734 Technology/Technologie
Mohsen Ajdari Rad, Azar Ajdari Rad and Gilles Schrevel
Evaluation of juice purification in sugar factories*
Bewertung der Saftreinigung in Zuckerfabriken
Despite the substantial improvement of beet quality which
has been achieved, still a relatively high content of nonsug-
ars remains in the raw juice extracted from sugar beet. New
analytical methods and instrumentation have helped to bet-
ter understand the various physical and chemical reactions
taking place during the different steps of juice purification
and so how they can be affected.
Some examples of developments over the past 20 years by
the R&D departments of the Südzucker Group, related to
the optimization of the juice purification system, are illus-
trated: raw juice viscosimetry, raw juice pre-alkalization,
optimal pH value of flocculation in the prelimer, optimal
course of pH value in the prelimer, optimal temperature/
retention time in the prelimer and main limer, optimal pH
value of 1st carbonatation, milk of lime optimization system
(LIMOS) to reduce limestone consumption, lime salts ana-
lyzer (LISA), optimization of decalcification, SZ/RT-juice
purification system with separation of the colloid fraction
after the prelimer.
Key words: extraction, raw juice, nonsugars, juice purification
1 Introduction
Improvement of beet quality, increased requirements of sugar
quality (such as reduction of ash and turbidity of sugar) and
the demand for reduction of both energy and processing aids’
(e.g. limestone) consumption have been important challenges
over the past 20 years, asking for further optimization of juice
purification in beet sugar manufacture. Numerous investiga-
tions have been performed to optimize the different process
steps of juice purification. More recently, the processing of
deteriorated beet came into focus due to prolonged beet pro-
cessing campaigns as a result of the reform of the EU Sugar
Regime.
Juice purification is an important step in sugar technology.
It has a significant impact on sugar quality and sugar yield.
Despite the substantial improvement of beet quality in recent
years, still a relatively high amount of nonsugar substances
* Paper presented at the XXIst Symposium organized by the Andrew VanHook Associa-
tion in Reims/France, 27 March 2014.
Trotz der deutlichen Verbesserung der Rübenqualität ver-
bleibt immer noch ein relativ hoher Gehalt an Nichtzucker-
stoffen nach der Extraktion im Rohsaft. Neue analytische
Methoden und Instrumente helfen, die in den einzelnen
Phasen der Saftreinigung stattfindenden physikalischen
und chemischen Reaktionen besser zu verstehen und zu
beeinflussen.
Während der letzten 20 Jahre hat die Abteilung Forschung
und Entwicklung der Südzucker verschiedene Verfahren
zur Optimierung der Saftreinigung entwickelt: Rohsaft-
Viskosimetrie, Rohsaftvorkalkung, Bestimmung des opti-
malen pH-Wertes des Flockungspunktes in der Vorkalkung,
optimaler Verlauf des pH-Wertes in der Vorkalkung, opti-
male Temperatur/Verweilzeit in Vor- und Hauptkalkung,
optimaler pH-Wert der ersten Carbonatation, Kalkmilch-
optimierung zur Reduzierung des Kalksteinverbrauchs
(LIMOS), Kalksalzanalyse (LISA), Optimierung der Ent-
kalkung, SZ/RT-Saftreinigung (Abtrennung der Kolloid-
fraktion nach der Vorkalkung).
Schlagwörter: Extraktion, Rohsaft, Nichtzuckerstoffe, Saft-
reinigung
remains in the raw beet juice. The presence of these nonsugars
requires a rather complicated and costly purification process
in order to enable the production of white sugar of the right
quality, as well as to limit any unnecessary sugar loss to molas-
ses. The task of juice purification is – above all – to increase
the juice purity by neutralization, coagulation, degradation
and separation of particular dissolved and colloidal nonsugar
substances in raw juice. After juice purification a thin juice is
aimed with higher purity, low color and lime salts content, and
good thermostability. New analytical methods and instrumen-
tation have helped to better understand the various physical
and chemical reactions taking place during the different steps
of juice purification and so how they can be affected.
Classical juice purification uses milk of lime in the pre-liming
and main liming and subsequently CO2 in the 1st carbonata-
tion and 2nd carbonatation in order to achieve the above-men-
tioned chemical and physical reactions. The precipitated and
insoluble nonsugars are removed by filtration and/or decanta-
tion.
Some examples of developments over the past 20 years by the
R&D department of the Südzucker Group related to the opti-
mization of the juice purification system will be illustrated:
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 Technology/Technologie 735

