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Volume CXVI Issue No. 1388

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

Editorial Comment

One 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 equip-ment 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 col-orimeters 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 obsoles-cence 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 Policyhttp://www.foreignpolicy.com/articles/2013/11/19/stuxnets_secret_twin_iran_nukes_cyber_attack?page=full

EXTRACT THE BESTFROM YOUR SUGAR CANE.

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.

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International Sugar Journal | August 20144

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Editorial:Editor: Arvind Chudasama MSc., MAgSt. (Qld), MCLIP Email: [email protected]

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

ISSN 0020-8841

International Sugar Journal is published monthly by Informa UK Ltd.

© 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.

Panel of RefereesL. 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.

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.

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

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.

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.

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Monthly Snapshot

August

Market Overview

Over the past three months, sugar prices have been in the range USc 16.5 -18.5/lb as global surplus continues to decline on the 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 184.6 mln tonnes last year. In their latest reports Czarnikow and Rabobank look to 2014/15 - the former notes a rebound in beet sugar production from 35.1 million tonnes raw value (mtrv) to 36.3 mtrv, while cane sugar production is forecast to decline from 148.8 mtrv to 147.9 mtrv. Both Cazarnikow and Rabobank indicate deficits of some 0.5 mln and 0.9 mtrv next year, respectively.

Brazil – drought has had impact in the current season in some regions of Sao Paulo, the main sugar producing state. Czarnikow puts 2014/15 sugar production at 32.9 mtrv compared with 34.3 mtrv in 2013/14.

India – with the cyclical production now becoming a feature of the past, over 26 mtrv sugar was produced in 2013/14, which Czarnikow forecasts may increase to 27.9 mtrv next year. This maybe, as Rabobank suggests due to Indian government extending the subsidy of INR 3.33/kg (USD 54/tonne) for exports of up to 4 mtrv sugar over the next two years until September 2014, at the same time increasing import duty on sugar from 15% to 40%.

China – 2013/14 sugar production was 13.8 mtrv. It could have been more if it wasn’t for the beet sugar production being down by 31% at 811,000 tonnes raw value. Czarnikow forecasts 2014/15 production to decline further to 13.2 mtrv, but consumption is estimated to grow by 4% to 17.6 mtrv.

Indonesia – 2014/15 sugar production is estimated to be 2.6 mtrv with no significant expansion in acreage. Government is expected to issue import licenses to refiners amounting 3.2 mtrv.

Thailand – a record 12.1 mtrv sugar was produced in 2013/14. This is likely to increase to 12.8 mtrv in 2014/15 according to Czarnikow. Compared with rice and cassava, sugarcane continues to be a profitable crop for farmers.

EU – 2014/15 sugar production is forecast at 17.7 mtrv, up by almost 5% on last year as producers battle for market share ahead of the abolition of quotas in 2017.

US – Sugar production is anticipated to decline 5.5% to 7.7 mtrv compared with last year.

F.O.Licht's International Sugar and Sweetener Report

Vol. 146, No. 18 / 16.06.2014 2014 F.O.Licht GmbH 313

Output in the European Union fell to 16.8 mln tonnes in 2013/14 – 0.4 mln above our February guidance but still down from 17.4 mln a year ago. Sugar supply in the EU is currently ample and the Commission has there-fore skipped plans mulled earlier in the year for a new round of tenders for imports at reduced duties and the conversion of out-of-quota sugar into quota sugar. In fact, supply is so ample and prices have fallen that sharply that 325,054 tonnes out of Brazil’s CXL import quota (totaling 334,054 tonnes) for 2013/14 (Oct/Sep) are still unused as nobody dares taking the risk to end up with sugar that cannot be sold on to a customer.

As already pointed out before F.O. Licht does not include the sugar equivalent of beet that were not pro-cessed into the end product crystal sugar (such as those used for fuel ethanol or biogas) in its sugar pro-duction estimates, which differs from the approach used by the bloc's sugar associations and official EU statis-tics.

Our estimate for Russia and Ukraine remain unchanged from our February guidance as the campaigns

had already been concluded at the time and the results were known. Russia's 2013/14 beet sugar output declined to 4.8 mln tonnes from 5.1 mln a year earlier, while Ukraine produced only 1.4 mln tonnes of sugar in 2013/14 compared with the previous year's 2.3 mln. Surplus stocks in the country have been re-duced sharply and area for 2014/15 has recovered somewhat. Turkey's sugar production rose by 0.2 mln

tonnes on the year to nearly 2.6 mln on high beet yields and sugar con-tent, which represents an upward revision of our February estimate of 2.4 mln.

Africa

African sugar production is now seen up at 12.1 mln tonnes in 2013/14 from 11.3 mln in 2012/13 - representing an upward revision of 47,000 tonnes from our previous forecast.

The y-o-y increase is mainly driven by a recovery in South Africa as well as capacity expansion in Ethiopia and Sudan.

It may be pointed that sugar pro-duction in the southern hemisphere producers of the continent (such as South Africa, Swaziland, Zimbabwe, Zambia etc.) on an Oct/Sep basis cuts across two local crop years. In the continent's top producer South Afri-ca, for example, the local 2013/14 crushing season lasted from April 2013 to January 2014, of which only the sugar produced from October 1, 2013 onwards belongs to the coun-try's output for the purpose of this

Quarterly World Sugar Balance (1000 tonnes, raw value) Oct/Dec Jan/Mar Apr/Jun Jul/Sep 2013 2012 2011 2014 2013 2012 2014 2013 2012 2014 2013 2012

Opening stocks 72,992 64,678 58,614 93,492 90,889 80,157 111,314 107,744 96,014 92,624 88,075 77,074 Output 63,069 69,330 63,325 60,478 59,304 56,410 25,362 24,370 21,880 32,291 31,593 33,308 Imports 16,486 16,723 15,195 15,025 14,665 13,290 14,459 15,508 14,769 15,332 16,307 16,386 Consumption * 43,391 42,721 41,455 42,188 41,467 40,460 43,542 42,683 41,597 46,456 45,539 44,606 Exports 15,664 17,121 15,522 15,493 15,646 13,384 14,970 16,865 13,992 17,708 17,445 17,485 Ending stocks 93,492 90,889 80,157 111,314 107,744 96,014 92,624 88,075 77,074 76,083 72,992 64,678 * Residual of the balance

World Sugar Balance Oct/Sep (1,000 tonnes, raw value)

Sugar 2013/14 2012/13 2011/12 2010/11 2009/10 Opening stocks 72,991.9 64,677.7 58,614.3 56,970.0 60,363.3 Production 181,200.1 184,596.8 174,924.6 165,524.5 159,026.7 Imports 61,302.2 63,202.8 59,640.6 59,612.7 62,357.3 Consumption 175,577.4 172,408.9 168,117.9 162,443.3 162,027.4 Exports 63,834.1 67,076.6 60,383.9 61,049.7 62,749.9 Ending stocks 76,082.7 72,991.9 64,677.7 58,614.3 56,970.0 +/-Production -3,396.7 9,672.2 9,400.1 6,497.8 7,198.6 +/-% -1.84 5.53 5.68 4.09 4.74 +/-Consumption 3,168.5 4,291.0 5,674.6 415.9 341.9 +/-% 1.84 2.55 3.49 0.26 0.21 Stocks in % of consumption

43.33 42.34 38.47 36.08 35.16

Global surplus/deficit

3,090.8 8,314.2 6,063.4 1,644.3 -3,393.3

Note: May not add due to roundings; consumption excluding unrecorded disappearance

