A process for the preparation of syrup from sugarcane

Abstract

The present disclosure provides a process for the preparation of syrup from sugarcane. The process of the present disclosure does not require or eliminate the need of lime and sulphur before clarification operation, thereby reducing the cost of preparation of syrup. The clarification in process of the present disclosure can be carried out at relatively lower temperature, thereby the process of the present disclosure is energy efficient.

Description

[0001] A PROCESS FOR THE PREPARATION OF SYRUP FROM SUGARCANE

[0002] FIEED

[0003] The present disclosure relates to the processing of sugarcane.

[0004] DEFINITIONS

[0005] As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used, indicate otherwise.

[0006] Biocide: The term “biocide” refers to a chemical substance or agent that is used to control or kill harmful microorganisms.

[0007] Bioethanol: The term “bioethanol” refers to a type of biofuel produced through the fermentation and distillation of sugars or starches, commonly derived from crops such as com, sugarcane and the like.

[0008] Biofuel: The term “biofuel” refers to a renewable fuel derived from organic materials, such as biomass, which includes bioethanol, biodiesel, other bio-based fuels and the like.

[0009] Biomass: The term “biomass” refers to organic matter, including plant materials that can be used as a feedstock for biofuel production.

[0010] Cane preparation: The term “cane preparation” refers to a process of cutting the sugarcane into short pieces and rupture the cells without extracting juice.

[0011] Clarification: The term “clarification” refers to a process of separating and removing solid impurities, suspended particles, or undesired substances from a liquid or solution to make it clear and free of visible or insoluble materials. In biofuel production or in sugar industry, clarification is typically employed to separate solid residues or impurities from the liquid feedstock or product, ensuring the desired quality and purity of the product.

[0012] Degree brix: The term “degree Brix” is a measure of the dissolved solids in a liquid, and is commonly used to measure dissolved sugar content of an aqueous solution. One-degree Brix is 1 gram of sucrose in 100 grams of solution and represents the strength of the solution as percentage by mass. Enzymatic hydrolysis: The term “enzymatic hydrolysis” refers to a process that involves the utilization of enzymes to break down complex organic materials, like cellulose and hemicellulose in biomass, into simpler sugars for fermentation into biofuels.

[0013] Fermentation: The term “fermentation” refers to the biological process in which microorganisms, such as yeast, bacteria and the like, convert sugars and starches into biofuels, such as bioethanol, by producing alcohol and carbon dioxide.

[0014] Fiberizing: The term “fiberizing” refers to a process when the sugarcane is subjected to a fiberizor equipment, wherein the sugarcane is tear into small fibers increasing the index of preparation (PI). Higher preparatory index results in higher extraction efficiency of milling plant.

[0015] Fiberized canes: The term “fiberized canes” refers to the canes obtained by fiberizing the canes in fiberizor equipment.

[0016] Prepared canes: The term “prepared canes” refers to the sugarcanes that are peeled off to remove the bark and cut off into small pieces by using cane preparation method.

[0017] Polymer active matter: The term “polymer active matter” refers to a product made by reacting coco di-methyl amine / alkyl amine with epi-chlorohydrine in a reaction vessel at a given reaction condition.

[0018] BACKGROUND

[0019] The background information herein below relates to the present disclosure but is not necessarily prior art.

[0020] Biofuels are renewable fuels derived from organic materials, typically a plant-based feedstock or an organic waste. Biofuels offer a sustainable and environmentally friendly alternative to conventional fossil fuels, as it helps reduce greenhouse gas emissions and decrease our reliance on non-renewable energy sources.

[0021] The current landscape of biofuel production primarily centers around the production of bioethanol and biodiesel. These biofuels are typically manufactured through a series of complex processes. Bioethanol, in particular, is produced through the fermentation and distillation of sugars or starches found in various crops, such as sugarcane, beet, com, wheat and the like. Biodiesel, on the other hand, is created through the transesterification of vegetable oils, animal fats and the like, making it suitable for use as a diesel engine fuel.

[0022] Current biofuel production methods come with several notable challenges. One of the most widely adopted methods for bioethanol production involves the utilization of sugarcane as the primary feedstock, bypassing the production of sugar. Conventionally, the sugarcane juice, known as mixed juice, undergoes a clarification process through defecation to remove impurities. Subsequently, lime is introduced to the mixed juice to achieve a precise pH level of 7.2 ± 0.2. The juice is then subjected to heating, typically reaching a temperature of 100°C, and a flocculant is added to aid in clarification. The clarified juice is further processed through evaporation to create a syrup with a high concentration of about 60 degrees Brix. Following appropriate cooling, the syrup is sent to the fermentation process within the distillery. To manage off-season storage, the syrup is treated with enzymes, antimicrobial chemicals, and antibiotics, or converted to invert sugar, with its brix level raised to a range of 80 to 85 degrees Brix. Furthermore, the biofuel production process generates substantial waste, presenting challenges in terms of waste disposal and environmental damage.

[0023] Conventionally, lime or CaO is essentially being used for juice clarification since beginning irrespective of the process such as sulfitation, carbonation, phosphor-floatation, simple defecation and the like. Lime also neutralizes the pH of the juice which is thought to be the integral part of the sugar processing. However, excavation of lime stone from Earth’s crust causes significant emission of CO2, converting the lime stone to quick lime by heating, which uses significant amount of coal (1 metric ton (MT) lime requires 0.5 MT coal). Transportation of lime from mines (Rajasthan) to sugar factories requires fuel, time and lead ultimately to pollution.

[0024] Therefore, there is a need to develop a lime and sulfur free process for the preparation of syrup that mitigates the drawbacks mentioned hereinabove or at least provides a useful alternative.

[0025] OBJECTS

[0026] Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows.

