CONTENT Introduction Process Characteristics Treatment of waste water Disposal of waste water production from beet 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. The sludge thus produced is called lime mud. It is dewatered on vacuum filters and the filtrate is recycled. The dewatered lime mud is disposed of the clarified juice is treated with sulfur dioxide to remove its pale yellow colour. Double carbonation may also be done. The juice is then heated further to remove moisture from it and is then passed through vacuum pans and crystallizers for further removal of moisture and to encourage crystallization. Moisture content of the juice at inlet to the crystallizer is about 46%. Centrifugation of the juice separates the crystals from the remaining moisture. This liquid is called molasses and is the raw material for production of alcohol. The sugar crystals sticking to the wall of the centrifuge are scraped off , sieved , graded and packed in bags. PRODUCTION FROM SUGAR CANE Cane, cut from the fields , is washed in water , cut into small pieces and crushed to extract the raw juice. This operation produces a solid waste in the form of bagasse , which is raw material for paper making. The juice is then heated to 102 C , its pH is adjusted between 7.6 and 7.8 with lime and it is settled in multitray clarifiers to remove suspended solid and unreacted lime from juice. Characteristics of waste water streams from various operations Treatment of waste water Plain settling: Data collected from the column settling tests were used to develop families of curves between overall percent removals versus overflow rate and detention time. An equation relating overall removal, initial suspended solids concentration and overflow rate was offered for the design of primary settling tank with initial suspended solids concentration up to 450 mg/l. In order to account for turbulence, inlet and outlet condition and other factors, which can affect settling process in actual practice. A factor ranging from 1.25 to 1.75 and detention time multiplied by a factor from 1.5 to 2.0 . Anaerobic digestion They concluded that UASB reactor offers a viable solution for handling sugar mill waste water. At a retention time of a 6 hours and an average temperature of 26 C, a loading rate of 12.5 kg COD/m per day gave 90% destruction of influent COD and methane production of 0.2 m per kg COD destroyed. The influent required nutrient supplementation; alkali addition at the rate of 0.6 g per gram of influent COD accounted for nearly 70% of the annual running cost. The granular sludge retained 50% of its methanogenic activity even after 100 days of storage. The sludge was found to readily adapt to distillery waste and slaughterhouse wastes. To get 97% removal efficiency of COD a modified rotating biological contactor with four compartments and fed it with synthetic sugar cane waste water to study the biokinetic coefficient based on Kornegay and Hudson model. It also coagulated turbidity from the waste water and removed the colour present in the waste water. Treatment in lagoons It is widely practiced in sugar industry. Aerobic lagoons is possible only if the organic load is limited to 60kg/ha/day. Aerobic pond system can produce a satisfactory quality effluent. This waste is high in carbohydrate but low in nitrogen and phosphorus. Activated sludge process It is adopted where land is not available for constructing ponds. Most full scale plants treating about 5000m/day operate at MLSS of 2000-4000 mg/l. Annul startup may take about 5 weeks to develop MLSS of 2000mg/l with molasses and sewage. A major problem with the activated sludge in bulking , which result in poor settling and rapid loss of biomass from the secondary clarifier. One or more of the following factors may be responsible for bulking, nutrient imbalance , low pH, low DO in aeration tank , high organic loading , greater than 0.7 kg BOD/kg MLSS/day. A BOD:N:P ratio from 100:2.5:0.5 to 100:5:1 was recommended by miller. Trickling filtration On a large scale trickling filtration has not been favoured bcz of long induction period, high recirculation rates for high strength wastes and the risk of blockages . Demonstrated BOD reduction from 70 to 90%. Media used were stone or plastic material. Two stage filtration was done. The use of rotating RBC for treating sugar mill effluent with more than 80% COD removals. The viability of biogas generation from a mixture of press mud and domestic sewage. The maximum COD removal efficiency was found to be 70% with biogas yield of 0.65 m per kg COD. Nitrogen content in the digested sludge was found to be 2.32%. Solid wastes The two solid wastes generated in the manufacturing of sugar are; 1) bagasse 2) press mud. Bagasse is produced during the crushing operation. It has calorific value of about 1920 Kcal/kg and is mainly used as a fuel in the factorys boiler. Press mud contains all non sucrose impurities along with caco3 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. GPCB standers Disposal of waste water Sugar mills are almost located in rural areas, where the raw material is easily available. Therefore disposal of the raw waste water may be done on land for irrigation. Direct disposal into nallas or streams in the vicinity of the mill leads to stagnation and generation of obnoxious small . The waste water also becomes black in colour the characteristics of the waste water show that it can pollute the land as well as ground water. The COD:BOD ratio is favorable for subjecting to the waste water to biological treatment. PRODUCTION FROM BEET Beets are dug of from the fields either mechanically or manually and conveyed to the factory through an open channel called flume. The fruits along the bottom of the flume and get partially washed. The flume end in a screen where the fruits are retained. While the water is collected treated by settling, filtration and disinfection before return to the head end of the flume. The washed beets are passed over a picking table where the spoiled beets and foreign material are removed and disposed of as animal feed. The washed beets are weighed sliced into long ,narrow V shaped pieces called cossettes and conveyed diffuser for extraction for sugar. The raw juice from the diffuser is heated and discharge into the first carbonation tank where it is treated with milk of lime and carbon dioxide. The sugar crystals are separated by centrifugation. The residue beet molasses is either sold or further treated for recovery of sugar by the steffens process. Sugar beet juice can also be treated with ion exchanger for the removal of non sugars from second carbonation before evaporation and crystallization. This increases sugar yield produce less molasses which are treated by ion exchanger and are converted into an edible product.