Sugarcane Processing Research Articles

SUGAR CANE BAGASSE ASH IN CONCRETE: A REVIEW

Sugarcane bagasse ash (SCBA), a by product of sugarcane processing, has shown great potential as a supplementary material in concrete production. A review of its application in concrete highlights its benefits, including improved mechanical properties, durability, and sustainability. SCBA contains high levels of silica, which can act as a pozzolanic material, enhancing the compressive strength and reducing the permeability of concrete. Incorporating SCBA also lowers the carbon footprint of concrete, contributing to greener construction practices by partially replacing cement. However, challenges remain, such as the variability in ash quality, proper ash treatment, and optimal blending ratios. Ongoing research focuses on refining these aspects to maximize the benefits of the SCBA in concrete, making it a promising alternative in the construction industry for sustainable development. Keyword - Sugarcane bagasse ash, Compression strength, Percentage strength, Sugarcane Workability, Slump test.

Development of corn seedlings under doses of vinhace

Corn (Zea mays L.) is the most planted grain throughout the world. However, it is a crop sensitive to nutritional deficiencies, such as nitrogen (N), phosphorus (P), potassium (K) and calcium (Ca). For this reason, numerous investigations have been carried out to find alternative ways of providing nutrients to corn crops. Among these alternatives, the wine, a by-product of the sugar cane process in sugar and alcohol plants, contains high concentrations of N, P, K and Ca. For the above, the objective of this work was to determine the ideal concentrations for. Prefertilization of corn crops through fertilization with wine. The experiment was carried out in a protected environment, with trays of sieved earth preferred with wine. The doses are determined based on the field capacity (CC), corresponding to 0% 25% 50% 75% and 100% of CC at 0, 79, 158, 237 and 316, L of wine m-3 of soil. The doses of wine did not significantly affect the emergence speed index, the length of the roots, the length of the shoots and the dry mass of the roots. The quadratic regression model was the one that presented the best adjustment for stem diameter, fresh mass of roots and shoots, as well as dry mass of shoots, and the optimal doses of wine for the aforementioned characteristics were 253.06 L m-3; 132.14; 205.99 Lm-3; 193.33 Lm-3.

Synergizing sugarcane waste valorization: Optimization of two-stage anaerobic co-digestion for enhanced methane recovery and organic matter removal

Multiple strategies have been used in anaerobic digestion of effluents aiming to enhance the efficiency of the methane (CH4) recovery process, where co-digestion and the two-stage process emerge as prominent methods. In this context, this study aimed at evaluating the co-digestion of sugarcane vinasse and molasse in a two-stage process using anaerobic fluidized bed reactors (AFBR), verifying the effect of increasing the organic loading rate (OLR) (5–22.5 kg COD.m−3.d−1) and temperature in the second stage methanogenic reactor. Regarding the two-stage process, sugarcane vinasse and molasses fermentation demonstrated the maximum energy potential (E.P) of 57.08 kJ.d−1 (7.5 g COD.L−1). Regarding the methanogenic sequential reactors, organic matter removal reached high values (up to 84.5 % in a thermophilic sequential reactor (TSR); up to 84.5 % in a mesophilic sequential reactor (MSR)). The highest CH4 yield (MY) of 306.77 ± 38.84 mL CH4.g−1 COD rem was observed in MSR (9 kg COD.m−3.d−1). Meanwhile, the maximum value of MPR (3.8 ± 0.5 L CH4.L−1.d−1) was observed in TSR (21 kg COD.m−3.d−1). Regarding the Archaea domain, a predominance of hydrogenotrophic microorganisms could be identified, in which the genera Methanobacterium and Methanothermobacter were the most abundant in MSR and TSR, respectively. This study demonstrates that anaerobic digestion of sugarcane vinasse and molasses enhances anaerobic treatment using two-stage AFBRs. It not only produces CH4 but also generates hydrogen and high-value products through an acidogenic reactor. This research marks a significant advancement in managing sugarcane processing by-products, offering promising approaches to maximize biogas production and improve pollutant removal efficiency.

Eco-conscious upcycling of sugarcane bagasse into flexible polyurethane foam for mechanical & acoustic relevance.

