مشروع تخرج لمعالجة المياه الصناعيه في مصر

1. Recycling of sugar industries wastewater
B.S.C. Project
by
Mohamed Magdy Hassan
Fourth level
Faculty of sugar and Integrated Industries Technology
Under the supervision of
Assoc.Prof /Atef Elnakeep
Faculty of Engineering, Supervisor of the Engineering Division at the Faculty of
Sugar and Integrated Industries Technology
Assiut
2022

2. i
Acknowledgement
First of all, I would like to show our gratitude to my project
supervisor, Assoc.Prof. Atef Elnakeep, who gave me this great
opportunity. I’m heartily thankful to him for their tireless guidance,
extraordinary, patience and constant encouragement. His
knowledge, creativity and passion always inspire me during this
work.
I also thank Prof. Dr. Dina Mamdouh, (The dean of the
faculty of sugar and integrated industry technology) and all staff
of the faculty.
Finally, but by no means least, thanks go to my parents for
almost unbelievable support. They are the most important people in
my world, and I dedicate project to them.

3. ii
List of Contents
Cover page
Acknowledgements i
List of Contents ii
List of Figures iv
abstract vi
Chapter 1 1
1-1-Introduction 2
1-2-Sources of wastewater 3
1-3-IMPORTANT CONTAMINATION OF WASTEWATER 4
Chapter 2 6
2-1-Nature & Characteristic of industrial wastewater 7
2-2-Physical characteristics 12
2-3-Chemical characteristics 18
2-4-Biological characteristics 18
Chapter 3 19

4. iii
3-1-industrial wastewater treatment 20
3-2-Primary treatment (physical treatment) 20
3-3-Chemical treatment 32
3-4-Biological treatment 35
4- Conclusion 41
5-References

5. iv
List of Figures
Figure (1): Classification of total solids 3
Figure (2): Mechanical Screen
21
Figure (3): mechanism of Mechanical Screen
Figure (4): Vacuum Flotation
21
22
Figure (5): Air Flotation 22
Figure (6): Rectangular basin 23
Figure (7): Circular basin 23
Figure (8): parallel plate 24
Figure (9): sand filter 25
Figure (10): Coagulation & Flocculation Process 28
Figure (11): Conventional Activated Sludge 31

6. v
Figure (12): Sequential Batch Reactor biological treatment 32
Figure. (13,14): trickling Filter " BiologicalAir Filters "
biological treatment”
33
Figure (15): Anaerobic Biological Treatment 34

7. vi
Abstract
Sugar industries have an important place in the Egypt economic
development. However, the wastewater generated from these industries
bear a high degree of pollution load. Sugar industries in Egypt generate
about 1,000 L of wastewater for one ton of sugar cane or beet crushed.
Wastewater from sugar industry, if discharged without treatment, poses
pollution problems in both aquatic and terrestrial ecosystems.
Due to high pollution load, sugar industry is considered as one of
the topmost pollutions generating industries affecting our environment.
Wastewater from sugar industry bears intricate properties and its
treatment is considered as one of the challenging tasks for environmental
engineers in terms of its treatment as well as reutilization. The brown
color, high temperature, low pH, high COD, high BOD, TDS, odor
problems and excessive percentage of dissolved organic and inorganic
Hallmarks the sugar industrial effluent. This effluent if discharged
untreated, poses problems for both marine and terrestrial ecosystems. The
cost effective and economical treatment of sugar industrial waste is a
challenging task.
Therefore, implication of appropriate and cost-effective method to
meet the discharge standards is the utterly required need of time. This
study gives a brief and concise overview of various advanced techniques
which employed for treating sugar industrial effluents.

8. 1
chapter 1

9. 2
1. 1. Introduction
Water pollution due to industrial, agricultural and domestic activities.
Has caused a significant threat to human as well as surrounding
environment.
All sugar factories require water and consequently discharge
wastewater. Beet, cane and refinery factories produce wastewater with
different organic strength, with beet being by far the most aggressive
effluents. Wastewater treatment plants are designed to comply with local
environmental regulation and vary from country to country. The principal
types of industries which contribute to water pollution are Chemical and
Pharmaceutical Industries, Sugar industries, Steel Plants, Coal, Soap and
Detergents, Paper and Pulp, Distilleries, Tanneries, Foods Processing
Plants etc.
These effluents when discharged through sewage system poison the
biological purification mechanism of sewage treatment and pose several
pollution problems. Wastewaters are characterized by high biological
oxygen demand (BOD), chemical oxygen demand (COD), and total
dissolve solids. Wastewater from sugar industry generally contains
carbohydrates, nutrients, oil and grease, chlorides, sulphates, and heavy
metal. BOD/COD causes rapid depletion of oxygen content of the waters,
creates foul smell, renders the stream unfit for propagating aquatic life,
drinking and for other purposes. Forced by the legislation, industries are
looking for the low-cost solutions for the required reduction of pollution
load. It is estimated that every year 1.8 million people die due to Suffering
from waterborne diseases. A large part of these Deaths can be indirectly
attributed to improper sanitation. Wastewater treatment is an important
initiative which has to be taken more seriously for the betterment of the