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F.O. Licht

Bearish sentiment continues to prevail in the market on the back of ample supplies from Brazil and Central America. The July delivery futures ended 17.04 cents/lb while the October ended at 17.85 cents/lb. London white futures for August contract was $465.20/tonne while the October was $473.90/tonne. According to India Meteorological Department, monsoon rains were 48% lower in early June, and expects below average rainfall in 2014. It dismissed the emerging impact of El Niňo weather phenomenon. By the second week of June, 117.50 million tonnes of cane was crushed in Brazil. This was practically unchanged from last year. Sugar production is down from last year to 5.439 million tonnes compared with 5.641 million tonnes, as is ethanol output, 4.838 billion litres compared with 4.876 billion litres. With current campaign in Mexico coming to end in mid-July, the output is forecast to reach 5.891 million tonnes compared with 6.811 million tonnes. China’s campaign ended in May with total output rising to 13.318 million tonnes, white value, up 1.9% from last year's 13.068 million tonnes. Cane sugar production rose 4.9% to 12,571,700 tonnes from 11,983,400 a year ago, while beet sugar output declined sharply to 746,300 tonnes from 1,085,000. According to FO Licht, sugar production estimate for India this year is marginally higher than last year (26.3 million vs 26.0 million tonnes). While the issue of cane payment arrears persists, farmers continue with growing cane as it is more profitable than others. The 2014/15 (Nov/Oct) sugar output in Thailand is expected to climb to 12 million tonnes, up by 6.3% from last year, according to the Thai Sugar Millers Corp, from 110 million tonnes cane. Exports in 2015 is expected to increase to 9 million tonnes from 8 million tonnes last year. In Queensland, Australia, unseasonally wet and cold weather at the start of the campaign has delayed harvesting – some 100 mm precipitation was received during the first week of June. Consumption growth in industrialised countries is expected to be 0.8% while that in developing countries is 2%, notes FO Licht. In emerging and developing economies - where sugar consumption growth tends to be highest - growth is projected to pick up gradually from 4.7% in 2013 to about 4.9% in 2014 and 5.3% in 2015.In China, growth is projected to drop fractionally from 7.7% in 2012 and 2013 to about 7.5% in



Argentina and Peru, but there have been no noteworthy adjustments from our previous forecast.

Asia

Asian sugar production is forecast to rise by 1.4 mln tonnes year-on-year to 68.6 mln, which is 0.6 mln above our February guidance. The upward revision is almost exclusively due to higher-than-expected output in Indonesia (+0.5 mln tonnes), with output in Thailand, India, and Pakistan coming in within striking distance of our previous projections.

We have increased our sugar production estimate for India marginally to 26.3 mln tonnes from 26.0 mln as the crushing season has come to an end in almost all states. There is a special season for the mills in Tamil Nadu and some of the mills in South Karnataka in August-September 2014, which is the reason why the numbers for the country cannot be finalized yet. While Indian production has been falling modestly for the past two years since reaching 28.6 mln tonnes in 2011/12, the country’s output exceeded domestic consumption for the fourth consecutive season in 2013/14. Also, output in 2014/15 can be expected to come in at a similar level as farmers are sticking with cane despite the industry’s critical financial situation and mounting arrears as cane prices look so attractive compared to other crops. The country is therefore likely to remain self-sufficient in 2014/15

for the fifth consecutive season though the 2013/14 crop was the smallest since 2009/10.

China's sugar production rose slightly to 14.5 mln tonnes in 2013/14 from 14.2 mln the year before, with output falling short of our previous forecast by just 0.2 mln tonnes. While the area under cultivation was down slightly, better weather allowed for the increase in production. Production in 2014/15 is likely to be lower as the industry is operating in the red and cane price arrears have piled up, which together with falling cane prices enticed farmers to switch to other crops. Thailand produced 11.6 mln tonnes of sugar in 2013/14, just fractionally below our February forecast of 11.7 mln and up considerably from the previous year’s 10.3 mln tonnes. It is self-understood that this volume represented a new record as crushing was aided by dry conditions and high sugar content. Farmers have been sticking to cane due to high cane prices aided by government sops.

Elsewhere, production in Indonesia is now seen up at 3.1 mln tonnes in 2013/14 from 2.8 mln a year ago due to conducive weather for the local 2014 crush (of which all produced by the end of September belongs to our 2013/14 balance year). Production in the Philippines is now seen higher than in February with the final total estimated at 2.4 mln tonnes compared with 2.3 mln three months ago but still somewhat below the nearly 2.5 mln tonnes produced in 2012/13.

Oceania

The sugar production estimate for Oceania has been left unchanged at February’s 4.6 mln tonnes, which would be down somewhat from 5.0 mln last year.

Australia's sugar production is seen falling to 4.4 mln tonnes in 2013/14 from 4.8 mln a year earlier. Harvesting in Australia has started earlier in June, with large-scale processing taking place from July onwards to October before production volumes drop off significantly up to the end of the calendar year. The number for 2013/14 therefore includes the tail end of last year's crush and the better part of the current 2014 crush, which is seen somewhat affected by a mid-April cyclone.

Sugar production in developing countries remains near record high

Sugar production in industrialised countries has resumed a downward trend and is seen reaching 40.0 mln tonnes in 2013/14, above our February estimate of 39.7 mln but still down significantly from 42.5 mln the year before.

World Sugar Production by Regions Oct/Sep (1,000 tonnes, raw value)

2013/14 2012/13 2011/12 2010/11 2009/10 EU 16,804 17,445 19,062 15,892 17,518 Europe 27,132 28,676 30,942 24,776 26,463 Africa 12,074 11,267 10,356 10,336 10,178 N. & C. America 22,439 23,709 20,490 18,860 18,856 South America 46,322 48,701 43,024 46,216 48,721 Asia 68,619 67,217 66,293 61,388 51,109 Oceania 4,615 5,028 3,820 3,949 3,700 Total 181,200 184,597 174,925 165,525 159,027 Note: May not add due to roundings

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F.O. Licht

Source: Czarnikow

2014/15 balance sheet – consumption exceeding production

Source: Czarnikow

Source: Czarnikow


Source: Czarnikow

Source: Czarnikow

Source: FO Licht

Indian swing cycle suspended over the last few years


Monthly Snapshot August‘14

World production estimates of cane and beet

Source: Czarnikow



Output in the European Union fell to 16.8 mln tonnes in 2013/14 – 0.4 mln above our February guidance but still down from 17.4 mln a year ago. Sugar supply in the EU is currently ample and the Commission has there-fore skipped plans mulled earlier in the year for a new round of tenders for imports at reduced duties and the conversion of out-of-quota sugar into quota sugar. In fact, supply is so ample and prices have fallen that sharply that 325,054 tonnes out of Brazil’s CXL import quota (totaling 334,054 tonnes) for 2013/14 (Oct/Sep) are still unused as nobody dares taking the risk to end up with sugar that cannot be sold on to a customer.

As already pointed out before F.O. Licht does not include the sugar equivalent of beet that were not pro-cessed into the end product crystal sugar (such as those used for fuel ethanol or biogas) in its sugar pro-duction estimates, which differs from the approach used by the bloc's sugar associations and official EU statis-tics.

Our estimate for Russia and Ukraine remain unchanged from our February guidance as the campaigns

had already been concluded at the time and the results were known. Russia's 2013/14 beet sugar output declined to 4.8 mln tonnes from 5.1 mln a year earlier, while Ukraine produced only 1.4 mln tonnes of sugar in 2013/14 compared with the previous year's 2.3 mln. Surplus stocks in the country have been re-duced sharply and area for 2014/15 has recovered somewhat. Turkey's sugar production rose by 0.2 mln

tonnes on the year to nearly 2.6 mln on high beet yields and sugar con-tent, which represents an upward revision of our February estimate of 2.4 mln.

Africa

African sugar production is now seen up at 12.1 mln tonnes in 2013/14 from 11.3 mln in 2012/13 - representing an upward revision of 47,000 tonnes from our previous forecast.

The y-o-y increase is mainly driven by a recovery in South Africa as well as capacity expansion in Ethiopia and Sudan.