– Raw juice viscosimetry

– Raw juice pre-alkalization
– Optimal pH value of flocculation in the prelimer
– Optimal course of pH value in the prelimer
– Optimal temperature/retention time in the prelimer
– Optimal pH value of 1st carbonatation
– Optimization of decalcification
– SZ/RT-Juice purification system with separation of the col-
loid fraction after the prelimer
The increase of the beet quality during recent years provided
the opportunity for a further optimization of juice purification
aiming at lower consumption of process aids such as limestone Fig. 1: Development of the purity of raw juice in the German factories
and coke. of Südzucker
Figure 1 shows the increase of the raw juice purity over the last
13 years in the German-factories of Südzucker. One can see an
approx. 1–2% increase of raw juice purity.
Figure 2 shows the increase of thick juice purity in the French
and German factories of the Südzucker Group during recent
years. The increase of thick juice purity was about 1% during
the last 13 years.
Figure 3 shows the total limestone consumption in the French
and German factories of the Südzucker Group during recent
years. Please note that for the German factories it also includes
lime used for alkalization of flume water.
After optimization of juice purification, the Südzucker facto-
ries could reduce the limestone consumption by about 5 kg/t
beet in the last 13 years. This means a reduction of approx.
18% of limestone and coke.
In the last 20 years the R&D department of the Südzucker Fig. 2: Increase of thick juice purity in the French and German factories
Group worked intensively for optimizing of juice purification of the Südzucker Group
and developed different ideas and patents. A few examples are
discussed.

2 Raw juice viscosimetry

Natural raw juice constitutes of a disperse system with sus-

pended heterogeneous particles. The continuous phase con-
sists of sucrose solution and the dispersed phase of particulate
structures of high molecular mass substances, mainly pro-
teins, nucleoproteins, hemicellulose, color substances, pectin,
dextran and levan (the latter two related to processing of frost-
damaged or deteriorated beet). The high molecular mass sub-
stances exert a dominant influence on the flow behaviour of
the (raw) juice in the process. The use of an on-line rheometer,
e.g. the Rheoswing RSD 1-1, enables the on-line monitoring of
changes in viscosity of the raw juice as a result of the change in
concentration of high molecular components of the raw juice.
The on-line viscosimetry of the raw juice is a way to control
the processing of deteriorated or frost-damaged beet material
with higher contents of colloidal substances such as dextran,
levan and pectin. Several rheological tests for the continuous
recording of raw juice viscosity show that the raw juice viscos-
ity can be used as a possible reference to control the amount of
milk of lime to be added to the main liming (or to set the main
liming alkalinity).
The on-line rheometer Physica Rheoswing determines the
dynamic and kinematic viscosity by the measurement of the
attenuation of the mechanical oscillator, which is excited at
Fig. 3: Decrease of limestone consumption in the French and German
factories of the Südzucker Group
its own frequency, and is immersed in the liquid to be anal-
ysed. The probe leads torsional vibrations in the nanometer
range, and causes the liquid to form a thin boundary layer. The
comparison of the attenuation in the liquid with the original
attenuation in air provides an excellent way to determine the
viscosity for different materials quickly and accurately. This
measurement system allows the simultaneous determination
of the temperature. The measurement system gives an abso-
lute determination of the dynamic and kinematic viscosity
when the density of the liquid is known. Because of that the
structural viscosity and complex viscosity can be detected
directly. Table 1 gives the specifications of the measurement
system.

