Method of extraction of juice from sugar cane

A continuous countercurrent process is provided of extracting juice from a bed of fibrous material such as sugar cane, the process comprising a plurality of stages, preferably three, with each stage including the removal of air, displacement of juice by a true plug-flow process, and drainage of the displaced juice and displacing medium.

FIELD OF THE INVENTION 
This invention relates to a method of extraction of juice from sugar cane 
for use in the manufacture of sugar. 
BACKGROUND OF THE INVENTION 
In cane, the sugar-rich juice that is required to be extracted, is stored 
in easily ruptured storage cells. Cane preparation methods such as 
shredding are capable of opening up to 94% of these juice-containing 
cells, resulting in a mixture of sugar-rich juice and fibre containing a 
large percentage of the low purity material which is not easily damaged in 
the breakdown of the storage cells. 
Traditional juice extraction methods such as dry pressure extraction, 
leaching and diffusion have been unable to take advantage of the structure 
of the prepared cane, and despite technical advancement, are still 
characterised by low efficiency. 
Theoretically, the isolation of the juice from the fibre may be achieved by 
physically displacing the juice with water. This was recognised as early 
as 1889 by Matthey who obtained UK Patent No. 21021 for his simple 
process. 
According to literature, the displacement is best effected by means of a 
counter-current flow of water and fibre-juice in which the water advances 
as a front (plug-flow) which operates similar to pistons by pushing 
through the ruptured cells and replacing the juice. 
To achieve an efficient plug-flow displacement system, there must be no 
disruptions in the bed of fibre and juice as this would lead to water 
by-passing the material. Further, mixing in the system reduces the 
counter-current flow and consequently expulsion of juice by pressing or 
squeezing is undesirable. 
Consequently the ideal system constitutes an undisturbed bed of fibre and 
juice and a plug-type water and juice flow. 
This ideal situation is difficult to achieve on a commercial scale but can 
be approximated by maintaining the undisturbed bed in a horizontal 
position and breaking down the plug flow liquid displacement into stages. 
The Silver Ring diffuser operates according to this principle but involves 
an 18 stage process where water is added from above a continuous bed, 
flows through the moving bed and drops into a juice compartment below. The 
reason for the length of the process is that mixing takes place preventing 
ideal plug-flow displacement. 
Another factor believed to hinder efficiency is the presence of a large 
volume of air in the bed. Air removal in batch diffusion in the beet sugar 
industry was considered essential. A process known as meichage was used 
commercially in 1930 in the Naudet process of bagasse batch diffusion. 
This involved removal of air by the addition of water from below, the 
advancing front of water carrying the air to the top of the bed from where 
it was released. This has, however, only been possible in a batch process. 
The construction of an efficient plant must be based upon a consideration 
of the structure and volumetric composition of the raw material which in 
prepared cane is characterised by a low bulk density and a high void 
volume (i.e. it is filled with air). 
In order to achieve an efficient extraction process, compaction of the bed 
must be avoided to prevent low percolation rates as well as expulsion of 
juice. Further voids in the bed of cane must be filled to facilitate a 
free flowing mixture of cane and juice. 
It is therefore an object of this invention to provide a method and 
apparatus for the continuous extraction of juice from sugar cane which 
takes advantage of the structure of prepared cane resulting in drastically 
improved extraction efficiency. 
THE INVENTION 
According to the invention, a process for the extraction of juice from a 
bed of fibrous material comprises a continuous countercurrent process in a 
plurality of stages, each stage including the steps of removal of air, 
displacement of the juice by means of a true plug-flow process, and 
drainage of the displaced juice and displacing medium. 
In the preferred form of the invention, the fibrous material prepared is 
sugar cane and the process comprises three stages, the displacing medium 
for stage one and stage two being the juice drained from stage two and 
stage three respectively, while water constitutes the displacing medium 
for stage three. 
Removal of air is achieved by meichage as described above. 
The three stage displacement process of the invention is preferably carried 
out on a conventional horizontal drag type conveyor, the speed of the 
conveyor being set according to the cane flow so that a bed of depth in 
the range 0.3 to 0.5 meters is maintained. This facilitates maintenance of 
a high percolation rate which, with the assistance of increased 
hydrostatic head, is typically 0.1 meters per second. This is a 
significant improvement on the 0.1 meters per minute typically obtained in 
the prior art process. 
In order for efficient extraction to take place, the juice content of the 
megasse must be of the order of twenty times the fibre content of the cane 
(i.e. the fibre content of the megasse must be less than 5%). Under these 
conditions, the megasse (cane fibre and juice) behaves like a liquid. This 
ensures that no mechanical handling of the megasse is required during 
meichage and displacement. 
EMBODIMENTS OF THE INVENTION

