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Water and Wastewater Minimization: A Case

Study of Lokmangal Sugar & Co-Generation
Industries Ltd, Bhandarkavathe

Article · August 2014

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 International Journal of Civil and Environmental Engineering, ISSN:1701-8285, Vol.36, Issue.2 1261

Water and Wastewater Minimization: A Case

Study of Lokmangal Sugar & Co-Generation
Industries Ltd, Bhandarkavathe
Prof. G. K. Deshmukh1
Chairman, Vidya Vikas Pratishthan, Solapur, Maharashtra, India
Email-id: gkdeshmukh155@rediffmail.com
Avinash A. Patil2
Student, Department of Technology, Shivaji University, Kolhapur, Maharashtra, India
Email-id: avipatil236@gmail.com
Sameer Salgar3
Chief Engineer, Lokamangal Sugar & Co-generation Industries Ltd., Solapur, Maharashtra, India
Email-id: sameer.salgar@lokmangalgroup.com
Capt. (Dr.) Nitin P. Sonaje4
Dy. Registrar, Shivaji University, Kolhapur, Maharashtra, India
Email-id: nitinsonaje@yahoo.co.in
ABSTRACT
The darker side of growth of the sugar industries in the
Sugar manufacturing process requires considerably a large country is environmental deterioration. i. e. water, soil and
amount of water. Waste water generated also is huge. air pollution. These environmental problems are affecting
Reducing the water consumption for industrial process is the future prospects for sugar industry development in the
challenging task. Conservation of this resource is country. The pollution prevention practices and waste
significant in the aspect of environmental and economical treatment methods require particular circumstance for
sustainability. success. Treatment processes are to be altered to suit the
Water and wastewater minimization is possible by Indian versatile climatic conditions. In the state of
implementing the optimum water utilization techniques. Maharashtra which is leading state for production of sugar
As cane it-self contents @ 67.5% of water out of which in India, there are few Industries who have kept the pace
13.4% goes in bagasse, 2.6% in Filter cake & 0.6% in with change in time and have not only conceptualized the
Final Molasses. Excess condensate water generated from necessary changes but have implemented them through
the process can used back in the process, reducing the cold their innovative ideas and now stand out as the success
water required for the cooling & other purpose. This stories in sugar industries sector.
excess condensate water can also be used for Turbine Lokmangal Sugar Ethanol & Co-generation Industries Ltd.
cooling towers as make up. A treatment of Aeration is to Is established in 2007 with crushing capacity 2500 TCD
be provided prior its usage in cooling tower. and, co-generation power plant capacity of 15 MW,
Keywords - Water minimization, sugar industry, Water situated at Bhandarkavthe, Tehsil: South Solapur, Dist.:
balance, Wastewater minimization. Solapur, at a distance of about 35 Kms. from Solapur city.
Since its inception the factory has adopted various policies
1. INTRODUCTION in the fields of cane development, technical efficiency and
water management. The factory has the present crushing
India is mainly an agro based country. The sugar factory is capacity of 6000 TCD with co-generation power plant
one of the most popular and second largest agro based capacity of 31.5 MW.
industries and there are about 600 sugar industries in India
as on 2013. These industries are playing a vital role in Over the past years, there has been growing awareness that
economic development of the country. These industries many end-of-pipe solutions have not been as effective in
are using huge quantities of water, raw material in their improving the aquatic environment as it was expected. As
production processes. The raw water requirement for sugar a result, the approach is now shifting from "waste
industry is 200- 500 lit/ tonne and wastewater produced is management" to "pollution prevention and waste
about 400-200 lit / tonne of sugarcane crushed. In the minimization", which is also referred to as "cleaner
production of sugar bye products such as, Press mud (3.5- production". The conventional End of pipe approach to
4 %), Bagasse (28-32%) and Molasses (3-4%) are waste management which provides for required treatment
produced. The molasses is utilized in fermentation of waste generated at various stages of process operation
industry (i. e. distillery) for the production of rectified does not lead to sound solution in the long run. It is so
spirit. because, firstly waste treatment in many instances leads to
mere transformation of pollutants from one phase to

