Note: Descriptions are shown in the official language in which they were submitted.
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
SUGAR PRODUCTION SYSTEM
This International Patent Cooperation Treaty Patent Application claims the
benefit
of United States Provisional Patent Application No. 60/457,516, filed March
24, 2003,
hereby incorporated by reference her ein.
I. TECHNICAL FIELD.
Generally, a system for the production of sugar from sucrose containing
liquids
obtained from plant material. Specifically, a sugar process liquid conditioner
that alters
sugar process liquid characteristics, and sugar process steps which utilize
sugar process
liquid having altered sugar process liquid characteristics, to produce sugar.
II. BACKGROUND
Sucrose, Cl2HaaOn, a disaccharide, is a condensation molecule that links one
glucose monosaccharide and one fructose monosaccharide. Sucrose occurs
naturally in
many fruits and vegetables of the plant kingdom, such as sugarcane, sugar
beets, sweet
sorghum, sugar palms, or sugar maples. The amount of sucrose produced by
plants can be
dependent on the genetic strain, soil or fertilization factors, weather
conditions during
growth, incidence of plant disease, degree of maturity, or the treatment
between
harvesting and processing, among many factors.
Sucrose may be concentrated in certain portions of the plant such as the sugar
beet
root or the stalks of the sugarcane plant. The entire plant, or a portion of
the plant, in
which the sucrose is concentrated can be harvested and the plant material
processed to
obtain a sugar process liquid containing an amount of sucrose. See for
example, "Sugar
Technology, Beet and Cane Sugar Manufacture" by P. W. van der Poel et al.
(1998);
"Beet-Sugar Technology" edited by R.A. McGinnis, Third Edition (1982); or
"Cane
Sugar I-Iandbook: A Manual for Cane Sugar I~Ianufacturers and Their Chemzsts"
by
James C. P. Chen, Ghung Chi Chou, 12th Edition (1993); and United States
Patent Nos.
6,051,075; 5,928,42; 5,4~80,4~90, each hereby incorporated by reference
herein.
1
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
Now referring to Figure l, as non-limiting example, sugar beets (1) can be
sliced
into thin strips called "cossettes" (2). The cossettes (2) can be introduced a
cossette mixer
(3) through which a flow of sugar process liquid (4) passes. The cossettes (2)
traverse the
cossette mixer (3) counter current to the flow of the sugar process liquid (4)
in the
cossette mixer (3). As the rosettes (2) traverse the rossette mixer (3) a
portion of the
sucrose in the rossettes (2) transfers to the flow of sugar process liquid
(3). The rossettes
(2) and a portion of the sugar process liquid (4.) ran be transferred to a
rossette slurry inlet
(5) at the first end of a diffuser (6) while a diffusion liquid (7) enters at
a diffusion liquid
inlet (8) at the second end (8) of the diffuser. The rossettes (2) traverse
the diffuser (7)
counter current to the flow of diffusion liquid (8). Counter current diffusion
of sugar beet
cossettes (2) ran transfer up to about ninety eight percent (98%) of the
sucrose along with
a variety of other materials from the cossette (2). The cossettes (2) are
transferred from
the diffuser (6) at the rosette slurry outlet (9) to a pulp press (10) in
which liquid is
squeezed from the cossettes (2). The liquid squeezed from the cossettes (2) is
often
referred to as "pulp press water" (11) can have a pH value of about 5 and is
returned to
the diffuser (6) at a pulp press water inlet (9) at the second end of the
diffuser (6) to
combine with the diffusion liquid (7). The flow of sugar process liquid (4)
from the
diffuser (6)(often referred to as "diffusion juice") returns the combined
diffusion liquid
(7), pulp press liquid (11), and other liquids) that may be introduced into
the diffuser (6)
to the rosette mixer (3). The flow of sugar process liquid (4) from the
diffuser (6) may be
split into two or more streams and other liquids may be combined into the flow
of sugar
process liquid (4) as it returns to the cossette mixer (3). The flow of sugar
process liquid
(4) entering the cossette mixer (3) traverses the cossette mixer (3) counter
current to the
rosettes (2). The sugar process liquid (4) transferred from the cossette mixer
(3) is often
referred to as "raw juice".
There are many alternative methods of transferring sucrose containing liquids
from plant material. As a second non-limiting example (not shown by the
figures), a
diffusion process for sugarcane utilizes a moving bed of finely prepared
sugarcane pieces
passed through a spray of diffusion liquid to transfer sucrose (along with a
variety of
other materials) from the plant material into the diffusion liquid.
As a third non-limiting example, a milling process for sugar cane passes sugar
cane stalks through rollers to squeeze sugar cane juice from the plant
material. This
2
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
process may be repeated several times down a series of mills to ensure that
substantially
all the sugar cane juice is removed.
Regardless of the process or method utilized to transfer sucrose from plant
material, the resulting sugar process liquid (4~) contains sucrose, non-
sucrose substances,
and water. The non-sucrose substances may include all manner of plant derived
substances and non-plant derived substances, including but not limited to:
insoluble
material, such as, plant fiber, soil particles, metal particles, or other
debris; and soluble
materials, such as, fertilizer, sucrose, saccharides other than sucrose,
organic and
inorganic non-sugars, organic acids (such as acetic acid, L-lactic acid, or I~-
lactic acid),
dissolved gases (such as G~2, S~2, or ~2), proteins, inorganic acids,
phosphates, metal
ions (for example, iron, aluminum, or magnesium ions) or pectins; colored
materials;
saponins; waxes; fats; or gums; as to each their associated or linked
moieties, or
derivatives thereof.
Now referring to Figure 2, a gradual addition of base (13) to the sugar
process
liquid (4) raises pH from within a range of between about 5.5 pH to about
6.SpH up to a
range of between about 11.5 pH to about 11.8pH. The rise in pH enables certain
non-
sucrose substances contained in the sugar process liquid (4) to reach their
respective iso-
electric points. This step is often referred to as "preliming" can be
performed in a
multiple cell prelimer (14). The term "preliming" is not meant to limit the
step of adding
base to sucrose containing sugar process liquids (4) solely to those process
systems that
refer to this addition of base as "preliming". Rather, it should be understood
that in the
various conventional juice process systems it may be desirable to first
utilize base to raise
pH or sugar process liquid (4) prior to subsequent clarification or
purification steps. The
subsequent clarification and purification steps can involve a filtration step,
as described
by United States Patent Nos. 4,432,806, 5,759,283, or the like; an ion
exchange step as
described in British Patent No. 1,043,102, or United States Patent Nos. 3,
618, 589,
3,785,863, 4,140,541, or 4,331,483, 5,466,294, or the like; a chromatography
step as
described by United states Patent Nos. 5,4~66,294~, 4,312,678, 2,985,589,
4,182,633,
4,412,866, or 5,102,553, or the like; or an ultrafilitration step as described
by United
States Patent No. 4~,4~32,806, or the like; phase separation as described by
United States
Patent No. 6,051,075, or the like; or process systems that add active
materials to the final
carbonation vessel as described by United States Patent No. 4,045,242, each as
an
3
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
alternative to the conventional sugar process steps of "main liming" and
"carbonation",
each reference hereby incorporated by reference herein.
The term "base" involves the use of any material capable of raising pH of a
juice
or sugar process liquids (4) including, but not limited to the use of lime or
the underflow
from processes that utilize lime, such as calcium carbonate sludge (13)
recovered after hot
liming and carbonation. The use of the term "lime" typically involves the
specific use of
quick lime or calcium oxides formed by heating calcium (generally in the form
of
limestone) in oxygen to form calcium oxide (15). Iellilk of lime is preferred
in many juice
process systems, and consists of a suspension of calcium hydroxide (Ca(OH)2)
in water
produced in a slaker (16) in accordance with the following reaction:
Ca0+H2 O ~ Ca(OH)2 +15.5 Cal.
The term "iso-electric point" involves the pH at which dissolved or colloidal
materials, such as proteins, within the sugar process liquid (4) have zero
electrical
potential. When such dissolved or colloidal materials reach their designated
iso-electric
points, they may form a plurality of solid particles, flocculate, or flocs in
the sugar
process liquid (4).
Flocculation may be further enhanced by the addition of calcium carbonate
materials to juice, which functionally form a core or substrate with which the
solid
particles or flocculates associate. This process increases the size, weight or
density of the
particles, thereby facilitating the filtration or settling of such solid
particles or materials
and their removal from the juice.
A conventional sugar process method further purifies the process liquids (4)
including residual lime, excess calcium carbonate, solid particles,
flocculant, or floc, to
stabilize the floc or particles formed in the preliming step. A cold main
liming step (not
shown in Figure 2) may involve the addition of about another 0.3-
0.7°J° lime by weight of
prelimed sugar process liquids (4)(or more depending on the quality of the
prelimed
juice) undertaken at a temperature of between about 30°C to about
40°C.
