Sugarcane Factory Research Articles

Improving sugarcane productivity on marginal soil in Takalar, Indonesia, through the application of sugarcane factory waste

Marginal soil with low nutrient content is a crucial problem in reducing crop productivity, including sugarcane. This study aimed to elucidate the possible improvement of the physical and chemical properties of marginal soil through the application of organic waste from sugar factories, namely kettle ash and press mud. Nine treatment combinations of 0, 10, and 20 t ha-1 of each kettle ash and press mud were arranged in a two-factor randomized factorial design with three replications. Soil organic matter, N, P, and K, soil aggregate stability, and sugarcane productivity were measured after planting sugarcane for five months. The results showed that the application of kettle ash and press mud, especially with a ratio of 20 t ha-1 kettle ash and 10 t ha-1 press mud, was able to reduce the leaching of organic matter and improve sugarcane growth, particularly increasing the number of tillers by 16%, stem height by 14%, and diameter by 16%. The sugarcane productivity obtained was 58.02 t ha-1. Other portions of kettle ash and press mud did not have a favorable effect on sugarcane productivity. This study provided practical insights for increasing agricultural productivity, especially in sugarcane plantations.

Descaling of Evaporator Tubes in Sugarcane Factories Using Molasses as a Green and Effective Technology

Deposition inside sugarcane factory evaporators (SFE) significantly lowers the heat transmission and can cause corrosion. This consequently reduces their efficiency, which is clearly a severe issue in the industrial sector. Up to the present time, caustic soda remains the most widely used reagent for descaling sugar industry evaporators. Understanding the scale's composition assists in determining which kinds of cleaners can effectively clean the evaporators. Scales are built in sugar evaporators as a result of the phosphitation or sulfitation processes used to chemically clean juice. In this perspective, molasses is used to descale SFE as a green manner. Molasses includes significant amounts of organic acids and nitrogenous chemical compounds, as shown by GC-mass analysis, and can be utilized as cleaning agents. XRD patterns for four scales from different sugar evaporators indicated that calcium sulfate and calcium phosphate were the predominant components at Egypt's Quos Sugarcane Factory and Dishina Sugarcane Factory, respectively. Actually, dispersed molasses demonstrated an acceptable removal effectiveness of up to 65% in all tested evaporative bodies. Furthermore, molasses solutions were tested in both basic and acidic settings and did not promote corrosion through the body's evaporative tubes. The oxidation of the molasses mixture with air or hydrogen peroxide showed that the efficacy of scale removal decreased. The findings suggested that molasses, as byproduct of sugarcane factories can be successfully employed in descaling as a green cleaning agent. This could be helpful in the development of descaling materials for the industrial sector.

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.

Pollution levels and risk assessment of heavy metals in the agricultural area affected by sugar cane factory’s fly ash: A case study from South Egypt

Pollution levels and risk assessment of heavy metals in the agricultural area affected by sugar cane factory’s fly ash: A case study from South Egypt

Optimal application of dextranase in a Louisiana sugarcane factory to mitigate severe processing problems after a freeze

A Louisiana (LA) state-wide severe freeze occurred from 23–26 December 2022, which was followed by warm weather and occasional fog causing severe deterioration of all sugarcane varieties in the fields. Dextranase was applied to break down dextran (glucose polysaccharide) into smaller, more manageable molecules, which can improve processing. The efficiency of dextranase application depends on the pH, dry solids content rds (Brix), temperature, retention time, and agitation, type, activity and dosage of the applied dextranase as well as the enzyme/substrate ratio. Dextranase applications to juice are more efficient and economical than adding to syrup because the high temperature and dry solids content of syrups impede its action. Heating juice to 50 °C and pre-liming to pH 5.9 is optimal for dextranase application, but after 50 °C the activity falls off quickly. One LA factory built a new juice liming system that was quickly modified for optimal dextranase application after the freeze. Optimum conditions for concentrated dextranase (92700 DU/mL) applied were: rds <25%, temperature 50 °C, juice pH = 5.90, 1:10 working solution of concentrated dextranase up to 5 mg/L dosage; retention time = 10 min; 0.624 s–1 agitation. These conditions were successful with >80% breakdown of Haze dextran and minimized processing problems associated with the freeze. Retention time was not as important as temperature and the pH of the juice. The use of dextranase allowed this factory to (i) process all the field sugarcane from the growers even when sucrose concentrations were very low (down to ~56% juice purities on the last day of cane delivery), (ii) continue to crystallize sugar at acceptable crystallization rates, (iii) keep crystal elongation factors to only 2.3 and largely prevent needle formation, and (iv) allow the production of raw sugar with no dextran penalties from the refinery.