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 International Journal of Civil and Environmental Engineering, ISSN:1701-8285, Vol.36, Issue.2
another. Secondly, it requires substantial investment and
budget to meet the operating cost.
In contrast modern approach to waste management aims at
optimizing production process and at minimizing
generation of waste then managing the unavoidable waste
in an environmentally acceptable and economical manner.
In most of the environmental problems, the cheapest and
most effective way is to reduce the pollution and if
possible avoid the production of the waste. Industries can
modify the production processes so that lesser quantities
of wastes are generated or the waste generation can be
totally eliminated.
Sugarcane is the raw material used for the production of
white sugar. While producing sugar it is mandatory to
keep our environment clean. The sugar industry generates
waste which could be very valuable by-products i.e.
molasses, bagasses and press mud cake, which have
provided an attractive source of revenue to sugar factories.
The press mud is used on agriculture land as manure and
bagasse is used as a fuel for generation of power or can be
used as a raw material in paper industry. It is advantageous
to have sugar and distillery units in the same premises as
the raw material would be easily available for rectified
spirit production. From rectified spirit, ethanol, liquors,
absolute alcohol, acetic acid, oxalic acid etc. can be
manufactured. These products are obtained by bio-
chemical processes of fermentation of molasses (a
carbohydrate raw material) resulting in liquid waste
known as spent wash characterized by low pH and high
organic and inorganic contents. It is highly polluting and
causing depletion of oxygen if discharged in to water
courses and may cause the salinity problems if used on
land without proper treatment.
Recycling and reclaiming materials that otherwise might
be discarded in the waste stream also reduces the
environmental pollution. Both these approaches usually
have economic as well as environmental benefits.
2. AIMS AND OBJECTIVES
a. To reduce the water consumption,
b. To achieve the substantial reduction in the water
and power bills,
c. To reduce the wastewater generation,
d. To reduce the expenditure on waste water disposal.
3. PROCESSES INVOLVED IN SUGAR
INDUSTRY
The sugar industry is of a seasonal nature and operates for
120 to 200 days in a year, beginning from early November
and ending on May or June. Large volumes of effluents
and wastes are produced during manufacture of sugar and
effluents contain a high pollution load. Because of the
sugar mills being located mostly in rural areas where there
are no suitable options like large flowing water courses for
effective disposal of the effluents by dilution and because
of the rainfall during the major part of the crushing season
being practically nil, extreme pollution of small rivers,
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1262
foul smell in the vicinity of sugar mills, and unpleasant
look inside the mill are commonly experienced. Variation
in volume of the effluent, its pollution load is due to
various causes like poor housekeeping, condition of plant
and machines, mode of their operation and maintenance,
and inefficient use of water.
3.1 Sequence of Steps in Sugar Production
Cane sugar production involve processes like reception of
cane, weighing, extraction, sulphitation, juice clarification,
evaporation, crystallization, centrifugation, drying,
weighing and packing of sugar, storing etc. as illustrated in
Figure-1. Cane sugar manufacturing is typically located
adjacent to the sources of raw materials to reduce costs
and transportation time, and to ensure fresh raw material.
3.1.1 Reception of Cane
Cane are unloaded from the transportation vehicles. The
sugarcane production line is a continuous process which
has to run round the clock. Earlier factories use to stop
their production once in a month for evaporator cleaning.
But now a days by putting additional spare equipment
(bodies) factories completes their season without any
cleaning. Cane processing, typically have substantial areas