4
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
The cold main limed juice may then be hot main limed (17) to further degrade
invert sugar and other components that are not stable to this step. Hot main
liming (17)
may involve the further addition of lime (18) to cause the pH of the limed
juice to
increase to a level of between about 12 pH to about12.5 pH. This results in a
portion of
the soluble non-sucrose materials that were not affected by preceding addition
of base or
lime to decompose. In particular, hot main liming (17) of the sugar process
liquid (4.) may
achieve thermostability by partial decomposition of invert sugar, amino acids,
amides,
and other dissolved non-sucrose materials.
After cold or hot main liming (17), the main limed sugar process liquid (4)
can be
subjected to a first carbonation step (18) in which carbon dioxide gas (19)
can be
combined with the main limed sugar process liquid (4). The carbon dioxide gas
(19)
reacts with residual lime in the main limed juice to produce calcium carbonate
precipitate
(13) or sludge. Not only may residual lime be removed by this procedure
(typically about
95% by weight of the residual lime), but also the surface-active calcium
carbonate
precipitate (13) may trap substantial amounts of remaining dissolved non-
sucrose
substances. Furthermore, the calcium carbonate precipitate (13) may function
as a filter
aid in the physical removal of solid materials from the main limed (17) and
carbonated
juice (18).
The clarified sugar process liquid (4) obtained from the first carbonation
step (18)
may then be subjected to additional liming steps, heating steps, a second
carbonation step
(20), filtering steps, membrane ultrafiltration steps, chromatography
separation steps, or
ion exchange steps as above described, or combinations, permutations, or
derivations
thereof, to further clarify or purify the juice obtained from the first
carbonation step
resulting in a sugar process liquid (4) referred to as "thin juice".
Now refernng to Figure 3, which provides a further non-limiting example, "thin
juice" may be thickened by evaporation of a portion of the water content to
yield a sugar
process liquid (4~) conventionally referred to as "thick juice". Evaporation
of a portion of
the water content may be performed in a multi-stage evaporator (21).
Now referring to Figure 4, as a non-limiting example, the thickened sugar
process
liquid (4) or "thick juice" mixed with other sugar process liquids ("thin
juice", centrifugal
5
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
wash liquids and syrups) and remelted (22) (23) lower grade sugar crystals
generated are
transferred to a "white pan" (24). In the "white pan" (24), even more water is
boiled off
until conditions are right for sucrose or sugar crystals to grow. Because it
may be
difficult to get the sucrose or sugar crystals to grow well, some seed
crystals of sucrose or
~ sugar are added to initiate crystal formation. ~nce the crystals have grown
the resulting
mixture of crystals and remaining thickened sugar process liquid (4) can be
separated in a
"white centrifuge" (25). The thickened sugar process liquid (4) from the
"white pan" is
transferred to the "high raw pan" (26) for recrystallization. The "high raw
sugar crystals"
(27) generated in the "high raw pan" (26) are separated from the thickened
sugar process
liquid (4) by the "high raw centrifuge" (28) and returned to the "high welter"
(22) to be
combined with incoming "thick juice", while the thickened process liquid (4)
from the
"white pan" (24) is recrystallized in the "low raw pan" (29). The "low raw pan
sugar
crystals" (30) are returned to the "low raw welter" (23) to be combined with
incoming
"thick juice". The remaining thickened sugar process liquid (4) from the "low
raw pan"
(29) which is not recrystallized is referred to as "molasses".
The sugar crystals from the "white pan" (31) after separation from the
thickened
sugar process liquid in the "white centrifuge" can be washed ("high wash")
(32) to
generate the desired color. The "high wash" (32) from the "white centrifuge"
contains a
substantial amount of sucrose and is returned to the "high welter" (22). The
separated
sucrose or sugar crystals (33) are then transferred to a sugar dryer (34) to
bring the sugar
crystals (33) to obtain the desired moisture content.
As can be understood from the above non-limiting examples numerous types of
sugar process liquids and sugar process products are generated by purification
of sucrose
containing liquid from plant material. Solids comprising the remaining plant
material;
solids separated from sugar process liquid during clarification, purification
or refining;
sugar or sucrose containing juices; crystallized sugar or sucrose; mother
liquors from
crystallization of sugar or sucrose; by products of the process system; and
various
combinations, permutations, or derivatives thereof, each having a level of
impurities
consistent with the process steps utilized in their production, or consistent
with
conventional standards for that type or kind of product produced, including,
but not
limited to: animal feeds containing exhausted plant material, such as,
exhausted beet
cossettes, pulp, or bagasse or other solids or juices separated from process
liquids; solid
6
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
fuel which can be burned to generate steam for electrical power production, or
to generate
low pressure steam that can be returned to the sugar process system, or to
generate low
grade heat; syrup ranging from pure sucrose solutions such as those sold to
industrial
users to treated syrups incorporating flavors and colors, or those
incorporating some
invert sugar to prevent crystallization of sucrose, for example, golden syrup;
molasses
obtained by removal of all or any part of the crystallizable sucrose or sugar,
or products
derived from molasses, one example being treacle; alcohol distilled from
molasses;
blanco directo or plantation sugars generated by sulfitation using sulfur
dioxide (S~2) as
a bleaching agent; juggeri or gur generated by boiling sucrose or sugai
containing juices
until essentially dry; juice sugar from melting refined white sugar or from
syrups) which
may be further decolorized; single-crystallization cane sugars often referred
to as
"unrefined sugar" in the United Kingdom or other parts of Europe, or referred
to as
"evaporated cane juice" in the North American natural foods industry to
describe a free-
flowing, single-crystallization cane sugar that is produced with a minimal
degree of
processing; milled cane; demerara; muscovado; rapedura; panela; turbina; raw
sugar
which can be about 94-98 percent sucrose, the balance being molasses, ash, and
other
trace elements; refined sugars such as extra fine granulated having a quality
based upon
"bottlers" quality specified by the National Soft Drink Association being
water white and
at least 99.9 percent sucrose; specialty white sugars, such as, caster sugar,
icing sugar,
sugar cubes, or preserving sugar; brown sugars that can be manufactured by
spraying and
blending white refined sugar with molasses which can be light or dark brown
sugar
depending on the characteristics of the molasses; or powdered sugar made in
various
degrees of fineness by pulverizing granulated sugar in a powder mill and which
may
further contain corn starch or other chemicals to prevent caking.
This list is not meant to be limiting with respect to the products generated
from
the sucrose containing liquids obtained from plant material or subsequently
generated
sugar process liquids during purification, but rather, is meant to be
illustrative of the
numerous and varied products that can be generated by conventional sugar
process
systems, including, but not limited to, the sugar process systems described
above, and
other sugar process systems not specifically described but understood
inherently from the
above description based upon the type of plant material processed or the final
product
obtained. Sugar process systems encompass numerous permutations and
combinations of
individual components or process steps which can result in the same or similar
or
7
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
different sugar process products and by products. It is to be understood that
the invention
can be useful in each type or kind of sugar process system whether expressly
or
inherently described herein.
There is a ccampetitive global commercial market for the products derived from
sugar process systems. because the market for sugar and by products of sugar
process
systems are vast, even a slight reduction in the cost of sugar or a by product
can yield a
substantial and desired monetary savings. While this strong commercial
incentive has
been coupled to a long history of sugar production of at least 1000 years, and
specifically
with regard to production of sugar from sugar beets for which commercial
process
systems have been established 100 years, there remain significant unresolved
problems
related to the production of sugar.
A significant problem related to the production of sugar can be the amount of
organic acids and inorganic acids in sugar process liquids. When plant cell
juice (3)
contains sufficient cations, hydroxide ion (OH-) can act as a anion, which
enables carbon
dioxide (C02) to dissolve into the juice (3) as carbonate ions (C03)-2, or as
bicarbonate
ions HC03-. The dissociation of HCO3- provides a very weak acid. However, when
juice
(3) contains an insufficient number of cations to allow dissolved COZ to form
carbonate
or bicarbonate ions, an equilibrium results between carbon dioxide and
carbonic acid
H2CO3. Carbonic acid can act as a strong acid in the pH range at which sugar
process
liquid (4) are processed.
Similarly, sulfur dioxide (S02) or ammonium bisulfate (NH4HS03) may be
introduced into the sugar process liquid (4) to control, reduce, or eliminate
microbiologic
activity, sucrose hydrolysis, formation of invert sugars, or loss of sucrose,
or to adjust pH
lower. Again, when sugar process liquid (4) contains sufficient cations, such
as calcium,
sulphites, such as calcium sulfite can result. However, when juice contains an
insufficient
number of cations to allow dissolved sulfur dioxide (SO2) to form sulphites,
an
equilibrium results between sulfur dioxide (SO2), sulfurous acid (H2SO3), and
sulfuric
acid (H2SO4). Sulfuric acid and sulfurous acid can also act as strong acids.