It may be pointed that sugar pro-duction in the southern hemisphere producers of the continent (such as South Africa, Swaziland, Zimbabwe, Zambia etc.) on an Oct/Sep basis cuts across two local crop years. In the continent's top producer South Afri-ca, for example, the local 2013/14 crushing season lasted from April 2013 to January 2014, of which only the sugar produced from October 1, 2013 onwards belongs to the coun-try's output for the purpose of this

Quarterly World Sugar Balance (1000 tonnes, raw value) Oct/Dec Jan/Mar Apr/Jun Jul/Sep 2013 2012 2011 2014 2013 2012 2014 2013 2012 2014 2013 2012

Opening stocks 72,992 64,678 58,614 93,492 90,889 80,157 111,314 107,744 96,014 92,624 88,075 77,074 Output 63,069 69,330 63,325 60,478 59,304 56,410 25,362 24,370 21,880 32,291 31,593 33,308 Imports 16,486 16,723 15,195 15,025 14,665 13,290 14,459 15,508 14,769 15,332 16,307 16,386 Consumption * 43,391 42,721 41,455 42,188 41,467 40,460 43,542 42,683 41,597 46,456 45,539 44,606 Exports 15,664 17,121 15,522 15,493 15,646 13,384 14,970 16,865 13,992 17,708 17,445 17,485 Ending stocks 93,492 90,889 80,157 111,314 107,744 96,014 92,624 88,075 77,074 76,083 72,992 64,678 * Residual of the balance

World Sugar Balance Oct/Sep (1,000 tonnes, raw value)

Sugar 2013/14 2012/13 2011/12 2010/11 2009/10 Opening stocks 72,991.9 64,677.7 58,614.3 56,970.0 60,363.3 Production 181,200.1 184,596.8 174,924.6 165,524.5 159,026.7 Imports 61,302.2 63,202.8 59,640.6 59,612.7 62,357.3 Consumption 175,577.4 172,408.9 168,117.9 162,443.3 162,027.4 Exports 63,834.1 67,076.6 60,383.9 61,049.7 62,749.9 Ending stocks 76,082.7 72,991.9 64,677.7 58,614.3 56,970.0 +/-Production -3,396.7 9,672.2 9,400.1 6,497.8 7,198.6 +/-% -1.84 5.53 5.68 4.09 4.74 +/-Consumption 3,168.5 4,291.0 5,674.6 415.9 341.9 +/-% 1.84 2.55 3.49 0.26 0.21 Stocks in % of consumption

43.33 42.34 38.47 36.08 35.16

Global surplus/deficit

3,090.8 8,314.2 6,063.4 1,644.3 -3,393.3

Note: May not add due to roundings; consumption excluding unrecorded disappearance

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/12

2012

/13

2013

/14

Ending StocksConsumptionProduction

Stocks Prod/Cons

World Sugar Balance(mln tonnes, raw value)

F.O. Licht

Source: FO Licht

World production estimates of cane and beet

Source: Czarnikow

Source: Czarnikow


Sugar Industry News

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

sugarJOURNAL

INTERNATIONAL

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

Thailand’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.

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

The 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.

Sugar Industry News

British Sugar actively encouraging female engineering graduates to join the company

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

Austrian researchers produce erythritol from straw

Researchers 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.


France - 2014/15 beet yield hitting fresh record

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French 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 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.

Ethiopia - Seven new sugar factories to start production in 2015


Sugar Industry News

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

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

Crops 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.

The 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

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


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Fiji – Prison inmates exploited to harvest sugar cane

Inmates 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.


Sugar Industry News

National Energy Commission (CNE) director Enrique Ramírez and technicians recently inspected the construction of the San Pedro Bio Energy biomass-fired 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.

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

Pakistan'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.

Pakistan - Mills fail to export quota

Coca-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.

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

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

Ugandan 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.


Bangladesh - Sugar output rises 20% in 2013/14

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

Sugar 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". 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.


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

experience in Asia which includes stint with Syngenta.

Steve Moon – Germain’s new Managing Director

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.

(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.

People and Places Steve Moon – Germain’s new Managing Director

Steve Moon – Germain’s new Managing Director

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.

(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.

Steve Moon Alan du-Rieu


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, and had a working knowledge of Portuguese. Desmond travelled widely to attend international conferences connected with the sugar industry and regularly visited many of the major sugar producing countries to stay abreast of operational and technological innovation 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 Series in 1977.

Desmond made very many friends within the sugar industry. He remained in touch with a good number of them even following his retirement and relocation to the warmer climate of the south of France. Since his passing many have commented how much they enjoyed his company and his dry sense of humour. He was well liked and respected in the industry, by friends and colleagues who describe him as having been an ‘old fashioned gentleman’; unfailingly polite and considerate, he was completely 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 grandchildren and two great granddaughters. He will be sadly missed by all his family and friends.

[Throughout his life Desmond supported numerous charities but he was especially keen on the work of Barnardo’s. A donations page has been set up at www.justgiving.com/desmondleighton.]

Obituary – 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

Obituary


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For the analysis of sugar mixtures Browne & Zerban (1948) use total solids by drying, which is an accurate but lengthy procedure; reading a refractometer Brix is simpler but requires the

corrections described below. F and G have an effect on the refractometer reading

(20oC and 589nm) because the calibration is based on a pure sucrose solution: F, G and S have different refractive index/concentration relationships. A correction, Δw, which applies whether S is present or not, is available (ICUMSA, 1998), its magnitude depending on both the total solids and the concentrations of F and G:

where win is the invert sugar mass fraction(%),wTSr the reading, the coefficients are A = 6.222x10-3, B = 2.3725x10-4 , C = -1.8165x10-6 , D = 1.8906x10-8 and E = 2.328x10-5. An example is shown below.

Δw is expressed in % and should be added to wTSr, giving the correct Brix value. If the mixture is read at a temperature other than 20oC (which should be avoided) then a further temperature correction, beyond that from the table of pure sucrose, is required.

Brix gives a concentration in terms of mass solute per 100g of solution while pol gives it per 100mL of solution. The concentrations need to be expressed in identical units and thus a second Brix correction, using the density of the solution, is required. For Brix values (20oC and 589nm) ranging from 0 to 25 % (g/100g) a density (D, g/100mL) is given by

D = 0.00151x(Brix%)2 + 0.38367xBrix% + 99.823

This result is based on data from Bubnik et al (1995) used in a polynomial regression; the fit is excellent.

The concentration of dissolved solids in g/100mL, Bxv, is then given by

Bxv = Brix reading x D/100

For example if the Brix reading is 18.2 g/100g, then

Bxv = 18.2x107.2183/100 = 19.5g/100mL

and F + G = Bxv

where F and G are the concentrations in g/100mL.The specific rotation is now used, namely

where P is the normal weight pol reading (g/100mL). These two equations can now be solved for F and G.

Browne & Zerban give an example for the analysis of a solution containing F, G and S. They note that when one of the sugars is non-reducing the accuracy of the procedure improves.

The three equations are:

where G, F and S represent concentrations in g/100mL, T is the total solids by drying (to be replaced by Brix as described above), R is the copper reducing power, which is zero for S, and P the normal weight pol reading, as described in the previous Blackboard1. Readings should be at 20oC.

Browne & Zerban give the following example. A solution with 5.43% F, 10.02% G and 16.16% S was analysed as described above. T was found to be 31.50%, R 15.24% and P +17.05o.

The equations can be solved manually or Excel Solver can be used, as shown below.

Analysis of sugar mixtures (part II)

Raoul Lionnet [email protected]


Solver gives G = 10.5%, F = 5.2% and S = 15.8 %, compared to the prepared concentrations of 10.02, 5.43 and 16.16 respectively. The errors are 5% and less which should be acceptable for process control. The chosen concentrations of G and S are high; ideally low concentrations (10-5% for each sugar) should be used to improve accuracy.

Browne & Zerban give much information on the early developments on the analysis of sugars; they provide considerable details about polarimetry, refractometry and redox reactions. Many procedures were then new and needed to be improved; fundamental concepts were therefore very relevant. It is very clear that these authors had a passion for analytical chemistry in its broadest term; their knowledge of sugar chemistry, the attention to detail and their vision for the future were exceptional.

Endnote

1. See Blackboard published in the July 2014 issue, pp 474-475.

References

Anon. (1998). ICUMSA: Specifications and Standard SPS3

(1998) Refractometry and Tables - Official

Browne CA & Zerban FW (1948). Physical and chemical

methods of sugar analyses. John Wiley & Sons.

Bubnik Z, Kadlec P, Urban D and Bruhns M (1995). Sugar

Technology Manual. Bartens.

[email protected] | www.praj.net.