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736 Technology/Technologie

Table 1: Specifications of the on-line rheometer Physica Rheoswing RSD 1-1 The viscosity signals could be interpreted based on an evalu-
Parameter Technical data ation chart, which was derived from the determined viscosity
Input range medium density in g/cm3 0.400 – 3.999 and laboratory data such as dry matter and sugar content of
Pressure range in bar 0 – 150 raw juice. The factory can use the evaluation chart as an early
Frequency range in Hz approx. 8500 (this case 8550)
warning system, indicating a change of raw juice quality and
Maximum ambient temperature in °C 110
then can take the necessary actions in the juice purification.
Measuring range of the kinematic viscosity
in m2 · s–1 0.1 – 3 · 10–6
Measuring range of the dynamic viscosity
in mPa · s 0.3 – 100 3 Raw juice pre-alkalization
Measured value acquisition in min–1 max. 52
The aims of the raw juice pre-alkalization are:
– Stabilization of raw juice before the raw juice heat exchanger;
Figure 4 shows the pilot system for raw juice viscosimetry. The – Reducing the microbiological activity within the raw juice
viscosity could be measured after desanding and depulping heat exchanger before the prelimer;
of the raw juice with the help of the viscosity measurement
system Rheoswing RSD1-1.
The raw juice feeds tangentially in the
separation tank for separating suspended
big pulp particles and sand. The pre-
cleaned raw juice is pumped to the mea-
surement cell; the viscosimeter is located
in the head of the measurement cell. The
dynamic viscosity of raw juice is mea-
sured every 15 seconds and the measured
data are registered in the data manage-
ment protocol of the factory. Warm water
is used for cleaning of the system.
After optimizing the flow rate, the sepa-
ration tank for big pulp particles and
sand and the CIP (cleaning in place) sys-
tem with warm water a stable viscosity
signal was obtained (Fig. 5). Fig. 5: Viscosity signal of technical raw juice during 24 h (Shahidizenouz, 2008)

Fig. 4: Pilot system for on-line raw juice viscosimetry (Ajdari Rad et al., 2008 a)

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– Destruction of the biofilm in the the raw juice heat exchanger;
– No flocculation: an alkaline coagulation of hydrocolloids
(floc formation) before the raw juice heat exchanger would
lead to filtration or settlement problems. Therefore, the
flocculation of raw juice colloids must be avoided in the raw
juice pre-alkalization;
– Reduction of lime salts content and color in thin juice.
Laboratory juice purification experiments using raw juice from
the pilot plant (with and without the pre-alkalization of the
raw juice before raw juice heat exchanger) were performed. The
influence of the pre-alkalization of the raw juice on the proper-
ties of intermediate products (filtration coefficient of the first
carbonatation juice) and thin juice (color and lime salts con-
tent) have been determined. For this purpose, laboratory juice
purification tests of raw juice with pre-alkalization (pH value
between 6 and 11) and without pre-alkalization before the raw
juice heat exchanger (preliming temperature between 50 °C
and 80 °C (∆T = 10 K) were carried out. Figure 6 shows the
effect of raw juice pre-alkalization with sodium hydroxide at
different temperatures on the increase of invert sugar content
in the raw juice during heating before the prelimer.
From the data it can be concluded, that raw juice pre-alkaliza-
tion reduces the sucrose hydrolysis in the juice during heating.
The reaction rate of sucrose hydrolysis depends on pH value
and temperature. Figure 7 shows the influence of the raw juice
pre-alkalization on the color of the thin juice.
The following significant influences from raw juice pre-alkali-
zation on thin juice color can be observed:
Fig. 6: Effect of raw juice pre-alkalization on the increase of invert sugar
content at different temperatures before prelimer (Shahidizenouz, 2008)
Fig. 7: Effect of raw juice pre-alkalization on thin juice color (Shahidizenouz,
2008; Ajdari Rad et al. 2008 b)
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Technology/Technologie 737
Fig. 8: Effect of raw juice pre-alkalization on thin juice lime salts’ contents
(Shahidizenouz, 2008; Ajdari Rad et al. 2008 b)
– The color of thin juice increases with increasing of preliming
temperature.
– The color of thin juice decreases after raw juice pre-alkaliza-
tion.
– The overall effect of raw juice pre-alkalization on the decrease
of the thin juice colour depends on the preliming temperature.
– The thin juice colour decreases approximately by 200 IU
at a preliming temperature of 50 °C and approximately by
500 IU at a preliming temperature of 80 °C.
Figure 8 shows the influence of the raw juice pre-alkalization
on the lime salts content in the thin juice.
From the results the following conclusions can be drawn:
– The lime salts’ content in thin juice increases with increasing
preliming temperature.
– The lime salts’ content of the thin juice decreases with
pre-alkalization of the raw juice before the raw juice heat
exchanger (minimal lime salts’ content at a certain optimum
pH value).
– The optimum pH value of raw juice before the heating pro-
cess for achieving the lowest possible lime salts content in
the thin juice is consistent with the required pH value for
low thin juice colour.
The technical investigation of raw juice pre-alkalization with
sodium hydroxide has enabled the reduction of lime salts’ con-
tent and color in thin juice; in addition microbiological activity
in the raw juice heat exchanger is largely suppressed.
3.1 In-line/on-line determination of process steps
in juice purification
The rheological characterization and description of the process
steps in juice purification at micro and macro level is a new
application area and enables the understanding of physical
and chemical reactions at a molecular level and thereby con-
firms earlier findings.
For example, with the torsional oscillator Rheoswing RSD 1-1
of the company Paar-Physica it is possible to continuously
detect structural changes in the juice by in-/on-line viscosity
measurement. Thus, rheological analysis can serve as a refer-
ence parameter for the control of particular steps in the juice
purification process.
738 Technology/Technologie