Additionally, other inorganic and organic acids can be generated by the plant
during normal growth and other acids are generated by microbial activity
including, but
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
not limited to: acetic acid; carbonic acid; propanonic acid; butanoic acid;
pentanoic acid;
phosphoric acid; hydrochloric acid; sulfuric acid; sulfurous acid; citric
acid; oxalic acid;
succinic acid; fumaric acid; glycolic acid; pyrrolidone-carboxylic acid;
formic acid;
butyric acid; malefic acid; 3-methylbutanoic; 5-methylhexanoic; hexanoic acid;
or a
heptanoic acid, individually or in various combinations and concentrations
Inorganic acids and organic acids contained within the sugar process liquids
(4)
lower pH of the sugar process liquids and must be neutralized with base. The
higher the
concentration of organic acids or inorganic acids within the sugar process
liquids (4~), the
greater the amount of base that may be necessary to raise the pH of the juice
to a desired
value in the prelimer (14.) or other step prior to subsequent purification
steps.
As discussed above, calcium oxide (15) or calcium hydroxide may be added to
sugar process liquid (4) to raise the pH allowing certain dissolved materials
to come out
of solution as solids, flocculent, or flocs. Calcium oxide is typically
obtained through
calcination of limestone a process in which the limestone is heated in a kiln
in the
presence of oxygen until carbon dioxide is released resulting in calcium
oxide.
Calcination can be expensive because it requires the purchase of a kiln,
limestone, and
fuel, such as gas, oil, coal, coke, or the like, which is combusted to raise
the temperature
of the kiln sufficiently to release carbon dioxide from the limestone.
Ancillary equipment
to transport the limestone and the fuel to the kiln and to remove the
resulting calcium
oxide from the kiln must also be provided along with equipment to scrub
certain kiln
gases and particles from the kiln air exhausted during calcination of the
limestone.
Additionally, calcium oxide generated by calcination must be converted to
calcium hydroxide for use in conventional sugar process systems. Again this
involves the
purchase of equipment to reduce the calcium oxide to suitably sized particles
and to mix
these particles with water to generate calcium hydroxide.
Another problem related to the use of base in conventional process systems can
be
disposal of precipitates, flocs, and calcimn carbonate formed in liming and
carbonation
steps When the sugar process system uses one or more carbonation steps
(18)(20) in
clarifying or purifying juice, the amount of calcium carbonate or other salts
formed, often
referred to as "sludge", "spent lime", or "carbonation lime" (13), will be
proportionate to
9
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
the amount of lime (15) added to sugar process liquids (4). Simply put, the
greater the
amount of lime (15) added to the sugar process liquids (4), the greater the
amount of
"spent lime" (13) formed during the carbonation steps. The "spent lime" (13)
may be
allowed to settle to the bottom of the carbonation vessel (18)(20) forming
what is
sometimes referred to as a "lime mud". The "lime mud" or "spent lime" (13) can
be
separated by a rotary vacuum filter (34~) or plate and frame press. The
product formed is
then called "lime cake"(35). The lime cake (35) or lime mud may largely be
calcium
carbonate pr ecipitate but may also contain sugars, other organic or inorganic
matter, or
water. These separated precipitates are almost always handled separately from
other
process system wastes and may, for example, ~ be slurried with water and
pumped to
settling ponds or areas surrounded by levees or transported to land fills.
Alternately, the carbonation lime, lime mud, or lime cake can be recalcined.
However, the cost of a recalcining kiln and the peripheral equipment to
recalcine spent
lime (13) can be substantially more expensive than a kiln for calcining
limestone.
Furthermore, the quality of recalcined "carbonation lime" can be different
than calcined
limestone. The purity of calcined limestone compared to recalcined carbonation
lime
may be, as but one example, 92% compared with 77%. As such, the amount of
recalcined
lime required to neutralize the same amount of hydronium ion in juice may be
correspondingly higher. Also, the carbon dioxide content of spent lime can be
much
higher than limestone. As such, not only can recalcined lime be expensive to
generate, it
can also require the use of substantially larger gas conduit and equipment to
transfer the
generated C02 from recalcining spent lime, larger conveying equipment to move
the
recalcined lime, larger carbonation tanks, or the like. Whether spent lime
(13)(35) is
disposed of in ponds, landfills, or by recycling, the greater the amount of
lime (15)
utilized in a particular process system, generally the greater the expense of
disposing the
spent lime.
Another significant problem with conventional sugar process systems may be an
incremental decrease in sugar process system throughput corresponding with an
incremental increase in the amount of lime (15) used in processing sugar
process liquid
(4). ~ne aspect of this problem may be that there is a limit to the amount of
or rate at
which lime (15) can be produced or provided to sugar process steps. As
discussed above,
lime stone must be calcined to produce calcium oxide (15) prior to its use as
a base in
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
sugar process systems. The amount of lime (15) produced may be limited in by
availability of limestone, kiln capacity, fuel availability, or the like. The
rate at which
lime (15) can be made available to the sugar process system may vary based on
the size,
kind, or amount of the lime generation equipment, available labor, or the
like. t~nother
aspect of this problem can be that the amount of lime (1~) used in the sugar
process
system may proportionately reduce volume available for sugar process liquid
(4) in the
sugar process system. Increased use of base, such as lime (15), may also
require the use
of larger containment areas, conduits, or the like to maintain throughput of
the same
volume of juice.
another significant problem with conventional sugar process systems, can be
limesalts in sugar process liquid (4) which are not precipitated during the
steps of
preliming (123), mainliming (17), and carbonation (18)(19), but none-the-less,
must be
removed from sugar process liquid (4) prior to evaporation of water from "thin
juice" to
prevent or reduce scale formation in the evaporator. For example, oxalate the
calcium
salt of oxalic acid often forms the main component of scale remains in sugar
process
liquids (4) after carbonation. However, "thin" or "thick" sugar process
liquids can contain
sufficient calcium to force oxalate out of solution as water is evaporated.
The process of
removing scale from the surfaces of equipment can be expensive, including, but
not
limited to, costs due to production slowdowns and efficiency losses, or the
reduction in
the effective life of equipment.
To remove limesalts prior to evaporation steps (21) to affect a reduction of
scale
deposition in the evaporators (21), sugar process liquids (4) can be passed
through an
anion exchanger (34) which binds calcium ion to anion exchange resin in
exchange for
the release of two sodium ions which are transferred to the sugar process
liquids (4)
(certain conventional process systems do not remove limesalts prior to
evaporation). The
calcium ion bound to the anion exchange resin is released by periodic washing
of the
column with a regenerate (35) such as sodium hydroxide solution or sulfuric
acid solution
depending on the type of exchange resin. The spent regenerant (35) primarily
made up of
calcium ion and hydroxide ion in solution(when sodium hydroxide in solution is
utilized
as a regenerate) has a high pH and can be recycled prelimer (14~) to
supplement to the
milk of lime (18). This can be a benefit by reducing the amount of milk of
lime (18)
needed to increase pH of the sugar process liquid (4) in the prelimer (14) to
achieve a pH
11
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
in the range of 11.5 to 11.8. However, when limesalts increase the amount of
spent
regenerant (35) produced also increases and can cause problems in balancing
the prelimer
(14) to operate consistently. Shifts in alkalinity and pH in the prelimer (14)
can result in
poor removal of non-sucrose materials and higher limesalts which in turn
requires more
frequent regeneration of the anion exchanger. All of which add cost to the
production of
sugar.
Another significant problem with conventional sugar process systems can be the
amount of other organic compounds in the sugar process liquid (4). These
organic
compounds can without limitation include: acetaldehydes; ethanol; acetone;
dimethylsulfide; 2-propenenitrile; methyl acetate; isopropanal; 2-methyl
propanal;
methacrolein; 2-methyl-2-propanol; propanenitrile; 1-propanol; 2-butanone; 2,3-
butanedion; ethyl acetate; 2 butanol; methyl propanoate; 2- butanal; 3-
methylbutanal; 3-
methyl-2-butanone; isopropal acetate; 2-methyl butanal; 1-butanol, 2-
butenenitrile; 2-
pentanone; 2,3-pentanedione; ethyl propanoate; propyl acetate; 3-methyl
butanentrile;
methyl isobutyl ketone; 2-methyl-2-butenal; 3 methyl-1-butanol; isopropyl
propanoate;
isobutyl acetate; 2-methyl-3-pentanol; 2,3-hexanedione; 2-hexanone; ethyl
butanoate;
butyl acetate; 4-methyl pentanenitrile; 2-hexenal; 3-methyl-1-butanol acetate;
3-
heptanone; 2-heptanone; 5-hepten-2-one; heptanal; 3-octene-2-one; 2-heptenal;
3-
octanone; butyl butanoate; 2-methoxy-3-isopropyl pyrazine; 2-methoxy-3-(1-
methylpropyl)pyrazine; alcohols; aldehydes; ketones; volatile acids; carbon
monoxide;
carbon dioxide; sulfur dioxide; esters; nitrites; sulfide; pyrazine;.