[0027] It is an object of the present disclosure to ameliorate one or more problems of the background art or to at least provide a useful alternative. An object of the present disclosure is to provide a process for the preparation of syrup from sugarcane.

[0028] Another object of the present disclosure is to provide a process for the preparation of syrup from sugarcane that is sustainable and less resource-intensive.

[0029] Still another object of the present disclosure is to provide a process for the preparation of syrup from sugarcane that does not require lime and sulphur treatment.

[0030] Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.

[0031] SUMMARY

[0032] The present disclosure provides a process for the preparation of syrup from sugarcane. The process comprising the following steps:

[0033] Prepared canes are obtained by pre-processing sugarcanes followed by treating the prepared canes with a predetermined amount of a first sanitizing agent to obtain sanitized canes. The sanitized canes are fiberized to obtain fiberized canes followed by feeding the fiberized canes to a primary mill to obtain a primary juice and bagasse. Separately, at least one secondary mill is treated with a predetermined amount of a second sanitizing agent followed by milling the bagasse in the secondary mill to obtain a secondary juice. The primary juice and the secondary juice are mixed followed by filtering to obtain a mixed juice. The mixed juice is heated to a first predetermined temperature to obtain a heated slurry. Predetermined amounts of a flocculant and optionally a first polymer formulation are added to the heated slurry to obtain a flocculated slurry. The flocculated slurry is clarified to obtain a clarified juice and a muddy juice. Optionally, a predetermined amount of a second polymer formulation to added to the clarified juice. The clarified juice is evaporated, optionally in the presence of vacuum to obtain a concentrated juice having a second predetermined temperature. The concentrated juice is treated with a predetermined amount of a biocidal agent, optionally a viscosity reducer and optionally a third polymer formulation to obtain the syrup. The process is carried out devoid of lime and sulphur.

[0034] In accordance with the present disclosure, the muddy juice so obtained is treated and recycled by the following sub-steps: The muddy juice is filtered to obtain a fdtered juice. The first sanitizing agent is added in an amount in the range of 0.01 ppm to 5.0 ppm to the filtered juice to obtain a sanitized juice. The sanitized juice is fed to the heated slurry.

[0035] In accordance with the present disclosure, the predetermined amount of the first sanitizing agent is in the range of 0.01 ppm to 10 ppm, the predetermined amount of the second sanitizing agent is in the range of 2 ppm to 15 ppm, the predetermined amount of the biocidal agent is in the range of 0.01 ppm to 15 ppm, the predetermined amount of the flocculant is in the range of 0.05 ppm to 10 ppm, the predetermined amount of the viscosity reducer is in the range of 0 ppm to 10 ppm, the predetermined amount of the first polymer formulation is in the range of 0 ppm to 20 ppm, the predetermined amount of the second polymer formulation is in the range of 0 ppm to 20 ppm, and the predetermined amount of the third polymer formulation is in the range of 0 ppm to 20 ppm.

[0036] In accordance with the present disclosure, the first sanitizing agent is a mixture of 25 mass% to 50 mass% of at least one dithiocarbamate compound; 0 mass% to 10 mass% of at least one dispersant; 0.01 mass% to 5 mass% of at least one penetrating agent; and 50 mass% to 75 mass% of water; wherein the dithiocarbamate compound is selected from the group consisting of sodium methyl dithiocarbamate, potassium methyl dithiocarbamate, sodium dimethyl dithiocarbamate, potassium dimethyl dithiocarbamate, sodium ethyl dithiocarbamate, potassium ethyl dithiocarbamate, sodium cyanodiethyl dithiocarbamate, and potassium cyanodiethyl dithiocarbamate; the dispersant is a non-ionic surfactant; and the penetrating agent is selected from the group consisting amine-based compound, polymer- based compound, phosphate -based compound, phosphonate-based compound, organo-sulfur- based compound and quinine-based compound.

[0037] In accordance with the present disclosure, the second sanitizing agent is a mixture of 25 mass% to 50 mass% of at least one dithiocarbamate compound, 0 mass% to 10 mass% of at least one penetrating agent, and 60 mass% to 75 mass% of water; wherein the dithiocarbamate compound is selected from the group consisting of sodium methyl dithiocarbamate, potassium methyl dithiocarbamate, sodium dimethyl dithiocarbamate, potassium dimethyl dithiocarbamate, sodium ethyl dithiocarbamate, potassium ethyl dithiocarbamate, sodium cyanodiethyl dithiocarbamate, and potassium cyanodiethyl dithiocarbamate; and the penetrating agent is selected from the group consisting of amine- based compound, polymer-based compound, phosphate-based compound, phosphonate-based compound, organo-sulfur-based compound and quinine-based compound.

[0038] In accordance with the present disclosure, the first polymer formulation, the second polymer formulation and the third polymer formulation are same and is an aqueous slurry of a polymer active matter; the polymer active matter is present in an amount in the range of 20 mass% to 60 mass% with respect to the total amount of said polymer formulation.

[0039] In accordance with the present disclosure, the viscosity reducer comprises: 5 mass% to 20 mass% of glycol fatty acid ester, 5 mass% to 20 mass% of polyglycerol fatty acid ester, 5 mass% to 20 mass% of sorbitin monoester, 0.5 mass% to 5 mass% of ammonium acetate, 2.5 mass% to 12.5 mass% of non-ionic surfactant, 0.1 mass% to 5 mass% of quaternary ammonium compound and q. s. water.

[0040] In accordance with the present disclosure, the biocidal agent is an aqueous solution of at least one compound selected from the group consisting of dithiocarbamate compound, quaternary ammonium compound, and an organic additive; wherein the dithiocarbamate compound is selected from the group consisting of sodium methyl dithiocarbamate, potassium methyl dithiocarbamate, sodium dimethyl dithiocarbamate, potassium dimethyl dithiocarbamate, sodium ethyl dithiocarbamate, potassium ethyl dithiocarbamate, sodium cyanodiethyl dithiocarbamate, and potassium cyanodiethyl dithiocarbamate; the quaternary ammonium compound is selected from the group consisting of quaternary long chain amines containing 1 to 25 carbon atoms, benzyl alkanium hydrochloride, chloroxylenol, and a mixture of chlorhexidine gluconate and cetrimide; and the organic additive is selected from the group consisting of amine compound, amide compound, phosphonates, quinine, guanidine, and organic sulfur compound.

