Background of The Invention
5 Field of Invention
[0001] The present disclosure relates to the field of sugarcane
juice processing from sugarcane and, more particularly, to replicable standardize
modular and scalable equipment packages for [[and scalable]] sugar cane
processing. The micro sugar and energy plants [[that]] utilize bagasse
10 gasification for energy production. It also pertains to the products produced by
the inventive systems and methods.
Description of Prior Art
[0002] An example of the prior art is EP3827672, which
15 discloses a method of preparing an extract from sugarcane bagasse or
sugarcane straw comprising: obtaining a dried sugarcane bagasse or a
dried sugarcane straw; milling the dried bagasse or the dried straw;
mixing the milled bagasse or straw with a solution comprising a solvent to
form a mixture; stirring the mixture; separating liquid fraction and solid
20 fraction of the mixture; concentrating the liquid fraction to obtain an
extract; optionally drying the liquid fraction to obtain a dry extract.
[0003] Another example is US11730178 which describes a
process for producing an extract derived from sugarcane, the process
comprising: i) mixing a sugarcane derived product with ethanol to
25 produce an extraction mixture comprising at least about 50% v/v ethanol;
ii) allowing a precipitate to form in the extraction mixture; iii) removing
the precipitate from the extraction mixture to obtain a supernatant; and iv)
removing ethanol from the supernatant to produce the extract derived
from sugarcane.
3
[0004] The prior art describes processes in conventional
sugarcane processing plants. Conventional sugarcane processing plants
are typically large, energy- intensive industrial facilities that source
sugarcane regionally. These plants often rely on a combination of fossil
5 fuels and sugar cane bagasse for their energy supply, which can have a
significant environmental impact. The scale and environmental footprint
of such facilities can pose challenges for producers of consumable sugar
products, as the associated costs may hinder commercial viability.
[0005] Moreover, the operation of traditional sugarcane
10 processing plants requires substantial amounts of external energy, which
may not be consistently available in certain geographical locations. Energy
is consumed throughout the process, including for conditioning the
sugarcane, filtering, evaporating, and drying the final sugar product.
[0006] [[However, existing]] Existing sugarcane processing
15 solutions face [[suffer from]] certain limitations in terms of energy efficiency,
environmental sustainability and scalability due to the massive size and
complexity of standardized multiple effect evaporators. [[and scalability.]] These
traditional sugar refinery plants often result in higher operational costs and high
skilled labor force. The present invention method produces a healthier sweetener
20 by retaining essential nutrients, avoiding chemical bleaching, not using a
centrifugal process, as well as offering a modular design making it accessible for
small-medium enterprises. The present invention provides novel solutions to these
limitations and differs from the prior art in that it can operate in a more climateresilient and non-polluting manner, while being adaptable to various scales of
25 production. A key difference is that the present invention utilizes pellets from
bagasse to create gasification for energy production.
[0007] It is noted that traditional industrial sugar refineries have
not utilized equipment that is used in maple syrup production because the volume
output via the use of traditional maple syrup production technology would be too
4
low in comparison. The production, in its traditional practice, would not be able
to meet the demands of large-scale commercial sugar production levels. The
foregoing is notable with the knowledge that maple syrup systems are
traditionally designed for small-batch, artisanal production, which contrast with
5 the continuous, high-throughput operations of conventional sugar plants that
require massive evaporators, centrifuges, and crystallization units to process
thousands of tons of sugarcane at a time. In contrast, the current invention micro
plant is designed for batch production approach which allows for more flexible
customization of evaporated cane juice also known as liquid syrup production.
10 This modular design not only facilitates low-skill workforce involvement but
provides opportunities for upskilling. The invention is a commitment to
sustainability and efficient energy use, A key differentiator is the containerized
CHP units gasifier systems. These compact, modular units allow for flexible, easy
installation and scalability, accommodating various site sizes and enabling rapid
15 deployment. This ensures that the invention of micro sugar and energy plants can
be easily integrated into diverse environments, unlike the fixed, large-scale
infrastructure of traditional refineries. The containerized CHP units primarily
utilize bagasse pellets, adaptable to other forms of biomass like coconut shells,
and wood chip pulp. These fuels are climate-resilient, offering carbon neutral,
20 low ash content, and high energy density. The use of a pelletizer ensures that
these pellets are reliable and easy to transport, facilitating seamless, efficient
energy production. This form of energy production eliminates the need for fossil
fuels, which are traditionally used in both sugar refineries and maple sugaring
facilities.
25
Brief Summary of The Invention
[0008] This summary is provided to introduce a selection of
concepts, in a simplified format, that are further described in the detailed
description of the invention. This summary is neither intended to
5
identify key or essential inventive concepts of the invention nor is it
intended for determining the scope of the invention.
[0009] In one aspect, the present invention provides a
modular and scalable sugarcane processing plant that utilizes pellets from
5 bagasse to create gasification for energy production. The plant comprises
a pellet bagasse gasifier configured to receive bagasse from a sugarcane
juice extraction process and produce a consumable gas, a sugarcane syrup
production segment with a rated processing capacity that defines a
corresponding heat energy requirement, and a central heating plant
10 configured to extract heat energy from the consumable gas produced by the
pellet bagasse gasifier. The heat energy output capacity of the central
heating plant is matched to the heat energy requirement of the sugarcane
syrup production segment, enabling the pellet bagasse gasifier and central
heating plant to supply sufficient energy to drive the syrup production
15 using solely the consumable gas produced from the bagasse.
[0010] In embodiments of the present invention, a combined
heat and power (CHP) configuration can be used for the simultaneous
generation of useful heat and electricity from the pellet bagasse. Pellet fuel
can be produced from the bagasse.
20 [0011] In a preferred embodiment, the sugarcane syrup
production segment includes a cane crushing system for extracting sugar
cane juice and outputting bagasse, bagasse into a pelletizer system for fuel
into the gasifier system, a filtration system for removing impurities from
the extracted juice, and a vacuum boiling system for concentrating the
25 filtered juice into syrup. The plant may further comprise a UV reverse
osmosis system powered by the central heating plant for separating water
from the filtered juice to produce a concentrated sugar water juice, and a
refrigerated silo with agitators for storing the concentrated juice.
