WATER BALANCE & SOURCES OF WASTEWATER

IN SUGAR MILL & REFINERY

Mr. Pastor Esmeris*

OBJECTIVES

To instill water conservation among the participants.

To present the water balance of a typical raw sugar factory and refinery.

To discuss some considerations and recommendations for the efficient use of water in
a sugar factory and present various applicable technologies.

Water Facts and Trivia:

The over-all amount of water on earth has remained the same for about two billion
years since the earth was formed.

Water moves around the earth in a water cycle, consisting of evaporation,

condensation, precipitation, infiltration and surface run-off.

Of all the water on earth, only 2.5% is fresh water. Fresh water is either groundwater
(0.5%) or readily accessible water in lakes, streams, rivers, etc. (0.01%)

Over 90% of the world's supply of fresh water is in Antartica.

Less than 1% of the water supply on earth can be used as drinking water.

More than 2 billion people on earth do not have a safe supply of water.

Two thirds of the water used in a home is used in the bathroom.

Groundwater supplies serve about 80% of the population, whereas up to 4% of usable

groundwater is already polluted.

It takes 450 liters (120 gal.) of water to produce one egg.

It takes 5,680 liters (1,500gal.) of water to process one barrel of beer.

It takes 7,000 liters (1,850 gal.) of water to refine one barrel of crude oil.

Conventionally, it takes 240-290 gal. (910-1,100 ltr.) of water to produce one Lkg of
raw sugar; but if managed well, it will take only 1-10 gallons.

WATER MANAGEMENT

*/

Nature's management of water is based on recycling and this principle should form the
basis of water management in the sugar industry.

Roughly 40% of the water entering in the cane is surplus. The more energy efficient a
factory is, the larger is the surplus water produced.

Lopez Sugar Corp.

WATER MANAGEMENT
FACTS:

Water, as a consumable in the process of sugar manufacture, has input costs.

Sugarcane carries its own fuel and water to enable its processing.

The process of sugar manufacture has no step wherein any liquid effluent must be
generated and discharged.

Pollution control laws now demand treatment of the plants effluents to strictly
conform to the pollution tolerance limits before disposal.

User fee or levy for the use of water will soon be imposed and this will increase input
costs.

Extra/ undesirable/ unnecessary use of water in the process results in: loss of heat
energy; input of salts and impurities through raw water is partly responsible for scale
formation in heat exchangers and melassegenic effects in exhaustion; extra energy
input is required for pumping; loss of sugar by dissolution in water and generation of
effluent.

Objectives of Water Management in the Sugar Factory

Work the plant on cane water, i.e. water brought in through sugarcane.

Minimize the use of ground/ surface water for the plant consumption.

Eliminate/ minimize the generation of plant effluents.

WATER REQUIREMENT

A conventional Raw Sugar Factory will require about 2.1 to 2.8 cu.m/ ton cane

For a 5000 TCD factory this is about 440 cu.m. /hr. to 580 cu.m./hr.

A 5000 TCD factory can manage to work with only 20 cu.m. /hr. water being put into
its water system.

WATER REQUIREMENT OF A REFINERY

Table2EnergyUsage
Cane sugar refining

TABLE 1

(1)

Steam to Raw Sugar Ratio

(a)
A typical refinery : 1.5 ton of steam to
one ton of raw sugar
(b)
A modern refinery : 0.55 ton of steam to
one ton of raw sugar

(2)

Electricity
(a)
A typical refinery : 75 kWh/ton raw sugar
(b)
A modern refinery : 4 5 kWh/ton raw sugar

(3)

Wa t e r
(a) A typical refinery : 150% of raw sugar
(b) A modern refinery : 50% of raw sugar

Estimated Water Consumption of Refinery in different arrangements

Purification
Decolourisation Estimated Water Consumption
Process
Process
Cu. Mt. Per tonne of melt
SI. No.
Process
Surface Conds.
(Fresh Water)
(Sea Water)
1 Phosphatation & Ion Exchange
1.15
55- 65
55- 65
2 Carbonatation & Ion Exchange
1.20
0.16
55- 65
3 Phosphatation & GAC Columns
0.20
55- 65
4 Carbonatation & GAC Columns

AL KHALEEJ SUGAR CO. U.A.E.