This study explores the use of sugarcane bagasse (SCB), a byproduct of sugarcane processing, as a bio-filler in the production of flexible polyurethane foam (FPU), focusing on its benefits for both the environment and the economy. By varying the inclusion of SCB waste from 1 to 6 wt%, the research aims to enhance the FPU's mechanical and acoustic characteristics. Techniques such as Fourier transform infrared (FTIR) spectroscopy and field emission scanning electron microscopy (FESEM) were utilized to analyze the chemical structure and surface characteristics of both SCB and the FPU/SCB composites. Additionally, tests on gel fraction, density, and mechanical properties were conducted. The results indicate that adding 4 wt% SCB to FPU considerably improved the foam's properties. This modification resulted in a 148.63% increase in apparent density, a 228.47% rise in compressive strength, and a 116.24% boost in tensile strength. Furthermore, sound absorption across various frequency ranges was enhanced compared to the control foam. Additionally, the findings show that SCB effectively shifts sound absorption characteristics to lower frequencies. Specifically, at a low frequency of 500 Hz, the sound absorption coefficient increased to 0.4 with a foam thickness of 20 mm. This demonstrates that SCB can significantly improve FPU's performance, making it an attractive option for applications requiring noise mitigation, such as in the automotive and construction industries, thereby offering a sustainable solution to waste management and materials innovation.

Energy assessment and heat integration of biofuel production from bio-oil produced through fast pyrolysis of sugarcane straw, and its upgrading via hydrotreatment

Sugarcane processing is one of the most important economic activities in Brazil, producing ethanol and sugar for domestic and international markets. Utilising the lignocellulosic residues of this industry, specifically bagasse and straw, would increase the second-generation biofuel production without increasing the sugarcane planted area. Among the processes available, the fast pyrolysis is a thermochemical conversion process that produces mainly bio-oil, a liquid with several advantages over solid biomass, regarding transportation, pumping, storage, and handling. Moreover, the bio-oil can be upgraded to obtain biofuels of higher added-value. Among feasible upgrading technologies, the hydrotreatment is one of the most promising methods for eliminating the reactive functionalities of the bio-oil by removing oxygen or cracking large molecules in the presence of hydrogen; however, this comes at the expense of a significant hydrogen consumption. Thus, the aim of this study is to evaluate the biofuel production through the fast pyrolysis of sugarcane straw, followed by the upgrading of the produced bio-oil via hydrotreatment. The evaluation is carried out by way of energy and mass balances of the processes, performed using the software Aspen Plus. Furthermore, the possibilities of integrating the bio-oil production and upgrading into the conventional ethanol and sugar production process will also be assessed through heat integration, applying the Pinch analysis. Results showed the potential for renewable gasoline and diesel production with yields of 0.086 kg/kg of dry straw and 0.08 kg/kg of dry straw, respectively. Additionally, integrating the pyrolysis process, including the bio-oil upgrading, into the ethanol production process can achieve a liquid fuel production (ethanol, gasoline and diesel) of 2289.8 MJ/t cane, which represents an increase of 29 %, while the surplus electricity increases in 5.3 %, when compared to the conventional ethanol production plant.

Gula Tebu Saka: Industri Tebu Rakyat di Nagari Bukik Batabuah, Kecamatan Canduang, Kabupaten Agam (1975-2021)

This study discusses about the saka sugarcane, like history, sugarcane plantations, and the impact of history of sugar cane industry to people in Nagari Bukik Batabuah District. The research for this thesis employs historical research methods with a socio-economic perspective. The research encompasses four stages: heuristics, source criticism, interpretation, and historiography. Sugarcane plantations have been an enduring tradition passed down through generations. The processing of sugarcane into sugar saka has become a daily routine for the people of Nagari Bukik Batabuah. Since 1975, traditional methods involving buffalo power for sugarcane grinding were still in use. However, in 2010, technological advancements led to increased production, impacting farmers' incomes and subsequently bringing about socio-economic changes within Nagari Bukik Batabuah.