6
[0012] Advantageously, the modular and scalable sugarcane
processing plant may include a bagasse dryer that utilizes heat recovered
from the central heating plant to dry the bagasse from the cane crushing
system, and a pelletizer for compressing the dried bagasse into fuel pellets
5 for the bagasse gasifier. The central heating plant may further comprise a
heat transfer fluid boiler for heating a heat transfer fluid using heat from
the consumable gas, and a heat exchanger for transferring heat from the
heated fluid to the syrup production segment.
[0013] In general, one inventive aspect of the present inventive
10 system is its scalability and configurability. As configured as a micro-plant, the
inventive system can support a modular, batch-based and customized production
process. The flexibility serves as an alternative to the traditional industrial-scale
sugar refining model. Unlike conventional sugar refineries, which operate as
large, continuous-processing plants requiring high-capacity throughput and
15 significant energy consumption, the present inventive system can utilize
independent evaporator lines that function as silos, allowing for flexible, smallbatch production based on available volumes of concentrated cane juice. This
being the case, the inventive system eliminates the inefficiencies of traditional
sugar plants, where an entire facility must be in operation at once, even when
20 processing lower volumes. The maple sugaring industry relies heavily on Reverse
Osmosis (RO) to concentrate sugar levels due to the low sugar level of the maple
water. The present invention system leverages RO technology to increase the
sugar content to double or triple, e.g., taking it from 15 Brix to 35 Brix, effectively
reducing processing time. This process separates the sugar concentrate from the
25 water, achieving up to a 54% water separation. This significantly decreases the
need for water usage, making the process less water-intensive micro plant
operation. The extracted water can be repurposed for equipment cleaning or
remineralization for agricultural use or drinking, supporting sustainable practices.
7
[0014] The present invention also provides a method for
producing cane sugar syrup in a climate-resilient and non-polluting
manner. The method involves extracting sugar cane juice and bagasse
from unprocessed sugar cane, gasifying the bagasse to produce a
5 consumable gas, processing the juice in a syrup production segment
having an energy requirement, extracting heat energy from the
consumable gas in a central heating plant, and supplying the extracted heat
energy to the syrup production segment to meet its energy requirement.
The energy supplied by the consumable gas from the bagasse is sufficient
10 to meet the energy requirement of the syrup production segment.
[0015] The results of practicing an embodiment of the inventive
method or utilizing an embodiment of the inventive system are products with
characteristics and natures that are defined directly by the steps of the inventive
methods, the elements of the inventive systems or both.
15 [0016] The foregoing and other features and advantages of the
invention will be apparent from the following more particular description
of preferred embodiments of the invention. The present disclosure
addresses the need for improved sugar cane processing systems that can
operate efficiently and sustainably, while being adaptable to various
20 scales of production. By integrating bagasse gasification and a central
heating plant matched to the energy requirements of the syrup production
segment, the modular and scalable plant design of the present invention
solves the problems associated with conventional sugar cane processing
facilities, such as reliance on fossil fuels and limited scalability. The
25 invention enables the production of cane sugar syrup in a climate-resilient
and non-polluting manner, with the potential for significant cost savings
and environmental benefits compared to traditional approaches.
[0017] Additional features and advantages of the invention
will be set forth in the description which follows, and in part will be
8
obvious from the description, or may be learned by the practice of the
invention. These and other features of the present invention will become
more fully apparent from the following description, or may be learned by
the practice of the invention as set forth hereinafter.
5
Brief Description of the Drawings
[0018] The various exemplary embodiments of the present
invention, which will become more apparent as the description proceeds, are
described in the following detailed description in conjunction with the
10 accompanying drawings, in which:
[0019] FIG.1 depicts a flow chart detailing an embodiment
of the steps for the transformation of raw sugar cane into high-quality
syrup.
[0020] FIG. 2 is a subsystem diagram for an organic cane
15 syrup processing plant.
[0021] FIG. 3 is an organic CHP electrical plant and sugar
processing plant diagram.
Detailed Description
20 [0022] In the following detailed description of the preferred
embodiments, reference is made to the accompanying drawings, which
form a part hereof and show, by way of illustration, specific embodiments
in which the invention may be practiced. It is to be understood that other
embodiments may be used and structural or logical changes may be made
25 without departing from the scope of the present invention. The following
detailed description, therefore, is not to be taken in a limiting sense, and
the scope of the present invention is defined by the appended claims.
[0023] The following description is provided as an enabling
teaching of the present systems, and/or methods in its best, currently
9
known aspect. To this end, those skilled in the relevant art will recognize and
appreciate that many changes can be made to the various aspects of the present
systems and methods described herein, while still obtaining the beneficial results
of the present disclosure. It will also be apparent that some of the desired
5 benefits of the present disclosure can be obtained by selecting some of the
features of the present disclosure without utilizing other features.
[0024] Accordingly, those who work in the art will
recognize that many modifications and adaptations to the present
disclosure are possible and can even be desirable in certain circumstances
10 and are a part of the present disclosure. Thus, the following description is
provided as illustrative of the principles of the present disclosure and not
in limitation thereof.
[0025] The terms "a" and "an" and "the" and similar references
used in the context of describing a particular embodiment of the present
15 invention (especially in the context of certain claims) are construed to cover
both the singular and the plural. The recitation of ranges of values herein is
merely intended to serve as a shorthand method of referring individually to
each separate value falling within the range. Unless otherwise indicated
herein, each individual value is incorporated into the specification as if it
20 were individually recited herein.
