The document discusses wastewater treatment in the sugar manufacturing process. It begins by providing an overview of the sugar manufacturing process and sources of wastewater generation at different stages. This includes wastewater from mill houses, boiling houses, boiler blow-downs, condenser cooling water, and soda/acid washes. Key characteristics of the wastewater like COD, BOD, pH, TSS are then described. Discharge norms for the sugar industry as per CPCB are listed. Conventional treatment involves an activated sludge process, while other options discussed are anaerobic lagoons, UASB, UBF reactors. A case study is summarized on treating sugar wastewater using a UAS

1. Wastewater
Engineering[3160513]
Government Engineering College,
Valsad
Chemical Engineering
Department
Project Work
Sr.no Enroll. no Name
1. 190190105003 Ajudiya Meetkumar . o
2. 190190105015 Chauhan Yashkumar .
Y
3. 190190105036 Jadav Chirag . A
4. 200190105524 Das Rakesh

2. Topics
Introduction of the sugar manufacturing process.
Wastewater generation sources during the sugar
manufacturing process.
Wastewater characteristics,
Discharge norms[standards].
Treatment flow diagram [based on case study or
book reference].
Any advancement in treatment.
Reference.

3. INTRODUCTION OF THE SUGAR
 What is a sugar ?
 Sugar is one type of sucrose.
Where basic material for human
being.
 It’s plant synthesized
carbohydrate & is a rich source
of energy.
 It’s a disaccharide of glucose &
fructose molecules.
 Molecular formula is
C12H22O11.

4. Source of
sugar
Sugar can be obtained from
1.Sugar cane
2.Sugar beet
 Sugar cane
It’s a juice plant which is
thick wall perennial grass
and grown in tropical &
subtropical regions.
Composition: it contains

5. Sugar
beet
It’s a tuberous root
which stored food. It
has high sugar
content.
Composition: it
contains 15-20%
sucrose.

6.  Composition of
sugarcane

7. Sugar manufacturing
process
Washing
Cutting & shredding
Extraction of juice
Clarification of juice/purification of juice
Concentration of juice & crystallization
Refining of sugar
Drying & packaging

8. washing
Washing with worm
water remove the
dust particle, rocks,
trash etc…
Cutting &
shredding
Sugarcane cut into small
piece with the help of cutter
& knifes.
Shredding: shredding cut
the cane into finest particles
this cut cane into

9. Extraction of
juice
Freshly cutting and shredding cane
is transported towards a series of
roller milles to extract juice.
Hot water is sprayed to facilitate
extraction.
Vesou
s
The extracted juice is
called Vesous. It
contains 95% or more
sucrose.
Purpose: sucrose
obtained from this juice
Baggas
Cellulosic material left after the
extraction of juice is known as
baggas.
It’s use as
Animal feed
As boiler fuel
Manufacturing of good quality

10. Clarification / purification
of juice
Extracted juice is dark
green colour so it
requires clarification.
Step
s
a]
Defecation
b]Coagulati
on
c] Filtration

11. a]
Defecation
In this process raw juice is
treated with limewater &
heated with steam.
purpose: to remove organic
acids.
Chemical
reaction
COOH COO
| + Ca[OH]2 | Ca +
2H2O
COOH COO
Oxalic acid calcium calcium
water
b]
Coagulation
By adding lime and
agitation cause
coagulation of colored &
nitrogenous compounds
and come on surface.
This coagulated material is
known as scum.
c] Filtration
Coated drum filters are
used to remove non
sugar impurities like
scum & precipitates.

12. d]
Carbonation
In this process, defecated
juice is treated with CO2.
purpose: To remove excess
Ca[OH]2 & to recover
sucrose from calcium
sucrate.
e]
Sulphitation
In this process,
defecated juice is
treated with SO2.
Purpose: To remove
excess Ca[OH]2 & to
recover sucrose from
calcium sucrate
Chemical reaction
Ca[OH]2 + CO2 CaCO3 +
H2O
Calcium Carbone calcium
water hydroxide
Chemical
reaction
Ca[OH]2 + SO2 CaSO3 +
H2O
Calcium sulfur calcium
water

13. Concentration & crystallization
of sugar
 Concentration
Purified juice contains 70-
75% water contents. To
remove water, juice is
evaporated for this purpose
following are used.
Multiple effect evaporator
Vaccum pan

14. crystallizatio
n
The concentrated sugar
[massecites] is further
crystallized for this purpose
following are used
Crystallizer
centrifugation

15. Refining of sugar
 Raw sugar
It contains 97.8% sucrose
and brown in colour. It is
required to be refined.
Refining of
sugar
Raw sugar from remove the colour.
Colour remove for use components
are
• Charcoal
• Polyethersulphone [PES]

16. Drying & packaging
Drying
Sugar drying remove excess
moisture from the sugar using
heat, while cooling the sugar
brings it to an ideal
temperature for storage and
transport
packagi
ng