[0041] In accordance with the present disclosure, the first predetermined temperature is in the range of 68 °C to 108 °C; and the second predetermined temperature is in the range of in the range of 35 °C to 65 °C.

[0042] In accordance with the present disclosure, the flocculant is selected from the group consisting of alum, poly-aluminum chloride and polyacrylamide based compounds. BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING

[0043] The present disclosure will now be described with the help of the accompanying drawing, in which:

[0044] Fig. 1 illustrates a flowchart representing a lime and sulphur free process for the preparation of syrup from sugarcane in accordance with the present disclosure;

[0045] Fig. 2 illustrates a flowchart describing the conventional method of preparing syrup from sugarcane; and

[0046] Fig. 3 illustrates a comparative graph of number of fermenter runs vs alcohol yield percentage by using the syrup prepared by the conventional process (normal) and by using the syrup prepared in accordance with the present disclosure (no lime).

[0047] DETAILED DESCRIPTION

[0048] The present disclosure relates to processing of sugarcane.

[0049] Embodiments, of the present disclosure, will now be described concerning the accompanying drawing.

[0050] Embodiments are provided to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known devices, patterns, and well-known techniques are not described in detail.

[0051] The terminology used, in the present disclosure, is only to explain a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open-ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units, and / or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.

[0052] As used herein, the term "and / or" includes any combinations of one or more of the associated listed elements.

[0053] The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer, or section from another component, region, layer, or section. Terms such as first, second, third, etc., when used herein do not imply a specific sequence or order unless suggested by the present disclosure.

[0054] The amounts measured in ppm or part per million herein represents the amounts measured in ppm on cane.

[0055] Lime or CaO is being used for juice clarification since beginning irrespective of the process, sulfitation, carbonation, phosphor-floatation or simple defecation and it is believed that clarification of sugarcane juice is not possible without using lime. Lime also neutralizes the pH of juice which is thought to be the integral part of the sugar processing.

[0056] Lime consumption is about 0.10% on cane when defecation process is used, or for crushing of 10 metric tons cane, lime requirement is 1000 MT. Saving of about 1000 MT lime per metric tons of cane crushed. For production of 1 MT quick lime (CaO), 2.2 MT lime stone (CaCOa) is burned using 450 Kg coke in a kiln. In this process huge amount of CO2 is liberated in the atmosphere apart from that during burning of coke.

[0057] This lime used is largely precipitated in filter cake and some dissolved in juice finds its way to molasses, spent wash and in remaining solid, when used as fertilizer. Thus, calcium is deposited / distributed in farm soil, which increases salinity of soil, making it low fertile and also increases hardness of river water when rain water passes through soil having more calcium.

[0058] Excess lime used is either precipitated as mud or goes to spent wash via molasses. This additional calcium is not removed and is present in fertilizer made using spent wash and / or pressed mud (filter cake). Thus, calcium naturally stored as lime stone in one area is spread / distributed in soil and also in water streams. This could be the reason of increased soil salinity and increased hardness of water in the significant area. In an aspect, the present disclosure provides a process for the preparation of syrup from sugarcane.

[0059] The process of the present disclosure comprising the following steps:

[0060] Sugarcanes are collected from the fields and are pre-processed by peeling and cutting into small pieces to obtain the prepared canes.

[0061] The prepared sugarcanes are treated with a predetermined amount of a first sanitizing agent to obtain sanitized canes.

[0062] In accordance with the present disclosure, the first sanitizing agent is a mixture of 25 mass% to 50 mass% of at least one dithiocarbamate compound, 0 mass% to 10 mass% of at least dispersant, 0.01 mass% to 5 mass% of at least one penetrating agent, and 50 mass% to 75 mass% of water. The dithiocarbamate compound is selected from the group consisting of sodium methyl dithiocarbamate, potassium methyl dithiocarbamate, sodium dimethyl dithiocarbamate, potassium dimethyl dithiocarbamate, sodium ethyl dithiocarbamate, potassium ethyl dithiocarbamate, sodium cyanodiethyl dithiocarbamate, and potassium cyanodiethyl dithiocarbamate. The dispersant is a non-ionic surfactant. In an embodiment, the dispersant is ethylene oxide based surfactant. The penetrating agent is selected from the group consisting amine-based compound, polymer-based compound, phosphate-based compound, phosphonate -based compound, organo-sulfur-based compound and quinine-based compound. In an exemplary embodiment, the first sanitizing agent is Polmax-supreme™

[0063] In accordance with an embodiment, the penetrating agent also acts as a chelating agent.

[0064] In accordance with the present disclosure, the predetermined amount of the first sanitizing agent is in the range of 0.01 ppm to 10 ppm on cane. In an exemplary embodiment, the predetermined amount of the first sanitizing agent is 7.5 ppm on cane.

[0065] The sanitized canes are fiberized to obtain fiberized canes followed by feeding the fiberized canes to a primary mill to obtain a primary juice and bagasse.

[0066] In an embodiment, the sanitized canes are fiberized in a fiberizor.