[0026] All systems described herein can be performed in any
suitable order unless otherwise indicated herein or otherwise clearly
contradicted by context. The use of any and all examples, or exemplary
language (for example, "such as") provided with respect to certain
25 embodiments herein is intended merely to better illuminate the application
and does not pose a limitation on the scope of the application otherwise
claimed. No language in the specification should be construed as indicating
any non-claimed element essential to the practice of the application. Thus,
10
for example, reference to "an element" can include two or more such
elements unless the context indicates otherwise.
[0027] As used herein, the terms "optional" or "optionally"
mean that the subsequently described event or circumstance can or cannot
5 occur, and that the description includes instances where said event or
circumstance occurs and instances where it does not.
[0028] The word or as used herein means any one member of
a particular list and also includes any combination of members of that list.
Further, one should note that conditional language, such as, among others,
10 "can," "could," "might", or "may" unless specifically stated otherwise, or
otherwise understood within the context as used, is generally intended to
convey that certain aspects include, while other aspects do not include, certain
features, elements and/or steps. Thus, such conditional language is not
generally intended to imply that features, elements and/or steps are in any way
15 required for one or more particular aspects or that one or more particular
aspects necessarily include logic for deciding, with or without user input or
prompting, whether these features, elements and/or steps are included or are
to be performed in any particular aspect.
[0029] The present invention can provide a more
20 environmentally friendly sugar production process. In one exemplary
embodiment, the system can condition and use process byproducts such
as conditioned bagasse as a primary energy source for producing liquid
sweeteners and sugarcane syrup.
[0030] In this embodiment, a Combined Heat and Power
25 (CHP) electrical power plant is able to use conditioned byproducts (e.g.,
bagasse) as fuel. Where the sugarcane treatment plant capacity is sized
according to the electrical power available from the CHP, the system's
energy production can closely match the processing energy demands. In
one approach to matching the plant capacity to the CHP energy production,
11
the equipment is sized to insure that the daily harvest approximates the daily
consumption. In one approach, where the matching is of daily or even shorter
duration, the process can approximate a continuous flow processing
capability. In effect, if the daily energy production matches the daily
5 consumption, the need for extensive material or energy storage can be
reduced or even eliminated.
[0031] FIG.1 depicts a flow chart detailing an embodiment
of the steps for the transformation of raw sugar cane into high-quality
syrup.
10 [0032] (Step 1) In one embodiment, the Processing Facility
receives material in the form of raw sugar cane at a receiving dock or
similar structure. The raw sugar cane may arrive via truck, train, barge, or
other conventional transportation mode.
[0033] (Step 2) According to an embodiment, the raw cane
15 is fed to a Cane Crushing Roller and mill Tandem System as its input. The
cane crushing system also receives energy input from the cogenerator that
is fueled by bagasse pellets. Cane crushers are typically powered by
electrical energy. In some embodiments, within the cane crushing system,
when raw cane is fed into the rolling crushing mills, cane juice is extracted
20 from the cane. The process comprises a few stages, including a shredder
configured to shred the stalk, grooved rollers to press the shredded stalk,
and a series of individual mills disposed in a uniformed tandem milling
arrangement for efficiency to extract maximum juice.
[0034] In one embodiment, all cane conditioning and juice25 extracting operations are mechanical operations. Mechanical power can be
obtained from internal combustion engines, steam engines, or electrical
motors. For ease of operation and equipment supply, electrical motors are
preferred. In another embodiment, the CHP bagasse-fired plant must be
12
sized such that its electrical power generation capacity exceeds the total
sugar cane processing plant electrical needs by about 25%.
[0035] (Step 2A) In some embodiments, the bagasse dryer
and conditioning system receives the shredded stalk. The shredded
5 bagasse or stalk is dried in a tumbler to prepare it to be compressed in the
pelletizer. Once processed, sugar cane stalk moisture content is above
50%, thereby eliminating all heating values from the bagasse. The
processed sugar cane stalks are passed through a rotary dryer, wherein an
incoming mixture of warm air, gasifier exhaust, producer gas-fired
10 electrical generator's engine, and boiler exhaust gases provide drying heat
for the bagasse. Recovering otherwise lost low-grade heat to dry bagasse
rather than using a gas-fired rotary dryer improved the overall sugar cane
processing plant.
[0036] (Step 2B) According to an embodiment, the pelletizer
15 is a machine configured to compress the shredded bagasse into pellets that
are consistent in size, shape, and weight for the purposes of fuel source.
The plant uses the bagasse as biomass fuel to eliminate the cost and
reliance on fossil fuels. As we know it today, fossil fuels are proven to
intensify environmental pollution that continues to harm the Earth. While
20 the pellet pressing system helps to solve environmental negative impact
problems, biomass pellets are a clean source of energy. In one embodiment,
shredded bagasse is first dried in a kiln; low-temperature warm air
recovered from the CHP plant and the evaporator's boiler, which would
otherwise be lost to the atmosphere, is ducted to the drying kiln. Dried bagasse
25 is then processed into pellets by the pelletizer. The pellets are then directed
to the CHP fuel bunker or to storage for the black start of the plant.
[0037] (Step 2C) In some embodiments, the CHP and boiler
operate on producer gas. Producer gas is a mixture of carbon monoxide
(CO) and hydrogen (H2) that can be used to fuel internal combustion
13
engines and boilers' burners. A gasifier is used for that process. Pellets are
fed into a reactor where partial combustion under a low-oxygen
atmosphere occurs. Carbon monoxide and hydrogen are generated,
filtered, compressed, and then piped to the CHP combustion engine and
5 boilers. Generated heat from the reactor is used for bagasse drying.
[0038] (Step 20) According to an embodiment, a cooling tower is a
specialized heat exchanger that takes in air and water, which are
brought into direct contact with each other to reduce the water's
temperature. When this occurs, a small volume of water is
10 evaporated, thereby reducing the temperature of the water being
circulated through the tower.
[0039] In one embodiment, the water, which enters after being heated
by an industrial process, is pumped into the cooling tower. The water
goes through a series of nozzles, reducing the temperature. As the
15 water flows through the cooling tower, it is exposed to air, which is
being pulled through the tower by the electric motor-driven fan.
