Description of Downstream Products
Downstream production is a core activity of Illovo Sugar, fulfilling the group's strategic intent to optimise the return on every stick of cane by adding value to its core commodity products - fibre, sugar and molasses. The group is a material player in most of the world markets in which it participates, and exports furfural, furfuryl alcohol, diacetyl, 2,3-pentanedione, natural methanol, ethyl alcohol and lactulose to 81 countries. In addition, BioMass Sugar, a liquid organic fertiliser derived from sugar cane, is being sold to a growing number of international markets.
In the financial year to 31 March 2010, downstream production contributed R595 million to total revenue and 7% to total operating profit of R1 499 million. The majority of earnings from downstream production are US$ and Euro-based.
Sezela Downstream plant
| Product Produced | Process | Uses | | 1. Furfural | Formed by hydrolosis (water treatment) of pentosans (found in bagasse, a by-product from the sugar milling process) under specific conditions of temperature and pressure. | It is mainly used for the production of furfuryl alcohol and in lube oil refineries as an extractive solvent in the purification of base oils. It is also used for specialist applications such as the manufacture of grinding wheels, friction pellets for brake pads, crucible manufacture, as a nematicide and to a small extent as a flavour ingredient. | | 2. Furfuryl Alcohol | Produced from furfural via a catalytic hydrogenation process. | It is mainly used to produce a resin used in the foundry industry as a polymeric binder for foundry sands. It is also used for wood treatment, to produce acid resistant coatings, to produce certain pharmaceuticals and as a flavour ingredient. | 3. Crop Guard®
Developed and marketed by Illovo’s “Agriguard” business as an agricultural chemical under the trade names Crop Guard® in South Africa and MultiGuard Protect in the USA.
| Is a uniquely formulated emulsifiable concentrate with furfural as the active ingredient. | Used an agricultural nematicide. | | 4. BioMass Sugar | Derived from sugar cane. | Used as a liquid organic fertiliser. | | 5. Diacetyl | Produced as a by-product of the manufacture of furfural. | It is used as an ingredient in butter flavourings. | | 6. 2,3-Pentanedione | Produced as a by-product of the manufacture of furfural. | It is used as an ingredient in butter flavourings and as an intermediate in the manufacture of pyrazines. | | 7. Natural Methanol | Produced as a by-product of the manufacture of furfural. | It is used in the manufacture of natural flavour ingredients. |
Merebank Downstream plant
| Product Produced | Process | Uses | 8a. Ethyl alcohol*
Potable Extra Neutral Alcohol (ENA) - 96.4%* | Ethyl alcohol is produced through the fermentation of sugar cane molasses, producing a “beer” which is then distilled to make the final product. (Molasses is a by-product of the sugar manufacturing process.) | A very high quality potable alcohol used by liquor industries for the production of branded alcoholic drinks (eg. canes, vodkas, gins, rums, liqueurs and aperitifs). | | 8b. Anhydrous Alcohol - 99.9% | | Used in the pharmaceutical industry to produce pharmaceutical intermediaries and products – for example, in cough mixtures, alcohol is used to dissolve ingredients not able to be dissolved by water. Also used in surgical spirits, medical disinfectants, etc. Used in the production of solvents for use in the printing ink and flexible packaging industries. | 8c. Rectified Extra Neutral Alcohol
(REN) - 96.4%
| | Also has pharmaceutical applications but used mainly in the personal care industry to produce cosmetics, hair care products, toiletries, fragrances and perfumes. Food industry: Used to produce flavours and Spirit Vinegar which is used in various pickling processes and in the production of condiments, e.g. tomato sauce, chutney, mayonnaise and salad dressings. | | 8d. Industrial Alcohol - 95% | | Used in the production of methylated spirits, solvents and thinners. | | 9. Lactulose | Lactulose is manufactured by the isomerisation of lactose using no other solvent than water. | Mild, natural laxative |
* - Potable Extra Neutral Alcohol is also produced at the Glendale Distillery on the KwaZulu-Natal North Coast of KwaZulu-Natal.
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Furfural
Furfuryl Alcohol
Diacetyl
2,3- Pentanedione
Ethyl alcohol
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