The papers presented at the Meeting are listed below, linked to an abstract of the paper.
#916 Keynote Speaker : [Mr. Brian O’Malley, Domino Foods]
#917 Projecting how many Reactivation Cycles Activated Carbon can Last
#918 Extending Life of Decolorization Resin by Aggressive Cleaning Procedures
#919 Pilot Plant Evaluation of Anaerobic Digestion to Extend the Capacity of the Waste Water Treatment Plant
#920 Microwave Technology: Process Control of Brix Measurement in the Sugar Factory
#921 The Right Microwave Measuring Technique for Brix Control
#922 On-Line NIR Applications
#923 Symposium - [NO ABSTRACTS]
#924 Value Added Functional Foods from Sugar Processing By-Products - CMS and Molasses
#925 Production of Fullerenes from Molasses
#926 Use of Vibroscreen in Sugar Industry for Improving Sugar Quality
#927 Behaviour Safety in the Sugar Industry - a Case Study
#928 Fast Track Implementation of one of the World's Largest and Most Complex Sugar Factory Projects
#929 An Overview of the Baltimore Refinery
#930 A Technical Report on Steps Taken to Achieve the Desired Results in the Vacuum Pan Automation Process of the Dangote Sugar Refinery plc
#931 Building a Collaborative Service Provider Network
#932 Sugar Research and Development – Do We Have a Tunnel Vision?
#933 Regulating Valves in Critical Processes with Low Pressure
#934 Discovery of Molassessenes from Sugar Industry Byproducts
#935 Characterization of Filter Clogging Material in Raw and White Cane Sugar
#916 SERVING THE CUSTOMER
Brian O’Malley, Domino Foods, Inc., Iselin, NJ, USA
No abstract available at this time.
#917 PROJECTING HOW MANY REACTIVATION CYCLES ACTIVATED CARBON CAN LAST
Mick Greenbank, Calgon Carbon Corporation, Pittsburgh, PA, USA
The life of a carbon granule in a reactivation process is dictated by how many carbon atoms can be gasified from its structure before destruction. This work demonstrates how doing a series of activations, starting with virgin activated carbon, it is possible to demonstrate how much carbon can be removed before hitting the 'reactivation wall' where no further alteration of the carbon skeleton can be achieved without destroying the particle. In theory, the less carbon skeleton in the original carbon granule, the less carbon atoms that can be removed before 'hitting the wall' and thus the fewer reactivation cycles the granule can go through.
The number of reactivation cycles left in a pool carbon is also determined by comparing an activation series starting with virgin CPG and one starting with reactivated CPG carbon from a corn syrup plant (easily related to reactivation at a cane sugar facility). Also comparisons of activation of virgin CPG, the new Systemax, and the new CPG-TR virgin carbons demonstrate the advantage of additional react cycles, and longer projected life, for the new higher density carbons, because they have more carbon skeleton. Data is also presented for Chinese agglomerated and nonagglomerated carbons with lower density, and less carbon skeleton, and thus fewer life cycles versus CPG.
#918 EXTENDING LIFE OF DECOLORIZATION RESIN BY AGGRESSIVE CLEANING PROCEDURES
Vadim Kochergin , Audubon Sugar Institute, Baton Rouge, LA, USA, William Jacob, Amalgamated Research Inc., Twin Falls, ID, USA, William Bornak and Michael Kearney, Recirculation Technologies, Inc., Warminster, PA, USA
Decolorization with ion exchange resins has become a standard operation in the sugar refining industry. Depending on the overall color loading, a combination of resins is often used, where colorants are subjected to anion exchange resins with different functional groups. Because of the large variety of colorants present in the feed solutions and the difficulty of controlling the completeness of resin regeneration decolorization capacity gradually declines with time. The capacity reduction is explained by organic fouling that cannot be removed by standard regeneration procedures. Often periodic acid cleaning is added to the routine alkaline brine regeneration procedures to fight the downward trend in resin performance. Resin is eventually replaced after standard procedures do not yield the desired results. The issues of resin fouling and cleanup have been addressed in our study, where a resin-based process was developed to potentially replace bone char operations in the refineries. Cane syrup with a color of 1 200 ICUMSA was subjected to ion exchange decolorization to establish the baseline resin performance. A technology developed by Recirculation Technologies Inc. has been tested for restoration of heavily fouled resins after continuous operation on both beet and cane derived syrups. Resin parameters and performance before and after the rejuvenation procedure have been compared. It has been established that the performance of anion exchange decolorization resin could be restored to a great extent. The results of chemical and microscopic resin examinations will be discussed along with decolorization performance before and after the treatment. Once proven on a commercial scale, the proposed rejuvenation procedures may reduce the operating cost related to the cost of resin replacement and reduce the regenerant usage due to a higher average resin performance.