[0040] In some embodiments, when the water and air meet, a small
amount of water is evaporated, creating a cooling action. The
cooled water is then pumped back to the condenser or process
20 equipment where it absorbs heat. It will then be pumped back to
the cooling tower to be cooled once again. Cooling Tower
Fundamentals provides a level of basic cooling.
[0041] (STEP 2E) In one embodiment, electrical power is
generated by producer-gas-fueled internal combustion engines'
25 electrical generators. The heat from the exhaust is recovered for
further use in evaporating the sugar cane concentrate. The heat
from the combustion engine cooling is recovered for use in the
bagasse drying process.
14
[0042] In another embodiment, the electrical generator output
must be sized to ensure about 125% of the total electrical needs
of the sugar plant.
[0043] (Step 3) According to an embodiment, once the juice is
5 extracted, it is sent into a pre-filtration system that separates
fresh juice from impurities and all unwanted floating particles.
The pre-filtration system is also powered by the cogeneration
system. A low-pressure electrical pump forces the juice through
a battery filter to remove impurities. The filtered juice is stored
10 in a settling tank.
[0044] (Step 4) In some embodiments, filtered fresh cane juice is
sent into a UV Reverse Osmosis system that separates the sugar
from water to produce a concentrated sugar water juice, thereby
reducing the evaporation time to produce syrup or sugar and thus
15 reducing the need for energy. The water that was separated from
the sugar juice flows into a basin to be reused throughout the plant.
The UV Reverse Osmosis system is powered by the cogeneration
system. Reversed osmosis (RO) is achieved by using a
specialized membrane that, when a pressure differential is
20 applied between the membrane faces, only water will pass through.
By removing water, the sugar concentration of the juice is
increased. RO is the most energy-efficient way of increasing the
sugar content of a solution. Electrically powered high-pressure
pumps are used to generate the pressure differential required for the
25 RO to occur.
[0045] (Step 5) According to an embodiment, the concentrated
sugar water juice is sent into a refrigerated silo with agitators to
be discharged when ready to use. The refrigerators are powered
by the cogeneration system. The concentrated juice is further
15
processed through an electrically powered micro- filtration unit.
Micro-filtration removes all microorganisms like yeast andbacteria, thereby preventing concentrate juice degradation.
Alternatively, pasteurization could also be used for the same
5 purpose.
[0046] (Step 6) In one embodiment, to make syrup, the sugar
content of the final product must be about 66.7° at the Brix scale,
and the sugars produces molasses. The process includes a rise in
sugar concentration by evaporation boiling and sugar cooking.
10 The color and taste are developed through that process. In
another embodiment, the typical RO process will increase the
sugar content to about 35° at the Brix scale typically from a
starting Brix average of 10-16 Brix; further rise in Brix must be
accomplished by evaporation. Boiling under a vacuum allows
15 for a lower boiling temperature. In turn, boiling at a lower
temperature provides a syrup with less color and taste.
[0047] In some embodiments, the concentrate is admitted in a
closed container under vacuum. The vacuum is maintained by
an electrically driven vacuum pump, and heat for boiling is
20 provided from a remote heat transfer fluid boiler. The heat
transfer fluid is circulated from the boiler to the container's heat
exchanger.
[0048] (STEP 7) According to an embodiment, thermal energy
required for boiling is generated in a pellet-fired boiler. A
25 circulating heat transfer fluid is first heated by the CHP's internal
combustion engine exhaust heat recuperator, and then the final heat
transfer fluid's required temperature is reached at the boiler.
Thermal energy is spent by boiling the juice and cooking the
sugar. The heat transfer fluid returns to the CHP's engine.
16
[0049] In one embodiment, the boiler is a standard ASME heat
transfer fluid boiler, wherein the fossil fuel burner is replaced by
a pellet burner.
[0050] (STEP 8) In some embodiments, a syrup evaporator's
5 purpose is to increase the sugar concentration of the juice by
boiling off excess water and caramelizing (cooking) the sugar.
The syrup-making process is linear; concentrate enters at one
end, travels through heat exchangers, loses water, and gains
internal thermal energy. Sugar cooking occurs, and the syrup
10 exits at the other end.
[0051] In one embodiment, a vertical evaporator is made of a
cylindrical body with heat exchangers mounted inside the
cylinder volume. Fresh concentrate is admitted at the top. As
water is evaporated, concentrate density increases, forcing the
15 concentrate downward. Traveling down, losing more water, and
increasing internal heat causes cooking of the sugar. The syrup is
retrieved at the bottom of the cylindrical evaporator.
[0052] (STEP 9) According to an embodiment, a basic filter press is
made of a fiber filter maintained in place by a metallic frame.
20 Syrup to be filtrated is pumped by an electric pump through the
filter. Diatomaceous Earth (DE) also known as a filter aide is
mixed with the hot syrup once drawn off from the evaporator. It
is mixed by hand and/or with an automatic mixing paddle to be
evenly distributed with the syrup. The DE helps the syrup to flow
25 through the filter press to ease the pressure of flow, but most
importantly to give a quality finished syrup by removing any
unwanted partials. In one preferred embodiment, the [[The]]
finishing syrup process [[along side]] calls for the use of [[the]]
Diatomaceous earth (DE). In addition, when customizing syrup batch
17
production, to maintain health properties but manipulate the color,
smell or taste profile, the use of activated carbon charcoal is required.
DE is mixed with the hot syrup ahead of the filter press to
facilitate the process by providing voids where debris can be
5 deposited. To provide more volume, several basic filter presses
are connected in parallel. To provide cleaner syrup, several basic
filter presses are connected in series.
[0053] (STEP 9A) In one embodiment, activated carbon is an
inert product made of carbon having a porous structure with
10 considerable inner surface area. For example, some inner
surface measures are in the range of about 700-2000 m2/g.
Activated carbon can thus trap unwanted molecules present in
liquids and gases in its pores by adsorption.