BioFuel News


sugarJOURNAL

INTERNATIONAL

Italy – 3 new cellulosic ethanol projects take shape

US EPA expands remit of federal biofuels mandate

The US Environmental Protection Agency (EPA) recently expanded the types of fuel that can be used to satisfy the federal biofuel mandate. This move could help bridge delayed targets for 2014 renewable fuel use, reports Reuters.

Three cellulosic ethanol projects are currently under development in Italy, according to local press reports. These will be developed by Biochemtex, a unit of Gruppo Mossi&Ghisolfi. The latter is a parental company of Beta Renewables operating the Crescentino cellulosic ethanol plant in Piedmont since late 2012.

Biosensor that sniffs out bacterial networks that breakdown lignin

A new biosensor invented at the University of British Columbia (UBC) could help optimize bio-refining processes that produce fuels, fine chemicals and advanced materials.


Denmark – EU funds cellulosic ethanol project

Sugazym was developed for the manufacture of raw and refined sugar from beets and cane. It frees the raw materials of starch and dextrans, enabling the fast, energy-efficient processing of sugar juice and syrup. The result is a crystal-clear sugar of the highest quality, with significantly lower production costs.

Your benefits:

• Higher sugar yield

• Optimum quality of the granulated sugar

• Better juice clarification

• Extended filter life

Dextranase and amylase for the sugar industry

SternEnzym GmbH & Co. KGKurt-Fischer-Straße 55 · 22926 Ahrensburg / GermanyPhone: + 49 / (0) 41 02 / 202-002 · Fax: [email protected] · www.sternenzym.de

A crystal-clear boost for production and quality: Sugazym.

Bloomberg reported that the Maabjerg Energy Concept won EUR39 mln from the European Commission's NER300 program for low-carbon projects. The EUR295 mln Maabjerg project, which includes Dong Energy and Novozymes, is a cellulosic ethanol plant in Midtjylland.


BioFuel News

Jamaica - Rising cane supplies likely to be diverted to the alcohol sector

US Joint BioEnergy Institute’s glycosyltransferase clone collection will support cellulosic biofuels production research

Researchers at the U.S. Department of Energy (DOE)’s Joint BioEnergy Institute (JBEI) have unveiled the first glycosyltransferase clone collection specifically targeted for the study of the biosynthesis of plant cell walls. The idea behind what is being called “the JBEI GT Collection” is to provide a functional genomic resource for researchers seeking to extract the sugars in plant biomass and synthesize them into biofuels.

Stakeholders in Jamaica currently discuss how to best use the additional volumes of sugarcane that might be available under the sugar transformation project.

Pakistan - Sugar surplus, weak ethanol prices hits Noon Sugar

Noon Sugar Mills for the six months ended on March 31, 2014 reported a decline in profitability following pressure on margins for sugar and ethanol production and a lack of stimulus from the ethanol export segment. Sales revenue rose by 19% year-on-year to PKR1.330 bln ($1=PKR97.94), while gross profit declined to PKR86 mln from PKR205 mln.


Peru – Maple Energy produces 3 million gallons ethanol from cane

Brazil - EPE expects slowing down in growth of fuel ethanol production

Maple Energy produced almost 3 million gallons of fuel-grade ethanol at its Peru-based biofuel plant between 1 January and 31 March this year according to a recent company update. E

mpresa de Pesquisa Energética (EPE), the research arm of Brazil's Energy Ministry, will adjust its long-term projection for fuel ethanol supplies in the country, following the crisis in the sector.

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Biobased Products News


sugarJOURNAL

INTERNATIONAL

BioAmber secures C$20 million to build biosuccinic acid plant in Canada

Researchers produce bioplastics from lignin

Some three to six million euros will be available in the Netherlands for research and development into biobased performance materials (BPM) over the next four years. The team in charge of the Top Sector for Chemicals (defined by the Dutch government as an investment priority) has approved a continuation of the BPM R&D programme which is currently coordinated by Wageningen UR Food & Biobased Research.

Dutch government and companies fund production of biobased performance materials

The biotech start-up BioAmber recently announced that its Canadian subsidiary BioAmber Sarnia Inc., a joint venture with Mitsui & Co., has secured a CAD$20 million (U$ 18.6 million) commercial loan to finance the ongoing construction of the Sarnia plant in Ontario, Canada.

Researchers from Biome Bioplastics collaborating with the University of Warwick’s Centre for Biotechnology and Biorefining, have demonstrated the feasibility of extracting organic chemicals from lignin for the manufacture of bioplastics.

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KEBOCIDDisinfectant for juice extraction andcooling water circuits

KEBOSPUMAntifoams for each range of temperature

KEBO-XBoiler feed water conditioning agent

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LITHSOLVENTInhibitors for the protection of metalmaterials against acids

KEBO-DSScale inhibitor in evaporation stations

KEBOSOLActivators for alkaline cleaning solutions

KEBOCORCorrosion inhibitors for longtimeconservation of metal surfaces aswell as for closed and semi-open cooling water systems

KEBOPLEXScale control aids for cooling water and waste water systems as well as alcohol distilleries

KEBOCIDDisinfectant for juice extraction andcooling water circuits

KEBOSPUMAntifoams for each range of temperature

KEBO-XBoiler feed water conditioning agent

KELLER & BOHACEK GMBH & CO. KGP.O. BOX 33 02 60 . D-40435 DÜSSELDORFTELEPHONE: (0211) 96 53-0TELEFAX: (0211) 65 52 02e-mail: [email protected]: http//www.kebo.de

C002_divider_KEBO-4col.qxd 13/11/07 09:44 Page 1

International Sugar Journal | August 201426 27www.internationalsugarjournal.com26 International Sugar Journal | August 2014

International SugarOrganization

23rd INTERNATIONAL SEMINAR

Sugar and Ethanol: Fresh Options

Tuesday 25th - Wednesday 26th November 2014

East Wintergarden, 43 Bank StreetCanary Wharf, London, E14 5NX

Tel: 44 20 7513 1144 e-mail: [email protected]: 44 20 7513 1146 http://www.isosugar.org

23rd INTERNATIONAL SEMINAR

Sugar and Ethanol: Fresh Options Tuesday 25th - Wednesday 26th November 2014

International Sugar

Oganization

East Wintergarden, 43 Bank Street, Canary Wharf, London, E14 5NX Tel: 44 20 7513 1144 e-mail: [email protected] Fax: 44 20 7513 1146 www.isosugar.org

08.15 Registration José Orive, Executive Director, ISO

09.30 WelcomeOpening remarks by Chairman

Farideh Bromfield, ED & F Man, London

COMMUNICATIONS – IS THE EVIDENCE ON SUGAR BEING MISPRESENTED?

09.45 How to deliver an effective communications message

Mike Love, UK, Chairman Burson-Marsteller

Media perceptions about sugar

Fergus Walsh, Medical Correspondent BBC, London*

The true facts about sugar nutrition

Dr Alison Boyd, Sugar Nutrition, London

11.15 Coffee break

11.45 Financial markets perspectives of the sugar industry

Simon Taurins, Managing Director, IBD, Credit Suisse, London

12.05 Risk management – options for sugar cane and sugar beet producers and processors

Rolando Rivera, Senior Originator Food & Agriculture, Vice President, Corporate Solutions, Swiss Reinsurance Co., Zurich

12.25 Discussion

12.45 Lunch break

THE RELEVANCE OF SUSTAINABILITY FOR SUGAR

14.30 Sugars to energy to chemicals

Jean-Alain Taupy, Raw Material Supply Senior Manager, Total SA, France

14.55 Cogeneration Jacques D’Unienville, Chief Executive Officer, OMNICANE, Mauritius

15.20 Climate change Dr Alex Guerra, Director, Institute for the Study of Climate Change, Guatemala

15.45 Discussion

16.20 Coffee break

AFRICA PANEL – INVESTMENT HOT SPOT

16.50 Nigeria sugar policy and project update

Dr Latif Busari, Chief Executive Officer National Sugar Development Council, Nigeria

