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SSP Pumps in Sugar Processing

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SSP Pumps in Sugar Processing SSP Pumps in Sugar Processing Inside View This document has been produced to support pump users at all levels, providing an invaluable reference tool. It includes information on the Sugar processes and provides guidelines as to the correct selection and successful application of SSP Rotary Lobe Pumps. Main sections are as follows: 1. Introduction 2. General Applications Guide 3. Cane Sugar Processing 4. Beet Sugar Processing 5. Refining 6. Pump Specification Options 7. The SSP Advantage 8. Pump Selection and Application Summary The information provided in this document is given in good faith, but Alfa Laval Ltd, SSP Pumps is not able to accept any responsibility for the accuracy of its content, or any consequences that may arise from the use of the information supplied or materials described. Contents Page Section 1.0: Introduction 3 Introduction of SSP Pumps in Sugar Processing Section 2.0: General Applications Guide 5 Overview of the pump ranges currently available from SSP Pumps and which particular pumps to apply within various application areas Section 3.0: Cane Sugar Processing 7 Description of how cane sugar is processed and where to find SSP rotary lobe pumps 3.1 Harvesting 7 3.2 Extraction 7 3.3 Evaporation 8 3.4 Crystallisation 9 3.5 Storage 10 Section 4.0: Beet Sugar Processing 13 Description of how beet sugar is processed and where to find SSP rotary lobe pumps 4.1 Harvesting 13 4.2 Extraction 13 4.3 Purification 14 4.4 Evaporation 14 4.5 Crystallisation 15 Section 5.0: Refining 19 Description of the sugar refining process and where to find SSP rotary lobe pumps 5.1 Affiniation 20 5.2 Carbonatation 21 5.3 Decolourisation 22 5.4 Evaporation/Crystallisation 23 5.5 Separation/Drying 24 Section 6.0: Pump Specification Options 27 Description of various pump specification options available on SSP rotary lobe pumps 6.1 Mechanical Seals 27 6.2 Heating Jackets and Saddles 28 6.3 Wear Plates 29 6.4 Bi-lobe Rotors 30 Section 7.0: The SSP Advantage 31 SSP Pumps comparison with other pump technologies 7.1 Other Technologies 33 7.1.1 Gear Pumps 33 7.1.2 Sliding Vane Pumps 33 7.1.3 Progressing Cavity Pumps 35 Section 8.0: Pump Selection and Application Summary 39 SSP Pump selection guidelines summary for the different pumped media found in Sugar Processing 1.0 Introduction Sugar is currently produced in 121 countries and global production now exceeds 120 million tonnes a year. Approximately 70% is produced from sugar cane, a very tall grass with large stems which is mostly grown in tropical countries. The remaining 30% is produced from sugar beet, a root crop resembling a large carrot grown mostly in the temperate zones of the northern hemisphere. Historically, sugar was only produced from sugar cane and then only in relatively small quantities. This resulted in it being considered a great luxury, particularly in Europe where cane could not be grown. Even today, it is difficult to ship food quality sugar across the world so a high proportion of cane sugar is made in two stages. Raw sugar is produced where the sugar cane grows and white sugar is produced from the raw sugar in the country where it is required. Beet sugar is easier to purify and most is grown where it is required so white sugar is produced in only one stage. As a recognised market leader in pumping technology SSP Pumps has been at the forefront of supplying rotary lobe pumps to the sugar industry for over 50 years. SSP rotary lobe pumps are to be found in numerous sugar processes, where their reliable low shear flow characteristics are ideally suited to the transfer of such wide-ranging media as magma, massecuite and thick juice. 3 2.0 General Applications Guide This section gives an overview of the pump ranges currently available from SSP Pumps and which particular pumps to apply within various application areas in the Sugar Industry. Within the various sugar industry processes many opportunities exist for utilising SSP rotary lobe pumps, not only for the final product but other processes such as by-products, sampling and waste. Walk the Process Sampling Waste By-Products Raw Material The Process Final Product Services Opportunities By-Products Sampling Waste The Process Raw Material Final Product 5 Within the sugar industry typical application areas for SSP Pumps are to be found in: • Carbonation • Crystallisation • Evaporation • Recovery • Separation • Storage • Tanker Loading • Transfer The table below indicates the typical pumped media found and which pump series can be generally applied: Pump Series Media Handled S D G Glucose ▲ - - High / Low Green Syrup ▲ - - Liquid Sugar ▲ - - Magma - ▲ ▲ Massecuite - ▲ ▲ Molasses ▲ ▲ - Sugar Syrup ▲ - - Thick Juice ▲ - - Treacle ▲ - - The