10. 3
society and our future. Wastewater treatment is a process, wherein the
contaminations are removed from waste water as well as household
sewage, to produce waste stream or solid waste suitable for discharge or
reuse. Wastewater treatment methods are categorized into three sub-
divisions, physical, chemical and biological.
Definition of wastewater:
The term wastewater is now increasingly used in place of sewage.
Wastewaters include both organic and mineral matter carried through
liquid media. While the organic portion of the wastewater is putrescible,
undergoing biological decomposition the mineral mailer may combine
with water to form dissolved solids, may form unsightly sludge deposits
and may contribute to the hardness of the water in the effluent.
Sources of wastewater:
● Sugar industry wastewater are produced mainly by cleaning operations
● washing of milling house floor, various division of boiling house like
evaporators, clarifiers, vacuum pans, etc. generates huge volume of
wastewater.
● Periodical cleaning of heat exchanger and evaporators with NaOH and
HCl to remove the scales on the tube surface contribute organic and
inorganic pollutant loading to wastewater.
● Leakage from pumps, pipelines, certification house also contribute to
wastewater produced.
● Except this wastewater is also produced from boiler blow down, spray
pond overflow, and from condenser cooling which is discharged as
wastewater when it gets contaminated with cane juice.

11. 4
Why do we need to treat wastewater?
•To prevent groundwater pollution
•To prevent marine life
•Protection of public health
•To reuse the treated effluent for agriculture, groundwater recharge and
industrial recycle.
IMPORTANT CONTAMINATION OF WASTEWATER (4):
 Suspended solids: suspended solids can lead to the development of
sludge deposits and anaerobic conditions when untreated wastewater
is discharged in the aquatic environment.
 Nutrients: both nitrogen and phosphate, along with carbon, are
essential nutrients for growth. When discharged to the aquatic
environment, these nutrients can lead to the growth of undesirable
aquatic life. When discharged in excessive amounts on land, they can
also lead to the pollution of groundwater.
 Priority pollutants: organic and inorganic compounds selected on the
basis of their known or suspected carcinogenicity, mutagenic,
teratogenicity, or high acute toxicity. Many of these compounds are
found in wastewater.
 Refractory organics: these organics tend to resist conventional
methods of wastewater treatment. Typical examples include
surfactants, phenols, and agricultural pesticides.
 Heavy metals: heavy metals are usually discharged to wastewater
from commercial and industrial activities and have to be removed if
the wastewater is to be reused.

12. 5
 Pathogens: communicable diseases can be transmitted by the
pathogenic organisms in wastewater.
 Dissolved inorganic matters: inorganic constituents such as calcium,
sodium and sulphate are added to the original domestic water supply
as a result of water use and may have to be removed if the wastewater
is to be reused.(4)
The goal of study is reviewing and awaring of new technologies in the
field of wastewater treatments

13. 6
Chapter 2

14. 7
2. Nature & Characteristics of Industrial Wastewater
2.1 Physical characteristics
The most important physical characteristic of wastewater is its total
solids content, which is composed of floating matter, settable matter,
colloidal matter and matter in solution. Other important physical
characteristics include odor, temperature, color and turbidity.(5)
Table 1: Characteristics of Wastewater from a Sugar Plant
Parameter Concentration
BOD
COD
pH
Temperature
Total suspended solids
Total dissolved solids
Total volatile solids
Oil and grease
Sulphates
Nitrogen
Phosphorus
Chlorides
Calcium
Magnesium
1250 mg/L
2250 mg/L
5-7
25 to 35 cº
600 mg/L
2000 mg/L
1300 mg/L
60 mg/L
500 mg/L
10 mg/L
60 mg/L
60 mg/L
180 mg/L
80 mg/L