3.2 Materials and methods juice in a 10 s interval. Table 2 shows the process conditions
during the juice purification experiments.
For the realization and evaluation of the rheological experi- Figure 10 shows the typical viscosity profile of the juice during
ments in the field of juice purification a discontinuous juice preliming.
purification system on a laboratory scale has been used The investigations of analyzing the rheological changes of
(Fig. 9). The juice purification system consists of a jacketed raw juice upon the addition of milk of lime helped to bet-
(for heating) 3 L reaction vessel (1). The raw juice is mixed ter understand the reactions during preliming. The obtained
in the reaction vessel by means of a variable-speed stirrer characteristic curve is unique and provides important infor-
throughout the juice purification process. For temperature mation concerning the structural changes of colloids and sus-
control of the juice during juice purification two thermostats pended solids during the preliming process. This investiga-
with circulators are used (2 and 3). The carbon dioxide (4) is tion shows that the physical reactions in the preliming have a
passed through a controllable valve to the gas distributor dur- significant influence on the rheological properties of the raw
ing the 1st and 2nd carbonatation. The gas distributor consists
of a circular perforated (holes diameter about 0.1 cm) copper
loop. Limed juice was continuously collected during the tests Table 2: Process conditions in the juice purification experiments
by means of a centrifugal pump (supplier company EHEIM, Process step Time Tempera- Comments
2400 min–1, flow rate of 10 L/min) via the drain valve of the in min ture in °C
reaction vessel and recirculated through a measurement flow Preliming 20 55 End pH value = 11.40
cell (5) in the reaction vessel. Main liming 20 85 Alkalinity = 1.1 g CaO/100 mL
The on-line rheometer (RSD 1-1) located in the measurement 1st carbonatation 15 85 End pH value = 11.20
cell (No. 6 at Fig. 9) determined the viscosity of the inflowing 2nd carbonatation 12 88 End pH value = 9.25

Fig. 9: Discontinuous laboratory juice purification system with rheometer 1 Reaction vessel; 2 and 3 Thermostat with circulator; 4 Carbon dioxide; 5 Flow
cell; 6 On-line rheometer (RSD 1-1); 7 Evaluation device of rheometer; 8 Monitor

Fig. 10: Course of the juice viscosity along the prelimer (Kraus, 1998; Ajdari Rad and Senge, 2002)