[0054] In another embodiment, activated carbon may be used in
15 decolorization, purification, decontamination, and
deodorization of a wide range of fluids. Three forms are typical:
powdered, granular, and pellet. Activated carbon charcoal is
also widely used in the food and beverage industry to eliminate
color, odor, and undesirable flavor. It also can stabilize the syrup
20 to prevent mold, bacterial growth from fermentation and
removal of contaminates. Pending the saturation time of
activated charcoal carbon, its additional use allows for color
gradation of the syrup. The various gradation of syrups also
relates to the odor, color and finished flavor. The lighter the
25 syrup the more absence of flavor of molasses.
[0055] (STEP 10) In some embodiments, the syrup must be
conditioned into transport containers at a temperature above
180°F to provide pasteurization. Since heat is lost in the filtering
process, reheating the syrup above 180°F is needed. Heat
18
transfer fluid from the evaporator heating circuit is used for that
purpose.
[0056] (STEP 11) According to an embodiment, the syrup must be
conditioned into transport containers at a temperature above
5 180°F to provide pasteurization. Since heat is lost in the filtering
process, reheating the syrup above 180°F is needed. Heat
transfer fluid from the evaporator heating circuit is used for that
purpose.
[0057] (STEP 12) In one embodiment, a great quantity of cold and
10 hot domestic water is required throughout the process.
Fortunately, RO provides a large quantity of water. RO waters
and used domestic waters are sent to a greywater collection
reservoir where the greywater is filtered. Needed domestic water
is pumped from that reservoir and heated as needed. Excess
15 filtered water is disposed of.
[0058] One specific embodiment of the present method invention
for the production of various unrefined cane syrup that maintains essential
nutrients and minerals while also allowing for customizable pure cane syrups
ranging in characteristics from clear to molasses measuring against ICUMSA
20 (International Commission for Uniformity Methods of Sugar Analysis)
colorimetric reader. This particular embodiment comprises in combination,
for example, the steps of starting with (A) extracting sugarcane juice from
fresh sugarcane using first cane crusher to macerate the sugar cane. The
extracted juice is then (B) Ultra filtered – not by centrifugal process - to
25 preserve the natural juice while removing impurities and retaining
polyphenols, amino acids, and antioxidants (minerals and vitamins). It is also
(C) treated with ultraviolet (UV) light with thin film reactor to eliminate
bacteria, yeast and microbes without using chemical agents. (D) Always
reverse osmosis is applied to separate water content and reduce evaporation
19
time and energy consumption while concentrating natural sugars. Then (E)
the concentrated juice (RO) is refrigerated for later evaporation. When ready,
(F) the concentrated juice (RO) is evaporated using one of three distinct
evaporation methods, each producing unique syrup characteristics: (i) open
5 flat pan evaporator, (ii) enclosed steam evaporator, or (iii) low pressure
vacuum boiler.
[0059] The open flat pan evaporator, which can be powered by
bagasse pellets, (i) requires continuous monitoring and designed with direct
heat exposure onto the flat, allowing for deeper flavor development from the
10 caramelization of sugar as evaporation progresses. Ideal for the production of
molasses rich syrups and/or syrup with more caramelization characteristics
such as 70+ Brix for traditional molasses- creating a rich, full-bodied syrup
with deep color and robust flavor. Ideal for traditional and artisanal syrupmaking, preserving the intense natural complexity of sugarcane flavors.
15 [0060] The steam evaporator (ii) is an enclosed unit that
accelerates production through precise thermal control. It functions as a
hybrid method, combining elements of both vacuum and open pan
evaporation. Controlled steam heat is used to accelerate evaporation while
partially caramelizing sugars. This element produces a medium-bodied syrup
20 with a balance of color, viscosity, and caramelized notes, offering a range
between light and molasses-type syrups, but faster volume production.
[0061] The vacuum boiler operates at lower temperature than
traditional evaporators, maintaining 185°F, using reduced atmospheric
pressure to gently remove water from the syrup and allows for (a) high density
25 while preserving sugar characteristics and (b) prevention of scorching the pans
or over cooking process. It thus maintains a delicate sugarcane flavor,
producing clear syrups with a light, mild taste with the ability to control Brix
level compared to molasses-based syrups.
20
[0062] After evaporation, (G) various filter aids are used with
charcoal carbon and diatomaceous earth to achieve various color and purity
levels without the use of bleaching agents. This step results in the selective
reduction of color and odor intensity with flavor depth maintained, and
5 through which a range of syrup profiles are enabled.
[0063] The inventive method also includes (H) adjusting Brix
levels and density for final consistency by employing a recalibrating system
and (I) ensuring batch consistency through routine quality control, calibration,
and inspection before each production run. Further, (J) the final syrup is
10 pasteurized above 180°F and hot-packed using a closed-loop heating system
to prevent microbial growth without altering its natural composition or high
pressure processing (HPP). Following the foregoing, (K) the final syrup is air
tight sealed for any and all appropriate packaging vessels and then stored in
temperature-controlled silos to maintain freshness and extend shelf life. The
15 final syrup product is preferably bottled to ensure retention of natural
properties without the use of artificial additives. Within the steps, (L) a
combined heat and power (CHP) system powered by biomass-derived bagasse
(biomass) pellets is used to produce energy to sustain plant operations.
[0064] In certain embodiments of the present invention of HPP,
20 at the final stage of syrup production, is a key step. The HPP step is
distinguishable from traditional heat-based and chemically preserved syrup
processing. For one, HPP ensures microbial safety, extended shelf stability,
and the preservation of natural nutrients. Unlike and as opposed to traditional
and conventional sugar refineries that rely on industrial-scale refining,
25 bleaching, crystallization chemical preservatives or high-heat pasteurization
(or combinations of the foregoing) —which can degrade the integrity of
natural cane syrup, HPP uses cold, high-pressure technology to eliminate
bacteria, mold, and microbes without altering the syrup’s natural composition.
