Antoine Charbonneau2, Phelipe Czelusniak2, Cyril Leenhardt2 and Olivier Pauwels1 #
1 Applexion SAS, 5 chemin du Pilon, 01700 Saint-Maurice de Beynost, France
2 Process Solutions Americas LLC (d/b/a Applexion), 560 Peoples Plaza, Newark, 19702, USA
Scaling in sugar evaporators, a major bottleneck in cane sugar production, is highly influenced by calcium and magnesium hardness in the extracted raw juice, often combined with silicates and oxalates. Traditional chemical softening methods face issues such as chemical consumption, waste generation, and pH control difficulties. Inspired by the NRS (New Regeneration System) softening process, ion exchange offers a cleaner, more efficient alternative. Adapted to cane juice’s complexity with high levels of divalent cations, organic fouling risks, and elevated temperatures, this solution evolves into the Applexion CSF process, aimed at reducing scaling and fouling phenomena during evaporation. It integrates ion-exchange technology with continuous self-cleaning filters for organic microfiber removal, optimized resin selection, and advanced regeneration strategies. Pilot- scale trials during the 2018-2019 campaigns in Brazil, and additional testing in Central America, demonstrated effective performance. Results showed 80-90% removal of hardness, consistent resin behaviour, and stable operation. Uniquely, the CSF process eliminates the need for chemical regenerants by using softened molasses, sourced from within the sugar process, as a substitute for conventional brine. This technology offers significant environmental benefits: reduced chemical use, minimal waste, and lower water consumption. Operational advantages include minimized evaporator scaling, decreased cleaning downtime, longer runtime, improved heat transfer, and enhanced crystal sugar purity (better colour and reduced residual colloids), ultimately boosting sugar yield. While full-scale industrial data is still being collected, early indicators point to substantial evaporation savings from shorter residence times, fewer shutdowns, and less reliance on mechanical cleaning services. CSF process represents a major advance in cane juice softening, combining sustainability, cost efficiency, and improved production performance. This work shows how ion exchange can revolutionize cane juice softening, and unveils a game changer for the cane industry, showcasing successful trials, and quantifying the economic benefits of this highly sustainable and cost-effective solution.