JORD DECOLOURISATION

PLANTS

1. Sugar Flowsheet

2. Carbon Decolourisation Plant Description

3. Fixed Bed Versus Pulse Bed

4. Carbon Regeneration Plant Description

5. Summary of Inputs and Outputs

6. Jord’s Experience

CONTENTS

SUGAR FLOWSHEET

1 . RAW SUGAR HANDLING

Raw sugar is received, weighed and stored in a warehouse before being cut and crushed.

2 . AFFINATION

Removing the film of adhering molasses from raw sugar crystals by treating with a heavy sugar affination syrup.

3 . CARBONATION/PHOSPHOTATION

For carbonation, melt sugar is mixed with milk of lime before being scrubbed with flue gas from natural gas fired boilers. The

scrubbing gas is pumped through mixing tanks to form calcium carbonate. This calcium carbonate entraps bulk contaminants

from the process. For phosphotation, phosphoric acid, air and a flocculant are used to extract the contaminants.

4 . MUD FILTRATION

Carbonate or phosphate cake is removed by filtration.

5 . DECOLOURISATION

Fixed bed or pulse bed granular activated carbon unit is used to reduce the liquor colour down to < 150 ICUMSA.

6 . EVAPORATION

Evaporators are used to concentrate the liquor to level required for crystallization (around 76brix)

7 . WHITE SUGAR BOILING AND CRYSTALLISATION

Vacuum pans are seeded and used to promote crystal growth.

8 . CENTRIFUGAL OPERATION

Centrifugal separation is used to separate crystals of desired size for product.

9 . SUGAR DRYING AND CONDITIONING

Rotary driers are commonly used to dry the final product before it is sent to final product silos.

General Sugar Refining Overview

CARBON DECOLOURISATION

PLANT DESCRIPTION

Choice of two systems:

1) Fixed Bed- Pairs of carbon-filled adsorber columns in parallel.

- Two columns in each pair operate in series.

- Large regeneration and spent carbon tanks.

- Adsorber columns taken off-line periodically for carbon regeneration.

2 ) Pulse Bed- Pairs of carbon filled adsorber columns in parallel.

- Two columns in each pair operate in parallel.

- No regeneration and spent carbon tanks.

- Carbon charge tank for each adsorber, pulse carbon once per day.

- Adsorber columns always on-line.

- Sweetening off tanks used to accept spent carbon for regeneration.

Carbon Decolourisation

Fixed Bed: Normal Operation

LEAD COLUMN

High Colour Raw Liquor Feed in

Low Colour Fine Liquor Product out

LAG COLUMN

Fixed Bed: Switch Column Duty

LEAD COLUMN

High Colour Raw Liquor

Feed in

To New Fresh Carbon Lag

Column

LAG COLUMN

LEADSWEETENING OFF

Fixed Bed: Sweetening Off

Regen Carbon From Regen Carbon Tank

Liquor to 1)Raw Liquor2) Sweet Water3) Dirty Water

SWEETENING OFF

Hot Water/Steam Wash

Spent Carbon to Spent Carbon Tank

Pulse Bed: Normal Operation

CARBON CHARGE TANKFull of fresh/regenerated carbon.

PULSE BED ADSORBERCarbon is adsorbing contaminants from liquor.High Colour Raw

Liquor Feed in

Low Colour Fine Liquor Product out

X 2 per module

Pulse Bed: Carbon Pulse

CARBON CHARGE TANK

PULSE BED ADSORBER

Open Transfer Valve

Spent Carbon to Sweetening Off Tank

Pulse Bed: Return to Normal Operation

CARBON CHARGE TANKFull of fresh carbon.

PULSE BED ADSORBERCarbon is adsorbing contaminants from liquor.

High Colour Raw Liquor Feed in

Low Colour Fine Liquor Product out

Regen Carbon from Quench Tank

FIXED BED vs PULSE BED

REACTIVATION PART

DECOLORIZING PART

Fixed Bed

Ad

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- Lowest building profile.- Little operator attention required.- Self filtering system.- Easy to inspect vessel interiors.- Requires lower inlet pressure to pass through the system.- Can handle large flow.- Can be designed for backwashing.

Dis

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- Requires greater plot area- Higher capital investment than a pulse bedsystem for the equivalent amount of carbon on stream.- If a single adsorber is used effluent quality will vary as a function of the on stream time of the column.- The treatment objective is reached at the same time as the column is disconnected from the system.

Pulse BedA

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- Requires less plot area.- Can be controlled to have the effluent quality close to the specification value.- Has the lowest carbon dosage in applications having a long mass transfer zone.- No peak consumption of water during the recovery of product.- If gas is present, or can be generated in the carbon bed, an up flow design is the better alternative.

Dis

adva

nta

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- Cannot treat liquids containing significantquantities of suspended solids.- Inspection and/or repairs can only be done by taking an adsorber off line and emptying the entirecarbon content.- Effluent contains carbon fines after each pulsing operation and should be filtered.

Pulse Bed 3D Model

Fixed Bed 3D Model

CARBON REGENERATION

PLANT DESCRIPTION

• A multiple hearth furnace consists of a series of hearths, fixed on top of each other in a

cylindrical vessel arrangement.

• A central shaft runs vertically through the centre of the vessel with rabble arms

extending across the floor of each hearth.

• Spent carbon is fed into the top of the vessel.

• The shaft rotates (approx. 1rpm), the rabble arms spread the carbon around each

hearth.

• Burners on each hearth as well as steam and hot air injection at the bottom of the

vessel, all provide the reaction conditions necessary to oxidise and evaporate the

contaminants from the pores of the carbon.