to stock enough raw materials to facilitate continuous
production.
3.1.2 Extraction of Cane Juice
Cane is mainly transported through Truck, Tractors &
bullock carts .After receipt of this cane is weighed at
factory premises & moved to extraction process.
Extraction of the sugar juice is achieved with roller mills
which press out the juice. The remains of the cane stalk
are called bagasse, which contains cellulose fiber. This is
mostly used in the process facility as fuel for energy
supply & to generate steam for process heating. If fuel is
available from another source; the bagasse may be used
for further processing in the cellulose industry. Cane juice
extraction may also be achieved by a diffusion leaching
process, which can result in higher rates of extraction with
50% lesser energy consumption than a mechanical mill.
But this diffusion leaching process requires more steam
than mechanical mills. This Diffusion process is very
popular worldwide & due to above advantages in India
also as some entrepreneurs installed such plants & getting
good results than mechanical milling.
3.1.3 Clarification
The juice resulting from the extraction process is acidic
and turbid called raw juice or mixed juice. This raw juice
is clarified by mixing it with milk of lime & SO 2 gas. The
juice on boiling fed to continuous flow clarifier from
which clear juice is decanted while settled impurities
known as mud is sent to rotary drum vacuum filter for
removal of impurities called press mud.
The sulphur dioxide (SO2) gas generated by burning of
sulphur granules in burners. This process is called as
sulphitation & is quite popular in India.
 International Journal of Civil and Environmental Engineering, ISSN:1701-8285, Vol.36, Issue.2
Then clear juice also called as „thin juice‟ goes to the
evaporator for further process.
3.1.4 Evaporation Crystallization and Centrifuge
After clarification, the clear juice has a sugar content of
approximately 15%. Concentrations more than 60% are
needed to allow sugar crystallization, and this is achieved
through evaporation. Water is removed from the clear
juice in a series of evaporating vessels until syrup with a
dry matter content of 55-65% is obtained. This thick juice
is further evaporated until sugar crystals to form at pan
floor, now this thick syrup is called as mascuitte,
Figure 1: Manufacturing & Water Circulation Process in Sugar Industry
4. WATER CONSUMPTION
The sugar industry consumes large quantity of water in
manufacturing process and resulting in huge wastewater
generation. Water required in the mill house includes the
water used as splashes to extract maximum amount of
juice and those used to cool the roller bearings.
The water used in sugar industry is of two types. One is
Cold water and the other is condensed hot water. The cold
water is used as make up water, injection water to the
condenser, cooling water for various accessories such as
engines, crystallizers, cold maceration, juice dilution, lime
preparation, laboratory testing and factory equipment
cleaning. The condensed water is hot and it is used as
boiler feed-water, maceration, juice dilution, lime and
sulphate preparation, oliver wash, molasses conditioning,
centrifugal, magma making, massecuite dilution, etc.
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1263
accompanying with sugar crystals and this mascuitte then
centrifuged to separate. The final separated mascuitte,
which contains about 50% sugar, is called molasses or
mother liquor.
Sugar crystals are then dried, graded, weighed and stored
in godowns. Molasses is the most important by-product of
the sugar production. Molasses can be used as cattle
fodder or as raw material in the fermentation industry. To
facilitate the use of the molasses, which is generated in
relatively high volumes, sugar factories may be combined
with distillation plants. The basis for the distillery can be
sugar juice, molasses, or a combination of these products.
A large volume of water is required in the barometric
condensers of the multiple effect evaporators and vacuum
pans. The water is usually partially or fully recirculated