Certain organic compounds can be highly colored or are the precursors to
colored
compounds which can be generated as pH and temperature of the sugar process
liquids
(4) are elevated during preliming (14) and hot main liming (17). A sugar
process system
as above-described processing about 8,500 tons per day of sliced sugar beets,
with thin
juice color at about 4,000 reference base units (RBU) produces a final white
sugar color
of about 43 RBU. To achieve a "standard" white sugar color of at least 40 RBU
the
"white centrifugal wash" (32) must be adjusted to bring the color of the
"white pan" sugar
crystals (33) from 43 RBU to 40 RBU. Adjustment of the centrifugal wash (32)
to reduce
color also reduces the amount of sugar (33) produced by about 0.65 tons/hour.
12
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
Another significant problem with conventional sugar processing systems may be
low purity of sugar process liquids (4) expressed as a percent ratio of sugar
to total dry
solids of sugar process liquid (4). Typically, the higher the concentration of
total dry
solids in sugar process liquid (4), including any of the above-described
materials or other
materials' relative to the amount of sucrose in the sugar process liquid (4~)9
the less
desirable the sugar process liquid (4). Understandably, any decrease in the
total dry
solids relative to sucrose in the sugar process liquid (4) yields a
comparatively better juice
for subsequent purification.
Soluble non-sucrose materials in sugar process liquid (4) can interfere with
subsequent processing or purification steps or adversely impact the quality or
quantity of
the resulting sugar or other products produced. It has been estimated that on
average each
pound of soluble non-sucrose substances reduces the quantity of sugar produced
by one
and one-half pounds. As such, it may be desirable to have all or a portion of
these soluble
non-sucrose substances separated from or removed from the sugar process
liquids (4).
For example, in the sugar process system above described, a thin juice color
of about
2,500 RBU with a "thin juice" purity of about 92.00 can produce about 57 tons
of white
sugar per hour at 30 RBU. If "thin juice" purity can be increased to about
92.40 white
sugar yield can be increased by 0.54 tons per hour.
The present invention provides a sugar process system involving both
apparatuses
and methods that address each of the above-mentioned problems.
III. DISCLOSURE OF INVENTION
Accordingly, a broad object of the invention can be to provide a sugar process
system
A first aspect of this broad object can be to provide an entire sugar process
system, including both apparatus and methods, to generate products from
sucrose
containing liquids or sugar process liquids. A second aspect of this broad
object can be to
provide apparatus and methods of conditioning sugar process liquid compatible
with
conventional sugar process system methods. As to this second aspect, the
invention can
provide method steps or apparatus, individually or in combination, that can be
further
13
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
added to, replace, or modify conventional methods and apparatus used to
process sugar
process liquids or other sucrose containing liquids.
A second broad object of the invention can to reduce the cost of generating
products from sugar process liquids or other sucrose containing liquids. One
aspect of
this object of the invention can be to increase sugar process liquid
throughput that may
be, in whole or in part, limited by availability of base, such as a reduced
availability of
limestone or the a lack of capacity to convert limestone to calcium oxide, or
the like.
Another aspect of this object of the invention can be to provide a cost
savings by reducing
the amount of base, such as lime, that has to be used to process sucrose
containing liquids
or juice into products. A third aspect of this object of the invention can be
to reduce the
amount of waste generated, such as a reduction in the amount of spent lime.
A third broad object of the invention can be to provide a conditioned sugar
process liquid having characteristics which are more desirable with respect to
subsequent
process or purification steps or which yield a greater amount of sugar per ton
of plant
material. One aspect of this object of the invention can be to provide a
conditioned sugar
process liquid having a reduced amount or reduced concentration of non-sucrose
materials relative to the concentration of sucrose. The conditioned sugar
process liquid
can have a reduced concentration of organic or inorganic acids (such as acetic
acid, D-
lactic acid, L-lactic acid, propionic acid, citric acid, hydrochloric acid,
sulfuric acid, or
the like), volatile organic compounds (such as alcohol), dissolved gases (such
as, C02 or
SOS), ammonia, or the like. A second aspect of this object of the invention
can be to
provide a conditioned sugar process liquid that has a higher pH value after
treatment in
accordance with the invention (whether or not base was added to the juice
prior to
treatment). A third aspect of this object of the invention can be to provide a
conditioned
sugar process liquid that has a higher pH even when an amount of base, such as
lime, or
the underflow from conventional processing of juice, or the like, has been
added prior to
treatment in accordance with the invention. A fourth aspect of this object of
the invention
can be to provide a conditioned sugar process liquid that has a reduced
capacity to
generate hydronium ion. A sixth aspect of this object of the invention can be
to provide a
conditioned sugar process liquid that requires less base to raise the pH to a
desired value,
iso-electric focus dissolved material(s), perform preliming or main liming
steps in
conventional process systems, degrade invert sugars, or otherwise generate
products from
14
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
sucrose containing liquids or juices. A seventh aspect of this object of the
invention can
be to provide a conditioned sugar process liquid with a higher concentration
of oxidized
material after treatment in accordance with the invention. An eighth aspect of
this object
of the invention can be to provide a conditioned sugar process liquid which
upon addition
of lime and subsequent addition of carbon dioxide to yields a sugar process
liquid having
a lower concentration of dissolved solids relative to the concentration of
sucrose as
compared to the same juice not treated in accordance with the invention.
A fourth broad object of the invention can be to provide methods and apparatus
that reduce the amount or concentration of non-sucrose material in juice
obtained from
plant material by conventional juice extraction procedures such as pressing,
milling, or
diffusion. One aspect of this object of the invention can be to provide a
method of
reducing the amount or concentration of non-sucrose material in sugar process
liquid
without the addition of base, prior to the addition of base, or after the
addition of base. A
second aspect of this object of the invention can be to provide a method of
conditioning
sugar process liquids that can be used prior to, in conjunction with, or after
the addition of
base to reduce the amount or concentration of non-sucrose material. A third
aspect of this
object of the invention can be to provide a method that assists in reducing
the amount or
concentration of non-sucrose material in sucrose containing liquid or juice. A
fourth
aspect of this object of the invention can be to provide a method of reducing
non-sucrose
material sugar process liquid or juices compatible with conventional juice
clarification or
purification methods, including but not limited to, preliming, main liming,
ion exchange,
or filtering, as above described.
A fifth broad object of the invention can be to provide various apparatuses
that
inject, introduce, or otherwise mix an amount of gas having desired partial
pressures with
sugar process liquid obtained from plant material. One aspect of this object
of the
invention can be to provide an apparatus to introduce a mixture of gases into
sugar
process liquids to provide a mixed stream of sugar process liquid and gas
having a desired
partial pressures.
A sixth broad object of the invention can be to provide various apparatuses
and
methods to increase the interface area of sugar process liquids mixed with a
gas having
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
desired partial pressures, or a desired mixture of gases to effect mass
transfer of non-
sucrose materials from the sugar process liquid.
A seventh broad object of the invention can be to provide various apparatuses
and
methods to separate or remove mixtures of gases which are in partial or
complete
equilibrium with the vapor pressures of non-sucrose material, or partial
pressures of gases
contained by or dissolved in sugar process liquids.
An eighth broad object of the invention can be to provide various apparatuses
and
methods to oxidize non-sucrose materials within juice
Naturally, further objects of the invention are disclosed throughout other
areas of
the specification and drawings.
IV. BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 provides a diagram illustrating a conventional process system for the
diffusion and pulp pressing of sugar beet cossettes to obtain a raw juice.
Figure 2 provides a diagram illustrating a conventional process system for
purification of raw juice obtained from the diffusion and pulp pressing of
sugar beet
cossettes as illustrated in Figure 1.
Figure 3 provides a diagram illustrating a conventional process system for
evaporation of water from thin juice produced by the purification system
illustrated in
Figure 2.
Figure 4 provides a diagram illustrating a conventional process system for
crystallization of thick juice produced from the evaporation system
illustrated in Figure 3.
Figure 5 provides a diagram of a particular embodiment of aeration chamber and
vacuum chamber components of the sugar process system invention.
16
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
Figure 6 provides a diagram which illustrates a method of purification in
accordance with the invention.
Figure 7 provides a diagram which illustrates a method of evaporation in
accordance with the invention.
Figure 8 provides a diagram which illustrates a method of crystallization of
sucrose in accordance with the invention.
V. ~IODE(S) FOR CARR~'ING OLTT THE INVENTION
As can be understood from the description of the methods and apparatus
relating
to the invention below, the invention provides a sugar process system which
conditions
sugar process liquid to alter various sugar process liquid characteristics
which affect the
quality and the quantity of sugar produced.