STABILZED RAMMED EARTH- A REVIEW

Rammed earth construction has gained prominence as a sustainable building technique due to its eco-friendly nature and aesthetic appeal. However, ensuring the long-term durability of rammed earth structures remains a critical challenge. This paper investigates the efficacy of incorporating stabilizers, including cement, bagasse ash, and glass fibers, to address these concerns and enhance the performance of rammed earth structures. Drawing upon extensive research and experimentation, the paper examines the impact of stabilizers on material composition, structural integrity, and long-term durability. Through comparative analysis and empirical studies, the effectiveness of various stabilizers in improving compressive strength and resistance to weathering is evaluated. The role of cement as a traditional stabilizer is scrutinized, alongside emerging alternatives such as bagasse ash, a byproduct of sugarcane processing, and innovative additives like glass fibers. Furthermore, the paper investigates the influence of stabilizer incorporation on construction practices and life cycle considerations. Key factors such as cost-effectiveness, sustainability, and compatibility with traditional rammed earth methods are analyzed to provide comprehensive guidance for practitioners and researchers. The findings highlight promising avenues for enhancing the durability and compressive strength of rammed earth structures through stabilizer utilization. Practical recommendations are offered for implementing these strategies in real-world construction projects, emphasizing the potential for innovation and sustainability in contemporary architectural practice. Keywords: · Stabilized Rammed Earth · Un-Stabilized Rammed Earth

The Lifting Performance and Experimental Study of a Variable Spiral Spike-Toothed Crop Divider

The contact between a traditional crop divider and sugarcane is unstable, and the sugarcane easily slides off of its surface. By analyzing the movement process of sugarcane, the influence of traditional spiral flightings on lifting performance was studied, and shortcomings were also found. Based on previous research and analysis, the variable spiral spike-toothed crop divider was designed by research groups. For sugarcane with different lodging states, the contact separation rule between the sugarcane and the spike tooth was studied, and the action time and angle of the spike tooth on sugarcane were obtained. At the same time, the interaction mechanism between sugarcane and the spike tooth was analyzed, and the conditions for lodged canes to be lifted were obtained. The influence of the spike tooth on the lifting performance was explored, and the working advantages were found for the spike-toothed crop divider. Then, a simulation test was conducted to obtain the contact force between the sugarcane and the crop divider. Finally, the crop divider was optimized and integrated into the harvester, and a field harvesting test was carried out to verify the working performance of the crop divider. This study was expected to provide a reference for the design of crop dividers and a theoretical basis for the analysis of the lifting process.

Design of a Sugarcane Crusher: Towards Sustainable Processing

Abstract: In order to answer the expanding demand for increased sustainability and efficiency in the sugar sector, this research focuses on the design and development of an innovative sugar cane crusher. The proposed crusher design includes cutting-edge elements that maximize juice extraction while consuming the least amount of energy. The structural integrity and mechanical reliability of the design are guaranteed through thorough study and testing, including finite element simulations. The study also looks at automation and control systems to improve crushing and keep product quality constant. In comparison to traditional models, the new crusher design achieves better rates of juice extraction and uses less power, showing promising outcomes in operational efficiency. The applicability of the design to various processing scenarios and sugar cane kinds is also illustrated.By providing a response that meets industry objectives for increased efficiency and sustainability, this research helps to improve sugar cane processing technology.

Pengendalian Kualitas Produk Gula Studi Kasus PT Madubaru PG. PS. Madukismo Yogyakarta

PG Madukismo is a sugar factory that was established in 1955 and is the only sugar factory in the province of the Special Region of Yogyakarta. This factory is located in Padokan Village, Tirtonirmolo Village, Kasihan District, Bantul Regency, Special Region of Yogyakarta. PT Madubaru, a company engaged in sugar cane processing, is a sugar and spirits factory located in the Yogyakarta area. Companies that produce cane sugar with SHS IA quality. Product defects are often found, resulting in a decrease in quality, therefore it is necessary to carry out quality control. This study uses the Failure Mode and Effect Analysis (FMEA) method to identify failure modes, Logic Tree Analysis (LTA) to determine the consequences of failure arising from failure modes and determine effective preventive maintenance policies for each machine. For the production quality control section, the Statistical Processing Control (SPC) method is used to analyze product defects to determine whether product defects are still within controllable limits or not. While the Failure Mode and Effect Analysis (FMEA) method is used to determine the failure mode in sugar production. For the quality control section on raw materials using the Economic Order Quantity (EOQ), Re-Order Point (ROP), Safety Stock (SS), and Total Inventory Cost (TIC) methods. The conclusion of this study is regarding the results of the analysis and calculations carried out with several settlement methods and there are several causes of production defects from 5 factors, such as: human factors, work methods, environment, raw materials and machines used. And provide solutions to companies in order to reduce defects by controlling product quality.