#919 PILOT PLANT EVALUATION OF ANAEROBIC DIGESTION TO EXTEND THE CAPACITY OF THE WASTE WATER TREATMENT PLANT
A. S. Vawda, M. R. Laullooo, Y. Al Thomali, and A. S. Banakr, United Sugar Company, Jeddah, Saudi Arabia
United Sugar Company is a standalone refinery located in Jeddah. Over the past ten years, the refined sugar output has increased from 550,000 thousand to just over 1 Million tonne per year. The expansion has placed additional load on the fully aerobic waste water treatment plant which is often overloaded. In order to cater for this load and for future increase in organic load, the refinery technical staff have looked at cost effective ways to expand the capacity of the current waste water treatment plant. A pilot anaerobic digester was built and operated under various conditions. This paper presents the results of the digester and it can be seen that anaerobic digestion can reduce the COD by up to 80% without additional power consumption.
#920 MICROWAVE TECHNOLOGY: PROCESS CONTROL OF BRIX MEASUREMENT IN THE SUGAR FACTORY
K.-H. Theisen and I. Geyer, pro-M-tec Theisen, GmbH, Ettlingen, Germany
The microwave concentration measurement is one of the most modern technologies used in industry for process measurement and control. Measurement systems have been successfully employed for Brix control on pans (batch and continuous) in the sugar making process. Recent developments allow the technology to be applied to virtually all measurement points requiring the process variable determination and control of concentration, density, or total solids in sugar plants. Over the last few months new applications, especially the concentration measurements in large pipelines and measurements in tanks, melters and mixers have shown that microwave technology thereby offers unique and new solutions to the sugar producing industry.
This paper discusses measurement experiences with microwave concentration measurement on large pipelines, in mixers, melters, vessels. Particular focus is on the concentration measurement of magma, molasses and mil of lime, with discussion of the technical aspects, considerations and advantages of the employment of microwave technology .
#921 THE RIGHT MICROWAVE MEASURING TECHNIQUE FOR BRIX CONTROL
Dipl.-Ing. Ulrich Klute, Berthold Technologies, Bad Wildbad, Germany
In recent years microwave measuring techniques for Brix control won worldwide recognition. The dry substance of sugar syrup and massecuite is measured online with high accuracy using microwave. This permits a continuous measurement during the complete crystallization process, both in the solution and the magma phase.
The report covers both signal analysis and processing of microwaves. Generally, great importance is attached to excellent signal analysis, even for low intensity microwaves. The microwave measuring system of Berthold Technologies is described, with its multi-frequency technique unique in the sugar industry. It is made clear that not every microwave measuring system presents an efficient solution to the problem at hand. The benefits for users by choosing the right signal processing are pointed out. The listed process samples demonstrate the high accuracy that is reached. Furthermore they serve to illustrate the various measuring applications for which users require an efficient measurement solution.
#922 ON-LINE NIR APPLICATIONS
Jan Kasprzak, Brimrose Corporation of America, Baltimore, MD, USA
Fast, accurate moisture measurement in bagasse fuel allows better control of the combustion process. In order to avoid extracting samples from the conveyer and carrying them to the lab for moisture measurement, Brimrose has introduced their AOTF-NIR On–Line Process Analyzer based on solid-state technology with no mechanical moving parts that will provide results in Real Time for process adjustments. Brimrose’s model 4030 is designed to be used or installed directly in the harsh production environment and is immune to dust, dirt, vibration, etc. In addition to single channel units, Brimrose also offers multi-channel units (up to 16 streams) to monitor Sucrose or Brix, % Acid, TA (Titratable Acidity), ash and pH.