Referring now primarily to Figure 5, a non-limiting embodiment of the
invention
which can be utilized for the production of sugar from sugar beets (other
sugar process
liquids obtained from other types of plant material), can include an aeration
chamber (36)
which receives sugar process liquids (4) from the cossette mixer (3). A sugar
process
liquid transfer means (40), such as a pump or gravity, allows transfer of
sugar process
liquids (4) from the cossette mixer (3) to the aeration chamber (36) at a
desired volume
and pressure (step 1020). The aeration chamber (36) can be configured to
provide a
contairnnent zone (37) having a boundary limited by the interior configuration
of the
aeration chamber (36). An amount of sugar process liquid (4) can be passed
through the
containment zone (37) coincident to passing an amount of at least one gas (38)
through
the containment zone (37)(step 1130). By passing an amount of at least one gas
(38)(a
mixture of gases or desired partial pressure of gases) through the containment
zone (37)
coincident with an amount of sugar process liquid (4), materials transferable
from the
sugar process liquid (4) move toward equilibrium with the amount of gas (38)
(step
1140). The amount of gas (38) passing through the containment zone can be
separated
from the amount of sugar process liquids (4~) passing through the contaimnent
zone (37)
(step 1150) and can be transferred from the aeration chamber (38) (step 1080).
17
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
Transferable non-sucrose materials are distributed between the amount of gas
(38)
and the sugar process liquid (4)(step 1030). As such, a portion of
transferable non-sucrose
materials transferred will be transferred to the amount of gas (38) and
transferred from the
aeration chamber (36)(step 1080) while a certain portion of the non-sucrose
materials will
remain in the sugar process liquid (4) as shown by step (1040) and step
(1050). 'The
process of transferring a portion of the non-sucrose materials from the sugar
process
liquid (4) results in an amount of heat lost from the sugar process liquid
(4)(step 1160).
The term "sugar process liquid" should be understood to broadly encompass any
sucrose containing liquid regardless of the manner obtained or the proportion
of sucrose
to non-sucrose substances or water which can occur in various proportions
depending
upon the quality or kind of plant material, the materials associated with the
plant material,
or the methods or steps used to process the plant material. As such, the term
"sugar
process liquid" may be used as a generic term to identify sucrose containing
liquids
obtained from a variety of plant materials by milling or pressing steps;
sucrose containing
liquids obtained from a variety of plant materials by diffusing the plant
material with
another liquid; sucrose containing liquids obtained or resulting from various
sugar
production process steps for the clarification or purification of liquids
obtained by milling
or diffusion; or sucrose containing liquids specifically defined by terms of
art utilized in
the sugar production industry such as "raw juice", "diffusion juice",
"diffusion liquids",
"limed juice", "thin juice", "thick juice", "carbonation juice", or the like.
The term "gas" broadly encompasses without limitation a purified gas, such as
oxygen, nitrogen, helium, ozone, carbon dioxide, neon, krypton; or a mixture
of gases
such as air, atmospheric gases, atmosphere, a mixture of gases containing an
amount of
ozone greater than atmosphere, a mixture of gases containing an amount of
oxygen
greater than atmosphere, a mixture of gases containing an amount of nitrogen
greater than
atmosphere, a mixture of gases containing an amount of hydrogen peroxide
greater than
atmosphere, a mixture of gases containing an amount of carbon dioxide greater
than
atmosphere, a mixture of gases containing an amount of argon greater than
atmosphere, a
mixture of gases containing an amount of helium greater than atmosphere, a
mixture of
gases containing an amount of krypton greater than atmosphere, a mixture of
gases
containing an amount of ozone less than atmosphere, a mixture of gases
containing an
amount of oxygen less than contained in atmosphere, a mixture of gases
containing an
18
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
amount of nitrogen less than atmosphere, a mixture of gases containing an
amount of
hydrogen peroxide less than atmosphere, a mixture of gases containing an
amount of
carbon dioxide less than atmosphere, a mixture of gases containing an amount
of argon
less than atmosphere, a mixture of gases containing an amount of helium less
than
atmosphere, a mixture of gases containing an amount of l~rrypton less than
atmosphere, or
the like; or a gas or mixture of gases that have been passed through one or
more filters to
reduce, or to substantially eliminate, non-biological particulate or
biological particles
(such as bacteria, viruses, pollen, microscopic flora or fauna, or other
pathogens); a gas or
a mixture of gases that have been passed through chemical scrubbers or
otherwise
processed to generate a desired concentration or range of concentrations of
partial
pressures of gases; or combinations or permutations thereof.
Gas filters) (not shown) responsive to a flow of gas can comprise a Hepa
filter, or
a Ulpa filter, or other type of macro-particulate or micro-particulate filter.
For example,
an unfiltered gas or mixture of gases can be drawn into a first stage
prefilter, then through
a second stage pre-filter, if desired, and then through a gas flow generator
(7). The
prefiltered mixture of gases can then flow through a gas filter (Hepa filter,
or Ulpa filter,
or other type of filter). The resulting filtered gas or filtered mixture of
gases can be up to
99.99% free of particles as small as about 0.3 microns when a Hepa filter is
used, and up
to 99.99% free of particles as small as about 0.12 microns when a Ulpa filter
is used.
Again referring primarily to Figure 5, the amount of gas delivered to the flow
of
sugar process liquid (4) (step 1130) can be transferred through a gas inlet
(39) which
terminates in a single or a plurality of aperture elements (not shown in
Figure 5). A gas
flow generator (40) can be adjusted to generate sufficient gas pressure to
deliver the
desired amount of at least one gas (3~) into the flow of sugar process liquid
(4) which
passes through the containment zone (37).
The flow of sugar process liquid (4~) which passes through the containment
zone
can be a continuous flow of sugar process liquid, or responsive to a sugar
process liquid
flow adjustment means, such as a valve, variable flow restrictor, or regulator
(mechanical
or electronic) coupled to the sugar process liquid transfer means (4~0)
whereby a
continuous, intermittent, or pulsed flow of sugar process liquid (4) can
established to
19
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
increase or decrease the duration of time the flow of sugar process liquid (4)
remains in
the containment zone (37).
As to certain embodiments of the aeration chamber, a sugar process liquid
distribution element (41) can divide the flovJ of sugar process liquid (4) to
create a
plurality of streams which pass through the containment zone (37). As to
certain sugar
process liquid distribution elements (41) (as a non-limiting example, nozzles
manufactured by SEX Incorporated, 37709 Schoolcraft Road, Livonia,
I~~Iichigan) the
plurality of streams of sugar process liquid (4.) can be directed to converge
which further
disperses the streaans in the containment zone (37). The flow of sugar process
liquid (4~)
can be further divided to generate a plurality of droplets which pass through
the
containment zone (37). Understandably, the smaller the droplets (whether
individually or
on average) generated by the juice distribution element (41) the greater the
cumulative
surface area of the sugar process liquid (4) presented to the amount of at
least one gas
(38) delivered into the containment zone (37). Understandably, the amount of
gas (38),
the amount of sugar process liquid (4), the dispersion pattern of the sugar
process liquid
(4), the amount of cumulative surface area, and heat loss (step 1160) can be
adjusted to
establish the rate at which transferable non-sucrose materials move toward
equilibrium
with the amount of gas (38) (step 1140). The sugar process liquid (4) received
at the
outlet of the aeration chamber (step 1050) can have various sugar process
liquid
characteristics altered to obtain certain desired affects in subsequent
processing steps as
described below.
Again referring primarily to Figure 6, a non-limiting embodiment of the
invention
which can be utilized for the production of sugar from sugar beets, can
include a vacuum
chamber (42) independent of or in combination with the aeration chamber (36)
to
condition sugar process liquids (4). Sugar process liquid (4) introduced into
the vacuum
chamber (42) can pass through a reduced pressure zone (43) generated by
reducing partial
pressures of gases in the vacuum chamber (step 1090) with a pressure reduction
means
(44~). The reduction in partial pressures of gases in the vacuum chamber (42)
can increase
the vapor pressure of non-sucrose materials (certain of which are above-
described as
organic and inorganic materials)(step 1170). ~y increasing the vapor pressure
of
transferable non-sucrose materials an amount of non-sucrose material can be
separated
from the sugar process liquids (4)(step 1080) and transferred from the vacuum
chamber
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
(step 1110). A portion of the non-sucrose material returns to the sugar
process liquid
(step 1070) and the conditioned sugar process liquid is transferred from the
vacuum
chamber (step 1100). The sugar process liquid received at the outlet of the
vacuum
chamber (step 1100) can have various sugar process liquid characteristics
altered to
obtain certain desired affects in subsequent processing steps as described
belo~~,r.