after cooling through a spray pond. This cooling water
gets polluted as it picks up some organic substances from
the vapour of boiling syrup in evaporators and vacuum
pan.
4.1 Milling Section
 Cold water- for mill bearing cooling (30 m3/hr),
shredder bearing cooling (20m3/hr) and mill gearing
cooling (76m3/hr).
 Hot water- requires for mill imbibition (85.8
m3/hr).i.e.28-32% on cane.
4.2 Clarification of juice
 International Journal of Civil and Environmental Engineering, ISSN:1701-8285, Vol.36, Issue.2
 Cold water- for sulphur station (11m3/hr), air
compressor (20 m3/hr) and pump gland cooling (8
m3/hr).
 Hot water- for milk of lime preparation (10.4 m3/hr)
i.e.4 % on cane and oliver filter washing i.e.5% on
cane (13 m3/hr).
4.3 Evaporation
 Hot water- for molasses conditioning (5.2 m3/hr),
melter (13 m3/hr), water movement for pan (5.2
m3/hr), magma and seed preparation (5.2 m3/hr)
i.e.2% on cane, makeup for C- mascuite reheating (4.5
m3/hr) i.e.@ 1.5 -2 % on cane.
 Cold water- injection water for vacuum pan (4640
m3/hr).
4.4 Boiler water
 Hot water as a boiler feed water(170 m3/hr) ,
 Cold water- boiler makeup water(13.9 m3/hr), RO
plant reject (4.17 m3/hr)
4.5 Washing & Miscellaneous use
 Water required for washing of centrifugal (2.6
m3/hr), floor, laboratories, etc.
5. WATER CONSERVATION
TECHNIQUES ADOPTED
It is generally observed that whenever for industry water is
available in plenty, such as from the river, the entire water
is replaced every day. Instead of to save the chemical cost
on the neutralization of water, restricted use of water
should be practiced. Avoiding neutralization for saving
chemicals is not desirable because if such water goes to
irrigation fields, it will adversely affect the crops.
Along with the factory production manager, we studied the
possible water conservation options, the implementation of
same techniques, achieved considerable reduction in water
requirement in the industry compared to the average
requirement of other sugar industries, or to the previous
requirement of same industry.
Water Conservation Techniques adopted in industries are
as follows:
5.1 Milling Plant
Hot condensate after cooling in two stage cooling towers
is fully used instead of fresh water supplement.
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1264
5.2 Boiler feed water
First body evaporator condensate only used as boiler feed
water as other bodies does not give the condensate of the
boiler quality. This first body condensate is also called as
exhaust condensate of temperature @ 110 degrees.
5.3 Clarification House Compressors
Recirculated the cooling waters.
5.4 Sulphur Burner
Water used is recirculated and connected to spray pond.
5.5 Oliver Filter
Instead of using fresh water, spray pond water is used to
create vacuum at vacuum pump and barometric
condensers. Hot water condensate is used for filter cake
washing.
5.6 Boiling and Centrifuge section
Here also cooled hot water condensate is used for cooling.
Water required to wash sugar mascuitte in centrifugal
machine is condensate from evaporator bodies.
5.7 Preparation of seed and mixture
Hot water is used instead of fresh water.
5.8 Cooling water
Mill drive, mill bearing, power house turbines, fiberisers,
compressor, cooling and vertical crystallizers is also
cooled condensate instead of fresh cold water & is
recirculated water.
5.9 Excess Condensate
Sent to cooling tower for cooling.
6. WATER BALANCE
The water balance in sugar industry is given in Figure-2
and 3. Based on the water balance, it may be possible to
completely eliminate the process water requirement and in
fact, it can generate some excess water which can be
stored and reused in the process. However, some water
may be required as makeup water for spray pond and for
drinking at the colonies, laboratories, hospitals, etc., which
may be around 10.0% of the cane crushed. It is also
possible to reuse the treated effluent water as makeup
water in spray pond, sulphur burner cooling water, wet-
scrubber, etc., and in which case the effluent quantity can
be further reduced to 9.0% of the cane crushed.
 International Journal of Civil and Environmental Engineering, ISSN:1701-8285, Vol.36, Issue.2 1265

