Composting of

Composting of Sugar
Sugar
Mill Waste
Mill Waste

By
By

Mohammad Awais
Mohammad Awais Qureshi
Qureshi
Executive Vice
Executive Vice President
President
Shakarganj Mills
Shakarganj Mills Limited,
Limited,
Jhang
Jhang
 Sugar Industry
Sugar Industry By
By Products
Products

Sugarcane

Milling

Juice Bagasse

Filter Cake Sugar Molasses Particle Board Steam Ash

Alcohol Stillage Surplus Power Power

Biocompost
 Effluent Quantities
Effluent Quantities in
in
M.Tons (PAKISTAN)
M.Tons (PAKISTAN)
By Product % on Quantity
Cane Million Tons.
Bagasse % 30.95 13.30
Filter Cake. % Cane 3.00 1.29
Molasses % Cane 4.87 2.09
Stillage - 0.54
Ash % C 2.5% of 0.33
Bagasse % C
 Sugar Industry
Sugar Industry By
By Products
Products
and Chemical
and Chemical Used
Used
By Source Chemical Purpose of Use
Product Used
Filter Cake Clarification CaO Separation of Phosphates
& Other Impurities from
Juice
Bagasse Milling _ _
Molasses Centrifugation _ _
H3PO4 To provide nutrients to
microbes
Stillage Distillery NH4NO3 To provide nutrients to
microbes
H2SO4 To adjust pH
 General Characteristics
General Characteristics of
of
SML Emissions
SML Emissions
Parameter NEQs
Effluent:
Quantity (m3/day) 4272
COD (mg/l) 1787 150
TSS (mg/l) 879 150
pH 6.5 6 10
Air Emission:
NOx (mg/Nm3) 30 400
COx (mg/Nm3) 346 800
PM (mg/Nm3) 219 300
 Some Logical
Some Logical Solutions
Solutions
(Triple R)
(Triple R)

Adoption of cleaner production options

a) Reduce b) Recycle c) Re-use
Biocomposting of filter cake & stillage /
Sugar Mills waste water
Use of Sugar Mill water for Irrigation
purpose
 Liquid Waste
Liquid Management
Waste Management

Turbine Bearing Cooling Recycled to Service Pit

(Mill & Power House)
Process Cooling
(SO2 Furnace, Vacuum
In House Lagooning
Pump, CO2 blowers &
Streams

boiler blowdown)
Total Recycling
Surplus Condensate
(Mills, Process, Distilley)

Spray Pond overflow

Irrigation
Floor washing
Sugar, Mills, Distillery
Distillery Spent Wash Composting Plant
Condensate Water
Condensate Water Management
Management

Sugarcane Close Circuit Use

Massecuite Cooling
Vacuum Pumps

Milling Distillery
Floor Washing

Recycling Condensate
Clarification (Hot Water)
Dilution of
Run Offs
Evaporation Washing of
Crystallization Sugar Crystals
Make up of
Spray Pond
Sugar Condensate
Boilers
(Steam Generation)
 Lagoon Water
Lagoon Water Management
Management

Sulphur Station Outlet

Lagoon-2
Vacuum Pumps
Lagoon-2
CO 2 Scrubber

Inlet Lagoon-1
CO 2 Compressor
Outlet
Air Compressor Lagoon-1

Boiler Feed Pumps

Lagoon-1 Irrigation of
Boiler Blowdown in house
Plantation
Lutter Water
 Biocomposting
Biocomposting

It is a process to treat effluents

making an environment
friendly stable product
which could increase
the productivity of
Soils and Plants
 Biocomposting at
Biocomposting at Shakarganj
Shakarganj
Filter Cake
Add Organic Stillage
Ash Matter and
Phosphates yAdd K, N, P,
Add K and Fe, Mn, Zn,
other Minerals Cu, B and
Yeast Cell
BIOCOMPOST
Aeration Microbes
(Trichoderma)
y Fast Composting
yControl of Obnoxious ySingle Cell Protein
Gases yMake the Product
yEnvironmental
Friendly Stable
COMPOSTING PLANT
COMPOSTING PLANT
COMPOSTING PLANT
COMPOSTING PLANT
COMPOSTING PLANT
COMPOSTING PLANT
COMPOST
COMPOST
COMPOSTING PLANT
COMPOSTING PLANT
COMPOSTING PLANT
COMPOSTING PLANT
 Capacity of
Capacity of Compost
Compost Plants
Plants