10 - Refinery Performance Comparison :

Year

Fuel
kg / t

Water
mt / t

Power
kw hr / t

Steam
kg / t

1997

77

382

121.64

938

1998

67

366

83.84

720

1999

47

245

72.588

597

2000

44

252

58.43

680

2001

48

281

61.38

635

2002

48

188

51.38

638

2003

47

179

58.186

645

2004

37

154

48.4

604

Definition of Terms

Service water: raw river water used in the factory

Filtered water: treated/potable water

External water: water entering the factory, other than water contained in the cane (i.e.
service or filtered water)

Injection cooling system: factory condenser cooling water circuit

Service cooling system: vacuum, crystallizer and bearing cooling water circuits

Process water: any source of water produced by factory operations (i.e. excludes
external water and water from the service cooling systems).

OVERALL MILL WATER BALANCE

FLASH

SATURATED
BOILER GASES

EVAPORATION
AT MILLS

SERVICE
WATER

FACTORY

CANE

BAGASSE

BOILERS

WET ASH
& SMUTS

EVAPORATION
MOLASSES

DRIFT
LOSS

COOLING
TOWERS/
POND

FILTER
CAKE

BOILER
BLOWDOWN

SURPLUS
CONDENSATE
SYSTEM
OVERFLOW

Over-all Balance

A cane sugar mill process more water than sugar

Roughly 40% of the water entering the cane is surplus which will find its way out of the
mill in an effluent stream.

Water enters the mill as constituents of sugarcane and part of it goes out in the bagasse.

Water Losses

Water in the raw juice is lost through filter cake, pan and evaporator condensers, final
molasses, sugar and boiler blowdowns.

Other losses are in the cooling tower or spray pond overflow and drift loss (typically
5% of the water flow in the cooling system) and water in the boiler smuts.

Evaporation Losses

Evaporation occurs from certain process streams and during juice flashing.

Part of the water condensed in condensers will evaporate in the cooling towers or spray
ponds to provide the evaporative cooling required. As much as 85% of the vapor
condensed evaporates to provide the cooling.

Evaporation in wet scrubbers is around 10% of the high-pressure steam generated.

SUGARFACTORYWATERBALANCE
Factory: Amatikulu

WATER IN

WATER OUT

Tons/hr.

In Cane:
420
15.3
16.1

Tons cane/hr
Fibre % cane
Brix % cane
Softened water to boilers

Tons/hr

In bagasse to boilers:

288.1

71.1

Moist % bagasse
Brix % bagasse

51.8
1.4
9.5

In filter cake:

Cake % cane
Moisture % cake
Raw water into factory

3
75

0
3.5

In molasses:
3.8
78

Molasses % cane
DS % molasses

4.2

Evaporation from extraction plant:

Evaporation % cane

Boiler blowdown:

5.9

Steam % cane
HP Steam produced
Blowdown % steam

55.9
234.8
2.5
2.7

Mixed Juice Flash:

121.2
103

Mixed juice % cane

Heated Juice Temp.

