Research on the topic Sugar industry " Industrial Waste Water Treatment Plant" .. Among the topics of Sanitary Engineering

1. SUGAR MILL WASTEs
BAGHDAD UNIVERSITY
SANITARY ENGINEERING DEPARTMENT
M.Sc. student : Marwa Mohammed

2. Introduction
• Production of sugar from sugar
cane is a seasonal operation,
depending on the availability of
sugar cane, which lasts from
October to May.
• Sugar can also be produced from
beet, the production activity being
limited to about 100 days in a year.
As a result of its seasonal nature ,
sugar industry presents peculiar
problems for pollution control.

3. Sugar mills have to be located near the sugarcane fields
because:
• sugarcane starts losing its sugar
content as soon as it is harvested. It
needs to be crushed immediately.
• sugarcane is bulky and heavy.
Therefore, its transportation cost is
high.

4. RAW MATERIALS------>>>
 Sugar cane
 Water Lime
 Calcium phosphate
 Sulphur-di-oxide gas
TypesOfSugarsProduced
 The sugarcane is a thick, tall, perennial grassthat
flourishes in tropical or subtropical regions . The reed accumulates sugar
to about 15percent of its weight.
Sugarcane yields about 2,600,000tons of sugarper year.
 The sugar beet is a beetroot variety with the highest sugar content, for
which it is specifically cultivated. About 3,700,000 tons of sugar are
manufactured from sugar beet.

5. Harvesting of sugar can
Fully mature Two types :
 Manual
 Mechanical

6. No Process Waste produce
1 Cut the Can from the fields
2 Washed in water
3 cut into small pieces
4 crushed : to extract the raw juice . solid waste in the form of bagasse
5 Heated to 1020 C with lime
6 Settled in multitray clarifiers to remove suspended solids
and unreacted lime from the juice.
Sludge called 'lime mud'.
7 Dewatered on vacuum filters and the filtrate is recycled The dewatered lime mud is disposed of
8 The clarified juice is treated with sulphur dioxide to remove its
pale yellow colour , Double carbonation may also be done.
9 The juice is then heated further to remove moisture from it
Sugar Manufacturing Process 1 :

7. Sugar Manufacturing Process 2 :
No Process Waste produce
10 Passed through vacuum pans and crystallizers for
further removal of moisture and to encourage
crystallization.
11 Centrifugation of the juice separates the crystals
from the remaining moisture. 'molasses'
molasses
12 The sugar crystals sticking to the wall of the
centrifuge are scraped off
13 Sieved
14 Graded and Packed in bags.

9. PRODUCTION FROM BEET , SUGAR

11. Washing

12. • To remove leaves and nodes
• Hammer mill shredder

15. PRODUCTS OF MILLS

16. • To remove non-sugars and impurities
– Liming
– Sulphitation
– Phosphatation
– Carbonation

17. • Mud from clarifier still contain some residual juice
• Filtered to extract residual juice in Rotary Vacuum Filters
FILTRATION

18. EVAPORATION & CRYSTALLIZATION
• Sugar syrup evaporated up to super saturation
• Crystallization
• Centrifugation to obtain refined sugar crystals

20. PACKAGING
FACTORS
AFFECTING
SUGAR STORAGE
1) Temperature
2) Moisture
3) Quality of sugar
4) Light
5) Grain size and distribution
6) Compression

21. 1. beet are dug from the field
2.convery to the factory in open channel
flume which the end is screen where the fruit
are retained ,water is collect treated by
settling, filtration and disinfection before
return to the head of the end flume
3.picking
4.slicing
5.diffusers
6.carbonation (double)
7.filter
8.treatment with SO2
9.evaporation
10.filter
11.vacuumoan evaporation
12.centrifugation
13.sugar
Production from beet

22. No Process Waste produce
1 Beets are dug up from the fields either
mechanically or manually
2 conveyed to the factory through an open channel,
called 'flume', in which water flows continuously.
3 The fruits roll along the bottom of the flume and
get partially washed.
4 The flume ends in a screen fruits are retained, while the water is collected
treated by settling, filtration and
disinfection before return to the head end of
the flume.
5 The washed beets are passed over a picking table the spoiled beets and foreign material are
removed and disposed of as animal feed.
6 The washed beets are weighed, sliced into long,
narrow V-shaped pieces called 'cossettes‘
PRODUCTION FROM BEET :