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juice because of structure-forming mechanisms. The obtained
viscosity curves can be divided into 6 sections:
– Functional stability of the juice (no change in viscosity);
– Approaching the isoelectric point of raw juice colloids;
– Dehydration of the colloids with a reduction in their particle
size and viscosity;
– Flocculation and precipitation of the colloids with an
increase of particle size and viscosity;
– Gradual continuation of the structure formation;
– End of the structure formation with a more or less constant
viscosity.
4 Optimal pH value of flocculation in the prelimer
During preliming – due to the addition of milk of lime – the
transition of a colloidal solution of high molecular mass com-
ponents in the raw juice into a structure of coarse particles
takes place. The basis of the rheological measurement prin-
ciple is the so-called hydraulic diameter of a molecule or a
particulate structure. The viscosity change in the preliming
can therefore be used as a measure of the structure formation
from colloidal components.
The viscosity of the limed juice varies during addition of lime
to the raw juice in the prelimer as a result two factors:
– Influence of the added lime on the dry substance content
(density) and so on the viscosity of the juice.
– The particle size increase because of the structure forma-
tion from the colloidal components causes a change of the
viscosity of the limed juice (Wittstock, 1953; Grabka, 1982).
The change of viscosity depends on pH value, temperature of
preliming, the buffer capacity of the raw juice and the type and
concentration of the high molecular mass components in the
raw juice. For the rheological determination of the optimum
flocculation point of preliming the milk of lime is added in
equal quantities per unit of time to the raw juice (for example
1 mL/min for 2500 mL raw juice). Figure 11 shows an example
of the rheological determination of the optimum flocculation
point = the pH end-point for preliming.
This is based on the rate at which the viscosity of the raw juice
in preliming changes over time. The rate of viscosity change
represents the structure formation rate as it is affected by raw
Fig. 11: Optimal flocculation point in the preliming (Ajdari Rad and
Senge, 2002)
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Technology/Technologie 739
juice alkalization. A comparison between rheological deter-
mination and the usual photometry determination of the
optimal flocculation point in the prelimer gives a very good
correlation.
5 Optimal course of pH value in the prelimer
The practical application of the results of rheological measure-
ments during the preliming is the definition of the optimal
pH value course in a so-called progressive preliming. Figure
12 shows the recommended pH value course of preliming as
based on maximum structure formation and thus optimal
flocculation and precipitation of the colloidal components.
According to the rheological behaviour of the juice four differ-
ent pH ranges can be distinguished:
– pH ≤ 8.5: pH range in which the charge of the colloid sub-
stances changes;
– 8.5 ≤ pH ≤ 10.0: pH range where the dehydration of proteins
begins, a necessary preliminary reaction in order to enable
optimal flocculation at the further increasing pH value;
– 10.0 ≤ pH ≤ 11.0: pH-range in which these preliminary reac-
tions continue resulting in the eventual floc formation;
– 11.0 ≤ pH ≤ 11.4: the pH value is reached for the optimum
flocculation, allowing the maturation and stabilization of
the colloidal floc materials before entering the high-alkaline
pH in the main liming.
Figure 12 is an example of the optimal pH value profile in a
Brieghel-Müller prelimer with seven compartments at a tem-
perature of 55 °C and a retention time of 28 min.
6 Optimal temperature/retention time in the
prelimer
The precipitation and coagulation of pectins and proteins
requires a certain temperature-dependent retention time
(Teschner, 1984; Kraus et al., 1997; Madsen, 2000).
A temperature increase in preliming at constant raw juice quality
and a similar alkalinity/pH value profile leads to an increased
rate of the precipitation reactions and consequently to a decrease
in the required retention time for preliming. The temperature-
retention time correlation in the preliming has been studied by
several authors on the basis of various analysis methods.
Fig. 12: Optimum pH value management of the preliming at a preliming
temperature of 55 °C (Ajdari Rad and Senge, 2002)
740 Technology/Technologie

Table 3 compares the correlations between temperature and

optimal retention time in preliming as determined by several
authors on the basis of various analytical methods. The opti-
mal temperature-retention time correlation in preliming as
determined by rheological measurements agrees largely with
the photometric investigations (turbidity measurement after
Kraus et al., 1997).
Equations 1 and 2 show the correlations of temperature (JProg)
and retention time (tProg) for the progressive addition of milk
of lime in the preliming by the developed rheological method.

tProg = 76.5 – 0.88 JProg [min] (1)

JProg = 86.8319 – 1.1333 tProg [°C] (2)