The Burdens of Occupational Heat Exposure-related Symptoms and Contributing Factors Among Workers in Sugarcane Factories in Ethiopia: Heat Stress Wet Bulb Globe Temperature Meter

BackgroundHeat stress is a harmful physical hazard in many occupational settings. However, consequences of occupational heat exposure among workers in a sugarcane factory in Ethiopia are not well characterized. This study aimed to assess the level of occupational heat exposure-related symptoms and contributing factors. MethodsIn this cross-sectional study, five workstations were selected for temperature measurement. Heat stress levels were measured using a wet-bulb globe temperature index meter. A stratified random sampling technique was used to select 1,524 participants. Heat-related symptoms were assessed using validated questionnaires. ResultsThe level of occupational heat exposure was 72.4% (95% CI: 70.2%–74.8%), while 71.6% (95% CI: 69.3%–74.9%) of participants experienced at least one symptom related to heat stress. The most common heat-related symptoms were swelling of hands and feet (78%), severe thirst (77.8%) and dry mouth (77.4%). The identified risk factors were a lack of reflective shields (AOR: 2.20, 95% CI: 1.53, 3.17), not-enclosed extreme heat sources (AOR: 1.76, 95% CI: 1.23, 2.51), a lack of access to shade (AOR: 9.62, 95% CI: 6.20, 14.92), and inappropriate protective clothing provision (AOR: 1.58, 95% CI: 1.27, 2.71). ConclusionsThe burden of occupational heat exposure and heat-induced symptoms was high. Lack of reflective shields, the absence of enclosed extreme heat sources, a lack of access to shade, and inappropriate protective clothing provision were considerable attributes of heat stress. Therefore, the use of mechanical solutions to stop heat emissions at their sources and the key factors identified were areas for future intervention.

Draft genomes of 17 bacterial isolates from Louisiana raw sugarcane factory juices and biofilms.

We report the draft genomes for 17 bacterial isolates belonging to the genera Gluconobacter, Leuconostoc, and Pantoea that were obtained from Louisiana raw sugarcane factory juice and biofilm samples.

Energy audit of a sugarcane plant to find out the main energy saving opportunities

Sugar extraction from sugarcane/sugar-beet is an energy-intensive process, both thermal and electrical energies. However, there are numerous opportunities for energy efficiency improvements. A number of tests were conducted in an old sugarcane factory, including the boiler, electricity generation, process, and mill section, to better understand these opportunities. During four years, specific energy consumption was 16-28 GJ/ton of raw sugar. Measurements and calculations revealed that some equipment, e.g. shredder's steam turbine and some gearboxes, require extensive repairs. The second set of areas for improvement relates to proper operation, such as determining the boiler excess air (which results in an average 0.6% efficiency reduction) and factory planning (near 200 MWh per year). The third type of improvement is to modify or integrate new elements into the existing plant, like water storage tank insulation (3.8 MW) and switching from load-unload operation to drive control for instrumentation compressors (43 MWh). Bangladesh J. Sci. Ind. Res. 58(1), 09-18, 2023

Improvement of Geo-engineering Properties of Expansive Clayey Soil by using Sodium Chloride and Bagasse Ash

Expansive soils contain minerals such as smectite clays that are capable of absorbing water accompanied by shrink and swell behavior and thus change in volume. The swell–shrink behavior of these soils could lead to instability of the structures found on them, specifically the light-weight structures and pavements. Expansive clay soil is encountered in most parts of Egypt. A comprehensive study was made in Sixth of October city to investigate the impact of lime sludge and bagasse ash as an industrial solid waste from sugar-cane factory and sodium chloride salt on geotechnical engineering properties of expansive soil. The macrostructural properties are quantified through laboratory testing for Free swell index, Plasticity index and infiltration tests. The microstructural aspects of the treated soil are observed through X-ray diffraction studies and SEM micrographs. The laboratory results showed that by increasing the lime sludge, Bagasse ash and NaCl concentrations the liquid limit decreased from 100% to 60% while the plastic limit increased from 100% to 90% respectively. In addition, the infiltration tests showed an increase in the infiltration rate from 10% to 80% when LS and Bagasse ash were added to the soil also the free swell decreased from 100% to 70 % sufficiently. XRD patterns showed the formation of new kaolin cementitious compound as the change of montmorillonite to kaolinite mineral took place due to the reaction of high amount of calcium ions produced from the stabilizer, the cation exchange took place between the calcium cation of the lime associated with the surfaces of the clay particles. The effect of cation exchange and attraction causes clay particles to became close to each other, this process is called flocculation which is accompanied by a series of pozzolanic reactions resulting in the formation of clay aggregates that are bound together by the new cementitious products such as calcium aluminate. Scanning Electron Microscopic images (SEM) and SEM micrographs determined the formation of organized dense clay matrices of aggregations that showed the reduction of Montmorillonite clay mineral peak intensities and an increase in kaolinite clay mineral peak intensities due to the change of expansive soil texture and reduction of interplanar spacing of the treated soil.