17. Sugar manufacturing flow
diagram

18. Sugar manufacturing
process

19. Wastewater generation source during the sugar
manufacturing process
Mill house:
The effluent consists of water used for cleaning
the mill house floor which is liable to be
converted by spills and pleased sugar juice (This
clearing up operation will prevent growth of
bacteria on the juice-covered floor).Water used
for cooling of mills also forms part of the waste
water from this source. Basically this water
contains organic matter like sucrose, bagacillo, oil
and grease from the bearings fitted in to the

20.  Waste Water from Boiling House:
 The waste water from boiling house results from
leakages through pumps, pipelines and the
washings of various section such as evaporators,
juice heaters, clarification, pans crystal is action,
and centrifugation etc. The cooling water from
various pumps also forms part of water.
Waste Water from Boiler Blow-down:
The water used in boiler contains suspended
solids dissolved solids like calcium salts,
magnesium salts, sodium salts, fatty salts etc.
These salts get concentrated after generation
stream from the original water volume. These
solids have to be expelled time to time to save

21. Excess Condensate:
The excess condensate does not normally contain any
pollutant and is used as boiler feed water and the washing
operations. Sometimes it gets contaminated with juice due
to entertainment of carry over of solids with the vapors
being condensed in that case if goes in to the waste water
drain. The treatment requirement in this case is almost
negligible and can replace fresh water or let out directly as
irrigation water after cooling it to ambient temperature.
Condenser cooling water:
Condenser cooling water is recirculated again unless it gets
contaminated with juice, which is possible due to defective
entrainment separators, faulty operation beyond the design
rate of evaporation etc. if gets contaminated, the water
should go into the drain invisibly. This volume of water is
also increased by additional condensing of vapor of trained

22. Soda and Acid Wastes:
The heat exchangers and evaporator are cleaned with
caustic soda and hydrochloric acid in order to remove the
formation of the deposits of scales on the surface of the
tubing. In India, most of the sugar factories let this
valuable chemical go into drains. The soda and acid wash
contribute considerable amounts of organic and inorganic
pollutions and may cause shock loads to waste water
treatment once in a fortnight or so.

23. Wastewater characteristics
 Physical
Characteristics
• Turbidity
• Color
• Odor
• Total solids
• Temperature
 Chemical
Characteristics due to
Chemical Impurities
• Chemical
Oxygen Demand
(COD)
• Total Organic
Carbon (TOC)
• Nitrogen
• Phosphorus
• Chlorides
• sulphates
• Alkalinity
• pH
 Biological
Characteristics due to
Contaminants
• Biochemical
Oxygen
Demand
(BOD)
• Oxygen
required for
nitrification
• Microbial
population

24.  Physical Characteristics of
Wastewater
• Color - Fresh sewage is normally brown
and yellowish in color but over time
becomes black in color.
• Odor - Wastewater that includes sewage
typically develops a strong odor.
• Temperature - Due to more biological
activity, wastewater will have a higher
temperature.
• Turbidity - Due to suspended solids in
wastewater, wastewater will have a higher

25. Chemical Characteristics of
Wastewater
• Wastewater contains different chemicals in various forms as mentioned
below.
• Chemical Oxygen Demand (COD) - COD is a measure of organic materials in
wastewater in terms of the oxygen required to oxidize the organic materials.
• Total Organic Carbon (TOC) - TOC is a measure of carbon within organic
materials.
• Nitrogen - Organic nitrogen is the amount of nitrogen present in organic
compounds.
• Phosphorous - Organic phosphorous (in protein) and inorganic phosphorous
(phosphates, PO4- )
• Chlorides (Cl-)
• Sulphates (SO4-2)
• Heavy metals
Mercury (Hg) Arsenic (As)

26.  Biological Characteristics of
Wastewater
• Biochemical Oxygen Demand (BOD) - BOD is the amount of
oxygen needed to stabilize organic matter using
microorganisms.
• Nitrogenous Oxygen Demand (NOD) - NOD is the amount of
oxygen needed to convert organic and ammonia nitrogen into
nitrates by nitrifying bacteria.
• Microbial life in wastewater - Wastewater contains the following
microbes:
• Bacteria
• Protozoa
• Fungi

27. Sr. no Industry Parameters Value
1. Sugar industry PH 5.5-8.5
TSS mg/l 100 [for
disposal on
land]
30 [for disposal
surface waters]
BOD mg/l 100[disposal on
land]
COD mg/l Less than 250
TDS mg/l 2100
Oil & grease 10
Discharge norms for
wastewater of sugar industry
Following the table vales for discharge
wastewater of sugar industry

28. Discharge norms are determined of central
pollution control board[CPCB]
CPCB established September,1974.
[CPCB] of India the permissible limit of
wastewater discharge is l <350BOD mg/l at 27c
for 3 days.
The final treated effluent discharge has been
restricted to 100 litter per tonne of cane crushed
& wastewater from spray pound overflow or
cooling tower blow down to be restricted to
100littres per tonne of cane crushed.
Final wastewater discharge limit 200 litter per

29. Sugar industry wastewater
treatment flow diagram
Conventional treatment method:
The conventional system of treating wastewater is by
activated sludge process[ASP] from various units of a sugar
plant. The various units include bar screen ,skimming tank,
equalization basin , aeration unit, clarifier and sludge drying
beds.
Other treatment options:
Anaerobic lagoon technique.
Anaerobic digestion.
Up flow anaerobic sludge blanket [UASB].
Up flow blanket filter[UBF].
Aerobic bioconversion.
Fixed film fixed bed reactor.