In similar fashion to that described for the aeration chamber (36), the flow
of
sugar process liquid in the vacuum chamber (42) can be dispersed or further
divided to
increase the surface area of the sugar process liquid (4~) on which the
reduced partial
pressures of gases within the evacuation zone (43) can act. The vacuum chamber
(4~2)
whether a single chamber or multiple vacuum chambers in serial or parallel can
be used
independent of the aeration chamber, or used with the aeration chamber or
multiple
aeration chambers whether in serial or in parallel to condition a sugar
process liquid.
A first characteristic of the sugar process liquid (4) that can be altered by
conditioning sugar process liquids (4) through the various embodiments of the
aeration
chamber (36), or the vacuum chamber (42), or both in various combinations or
permutations, can be pH. The pH of the sugar process liquid (4) can be
increased by
about 0.01 pH units, about 0.05 pH units, about 0.1 pH units, about 0.2 pH
units, about
0.3 pH units, about 0.4 pH units, about 0.5 pH units, about 0.6 pH units,
about 0.7 pH
units, about 0.8 pH units, about 0.9 pH units, about 1.0 pH units, about 1.1
pH units,
about 1.2 pH units, about 1.3 pH units, about 1.4 pH units, about 1.5 pH
units, about 1.6
pH units, about 1.7 pH units, about 1.8 pH units, about 1.9 pH units, or about
2.0 pH
units.
The increase in pH of the sugar process liquids prior to preliming (13) can
affect
the demand of the sugar process liquid (4) for base, such as lime (15), to
achieve a
necessary or desired pH, concentration of hydronium ion, or acidity as
compared to
unconditioned sugar process liquid (4~) or conventionally processed sugar
process liquid
(4~). The amount of lime added after conditioning of the sugar process liquid
(4) in
accordance with the invention can be substantially less to establish a desired
pH value,
such as, between about 11.0 to about 12.0, or between 11.5 to about 12.5, or
the range of
pH used to "prelime", "main lime", "intermediate lime, or to establish a pH
value
corresponding to the iso-electric point of any particular non-sucrose material
in the sugar
21
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
process liquid (4), or required to adjust the acidity or alkalinity of the
juice to a desired
concentration. As a non-limiting example, sugar process liquid (4) conditioned
as above
described, can exhibit a reduced lime demand of up to 30%. Now referring
primarily to
Figure 2, if a 30°/~ reduction in lime demand can be achieved a savings
of $70.00 per
day ($141,163.00 over a 200 day campaign) could be achieved.
A second characteristic of the sugar process liquid (4~) that can be altered
by
conditioning sugar process liquids (4) through the various embodiments of the
aeration
chamber (37)9 or the vacuum chamber (43), or both in various combinations or
permutations, can be color. Importantly, even a minor reduction in "thin
juice" color can
substantially increase the amount of white sugar (33) produced from a ton of
sugar beets
or sugar cane, or per unit of process liquid (4).
In certain embodiments of the invention, materials which generate color in
sugar
process liquids (4) or in sugar (33) can be transferred from the flow of sugar
process
liquid (4) as it passes through the aeration chamber (36) or the vacuum
chamber (42)
(steps 1150, 1040, 1060, and 1070). The removal of these color generation
materials
correspondingly reduces the amount of color generated in the conditioned sugar
process
liquid (4), introduces a conditioned sugar process liquid (3) with less color
in subsequent
sugar process steps, and can result in less color in sugar crystals
(33)(27)(30). In this
regard and referring now to Example 4, Table 4, as a non-limiting example,
color
generation materials such as 2,3 butanedione and 2-butanone can be removed
from the
flow of sugar process liquid (4) as it passes through the contaimnent zone
(37) of the
aeration chamber (36). These materials are known to generate color in juice
and removal
can reduce juice color and sugar (33) color.
In other embodiments of the invention, the molecular structure of certain
materials
contained in the sugar process liquids (4) can be oxidized by conditioning the
sugar
process liquid (4) in accordance with the invention. The corresponding
oxidized forms of
certain materials array generate less color or generate no color in sugar
process liquid (4)
or in the resulting sugar (33). As a non-limiting example, primary alcohols
can be
converted to the corresponding aldehydes or carboxylic acids.
22
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
With respect to certain embodiments of the invention the amount of gas (38) or
partial pressures of gases can be adjusted to include or increase the amount
of an oxidant
in the gas (38) delivered to the containment zone (37) of the aeration chamber
(36)
including, but not limited to, oxygen, ozone, peroxide, air stripped of
certain partial
pressures of gases, or an amount of oxidant capable of converting primary
alcohols to
corresponding aldehydes or carboxylic acids. A separate oxidant flow generator
(45) can
be used to disperse oxidants) into the flow of sugar process liquid (4) which
passes
through the containment zone (37).
IVow referring to Figures 2 and 6, a conventional sugar process system can be
compared with a sugar process system in accordance with the invention. A
conventional
sugar process system processing about 335 tons of sugar beet cossettes (2) per
hour (see
Figure 1) can have a "thin juice" color after the second carbonation (20) of
about 3,414
RBU (see Figure 2). A sugar process system which further includes an aeration
chamber
(37) and a vacuum chamber (42) in accordance with the invention processing the
same
tonnage of sugar beet cosettes can produce a "thin juice" after the second
carbonation
(20) of about 2,911 RBU (see Figure 6). Under these conditions the
conventional sugar
process system achieves a final white sugar color of 37 RBU (see Figure 4)
while the
sugar process system in accordance with the invention achieves a final white
sugar color
of 34 RBU. In the conventional sugar process system as described above, "thin
juice"
having color greater than 3,000 RBU can result in a loss of up to $12,000.00
per day in
sugar loss, sugar recovery and energy with every 500-1000 RBU increase in
sugar
process liquid color.
As a further example, a conventional sugar process system operating at about
8,500 tons per day of sliced sugar beets, with thin juice color at about 4,000
RBU
produces a final white sugar color of about 43 RBU. To achieve a "standard"
white sugar
color of 40 RBU the centrifugal wash procedure must be adjusted to reduce the
recycle of
sugar at the sugar end. This results in more sugar to washed out and
ultimately into
molasses reducing sugar yield by about 0.65 tons/hour.
Additionally, a centrifugal wash (32) or a longer centrifugal wash of sugar
crystals
(33) in the "white centrifuge" (25) results in less sugar end capacity and
reduces
23
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
throughput of sugar process liquid (4). Moreover, a reduction in color of
sugar process
liquids can result in lower color molasses for desugarization with increased
extract yield.
A third characteristic of the sugar process liquid (4) that can be altered by
conditioning sugar process liquid (4) with the aeration chamber (3~), or the
vacuum
chamber (42), or both, in various permutations or combinations, can be
concentration of
limesalts. Because conditioning of sugar process liquid (4) in accordance with
the
invention removes certain anions, "raw juice" forms few limesalts to be
carried forward
into carbonation steps (18)(19). As described above, limesalts may not
precipitate during
the steps of preliming (14), mainliming (17), or carbonation (18)(19) because
the
solubility of such salts in sugar process liquid (4).
When limesalts are not removed prior to the evaporators (21 ), precipitates of
limesalts can form on the surface of evaporators (21) as water is removed from
sugar
process liquid (4). Boiling out evaporators (21) to remove scale can be costly
because of
the labor and equipment involved to perform the procedure. The removal of
scale from
evaporators and associated equipment can also result in additional days to the
sugar
process campaign.
Limesalts or sodium salts when limesalts are exchanged carry sucrose to
molasses.
For example, when limesalts are removed from sugar process liquid (4) by ion
exchange
and replaced with the corresponding sodium salts during regenration (sodium
salts
recycled into liming steps as described above) each pound of sodium salt can
carry
between about 0.9 pound and about 1.5 pounds of sucrose to molasses. If
limesalts are
reduced by 25 parts per million, additional sugar (33) produced per day (about
0.56 tons
at a 8,000 ton slice rate per day of sugar beets) has a value of about $246.40
at $22.00 per
hundred weight. At 200 parts per million in the same process system a savings
of about
$2000.00 can be achieved per day.
Additionally, as the part million limesalts are reduced there is a
corresponding
reduction in caustic used to regenerate the ion exchange resin. For sugar
process liquid
(4~) generated from a beet slice rate of 8,000 ton per day with a 25 ppm
reduction in
limesalts achieved in accordance with the invention the corresponding
reduction in
24
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
caustic saves about $142.00. If a reduction in limesalts of 200 ppm can be
achieved in
the same system about $2,000.00 can be saved.
le~Ioreover, the more frequent regeneration of the anion exchange resin
further
slows the sugar end of conventional sugar process systems.
A fourth characteristic of the sugar process liquid (4~) that can be altered
by
conditioning sugar process liquid (4~) with the aeration chamber (36), or the
vacuum
chamber (42), or both, in various permutations or combinations, can be purity.
Purity as a
percent relates the amount of sucrose in sugar process liquids to the amount
of soluble
non-sucrose materials in sugar process liquid.