#923 SYMPOSIUM - A: ON LINE PROCESS CONTROL MEASUREMENT- No abstracts at this time
#923 SYMPOSIUM - B: DRYING AND CONDITIONING OF GRANULATED SUGAR- No abstracts at this time
#924 VALUE ADDED FUNCTIONAL FOODS FROM SUGAR PROCESSING BY-PRODUCTS – CMS AND MOLASSES
Dr. Wen Hong Gao, South China Univ. of Technology, Jeng Yang, Vedan Enterprise Holding Corp, Taiwan, and Dr. Chung Chi Chou, South China Univ. of Technology, China
Recent studies has shown relationship between the aging process and the damaging effects of free radicals on tissue cells, and the beneficial impact on blood plasma antioxidant capacity of the increased daily intake of antioxidant-rich foods. In two Japanese studies, published in 2001 and 2002 Sugar Industries Technologists Technical proceedings, sugarcane extracts are found to have many other beneficial physiological functions
The Oxygen Radical Absorbance Capacity (ORAC) method to quantify the antioxidant property was developed at USDA several years ago, and has since then been used to rank (ORAC units/100 g) common foods. Prunes (5,770), raisins (2,830), and blueberries (2,400) top the list, trailed by such health food industry favorites as kale (1,770), spinach (1,260) and Brussels sprouts (980). USDA scientists have recommended an intake of 3000 to 5000 ORAC units/ per day. Antioxidants in concentrated sugarcane extracts obtained from cane juice, using the Cti process for extraction, was found to contain over one million ORAC units/100g
Besides ORAC units, analysis was also performed on polyphenols and cathechin. The % of polyphenols is comparable to that of grape seeds extract, currently one of the more popular antioxidants on the market. In this study, Cti process is employed to extract polyphenols from cane molasses and concentrated molasses fermentation soluble, a by-product of monosodium glutamate production by fermentation of cane molasses. Two eluents, namely alkaline aqueous solution and ethanol alcohol, were used and results are expressed in term of polyphenol content.
#925 PRODUCTION OF FULLERENES FROM MOLASSES
Kaman Singh and Ram Bharose, University of Lucknow, Lucknow, India
On account of their diverse applications, fullerenes will be required in large quantities. Such quantities so far have been produced by heating or arching of graphite. However, graphite is expensive, costing $ 1,000-5,000 per tonne. Pang et al. (1991) have prepared gram quantities of fullerenes from coal derived coke, but the coke costs about $ 500 per tonne. Commercial preparation of fullerenes from relatively cheap and abundant sources, hence, is desirable. Fullerenes were discovered from commercially available material; molasses; a byproduct of sugar industry and patent filed. Hence, a new term “MOLASSESENES” has been coined by the authors to acknowledge the potential importance of the molasses in the commercial production of fullerenes with tremendous potentialities across the fields from high tech to nanotech, electronics to catalysts and from defence to medicine. Furthermore, production of fullerene from molasses would be more than 90 times cheaper than produced from graphite. The current price of C60 is very roughly the price of gold, for C70, it is about an order of magnitude larger, and that of higher fullerenes very much higher. With the present cost of molasses about $ 1-2 per tonne, its use as an industrial source of fullerenes would greatly improve the economics of production. Hence, a waste molasses may be a boon for sugar industry. Thus, it could be major breakthrough for the sugar industry in the commercial production of fullerenes.
#926 USE OF VIBROSCREEN IN SUGAR INDUSTRY FOR IMPROVING SUGAR QUALITY
A K. Jain, Nanokar Enterprises, Delhi, India
Usually we always focus on the purity when one intends to improve sugar processing, however if one changes the approach and emphasize on impurities; many difficulties that are likely to trouble at later stages can be known and minimized. These impurities could gain entry via process parameters or may be generated during process. Part 1 deals with the insoluble impurities that are generated during process and or gain entry via process additives. Bagacillo from mixed juice / filtrate, grit / sand from MOL, un-wanted dust in seed and un-dissolved sugar particles and foreign material in melt can cause huge damage to the sugar quality and some especially bagacillo can enhance process difficulties that influences both – sugar quality and cost of production. Entry of these impurities can be minimized effectively by selecting proper screens using specially designed Vibroscreens having gyro – motion. Such Vibroscreens are being used successfully to improve quality of MOL, remove suspended impurities from melt, dust from seed slurry and fine bagacillo from mixed juice and filtrate. It is found that use of such Vibroscreens is effective in controlling color and quality of sugar and being low cost but effective technology such Vibroscreens are found to be significantly economical.
