SUGAR INDUSTRY

Presented by APARNA PRASENAN Enroll. No.-12519001

Sucrose Content in different Sugar types

White table sugar is almost 100 percent pure sucrose. Brown sugar is about 95 percent sucrose. Maple syrup is about 56 percent sucrose. Honey, on the other hand, contains less than 1 percent sucrose. Molasses is about 35 percent sucrose, and 7 percent fructose.

 Depending upon the variety and sowing time it takes about 12 to 18 months to mature. In general January to march is the period of planting and December to March is the period of harvesting. In some states sugarcane is grown round the year.
Season and sowing time Adisali(juneaugust) Pre-seasonal(octnov) Plant population/acre 1700-1900 2000-2400 Crop duration in months 18 15-16

Suru(jan-feb)

6000-9000

12

MATERIAL BALANCE

 Environmental issues in sugar manufacturing projects primarily include the following: Molasses Wastewater Solid waste and by-products Emissions to air

 It has been found that average production of molasses is 4.2% of the cane crushed. Many industries still follow the practice of storing molasses in unlined pits locally termed as kutcha pits. During rainy season and also owing to groundwater table conditions, molasses gets diluted and becomes unsuitable for fermentation. This diluted molasses has a BOD concentration varying between 50000 and 80000 mg/l, which are to be disposed off to the natural water bodies thereby causing heavy pollution.

TREATMENT OF MOLASSES
Molasses serves as the raw material for the distillery industry and is transported to the distilleries unit at frequent intervals. An associated distillery may employ batch or continuous fermentation, followed by distillation, to produce ethanol with a purity of 95%. This ethanol can be used in other industries or further processed and blended with gasoline. Waste from the distillation process is known as vinasse or spent wash. Anaerobic digestion of this waste is used to produce biogas,

Remaining waste can be returned to agricultural fields and / or used in the composting of organic solids emanating from processing.

 Sugar mills consume around 1,500-2,000 litres of water and generate about 1,000 litres of wastewater for per tonne of cane crushed, the effluent is mainly floor washing wastewater and condensate water, leakage in valves of the pipeline add sugarcane juice, syrup and molasses in the effluent, Regarding water consumption and effluent generation, specified standards are 1 ,000 Iltres and 400 litres respectively for per tonne of cane crushed.

There are mainly two effluent streams from sugar industry Cooling water and excess condensate-they dont require much treatment as compared to the house effluents and could be treated separately House effluent-in this category floor washings and mill house washings should be well-treated. Suggested methods are 1. Preliminary treatment 2.Biological treatment

A. Preliminary treatment To remove the inorganic settleable solids, oil & grease matter an oil & grease trap, a catch trap should be provided.

B. Biological treatment
Lagoons Land is available Soil possesses impermeable characteristics Aerobic or/and anaerobic

C. Extended aeration When lagoons are not suitable It is cheap and economical. D. Activated sludge and trickling filters Expensive in view of greater controls and operational costs. Recommended for sugar factories having an installed capacity of more than 5000 TCD

VARIOUS METHODS TO TREAT SUGAR MILL EFFLUENTS

 Most of mills the use bagasse as fuel in boilers, which produces particulate matter, oxides of nitrogen, carbon, sulphur and water. As per general emission standards, particulate matter is required to be within 150 mg/ cubic metre. In case of bagasse fired boilers, the particulate matter emission is within 500-800 mg/ cubic metre

EMISSION RATIO kg CO2eq ton-1 sugar - 241 kg CO2eq ha-1- 2406 kg CO2eq ton-1 sugarcane- 26.5

 1. Wet-Scrubbers (Sugar Units without Co-generation) 2. Electrostatic Precipitator (Sugar Units with co-generation)

ODOUR MANAGEMENT
Recommended measures to prevent or control odour in beet processing facilities include the following: Keep cane processing and storage facilities clean to avoid the accumulation and fermentation of juice Use wet scrubbers to remove odours with a high affinity to water(e.g. the ammonia emitted from the drying of cane pulp) Consider use of bio-treatments

 Generally the solid waste generated in sugar factory can be broadly categorized as Bagasse and Press mud.

Bagasse has a calorific value of 2100 kilocalories per kilogram (kCal/kg) at 50% moisture which is used as a fuel in boilers for steam and power generation.
About 90 96% of bagasse is consumed in this way and the rest of it is either sold to paper mills or hands pressing paper mills and card board manufacturing units.

 Press mud originates from the settled sludge in the juice clarification process. The quantity of press mud varies with the process used for clarification and is in the range of 2 9.9% in the carbonation process. As the press mud of double sulphitation process contains valuable nutrients like nitrogen, phosphorous, potassium, etc., it is used mainly as organic manure and does not pose any problem of disposal.

PRESS MUD CHARACTERISTICS

Biomethanation of spent wash of a 30,000 lpd distillery can yield biogas valued at Rs. 112.54 lakhs per annum and the payback period of the project is only 1.75 years. India is almost entirely dependent upon foreign sources for supply of vegetable waxes. Assuming that refined cane wax is aggressively priced at Rs. 34 per kg, at 70% of price of carnauba was, he country has the potential to manufacture refined cane wax valued at Rs. 306 crores.

 Study of waste control and treatment measures taken by small and medium scale industries in Nepal. Only Sri Ram Sugar Mill Ltd., Rautahat has established Anaerobic Digestion Process (ADP) for the treatment of effluents of sugar and distillery plants which is an advance step for controlling environmental pollution.

SOURCE REDUCTION
Improved harvesting techniques to obtain clean cane Use of aluminum sulphate instead of basic lead sub-acetate in the laboratory testing are examples of input material change. Huge potentials exist for the control of leaks and spills, proper handling and storage of materials Maintaining of proper operating parameters, segregation of waste streams under good housekeeping and operational practices.

OTHER METHODS

Reuse and Recycling Lagoons Anaerobic digestion process

 Sri Ram Sugar Mills Ltd., Garuda, Rautahat has successfully used two-stage Anaerobic Digestion Process (ADP) for the treatment of spent wash from the distillery plant. This is the first effluent treatment plant used by a sugar mill cum distillery plant in Nepal The COD content of the distillery spent wash is very high (more than 100000 mg/l) at a temperature of approximately 1000C.

Current Practices in Nepalese Sugar Mills

Only some newly established Nepalese sugar mills have adopted source reduction concept partially. Recycling and reuse strategy is most popular among Nepalese sugar mills. Recycling of wastewater is not very much common. However, bagasse is commonly Everest Sugar and Chemical Industries Ltd., Ramnagar, Mahottari has been selling its excess bagasse to its sister concern Everest Paper Mills P. Ltd., Mahendranagar, Dhanusha to manufacture different types of paper. The other waste item is press mud which contains minerals and organic matters including wax which can be used for soil

CONCLUSION
1. Solvable issue with proper management 2. Solid wastes can be reused 3. Wastewater is a bigger problem as it cant be recycled easily 4. Anaerobic treatment is better as potentially more cost effective and energy saving. produces less sludge because the energy yield of the process is lower. produces useful gas methane as an end product which can be used to generate steam or electricity. is suitable for treating high polluting industrial waste (high BOD values).

THANK YOU!!!!