Particulars Quantity Units

Weight of filter cake 350 T/day
Specific gravity of filter cake 610 Kg/m3
Vol. Of filter cake 574 m3/day
Vol. Of compost plant-I 3084 m3
Effluents handling capacity of plant-I 5.37 Days
Vol. Of composting plant-II 3644 m3
Effluents handling capacity of plant-II 6.35 Days
Total effluents handling capacity of both plants 11.72 Days
 Comparison of
Comparison of Filter
Filter Cake,
Cake,
Stillage and Biocompost
Stillage and Biocompost

Parameters Filter Cake Stillage Biocompost

PH (1:10) 7.0 - 7.2 4.2 4.7 6.5 7.2
-1
EC (dSm ) 16 - 20 27 32 40 60
(1:10)
Total N (%) 1.50 1.60 0.13 0.22 1.45 1.70
Total P(%) 1.15 1.25 0.05 0.09 1.35 1.55
Total K(%) 0.75 1.00 0.90 1.10 3.30 3.80
Organic 65 75 55 60 55 - 65
Matter (%)
 Rate of
Rate of Consumption
Consumption ofof
Stillage in
Stillage in Filtercake
Filtercake

Days Stillage Rate of Stillage

Consumption (%) Consumption (%)
th
5 27 27
th
10 20 47
th
15 25 72
th
20 20 92
th
25 25 127
 Effect of
Effect of pH
pH on
on Compost
Compost
in different
in different time
time period
period
S.No Months Fresh 5 10 15
Days
1. Nov.1999 6.92 6.81 6.43 6.41
2. Dec. 1999 7.30 7.07 6.80 6.73
3. Jan. 2000 7.46 6.69 6.68 6.80
4. Feb. 2000 7.24 6.37 5.85 5.72
5. Mar. 2000 7.11 5.92 5.63 5.60
Mean 7.20 6.52 6.27 6.25
 Effect of
Effect of Time
Time on
on Maturity
Maturity
of Compost
of Compost

Maturity PH E.C. O.M. N P K

(Days) (dS m -1) (%) (%) (%) (%)

12 6.40 75 68 3.36 1.46 1.36

15 6.36 93 63 3.70 1.50 1.42

18 6.32 100 60 3.82 1.58 1.44

21 6.30 110 58 3.97 1.64 1.46

 Nature To
Nature To Nature
Nature

Sugarcane Milling Juice Clarification Syrup

Crystallization

Sugar
Agricultural
Fields Filter Cake Molasses

Fermentation

Alcohol
Organic
Fertilizer
Biocomposting Stillage
 Utilization of
Utilization of Biocompost
Biocompost produced
produced from
from
Filtercake and
Filtercake and Stillage
Stillage at
at
Shakarganj Sugar
Shakarganj Sugar Research
Research Institute,
Institute, Jhang
Jhang

Duration: Sept., 1991 to Nov., 1992

N P2O5 K2O Yield % Yield
Treatment ------(Kg/ha)------ (Compost) (t/ha) increase
over (T1)
T1 0 0 0 0 58.50 -
T2 0 0 0 20 131.00 126
T3 100 0 0 0 112.80 95
T4 100 0 0 20 147.70 152

Conclusion:Combination of biocompost and Urea produced cane

yield of 147.70 t/ha with Net Farm Income of Rs. 22348 per ha.
Pak. Sugar Journal April-June, 1994.
 Effect of
Effect of Biocompost
Biocompost on
on Sugarcane
Sugarcane Crop
Crop
Duration: March,
Duration: March, 1992
1992 to
to January,
January, 1993
1993

N P2O5 K2O Yield

% Yield
Treatment ------(Kg/ha)------ (Compost) (t/ha)
increase
over (T2)
T1 0 0 0 0 112.10 -
T2 100 100 50 0 115.70 -
T3 0 0 0 25 127.40 10.11
T4 100 100 50 25 133.80 15.64
T5 100 100 50 50 146.60 26.70
Conclusion: Biocompost increased the efficiency of nitrogen,
phosphorus and potassium, thus saving in the use of costlier
chemical fertilizers through complimentary effect.
Pak. Sugar Journal July-September, 1994
 Response of Sugarcane to Biocompost
Prepared from Filter Cake and Stillage
Duration March, 1992 - March, 1995

N P 2 O5 K 2 O Yield % Yield
Treatment ------(Kg/ha)------ (Compost) (t/ha) increase
over (T 1)
T1 0 0 0 0 65.70 -
T2 150 100 0 0 73.10 13
T3 0 0 0 25 95.60 46
T4 150 100 0 25 101.0 55
T5 75 50 0 25 99.50 52