table shown below gives a general guide as to the SSP pump series required to suit the application General Requirements Pump Series SDG Pumped Media Max. Viscosity - cP 1000000 1000000 1000000 Max. Pumping Temperature 200°C (392°F) 200°C (392°F) 200°C (392°F) Min. Pumping Temperature -20°C (-4°F) -20°C (-4°F) -20°C (-4°F) Ability to pump abrasive products 899 Ability to pump fluids containing air or gases 999 Abilty to pump solids in suspension 999 CIP capability 988 Dry running capability (when fitted with flushed mechanical seals) 999 Self draining capability 988 Performance Max. Capacity - m³/h 106 120 680 Max. Capacity - US gall/min 466 528 2992 Max. Discharge Pressure - bar 20 15 10 Max. Discharge Pressure - psig 290 215 145 6 3.0 Cane Sugar Processing The processing of sugar from sugar cane can be divided into the following steps: • Harvesting • Extraction • Evaporation • Crystallisation • Storage 3.1 Harvesting Cane grows very tall, up to 3 metres, in good growing regions. Harvesting is done either by hand or by machine. Hand cut cane is cut about ground level and assembled in bundles. These bundles are then transferred to a large vehicle and transported to the mill. Most machine-cut cane is chopped into short lengths but otherwise handled in a similar way. 3.2 Extraction The cane must be processed as soon as possible after delivery to the sugar mill. Typically, cane is processed within 24 hours of cutting. Cane preparation is critical to good sugar extraction. This is achieved with rotating knives and hammer mills called shredders. The extraction is conducted as a counter-current process using fresh hot water pumped through the chain of multiple roller mills or the continuous diffuser. The more water that is used, the more sugar is extracted but the more dilute the mixed juice is. In best milling practice more than 95% of the sugar in the cane goes into the juice. A typical mixed juice from extraction will contain 15% sugar. The residual fibre produced from crushing the cane is known as ‘bagasse’, which also contains the un-extracted sugar and 45-55% water. The bagasse is subsequently sent to the boilers to be used as fuel. 7 3.3 Evaporation The dark-green mixed juice from the mills is acid and turbid. The clarification process uses heat and lime as clarifying agents. The mixed juice is preheated before milk of lime {calcium hydroxide Ca(OH)2}, to approximately 0.5 kg per tonne of cane, is added to the juice. The lime neutralises the natural acidity and insoluble lime salts, like calcium phosphate precipitate. Heating the limed juice to boiling coagulates the proteins and some of the fats, waxes and gums. The juice goes through a gravitational settling tank, known as a clarifier, where the solids settle out and clear juice exits. The mud from the clarifier still contains valuable raw sugar so it is filtered on rotary drum vacuum filters where the residual juice is extracted and the mud can be washed before discharge, producing a sweet water. The filtered juice and sweet water is returned to the clarified juice; the press cake is discarded or used as fertiliser. The clear juice is heated in a number of juice heaters and concentrated in a multi-stage evaporator to 60-75 Brix and is now called syrup or raw syrup. 8 A direct consumption white sugar can be manufactured from concentrated cane juice if sulfur dioxide (SO2) or carbon dioxide (CO2) is used in conjunction with lime i.e. the sulphitation or carbonation process. The sulphitation process can be carried out either as an acid or alkaline sulphitation depending on whether the sulfur dioxide (SO2) or lime is added first. In the carbonation process, first quick lime and carbon dioxide (CO2) are produced in a limekiln. The quick lime is mixed with water to produce lime milk and added to the juice. The lime is precipitated with carbon dioxide (CO2) in two steps, 1st and 2nd carbonation. Before concentrating the juice it is often decolorized by adding (sulfur dioxide (SO2). Cane Bagasse Purification 2nd Carbonation Screen Lime Kiln CO2 Milk of Lime Sulphitation SO2 1st Carbonation Pre-heating Filter Liming Clarified CO2 Juice SSP Pump Application Cake Processing 3.4 Crystallisation The syrup is boiled in the vacuum pans, crystallised and separated into white sugar and remaining sugar syrup. Physical chemistry assists with sugar purification during the crystallisation process as there is a natural tendency for the sugar crystals to form as pure sucrose, rejecting the non-sugars. Thus, when the sugar crystals are grown in the mother liquor they tend to be pure and the mother liquor becomes more impure. Most remaining non-sugar in the product is contained in the coating of the mother liquor left on the crystals. The mother liquor still contains valuable sugar, so the crystallisation is repeated several times.
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