[0067] Separately, at least one secondary mill is treated with a predetermined amount of a second sanitizing agent followed by milling the bagasse in the secondary mill to obtain a secondary juice. In accordance with the present disclosure, the second sanitizing agent is a mixture of 25 mass% to 50 mass% of at least one dithiocarbamate compound, 0 mass% to 10 mass% of at least one penetrating agent and 60 mass% to 75 mass% of water. The dithiocarbamate compound is selected from the group consisting of sodium methyl dithiocarbamate, potassium methyl dithiocarbamate, sodium dimethyl dithiocarbamate, potassium dimethyl dithiocarbamate, sodium ethyl dithiocarbamate, potassium ethyl dithiocarbamate, sodium cyanodiethyl dithiocarbamate, and potassium cyanodiethyl dithiocarbamate. The penetrating agent is selected from the group consisting of amine-based compound, polymer-based compound, phosphate-based compound, phosphonate-based compound, organo-sulfur-based compound and quinine-based compound. In an exemplary embodiment, the second sanitizing agent is Polmax-ESR™

[0068] In accordance with the present disclosure, the predetermined amount of the second sanitizing agent is in the range of 2 ppm to 15 ppm on cane. In an exemplary embodiment, the predetermined amount of the second sanitizing agent is 10 ppm on cane.

[0069] The primary juice and the secondary juice are mixed and filtered to obtain a mixed juice.

[0070] In accordance with the present disclosure, the filter used in the present disclosure is a rotary vacuum drum filter (RVDF) or a decanter.

[0071] The mixed juice is heated to a first predetermined temperature to obtain a heated slurry.

[0072] In accordance with the present disclosure, the first predetermined temperature is in the range of 68 °C to 108 °C. In an exemplary embodiment, the first predetermined temperature is 82 °C when the desired subsequent product of syrup is sugar. In another embodiment, the first predetermined temperature is 102 °C.

[0073] The step of heating the slurry not only aids in sanitization process but also prepares the slurry for subsequent steps.

[0074] Predetermined amounts of a flocculant and optionally a first polymer formulation are added to the heated slurry to obtain a flocculated slurry.

[0075] In accordance with the present disclosure, the flocculant is selected from the group consisting of alum, poly-aluminum chloride and polyacrylamide compounds. In an exemplary embodiment, the flocculant is poly-aluminum chloride. In an embodiment, the flocculant is polyacrylamide compounds. In an exemplary embodiment, the flocculant is Magnafloc LT- 27™.

[0076] In accordance with the present disclosure, the predetermined amount of the flocculant is in the range of 0.05 ppm to 10 ppm on cane. In an exemplary embodiment, the predetermined amount of the flocculant is 2.5 ppm.

[0077] In accordance with the present disclosure, the first polymer formulation is an aqueous solution of polymer active matter. The polymer active matter is present in an amount in the range of 20 to 60% with respect to the total amount of the polymer formulation. The amount of polymer active matter in the polymer formulation is preferably 45%. The polymer active matter is made by reacting coco di-methyl amine / alkyl amine with epi-chlorohydrine in a reaction vessel. The process consists the steps of adding 10 to 40 parts of coco di-methyl or alkyl amine with continuous stirring, cooling and adding 8 to 42 parts of epi-chlorohydrine slowly to carry out reaction between 25 °C to 60 °C, and then transferring the milky white reaction mixture in air tight containers and allowing reaction mixture to become a translucent viscous liquid. Other agents such as color precipitants and / or flocculants may be added depending on the requirement.

[0078] In accordance with the present disclosure, the predetermined amount of the first polymer formulation is 0 ppm on cane to 20 ppm on cane. In an exemplary embodiment, the predetermined amount of the polymer formulation is 5 ppm on cane. When the desired ultimate product is biofuel, the first polymer formulation is not added. The first polymer formulation is added to the heated slurry when the ultimate product is sugar.

[0079] The flocculated slurry is clarified to obtain a clarified juice and a muddy juice separately.

[0080] The heated slurry undergoes a clarification process by being passing through a clarifier commonly utilized in traditional sugarcane processing, such as a 4 X 4 Dorr™, Graver™ clarifier, short retention (SRT) clarifier, lamella clarifier, or similar equipment. In the clarifier, a flocculant is added to ensure effective separation of impurities, leading to a clarified juice.

[0081] The so obtained clarified juice can be used as a primary feedstock for biofuel production, bypassing the conventional sugar production step.

[0082] Optionally, a predetermined amount of the second polymer formulation is added to the clarified juice. The predetermined amount of the second polymer formulation is in the range of 0 ppm to 20 ppm on cane. In an exemplary embodiment, the predetermined amount of the polymer formulation is 5 ppm on cane. The second polymer formulation is added to clarified juice when the ultimate product is sugar.

[0083] The clarified juice is evaporated, optionally in the presence of vacuum to obtain a concentrated juice having a second predetermined temperature.

[0084] In accordance with the present disclosure, the second predetermined temperature is in the range of in the range of 35 °C to 65 °C. In an exemplary embodiment, the second predetermined temperature is 55 °C.

[0085] In accordance with the present disclosure, the clarified juice can be evaporated at a temperature in the range of 102 °C to 40 °C by using a multi-effect evaporator that utilized vacuum to reduce the boiling temperature required for evaporation.

[0086] The concentrated juice has a brix value in the range of 55° brix to 65° brix. In an exemplary embodiment, the concentrated juice has a brix value of 60° brix.

[0087] In an embodiment, the concentrated juice so obtained can be forwarded to a fermentation process within the distillery for ethanol production.

[0088] The concentrated juice is treated with predetermined amounts of a biocidal agent optionally a viscosity reducer, and optionally a third polymer formulation to obtain the syrup.