4.4

In boiler smuts
Smuts % cane
Moist % smuts

1.5
70

From cooling pond: Drift loss

1.6
66

Evaporation
Pan evaporation
Jigger steam
Final effect evaporation
inj water tempsin
out
inj water flow to mill
inj water flow from mill

42.3
1.1
34.2
33
47.7
3125
3201
23.5

Flow wet scrubbers:

288.1

Total

Total

TOTAL SURPLUS

192.3

95.8

FACTORYWATERSYSTEM
Evaporation

Flash

MILLS

CLARIFICATION

FEED
WATER
STORAGE

PAN HOUSE

EVAPORATION

Filter
Wash Water

Imbibition

High Quality
Condensate

Condensate

Process
Water

Evaporation

LIME
PLANT

FLOCCULANT
MAKE-UP

CONDENSATE
FOR
PROCESS
USE

PROCESS
COOLING
TOWERS
Drift Less

Evaporation

Evaporation

Emergency
Make-up

Drift Less

BOILERS

Make-up
Blow Down

LOW QUALITY
SERVICE
WATER SYSTEM

SERVICE
COOLING
TOWERS

BOILERS
SCRUBBERS

External
Suppy

Over Flow

Internal Balances within the Factory

The quantity of condensate is much larger than the amount required in the boilers.
Within the factory, condensate is recycled as boiler feed water and as process water.

The best quality condensate is used for boiler feed water (usually the exhaust
condensate from the first effect evaporator and the second effect vapor condensate.

CONDENSATE

At higher pressures used to achieve very high thermal efficiencies, a steam

transformer may be used (Magasiner, 1996)

In evaporators and pans, the condensing steam is at higher pressure than the liquid
being boiled.

In juice heaters the pressure of the liquid in the tubes is higher than that on the steam
side. Heater condensate should generally not be used for boiler feed water.
STEAM CONDENSATE BALANCE SHEET 7,000 TCD MILLING RATE
STEAM
GENERATION
Boiler

Capacity

Mill
1

453.074

% Gen

80.00%

Steam
Gen

362.459

EXHAUST
AVAILABLE

LIVE STEAM CONSUMER

Equipt

No.
of
unit
1.00

Power
(Hp)

Steam
(lb/hr)

Water
Rate

500.00

12,982

25.96

EXHAUST
CONSUMER

Exhaust
(lb/hr)
12,333

Equipt

CONDENSATE

Exhaust
(lb/hr)

3rd Heater

28,545

For Boiler

For Process Use

Equipt

(lb/hr)

Equipt

1st Evap

215,137

3 Evap

nd

(lb/hr)

rd

105,645

th

1.00

800.00

25.96

20,772

19,733

Pans

53,295

2 Evap

133,574

4 Evap

105,645

Shredder

1.00

2,800.00

25.96

72,701

69,066

Evaporator

248,320

50% Pans

53,295

50% Pans

53,295

Mill Drive

5.00

650.00

25.96

84,385

80,165

Misc (5%)

16,508

1st Heater

27,929

nd

Power
House
5 MWTG

1.00

2.5 MWTG

2.00

4500*

26.49

159,819

2 Heater

28,268

3rd Heater

28,545

Total

349,326

151,828

STAND BY

Boiling
House
Make-up
for Exhaust
Total

11,801
362,459

333,125

Total

346,668

Total

402,006

*Power in
EXHAUST BALANCE
Exhaust available for process
333,125 lb/hr

BOILER FEED WATER BALANCE

Steam Generated by boiler
362,459 lb/hr

BAGASSE BALANCE
Bagasse from cane
99.43 ton/hr

Exhaust requirement of the process

Blowdown 5%

Desuperheated steam make-up

346,668 lb/hr
13,544 lb/hr
6

Percent steam make-up

Specific Steam Consumption

ton/hr

4%
1,090

19,077 lb/hr

Bagasse from fuel

76.36

ton/hr

Total feed water to boiler

381,536 lb/hr

Excess Bagasse

23.07

ton/hr

Condensate available for

boiler feed
Excess condensate for boiler

402,006 lb/hr
20,470 lb/hr

lb/TC

Sugar trace monitoring is normally done by measuring the condensate conductivity. It

is an approximate method since it does not measure sugar at all. Sometimes spurious
high conductivity readings are obtained and result in unnecessary dumping of
condensate. Conductivity measurements cannot replace routine laboratory sugar trace
checks.