As discussed above, there can be a significant reduction in the amount of
volatile
inorganic materials and organic materials when "raw juice" is conditioned in
accordance
with the invention. The reduction in these non-sucrose materials by
transferring them to
atmosphere (steps 100 and 1100) can increase purity of sugar process liquids
(4) from
the cossette mixer in the range of about 0.2% and about 0.4% and can increase
purity of
thin juice in the range of between about 0.15% and about 0.35%. This increase
in purity
corresponds to an increase in sugar (33) production of between about 1 pound
and 3
pounds per ton of sugar beets sliced. For a sugar process system in accordance
with the
invention having a slice rate of X000 pounds per day a savings of between
about
$1,500.00 and about $5,000.00 a day can be achieved.
Additionally, the same purity of thin juice can be achieved at greater
throughput in
a sugar process system in accordance with the invention. Colloidal particles,
or other
particles, in sugar process liquid (4) can be contaminated by electrostatic
adsorption of
ions to the surface. This primary adsorption layer can give rise to a
substantial surface
charge (electric potential at the surface). This surface charge can cause a
repulsion to
exist between two particles when they approach each other and can also attract
counter
ions into the vicinity of the particle.
Thus, the colloidal or other particles can have a charged surface with an
associated
"ion cloud" which extends into the sugar process liquid (4~) some distance
away from
particles to balance the surface charge. The thickness of this ion cloud
around the particle
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
determines how close two particles can get to each other before they start
experiencing
repulsive forces. The size of this "ion cloud" depends on the magnitude of the
surface
charge which depends on the solution concentration of the adsorbing ion, and
the
concentration of electrolyte in solution.
The volume defined by the entire ion cloud surrounding a particle and that
defined
by the slip plane for a particle are not the same things. The counter-ion
layer thickness is
the thickness of the solution layer around the particle that is required so as
to contain
enough counter-ions to "balance" the surface charge, while the slip plane
involves the
thickness of the solvent/ion film which moves with the particle.
Zeta potential (x ) is the electric potential that exists at the "slip plane" -
the
interface between the hydrated particle and the bulk solution. It is the
measurable
potential of a solid surface and also called electrokinetic potential.
According to the
electrostatic principles zeta potential is calculated by the equation,
x=4psd/D
d : thickness of the electrical double layer
s : the electrical charge in the Stern layer
D : dielectrical constant.
The relationship between the value of the zeta potential and flocculation or
dispersion in the sugar process liquid (4) favors flocculation of colloidal
particles or other
particles at low zeta potential values and favors dispersion of colloidal
particles at high
zeta potential values.
As to certain embodiments of the invention, the amount of energy imparted to
the
sugar process liquid (4) by increasing velocity, distribution, and delivery of
at least one
gas (38) into the flow of sugar process liquid (4) in the containment zone
(37) can be
adjusted to overcome the zeta potential of the colloidal particles in the
sugar process
liquid (4~) to promote additional particle to particle collisions. As a non-
limiting
example, sugar process liquid (4) can be flowed through the juice distribution
element
(4~1)(without limitation a SEX PS~J 3FPS140) at about 200 gallons per aninute
to about
300 gallons per minute (between about 27 cubic feet per minute and 40 cubic
feet per
26
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
minute) at a pressure of about 10 psi to about 40 psi. Between about 108 cubic
feet and
about 160 cubic feet per minute of gas (38) (air or atmosphere) can be
delivered into the
dispersion of that amount of sugar process liquid (4) as it passes through the
containment
zone (37). Conditioned sugar process liquid (4) manifests a more rapid
production of
floc as pH is increased (typically from a range of between about 5.5 pH 6.5 pH
to a range
of between about 11.5 pII to about 11.8 pH) and increased juice purity with
lower sugar
color.
Now referring primarily to Figures 2 and 6, a conventional sugar process
system
can be compared with an embodiment of a sugar process system in accordance
with the
invention. A conventional sugar process system processing about 335 tons of
sugar beet
cossettes (2) per hour (see Figure 1) can generate a "thin juice" purity after
the second
carbonation (20) of about 91.82 percent (see Figure 2). A sugar process system
which
further includes an aeration chamber (37) and a vacuum chamber (42) in
accordance with
the invention processing the same tonnage of sugar beet cosettes can generate
a "thin
juice" purity of about 93.02 percent.
Now refen-ing to Figures 4 and 8, the same conventional sugar process system
as
described above can generate a sugar process liquid (4) separated from sugar
crystals
from the "white pan" (24) of about 93.52 percent while the sugar process
system which
further includes an aeration chamber (37) and a vacuum chamber (42) in
accordance with
the invention generates a sugar process liquid (4) separated from sugar
crystals from the
"white pan" of about 94.17 percent.
Again referring to Figures 4 and 8, the conventional sugar process system
operated as described above generates about 49.92 tons of sugar per hour
having a color
of 37 RBU while the sugar process system in accordance with the invention
which further
includes an aeration chamber (36) and a vacuum chamber (42) can generate a
greater
amount of sugar (33) about 51.55 tons of sugar per hour having a lower color
of 34 lhBU.
The additional 1.63 tons of sugar (33) per hour equates to about $5,700.00 of
revenue per
day.
27
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
While additional sugar (33) production may vary in a sugar process system
operated in accordance with the invention, additional revenue calculated for a
200 day
campaign can easily be in excess of $1,000,000.00.
The following further non-limiting examples along v~ith the description above
are
sufficient for the, person of ordinary skill in the art to make and use the
numerous and
varied embodiments of the invention.
EXAMPLE 1
Juice was obtained by conventional tower diffusion of sugar beet cossettes. A
control group and an experimental group each consisting of six substantially
identical 500
mL aliquots of the diffusion juice were generated. Each aliquot within the
control group
and the experimental group was analyzed to ascertain the pH value. As to each
aliquot of
the diffusion juice in the control group the pH value was about 6.3. Each
aliquot within
the control group without any further treatment was titrated to an 11.2 pH
endpoint with a
solution of 50% wt./vol. caustic soda. Each aliquot within the experimental
group was
treated in accordance with the invention after which the pH of each aliquot
was
ascertained and each experimental aliquot titrated in substantially identical
fashion to the
control group to an 11.2 pH endpoint with a solution of 50% wt./vol. caustic
soda.
The results are set out in Table 1 below. As can be understood from the table
each
aliquot of juice prior to any treatment had a pH of about 6.3. The
experimental group
after treatment in accordance with the invention had increased pH values
without the
addition of any base, and required a reduced amount of caustic soda to achieve
the 11.2
pH endpoint as compared to the control group.
28
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
TABLE 1.
Untreated JuicemL Treated mL % reduction
pI-I Caustic Juice Caustic Caustic
Soda pI-i Soda Soda
6.3 1.S 6.5 1.5 16.6
6.3 1.8 6.6 1.4 22.2
6.3 1.~ 6.6 1.4 22.2
6.3 1.9 6.6 1.6 15.8
6.3 1.9 6.5 1.5 21.0
6.3 1.9 6.5 1.6 15.5
The reduction in the amount of caustic soda to reach the 11.2 pH endpoint for
the
aliquots of juice in the experimental group treated in accordance with the
invention as
compared to the aliquots of juice in the untreated control group was between
about 15.5%
and about 22.2%.
EXAMPLE 2.
Juice was obtained by conventional tower diffusion of sugar beet cossettes. A
control group and an experimental group each consisting of five substantially
identical
500 mL aliquots of the diffusion juice were generated. Each aliquot within the
control
group and the experimental group was analyzed to ascertain the pH value. As to
each
aliquot of the diffusion juice in the control group the pH value was about
6.1. Each
aliquot within the control group without any further treatment was titrated to
an 11.2 pH
endpoint with a solution of 30 brixs milk of lime. Each aliquot within the
experimental
group was treated in accordance with the invention after which the pH of each
aliquot
was ascertained and each experimental aliquot titrated in substantially
identical fashion to
the control group to an 11.2 pH endpoint with a solution of 30 brixs milk of
lime.
The results are set out in Table 2 below. As can be understood from the table
each
aliquot of juice prior to any treatment had a pH of about 6.1. The
experimental group
after treatment in accordance with the invention had increased pH values
without the
29
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
addition of any base, and required a reduced amount of milk of lime to achieve
the 11.2
pH endpoint as compared to the control group.
TAELE 2.
tTntreated JuiceanL Ivlilk Treated mL Milk % reduction
pl-T of Tuice of Ivlilk of
Lime . pH Lime Lime
6.1 4.6 6.5 3.3 , 28.3
6.1 4.4 6.6 3.2 27.3
6.1 4.7 6.6 3.5 25.5
6.1 4.4 6.6 3.3 25.0
6.1 4.5 6.6 I 3.3 ~ 26.7
' The reduction in the amount of milk of lime to reach the 11.2 pH endpoint
for the
aliquots of juice in the experimental group treated in accordance with the
invention as
compared to the aliquots of juice in the untreated control group was between
about 25.0%
and about 28.3%.