#927 BEHAVIOUR SAFETY IN THE SUGAR INDUSTRY – A CASE STUDY
Peter Briggs, United States Sugar Corporation, Clewiston, FL, USA and Alan Grant, Behavioral Science Technology, Inc., Ojai, CA, USA
US Sugar Corporation reduced workers compensation costs by 62% and overall injury rates by 54% in four years. With a data-driven, behavior-based process, this company took a proactive approach to reduce exposures in the workplace. This session covers the assessment, intervention, and principles that brought about those changes. You’ll learn the scientific grounding of the assessment tool, the Organizational Culture Diagnostic Instrument, with its nine scales predictive of performance outcomes. You’ll see a model explaining why people do what they do relative to antecedents (triggers) and consequences (outcomes) and how U.S. Sugar’s safety process used these two forces to drive desired safe behaviors. An examination of the model in action will give you an understanding of how the increasing frequency and quality of their safety interactions resulted in a statistically significant improvement on their control charts even to the point of having an authentic systems change in three departments. The change also shows that the variation in the safety system now is less than it was prior to the intervention. We’ll also examine what happens in the safety interactions (peer-to-peer observations) and the application of the principles that contributed to the changes seen in the data. We’ll show how organizational factors, teamwork factors, and safety-specific factors all affect the organization’s safety outcomes. Besides the hard data, we’ll take a look at anecdotal evidence to gain more understanding of the organizational and interpersonal dynamics involved in what site representatives identify as a true culture change.
#928 FAST TRACK IMPLEMENTATION OF ONE OF THE WORLD’S LARGEST AND MOST COMPLEX SUGAR FACTORY PROJECTS
M. Wade, US Sugar Corporation, Clewiston, FL, USA and Arno Jansen, Schaffer and Associates, Baton Rouge, LA, USA
United States Sugar Corporation owns and operates two large cane sugar milling operations in the South Florida region around Lake Okeechobee. The rated grinding rate of the Clewiston and Bryant facilities is 22,000 tons cane per day and 18,000 tons cane per day respectively. A decision was taken in early 2004 to consolidate, expand and modernize the sugar milling operations by combining both facilities into one on the Clewiston site with a view of enabling United States Sugar Corporation to becoming a low cost producer thereby enhancing the long term future of the company. At the time, the project termed “Breakthrough” was one of the largest private industrial construction projects in the United States.
To make the project as cost effective as possible, required that the project be implemented over a three year, three phase program to coincide with the harvesting season. Under these constraints the requirement was to get the project operational as fast as possible which required a fast track approach utilizing specially tailored unique project management, procurement and construction methods.
This very aggressive fast track complex project demanded that engineering, procurement and construction were conducted almost in parallel, in an environment where both the existing raw sugar milling and refinery facilities were in operation.
This paper discusses the project and construction management approach, together with the numerous challenges which were encountered along the way.
#929 AN OVERVIEW OF THE BALTIMORE REFINERY
Stuart J. FitzGibbon, American Sugar Refining, Inc., Baltimore, MD, USA
The city of Baltimore’s inner harbor is one of the most sought after tourist destinations in the world. The most recognizable feature of the harbor is the iconic “Domino Sugars” neon sign. Under this sign American Sugar Refining’s Baltimore refinery stands as testimony to the opportunities that abound for industries which are able to adapt to the increasingly competitive pressures of the global economy.
When commissioned in 1922 the Baltimore refinery processed 2 million pounds of raw (cane) sugar per day. The refinery’s capacity was increased over the subsequent decades in response to increasing consumer demand. In the 1980’s competitive pressure from HFCS and beet sugars resulted in a significant consolidation of the US sugar industry. The site responded through an increase in its retail and industrial packaging capabilities supported by a significant increase in refining capacity.
