Hybrid Sugar Purification Process Merging Carbonatation and Phosphatation
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Solution Overview
Problem
Current sugar processing methods like carbonatation, phosphatation, and sulphitation produce significant waste, are costly, and have environmental drawbacks, such as residual SO2 and phosphate contamination, due to their separate and discrete nature.
Innovation Solution
A hybrid process combining carbonatation, phosphatation, or sulphitation in a single step, using phosphoric or sulphur-based acids and carbon dioxide to form a precipitate that removes contaminants, including color bodies, with recycling of CO2 and pH adjustment to optimize contaminant removal efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional separate processes (carbonatation, phosphatation, or sulphitation) are used for clarification and decolourisation, then purification performance is achieved, but waste production increases and operating costs rise
Solution Approach 1:
The patent combines carbonatation, phosphatation, and sulphitation into a single integrated process where lime is added to the liquor followed by carbon dioxide, creating a hybrid treatment that achieves the purification benefits of all three processes simultaneously while producing a single consolidated waste stream instead of multiple separate waste products
Solution Approach 2:
The integrated process serves multiple functions in one operation: it clarifies the liquor, decolourises it, and controls pH, thereby achieving the effects of three separate processes through a unified multi-functional treatment system
2Manufacturing precision
If carbonatation is used for highly turbid and coloured streams, then decolourisation efficiency is improved, but capital expenditure increases due to high pressure filtration requirements
Solution Approach 1:
By merging carbonatation with phosphatation and sulphitation in a single process sequence, the patent achieves enhanced decolourisation efficiency without requiring the high pressure filtration systems needed for pure carbonatation, as the combined process produces a different precipitate composition that is easier to handle
3Loss of substance
If phosphatation is used to reduce waste volume, then waste production decreases, but operating costs increase due to expensive phosphoric acid and colour precipitating chemicals
Solution Approach 1:
The patent merges phosphatation with carbonatation and sulphitation, allowing the use of phosphoric acid in combination with lime and carbon dioxide to achieve effective purification with reduced waste volume, while the synergistic effect of the combined processes reduces the total amount of expensive chemicals required compared to using phosphatation alone
4Manufacturing precision
If sulphitation is used for purification, then clarification is achieved, but environmental harm increases due to residual SO2 and sulphur in the product
Solution Approach 1:
By combining sulphitation with carbonatation and phosphatation in an integrated process, the patent achieves effective clarification while the presence of lime and the sequential addition of carbon dioxide helps neutralize and remove residual SO2 and sulphur, preventing them from contaminating the final product
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The hybrid process achieves high contaminant removal efficiency, up to 75% color removal, reduces waste, and minimizes the use of expensive chemicals, making it more economically viable and environmentally friendly compared to traditional methods.
Implementation Method 1
a process for the removal of contaminants from a liquor, the process comprising a combination of two or more of carbonatation, phosphatation or sulphitation to form precipitate comprising at least some of the contaminants from the liquor and separating the precipitate from the liquor
Implementation Method 2
introducing carbon dioxide into the liquor
Implementation Method 3
separating the precipitate from the liquor
Data Source
AI summary
A process for the removal of contaminants from a liquor, including two or more of carbonatation, phosphatation and sulphitation of the liquor to form a precipitate having at least some of the contaminants from the liquor, and separating the precipitate from the liquor. The processes may be included in sugar refining or water decontamination processes.