Molassugar process -
Conversion of all refinery molasses into value added brown sugar products

(Refinery Sugar yield 99%)

 
Dr Chou Technologies, Inc. was founded in 2001 with a goal to simplify refining process to save resources for next generation. The goal envisions a VHP refinery with a) NO need for GAC process and No need for Ion exchange system for decolorization, b) NO need for silo for sugar conditioning, and most importantly c) NO production of molasses. All molasses is converted to brown sugar to increase the refinery sucrose yield to over 99%. The former a) and b) have been easily implemented with proper selection of processes and engineering design. The above c) is the primary subject for presentation.
 

There are many VHP refineries annexed to raw sugar mills/factories with 2/3/4 molasses/syrup  recycled back to the mill for further processing to recover additional sugar during the crop seasons. However, during the "off crop" season, continued boiling to 4/5/6 molasses is very inefficient due to extreme high viscosity resulting in low sugar yield and high energy cost. The Molassugar process is to :

    1) eliminate the boiling of 4/5/6 molasses and
    2) to convert these molasses into value added products

 

Presently there are three commercial processes to do the conversion to quantum jump sugar yield from conventional VHP refinery sugar yield of 96.5/97.5% to a new high of 98.5/99.5%. The processes include:

a) Micro-crystallization process - a continuous process with limited capacity about 30 GPM which is expensive both in capital and operating cost

    b) Muscavado process is a batch process also with limited capacity and

    c) Areado process which is practiced at RAR refinery in Portugal for over 30 years, and described in chapter 32 of the "Handbook of Sugar Refining" by Dr. Chou

 
The molassugar process is an updated and improved version of the Areado process. Below are brief discussions of this process:
 

Molassugar process

The PFD of the process

 

Conversion of molasses into  value added products--Molassugar

    1) Conventional boiling to extract sucrose from molasses is not economical due to high viscosity

    2) The whole massecuite of molasses transformed into Molasssugar

    3) The molassugar consists of aggregate of microcrystalline, Flavor ingredients can be added for profit enhancement

    4) No molasses is produce in the refinery

 

Operating requirements for Molasses conversion

    1) Massecuite purity minimum: 88

    2) % invert maximum in massecuite: 7%

    3) Massecuite temperature over  for high heat of crystallization

    4) Massecuite brix minimum 94 brix

    5) Agitation to create surface area for evaporation

    6) Evaporated vapor must be carried away via vacuum or air

 
Product Characteristics
These products, in the form of aggregates, with crystals size ranging from 20 to 100 micron as formed in the processes are bound to one another partly by the moisture remaining in the product and partly by non-sucrose.
 
Various flavors, such as apple, strawberry, blue berry can be added to produce many value added brown sugar products.
 

Characteristics of Molassugars

Characteristic

Areador

Muscovado Sugar

Molassugar process

Purity

97 to 98

90 to 92

94 to 96

% moisture

2.5%

1.2 to 1.5

<0.9

Color

3000

8,000 to 10,000

1,500 to 3,000

 

Pro & Con of Molassugar process

Characteristics

Areador

Muscovado Sugar

Molassugar process

Pro

1) high yield per batch

1) high yield over all

2) purity just right

1) semi automated

2) high yield

3) purity around 95

4) high capacity

Con

1) high capital cost

2) low capacity utilization

3) purity too high around 98

1) low capacity/unit

1) high in capital cost

 

Characteristic of a simplified VHP refinery - for resources saving

    1) No Affination Process

    2) No carbonation

    3) No Ion Exchange process

    4) No silo for sugar conditioning

    5) No GAC process

    6) No Molasses produced

    7) Minimum waste water discharged

 
 
 

last updated 10/27/2017