Evaluating the Potential Socioeconomic Impact of a Proposed Sugarcane Factory on the Village of Mueang Phia, Thailand

Thailand is the world’s second largest exporter of sugar, and under the 10-Year Cane and Sugar Strategy (2015–2024), the Thai government has granted an expansion of 13 new sugarcane factories. While most research focuses on the environmental consequences of sugarcane production, this paper examines the potential socioeconomic impact of a proposed sugarcane factory on a nearby (base) village by comparing it to a similar (treatment) village within the same region near an existing sugarcane factory. We find that treatment villagers have higher household income mainly due to their sugarcane-based village economy. They also disclose better perceived environmental quality while results for perceived health status are mixed. Yet, base villagers report higher perceived quality of life, likely due to factors beyond the socioeconomic conditions investigated in this study. Thus, the presence of a sugarcane factory, while socioeconomically favorable, may compromise other aspects of village life that contribute to its overall quality.

Effect of welding current on the microstructure and corrosion of discrete arced weld droplets deposited on sugarcane roller shells

This paper reports on the relationship between the arcing current and the microstructural and corrosion behavior of discrete weld droplet deposited on sugar mill roller shells made from grey cast iron during hardfacing in a typical sugarcane factory. Hardfaced droplet deposits were removed from three simulated roller shells, which were arced with different current, and subjected to porosity, microhardness and corrosion tests. The results revealed that the percentage porosity, microhardness value and corrosion rate significantly depended on the welding current; the rate of corrosion generally increased with a decrease in porosity and an increase in microhardness.

Sustainability analysis of bioethanol production in Mexico by a retrofitted sugarcane industry based on the Brazilian expertise

Bioethanol as fuel oxygenator is currently being introduced in Mexico with an estimated yearly demand of 3 billion liters expected to be produced mainly from sugarcane. This paper studies how to employ some of the expertise acquired by Brazil during its transition from typical mills into advanced biorefineries to retrofit the Mexican sucroalcohol industry. A typical Mexican sugarcane factory design is retrofitted to three biorefinery designs commonly found in Brazil, which are an autonomous distillery, a biorefinery with 50:50 feedstock ratio for ethanol and sugar production and a molasses distillery. The results of a techno-economic analysis considering these four designs under Mexican conditions are presented, followed by an economic comparison of the autonomous distillery design operating under Mexican and Brazilian conditions. Sustainability analysis is then carried out to identify the advantages and drawbacks of each design. The analysis compares an environment-driven scenario promoting bioethanol production and use for phasing out fossil fuels, against a commercially focused framework considering only environmental and economic issues affecting stakeholders’ profit. Results show in monetary terms the impact of each indicator of a retrofitting path from currently profitable biorefineries coproducing sugar and alcohol to sustainable distilleries using molasses and juice as feedstock to produce bioethanol.

The SMRI-NIRS technology: development, validation and benefit

The Sugar Milling Research Institute NPC (SMRI) has developed a simple to use near-infrared spectroscopy (NIRS) transmission-based analysis method as an alternative to conventional methods for analysis of sugarcane factory stream samples. The technology provides rapid, simultaneous analysis of refractometric dry substance (rds), polarimetric sugar, sucrose, glucose, fructose, conductivity ash contents as well as colour and pH for all streams and additionally, dry solids for final molasses and eliminates the need for sample clarification chemicals. The analyte prediction equations were developed using conventional results of samples from 14 South African factories, analysed at SMRI using SANAS/ISO17025 accredited test methods, and NIRS scans of the same samples using up to 16 different NIRS instruments. The NIRS analyte prediction equations were validated against more than 1,500 independent factory samples that had been analysed by conventional methods of analysis, including samples from factories outside South Africa. The reproducibility of the NIRS results were equivalent to existing conventional analysis reproducibility values (juice and final molasses) and previously undocumented values determined for this study for conventional raw house analysis methods. Correlation coefficients of greater than 0.97 were recorded for all major analytes and greater than 0.9 for minor analytes when predicted results were compared against conventional results. A maintenance protocol was also developed to ensure that the prediction equations remain robust and can account for sample matrix variations that can occur from season to season. The SMRI-NIRS technology was installed at all 14 South African factories and found to be robust and give equivalent results to conventional methods of analysis.