In FIG. 1, shredder 10 delivers shredded cane onto the conveyor. The 
conveyor moves at a speed set according to the cane flow so that a layer 
of depth of approximately 0.3 m is moved along over the perforated bottom 
11 of the conveyor. 
Meichage juice is pumped from tank 18 by variable speed pump 13 at 
controlled rate and pressure. The rates maintained are sufficient to 
ensure that the level of the juice just covers the surface of the layer of 
the cane leaving the meichage part (A) of the conveyor. 
In the displacement section (B), displacement juice is fed from overhead 
trough 15 in a rain tray pattern. This prevents mixing and improves the 
efficiency of the displacement and is achieved by delivery of the juice 
onto the upper deck of the conveyor. 
The level of the juice is maintained by means of automatic valves 16 in 
drainage pipes 17. The juice from the displacement (B) and drainage (C) 
sections drains down pipe 17 into tank 18. 
It should be noted that in order to ensure sufficient hydrostatic head for 
the plug flow displacement process and for quick drainage of the megasse 
leaving each stage, the level of juice in the receiving tank 18 in each 
stage must be at least 2 meters, and preferably between 3 to 4 meters 
lower than the level of juice in the conveyor (top of the cane bed). 
This process is repeated in stages two and three, the only variations being 
in the sugar content of the displacement and meichage juices. Displacement 
juice for stage two is the drainage (displaced) juice from stage three, 
while in stage three the displacement juice is actually water from the 
dewatering mill. 
The megasse (cane fibre and juice) is discharged from the conveyor via 
chute 19 into the pre-extractor 20 which is a tilted three roller mill 
designed to remove half the juice content of the megasse. 
The bagasse emerging from the pre-extractor is conveyed via a closed chute 
22 (Meinecke chute) to the base of the conventional bagasse elevator 23 
feeding the (Donelly) chute of the final dewatering mill 24. This mill is 
a conventional four roller mill. 
Turning now to FIG. 2, a cross-flow displacement system is illustrated, 
which is useful for plants with high load capacities. 
In this system, a portion of meichage juice is added from overhead tank 5 
and incorporated into the solid feed (shredded cane) while it is being 
thinned out by macerator 1. The resultant slurry is thrown down curved 
plate 2 into open trough 4. 
At this point, a second portion of meichage juice is added, this time from 
below via the perforated bottom 3 of the open trough 4. The slurry then 
flows under the influence of gravity to the displacement section B. 
The displacement section comprises a curved perforated bottom through which 
the displaced juice flows. To prevent clogging, the bottom is scraped by 
perforated drum 5 which also assists in moving the megasse along once it 
becomes more solid in the drainage section. To this end, the drum is 
fitted with spikes 6 which are welded to the drum in twelve generating 
lines. The scraping action is facilitated by scraper plates 7 welded to 
the tips of each row of spikes 
Displacement juice is admitted inside the perforated drum, above the 
displacement section. 
For that purpose the perforated drum is open at each end. A thick steel 
disk is welded inside the perforated drum, half way between the ends. This 
disc is welded to a hub, wedged to the shaft. The drum is driven by a 
hydraulic or electric variable speed motor, at a speed of 1 to 2 RPM. 
Displacement juice can be admitted inside the perforated drum (in a 
distribution box 8 from each end) (FIG. 3), through the flanges from an 
outside box in which the level of juice can be controlled so that no air 
is admitted. In this way, displacement juice, uniformly distributed over 
the megasse in the displacement section, can flow across and collect into 
the double bottom, from which it drains to the receiving tank below. The 
flow of displaced juice is controlled by an automatic valve on the 
discharge pipe monitored by the level in juice box 9. 
In the drainage section C, air is admitted on top of the bed megasse 
allowing the remaining juice to be drawn down by the hydrostatic head 
between the top of the bed of cane and the level of juice in the receiving 
tank below, via pipe 10. 
The drained megasse is then discharged by the action of gravity, assisted 
by the spikes of the perforated drum, down a 60.degree. slope. To 
supplement the flow properties of the megasse, into the next stage of the 
extraction, meichage juice from that stage is admitted into distribution 
box 11 in the drum, through the flanges located either side thereof. 
The megasse then undergoes the same process twice more in the same 
sequence. 
The importance of the hydrostatic head should be emphasised. 
In commercial diffusers the juice is discharged from the perforated bottom 
in open tanks, so that the hydrostatic head can not be more than the 
thickness of the bed of cane (1 to 2 meters). In fact it is much less due 
to the presence of air in the bed. 
In the present process the juice is collected in a closed bottom. Providing 
that the pipe discharging the juice into the receiving tank below, is kept 
full (by control valve), the hydrostatic head can be increased to 2 to 4 
meters (or more) as it is equal to the difference of level between the 
juice in the bed of cane and the juice in the receiving tank. 
The discharge pipe acts as a barometric leg, pulling down the juice with 
the same driving force as if the level of juice over the surface of the 
can bed were 2 to 4 meters high.