As one of the largest sugar refineries in North America, the facility now refines 6 million pounds of raw (cane) sugar per day. The refinery has modernized unit processes and energy recovery systems, including significant process automation, carbonatation, GAC, co-crystallization, wedge wire filtration as well as a significant increase in white sugar drying capacity. Energy conservation has been a strategic goal over the last 10 years. This program has included the additions of a falling film evaporator, plate and frame heat exchangers, vapor melting and a high pressure boiler. The ability to add value through improved packaging and service is Baltimore’s most important asset. With 20 packaging lines, bulk granulated and liquid sugar production capabilities the plant has one of the largest and most versatile packaging facilities in North America.
#930 A TECHNICAL REPORT ON STEPS TAKEN TO ACHIEVE THE DESIRED RESULTS IN THE VACUUM PAN AUTOMATION PROCESS OF THE DANGOTE SUGAR REFINERY PLC
Anthony Ogheneovo, Dangote Sugar Refinery, Lagos, Nigeria
All the sequence in the original design program of the high-grade vacuum pan automation such as Pan seeding, lubrication, concentrating the liquor and feeding etc. was based on super saturation of the massecuite (material) in the pan. Quality of sugar crystals produced from the automated pans was not satisfactory as was evident by the results of the MA, CV, dust content and others taken from over 50 samples. Tabulation and graphical representation showed a wide range of deviation from the acceptable standard values.
Investigation revealed that the Pan Brix Probes (controller) were transmitting false results and hence generating false values of Super Saturation which is tied directly to the Brix. Consequently there was a serious interference in the whole boiling sequence as they are either delayed, overlapping, or are transmitted earlier. Further investigation revealed that the Brix controller needed more frequent recalibration for more accurate transmission. Secondly it was observed that the 3 bar steam used for washing the pans after dropping its content was destroying the Brix sensor whose thermal resistance can not cope with this temperature and pressure. Washing with the 1.5Bar steam yielded an excellent result. For optimization and steam economy, the automation process was extended to the Boiler and power transmission section of the process.
Yield crystal size, CV, boiling time, dust content, less number of personnel to operate the pans amongst others are the benefit we enjoy from this automation process.
#931 BUILDING A COLLABORATIVE SERVICE PROVIDER NETWORK
Raymond Smith, United Sugars Corporation, Edina, MN, USA
A relationship with your Third Party Service Providers (TPSP) built on collaboration provides the necessary means to develop a strong and representative TPSP network. The benefits of such a collaborative process results in a Win/Win/Win success for all three stakeholders, your organization /your TPSP/ and your Customers.
The deployment of a TPSP can be an effective strategy to complement and expand the reach of your distribution system. Not only can their use result in effective competitive cost options, but they can also provide a functional expertise that may not necessarily be a part of your organization’s core competency.
In effect, a TPSP becomes the face and service of your organization to your customer. This extension of your company’s service function is perceived by your customer as just that – simply another facet of your organization. Your customer does not judge the TPSP performance as simply the performance of the TPSP. Your TPSP’s performance is accepted as your performance. Hence, you are presented with the challenge of assuring all TPSPs interact with your customers in a manner representative of your organization’s philosophy and business methods. Much of this assurance is instilled through tangible metrics such as standards, specifications, and the following of defined operating procedures. However, it takes much more than specifications to accomplish the type of relationships needed to establish your TPSP as a competent representative of your organization.
An integration of a full working understanding between your organization and your TPSPs must be attained. A much more intimate relationship, rather than reliance upon traditional customer/vendor models, is needed to develop the type of respect, trust, and confidence between you and your TPSPs to effectively transform them into an extension of your organization.
#932 SUGAR RESEARCH AND DEVELOPMENT – DO WE HAVE A TUNNEL VISION?
Dr. Chung Chi Chou, President, Dr. Chou Technologies, Inc. New York, USA
In a paper entitled Thirty Years of Research in the Sugar Industry (SIT 1999), Ms Mary Ann Godshall, formerly Managing Director of Sugar Processing Research Institute, and I cited research achievement in the past thirty years and listed numerous incremental improvement in processing technologies, analytical methods and equipments. However, there are very few commercialized new process/products over the years in the sugar industry.