Also, the data set out in Table 1 and Table 2 provides a comparison of two
different types of'diffusion apparatus and diffusion methods. Importantly, the
data shows
that different diffusers or different diffusion methods can generate diffusion
juice having
significantly different pH values even though pH values attributed to each
type of
diffusion technology can be substantially internally consistent. See for
example the initial
pH value of the untreated diffusion juice in Table 1 which shows a pH value of
6.3 as
compared to the untreated diffusion juice in Table 2 which a pH value of 6.1.
EXAMPLE 3.
Diffusion juice was obtained by conventional tower diffusion of sugar beet
cossettes and treated in accordance with the invention using the embodiment
shown by
Figures 12 and 13 having location between the mixer arid the pre-limey.
Diffusion juice
dispersed at a rate of about 100 cubic foot per minute into a flow of
atmospheric gases
generated at a rate of about 400 cubic foot per minute (counter current path
of 72 inches x
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
72 inches with couter current path height of about 144 inches) generated
transfer a variety
of substances from the dispersed juice as identified by gas chromatograph/mass
spectra
analysis shown in Tables 1 and 2 below:
S TABLE 3.
1 ftccnc
2 f'roPnnoic
J 3-Methylhulannic
d Duuanoic
5 4-Mtsthyltaantanoic
6 Pontataoic
7 5-hlcthyliteaanoic
N Hnxa,eoic
, . ~ i,ePinnois
SI~tI3SC # 1
S1~I135C # 2
a
J 4 ' c '
_ _ _
r,..~..~",....t,.-.T.~~..r..~,..~-.T.r-.r.T.-...;"r.rrrr,, ~.rr-.-.i-
rm,l...~~.-rr~.~"~r,~"t:.r., ..r.r..T..,~t",~~ r"~t~,r.~.~..r.~
xo as a.a so ao zo ~ a.a on tc.u as ~~ m.o tao ~ tao
Table 3 shows gas chromatography analysis of samples SMBSC 1 and SMBSC 2
(condensates obtained from gas flow after counter current exchange with juice
as
described herein) with the chromatographs of those samples compared with a gas
chromatograph of a sample of a standard mixture of organic acids listed as 1-9
above. As
can be understood, treatment of juice in accordance with the invention removed
varying
amounts of each organic acid included in the standard mixture.
31
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
TABLE 4.
~. acera~aenyae. 9. Eihyl acetate
,
2. , Eihanol ~ 0. 2-ldiethyl-1-pr~panc
3. Acet~ne 11. 3-69ethyl
taut~nal
4. Ofmethyi~ul~tde12. 2-Niechyl
but~nal
/aharnd~n~ 5. h9etllyl
aCEt~te
6. 2-Nlethyi
propanal
7. 2,3-~tataned(~ne
~QOaooc
0
IS
rma->
Table 4 shows gas chromatography/ mass spectrometry analysis of sample
SMBSC 5 D (condensates obtained from gas flow after counter current exchange
with
20 juice as described herein without use of reduced pressure with a juice
temperature of
between 60°C and 70°C with the chromatograph of this sample
showing various volatile
compounds rising above a base line having a curvature predominated by a
variety of
alcohols.
25 The basic concepts of the invention may be embodied and claimed in a
variety of ways. The invention involves a juice conditioner system useful for
the
production of sugar, methods of making and using embodiments of the invention,
and
products generated by using the invention.
30 While specific illustrative examples of the invention are disclosed in the
description and drawings, it should be understood that these illustrative
examples are not
intended to be limiting with respect to the generic nature of the invention
which
encompasses numerous and varied embodiments; many alternatives are implicit or
inherent. Each feature or element of the invention is to be understood to be
representative
32
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
of a broader function or of a great variety of alternative or equivalent
elements. Where
the feature or element is described in device-oriented terminology, each
element of the
device is to be understood to perform a function. Neither the description nor
the
terminology is intended to limit the scope of the claims herein included
solely to an
apparatus or to a method.
Particularly, it should be understood that as the disclosure relates to
elements of
the invention, the words for each element may be expressed by equivalent
apparatus
terms or method terms -- even if only the function or result is the same. Such
equivalent,
broader, or even more generic terms should be considered to be encompassed in
the
description of each element or action. Such terms can be substituted where
desired to
make explicit the implicitly broad coverage to which this invention is
entitled. As but one
example, it should be understood that all actions may be expressed as a means
for taking
that action or as an element which causes that action. Similarly, each
physical element
disclosed should be understood to encompass a disclosure of the action which
that
physical element facilitates. Regarding this last aspect, as but one example,
the disclosure
of a "flow of sugar process liquid" should be understood to encompass
disclosure of the
act of "flowing sugar process liquid" -- whether explicitly discussed or not --
and,
conversely, were there effectively disclosure of the act of "flowing sugar
process liquid",
such a disclosure should be understood to encompass disclosure of a "flow of
sugar
process liquid" and even a "means for flowing sugar process liquid". Such
changes and
alternative terms are to be understood to be explicitly included in the
description.
As such, it should be understood that a variety of changes may be made to the
invention as described without departing from the essence of the invention. '
The
disclosure encompassing both the explicit embodiments) shown, the great
variety of
implicit alternative embodiments, and the methods or processes are relied upon
to support
the claims of this application.
Any patents, publications, or other references mentioned in this application
for
patent are hereby incorporated by reference. In addition, as to each term used
it should be
understood that unless its utilisation is inconsistent with such
interpretatioai, common
dictionary definitions should be understood as incorporated by reference for
each term
33
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
and all definitions, alternative terms, and synonyms such as contained in the
Random
House Webster's Unabridged Dictionary, second edition.
Thus, the applicants) should be understood to claim at least: i) each of the
juice
conditioner systen~as as herein disclosed and described, ii) tlm related
methods disclosed
and described, iii) similar, equivalent, and even implicit variations of each
of these
devices and methods, iv) those alternative designs which accomplish each of
the
functions 'shown as are disclosed and described, v) those alternative designs
and methods
which accomplish each of the functions shown as are implicit to accomplish
that which is
disclosed and described, vi) each feature, component, and step shown as
separate and
independent inventions, vii) the applications enhanced by the various systems
or
components disclosed, viii) the resulting products produced by such systems or
components, ix) methods and apparatuses substantially as described
hereinbefore and
with reference to any of the accompanying examples, x) the related methods
disclosed
and described, xi) similar, equivalent, and even implicit variations of each
of these
systems and methods, xii) those alternative designs which accomplish each of
the
functions shown as are disclosed and described, xiii) those alternative
devices and
methods which accomplish each of the functions shown as are implicit to
accomplish that
which is disclosed and described, ivx) each feature, component, and step shown
as
separate and independent inventions, xv) the various combinations and
permutations of
each of the above, and xvi) each potentially dependent claim or concept as a
dependency
on each and every one of the independent claims or concepts presented.
It should be understood for practical reasons, the applicant may initially
present
only apparatus or method claims and then only with initial dependencies. The
applicant
does not waive any right to present additional independent or dependent claims
which are
supported by the description during the prosecution of this application. The
applicant
specifically reserves all rights to file continuation, division, continuation-
in-part, or other
continuing applications to claim the various inventions described without
limitation by
any claim made in a prior application to the generic nature of the invention
or the breadth
of any claim made in a subsequent application.
Further, the use of the transitional phrase "comprising" is used to maintain
"open
end" claims herein, according to traditional claim interpretation. Thus,
unless the context
34
CA 02520524 2005-09-23
WO 2004/085684 PCT/US2004/009241
requires otherwise, it should be understood that the term "comprise" 'or
variations such as
"comprises" or "comprising", are intended to imply the inclusion of a stated
element or
step or group of elements or steps but not the exclusion of any other element
or step or
group of elements or steps. Such terms should be interpreted in their most
expansive
form so as to afford the applicant the broadest coverage legally permissible.
The claims set forth in this specification are hereby incorporated by
reference as
part of this description of the invention, and the applicant expressly
reserves the right to
use all of or a portion of such incorporated content of such claims as
additional
description to support any of or all of the claims or any element or component
thereof,
and the applicant further expressly reserves the right to move any portion of
or all of the
incorporated content of such claims or any element or component thereof from
the
description into the claims or vice-versa as necessary to define the matter
for which
protection is sought by this application or by any subsequent continuation,
division, or
continuation-in-part application thereof, or to obtain any benefit of,
reduction in fees
pursuant to, or to comply with the patent laws, rules, or regulations of any
country or
treaty, and such content incorporated by reference shall survive during the
entire
pendency of this application including any subsequent continuation, division,
or
continuation-in-part application thereof or any reissue or extension thereon.
f