Boiler Pressure (bar)

Maximum Sugar Content (ppm)

20

15

30

10

>40

Nil

The maximum amount of sugar contamination

acceptable in boiler feed water depends on the
boiler pressure.

PRESSURE- DEPENDENT QUALITY PARAMETERS

Pressure (bar)

20

40

60

80

Total hardness (mg/l as

CaCO3)

10

20

0.5

Not
Detectable

8.5-9.5

8.5-9.5

8.5-9.5

8.5-9.5

0.05

0.02

0.01

0.005

0.02

0.02

pH value
Oxygen (mg/l as O2 max.
Iron+ copper + nickel+ (mg/l)

Not applicable

Total solids, alkalinity, Silica

Numerical value depend on circumstances

Oil

Not detectable

Inventory of Water Requirement

The water demand in the factory can be classified in two broad categories:
a) Cooling water which is directly reclaimable and
b) Process water which gets mixed up in the process and is reclaimable in different stages.
a) Cooling water requirements
Table 1 below gives the requirements of cooling water at different stations worked out on
the basis of the makers prescription and/ or experience of operations.
TABLE 1
Purpose
Equipment

Basis
for Estimation
3

Total Requirement
3
m /hr

1.

Mill Drivers: No. 4 standard

horizontal steam turbines
of two pedestal bearings
split casing impulse type
provide with forced lubrication capable of developing 500 BHP

Mill
Turbines
and
reduction
gear oil
cooling

6.8% m /hr
for each
turbine (as
per rating)

28.00

2.

Mill Bearings: Mill size 850

mm x 1675 mm journal dia
425 mm total hydraulic
pressure 270 tones

Cooling
of mill bearing

4.5m /hr for

each mill
(as calculated)

18.00

3.

Power house Turbines: 1 No.

horizontal multi/stage
impulse steam turbine
capable of developing 1500
KW with alternator

Turbine and
reduction gear
cooling

18 m /hr
(as per makers
manual)

18.00

4.

Diesel Generating Set:

one Skoda diesel engine
generating set capable of
developing 800 BHP

Cooling

(As per makers

manual)

3.5

5.

Sulphitation Station
(i) 4 Nos. sulfur furnace of
continuous type (2 working)
(ii) Two electrically driven
water cooler air com3
pressor of 500 m /hr
3
and 250 m /hr respectively

(a) Water
cooling jacket
(b) Scrubber for
cooling
-

2.0 m per
jacket
3
0.35 m per
house (estimated)
(as per makers
manual)

4.0
7.0
3.5

6.

Vacuum Filter: One Oliver

condenser

(a) For condenser

(b) For vacuum
pump bearing
(c) For gland
cooling of light
and heavy
filtrate pumps

(As per makers

manual)

7.

Crystallizers: 7 Nos. water

cooled crystallizers of 55
tonnes capacity each

for cooling
C massecuites

0.8 m of cold
water per ton
of massecuite

10.80

8.

Centrifugals: 15 Nos.
Centrifugals of Robert's
design of 450 kg/ charge
capacity

For cooling of
brake drum

(as per makers

manual)

32.20

9.

Hot liquor pumps

For gland
cooling, etc.

Estimated

3.15

TOTAL

129.50

b.

10.80

Water for other process consumption

Table 2 below gives the requirement of water at various processing points:

TABLE 2
Purpose

Basis
of estimation

Water Temp.
preferred

1.

Imbibition

23% on cane

Hot 73 C

2.

Make up water
for boiler

5% of total
generation

Hot

3.30

3.

Milk of lime
(by volume)

1.2% cane

Hot

1.50

4.

Oliver and Eimco

(as per makers

manual)

Hot

10.80

5.

At pans

5% on cane

Hot

6.50

Qty. of require3
ment in m /hr
23.60

6.

Make up water
for condensing
system

3% loss on
evaporation and 2%
windage loss i.e. 5%
of total spray capacity
of 9 lakh gph

Cold

202.50*

7.