High Torque and Increased Wear Redefine Gearbox Longevity in Electric Motors

This study explores the accelerated wear of gearboxes driven by electric motors compared to gearboxes in combustion engines, highlighting the important role of lubrication quality. The continuous operation of sugarcane processing machines requires durable gearboxes, especially under the high torque load of electric motors. By analyzing gearbox wear through standard load tests and various lubricant qualities, the findings reveal that superior lubricants significantly reduce wear. These results not only demonstrate the need for customized gearbox designs for electric motors, but also show that improvements in lubrication practices can extend gearbox life and increase efficiency in industrial applications globally. Highlights: Continuous operation vital for production targets. Electric motorbike gearboxes need frequent maintenance. Quality lubrication crucial for gearbox longevity. Keywords: Gearbox, Grind, Sugar Factory

Characterization and assessment of free amino acids in different varieties of sugarcane

A better understanding of amino acids (AA) characteristics is beneficial for breeding, processing and storage of sugarcane. The differences and classification in AA of 10 different sugarcane varieties (S1-S10) were investigated in this study. Varieties affected components and concentrations of free AA (p ＜ 0.05) significantly. The total AA of sugarcanes ranged from 51.44 to 781.61 mg/L, while the content of essential amino acids (EAA) was in the range of 0.72–60.98 mg/L. Glu (glutamic acid) was the most abundant free amino acids in all varieties of sugarcane except S4. Even though S6 had the highest concentration of medicinal AA (781.61 mg/L), the highest proportion of medicinal AA in total AA was found in S5 (81.76%). S6 got the highest comprehensive score in amino acids based on the results of Principal Component Analysis (PCA). The cluster analysis roughly divided the sugarcanes into 2 groups. Group Ⅰ including S1, S6, S2 and S5 got positive scores in PCA might had great edible and medicinal development and utilization value.

Electrocoagulation treatment of sugarcane vinasse: Operating parameters and cost analysis by response surface methodology

The production of ethanol biofuel using sugarcane as substrate generates vinasse as the main wastewater from the fermentation–distillation process. The Brazilian legislation allows the use of vinasse for fertigation in limited volumes, and the remaining effluent must be treated prior to its reuse or discharge into the environment. The study aimed to evaluate the electrocoagulation (EC) technique as an alternative treatment process for raw sugarcane vinasse. The effects of the electrode gap (1–3 cm), applied electric charge (0–39000 C/L), current density (2.2–20 mA/cm2), and stirrer speed (0–680 rpm) were evaluated in a batch electrolytic reactor with aluminum electrodes. The evaluation results revealed that dissolved solids were removed and the pH increased during electrolysis in all experimental conditions, which suggested that EC was suitable for the pH neutralization of vinasse without the requirement of salt addition. An electrode gap of 1 cm and a current density of 2.2 mA/cm2 resulted in the lowest electric energy consumption (11.0 kW h/m3) and the lowest increment in the electrolyte temperature (9.5 °C). High vinasse clarification was achieved under the optimal operating conditions of 1 cm electrode gap, 31,000 C/L applied electric charge, 6.1 mA/cm2 current density, and 430 rpm stirrer speed, with 13.5 kW h/m3 and 2.88 kg Al/m3 of consumption. The treatment cost was calculated to be 6.95 US$/m3, from which the electrode dissolution was determined to be 75%. The sludge settling velocity was 0.14 cm/min, which suggested poor sedimentability, possibly due to bubble gas adsorption on the surface of the formed flocs. Results of the proposed operational parameters indicate that EC can be used as a pre-treatment of vinasse, adapting the main sugarcane processing wastewater biotechnological use.