The Influence of Discharge Effluents on the River Nile Water Quality at Aswan Governorate, Egypt

The disposal of El-Sail drain, Kom Ombo drain, Edfu ferroalloys factory, and Edfu sugar cane factory around Aswan city poses a serious threat to the River Nile waters, especially El-Sail and Kom Ombo drains which recorded higher microbial load. Kom Ombo drain recorded higher total bacterial counts (TBC) at 22 oC (1800 x103 cfu/ml), thermophilic bacteria (259 cfu/ml) and spore-forming bacteria (15.8 x103 cfu/ml). While El-Sail drain recorded higher TBC at 37 oC (137 x103 cfu/ml) and higher values for indicator bacteria (total coliforms, faecal coliforms, and faecal streptococci). In addition, warmer seasons (spring and summer) showed higher counts of indicator bacteria Salmonella sp. and Shigella sp. in 22 and 30 % of samples, respectively, whereas Escherichia coli was detected in all sites, recording the highest values at El-Sail drain samples. Furthermore, El-Sail drain samples recorded the highest values for electrical conductivity, total dissolved solids, biochemical oxygen demand, NH3, NO2- and PO43-, while Kom Ombo drain samples recorded the highest values for water temperature and NO3-. Ranks of water quality index (WQI) were good in all sites, except for the disposal sites which ranged from fair to marginal. In conclusion, the River Nile water at Aswan governorate is heavily polluted, especially at El-Sail drain and Kom Ombo drain. Consequently, treatment and safe disposal of different industrial and domestic wastes are recommended.

Utilization of Lime Sludge Activated by Salt in Egyptian Expansive Soil Improvement

Expansive soils are active clays which cause engineering problems all over the world. This research deals with the impact of lime sludge (LS) as industrial solid waste from sugar-cane factory and sodium chloride salt (NaCl) on engineering properties of expansive soil. In this research, an analytical study of chemical and physical properties of Egyptian expansive soil in Sixth of October City was made as a case study. The laboratory results showed improvement of chemical, microstructural properties and thus the engineering properties of this soil. The results of chemical analysis showed the ability of soil to improve pH; soil alkalinity raise to the required level of stabilization. After soil treatment, Microstructure scanning electron with energy dispersive spectroscopy (SEM-EDX) analyses showed that new cementitious compounds are formed and soil was changed from a weak dispersed structure to strong flocculated structure. It was also observed by increasing LS and NaCl concentrations the plastic limit increased and the liquid limit decreased, hence decreased plasticity index; the rate of soil free swelling is decreased due to change of expansive soil texture. Therefore, lime sludge activated by NaCl has positive effects on engineering properties of soil. By this way we protect the environment from industrial solid wastes.

Graphic Applications of Unmanned Aerial Vehicles (UAVs) in the Study of Industrial Heritage Assets

As a typology of cultural heritage, a wide range of singularities must to be taken into account when analysing industrial heritage assets. Graphical resources have been usually employed in heritage assets research. Nowadays, Unmanned Aerial Vehicles (UAVs) offer the possibility to obtain images of complex and difficult access areas that cannot be observed on the ground. Furthermore, aerial images allow to analyse heritage assets as a whole. Therefore, in this work, different photographs and videos has been carried out in the San Joaquin sugar cane factory and in the Aguila aqueduct, located in Nerja (Spain). These images have been used to analyse both assets as a set. Different indirect measurements on the factory chimney and irrigation water pond were taken. A Strengths, Weaknesses, Opportunities, and Threats (SWOT) about the use of UAV graphic applications in heritage assets was developed. Finally, the possibilities of conventional photograph technologies and UAV application were compared. Using UAVs allows more image acquisition possibilities than conventional systems. However, both technologies can be complemented and applied together when analysing heritage assets.

Heat Stress, Physiological Response, and Heat-Related Symptoms among Thai Sugarcane Workers.