Cleaning and
washing

Estimated

9.00

Water for drinking

and other purposes
( a) for factory
(taking for 300 persons
per shift)
(b) For colony
(for 5000 persons)
(c) For Laboratory

20 gallon per head

Cold

3.85

at 20 gallons
per head
by actual measurement

19.80
-

9.00

Total

87.25

Factory Water Requirements (Hugot, 1986 Ed. p. 893)

Boilers. Taking the total steam requirement as 450 kg/t.c. and expressing the capacity of the factory in tch as
A. Water for the boiler must be assumed as 10-15 %, normally 10%. We have then
0.05A

Washing of cane. Depends on conditions

Cooling mill bearings; assuming 5 mills, say

Imbibition. Assuming 30%

Filtration. Assuming water 100% on cake

Cooling A masc; with a Werkspoor, we may reckon 1.5 l/l

masc. and 130 1/1 of masc/tc=
0.130 x 1.5

Cooling B masc. Similarly

0.060 x 1.5

0.09A

Cooling C masc. Similarly

0.040 x 1.5

0.06A

Movement water for pans

0.02A

Water for coolers

0.30A

Water at centrifugals

0.01A

0.20A
0.30A
0.04A

0.20A

1.27A

Guidelines/ Suitable Designs of a Closed Water Circuit System (Mangal Singh, 1994)

Evaporator station with multiple bleeding of vapors for vacuum pan use, juice heating by
VLIH and by vapors bled from the evaporator bodies.

Boiler feed water requirements being met by condensates from the pre-evaporator and 1st and
2nd bodies of the evaporators with arrangements of surplus storage and pumping back.

Reclamation of all water in the form of condensates.

Classification, collection and recycling of condensates for various process requirements and
steam generation.

Centralized collection of all hot condensates other than those for boiler use in an overhead
collection tank providing for draw down lines incorporating preferential distribution system
to various consumption points, e.g. lime slaking, cake washing, centrifugals and magmas,
pans and maceration, etc.

Provision in the central collection tank of raw water make-up to meet deficiencies if any, and
its automated working with tank level control and resultant removal of parallel cold water
lines from the process house or no provision thereof in case of new installations.

Creating sub-circuits for total recirculation of cooling waters.

Closed circuit of hot water for heating of massecuites in crystallizers and pugmills with
provision of heating the water in circulation with thermostatic temperature control.

Arrangements for collection of all cooling waters in a suitably sized masonry or steel tank
which could also be designed to effect cooling as well as receiving the make-up water from
the raw water source, as well as arrangement for collection of boiler and feed water tank
overflows with provisions of pumping back when required and collection of surplus hot
water from the overflow of the overhead hot water tank and its being pumped for maceration
and/or back to the overhead tank for make-ups when required.

Designing/lay-out of the boiling/ centrifugal house floor and drains to enable collection of
spillages, leaks and washings for pumping back to the process.

Reclaiming continuously the condensates from the VLIH whether in operation or not and
diverting it to maceration.

Arrangement to divert the lime house and grit washings into the condenser water channel to
reclaim both the water and residual lime which helps to make up the condenser water pH.

Treatment & Recycling of Effluent

All mills will have a surplus of water to dispose of. Disposal methods:
1. Fert-irrigation effluent diluted with irrigation water
2. Ponding system surplus water is contained during the crushing season and
treated during the off-season.

In all other cases, the surplus has to be treated before it can either be re-used or
returned to the watercourse. Attempts should be made to reduce the quantity and the
concentration of dissolved substances in the effluent.