[0089] In accordance with the present disclosure, the biocidal agent is an aqueous solution of at least one compound selected from the group consisting of dithiocarbamate compound, quaternary ammonium compound, and an organic additive. The dithiocarbamate compound is selected from the group consisting of sodium methyl dithiocarbamate, potassium methyl dithiocarbamate, sodium dimethyl dithiocarbamate, potassium dimethyl dithiocarbamate, sodium ethyl dithiocarbamate, potassium ethyl dithiocarbamate, sodium cyanodiethyl dithiocarbamate, and potassium cyanodiethyl dithiocarbamate. The quaternary ammonium compound is selected from the group consisting of quaternary long chain amines containing 1 to 25 carbon atoms, benzyl alkanium hydrochloride, chloroxylenol, and a mixture of chlorhexidine gluconate and cetrimide. The organic additive is selected from the group consisting of amine compound, amide compound, phosphonates, quinine, guanidine, and organic sulfur compound. In an exemplary embodiment, the biocidal agent is SypSaver™. In accordance with the present disclosure, the predetermined amount of the biocidal agent is in the range of 0.01 ppm to 15 ppm. In an exemplary embodiment, the predetermined amount of the biocidal agent is 10 ppm.

[0090] In accordance with the present disclosure, the first polymer formulation, the second polymer formulation and the third polymer formulation are same and is an aqueous slurry of a polymer active matter, wherein the polymer active matter is present in an amount in the range of 20 mass% to 60 mass% with respect to the total amount of the polymer formulation.

[0091] In accordance with the present disclosure, the predetermined amount of the third polymer formulation is in the range of 0 ppm to 20 ppm on cane. In an exemplary embodiment, the predetermined amount of the third polymer formulation is 5 ppm on cane.

[0092] In accordance with the present disclosure, the viscosity reducer comprises 5 mass% to 20 mass% of glycol fatty acid ester, 5 mass% to 20 mass% of polyglycerol fatty acid ester, 5 mass% to 20 mass% of sorbitin monoester, 0.5 mass% to 5 mass% of ammonium acetate, 2.5 mass% to 12.5 mass% of non-ionic surfactant, 0.1 mass% to 5 mass% of quaternary ammonium compound and 20 mass% to 85 mass% of water.

[0093] In accordance with the present disclosure, the predetermined amount of the viscosity reducer is in the range of 0 ppm to 10 ppm on cane. In an exemplary embodiment, the predetermined amount of the viscosity reducer is 5 ppm on cane.

[0094] The polymer formulations and the viscosity reducers are added to clarified juice when the ultimate product is sugar. The addition of the polymer formulations reduces the darkening of the syrup, so as to obtain transparent white sugar.

[0095] In accordance with the present disclosure, the process carried out devoid of lime and sulphur.

[0096] The muddy juice is further treated and recycled by the following sub-steps:

[0097] The muddy juice is filtered to obtain a filtered juice. The first sanitizing agent is added in an amount in the range of 0.01 ppm to 5 ppm on cane to the filtered juice to obtain a sanitized juice. Then, the sanitized juice is fed to the heated slurry and subsequently for clarification. In an exemplary embodiment, the first sanitizing agent is added in an amount of 2.5 ppm on cane to the filtered juice to obtain the sanitized juice, which is then recycled to heated slurry for clarification. The process of the present disclosure incorporates a sustainable approach to manage the muddy juice, derived during the clarification process. This muddy juice is efficiently filtered, the mud separated, and the filtered juice is redirected back for the clarification. This recirculation, after being treated with a first sanitizing agent ensures a closed-loop system that minimizes waste and maximizes resource efficiency.

[0098] The first sanitizing agent, the second sanitizing agent and the biocidal agent work collectively to achieve elimination of 90% of microbes within a span of just one minute.

[0099] When the first sanitizing agent is used for sanitizing cane and the second sanitizing agent is used for mill sanitization, there is no rise in the reduced sugar content and acidity as determined by titration of the juice. There is no polysaccharide formation and sucrose destruction during the process of the present disclosure.

[0100] For the off-season storage of the syrup, the process of the present disclosure employs cooling techniques and a biocidal agent. This syrup is stored in storage tanks, using standard cooling and recirculation arrangements, ensuring that the end product remains well-preserved and accessible when needed. The syrup can be stored easily without fear of crystallization of sucrose as invert sugars are more.

[0101] The process of the present disclosure is designed to optimize the biofuel production process, mitigate drawbacks, and contribute to a more sustainable and resource-efficient biofuel industry. The process of the present disclosure does not utilize the polymer formulation and / or viscosity reducer, when the process is performed to obtain the syrup which is ultimately used for biofuel production.

[0102] During the process of the present disclosure the polymer formulations may be added continuously, if necessary, to the juice or syrup for removal of impurities from syrup in a quantity preferably 5 ppm and can vary from 2 to 20 ppm depending upon the quality of juice and / or syrup or to obtain desired quality of sugar. Also, if necessary, viscosity reducers may be added continuously with suitable dilution to the syrup to reduce viscosity and improve crystallization and washing of sugar in centrifuge.

[0103] The process of the present disclosure eliminates the need for lime, resulting in significant cost savings. This not only reduces production expenses but also contributes to environmental benefits. Specifically, it leads to a substantial reduction in CO2 emissions by bypassing the excavation of limestone from the Earth's crust, which typically involves energy-intensive processes such as heating and coal consumption, as well as transportation from mines to sugar factories.

[0104] Furthermore, the process of the present disclosure facilitates clarification at lower temperatures, offering cost savings on energy and reduced emissions. The resulting syrup has a reduced chance of crystallization, ensuring ease of storage.

[0105] In the conventional processes, there is rise in the calcium content due to the use of lime, which affects the yeast performance during fermentation. In the process of the present disclosure, there is no rise in the calcium content of the juice or syrup, thereby preserves the yeast performance during biofuel production.

[0106] During the process of the present disclosure, the juice can be heated to a relatively lower temperature than the conventional process for clarification, which, in turn, optimizes heat exchange in evaporators, minimizing tube scaling and reducing the associated chemical cleaning costs while extending tube life. Lastly, the lower temperature clarification process results in juice and syrup with reduced color and fewer impurities, improving biofuel production and enhancing overall effluent treatment efficiency, marking a significant step toward sustainability and environmental responsibility in ethanol production.