Fig. 13: Temperature-retention time correlation of preliming with regard This new temperature-residence time correlation on the basis
to pectin precipitation (Kraus et al., 1997) of the rheological measurement method provides a precise
adjustment possibility of the preliming in sugar production
and has been successfully tested during several campaigns in
Figure 13 shows the optimal combinations of temperature different factories within the Südzucker Group.
and retention time in the preliming with regard to a maximum
removal of pectin by precipitation (Kraus et al,. 1997).
Figure 14 similarly shows the optimal combinations of tem- 7 Optimal pH value of 1st carbonatation
perature and retention time in preliming with regard to the
structural change of all suspended solids and colloidal matter The rheological determination of the optimum pH end-point
in the juice along the prelimer, as is determined by viscosim- of the 1st carbonatation (i.e. the viscosity profile of the 1st
etry. carbonatation) has been carried out with the help of a con-
tinuous on-line viscosity measurement device with a high
resolution (Physica Rheoswing RSD 1-1). The change in juice
viscosity during a batch-wise 1st carbonatation of main limed
Table 3: Temperature-retention time-correlation in the prelimer juice was recorded against the decreasing juice pH value. Fig-
Optimal retention time in the prelimer ure 15 shows the comparison of the changes in viscosity and
Temperature at Teschner (1984) Kraus et al. Ajdari Rad and pH value in the course of the 1st carbonatation.
prelimer (1997) Senge (2002)
During 1st carbonatation a reduction of viscosity of the juice
Protein Pectin Rheology
35 23.0 58.0 45.7
is observed because of CaCO3 formation and the adsorption
40 20.0 52.5 41.3 of colloidal matter on the surface of the CaCO3 crystals. The
55 15.0 36.0 28.1 optimum pH value of the 1st carbonatation is approx. 11.2.
70 7.0 19.5 14.9 Further introduction of CO2 would cause an unwanted fur-
ther pH value decrease at which calcium
carbonate starts to redissolve. In addi-
tion, colloidal matter will desorb from
the surface of the CaCO3 crystals to the
liquid phase, which then results in an
increased juice viscosity. From the mini-
mum value in the viscosity curve the
optimum pH end-point of the 1st carbo-
natation can be readily derived.
The rheological determination of the
optimum pH value of 1st carbonatation
is an alternative way to determine the
optimum pH end-point of the 1st carbo-
natation. Both the rheological determi-
nation and the generally applied photo-
metric determination of the optimum
pH value in the 1st carbonatation agree
very well. The rheological method can be
considered as an alternative direct (in/
on-line) method with higher accuracy
Fig. 14: Temperature-retention time correlation of preliming with regard to colloid precipitation and requiring less effort than the photo-
and structure formation (Ajdari Rad and Senge, 2002) metric method.

