Professional Documents
Culture Documents
June 1995
Introduction
Extraction
Over the last 10 years, industry records show that conversion to difisers has created substantial performance gains
in terms of extraction, corrected reduced extraction (CRE),
and bagasse pol. During the reviewed five year period, the
average sucrose extraction of difisers was 97,85 versus 97,47
by the remaining milling trains. Assuming a boiling house
recovery (BHR) of 76 is obtained with the marginal juice,
the difference in extraction is estimated to be worth 6700
tons/season in additional sugar to the industry.
Improved performances of this magnitude and more are
now seen as an expected norm in the industry, where over
the years, new diffuser installations were usually justified on
previous poor performance of old and inefficient milling
trains. However in cases where efficient milling trains operate side by side with diffusers the performance difference
is almost negligible and in achieving their higher extraction,
diffusers have required an average of 46% more imbibition
on fibre than the mills (Table 1).
Table 1
Performance and bagasse composition
D~ffusers M ~ l l s
Sucrose % cane
F ~ b r e% cane
I m b i b ~ t ~ oO/on fibre
Extract~on
CRE
Pol % bagasse
Molsture % bagasse
Gledhow extraction
13,26
15,12
390
97,85
97,64
0,87
51,41
97,92
13,18
15,19
344
97,47
97,32
1,03
51,93
98,09
D'z~r
- Slgn~ficance
0,08
-0,07
46
0,38
0,32
-0,16
-0,52
-0,17
NS
NS
S
S
NS
NS
Diffusers
Mills
DiE$r-
Significance
87,53
85,56
86,53
87,85
85,32
86,Ol
-0,32
0,24
0,52
No
No
Yes
0,23
1,98
6,3
0,42
2,16
6,6
-0,19
-0,18
-0,3
Yes
No
No
1,OO
0,14
1,00
0,71
0,OO
-0,57
No
Yes
380
540
-160
Yes
Extraction of non-sucrose
The possibility of extracting more non-sucrose in diffusion
than milling, and thereby producing more molasses and undoing the sucrose extraction gains, has been a point which
has been debated by technologists for some time.
According to Illovo Sugar's reported figures, a small, but
significant difference does exist in molasses quantity per unit
of non-sucrose in cane, diffusers producing 1,63 tons molasses compared with 1,55 tons from milling factories. Over
the five year period, diffusers performed a non-sucrose extraction of 88,6% against 86,9% by milling trains, leaving
behind residual juice of 48,8 and 49,9 purity respectively.
The amount of non-sucrose extraction per unit of sucrose
extraction was 0,906 for diffusers and 0,891 for mills (Table
3). This apparent tendency by the diffusers towards higher
non-sucrose extraction can probably be explained by the
level at which sucrose extraction occurs rather than by any
preferential selection of non-sucrose by the diffusers. In order to try to establish this from reported data, the same set
of results were compared with a five year period (1981-86)
when the average extraction of sucrose was 0,5 unit lower
(see Table 4). In this comparison, the industrial rise in su-
EXTRACTION O F N O N S U C R O S E
Extraction of non-sucrose
DIFFUSERS
Sucrose extraction
Brix extraction
Non-sucrose extraction
Non-sucrose extraction per unit sucrose
Purity of residual juice
Molasses % cane
Molasses non-sucrose in cane
Molasses non-sucrose in juice
Diffusers
Mills
Difference
97,85
96,32
88,61
0,906
48,83
4,07
1,63
1,84
97,47
95,76
86,87
0,891
49,89
3,86
1,55
1,79
0,38
0,56
-1,74
0,015
-1,l
0,21
0,08
0,05
Table 4
Extraction of non-sucrose due to improved sucrose extraction
Diffusers
Mills
Industry
97,35
97,85
0,50
52,55
48,83
78,2
035
0,98
97,OO
97,47
0,47
51,45
50,67
61,9
0,63
1,26
97,18
97,66
0,48
52,OO
49,36
70,3
0,59
1,12
77
95
97
99
S U C R O S E EXTRACTION
FIGURE 2
crose extraction of 0,48 unit resulted in change in non-sucrose extraction of 1,l (86,6 to 87,7). Purity of residual juice
dropped from 52 to 49,4, implying a purity of 70,3 for the
marginally extracted juice.
Diffusers improved by 0,50 in sucrose extraction over the
same period, lowering residual juice purity from 52,5 to 48,8,
and increasing non-sucrose extraction by 1,O unit, while mills
showed a greater increase in non-sucrose extraction (+ 1,3)
for a smaller (0,47) increment in sucrose extraction (see Figures 1 to 3).
EXTRACTION OF N O N SUCROSE
DIFFUSERS VS
MILLS
SUCROSE EXTRACTION
FIGURE 3
DIFFUSERS
+
FIGURE 1
MILLS
Mills
Difference
Moisture % bagasse
Ash % bagasse (calculated from ash % cane)
Brix % bagasse
Lower calorific value: M/kg
kg bagasse/ton fibre cane
51,41
3,44
1,75
6906
2103
51,93
2,66
2,04
6942
2066
-0,52
0,78
-0,30
-36
37
2076
14339
100
1975
13710
96
101
628
4
Table 7
Imbibition % fibre
Imbibition per ton cane
Mixed juice % cane
Brix % mixed juice
Filter wash index
Wash waterlton cane
Bnx % evaporation feed
kg water to evaporatekon cane
Relative evaporation load
Table 5
Diffusers
Mills
Difference
390
0,571
127,5
11,96
102,4
0,03 1
11,68
1081
100
344
0,485
120,7
12,58
104,8
0,058
12,OO
1045
97
46
0,09
7
-0,62
-2
-0,028
-0,32
35
3
Mills
0,22
2,4
0,23
1,22
3,2
9,1
8,5
1,98
3,9
04
128
0,75
5,6
0,42
0,96
0,8
19,3
9,7
1,07
4,4
1,35
104
-0,53
-3,2
-0,19
0,26
2,4
- 10,2
-1,2
0,91
-0,5
-0,95
23
Energy data
Energy value of bagasse produced
~Water
~ to
~ be
~ evaporated in order to produce 68 brix syrup
has been calculated as 1050 kg/ton cane for diffusers compared with 987 kg/ton cane for mills, i.e. the evaporation
requirement of mills is 94% of that of diffusers (Table 7).
Chemical usages tend mostly to vary from factory to factory according to specific needs such as final product specification and the process used as well as through geographic
variations in cane quality, e.g. phosphoric acid is only added
in the midlands.
Table 8
Colour and sugar quality
VHP sugar to terminal 1989 to 1994
Diffusers
Colour of whole sugar
Affinated sugar
Starch (ppm Bx)
Gums (1 989)
Mills
Di2fir
Conclusions
124
714
-41
-99
813
Diffusers
mills -
Diffusers
Mills
Diffusers
mills -
683
667
Diffusers
Clear juice
Syrup
VHP sugar
VHP affinated colour
Table 9
Process chemicals
REFERENCES
Lionnet, GRE (1983). Investigations into mud and filtrate qualities. SMRI
Technical Report. No. 1357.