The Kenyan sugar industry at a crossroads, easing the pressure

Rosemary Mkok, Chief Executive Officer, Kenya Sugar Board, Nairobi

Ethiopia: Building a competitive sugar industry

HE Shiferaw Jarso, Director General, Ethiopia Sugar Corporation, Addis Ababa

17.30 Expectations for the changes ahead

Toby Cohen, Director, Czarnikow, London

Close of first day

Reception: Museum of London Docklands, 1 Warehouse, West India Quay, London E14 4AL

23rd ISO SEMINAR - PROGRAMMETuesday, 25th November 2014

EU PANEL – POTENTIAL IMPACT POST REFORM

09.00 EU sugar reform: process, timetable and substance

Joost Korte, Deputy Director General, DG Agri Brussels

Isoglucose Martin Todd, Managing Director, LMC, Oxford

Post 2017 - survival of the fittest

Johann Marihart, President, Comité Européen de Fabricants du Sucre, and Chief Executive Officer, Agrana, Austria

10.45 Coffee break

11.10 CIS Customs Union & sugar policy integration

Andrey Bodin, Chairman of the Board Russian Sugar Producers, Moscow

BRAZIL PANEL

11.50 Increasing efficiencies in Brazil

Luis Pogetti, President, Copersucar, Brazil

Performance and competitiveness indicators for the Brazilian industry

Gui Nastari, Director, DATAGRO, Brazil

13.00 Lunch break

15.00 The world sugar market in 2030

Dr Leonardo Bichara Rocha, Senior Economist, ISO, London

TRADE PANEL

15.40 A brave new world in search of profit

Andres Galindo, Head of Raw Sugar Trading,ED&F Man, London

Barry Callingham, Senior Sugar Trader, Bunge, London

Nick Penney, Senior Sugar Trader, Sucden Financial, London

Helder Gosling, Commercial Executive Director, São Martinho, Brazil

17.10 Close of seminar

Wednesday, 26th November 2014

For reasons not under the organizers’ control, this agenda may be altered until the date of the event.

RegistrationThe registration fee of £895.00 also covers: an evening reception on 25 November, refreshments on 25 and 26 November, the ISO Sugar Yearbook and copies on the ISO’s website (with a username and password) of the Statistical Bulletin; Monthly Market Report (in English, French, Russian or Spanish); Quarterly Market Outlook (in English, French, Russian or Spanish); and online access to the Seminar Proceedings immediately following the event. Space is strictly limited so early registration is recommended.

Please contact Catherine Roussière at ISO: [email protected] | Tel: + 44 20 7513 1144

International Sugar Journal | August 201426 27www.internationalsugarjournal.com

A US NGO awarded a grant to promote production of biochemicals

INVISTA and Eucodis Bioscience partner to develop enzymes for biochemicals production

The Elmina B. Sewall Foundation awarded a $100,000 grant for an innovative project to promote biobased manufacturing in Maine, USA recently, which aims to convert sustainably harvested wood chips and agricultural waste into value-added renewable chemicals, biobased plastics, and advanced biofuels.

INVISTA and Eucodis Bioscience, an Austrian biotechnology company with strong expertise in enzyme engineering and industrial enzyme development, recently announce a collaboration for the screening and engineering of enzymes to further develop biobased processes for the production of industrial chemicals.


Biobased Product News

Researchers produce cellulose fibres that are stronger than steel

Calysta produces lactic acid from methane in lab

A Swedish-German research team has successfully tested a new method for the production of ultra-strong cellulose fibres at DESY's (Deutsches Elektronen-Synchrotron) research light source PETRA III. The novel procedure spins extremely tough filaments from tiny cellulose fibrils by aligning them all in parallel during the production process.

Calysta recently announced it has successfully fermented methane into lactic acid, under a research collaboration with NatureWorks. Lactic acid is the building block for NatureWorks Ingeo™ lactide intermediates and polymers used in consumer and industrial products worldwide.

For over 30 years Veco has been producing high-quality electroformed screens for continuous centrifuges. This experiencewas used to develop a sugar screen with superior characteristics: VecoFlux. Featuring all the benefi ts of our standard screens, such as conical holes to reduce blinding and clogging, the thicker VecoFlux screen has a much higher open area for more throughputand is available with smaller slots for capturing even the tiniest sugar crystals. www.vecoprecision.com

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industry news visit www.internationalsugarjournal.com

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Plant productivity increased in mutant plants – regulatory pathway sought

Scientists have identified a new mutant plant that accumulates excessive amounts of starch, which could help to boost crop yields and increase the productivity of plants grown for biofuels.

Scientists discover how plants respond to elevated carbon dioxide levels

Biologists at UC San Diego have solved a long-standing mystery concerning the way plants reduce the numbers of their breathing pores in response to rising carbon dioxide levels in the atmosphere.

Soil carbon restored within three years where sugarcane is planted in pastures in Brazil

The reduction of soil carbon stock caused by the conversion of pasture areas into sugarcane plantations – a very common change in Brazil in recent years – may be offset within two or three years of cultivation.


Near-infrared reflectance (NIR) spectroscopy as a high-throughput screening tool for pest and disease resistance in a sugarcane breeding programme*

Contact author: [email protected]

Abstract Pests and diseases cause major production and economic losses in sugarcane cropping systems. The

most effective form of long-term protection is through the use of resistant varieties. However, phenotyping

sugarcane genotypes for pest and disease resistance is difficult and costly. Near-infrared reflectance (NIR)

spectroscopy was investigated for its potential to predict the constitutive components of resistance to pests

and diseases in germplasm in the South African sugarcane breeding programme. Two hundred and twenty-

two genotypes were scanned over the 1100-2300 nm wavelength range using a fiber-optic probe. Partial

least square (PLS) regressions were applied to bud, internode and leaf spectra that were pretreated (second

derivative) and scatter-corrected (SNV and de-trending). Calibration models resulting from the correlations

between NIR measurements and existing ratings, gave coefficients of determination for calibration (R2c, the

closer to one the better) and standard errors of prediction by leverage correction (SEP, the lower the better)

of 0.72 (SEP 1.19) for resistance to the African stalk borer (Eldana saccharina), 0.62 (SEP 1.50) for smut

(Sporisorium scitamineum), 0.62 (SEP 1.07) for sugarcane thrips (Fulmekiola serrata) and 0.67 (SEP 1.02) for

brown rust (Puccinia melanocephala) ratings, respectively. Performance of the calibration models in prediction

are encouraging and demonstrate the potential of NIR spectroscopy as a high-throughput screening method

to evaluate sugarcane genotypes for resistance to pests and diseases. We believe that NIR spectroscopy can

be used as an additional screening method, in the early selection stages of the breeding programme, which

should increase the proportion of resistant genotypes carried forward to later selection stages.

Keywords: African stalk borer (Eldana saccharina), smut (Sporisorium scitamineum), brown rust (Puccinia

melanocephala), sugarcane thrips (Fulmekiola serrata), constitutive resistance, sugarcane

DR Sabatier 1,2, CM Moon 1,2, TT Mhora1,2, RS Rutherford1,2

and MD Laing2

Introduction

Sugarcane is attacked by a multitude of pests and diseases that can cause severe damage and lead to significant yield losses. Pests and diseases that impact significantly on the sugarcane industry in South Africa include the African stalk borer (Eldana saccharina), smut (Sporisorium scitamineum), sugarcane thrips (Fulmekiola serrata) and brown rust (Puccinia melanocephala). Varietal resistance to these pests and diseases are selection criteria in the plant breeding programme at the South African Sugarcane Research Institute (SASRI). The release

of better performing and resistant varieties is a prerequisite for maintaining satisfactory production levels for growers and for long-term sustainability. However, selection of genotypes for resistance (phenotyping) remains difficult and costly in the initial selection stages, due to (i) the large numbers of clones (35 000 per site in the second stage) and (ii) technical complexities in ensuring even pest and disease exposure levels in field trials carried out over several years.

1South African Sugarcane Research Institute. P/Bag X02, Mount Edgecombe, 4300, South Africa2College of Agriculture, Engineering and Science, University of KwaZulu-Natal, P/Bag X01, Scottsville, 3209, South Africa


Improving refined sugar pan yields following the continuous improvement methodologies at Manildra Harwood Sugars Refinery*

Abstract The crystallisation process in a refinery is regarded as a crucial step in determining the overall product

quality and has a major impact on the efficiency on the refinery operations. For this reason pan yield in the

Refinery is considered to be a critical key performance indicator. Any reduction of the pan yield will result

in increased costs for steam and electricity due to higher recycle syrup streams. Pan yield can be improved

by monitoring and adjusting a few basic parameters in the crystallisation and centrifuging processes.

