Process development of beet sugar factories: Masterplan for the reduction of fossil energies based on technology improvements.

The rising prices of fossil fuels and increasing costs for environmental protection are prompting sugar manufacturers to invest in innovative processes aimed at reducing production costs. As a result, development projects around the globe are primarily focused on minimizing steam and electricity consumption, as well as optimizing the secondary utilization of waste energy and CO₂ emissions. One significant challenge in implementing new technologies at certain sugar factories is the reliance on outdated or under-invested machinery. Depending on the specific technology and processing methods employed in each factory, various scenarios and developmental pathways can be recommended. A major obstacle, particularly for factories with moderate to high energy demands, is the gradual and costly transition required to reach a processing level where these innovative measures can be effectively applied. This paper summarizes insights from a long-term development project involving beet factories, highlighting several technological improvements achieved between 2009 and 2022. It provides a detailed account of experiences in optimizing process technology and reducing manufacturing costs in a form of “master plan” of process development. The contribution presents practical process scenarios of the master plan that have emerged from recent technological advancements. The actual campaign performance is described through footprint balances, leading to identification of possible process modifications. The first scenario focuses on moderate investments aimed at optimizing heat exchange and evaporation. Another scenario discusses the extension of the evaporation station from five to six effects, enhancing optimal vapor utilization. A subsequent scenario examines the impact of low temperature drying on fossil energy demand. Finally, the paper presents a scenario involving vapor compression in both evaporation and sugar house processing. Selected projects are categorized by investment costs, ranging from moderate and mid-term improvements to more strategic investments. The payback period and return on investment are central themes throughout this paper. The primary challenge remains how to reduce the overall energy requirement of the process while simultaneously identifying the right technologies that significantly lower CO₂ emissions in a financially viable manner.