CONDENSATE USE IN THE PROCESS OF CANE CRUSHED

MILL MILK OF LIME OLIVER PAN CENTRIFUGA LAB & FLOOR BOILER
IMBIBITION PREPARATION FILTER MOVEMENT L WASHING WASHING BLOW DOWN
(33%) (4%) (5%) (2%) (1%) (1%) (5%)

RECYCLING

ETP

Figure 2: Water Balance and Wastewater Generation in Sugar Industries (A)

RAW WATER

SPRAY POND MAKE UP COLONY AND OFFICE GARDENING LABORATATORY

WATER (6%) (2%) (2.5%) (1%)

SPRAY POND OVERFLOW

(6%)
ETP (1.5%) WASTE ETP
TREATED SEPERATLY (NIL)
(RECYCLED FOR
ETP
GARDENING)
(RECYCLED AS
MAKE-UP WATER)
(3%)

Figure 3: Water Balance and Wastewater Generation in Sugar Industries (B)

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 International Journal of Civil and Environmental Engineering, ISSN:1701-8285, Vol.36, Issue.2 1266

6.1 Case Study of Lokmangal Sugar Factory

Table 1 Water Balance - Lokmangal (260 Tch) With Condensing Turbine

TCH 260
A Hot water Required T/hr Hot water available T/hr
Clean Condensate Clean Condensate
Boiler (170 t/hr) 170 Condensate from Evaporator - I 110
Blow down & Emergencies (3% of boiler
cap.) 5.1 Cl J 2 0
For Desuperheating (2%) 5.20 Surface condenser (TG) 32
HP heater 15.00
Dearator 9
Ejector (TG) 0.4

180.3 166.4 -13.9

Hot water Hot water
Mill Imbibition (230% on Fibre), 33% cane 85.8
Condensate from Evaporator -
Movement water for Pans - 2% 5.20 II to V 85.00
For molasses conditioners (2%) 5.2
Melter (5 %) 13 Condensate from Pans 54
For magma & seed preparation (2 %) 5.2
Oliver filter 13 Condensate from Juice Heaters 36
For Milk of lime preparation (4%) 10.4
Water at C / F washings (1%) 2.6 Oliver filter 13
Misc - washings & losses & unacconted (1
%) 2.6
Make for C massecuite reheating 0.4
m3/m3 4.5

Total hot water required 147.5 Total hot water available 188.0
Net
balance hot
water 40.5

Make
B Cold water required up Cold water available
water to be recirculated
Hot water cooled(Surplus) 40.5
For Shredder bearing cooling 20 0.2
For Mill bearing cooling 30 0.3
For mill gear cooling (5 mil l+ 1 GRPF) 76 0.76
Injection water at pans+Evp (42000+10%
more) 4640.0 0
Sulphur Station 11 1.1
B & C Massecuite cooling , 0.8 m3/m3 25.5 0.255
Air compressors 20 0.2
Pump gland cooling 8 8
For Lab. & washings & unaccounted, losses
1% 2.6 2.6
DM water regeneration 0 0
Total raw water requirement (m3/hr) 13.415
(-) surplus vapour condensate (cooled) 40.5 -40.5
-
(-) surplus vapour condensate available 27.085
Boiler Make up water 13.9 13.9

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 International Journal of Civil and Environmental Engineering, ISSN:1701-8285, Vol.36, Issue.2 1267

R.O plant Reject 4.17 4.17

Cooling Tower requirement (Turbine) 42 42
Total cold water required 4833 60.07
Total make up cold water 60.070
1441.68 m3/day
~ 1400.00 m3/day
Water to be sent to Effluent Treatment
Plant
Misc. Lab & washings 1
Gland sealing 8
Tank overflows +leakages 1
Misc. + unacconted 1
Spray Pond overflow 18
Cooling Tower Blow down (Turbine) 12
41.00
984 m3/day
~ 950 m3/day

7. WASTE MINIMIZATION  Effluents which do not require any pre-treatment,

As the process of sugar manufacture has many stages and
in most of the stages pollution/wastes are generated in
different forms like wastewater, solid wastes and air
pollutants. The causes of these forms of pollution are
leakage, spillover, overloading, indifferent handling and
crushing operations, improper molasses storage and
handling and so on.
The different sources/stations where generation of
pollution is of concern are: cane yard & cane unloading
section, cane carrier section, milling station, bagasse
handling, boilers, washings, clarification and evaporation
section, filter washings, sugar house and so on. Sugar
industry generates three types of effluents.
 Effluents requiring pre-treatment like oil and
grease separation, pH correction etc., before
going to ETP.
but highly polluted and need treatment in ETP.
 Effluents with little or no pollution, which do not
require treatment.
From all such sources/operations, the pollution load can be
reduced considerably by adopting various pollution
prevention measures. These measures could include good
housekeeping practices, change in the materials/process/
design, improving current operation and maintenance
procedures, water and waste minimization, clean
technology options, etc.
7.1 Techniques Adopted For Wastewater
Minimization
The waste minimization in sugar industry can be obtained
by adopting the following suggested techniques at
different stages as mentioned in Table-2.