A paper presented at the 2009 SIT conference (#962) by Mr George Carter gave an insight on how the

Redpath refinery succeeded in improving their pan yield. This paper discusses the formalised continuous

improvement process followed by a team at the Manildra Harwood Sugars Refinery to review the current

practices and then to modify the operations to achieve an increase in yields. The savings achieved are also

presented. The process involved a cross functional team to achieve a common goal to increase the pan yield.

Keywords: continuous improvement, pan yield, employee engagement, PDCA cycle

Production Co-ordinator – Manildra Harwood Sugars Refinery, NSW, Australia

Eashan R Thenabadu

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.

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


2

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.

Figure 1 – Unit Operations at MHS Refinery

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 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

Clarified Liquor 600 ICU

Affination

Melting

Phosphatation

Filtration

Ion Exchange

Crystallization

Centrifugation

Affined Sugar 800 ICU

Raw Sugar 99.2Pol, 1600 ICU

Melt Liquor

Clarified Liquor Filtered Liquor 600 ICU

Filtered Liquor Fine Liquor 200 ICU

Drying Refined Sugar 25 ICU

Mike 25/6/14 07:35Comment [1]: At 34 t/h I would have to melt for 8235 hours a year … don’t believe it. The best refineries probably only achieve 7800 hours

Figure 1. Unit Operations at MHS Refinery


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.

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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

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 non-saturated storage techniques.

This paper highlights the new challenges and gives perspectives on storage systems and their potential for large-scale application.

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

Contact author: [email protected] | [email protected] | [email protected]

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

BS Purchase, S Rosettenstein and DV Bezuidenhoudt


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

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

1BMA Braunschweigische Maschinenbauanstalt AG, Germany2Indian Cane Power Ltd, India

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

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

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.

Contact author: [email protected] | [email protected]

International Sugar Journal | August 201436 37www.internationalsugarjournal.comBROQUET PUMPS - 15 rue Jean Poulmarch - 95100 Argenteuil - France - www.broquetpumps.com

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

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

1Audubon Sugar Institute, Louisiana State University Agricultural Center,St. Gabriel, Louisiana, USA2SRRC-USDA-ARS, New Orleans, Louisiana, USA3Sucreries Raffineries De Cannes (SURAC), Morocco

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

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

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.



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International Sugar Journal | August 201440 41www.internationalsugarjournal.comInternational Sugar Journal | August 201440 41www.internationalsugarjournal.com

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INDIA THAILAND


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

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 Turbulence (LLT) Clarifier.

Crompion International is a Louisiana-based, globally operational leader in providing specialty stainless solutions and consulting services to a broad range of industries - including sugar. As the world's leading manufacturer and distributor of Cromgard high-performance stainless steel products, Crompion International prides itself not only on selling specialty products, but on understanding how sugar producers use these products.

In order to improve customer efficiency and productivity, through two patented technologies developed with strategic partners, Crompion International has developed products that are dramatically evolving the sugar industry - The Crompion LLT Clarifier and the Crompion LLT Filtrate Juice Clarifier.

In conjunction with the Louisiana State University (LSU) AgCenter's Audubon Sugar Institute and global sugar industry specialists, Crompion International has developed these new types of low-residence time clarifiers for the clarification of cane juice.

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 the clarifier at a constant

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.

As a consequence of these two clarifier design additions, the Crompion LLT Clarifier provides shorter retention time, reduces sucrose losses and provides juice of high quality compared to other clarifier available in the industry. In addition, the Crompion LLT Clarifier is built with Cromgard Specialty Stainless Steel, which increases abrasion resistance and reduces corrosion, leading to less maintenance needs.

A top and side view of the Crompion LLT Clarifier can be observed in figure 1.

The Crompion LLT Clarifier reduces juice turbidity at a retention time of 30 minutes or lower. Industrial trials in which the

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. As a consequence of these two clarifier design additions, the Crompion LLT Clarifier provides shorter retention time, reduces sucrose losses and provides juice of high quality compared to other clarifier available in the industry. In addition, the Crompion LLT Clarifier is built with Cromgard Specialty Stainless Steel, which increases abrasion resistance and reduces corrosion, leading to less maintenance needs.

A top and side view of the Crompion LLT Clarifier can be observed in figure 1.

Figure 1: The Crompion LLT Clarifier.

The Crompion LLT Clarifier reduces juice turbidity at a retention time of 30 minutes or lower. Industrial trials in which the Crompion LLT Clarifier was run side-by-side with alternative clarifier designs validate these results. The majority of clarifiers still in use today have a retention span in the range of one to two hours. Some of the new “best technology” clarifiers range between 45-60 minutes. Commercial tests have demonstrated that the Crompion LLT Clarifier design outperforms the conventional designs in terms of turbidity levels. The Crompion LLT Clarifier operating principle consists of a uniform pathway for the juice inlet, which evenly distributes the juice to several end-points uniformly positioned around the cross sectional area of the clarifier. After this, the juice reaches the end-point of the pipe where a patented Turbulence Reduction Device is installed to reduce the turbulent eddies present in the juice by dissipating the momentum (figure 2).

Figure 1. The Crompion LLT Clarifier


Crompion LLT Clarifier was run side-by-side with alternative clarifier designs validate these results. The majority of clarifiers still in use today have a retention span in the range of one to two hours. Some of the new “best technology” clarifiers range between 45-60 minutes. Commercial tests have demonstrated that the Crompion LLT Clarifier design outperforms the conventional designs in terms of turbidity levels.

The Crompion LLT Clarifier operating principle consists of a uniform pathway for the juice inlet, which evenly distributes the juice to several end-points uniformly positioned around the cross sectional area of the clarifier. After this, the juice reaches the end-point of the pipe where a patented Turbulence Reduction Device is installed to reduce the turbulent eddies present in the juice by dissipating the momentum (figure 2).

The Crompion LLT Clarifier's shorter residence time results in less sucrose destruction and color formation. With residence time at a minimum of 30 minutes, it is estimated that the money saved on sugar loss from a traditional clarifier could pay for the Crompion LLT Clarifier in just over a year. Because of the shorter residence time, heat losses are also reduced, which results in energy savings.

The new Crompion LLT Clarifier uses less steel, and the capital outlay of the new design is estimated to be significantly less than that of alternative conventional designs. Several standard designs are available for mills of different sizes. Additional long-term savings may be realized by using Crompion International's high-performing, cost-efficient Cromgard Specialty Stainless Steel to build the new Crompion LLT clarifier.

The performance of the Crompion LLT Clarifier has been compared to other clarifiers under Louisiana conditions, which are characterized by high mud content in cane that can be as high as 15%. The typical residence time achieved in a Crompion LLT Clarifier ranges between 25-30 minutes, compared to the Graver and Dorr type clarifiers, which have between 350-400% more retention time than the Crompion LLT Clarifier. Additionally, compared to a SRT type clarifier that can range between 30 and 60 minutes, the Crompion LLT clarifier has between 50 and 100% less retention time.Moreover, the longer the retention times in the clarifier, the higher the inversion of sucrose. An estimation of the sugar inversion generated in each of the previously discussed clarifiers

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.

In addition, another application of the LLT Clarifier is Filtrate Clarification. Filtrate Clarification has many benefits: reduction of sucrose inversion by avoiding recirculation, which is detrimental to the process; increase in clarification capacity of the main clarifier by 15 to 20%; and reduction of invert sugars, which can lead to additional color generation in the factory.

For this reason, the company has also introduced the Crompion LLT Filtrate Juice Clarifier, which was designed to produce a residence time in clear juice of approximately 8-10 minutes, a significantly lower residence time than that of many clarifiers currently operating in the industry (45 to 120 min). The results obtained during the initial trials have shown the removal of approximately 95% of suspended solids.