Life Cycle Analysis of Succinic Acid Production in the Brazilian Biorefinery Context

Succinic acid is an essential component of the chemical industry. Traditionally produced from fossil resources, its sustainable production using renewable resources faces challenges due to the complexities of cultivation and purification. This study assessed the environmental impacts of succinic acid production from sugarcane through a life cycle analysis and compared it with three other scenarios: using sorghum, apple pomace, and the traditional chemical route. Employing the ReCiPe midpoint methodology with a cradle-to-gate approach, the analysis highlighted significant environmental impacts linked to the agricultural stage in the sugarcane process. The use of pesticides, fertilizers, and energy demand resulted in elevated impacts compared to other stages of the process. The other scenarios also presented strong contributions in the purification stages. The production from sugarcane proved advantageous compared to other scenarios, minimizing impacts in 6 out of 10 categories. It is evident that the selection of the correct biomass is crucial for process sustainability, and the use of second-generation inputs can help reduce impacts in the agricultural stage. However, advancements in the fermentation stage are necessary, along with a reduction in the complexity of the purification steps. This study emphasizes the potential of renewable succinic acid production from sugarcane juice in the Brazilian scenario. Utilizing this process could reduce succinic acid’s environmental impacts by 70% to 99% compared to the petrochemical route. The process should be considered as a sustainable alternative to be included in the portfolio of biorefineries, enhancing factory profitability.

Value-added product from sugarcane molasses: Conversion of sugarcane molasses to non-caloric sweetener for applications in food and pharmaceutical industries

Molasses is a by-product from sugarcane processing industries that contains some useful natural compounds. This paper proposes a method to produce sucralose, a non-caloric sweetener, from sugarcane molasses. In the first step, sugarcane molasses was converted to dried molasses powder using the low-temperature spray drying process in order to preserve natural compounds. Response surface methodology and artificial neural network were used to determine the experimental condition for maximal bioactive compounds content and antioxidant activity. Dried molasses powder could be produced with maximal values of sucrose yield, total phenolic content, total flavonoid content and antioxidant activity. In the final step, sucralose was derived from dried molasses powder. The yield of molasses-derived sucralose obtained from the proposed method was 0.628±0.01 g/g dried molasses powder with the purity of 99.95±0.02 %. The proposed method paves the way to convert sugarcane molasses to a non-caloric sweetener for applications in food and pharmaceutical industries.

Socio-Economic and Psychological Attributes of Sugarcane Grovers of Barelilly District of Uttar Pradesh

The study was conducted in Bareilly district U.P., and the result of study will assist to various government organisation, stakeholders, sugarcane industry and NGOs to frame a specific programme, plan and policy for their further developments. The sugarcane industry refers to processing, manufacturing and value addition of sugarcane produces to produce jaggery, sugar, bagasse, molasses, papers, plastic, alcohol and biofuels etc. It is one of the most important sectors of the Indian economy, as it contributes to the rural development, employment generation, and export earnings. The study was carried out with 100 respondents. The result explore that, majority of respondents (70%) belong to middle age group, most of them (80%) were literate with formally educated (25%) up to high school level, majority of them (58%) were belongs to other backward cast, with mostly of them (96%) were Hindu, their family were nuclear type (64%) with medium family size (65%), majority of them (42%) were small land holders, maximum (87%) had pukka house, and agriculture as a main occupation, majority of respondents (45%) belong to ₹120001- ₹180000 annual income, they were (100%) ensure participation in gram panchayat activity, majority of them (62%) have medium level of overall material possession, under the various aspect of material possession, most of respondents (93%) possess diesel engine, they were (100%) perform their agriculture field operation by use of sickle, most of them (99%) were also use bicycle as a transportation mean, they (100%) had cots as household materials possession, most of them (55%) were medium level of communicational media, also most of them (65%) and (66%) were have medium level of economic motivation and risk orientation respectively.

Characterization of Levan Fructan Produced by a Gluconobacter japonicus Strain Isolated from a Sugarcane Processing Facility.