Treatment Methods

Aerobic treatment
Anaerobic treatment
Recovery of leaks/ spillages
Cleaning
Distillery slops concentration and incineration

Disposal of Slops

The following are the methods available for Disposal.

o Fert-irrigation
o Composting with Filter mud from Sugar mill.
o Anaerobic Digestion to Generate Bio-gas and Composting.
o Slops Concentration and Incineration in a Boiler.
o Concentration and Incineration in a boiler is attracting a lot of attention, because of
cleanliness and economics. The incineration plant can meet 75% of the steam and
power requirements of the Distillery.
This concentration and
incineration is a technology
already established.
The Figure shows the installation
in a 80 KLPD distillery plant
commissioned a few years ago.
The operation of the plant has
been very good.

Many more Projects are under

implementation in India.
China also has a few installations
operating successfully.

Disposal of Other Effluents

The sludge from Fermentation could be fed into the boiler, by mixing with slops or mixing
with the supplementary fuel.

The ash from the boiler is a source of potash and could be a field nutrient.

The condensate from the Slops Evaporation plant and spent lees treated in a RO plant and
the permeate used for molasses dilution or for Cooling tower make up. RO Reject taken to
slops concentration plant.

The blow down from cooling tower and boiler (harmless effluents) are cooled and taken to
sugar plant's effluent treatment plant.

Zero Effluent Sugar Factory

As defined is one where all surplus water leaving the factory meets the general discharge
standards, without requiring conventional downstream effluent treatment. It does not mean
that the factory has no exit water stream, as the water balance of any cane sugar factory
results in a water excess due to the high water content in cane.

Typical Sugar Mill

Zero Effluent Water Management

Imbibition Tank

Imbibition Tank

Boilers & Scrubbers

Boilers & Scrubbers

Process C. Towers

Process C. Towers

Service C. Towers

Service C. Towers
Flocculant & Lime

Flocculant & Lime

Service
Water

Effluent
Overflows & Leaks

Surplus
Water

Service
Water

Overflows & Leaks

Evaporators

Evaporators

General Cleaning

General Cleaning

Fire System

Fire System

Stormwater Drains

2A

R
e
c
y
c
l
e

Stormwater Drains

2B

Figure 2. Comparison of Standard and Zero Effluent water management systems

Key Principles of 'Zero Effluents' Water Management System

Eliminate water usage where possible. (e.g. water- cooler air compressors were replaced
with air-cooled compressors.

Minimize usage where external water is essential (e.g. high-pressure water-jetting

machines are used for factory cleaning)

Minimize water losses from service cooling water circuits.

Substitute external water with a process water stream of the minimum required quality.

Substitute condensate with lower quality process water where appropriate. (This increases
the amount of condensate available for users which require high quality water.)

Monitor the use and availability of process water throughout the factory to ensure that
factory users have an adequate supply of water at all times. Flowmeters are used to monitor
water usage; and level transmitters, on storage tanks/sumps, are used to monitor water
availability. Sufficient storage capacity or some form of make-up facility is provided for
each source of process water, such that unsteady operating conditions are catered for.

APPLIED TECHNOLOGIES
ADVANTAGE
Reduction of steam consumption by 2-5%.
Centralized System of condensate r emoval without
pumps.
No level and control valves required.
Exhaust condensate heat recovery without any

CONDENSATE FLASH CIGAR

contamination.
Light weight Stainless Steel Design.
Reduces Final condensate temperature to

required level for processes l ike

imbibitons, washing filter-cake,

Prevent the Escape of Heat

Use the Heat Over Again

dilution of molasses etc.

CONDENSATE FLASH RECOVERY

DIRECT CONDENSER (DC) vs SURFACE CONDENSER (SC)

DIRECT CONDENSER (DC)

EXAMPLES:
Barometric Condensers
counter-current type
parallel-current type
multi-jet

SURFACE CONDENSER (SC)

EXAMPLES:
Water-cooled
Shell and Tube
Plate type
Spiral type
Air-cooled
Fin Fan Condenser

DC

SC

MULTI-JET CONDENSER

MULTI-JET with
CONTROL VALVES

FIN FAN TUBE

MIXED JUICE
FROM MILL

VAPOR FROM EVAP.

