R P U75 CT F125 PT PT SC F240 LIC PIC P255 U115 T230 PFD-1: EFFLUENTS PFD-2: EFFLUENTS P235 HE245 P250 PFD-3: EFFLUENTS MX295 HW PFD-3: NaCl 25% NF PERMEATE 1 F165 TIC NF PERMEATE 2 WARM WATER FIC SC DS HE115 SW PT RW HW SC steam TIC LT DSB F226 CSB optional PT LT T100 P105 condensate F110 LT T130 T160 P155 T150 e T200 22-102 PR01.03 LT LT LT LT T140 P205 NFP NFR LSL LT CT FIC SC CT FIC steam PT FS HW TIC LT HE210 T220 P225 P270 optional T275 P276 T280 P285 HE290 condensate 1/1 BRINE PREPARATION/EFFLUENTS REV 0 Applexion SAS PFD-3 DATE DESIGN CHECK FR 20/01/2006 RM FIC COLD WATER AIR 3 bar PT T320 TO COLUMNS IF ACID DEPOLLUTION MX310 HCl 33% DECANTER LT FIC SC HCl 33% NaOH 50% LT P375 SC SC SC LT T370 T360 P365 P305 P335 optional P325 B345 WASTE DISPOSAL HCl NaOH PFD-2: EFFLUENTS SALT NF PERMEATE 2 LT LT pHT P355 T300 NEUTRAL BRINE 300 g/l PREPARATION TANK T350 10xm3 Effluent/t S 6 5 SAND FILTER F340 NaOH 50% 10xm3 Water /tS 8 7 PFD-2: NaCl 25% PFD-1: HCl 33% Kg NaCl /tS EFFLUENTS NEUTRALIZATION TANK 4 3 2 1 0 Decolo NF VAP/NF Decolorization of Raw Cane Sugar syrup S Success d driven i by b continued ti d cooperation ti and d shared h d 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 in Montreal 2000 tons sugar/day 1990-2009 : Cosumar in Casablanca 3000 tons sugar/day 2000-2009 : Cevital in Bejaia 5000 tons sugar/day Decolorization of Raw Cane Sugar syrup Presentations from many team members at professional exhibitions hibiti and d industry i d t meetings: ti 2000 CANE SUGAR REFINING HANDBOOK Dr Chi-Chou 2nd Edition - John Wiley & Sons CHAPTER 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 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 RESINS RESINS. Francis Gula/Dominique Paillat SIT 2006 NEW DEVELOPMENTS FOR THE REDUCTION OF THE CHEMICAL CONSUMPTIONS AND THE PRODUCTION OF EFFLUENTS IN MODERN ION ION-EXCHANGE 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 Decolorization of Raw Cane Sugar syrup 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’IONS DANS L’INDUSTRIE SUCRIERE Xavier Lancrenon IAA 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 EFFLUENT Stéphanie Cartier/Marc-André Théoleyre/Martine Decloux SPRI 1999 RESIN DECOLORIZATION OF HIGH COLOR SYRUPS THANKS TO REGENERATION RECOVERY François Rousset Decolorization of Raw Cane Sugar syrup Next steps ? Further innovation for greener process 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
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