30. Sugar wastewater treatment flow
diagram
Book reference: International journal of
environmental sciences volume 1
Schematic flow diagram of UASB

31. Anaerobic treatment of sugar industry
wastewater by Upflow anaerobic sludge
blanket reactor at ambient temperature
 Sugar industry wastewater was treated in a UASB reactor seeded with nongranular
anaerobically digested sewage sludge. The ambient room temperature during the study
period was between 29-37 C . Successful reactor startup with granulation was achieved
within 95 days of operation. The reactor was started with an OLR of 0.5 g COD/L. d. and
was loaded up to 16 g COD/L. d. During startup the HRT was reduced from 48-8 h.
The optimum HRT was found as 6 h. After the startup
the loading was increased at constant HRT of 6 h by increasing the COD concentration of
the feed. A maximum COD removal efficiency of 89.4% was achieved. The COD removal
rate linearly increased with increase in OLR. The ratio of VFA to alkalinity was varied
between 0.19-0.33 during the treatment. Maximum volumetric biogas production was
4.66 L/L. d. at OLR of 16 g COD/L. d. The methane content in the biogas was found
to be between 73 and 82% at steady state conditions. After reaching an OLR of 16 g
COD/l. d. the loading was increased by reducing HRT to 4 h. Reactor
performance deteriorated when loading increased to 24 g COD/L. d. It
was concluded that sugar industry wastewater can be treated at maximum loading of 16 g
COD/L. d. at low HRT of 6 at ambient temperature.

32. Laboratory scale UASB flow
diagram

33. Results:
 The reactor was started with an initial organic loading rate (OLR) of 0.5 g
COD/L . d at a constant hydraulic retention time of 48 h . The study
was conducted under ambient environmental conditions. The
OLR was increased from 0.5 to 1 g COD/L. d by decreasing the
HRT stepwise from 48 hours to 24 hours during initial 35 days of
operation. On the day 36 the COD concentration of the substrate increased
to 2000 mg/L at HRT of 24 h resulting in increase of OLR to 2 g
COD/L. d. Then the OLR was increased up to 16 g COD/L. d. by reducing
HRT stepwise from 24 to 6 h. The ambient room temperature during most of
the period of the study varied between 29 C and 37 C.
Conclusions:
 Startup of an UASB reactor can be achieved within 99 days
with anaerobic nongranular sludge and sugar industry
wastewater as substrate. UASB design is feasible to treat sugar
industry wastewater efficiently up to an OLR of 16 g
COD/L. d. with a COD removal efficiency of 89% at much
lower HRT of 6 h. Methane rich (more than
75%) biogas can be produced at the rate of 4.66 L/L. d.

34. Reference:Hampannavar, U.S ,
Shivayogimath, C.B, Anaerobic
treatment of sugar industry
wastewater by Upflow anaerobic
sludge blanket reactor at ambient
temperature, International Journal Of
Environmental Sciences Volume 1,
No 4, 2010.

35. Any advancement in
treatment
Expansion of the sludge bed.
In additional tall column configuration is
frequently adopted to further increase the flow
velocity.
This optimum temperature to achieved to
enhance methane gas production[27-39].
The PH is very important variable in the UASB
process. When the PH in the reactor is too low
[<6], the consumption of fatty acids gets
strongly inhibited. if the PH is too high [>8], the
bacteria are limited in their growth by low

36. References
Letting, G. and Hulshoff Pol, L.W., 1991. “UASB process design for various
types of wastewaters”. Water Science and Technology, 24, pp 87107.
Mehrdad Farhadian, Mehdi Borghei and Valentina V. Umrania,
2007. “Treatment of beet sugar wastewater by UAFB bioprocess”, Bioresource
Technology, 98, pp 3080 3083
Mijaylova Nacheva, P., Moeller Chávez, G., Matías Chacón, J. and Canul
Chuil, A., 2009. “Treatment of cane sugar mill wastewater in an upflow
anaerobic sludge bed reactor”. Water Science and Technology, Vol. 60, No. 5,
pp 13471352.
Hampannavar, U.S , Shivayogimath, C.B, Anaerobic treatment of sugar
industry wastewater by Upflow anaerobicsludge blanket reactor at ambient
temperature, International Journal Of Environmental Sciences Volume 1, No 4,
2010.
G.Lettinga and L.W.Hulshoff Pol, UASB Process Design for Various types of
Wastewaters, Wat.Sci.Tech.Vol.24. No.8, pp.87-107, 1986.
Guruprasad H. Huger, Anaerobic Treatment of Sugar Industry Wastewater

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