MIXED JUICE TO
HEATER STATION

SEALING
WATER
VACUUM LINE

JUICE
HEATER
LAST CELL
EVAPORATOR

VAPOR

CONDENSATE
SEPARATOR

CONDENSATE TO
SEALING TANK

VAPOR LINE JUICE

HEATER

Use Waste Heat

BAROMETRIC
CONDENSER

LSC VAPOR-LINE JUICE HEATER PERFORMANCE

PARAMETER
Mixed Juice Flow (tons/hr)
0
M.J. Inlet Temp. ( C)
0
M.J. Outlet Temp. ( C)
0
Vapor Temp. ( C)
Condensate Flow (tons/hr)

RANGE
260-280
32-38
50-55
60-63
4.8-9.9

AVE.
270
35
52
62
6.1

HEAT TRANSFERRED to MIXED JUICE

Q=MCp (To-Ti)
Q=270 x 0.9 x 17
Q=4131 Mcal or 4804 kWh
EQUIVALENT AMOUNT OF EXHAUST
@ 620 watt-h/kg = 7.7 tons/hr
AVE. CONDENSATE FLOW
6.1tons/hr
SAVINGS IN COOLING WATER
305 tons/hr or 1343 gpm

ADVANTAGES OF SURFACE CONDENSER

CONDENSED VAPOR DOES NOT MIX AND BECOME POLLUTED

CONDENSATE CAN BE RECYCLED OR RECOVERED
NO EXTRA COOLING WATER TO BE HANDLED
NOT MUCH AFFECTED BY FLUCTUATIONS IN THE SUPPLY OF THE
COOLING MEDIUM
I F I N TA N D E M W I T H A B A R O M E T R I C C O N D E N S E R O R A
COMPENSATOR, WILL MAKE THE OPERATION OF THE VACUUM PUMP
MORE EFFICIENT BECAUSE OF IMPROVED DEGASSING AND SUBCOOLING OF INCONDENSABLE GASES RESULTING TO REDUCED LOAD
OF THE VACUUM PUMP.

BENEFITS OF SURFACE CONDENSER

STEAM SAVINGS due LOST HEAT RECOVERY

RECOVERY OF CONDENSATE FOR PROCESS WATER
COST SAVINGS IN THE PRODUCTION, TREATMENT AND CONDITIONING
OF FRESH WATER
COST SAVINGS IN WASTE WATER TREATMENT

IN SHORT: WATER &

ENERGY SAVINGS!
LSC SURFACE CONDENSER ENERGY SAVINGS
HEAT SAVED
Q=MCp (To-Ti) Q=20 x
1 x (60-28) Q=640 Mcal
or 744 kWh
EQUIVALENT AMOUNT OF EXHAUST
@620watt-h/kg=1.2 tons/hr
AVE. CONDENSATE FLOW
20 tons/hr
SAVINGS IN BAGASSE
0.52 tons/hr

Feed
Temperatu
re
Gauge

Feed
Pressu
re
Gauge

TYPICAL RO SYSTEM
Pump
Low
Suction Suction
Pressu Pressu
re
re
Gauge Switch

Chemic
al
Addition

5 - 10
Filter

Feed
Pressure
Control Valve

High
Pressure
Pump

Reverse Osmosis
Membrane
Elements

Pressure
Vessel

Permeate
Flow
Concentra
Flo te
Pressurew
Gauge

RO
PuF
meped
Discharge

Feedwater
Sampling
Point

Flow
Indicator
Concentrate
Sampling
Point

Combined
Permeate
Sampling Point

Brin
e
Flow
Indicator

Concentrat
e Sampling
Valve

Permeate
Flow
Permeate to Drain
Flow
to Point of
Use

Dr. Chous CHALLENGES FOR 21st

CENTURY - NEW SUGAR REFINERY DESIGN CRITERIA

WATER USAGE
Take 100 kg of 65 brix sugar liquor:
(a) Water needed is 35 kg per 65 kg of raw sugar
(b) Water to be recovered by surface condenser is 21.7 kg
(c) Total water needed % raw sugar:
= (35-21.7) x 100/65 = 20.5%