Dr. Mohamed Mathlouthi of Universite de Reims Champagne – Ardenne, published a paper in the SPRI 2000 conference entitled “Highlights of Twentieth Century Process in Sugar Technology and the Prospects for the 21st. Century.” His paper covered the beet sugar industry. Again, he reported numerous improvements in equipment, processing technologies and analytical method, but very few major break-through in processing methods.
In conjunction with a consulting assignment, I have reviewed the publications in SIT Technical Proceedings from 1947 to 2002 and SPRI Research Conference Proceedings from 1964 to 2000. As author/coauthor of two sugar handbooks and 40 years experience in the sugar industry with highly visible/responsible position, I am well aware of current processes being used in the industry. Base on my best knowledge, I have found/listed only fifteen (15) commercialized new processes/analytical methods in the sugar industry over the past half a century”, of which eleven were published in SIT and/ or SPRI. Of the fifteen commercialized technologies, five have discontinued operation due to failure or plants closing!
In this paper criteria used for projects selection and research approaches are described in order to ensure high probability of success. Challenging projects with considerable commercial benefits for future research are presented.
#933 REGULATING VALVES IN CRITICAL PROCESSES WITH LOW PRESSURE
Eberhard Hanelt, Crane Process Flow Technologies, GauBster, Germany
No abstract available at this time.
#934 PRODUCTION OF FULLERENES FROM MOLASSES
Kaman Singh and Ram Bharose, University of Lucknow, Lucknow, India
On account of their diverse applications, fullerenes will be required in large quantities. Such quantities so far have been produced by heating or arching of graphite. However, graphite is expensive, costing $ 1,000-5,000 per tonne. Pang et al. (1991) have prepared gram quantities of fullerenes from coal derived coke, but the coke costs about $ 500 per tonne. Commercial preparation of fullerenes from relatively cheap and abundant sources, hence, is desirable. Fullerenes were discovered from commercially available material; molasses; a byproduct of sugar industry and patent filed. Hence, a new term “MOLASSESENES” has been coined by the authors to acknowledge the potential importance of the molasses in the commercial production of fullerenes with tremendous potentialities across the fields from high tech to nanotech, electronics to catalysts and from defence to medicine. Furthermore, production of fullerene from molasses would be more than 90 times cheaper than produced from graphite. The current price of C60 is very roughly the price of gold, for C70, it is about an order of magnitude larger, and that of higher fullerenes very much higher. With the present cost of molasses about $ 1-2 per tonne, its use as an industrial source of fullerenes would greatly improve the economics of production. Hence, a waste molasses may be a boon for sugar industry. Thus, it could be major breakthrough for the sugar industry in the commercial production of fullerenes.
#935 CHARACTERIZATION OF FILTER CLOGGING MATERIAL IN RAW AND WHITE CANE SUGAR
Marianne McKee, Mary An Godshall, Ron Triche and Charley Richard, Sugar Processing Research Institute, New Orleans, LA, USA, and Walton Goynes, Southern Regional Research Center, New Orleans, LA, USA
Solutions of raw and refined sugar were sequentially filtered on Millipore membranes with pore sizes ranging from 60μ to 0.45μ. The material that coated on the membrane surfaces was examined by electron microscopy. The microscopy images showed that membranes with pore sizes of 1.2 μ or smaller were completely coated with an amorphous, gel-like material. It is speculated that this material contributes both color and turbidity during sugar processing and may arise from highly degraded bagacillo. Filtration studies showed that most refined cane sugar solutions will clog a 0.45μ membrane before a solution containing 100 g of sugar can be completely filtered. Enzyme studies showed that cellulase and hemicellulase treatment of raw sugar solutions improved filtration. Hydrolysis and gas chromatographic examination of the filter-clogging material showed a polysaccharide-rich component that was high in mannose and glucose, indicating a different composition from the soluble indigenous cell wall polysaccharide of cane. The material was also shown to coat ion exchange resin beads used in a sugar refinery.