Peroxy Acid Biocide for Sugar Flume Microbial Control

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Solution Overview

Problem

Sugar processing plants face challenges in controlling microbial growth due to inadequate liming capacity and high costs associated with maintaining a high pH flume system, leading to excessive lime usage, equipment corrosion, and sugar losses.

Innovation Solution

The introduction of peroxy acid, such as peracetic acid, as a biocide to control bacterial proliferation in the flume system, combined with genome testing and monitoring equipment to maintain optimal pH levels, providing a cost-effective alternative to traditional lime-based methods.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If lime is added to maintain high pH in flume system, then microbial growth is controlled, but operational costs increase and equipment corrosion occurs

Engineering Contradiction:

Improvemicrobial growth controlVSAvoidoperational costs

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent changes the chemical parameter from lime (calcium hydroxide) to chlorine-based biocides (sodium hypochlorite, calcium hypochlorite, or chlorine gas), maintaining the same functional goal of microbial control while altering the chemical mechanism to reduce operational costs and equipment corrosion

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs chlorine-based biocides that are more cost-effective than lime, accepting that these chemicals have shorter residual effectiveness but are replenished continuously at lower cost, replacing the need for expensive and corrosive lime maintenance

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If lime is added to control bacteria, then bacterial proliferation is suppressed, but excessive lime usage occurs and equipment corrosion accelerates

Engineering Contradiction:

Improvebacterial proliferation controlVSAvoidequipment corrosion

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the chemical agent from lime to chlorine-based biocides, which achieve the same bacterial suppression function without the severe corrosive effects of high pH lime on equipment

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces chlorine-based biocides as intermediary substances that perform the microbial control function without directly causing equipment corrosion, acting as a mediator between the need for sanitation and equipment protection

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If high pH is maintained using lime, then microbial activity is suppressed, but sugar losses occur due to excessive lime expenditure

Engineering Contradiction:

Improvemicrobial activity suppressionVSAvoidsugar losses

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent changes the chemical parameter from high pH maintenance using lime to chlorine-based biocide application, achieving microbial suppression through a different chemical mechanism that does not consume sugar or require excessive chemical expenditure

Inventive Principle:

Principle #35Parameter changes

4Device complexity

If lime capacity is insufficient, then pH control is compromised, but sugar recovery decreases due to inadequate microbial control

Engineering Contradiction:

Improveliming capacityVSAvoidsugar recovery

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The patent changes the chemical parameter from lime-based pH control to chlorine-based biocide control, achieving effective microbial suppression without requiring large-scale liming infrastructure or capacity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent substitutes the mechanical/chemical infrastructure of lime kilns and large-scale lime delivery systems with simpler chlorine-based biocide application systems, maintaining microbial control effectiveness while reducing infrastructure complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

This approach effectively manages bacterial growth, reduces sugar losses, minimizes lime usage, prevents equipment corrosion, and stabilizes pH, resulting in improved sugar recovery and reduced operational costs.

Implementation Method 1

adding a peroxy acid into water of a flume system used for transporting a sugar-containing plant material

Methodology Applied

Scientific EffectOxidation: Oxidation

Implementation Method 2

maintain the pH in the alkaline range using lime. Maintaining this high pH controls acid forming bacterial activity

Methodology Applied

Scientific EffectpH adjustment through base addition:

Data Source

PatentUS20230270108A1Method for Controlling Microbial Growth in Sugar Processing

Publication Date: 2023.08.31 HYDRITE CHEMICAL CO

AI summary

A method for controlling microbial growth in a sugar processing system is disclosed, wherein the method comprises adding a peroxy acid into water of a flume system used for transporting a sugar-containing plant material from a delivery or storage location to a wash system. In one non-limiting example embodiment, the sugar-containing plant material comprises sugar beets, and the peroxy acid comprises peracetic acid.