Utilizing the Crompion LLT Clarification technology to achieve low residence times, the Crompion LLT Filtrate Juice Clarifier operating principle consists of a uniform pathway for the juice inlet, which evenly distributes the juice to several end-points positioned around a cross-sectional area of the clarifier. The juice then reaches the end-point of the pipe where the TRD is installed to reduce the turbulent eddies present in the juice by dissipating the momentum.

Filtrate juice, which accounts for roughly 15 to 20% of the mixed juice produced in a raw sugar factory, is typically recirculated through the original clarifier. This recirculation is detrimental to the process and leads to a reduced clarification capacity; higher sucrose losses, caused by inversion or microbial activity; as well as color generation and increased turbidity, due to the recirculation of very fine particles.

In addition, the Filtrate Juice Clarifier also uses the same built-in flash trough as the Crompion LLT Clarifier for enhanced degassing of juice.

The Crompion LLT Clarifier technology will undoubtedly benefit sugar mills due to its ability to provide savings as a result of both sugar loss reduction and reduced energy usage, the lowest cost design made of high performance Cromgard Stainless Steel and the lowest turbidity juice and residence time to reach the global sugar market.

Figure 2: Layout of the TRD inside the Clarifier.

The Crompion LLT Clarifier's shorter residence time results in less sucrose destruction and color formation. With residence time at a minimum of 30 minutes, it is estimated that the money saved on sugar loss from a traditional clarifier could pay for the Crompion LLT Clarifier in just over a year. Because of the shorter residence time, heat losses are also reduced, which results in energy savings. The new Crompion LLT Clarifier uses less steel, and the capital outlay of the new design is estimated to be significantly less than that of alternative conventional designs. Several standard designs are available for mills of different sizes. Additional long-term savings may be realized by using Crompion International's high-performing, cost-efficient Cromgard Specialty Stainless Steel to build the new Crompion LLT clarifier. The performance of the Crompion LLT Clarifier has been compared to other clarifiers under Louisiana conditions, which are characterized by high mud content in cane that can be as high as 15%. The typical residence time achieved in a Crompion LLT Clarifier ranges between 25-30 minutes, compared to the Graver and Dorr type clarifiers, which have between 350-400% more retention time than the Crompion LLT Clarifier. Additionally, compared to a SRT type clarifier that can range between 30 and 60 minutes, the Crompion LLT clarifier has between 50 and 100% less retention time.

Moreover, the longer the retention times in the clarifier, the higher the inversion of sucrose. An estimation of the sugar inversion generated in each of the previously discussed clarifiers 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

Figure 2. Layout of the TRD inside the Clarifier.

Table 1. Inversion estimations in different types of clarifiers

LLT SRT Type

Graver Type

Price of Sugar (¢/lb) 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

Total Gain ($/Million TC) - 43,282 129,847


Falling film evaporators in cane industryAlexandre Mesmacque | Fives, France

Email: [email protected]

www.fivesgroup.com

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.

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

The Cail & Fletcher

2 ISJ 2014

Figure 1: Main components of the falling film evaporator

The Fives Cail calandria is equipped with a steam inlet 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 off-center 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 vibration,

Figure 2: Steam distribution in calandria

Central removal of incondensable gases

Off-‐centered tubes bundle

Steam inlet

Incondensable gases extraction

Juice distribution system

(buse)

Tubes bundle

Droplet separator

‘’Flash’’ and juice circulation box

Protecting skirt

Juice outlet to next effect

Juice outlet to juice pump

Figure 1. Main components of the falling film evaporator

Off-centered tubes bundle

Central removal of incondensable gases

Figure 2. Steam distribution in calandria


calandria is equipped with a steam inlet 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 off-center 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 vibration,

Incondensable gases are extracted along a single central pipe, drilled vertically along its length. This design permits efficient sweeping of the incondensable gases from the periphery through the tube bundle to the central pipe.,

Juice distribution system

The main inherent technical issue associated with falling film evaporators is the need for uniform juice flow along the tubes. It is critical that the entire heating surface is always fully wetted with juice in order to avoid 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 pumped to the upper part of the evaporator. The juice is pumped from the bottom of the evaporator

to the top of the evaporator and then distributed in three stages.Stage 1: The juice supply is distributed by a star shaped feed

system around the central vertical inlet (see Figure 3). Each branch of the star has a horizontal length which then bends at 90 degrees discharging onto a disc thus avoiding a direct fall into the tank. The purpose of this device is to distribute the juice evenly and at a low rate as to cause minimal disturbances on the free surface of juice which is established in the upper distribution tank.

Stage 2: The juice then flows through orifices located in the

Figure 3. Juice distribution system (schematic view)

Figure 4. Juice distribution plate under distribution tank

4 ISJ 2014

Figure 3 : Juice distribution system (schematic view) Figure 4 : Juice distribution plate under distribution tank

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%.

Figure 5. Distribution of juice in tubes in Fives evaporators


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.

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

Figure 6. Extraction of incondensable gases

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


wall and the boiling juice is the coefficient which limits the heat transfer in the evaporation of cane juice.

The studies carried out on the most recent installations of falling film evaporators supplied by Fives, which are installed in 1st and 2nd effects, have assessed the global heat transfer coefficients.

The global heat transfer coefficient Hg, as illustrated in Figure 8, includes the thermal conduction heat transfer through 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 :

Hg = Φ/ (S.ΔT)

With:Φ : Heat exchanged in WΦ = Latent enthalpy of inlet steam –

Enthalpy of condensates - Losses S : Heating surface in m², calculated on

internal diameter of the tubesΔT : Difference of temperature between heating steam and

outlet juice in °K.

The results obtained for the global heat exchange coefficient for the falling film evaporators ranged from 2800 to more than 3000 W/m².°K when the evaporator is clean, for effects 1 and 2.

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.

Falling film evaporator cleaning

Falling film evaporators permit an efficient and safe chemical and/or mechanical cleaning.

The same distribution system described on figures 3 and 4 is used to distribute the caustic soda solution for chemical cleaning. This provides uniform distribution of the caustic soda across the heating surface and consequently achieves effective cleaning of tubes.

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

The mechanical cleaning is carried out by high pressure water jet (800 bars; Hydrojet type) after opening of the manholes for access and lifting of distribution tank.

The design of evaporators allows the operators accessibility to

7 ISJ 2014

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

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.

Figure 8 : Temperature profile along the steam heating medium, flow condensing film, tube wall, flow juice film and finally bulk juice flow.

The heat transfer coefficient h between the inside of the tube wall and the boiling juice is the

coefficient which limits the heat transfer in the evaporation of cane juice.

The studies carried out on the most recent installations of falling film evaporators supplied by Fives

Cail, which are installed in 1st and 2nd effects, have assessed the global heat transfer coefficients.

Flowing condensates film ruisselant

Heating steam Flowing juice film

Figure 8. Temperature profile along the steam heating medium, flow condensing film, tube wall, flow juice film and finally bulk juice flow

Table 1. Global heat exchange coefficient W/(m².K)

Type evaporator* 1st effet 2nd effet

Robert * 2800-2500 1800-3000

Kestner * 2900 2100

Falling film (plates)* 2600-3000 -

Falling film (tubes) 2800 - >3000 > 2600

*Rein (2007)

9 ISJ 2014

Figure 9 : Heat transfer coefficients for different evaporator technologies

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.

Falling film evaporator cleaning

Falling film evaporators permit an efficient and safe chemical and/or mechanical cleaning.

The same distribution system described on figures 3 and 4 is used to distribute the caustic soda

solution for chemical cleaning. This provides uniform distribution of the caustic soda across the

heating surface and consequently achieves effective cleaning of tubes.

The installation of automatic valves allows for safe cleaning operation. Automation of cleaning

eliminates the risk of error related to manual manipulation of isolating valves.

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

opening of the manholes for access and lifting of distribution tank.

The design of evaporators allows the operators accessibility to the tubes and the time required to

clean one tube wil not exceed 30 seconds.

In all the cases, the periodicity of chemical and mechanical cleanings will have to be optimized. As a

matter of fact, it may not be easy to implement mechanical cleaning during the course of the

campaign, as it requires to stop the evaporator for a longer time than chemical cleaning,

The ease of cleaning is an important asset of the falling film evaporator.

