fUTURECYCLING
Technology a.s.

In the purification process, the RECLIME® system continuously recycles calcium compounds (Ca²⁺), mainly in the form of crystalline calcium carbonate (CaCO₃) with adsorbed non-sugars, separated as carbonation slurry. This enables the substitution of fresh lime (CaO) by recycled calcium compounds (Ca²⁺) within the purification process.

A selected portion of the carbonation slurry is hydromechanically processed and divided into two flows in the patent-protected RECLIMER: a concentrated CaCO₃-rich fraction (HPH) suitable for recycling and a lighter fraction (RPH) containing the majority of non-sugars. The RECLIME® system uses the HPH fraction for controlled recycling. Chemical reactivation is achieved by the addition of milk of lime containing active lime (CaO), with continuous processing into RECLIME® milk in the reactor.

RECLIME® milk is applied at selected stages of the purification process, particularly during preliming. It acts as a filtration and purification agent with high adsorption capacity for non-sugars and strong agglomeration properties.

The RECLIME® system provides real-time process monitoring and control. It integrates advanced automation and digitalisation to ensure precise and reliable dosing of RECLIME® milk throughout the purification process. The process is continuously monitored to prevent excess lime (CaO) at any stage of purification, ensuring consistent process conditions and optimal utilisation of calcium compounds (Ca²⁺).

The installation and operation of the RECLIME® system result in significant operational cost savings through reduced consumption of lime (CaO), raw materials, and energy. Fresh lime (CaO) consumption can be reduced by 25–60% compared to conventional operation, depending on process conditions.

The expected return on investment for a RECLIME® unit is typically 4–6 years. This makes the system not only a purification technology, but also a practical investment in more resource-efficient and cost-efficient sugar production.

For a sugar factory producing approximately 100,000 tonnes of sugar annually, the application of the RECLIME® system can reduce limestone consumption by 4,670 tonnes, coke consumption by 440 tonnes, filtration cake production by 6,920 tonnes, and total CO₂ emissions by 3,240 tonnes. This corresponds to operational cost savings of €3.5–6.2 per tonne of white sugar produced.

In addition to economic benefits, RECLIME® delivers a measurable reduction in environmental impact and resource use. It reduces CO₂ emissions, raw material demand, and transport requirements through lower consumption of limestone and coke, as well as reduced filtration cake production in the purification process.

Under typical operating conditions, this corresponds to a reduction of 3.5–6.9 tonnes of CO₂ per 1,000 tonnes of processed beet, together with a reduction in transported raw materials and by-products of 13–26 tonnes per 1,000 tonnes of processed beet. For a sugar factory processing around 1.2 million tonnes of beet per campaign, this represents a reduction of 5,830 tonnes of CO₂ emissions and a decrease in transported materials of 21,660 tonnes annually.

Additional process benefits include reduced milk of lime consumption, reduced filtration cake volume and filterpress cycles, reduced sugar losses in filtration cake, lower water demand for desweetening and lime slaking, reduced pumping demand, lower wear and load on key equipment, real-time process control for stable purification, and increased competitiveness through lower operating costs.