Conclusion: why the average usage is over 60%

The problem:
Humans use more and more water each year. Today at least 400 Million people have severe water
shortages. Over 70,000 different water contaminants have been identified. There are 12,000
different toxic chemicals in industrial use today, and more than 500 new chemicals are developed
each year.
The solution:
WATER CONSERVATION
WATER RECYCLING
WATER TREATMENT
If all new sources of contamination could be eliminated, in 10 years, 98% of all available ground
water would then be free of pollution.

Introduction: Climate Change

Climate change caused by both natural events (like volcanic eruptions) and human
activities (Greenhouse gas emissions)

There is now a global concern about climate as indicated by:

o The melting of polar caps/glaciers, radical shifts in weather patterns (El Nio/
La Nia)
o Increased occurrence of dramatic weather conditions such as hurricanes and
droughts in all parts of the earth
o Increasing Global Mean Temperature.

Climate change is primarily attributed to human activities particularly, the release of

greenhouse gases (GHG) from energy generation, industrial activity, land use and
forestry which in turn, cause global warming.
Temperature Relative to 1880-1899 Mean (C)

1.0

0.8

0.6
Smooth Curve
0.4
Annual values
0.2

0.0

-0.2

-0.4
1860

1880

1900

1920

1940
Year

Sea ice

1960

1980

2000

Green House Gas Effect

Earth is kept warm by its atmosphere

Without atmosphere average surface temperature

would be 18-deg. C

Heat from sun passes through atmosphere

warming it up, and most of it warms surface of
earth

As earth warms up it emits heat as infra-red

radiation. Some heat is trapped by atmosphere

Green House Gases make the atmosphere trap

more of radiation, so it gradually warms earth up
more.

SUN

Some solar radiation is

reflected by the Earth and
the atmosphere.

ATMOSPHERE
Some of the
infrared radiation
is absorbed and
re-emitted by the
greenhouse
gases. The effect
of this is to warm
the surface and
the lower
atmosphere.

Solar
radiation
passes
through the
clear
atmosphere.

Most radiation is
absorbed by the
Earths surface
and warms it.

EARTH

Human Sources of GHGs

Carbon Dioxide (CO2) Most prevalent GHG
Methane (CH4) Second most common, 21x the potency of CO2
Nitrous Oxide (N2O) 310x the potency of CO2
Other Gases HFCs, PFCs, and SF6 = range 600 23900x potency of CO2

Transportation
Energy Generation
Industrial Processes

Land Use:
Agriculture & Forestry

Infrared radiation
is emitted from the
Earths surface.

GHG and Environmental Impacts

Changes in temperature, weather patterns and sea level rise
Agriculture: Changes
in crop yields Irrigation
demands, Productivity

Coastal Areas:
Erosion and flooding
Inundation
Change in wetlands

Water Resources:
Changes in water supply
and water quality
Competition/Trans-border
Issues

Forests: Change in
Ecologies, Geographic range
of species, and
Health and productivity

Human Health:
Weather related
mortality
Infectious disease Air
quality - respiratory
illness

Industry and
Energy: Changes
in Energy demand
Product demand &
Supply

Rising temperatures results in changing weather patterns

Increased occurrence of dramatic weather such as hurricane

Melting polar caps, glaciers

Shifts in weather patterns

Global-Mean Temperatures

Temperature Relative to 1880-1899 Mean (C)

1.0

0.8

0.6
Smooth Curve
0.4
Annual values
0.2

0.0

-0.2

-0.4
1860

1880

1900

1920

1940

1960

1980

2000

Year

SAVE WATER

THE WORLD
IS IN
YOUR HANDS

Positive Proof of Global Warming