A.Baloh measurements:

1 : Evaporator type Roberts

2 : Evaporator type Kestner

3 : Falling film evaporator

Dry substance content (%)

Globa

l hea

t trans

fer c

oefficient (W

/(m².°

K)

FUEL (Mauritius Island)

Gardel (Guadeloup island)

Le Gol (Reunion island)

Equipav (Brazil)

Fives Cail trials :

Figure 9. Heat transfer coefficients for different evaporator technologies


the tubes and the time required to clean one tube will not exceed 30 seconds.

In all the cases, the periodicity of chemical and mechanical cleanings will have to be optimized. As a matter of fact, it may not be easy to implement mechanical cleaning during the course of the campaign, as it requires to stop the evaporator for a longer time than chemical cleaning,

The ease of cleaning is an important asset of the falling film evaporator.

Trials performed on falling film evaporators show the global heat exchange coefficients is about 3000 to 3500 W/m².K when the evaporator is clean and this reduces progressively during operation. After 7 days, the evaporator is chemically cleaned and the initial performance is restored. Figure 10 presents the progression of the heat transfer coefficient 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.

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

References

[1] Boris Morgenroth, Darren Jayatilaka and Gary Punter (1997) :

Development of plate evaporator technology, the market place and the

choice for the sugar engineer. EuroTech Link 97, British Sugar

[2] Rein, P. (2007): Cane sugar engineering, Verlag Dr. Albert Bartens,

Berlin, p. 293

[3] Baloh, A. (1991): Energiewirtschaft in der Zuckerindustrie, Berlin, Verlag

Dr. Albert Bartens, p. 283- 287

[4] J.Coustel and G.Journet (2009): Falling-film evaporator performance

results from two Reunion Island factories – ZuckerIndustrie, 134 (4): :225-

228

10 ISJ 2014

Trials performed on falling film evaporators show the global heat exchange coefficients is about 3000

to3500 W/m².K when the evaporator is clean and this reduces progressively during operation. After 7

days, the evaporator is chemically cleaned and the initial performance is restored. Figure 10 presents

the progression of the heat transfer coefficient 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 Conclusions of falling film evaporator installation

Developments carried out by Fives Cail on falling film evaporators in the cane industry have overcome

the problems related to high thermal sensitivity of the concentrated cane juice and the high propensity

for encrustation of the distribution system and heating surface. Numerous evaporators installed by

Fives Cail in Brazil, Guadeloup Island and Mauritius Island demonstrate easy operation and

maintenance, and good thermal performance. Through operation with smaller temperature differences

in the falling film evaporators changes to the configurations of the sets have been possible, resulting in

reduced steam consumptions, substantial increases in factory incomes and reductions in the

environmental footprints.

0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

0 7 14 21 28 35 42 49 56 63 70 77 84 91 98 105Durée d'Exploitation (jour)

Coe

ffici

ent d

'Ech

ange

(W

/m2.

°C)

brix moyen = 27,7 %delta_T moyen = 5,2 °C

taux d'évaporation moyen = 28,4 kg/h.m2

Globa

l hea

t excha

nge co

effic

ient (W

/m².°

K)

Operation time (days)

Average Brix = 27.7% Average ΔT = 5.2°C Average evaporation rate = 28.4 kg/h.m²

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


Factory modeling with a view of improving energy efficiency and predicting sugar colour

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.dsengineers.com [email protected]


(e.g. the dry substance content of a sugar solution, the volume fraction of a certain gas or the flow, the alkalinity of a limed 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, …).5. The global parameters of the simulation. Our software allows us to adapt, inter alia, the communication language and the number of iterations used to reach the model convergence.With this information, each unitary operation calls for a Matlab®

function which computes the properties of the outlet and inlet flows and also basis of design for the main equipments (surface of heat exchangers and evaporators, sugar pan volume, electrical power of a turbine generating set …). Further to several iterations the model converges to the solution corresponding to the expected Mass, Colour and Heat Balance of the plant.

A predictive model of the end sugar colour

The innovation of DSEC’s model is its capability to follow the colour and the purity of sugar solutions (juice, syrups, run-offs, 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

model starting from 1000 IU standard liquor. By considering a colour profile for the crystal instead of a mean determined by pre-established ratios, our model is able to deal with more complex process features with the purpose of optimizing the client’s project. In this simple example, the centrifugation will affect the extern layers of the crystals which contain the higher concentration of coloured molecules. The result of our model will be significantly more precise that any other simulation.

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

Figure 1. The model’s architecture showing the arrangements of blocks representing unitary operations (e.g. Crystallisation Pan R1) and arrows describing streams’ properties.

Figure 2. Crystal colour profile starting from a 1000 IU standard liquor.


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.

Centrifugation

To model the centrifugation DSEC once again base its equations on physical parameters:

1. Massecuite properties• Temperature, viscosity, % of crystal, colour…• Size of sugar crystals (MA/CV)

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 a centrifugation line. Figure 5 shows the evolution of sugar colour inside the centrifugal during the cycle, demonstrating the influence of some physical parameters on the final colour e.g: centrifugal speed, timing for washing.

This model has been validated in beet and cane factories as well as in sugar refineries for several years. DSEC has taken part in many projects design and have advised many factories for reshaping their decolourization process.

Only a flexible and trustable predictive model (figure 6) can ensure the best possible process optimization project in order to provide reliable performance guarantees on the end-sugar specification, energy, water and chemicals consumptions and utilities requirements.

Figure 3. Crystal colour profiles starting with the same standard liquors but injected into the vacuum pan in a different timing.

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 4. Different crystal colour profile showing the influence of the history of the crystal through the model. In case of seeding with a crystal formed in another strike, the initial profile is kept.

Figure 3. Crystal colour profiles starting with the same standard liquors but injected into the vacuum pan in a different timing.

Centrifugation

To model the centrifugation DSEC once again base its equations on physical parameters:

1. Massecuite properties • Temperature, viscosity, % of crystal, colour… • Size of sugar crystals (MA/CV)

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 a centrifugation line. Figure 5 shows the evolution of sugar colour inside the centrifugal during the cycle, demonstrating the influence of some physical parameters on the final colour e.g: centrifugal speed, timing for washing.

Figure 4. Different crystal colour profile showing the influence of the history of the crystal through the model. In case of seeding with a crystal formed in another strike, the initial profile is kept.

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

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

This model has been validated in beet and cane factories as well as in sugar refineries for several years. DSEC has taken part in many projects design and have advised many factories for reshaping their decolourization process.

Only a flexible and trustable predictive model (figure 6) can ensure the best possible process optimization project in order to provide reliable performance guarantees on the end-sugar specification, energy, water and chemicals consumptions and utilities requirements.

Figure 6. DSEC’s model overview of a complete plant showing the integration of all 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.


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Larry RiddleCommercial DirectorIllovo Sugar LimitedSouth Africa

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Rosemary Mkok CEOKenya Sugar Board

Farhan NakhoodaProjects DirectorKakira Sugar LtdUganda

Lindsay JollySenior EconomistInternational Sugar Organization

Kokeb KetselaSenior Statistician, Planning and Project Division, Ethiopian Sugar Corporation

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Penalto MiguelCEOSILVAPEN GROUPBrazil

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Geraldine KutasHead of International AffairsUNICA

Suresh KumarExecutive Vice President, Africa and ExecutionPRAJ

Jonas StrömbergDirector Sustainable SolutionsScania, Sweden

Farid MohamedManaging DirectorLion’s HeadKenya

Rob VierhoutSecretary GeneralePURE

Shi-Zhong LiExecutive DirectorMOST-USDA Joint Research Center for Biofuels, China

Stuart Rayner Principal EngineerFord Motor CompanySouth Africa

Josef ModlExecutive Vice PresidentVogelbusch GmbHAustria

Low de VriesRenewable Energy Engineer AnalystTongaat HulettSouth Africa

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An outstanding line-up of sugar and ethanol producers across Africa and international industry experts including:

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ETHANOL PRODUCTIONTECHNOLOGY FORUMFOCUSING ON:

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

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

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implement new technologies and manage cost and financial demands for an ethanol business.

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