Table 2 Techniques Adopted for Waste Minimization

Sr. Station Preventive Measures Waste management options
No. Nature Type
1 Milling section Oil & grease Provide collection trays, Can be sold as low grade
lubricant can be easily lubricants or burnt in boilers after
withdrawn & stored in mixing with bagasse or may be
drum used directly on open gearing.
Floor washings Bagasse dry cleaning, ---------------
with proper slope to
floors
Leakages & Use mechanical seals for Collect leakages & spillages in a
spillovers all pump glands & pit and recycle into process
alarms for overflow
Cooling waters Collect desuperheater & Recycle
mill bearing cooling
water
2 Clarification- on and Leakages from Install overflow alarms Recycle the cooling waters
Vacuum filters pumps, glands & & provide mechanical

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 International Journal of Civil and Environmental Engineering, ISSN:1701-8285, Vol.36, Issue.2 1268

Pipes overflow seals

3 Boiler house Boiler blow down Maintain boiler Use it for irrigation along with
condition & also feed other effluents
water quality
4 Crystallizer & pan Leakages from Provide mechanical seals Recycle the cooling waters
boiling pumps wherever it is
appropriate
Spillovers Recycle all cooling Collect spillages & recycle in
waters process
Avoid overloading the
equipment
5 Evaporator & juice Sugar - Provide additional Recycle the water if there is no
heating entrainment external catchers for the entrainment and in case there is
last body evaporators & entrainment use it for irrigation
all vacuum pans
- use poly baffle stainless
steel instead of umbrella
type savealls
- pump gland shall be
provided with
mechanical seals to
prevent leakages
6 Cleanings of vessels, High BOD & - Recycle NaOH for next Controlled loading in ETP from a
boilers etc., & COD, chemicals cleaning storage tank
laboratory washings as NaOH, - Provide standby units
Sulphuric Acid, to have continuous Segregate laboratory effluents and
lead operations join to storage tank
- Store the effluent in a
holding tank to avoid
shock loads on ETP

8. PROCESS MODIFICATIONS
Now-a-days it is a necessary to establish co-generation
unit along with sugar industry from economic
sustainability point of view and also raw material required
for this is available in the form of bagasse, which is by-
product of sugar industry. In this co-generation plant either
condensing or back pressure turbines can be used. From
the water minimization point of view, back pressure
turbine shall be preferred instead of condensing turbine as
a process modification.
Also cooling towers in condensing turbines requires huge
amount of fresh cooling water which can be minimised to
zero by installing air cooled condensers for these turbines.
Condensate polishing unit will lead to achieve “water” as a
by-product of sugar industry. The Excess condensate is get
contaminated to certain extent after repetitive recycling as
it catches some of the sugar traces. This condensate water
shall be treated by installing condensate polishing unit so
that instead of taking the fresh water from the nature this
treated water can become a by-product of sugar industry.
Due to this process modification, the wastewater load on
ETP is reduced tremendously.
9. CONCLUSION
Water is the most costly and instantly affecting natural
resource. Scarcity of water is the major problem
throughout the world, so the conservation of water is
essential at every junction. Conservation of water is
significant aspect of environmental and economical
sustainability.
Sugar industry demands large quantity of water. In this
process of making sugar from the cane juice, water comes
out as by-product, in the form of excess condensate. There
is a considerable amount of water generated which has
large potential of being reused back in the industry for
various process, which reduces the demand of raw water.
The processes like mill imbibition, milk of lime
preparation, washing, etc. requires considerable amount of
water. This requirement of water can be fulfilled from the
excess condensate, thus making the industry a zero water
intake industry. This reduction in raw water intake also
reduced the water bill. It also helps to reduce the quantity
of waste water generated. Thus size of different units of
ETP turns to reduce.
Thus process modification like use of back pressure
turbine instead of condensing type, installation of
condensate polishing unit with good housekeeping,
efficient operation & maintenance of industry with
optimum use of water will lead to achieve water
minimization in sugar industry.

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 International Journal of Civil and Environmental Engineering, ISSN:1701-8285, Vol.36, Issue.2 1269

REFERENCES
[1] Sapkal “Water and Wastewater Conservation”
[2] Sushilkumar Bhandare, “Water Consumption -
Optimisation and Its Reuse Case Study Implemented
at Shri Datta SSK Ltd, Shirol.”
Book Reference:
[3] E. Hugot, “Handbook of Cane Sugar Engineering”

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