[0107] Heat exchange in evaporators is better as there is no rise in calcium, scaling of evaporator tubes is minimized, resulting in reduced chemical cost for cleaning and increase in tube life.

[0108] Low temperature clarification reduces color of juice / syrup, hence less color and other impurities in spent wash. This can improve biofuel production and overall effluent treatment efficiency.

[0109] Due to the process of the present disclosure, CO2 emissions reduced significantly by avoiding excavation of lime stone from Earth’s crust, converting lime stone to quick lime by heating using significant amount of coal (1 MT lime requires 0.5 MT coal) and saving precious fuel and pollution required fortransporting lime from mines (Rajasthan) to sugar factories.

[0110] The process of the present disclosure eliminates or reduces the use of lime and sulphur. The process of the present disclosure is sustainable and cost-effective.

[0111] The foregoing description of the embodiments has been provided for purposes of illustration and is not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.

[0112] The present disclosure is further illustrated herein below with the help of the following experiments. The experiments used herein are intended merely to facilitate an understanding of the ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the experiments should not be construed as limiting the scope of embodiments herein.

[0113] EXPERIMENTAL DETAILS:

[0114] Example 1 : Process for the preparation of syrup from sugarcane in accordance with present disclosure

[0115] The sugarcanes were obtained from Nagpur, Maharashtra, India.

[0116] The sugarcanes were peeled and cut into small size by the cane preparation method to obtain prepared canes. The prepared canes were treated with 7.5 ppm on cane of Pohnax-supreme™ (first sanitizing agent) to obtain sanitized canes. The sanitized canes were fiberized in fiberizor to obtain fiberized canes and fed to a primary mill to obtain a primary juice and bagasse. Separately, each of the three secondary mills were treated with 10 ppm on cane Polmax-ESR™ (second sanitizing agent) followed by milling the bagasse in the sanitized secondary mills to obtain a secondary juice. The primary juice and the secondary juice were mixed followed by filtering to obtain a mixed juice. The mixed juice was heated to 102 °C to obtain a heated slurry. 2.5 ppm on cane of Magnafloc LT-27™ (flocculant) was added to the heated slurry to obtain a flocculated slurry. The flocculated slurry was clarified at -102 °C to obtain a clarified juice and a muddy juice separately. The clarified juice was evaporated in a multi -effect evaporator to obtain a concentrated juice having a temperature of 55 °C and a concentration of 60° Brix. The concentrated juice was treated with 10 ppm on cane of SypSaver™ (biocidal agent) to obtain a syrup. The muddy juice so obtained was treated and recycled. The muddy juice was filtered to obtain a filtered juice and a separated mud. The filtered juice was treated with 2.5 ppm on cane of Polmax Supreme™, and sent back for the clarification along with the heated slurry. The so obtained syrup was stored under regular cooling and recirculation arrangement or sent for further fermentation for biofuel production.

[0117] The process of the present disclosure is illustrated in Fig. 1 was run for 28 days.

[0118] The amounts are measured in ppm or part per million herein represents the amounts measured in ppm on cane. For example, 7.5 ppm on cane of the first sanitizing agent means, for 100 metric tons (MT) of cane the first sanitizing agent used was (100*7.5)71000000 =0.00075 MT=0. 75 kg.

[0119] Example 2: Process for the preparation of syrup from sugarcane in accordance with present disclosure

[0120] The sugarcanes were obtained from Nagpur, Maharashtra, India.

[0121] The sugarcanes were peeled and cut into small size by the cane preparation method to obtained prepared canes. The prepared canes were treated with 7.5 ppm on cane of Polmax- supreme™ (a first sanitizing agent) to obtain sanitized canes. The sanitized canes were fiberized in fiberizor to obtain fiberized canes and fed to a primary mill to obtain a primary juice and bagasse. Separately, each of the three secondary mills were treated with 10 ppm on cane of Polmax-ESR™ (second sanitizing agent) followed by milling the bagasse in the sanitized secondary mills to obtain a secondary juice. The primary juice and the secondary juice were mixed followed by filtering to obtain the mixed juice. The mixed juice was heated to 82 °C to obtain a heated slurry. 2.5 ppm on cane of Magnafloc LT-27™ (flocculant) and 5 ppm on cane of a polymer formulation was added to the heated slurry to obtain a flocculated slurry. The flocculated slurry was clarified at 85 °C to obtain a clarified juice and a muddy juice. To the clarified juice, 5 ppm of the polymer formulation was added. The clarified juice was evaporated in a multi-effect evaporator to obtain a concentrated juice having a temperature of 55 °C and a concentration of 60° Brix. The concentrated juice was treated with 10 ppm on cane of SypSaver™ (biocidal agent), 5 ppm on cane of the viscosity reducer and 5 ppm on cane of the polymer formulation to obtain a syrup. The muddy juice so obtained was treated and recycled. The muddy juice was filtered to obtain a filtered juice and a separated mud. The filtered juice was treated with 2.5 ppm on cane of Polmax Supreme™ (first sanitizing agent), and sent back for the clarification along with the heated slurry. The so obtained syrup was stored under regular cooling and recirculation arrangement or sent for sugar preparation. The process of the present disclosure is illustrated in Fig.l was run for 28 days. Example 3 (Conventional process): A conventional process for the preparation of syrup from sugarcane