During raw sugarcane processing, a significant portion of lost sucrose is attributable to microbial degradation. Sucrose consumption by many bacteria is also linked to the production of exopolysaccharides (EPS) such as dextrans and fructans. These resulting EPS cause operational challenges during raw sugar manufacturing. Here, we report the characterization of EPS from a fructan-forming Gluconobacter japonicus bacterium that we previously isolated from a Louisiana sugarcane factory. The genome sequencing revealed the presence of two encoded levansucrase genes, lsrA and lsrB. One levansucrase, LsrB, was detected in the secreted protein fraction of G. japonicus LASM12 by QTOF LC-MS. The spotting assays indicated that G. japonicus produces EPS using sucrose and raffinose as substrates. The G. japonicus EPS correlated with levan fructan commercial standards by 1H-NMR, and with the characteristic carbohydrate fingerprint region for FTIR spectra, confirming that the G. japonicus EPS is levan fructan. The glycosyl composition and glycosyl linkage analysis revealed a linear β-2,6-fructofuranosyl polysaccharide with occasional (5.7%) β-2,1-fructofuranosyl branches. The gel permeation chromatography of the levan fructan EPS showed two main peaks at 4.5 kDa and 8 kDa and a very minor peak at 500 kDa. G. japonicus was identified as a producer of levan fructan. These findings will be useful for future studies aimed at evaluating the impact of levan fructans on sugar crop processing, which have been historically underestimated in industry.

The effect of feedstock densification on the process and product properties of sugarcane leaves pyrolysis

<p>Sugarcane leaves are the main residue constitute approximately 14% of the total weight of the remaining sugarcane after harvesting. An effective method for processing sugarcane leaves residues is needed at low cost without causing any environmental problem. This research aims to disclose the effect of sugarcane leaves densification method applied prior to pyrolysis process in a pilot scale reactor. To evaluate the process and its product, the experiments were carried out into two types: (<italic>i</italic>) pyrolysis of sugarcane leaves without densification at 320 ℃ with a variation of pyrolysis time for 100,120, and 130 minutes and (<italic>ii</italic>) pyrolysis of densified sugarcane leaves with the variation of pyrolysis temperature 320 ℃ and 420 ℃. The investigated conditions showed that the effect of sugarcane leaves densification prolong the pyrolysis time up to 240 minutes at a pyrolysis temperature of 320 ℃, and increased the yield of biochar and bio-oil products up to 41% and 38%, respectively. However, in term of the physical properties of biochar products, the fixed carbon content decreased by 7% when the sugarcane leaves were compacted. While other parameters found no significant difference in pyrolysis at 320 ℃, the effect of sugarcane leaves densification is very beneficial especially when the pyrolysis was performed at 420 ℃.</p>

Noise mapping technique for an unrefined sugar cane processing factory

Noise mapping technique for an unrefined sugar cane processing factory

QUALITY CONTROL IN SUGAR AGROINDUSTRY USING FAILURE MODE AND EFFECT ANALYSIS (FMEA) METHOD IN BONDOWOSO REGENCY

The sugar agroindustry in Bondowoso, particularly PG Pradjekan, is a part of the business unit of PTPN XI that focuses on sugarcane processing. Its main product is white crystalline sugar, which must adhere to the Indonesian National Standard (SNI), with quality characteristics measured through sugar solution color (ICUMSA) and Grain Size (BJB). The quality of the produced white crystalline sugar is maintained through a monitoring process to ensure compliance with government-established standards.Quality monitoring involves control over ICUMSA and BJB, with the understanding that a smaller BJB results in a whiter ICUMSA, indicating better quality. The efforts in quality control aim to assist the company in maintaining and enhancing product quality in accordance with government standards. The company's target is to achieve zero defects, with a tolerance of 0.5%.Data from the milling process in 2022 at PG Pradjekan recorded sugar production of 16,693 tons. However, there was a defect rate of 0.92% of the total production, equivalent to 155 tons. These defects incur losses for the company as rejected products undergo reprocessing, leading to increased costs and prolonged production time. Therefore, improving quality control is crucial to reducing defect rates and enhancing overall production efficiency.