23. No Process Waste produce
8 Factories may operate on what is known as 'Straight
House' in which sugar is extracted from the cossettes till a
thick, , heavy molasses is obtained, or on 'Steffens House'
for further extraction of sugar.
heavy molasses is obtained
9 The raw juice from the diffusers is heated
10 discharged into the first carbonation tank where it is
treated with milk of lime and carbon dioxide.
11 Theprecipitateisfilteredorsettledandthefiltrateis
carbonatedasecondtime,againfiltered
The sludge and material retained
on the filters is called 'lime cake'. It
is diluted and discharged as slurry.
12 treated with sulphur dioxide gas with further filtration.
13 The juice is concentrated in multiple effect evaporators,
and filtered
14 sugar recovered by evaporation in vacuum pans until the
desired crystal size is obtained.

24. No Process Waste produce
15 The sugar crystals are separated by centrifugation.
16 The residue, beet molasses' is either sold or further treated
for recovery of sugar by the 'Steffens Process'. This process
consists of diluting the molasses to a specific concentration
17 treating with lime to produce insoluble calcium saccharate,
which is removed from the liquor by filtration
18 introducedintotherawsugarliquoratthemainpurificationstepof
thenormalextractionprocess,wherethesugarisrecoveredby
treatingwithcarbondioxide
PRODUCTION FROM BEET :

25. The Wastes

26. Waste product for each stage

27. LIQUID WASTES :-
Cold water is required in the sugar industry mainlyfor
machinery cooling, daily and monthly cleanings.
The quantity of raw water consumption and wastewater can
be minimized considerablythrough proper re-circulation of
machinery cooling water
reuse of condensate water.

28. Parameters Values
Rate of flow (L/t of cane crushed) 230-1640
pH 4.6-9.5
COD mg/L 600-4380
BOD mg/L 300-2000
TSS mg/L 220-800
COD/BOD Ratio 1.3-2.0
Characteristics of waste waters

29. (i) Bagasse .
extraction of furfural from bagasse, followed by production of single
cell protein (SCP) without appreciably reducing its calorific value,
so that it can be used either as fuel or as raw material in paper
making.
(i) Press mud .
Press mud contains all non-sucrose impurities along with CaC03
precipitate and sulphate Press mud from double sulphitation
contains valuable nutrients like nitrogen, phosphorus, potassium,
etc. and is, therefore, used as a fertilizer. Press mud from double
carbonation is used as a landfill
SOLID WASTES :-

30. USE OF BAGASSE
• To boiler as fuel
• To paper mill
• Used to make paper,
chipboard, animal feed and
also used as a fuel to
produce electricity to run
machinery in sugar mills
• To composting with
distillery spent wash

31. Treatment Of
WasteWater

32. EFFECTS OF THE WASTE ON RECEIVING WATER
o Disposal of the raw waste water may be
done on land for irrigation.
o Direct disposal into nallas or streams in
the vicinity of the mill leads to stagnation
and generation of obnoxious smell.
o The waste water also becomes black in
colour

33. WATER EFFLUENTS
A major source of organic pollutants in the wastewater is
entrainment (the absorption of sugar particles into cooling
and condenser waters) during evaporation and
crystallization processes, which is reduced to some extent
where entrainment separators are used in evaporators and
vacuum pumps. Washing the filter clothes used for sludge
from the clarifier increases the suspended solids
concentration and BOD of the wastewater. In general,
sugar mill effluents contain acidic and alkaline
compounds, a significant concentration of suspended
solids and a high BOD, COD, and sugar concentration.

34. • Lagoons
• Trickling filters
• Upflow Anaerobic Sludge Blanket (UASB) reactors and
• Activated Sludge Treatment (sequential batch reactors).
Available end-of-pipe effluent treatment options
include the use of
costs can be reduced by using this as a secondary treatment after
effluents have been treated with Upflow Anaerobic Sludge
Blanket (UASB) technology. The UASB system, a much cheaper
option because it only requires energy to run a few aeration
pumps, can potentially remove up to 80 – 90 % of the BOD.
WASTE WATER TREATMENT

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