This step of preferred embodiments retains the full nutritional profile of
21
unrefined sugarcane, ensuring that the syrup remains chemical-free, shelfstable, and rich in naturally occurring minerals. In addition, by combining
batch-based quality control, renewable energy, and advanced food safety
technology, embodiments of the present inventive system redefine sugar
5 manufacturing for the modern, health-conscious consumer while maintaining
the highest standards of sustainability and purity. Further, the present
inventive system, with the HPP step, supports a scalable, energy-efficient
alternative to centralized sugar refining, allowing for adaptive production
cycles that respond to market demands, seasonal cane availability, and
10 operational efficiency requirements.
[0065] In some embodiments, the cane crushing system
includes a syrup output and a bagasse output. As the cane is crushed,
sugar syrup is released and extracted. The sugar syrup gathers in a lower
catch basin and exits via a syrup output. While the figure shows this
15 generally, for clarity of presentation, some of the known subsystems,
such as filters, valves, pumps, or other implementation details, are not
included. One skilled in the art would implement such components and
subsystems according to the general system design. For example,
coarse filter size, aperture sizes, catch basin size, and angle of gravity
20 feed would be design choices that depend on the target system capacity,
characteristics of the input material, and other known considerations.
[0066] According to an embodiment, the cane crushing system
also includes a bagasse channel. The bagasse channel outputs the
remaining material, much of which is crushed fibrous remnants
25 of the input sugar cane.
[0067] In one embodiment, a bagasse dryer receives the output
bagasse material from the cane crushing system via the bagasse
output channel. There, moisture and other undesirable materials
22
are removed. Bagasse drying and conditioning (pelletized)
energy is provided by the CHP.
[0068] In some embodiments, CHP is fueled by bagasse pellets,
using a gasification process to turn bagasse pellets into gaseous
5 fuel that supplies a spark ignition or diesel motor that, in turn,
powers an electrical generator.
[0069] The Pellet fuel is the main power (energy) like the others
use bagasse as raw material for fuel, but rather than using loose
bagasse it goes through a pelletizer system. The pelletizer uses
10 the raw material into homogeneous mass and then gets feed into
a gasifier co-generator system to the boiler for steam and that
steam recirculates back, as per the diagram.
[0070] According to an embodiment, either a bagasse pelletfueled evaporator or a bagasse pellet-fueled boiler provides the
15 thermal energy required to increase the sugar content of the
sugarcane juice to the needed concentration.
[0071] In one embodiment, the sugarcane sweetener process uses
vacuum boiling to prevent sugar cooking by keeping a low
boiling temperature.
20 [0072] In some embodiments, the process described herein may
be used to produce various types of syrups with different
characteristics by adjusting process parameters. By way of
example and not limitation, the concentration of sugar in the
final syrup product, known as the brix level, can optionally be
25 varied to produce syrups of different sweetness.
[0073] The amount of molasses included might be adjusted to
control the color and flavor profile of the syrup. Characteristics
such as aroma and viscosity can also generally be customized
23
for different applications by modifying factors including but not
limited to the cooking temperature and time in the evaporator.
[0074] By altering these parameters, this process may be used to
manufacture syrups to different specifications, ranging from
5 light-colored and mild-flavored to dark, strongly-flavored, and
substantially more viscous. This flexibility allows the production
of syrups tailored for various uses, such as table syrups, cooking
ingredients, or industrial sweeteners.
[0075] The chemical makeup of the process can include low GL
10 (glycemic load) compositions.
[0076] In embodiments of the present invention, FIG. 2 is a
subsystem diagram for an organic cane syrup processing plant,
and FIG. 3 is an organic CHP electrical plant and sugar
processing plant diagram.
15 [0077] One specific embodiment of the present inventive system
producing various unrefined cane syrup in a modular takes the form of a
scalable sugarcane processing plant that is powered by renewable bio-mass
energy. This particular embodiment is designed to create customizable pure
cane syrups ranging in color hue from translucent clear non-centrifugal syrup
20 to dark robust molasses, clear, pale yellow, golden, amber and dark brown.
Its elements include, for example, (A) a non-centrifugal juice extraction
system, which can preserve essential minerals and nutrients, (B) a filtration
system for removing impurities, while retaining natural sugarcane
compounds; (C) a UV light with thin film reactor to prevent yeast, bacteria
25 growth or fermentation of cane juice, (D) a reverse osmosis unit to concentrate
sugar while reducing evaporation time and energy consumption, and (E) a
selected use evaporator system.
[0078] The method used by the evaporator determines the final
syrup characteristics as customization. The evaporator element itself
24
preferably includes (i) a vacuum boiling system at 185°F for clear syrups with
no caramelization (producing light-colored, mild-flavored syrup), (ii) a flat
pan (open pan) evaporator for molasses production exceeding 70+ Brix,
creating a deeply caramelized, full-bodied syrup, and (iii) a steam evaporator
5 as a hybrid system, achieving controlled caramelization for medium-bodied
syrups and higher volume production
[0079] The system set forth immediately above also preferably
includes (F) a natural filtration system utilizing activated charcoal carbon and
diatomaceous earth to modify color, odor, and flavor intensity post10 evaporation; for quality and purity, (G) a recalibrating unit for adjusting syrup
density and consistency, (H) a quality control monitoring system ensuring
uniformity across batches through routine calibration and inspection, (I) a
closed-loop pasteurization system ensuring microbial stability without
chemical preservatives, (J) a refrigerated storage system to maintain the
15 syrups integrity and extend shelf life, (K) a combined heat and power (CHP)
energy system utilizing biomass from bagasse or coconut shell pellets to
generate electricity and thermal energy; with a generator and an Organic
Rankine Cycle (ORC) system that recycle waste heat energy back to the
generator for efficient energy production. (L) a packaging system that
20 preserves syrup integrity without synthetic additives or excessive processing.