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Fig 15: Optimal pH end-point in the 1 carbonatation (Ajdari Rad and Senge, 2002). 1 = Optimal
st
flocculation point in the 1st carbonatation
8 Optimization of decalcification
Decalcification has two main targets: to prevent scale forma-
tion in evaporation and to reduce turbidity in the final sugar.
Softening of hard thin juice (after 2nd carbonatation) is carried
out by ion exchange. Three different processes are applied in
the Südzucker Group:
– NRS (New Regeneration System): cationic exchange resin
in sodium form (use of NaOH as regenerant); it is the most
commonly used way of juice softening;
– Tasco system: Amalgamated sugar; weak acid cationic
exchange resin (use of H2SO4 as regenerant);
– Gryllus system: cationic resin in the potassium form (use of
molasses or B green run-off as a regenerant).
A target of max. 6 mg CaO/100 g DS lime salts in the thin juice
after decalcification is usually set in beet sugar factories.
– above 12 mg CaO/100 g DS is considered to represent a high
risk of scale formation and of turbidity in sugar;
– between 6 and 12 mg CaO/100 g DS has limited risk of tur-
bidity in sugar;
– below 6 mg CaO/100 g DS is the optimal zone without any
risk of turbidity in sugar.
9 SZ/RT-Juice purification system with separa- a turbidity between 100–300 NTU [Nephelometric Turbidity
tion of the colloid fraction after the prelimer – Unit]). The solids content of the overflow is about 0.05 vol-%.
goals and advantages
The separation of the colloidal fraction from prelimed juice has
been already reported by Spengler et al. (1932). Weidenhagen
(1950) reported again about technical trials on this topic with
a discontinuous plate-seperator in the Offstein factory in the
1949 campaign. Well, for technical reasons, it took another 50
years until Südzucker developed a successful process for the
separation of the colloids fraction after preliming (Ajdari Rad
et al., 2008 a; Deneus et al., 2008; Ajdari Rad et al., 2011).
The SZ/RT-juice purification system can be seen as a further
development of the classical juice purification. The effects
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Technology/Technologie 741
and the expected advantages of the SZ/
RT-juice purification system are, among
others:
– Reduction of the limestone consump-
tion for the same quality of thin juice
and a corresponding relief of the lime
kiln;
– Reduction of the coke consumption
and CO2 emission of the lime kiln;
– Improvement of filterability of 1st car-
bonatation juice and thus a relief of
the 1st filtration;
– Possibility to process deteriorated
beets during prolonged campaigns;
– Reduction of the carbonatation lime
quantity resulting in a relief of the
lime presses;
– Significant reduction of the phosphate
and sulphur content in the carbonata-
tion lime;
– Reduction of the energy consumption.
Figure 16 shows the principle of SZ/RT-juice purification with
separation of the colloid fraction in the juice after the prelimer.
The SZ/RT-juice purification system has been integrated in
the classical juice purification system at the factory of Off-
stein by using a clarifier for separating the protein-contain-
ing colloidal fraction from the prelimed juice and a decanter
centrifuge for thickening a partial flow of this colloidal frac-
tion.
After the addition of a flocculant, the prelimed juice enters
the clarifier. The protein-containing fraction is removed in the
clarifier underflow. The sludge is further thickened in decanter
centrifuges after which about 0.8 kg DS/100 kg beet of the
protein-containing fraction is obtained. The protein-contain-
ing fraction is produced with a dry matter content of 38 to
42% and is continuously added to the pressed pulp before the
pulp dryer. It acts as a processing aid and reduces approxi-
mately 18% of the TOC emission in the exhaust gases of the
pulp drying plant (Ajdari Rad et al., 2007).
The clear run-off from the decanter centrifuge is recirculated
into the cold main liming or to the inlet of prelimed juice to
the clarifier. The clear overflow of the clarifier is forwarded to
the cold main liming.
The clarifier overflow (Fig. 17) is free of sand and pulp and
has a turbidity value below 2000 IU at 530 nm (i.e. similar to
The suspended solids balance over the clarifier indicates an
excellent removal of the solids from the prelimed juice with
about 99 %.
The clarifier overflow, with a very low content of colloids, can
be processed in the main liming at a rather low alkalinity of
0.6 g CaO/100 mL. Consequently, a substantial reduction in
lime consumption can be achieved in sugar factories having
filtration.
Figure 18 shows the phosphate contents of the feed, overflow
and underflow of the clarifier in kg/h. From the data obtained,
a phosphate reduction of over 94% was established in the
overflow.
742 Technology/Technologie
Fig. 16: Principle of SZ/RT-juice purification procedure with separating the colloids (Deneus et al., 2008)
Fig. 17: Clarifier overflow of the SZ/RT-juice purification procedure with
separating the colloids (Deneus et al., 2008)
Fig. 18: Phosphate balance of the clarifier after prelimer
Fig. 19: Balance of the HCl insoluble components using a hydrocyclone
(jet size 8 mm) for de-sanding of the underflow of the clarifier as feed
This is of particular interest for companies which have difficul-
ties with a high phosphate content in the carbonatation lime
as fertilizer. The underflow of clarifier was de-sanded with the
aid of a hydrocyclone before the centrifuge (Fig. 19).
Investigation of the de-sanding system showed a significant
reduction of the HCl-insoluble components. The separation
efficiency of the cyclone is approximately 20–40% for HCl-
insoluble ash. Under optimum operating conditions a very
low limestone consumption in the juice purification is pos-
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 Technology/Technologie 743

Table 4: Resulting raw juice quality from deteriorated beet material

(Ajdari Rad et al., 2008 a)
Dry substance content in % 17.0
Sugar content in % 13.5
Purity in % 79.4
pH value 5.4
Acidity in g CaO/100 mL 0.055
Invert sugar content in g/100 g sugar 6.21