Conclusion:Utilization of biocom post was the best way to exploit

the environm ent polluting effluents and to im prove the soil and
plant health.
Submitted for publication
 Significance of
Significance of Ethanol
Ethanol Stillage
Stillage for
for Soil
Soil and
and
Crop Improvement
Crop Improvement Duration
Duration 1992
1992 -- 1995
1995

Crops N P2O5 K2O Yield % Yield

------(Kg/ha)------ (Stillage) (t/ha) increase
over (T1)
Sugar T1 170 89 0 1:2 ratio 72.00 -
cane T2 86 44 0 (6-irrigations) 95.00 32
Wheat T1 113 70 0 1:20 ratio 3.20 -
Grain T2 56 35 0 (2-irrigations) 4.55 63
Paddy T1 113 70 0 1:20 ratio 2.31 -
T2 56 35 0 (4-irrigations) 3.35 44
Maize T1 142 70 0 1:20 ratio 38.50 -
Fodder T2 71 35 0 (3-irrigations) 50.00 32
Conclusion:Application of Stillage to soil increase the yield of all crops by providing
the plant nutrients. Recycling of stillage to the fields is the best way to exploit this
polluting effluent. Pak. Sugar Journal. Jan-Feb, 1999
 Effect of
Effect of Biocompost
Biocompost on
on Paddy
Paddy
Crop during
Crop during 1994
1994

Treatment Yield % Yield

N P2O5 K2O Compost (t/ha) Increase
(t/ha) over
control
T1 0 0 0 0 2.0
T2 116 70 0 25 2.5 25
T3 0 0 0 25 3.0 50
T4 58 0 0 25 3.1 55
Use of compost in Paddy Crop increased 55% yield, saved half
nitrogen and all Phosphorus and Potassium (Unpublished)
 Effect of
Effect of Biocompost
Biocompost on
on Maize
Maize
Fodder Crop
Fodder Crop during
during 1994
1994

Treatment Yield % Yield

N P2O5 K2O Compost (t/ha) Increase
(t/ha) over
control
T1 0 0 0 25.0
T2 140 65 0 0 28.2 12.8
T3 0 0 0 20 32.6 30.4
T4 70 0 0 20 37.5 50.0
Application of compost increased 50% yield of main fodder and
saved 100% phosphorus and potassium and 50% nitrogen
(Unpublished)
 Effect of
Effect of Biocompost
Biocompost & & Chemical
Chemical
Fertilizers on
Fertilizers on Wheat
Wheat Crop
Crop Sowing
Sowing
Date: Nov.
Date: Nov. 1993
1993
N P2O5 K2O Yield % Yield
Treatment ------(Kg/ha)------ (Compost) (t/ha) increase
over (T1)
T1 0 0 0 0 2.171 -
T2 0 0 0 15 2.849 46
T3 50 0 0 15 4.632 138
T4 50 50 0 15 4.863 139

Conclusio n:Use of biocompost saved half nitrogen and

phosphorus and all potassium with a significant increase in wheat
grain yield.
Journal of Animal and Plant Science vol. 4, No. 3-4 (1994)
 Response of
Response of Wheat
Wheat Crop
Crop to
to Bicompost
Bicompost
in Sandy
in Sandy Soil
Soil (Duration:1998
(Duration:1998-99)
-99)

Parameters Without With

Compost Compost
No. of Tillers per Plant 3.00 10.00
No. of Grains per Spike 34.00 81.00
100 Grains Weight (g) 3.10 4.00
Straw Yield Maunds per Acre 31.00 120.00
Grain Yield Maunds per Acre 20.00 65.00
% increase in Yield - 225.00
Conclusion: Biocompost increased the Yield of Wheat Grains to
about three fold in Sandy Soils which were highly deficient in
Organic Matter.
 Wheat crop
Wheat crop in
in Sandy
Sandy Soil
Soil

With bio-compost Without bio-compost

 Response of
Response of Wheat
Wheat to
to
Bio-compost
Bio at maturity
-compost at maturity
Recommendations
1. The decomposition of Sugar Mill
Waste to be adopted by all the Sugar
Mills
2. Biocomposting Plants to be
popularized in the main cities with a
view to decompose organic waste
specially from fruit and vegetable
markets
Recommendations
3. The organic garbage from the cities is
recommended to be collected
specially in order to decompose the
stuff
4. All the decomposed material to be
recycled to agricultural farms to
reduce fertilizer costs and improve
crop yields