[0080] A product produced by the inventive systems and method
retains its natural mineral and vitamins content due to the absence of
centrifugal separation, high temperature heat and chemical bleaching. The
syrups evaporation process used to produce such products is customized and
25 allows (i) clear syrup production at 185°F using a vacuum boiling system,
preventing caramelization while maintaining a mild, delicate flavor, (ii)
molasses formation exceeding 70 Brix using a flat pan (open pan) evaporator,
producing a rich, deeply caramelized syrup, and (iii) balanced syrup
production using a steam evaporator, creating a hybrid syrup with medium
25
caramelization. Further, product (i) has a color and odor intensity are
selectively reduced through activated charcoal filtration, allowing for a range
of syrup variations from dark molasses to lighter, refined syrups; (ii)
maintains a low glycemic load and glycemic index, making it a healthier
5 alternative to refined sugars and high-fructose corn syrup; and (iii) is storable
in temperature-controlled silos to ensure freshness and prevent crystallization.
[0081] One of ordinary skill in the art would recognize that the
scalability of the present invention – both as methods and as systems - allows
for, for example: (a) individualized evaporator lines to be operated
10 independently or simultaneously, depending on production needs; (b) batchcontrolled processing, enabling quality consistency while optimizing energy
use; and (c) decentralized deployment, reducing capital expenditure and
logistical constraints compared to large-scale refineries. The independent
evaporator lines and modular silos support configurability and batch control.
15 As such, their use represents a different approach from the use of centralized,
continuous sugar refinery models. In particular, with the integration of HPP
at the final stage, the inventive methods and/or systems facilitate the
production of shelf-stable, unrefined cane syrup without the use of industrialscale refining, chemical additives, or excessive heat treatment. This approach
20 can be a new standard for sustainable, small-footprint sugar processing,
offering a disruptive alternative to traditional refining models while
maintaining the flexibility and efficiency required for modern food production
and global market adaptability.
[0082] The inventive methods and systems in some ways, through
25 their novel methodologies and configurations, integrate maple syrup
technology into sugarcane processing, allowing for unprecedented flexibility,
ease of scalability, and operational simplicity. Unlike traditional refineries,
which require specialized engineers and high-maintenance industrial
equipment, the inventive system, for example: (a) utilizes multiple,
26
independent evaporator lines that function like silos, allowing for batch-based
production rather than requiring an entire facility to operate at once; (b) offers
ease of scalability, where additional lines can be brought online as needed to
increase production capacity without the capital-intensive expansion required
5 by large industrial plants; and (c) simplifies operations, making it accessible
for upskilled workers rather than requiring specialized engineers, thereby
reducing labor costs and expanding workforce accessibility.
[0083] By utilizing certain aspects of maple syrup technology for
sugarcane evaporation, the present invention creates a more adaptable,
10 energy-efficient, and modular processing system. As such, the barriers to entry
are lowered for new market participants and sugar production can be deployed
in regions where traditional industrial refineries are impractical or costprohibitive. The result is a highly customizable, decentralized approach to
sugarcane processing that meets modern demands for sustainability,
15 traceability, economic viability and healthier sweetener.
[0084] In comparison with the characteristic and attributes of the
present invention, the prior art teaches and suggests, for example: (a) maple
syrup is mostly water and sugar, while sugarcane juice contains high fibers
and impurities that require robust equipment, and thus it would not be obvious
20 to use maple syrup technology in the production of sugarcane; (b) sugarcane
involves crushing and clarifying, and these steps are not required for maple
syrup production, thus the use of equipment needed to handle the sugarcane
load is not associated with maple syrup production; (c) maple syrup is boiled
at lower temperatures, thus the thought of precise, higher temperature
25 requirements of sugarcane syrup would not be immediately considered since
maple syrup equipment is not designed for that level of support; (d) sugarcane
processing is typically larger scale, industrial manufacturing and since maple
syrup canning equipment is designed for smaller volume batches, the scaling
up of such equipment is not suggested; (e) sugarcane's fibrous nature leaves
27
more residue, demanding specialized cleaning protocols that is meaningfully
different from cleaning protocols associated with the use of maple syrup
equipment; (f) sugarcane juice has a different sugar composition, affecting
crystallization differently than sap juice that becomes maple syrup; (g)
5 sugarcane requires faster evaporation, that is not relevant in the production of
maple syrup; (h) sugarcane's high volume and fiber demand require sturdier
equipment, while maple syrup equipment is not as robust; (i) noting that
different industries have unique regulatory standards, maple syrup equipment
likely have different standards than sugarcane equipment; and (j) operators are
10 trained for sugarcane-specific processes, which differ from maple syrup,
accordingly, using maple syrup equipment requires retraining or adaptation.
[0085] More particularly, maple syrup evaporation typically occurs
at lower temperature than sugarcane processing, around 219°F, because of the
concentration from sap into syrup. For sugarcane, the juice is boiled at higher
15 temperatures, often above 220°F, to crystallize the sugar. The rate depends on
factors like equipment type, juice composition, and desired product. Typically,
sugarcane processes are faster due to higher sugar content. sugarcane juice,
temperatures can range from around 221°F to 230°F, depending on the stage of
evaporation and the equipment. The goal in the use of the present invention is to
20 concentrate the juice until it thickens and forms sugar crystals. Different stages
require slightly different temperatures, especially when refining the product.
[0086] Based on the detailed description provided herein, a skilled
artisan would be able to re-create the claimed invention without undue
experimentation. The examples herein describe the key aspects of the
25 invention in sufficient detail to allow a person having ordinary skill in
the field of sugar processing to make and use the invention.
[0087] The embodiments described herein are given for the purpose
of facilitating the understanding of the present invention and are not
intended to limit the interpretation of the present invention. The
28
respective elements and their arrangements, materials, conditions,
shapes, sizes, or the like of the embodiment are not limitedto theillustrated examples but may be appropriately changed. Further, the
constituents described in the embodiment may be partially replaced or
5 combined together.