Prolonged or intense exposure to heat can lead to a range of health effects. This study investigated heat exposure and heat-related symptoms which sugarcane workers (90 sugarcane cutters and 93 factory workers) experienced during a harvesting season in Thailand. During the hottest month of harvesting season, wet bulb globe temperature was collected in the work environment, and workloads observed, to assess heat stress. Urine samples for dehydration test, blood pressure, heart rate, and body temperature were measured pre- and post-shift to measure heat strain. Fluid intake and heat-related symptoms which subjects had experienced during the harvesting season were gathered via interviews at the end of the season. From the results, sugarcane cutters showed high risk for heat stress and strain, unlike factory workers who had low risk based on the American Conference of Governmental Industrial Hygiene (ACGIH) threshold limit values (TLVs) for heat stress. Dehydration was observed among sugarcane cutters and significant physiological changes including heart rate, body temperature, and systolic blood pressure occurred across the work shift. Significantly more sugarcane cutters reported experiencing heat-related symptoms including weakness/fatigue, heavy sweating, headache, rash, muscle cramp, dry mouth, dizziness, fever, dry/cracking skin, and swelling, compared to sugarcane factory workers. We conclude that the heat stress experienced by sugarcane cutters working in extremely hot environments, with high workloads, is associated with acute health effects. Preventive and control measures for heat stress are needed to reduce the risk of heat strain.

Knowledge of Workers about their Occupational Hazards at Sugarcane Factory in Luxor Governorate

Background: Workers in sugar mills are exposed to occupational hazards as accidents, bagassosis and hearing loss in many manufacture parts of the sugar production. The aim of the study: to assess knowledge of workers regarding their occupational hazards at Sugarcane Factory Methods: Cross sectional research design was used in this study. It conducted at Sugarcane Factory. The total number of the studied sample was 541 workers; Simple random sample was used. Tools of the study: self-administrated questionnaire was used which included personal data, questions to determine their occupational hazards and knowledge of workers regarding occupational hazards Results: The mean age of workers was 45.74 ± 8.44, 62.1% of them had secondary education and 76.7% of them had >10 years of experience. According to their occupational hazard, 68.2% of workers had back pain, 63.2% complained from nervousness. According to their knowledge about occupational hazards, 71.2% of workers had poor knowledge. Also, there is statistically significant relationship between knowledge and their educational level (P value = 0.037). Conclusion: Almost of workers had poor of knowledge about occupational hazards also; the occupational hazards were prevalent among them. Recommendations: Training and health education programs should be implemented to increase workers’ knowledge about occupational health hazard in sugarcane factory.

Factors Associated with Behavior Usage of Respiratory Protective Equipment among Sugarcane Factory Workers in Northeast of Thailand

Several sugar industries in Thailand are highly effected to environmental health, including a safety at work, mainly the areas surrounded of bagasse. This research aimed to study on factors associated with behavior usage of Respiratory Protective Equipment (RPE) among sugarcane factory workers. A cross-sectional study was conducted among 588 workers at 4 sugarcane factories in Northeast of Thailand, between December 2017 to April 2018. Workers were selected by multi-stage random sampling to completed structure questionnaires. The multivariable analysis was used by multiple logistic regressions. The majority were males (71.94%). Their mean age was 38.28 (±10.56) years old. Financial status was poor (65.65%). Department were juice extraction machine (67.52%). The majority types of RPE usage were cotton masks (94.56%) and their behaviors usage of RPE had good level (64.80%, 95% CI: 60.92-68.67). Additionally, factors associated with good behavior usage of RPE were included age (AOR = 1.65, 95% CI: 1.14 to 2.38; p = 0.007), financial status (AOR = 1.57, 95% CI: 1.07 to 2.29; p = 0.021) and department of work (AOR = 0.66, 95% CI: 0.31 to 1.40; p = 0.017). Almost two-third of sugarcane factory workers had good behavior usage of RPE. Work safety awareness is important to prevent and promote among sugarcane factory workers to the adaptation their working environment.

Physical Wastewater from Assalaya Sugarcane Factory: Reality and Perception

Wastewater physical examination is acknowledged as one of the fundamental parameters for identifying water quality and alleviating the environmental ramifications caused by waste. This study aims to analyze water quality and determine possible consequences on the White Nile River by performing waste analysis generated by Assalaya factory located in Assalaya province, White Nile state, Republic of Sudan. Samples collected included Total Dissolved Solids (TDS), Turbidity, Total Suspended Solids (TSS), Odor, Color, temperature, and conductivity. This study employed questionnaires to recognize community perceptions. Data analysis revealed that the river had been significantly contaminated. The highest recorded concentrations for TDS, Turbidity, TSS, Odor, and Color were 1186 ppm, 28500 NTU, 2333 Mg/l, unacceptable,840 TCU,1830 µS/cm and 37.5 ⁰C, respectively. These results are not recommended by the international standard for water quality (WHO) approved range. Hence, to avoid the aftermath of the factory wastewater, this study recommends some actions to promote biological treatments. The stakeholders should inevitably follow the environmental water policy and establish the medication near the river. The government should independently administrate this manner. On the other hand, the factory should obey global transformation towards their production schemes such as Eco-friendly, Green-economy, and Sustainability concept in line with social, economic, and ecology sectors.