• Alternate feed gaps in the floor of each hearth allow transfer of carbon from hearth to

hearth, down through the column, providing maximum contact time with reaction gases.

• Combustion gases are fed directly to an afterburner.

• Shaft cooling air cools the rabble arms and central shaft.

Carbon Regeneration

MHF: Carbon RegenerationSpent Carbon From

Spent Carbon Tank or Sweetening Off Tank

Steam andHot Air

Hearth 1

Hearth 2

Hearth 3

Hearth 4

etc.....

Regen Carbon to Quench Tank

Flue Gas to Afterburner

Refractory and Rabble Arms

SUMMARY OF PLANT

INPUTS AND OUTPUTS

DECOLORIZATION

Sucrose 162.5te/hr

Water 87.5te/hr

Colour 700 ICUMSA

Carbon 7kg/te sucrose

Make-up

Carbon

0.3kg/te sucrose

Make-up

Water

15litres/te sucrose

IN OUT

Sucrose 162.5te/hr

Water 87.5te/hr

Colour 113 ICUMSA

Carbon 7kg/te sucrose

Carbon

Loss

0.3kg/te sucrose

Waste

Water

15litres/te sucrose

CARBON REGENERATION

Spent Carbon 8.4kg/te sucrose(includes 20wt% adsorbed

material)

Water 7litres/te sucrose

Fuel 2.7kg/te sucrose

Steam 7kg/te sucrose

Make-up

Water

15litres/te sucrose

Regenerated

Carbon

7kg/te sucrose

Water Vapour 7litres/te sucrose

Waste Water 15litres/te sucrose

(overflows from screw and

quench tank)

Particulates 7g/te sucrose

Carbon

monoxide

2g/te sucrose

Nitrogen oxides 14g/te sucrose

Electricity Consumption0.6kwhr/te sucrose

Electricity Consumption0.6kwhr/te sucrose

JORD’S EXPERIENCE

Job No. Company Plant Year

J651CSR Limited

Pyrmont RefinerySydney NSW Australia

50 tph dry sugar complete Granular Carbon Plant including multiple hearth furnace

1981

J1649CSR Limited

New Farm Refinery,Brisbane, QLD Australia

50 tph dry sugar complete Granular Carbon Plant including multiple hearth furnace

1985

J3936CSR Limited

Yarraville Refinery, Melbourne, VIC, Australia

75 tph dry sugar complete Granular Carbon Plant including multiple hearth furnace

1991

J4183Bundaberg Sugar Co Bundaberg, QLD

Australia66” x 8 Hearth Furnace System 1991

J5098 / J5365Al Khaleej Sugar Co

Dubai, United Arab Emirates110 tph dry sugar complete Granular Carbon Plant

including multiple hearth furnace1994

J5195 / J5268Mackay Sugar LimitedMackay, Queensland

75 tph dry sugar complete Granular Carbon Plant including multiple hearth furnace

1994

J6135United Sugar Co

Jeddah, Saudi Arabia67 tph dry sugar Granular Sugar Carbon Plant

regeneration only1995

C1549United Sugar Co

Sokhna Egypt100 tph dry sugar Granular Sugar Carbon Plant

regeneration only2006

C2459Middle East Factories for Sugar

Homs, Syria83.3 tph sugar granular carbon plant, complete plant

including regeneration2007

GAC Sugar Decolourisation

Job No. Company Hearth Size Process

J651CSR Limited

Pyrmont RefinerySydney NSW Australia

3300mm OD x 6 hearthReactivating spent activated carbon from

cane sugar decolourising plant

J1649CSR Limited

New Farm Refinery, Brisbane, QLD Australia

3300mm OD x 6 hearthReactivating spent activated carbon from

cane sugar decolourising plant

J3936CSR Limited

Yarraville Refinery, Melbourne, VIC, Australia

3900mm OD x 6 hearthReactivating spent activated carbon from

cane sugar decolourising plant

J4183Millaquin Sugar Co Bundaberg, QLD

Australia 2362mm OD x 8 hearthReactivating spent activated carbon from

cane sugar decolourising plant

J5098Al Khaleej Sugar Co

Dubai, UAE 4366mm OD x 7 hearthReactivating spent activated carbon from

cane sugar decolourising plant

J5268Mackay Sugar LimitedMackay, QLD Australia 3900mm OD x 6 hearth

Reactivating spent activated carbon from cane sugar decolourising plant

J6135United Sugar Co.

Jeddah, Saudi Arabia 3900mm OD x 6 hearthReactivating spent activated carbon from

cane sugar decolourising plant

C1549United Sugar CoSokhna, Egypt 4366mm OD x 5 hearth

Reactivating spent activated carbon from cane sugar decolourising plant

C2459Middle East Factories for sugar

Homs, Syria3900mm0D x 5 Hearth

Reactivating spent activated carbon from cane sugar decolourising plant

Multiple Hearth Furnace

+ multiple references in magnesia and uranium

BHP Port Kembla

Complete granular

activated carbon plant

turnkey

6 Hearth Furnace

Activated Carbon

Dubai, UAE

Sugar decolourising and

carbon regeneration plant

,

Activated Carbon

SYRIA, 2007

Complete turnkey

sugar decolourisation

and regeneration plant

Activated Carbon

QUEENSLAND, AUSTRALIA, 2009

Queensland Magnesia, MHF (17hearth, 7.85m diameter), baghouse and conveyor system.

Magnesia

WMC OLYPIC DAM

Complete plant

turnkey

6 Hearth Furnace

Venturi Exhaust

Scrubber System

Uranium Yellow Cake