The potential of different juice purification processes to

improve the filterability of technical juices was examined in
the PhD study of Miss Ajdari Rad (Shahidizenouz, 2008). In
laboratory juice purification experiments with raw juices from
processed damaged and deteriorated beet material (Fig. 20
Fig. 20: Deteriorated beet material (Ajdari Rad et al., 2008 a) and Table 4) the effectiveness of different juice purification
processes was tested.
As shown in Figure 21, the filtration coefficient of 1st car-
sible (e.g. total limestone consumption of 16–18 kg/t beet in bonatation juice decreased with the increasing main liming
comparison with approx. 20–24 kg/t beet for the classical juice alkalinity. When using classical juice purification, even a main
purification system). liming alkalinity of 1.8 g CaO/100 mL would not be sufficient
to produce a filterable juice.
Figure 22 shows the filtration coefficient
of the 1st carbonatation juice when pro-
cessing raw juice from frost-damaged
beet by applying different juice purifica-
tion processes.
– The use of defeco-carbonatation
(at a main liming alkalinity of 1.8 g
CaO/100 mL) significantly improved
filtration properties in comparison to
the classical juice purification process.
– The use of 20 mg/kg dextranase in
combination with classical juice puri-
fication (at main liming alkalinity of
1.8 g CaO/100 mL) improved the fil-
tration coefficient of the 1 st carbon-
atation juice to the same extent as the
defeco-carbonatation.
Fig. 21: 1st carbonatation filtration coefficients for processed deteriorated beet material at different – The SZ/RT-juice purification system
main liming alkalinities (Ajdari Rad et al., 2008 a) showed the best filtration coefficient
in comparison to the other processes
even at a low main liming alkalinity of
0.6 g CaO/100 mL.

10 Conclusions

The optimization of the juice purifica-

tion and the reduction of energy and
use of processing aids such as limestone,
especially when processing deteriorated
beet material, were the main R&D chal-
lenges during the past 20 years for the
Südzucker Group. Rheological methods
for exploring physico-chemical reactions
during the processing of raw materials
Fig. 22: 1st carbonatation filtration coefficients for processed deteriorated beet material by applying to food are among the newer methods
different juice purification procedures (Ajdari Rad et al., 2008 a) for investigation in food technology. A

No. 12 (2014) Sugar Industry 139 | 734–744

744 Technology/Technologie
viscosity in-line-on-line measurement method has been devel-
oped and successfully applied to record and optimize process
steps. The aim of the developments in the juice purification
was to extend the state of knowledge regarding the chemical
and physical reactions in the juice purification process steps.
The acquired knowledge has been used to further optimise
juice purification parameters (such as optimum flocculation
in the preliming, optimum pH end-point in the 1st carbonata-
tion) for a more intensive, economical and product quality
operation of the juice purification, in particular when process-
ing deteriorated and frost-damaged beet material. Important
is the possible use of the process juice viscosity as a reference
variable and warning signal for process control and optimiza-
tion in juice purification such as e.g. raw juice viscosimetry.
The aim of the raw juice pre-alkalization is the stabilization of
the raw juice before the raw juice heat exchanger. Thereby, the
colour and the lime salts’ content of the thin juice could be
improved. In addition, raw juice pre-alkalization leads to the
destruction of the bio-film and microbial activities within the
raw juice heat exchanger.
The development and testing of the SZ/RT-juice purification
system with separation of the colloidal fraction after preliming
has been a successful industry-oriented research. The separa-
tion of the colloidal fraction results in a significant operational
improvement, particularly concerning the filterability of the
1st carbonatation juices. In view of the increasingly long cam-
paigns with higher probability of receiving deteriorated beet
material a better performance of the filtration system is very
important.
The carbonatation sludge of the SZ/RT-juice purification has a
low phosphate content which in some cases is of importance.
The phosphate has been shifted to the colloid fraction. There-
fore the separated colloidal fraction can be utilized for several
other applications (for fermentation purpose, as fertilizer …).
Investigations in this field are ongoing.
Author’s addresses: Dr. Mohsen Ajdari Rad, Südzucker AG Mannheim/Ochsenfurt, Central Department Research, Development
and Technological Services (CRDS), Wormser Str. 11, 67283 Obrigheim, Germany; Dr. Azar Ajdari Rad, Südzucker AG Mannheim/
Ochsenfurt, GBZS, Marktbreiter Straße 74, 97199 Ochsenfurt, Germany; Gilles Schrevel, Raffinerie Tirlemontoise, Avenue de Ter-
vueren 182, 1150 Bruxelles, Belgium; e-mail: mohsen.ajdarirad@suedzucker.de
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