[0122] The sugarcanes were peeled and cut into small pieces by the cane preparation method to obtain prepared canes. The prepared canes were fiberized in fiberizor to obtain fiberized canes and fed to a primary mill to obtain a primary juice and bagasse. Separately, each of the three secondary mills were treated with dithiocarbamate followed by milling the bagasse in the sanitized secondary mills to obtain a secondary juice. The primary juice and the secondary juice were mixed followed by filtering to obtain the mixed juice. The mixed juice was heated to 100°C to obtain a heated slurry. 5 ppm of a flocculant and quick lime solution were added to the heated slurry to obtain a heated slurry having flocculant and lime. The heated slurry having flocculant and lime was clarified at 100 °C to obtain a clarified juice and a muddy juice. The clarified juice was evaporated at 100°C in a multi -effect evaporator to obtain a syrup having a temperature of ~40 °C and a concentration of 60° Brix. The syrup was further cooled to 27°C for storage. The muddy juice so obtained was filtered to obtain a filtered juice and a separated mud. The filtered juice was sent back to heated slurry for clarification. The so obtained syrup was treated with enzymes or preservatives, and the treated syrup was stored under regular cooling and recirculation arrangement or sent for further fermentation. The conventional process of preparing syrup from sugarcane is illustrated in Fig. 2.

[0123] Analysis and fermentation of the syrup

[0124] The pH of syrup so obtained by using the process of example 1 and example 2 was 5.5 to 5.8 and calcium levels were extremely low < 600 ppm. The color of the clarified juice was visually very low, however, it was turbid as expected. The bacterial infection was not seen.

[0125] The so obtained syrup by using the process of the present disclosure was fermented at pH above 4.0. The fermentation was slightly faster. The reducing sugar remaining reduced to 0.4% against 0.69% when lime was used. Fig. 3 illustrates a comparative graph of number of fermenter runs vs alcohol yield percentage by using the syrup prepared by the conventional process (normal) and by using the syrup prepared in accordance with the present disclosure (no lime). Alcohol yield was better, alcohol percentages was 12.08% by using the syrup prepared in accordance with the present disclosure as against 11.26% by using the syrup prepared by the conventional process, and the results are as shown in Fig. 3. Ethanol yield increased to 344.9 liter / metric ton (MT) syrup of the present disclosure against 327.5 liter / MT syrup when lime was used during processing. pH of ethanol averaged 5.95 (initial fermenter pH 4.0) against 5.62 for convention process, wherein the fermentation pH was purposely raised to 5.59 (average) so as to maintain ethanol pH above 5.5. The quality of ethanol so obtained by using the syrup prepared in accordance with the present disclosure was good.

[0126] Cost analysis of the process in accordance with the present disclosure

[0127] In a conventionally used double sulfitation process for the preparation of sugar syrup from raw juice, lime consumption is in the range of 0.15% to 0.2% on cane. For crushing of 10 metric ton (MT) cane, lime requirement is 1500 MT to 2000 MT. The process of the present disclosure reduced the lime requirement to less than 0.1% or less than 1000 MT. Thus, the process of the present disclosure saves about 500 MT to 1000 MT of lime. For the production of 1 MT quick lime (CaO), 2.2 MT lime stone (CaCOa) is burned using 450 Kg coke in a kiln. In this process of conversion of lime stone to quick lime, huge amount of CO2 liberated in the atmosphere apart from that from burning of coke. The CO2 release by way of burning coal is around 1.833 MT CO2 per MT quick lime, plus release of CO2 from lime stone excavation is around 0.968 MT. Thus, totally 2.8 MT CO2 is generated per MT if quick lime used in the process.

[0128] Further, trailer carrying 30 MT lime requires one-liter diesel for travelling 3 km, average distance of limestone mines to sugar factory is about 750 km, thus about 500 liters’ diesel will be required for every 30 MT lime. The process of the present disclosure saves the transportation cost for huge amount of lime required in the conventional process.

[0129] TECHNICAL ADVANCEMENTS

[0130] The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a process for the preparation of syrup from sugarcane, that

[0131] • requires no lime, thus saving significant cost of lime and its transportation;

[0132] • reduces CO2 emissions significantly due to avoiding excavation of lime stone from Earth’s crust, and avoiding converting lime stone to quick lime by heating; • requires lower temperature of clarification and does not increase the calcium content of the juice / syrup, thereby reducing the scaling of evaporator tubes resulting in reduced chemical cost for cleaning and increase in clarifier life;

[0133] • has reduced energy cost significantly and reduced emissions;

[0134] • does not increase the calcium content of the juice / syrup, thereby yeast performance is not affected during biofuel production; and

[0135] • low temperature clarification can be carried out, thereby reducing color of juice / syrup, hence discharge less color and other impurities in spent wash resulting into improved biogas production and overall effluent treatment efficiency.

[0136] The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

[0137] The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and / or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

[0138] The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the invention to achieve one or more of the desired objects or results. While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Variations or modifications to the formulation of this invention, within the scope of the invention, may occur to those skilled in the art upon reviewing the disclosure herein. Such variations or modifications are well within the spirit of this invention.

[0139] The numerical values given for various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the invention unless there is a statement in the specification to the contrary.

[0140] Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.

[0141] The numerical values given for various physical parameters, dimensions, and quantities are only approximate values and it is envisaged that the values higher than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the invention unless there is a statement in the specification to the contrary.