10
15
20
25
30
35
40
29
WE CLAIM :
1. A modular and scalable sugarcane and cane juice processing plant
5 comprising:
• a bagasse gasifier configured to receive bagasse from a sugarcane juice
extraction process and to produce a consumable gas from the bagasse;
• a sugarcane syrup production segment having a rated sugarcane processing
capacity that defines a corresponding heat energy requirement; and
10 • a central heating plant configured to extract heat energy from the
consumable gas produced by the bagasse gasifier, the central heating plant
having a heat energy output capacity matched to the heat energy
requirement of the sugar cane syrup production segment;
• wherein the bagasse gasifier and central heating plant are configured to
15 supply sufficient energy to drive the sugar cane syrup production segment
using solely the consumable gas produced from the bagasse; and
• wherein the bagasse gasifier and central heating plant are configured to
supply sufficient energy to drive the sugar cane syrup production segment
using solely the consumable gas produced from the bagasse.
20
2. The modular and scalable cane sugar processing plant of claim 1, wherein
the sugar cane syrup production segment comprises:
• a cane crushing system configured to extract sugar cane juice from sugar
cane and output bagasse;
25 • a filtration system configured to remove impurities from the extracted sugar
cane juice; and
• a vacuum boiling system configured to concentrate the filtered sugar cane
juice into sugar cane syrup.
30
30
3. The modular and scalable cane sugar processing plant of claim 2, further
comprising a UV reverse osmosis system configured to separate water
from the filtered sugarcane juice to produce a concentrated sugar water
juice, wherein the UV reverse osmosis system is powered by the central
5 heating plant. The concentrated juice reduced evaporation time and reduce
energy consumption. The separation of water to concentrate further claims
climate resiliency and sustainability with the upcycle of water as use of
clean water for cleaning.
10 4. The modular and scalable sugarcane processing plant of claim 2, further
comprising a refrigerated silo with agitators configured to store the
concentrated sugar water juice, wherein the refrigerated silo is powered by
the central heating plant.
15 5. The modular and scalable sugarcane processing plant of claim 1, further
comprising a bagasse dryer configured to receive the bagasse from the cane
crushing system and to dry the bagasse using heat recovered from the
central heating plant.
20 6. The modular and scalable cane sugar processing plant of claim 5, further
comprising a pelletizer configured to compress the dried bagasse into fuel
pellets for the bagasse gasifier, wherein the is not limited to matching the
energy production to the rest of the system.
25 7. The modular and scalable sugarcane processing plant of claim 1, wherein
the central heating plant further comprises:
• a heat transfer fluid boiler configured to heat a heat transfer fluid using heat
from the consumable gas; and
• a heat exchanger configured to transfer heat from the heated heat transfer
30 fluid to the sugar cane syrup production segment.
31
8. The modular and scalable sugarcane processing plant of claim 1, further
comprising a water cooling tower configured to cool water heated by the
sugar cane syrup production segment for reuse.
5
9. The modular and scalable sugarcane processing plant of claim 2, further
comprising a reheater configured to heat the sugarcane syrup above 180°F
for pasteurization using heat transfer fluid from the vacuum boiling
system.
10
10. The modular and scalable sugarcane processing plant of claim 1, further
comprising a recirculating water filtration system configured to filter water
from the sugarcane syrup production segment for reuse as domestic water
in the plant.
15
11. A system for producing various unrefined cane syrup in a modular, scalable
sugarcane processing plant comprising:
• a non-centrifugal juice extraction system, which can preserve essential
minerals and nutrients,
20 • a filtration system for removing impurities, while retaining natural
sugarcane compounds;
• a UV light with thin film reactor to prevent yeast, bacteria growth or
fermentation of cane juice;
• a reverse osmosis unit to concentrate sugar while reducing evaporation time
25 and energy consumption;
• a selected use evaporator system;
• a natural filtration system utilizing activated charcoal carbon and
diatomaceous earth to modify color, odor, and flavor intensity postevaporation; for quality and purity;
30 • a recalibration unit for adjusting syrup density and consistency;
32
• a quality control monitoring system ensuring uniformity across batches
through routine calibration and inspection;
• a closed-loop pasteurization system ensuring microbial stability without
chemical preservatives;
5 • a refrigerated storage system to maintain the syrups integrity and extend
shelf life;
• a combined CHP energy system utilizing biomass from bagasse pellets to
generate electricity and thermal energy; and
• a pasteurization element for temperatures above 180°F to hot-packed or
10 HPP and packaging system that preserves syrup integrity without synthetic
additives or excessive refining.
12. The system of claim 11, wherein the evaporation system determines the final
syrup characteristics through the use of (a) a vacuum boiling system at
15 185°F for clear syrups with no caramelization, producing light-colored,
mild-flavored syrup; (b) a flat pan (open pan) evaporator for molasses
production exceeding 70+ Brix, creating a deeply caramelized, full-bodied
syrup; and (c) a steam evaporator as a hybrid system, achieving controlled
caramelization for medium-bodied syrups and higher volume production.
20
13. Sugar cane products produced through the use of the system in claim 1,
wherein the product retains its natural mineral and vitamins content due to
the absence of centrifugal separation, high temperature heat and chemical
bleaching, and wherein
25
(i) has a color and odor intensity are selectively reduced through
activated charcoal filtration, allowing for a range of syrup variations from
dark molasses to lighter, refined syrups;
33
(ii) maintains a low glycemic load and glycemic index, making it a healthier
alternative to refined sugars and high-fructose corn syrup; and
(iii) is storable in temperature-controlled silos to ensure freshness and prevent
crystallization.
5
14. Sugar cane products produced through the use of the system in claim 11,
wherein the product retains its natural mineral and vitamins content due to
the absence of centrifugal separation, high temperature heat and chemical
bleaching and wherein
10
(i) has a color and odor intensity are selectively reduced through
activated charcoal filtration, allowing for a range of syrup variations from
dark molasses to lighter, refined syrups;
15 (ii) maintains a low glycemic load and glycemic index, making it a healthier
alternative to refined sugars and high-fructose corn syrup; and
(iii) is storable in temperature-controlled silos to ensure freshness and prevent
crystallization.