[0142] While considerable emphasis has been placed herein on the specific features of the preferred embodiment, it will be appreciated that many additional features can be added and that many changes can be made in the preferred embodiment without departing from the principles of the disclosure. These and other changes in the preferred embodiment of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

Claims

CLAIMS:1) A process for the preparation of syrup from sugarcane, said process comprising the following steps:(i) obtaining prepared canes by pre-processing sugarcanes followed by treating said prepared canes with a predetermined amount of a first sanitizing agent to obtain sanitized canes;(ii) fiberizing said sanitized canes to obtain fiberized canes followed by feeding said fiberized canes to a primary mill to obtain a primary juice and bagasse;(iii) separately, treating at least one secondary mill with a predetermined amount of a second sanitizing agent followed by milling said bagasse in said secondary mill to obtain a secondary juice;(iv) mixing said primary juice and said secondary juice followed by filtering to obtain a mixed juice;(v) heating said mixed juice to a first predetermined temperature to obtain a heated slurry;(vi) adding predetermined amounts of a flocculant and optionally a first polymer formulation to said heated slurry to obtain a flocculated slurry;(vii) clarifying said flocculated slurry to obtain a clarified juice and a muddy juice;(viii) optionally, adding a predetermined amount of a second polymer formulation to said clarifiedjuice;(ix) evaporating said clarified juice, optionally in the presence of vacuum to obtain a concentrated juice having a second predetermined temperature; and(x) treating said concentrated juice with predetermined amounts of a biocidal agent, optionally a viscosity reducer and optionally a third polymer formulation to obtain said syrup; wherein said process is carried out devoid of lime and sulphur.2) The process as claimed in claim 1, wherein said muddy juice obtained in step (vii) is treated and recycled by the following sub-steps:• filtering said muddy juice to obtain a filtered juice;• adding said first sanitizing agent in an amount in the range of 0.01 ppm to 5.0 ppm to said filtered juice to obtain a sanitized juice; and• feeding said sanitized juice to said heated slurry of step (v).3) The process as claimed in claim 1, wherein• the predetermined amount of said first sanitizing agent is in the range of 0.01 ppm to 10 ppm;• the predetermined amount of said second sanitizing agent is in the range of 2 ppm to 15 ppm;• the predetermined amount of said biocidal agent is in the range of 0.01 ppm to 15 ppm;• the predetermined amount of said flocculant is in the range of 0.05 ppm to 10 ppm;• the predetermined amount of said viscosity reducer is in the range of 0 ppm to 10 ppm;• the predetermined amount of said first polymer formulation is in the range of 0 ppm to 20 ppm;• the predetermined amount of said second polymer formulation is in the range of 0 ppm to 20 ppm; and• the predetermined amount of said third polymer formulation is in the range of 0 ppm to 20 ppm.4) The process as claimed in claim 1, wherein said first sanitizing agent is a mixture of:• 25 mass% to 50 mass% of at least one dithiocarbamate compound;• 0 mass% to 10 mass% of at least one dispersant;• 0.01 mass% to 5 mass% of at least one penetrating agent; and• 50 mass% to 75 mass% of water. wherein o said dithiocarbamate compound is selected from the group consisting of sodium methyl dithiocarbamate, potassium methyl dithiocarbamate, sodium dimethyl dithiocarbamate, potassium dimethyl dithiocarbamate, sodium ethyl dithiocarbamate, potassium ethyl dithiocarbamate, sodium cyanodiethyl dithiocarbamate, and potassium cyanodiethyl dithiocarbamate; o said dispersant is a non-ionic surfactant; and o said penetrating agent is selected from the group consisting amine-based compound, polymer-based compound, phosphate-based compound, phosphonate-based compound, organo-sulfur-based compound and quinine- based compound.5) The process as claimed in claim 1, wherein said second sanitizing agent is a mixture of:• 25 mass% to 50 mass% of at least one dithiocarbamate compound;• 0 mass% to 10 mass% of at least one penetrating agent; and• 60 mass% to 75 mass% of water; wherein o said dithiocarbamate compound is selected from the group consisting of sodium methyl dithiocarbamate, potassium methyl dithiocarbamate, sodium dimethyl dithiocarbamate, potassium dimethyl dithiocarbamate, sodium ethyl dithiocarbamate, potassium ethyl dithiocarbamate, sodium cyanodiethyl dithiocarbamate, and potassium cyanodiethyl dithiocarbamate; and o said penetrating agent is selected from the group consisting of amine-based compound, polymer-based compound, phosphate-based compound, phosphonate-based compound, organo-sulfur-based compound and quinine- based compound.6) The process as claimed in claim 1, wherein said first polymer formulation, said second polymer formulation and said third polymer formulation are same and is an aqueous slurry of a polymer active matter, wherein said polymer active matter is present in an amount in the range of 20 mass% to 60 mass% with respect to the total amount of said polymer formulation.7) The process as claimed in claim 1, wherein said viscosity reducer comprises: 5 mass% to 20 mass% of glycol fatty acid ester, 5 mass% to 20 mass% of polyglycerol fatty acid ester, 5 mass% to 20 mass% of sorbitin monoester, 0.5 mass% to 5 mass% of ammonium acetate, 2.5 mass% to 12.5 mass% of non-ionic surfactant, 0.1 mass% to 5 mass% of quaternary ammonium compound and 20 mass% to 85 mass% of water.8) The process as claimed in claim 1, wherein said biocidal agent is an aqueous solution of at least one compound selected from the group consisting of dithiocarbamate compound, quaternary ammonium compound, and an organic additive; wherein• said dithiocarbamate compound is selected from the group consisting of sodium methyl dithiocarbamate, potassium methyl dithiocarbamate, sodium dimethyl dithiocarbamate, potassium dimethyl dithiocarbamate, sodium ethyl dithiocarbamate, potassium ethyl dithiocarbamate, sodium cyanodiethyl dithiocarbamate, and potassium cyanodiethyl dithiocarbamate;• said quaternary ammonium compound is selected from the group consisting of quaternary long chain amines containing 1 to 25 carbon atoms, benzyl alkanium hydrochloride, chloroxylenol, and a mixture of chlorhexidine gluconate and cetrimide; and • said organic additive is selected from the group consisting of amine compound, amide compound, phosphonates, quinine, guanidine, and organic sulfur compound.9) The process as claimed in claim 1, wherein• said first predetermined temperature is in the range of 68 °C to 108 °C; and • said second predetermined temperature is in the range of in the range of 35 °C to 65°C.10) The process as claimed in claim 1, wherein said flocculant is selected from the group consisting of alum, poly-aluminum chloride and polyacrylamide compounds.

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