15. 8
a) Total solids
Analytically the total solids content of wastewater is defined as all
the matter that remains as residue upon evaporator at 103C to 105C.matter
that has a significant vapors pressure at this temperature is lost during
evaporation and is not defined as solid. Settable solids are those solids that
will settle to the bottom of a cone shaped container in a 60-minute period.
Settable solids, expressed as ml/L, are an approximate measure of the
quantity of sludge that will be removed by primary sedimentation. Total
solids, or residue upon evaporation, can be further classified as non-
filterable or filterable by passing a known volume of liquid through a
filter. (6)
The filterable-solids fraction consists of colloidal and dissolved
solids. The colloidal fraction consists of the particulate matter with an
approximate size range from 0.001 to 1 micro. The dissolved solids
consist of both organic and inorganic molecules and ions that are present
in true solution inwater.
Each of the categories of solids may be further classified on the basis
of their volatility at 550+50C. The organic fraction will have oxidized
and will be driven off as gas at this temperature, and the inorganic fraction
remains behind as ash. The volatile-solids analysis is applied most
commonly to wastewater sludge to measure their biological stability. The
sugar industry wastewater is characterized by its high total solids and
high percentage of dissolved organic and inorganic matter.

16. 9
Fig. (1): Show the Classification of total solids
b) Odors
Odors are usually caused by gases produced by the decomposition
of organic matter or by substances added to the wastewater. Industrial
wastewater may contain both odors compounds that produce odors during
the process of wastewater treatment. The sugar industry wastewater is
characterized by its odors problem. (7)

17. 10
Table (2): shows the origin of odors in different industries
Industries Origin of odors
Pharmaceutical industries Fermentation produces
Food industries Fermentation produces
Food industries (fish) Amines, sulphides, mercaptans
Rubber industries sulphides, mercaptans
Textile industries phenolic compounds
Paper pulp industries H2s, so2
Organics compost Ammonia, Sulphur compounds
C) Temperature
The temperature of wastewater is a very important parameter
because of its effect on chemical reactions and reactions rates, aquatic life,
and the suitability of the water for beneficial uses. Industrial
establishments that use surface water for cooling water purposes are
particularly with the temperature of the intake water. In addition, oxygen
is less soluble in warm water than in cold water. The increase in the rate
of biochemical reactions that accompanies an increase in temperature,
combined with the decrease in the quantity of the of oxygen present in
surface water can often cause serious depletions in dissolved oxygen
concentration in the summer months when significantly large quantities
of heat water are discharged to natural receiving water, these effects are
magnified. It should also be realized that a sudden change in temperature
can result in high rate of mortality of aquatic life. Moreover, abnormally

18. 11
high can foster the growth of undesirable water plants and wastewater
fungus. (8)
e) Color
Color of industrial wastewater varies according to the type of the
industry; the sugar industry wastewater is characterized by its brown
color. Knowledge of the character and measurement of color is essential.
Since most colored matter is in a dissolved state, it is not altered by
conventional primary devices, although secondary treatment units, such
as activated sludge and trickling filters, remove a certain percentage of
some types of colored matter. Sometime color matters need chemical
oxidation procedures for removal. Color of industrial wastewater varies
according to the type of industry. Most colored matter is in a dissolved
state. (9)
f) Turbidity
Turbidity, a measure of the light-transmitting properties of water, is
another test used to indicate the quality of wastewater discharges and
natural waters with respect to colloidal and residual suspended matter. In
general, there is no relationship between turbidity and the concentration
of suspended solids in untreated wastewater. There is however, a
reasonable relationship between turbidity and suspended solid for the
settled secondary effluent form the activated sludge process. Turbidity a
measure of the light-transmitting properties of water, is another test used
to indicate the quality of wastewater discharges and natural waters with
respect to colloidal and residual suspended matter.(9)

19. 12
2.2 Chemical characteristics
a) Organic matter
Organic compounds are normally composed of combination of
carbon, hydrogen and oxygen together with nitrogen in some cases. Other
important elements, such as sulfur, phosphorus, 11 and may also be
present. Also, industrial wastewater may contain small quantities of a
large number of different synthetic organic molecules ranging from
simple to extremely complex in structure. Typical examples include
surfactants, organic priority pollutants, volatile organic compounds and
agricultural pesticides. The presence of these substances has complicated
industrial wastewater treatment because many of them either cannot be or
are very slowly decomposed biologically. (10)
● Fats, oil and grease
Fats are among the more stable of organic compounds and are not
easily decomposed by bacteria. Kerosene, lubricating oils reach the sewer
from workshops and garages, for the most part they float on the
wastewater, although a portion is carried into the sludge on settling solids.
To an even greater extent than fats, oils, and soaps, the mineral oils tend
to coat surface causing maintenance problems. If grease is not removed
before discharge of wastewater, it can interface with biological life in the
surface waters and create unsightly floating matter and films. The oil and
grease (O&G) are a very important test used to determine the hydrocarbon
content of industrial wastewater. O&G tests include free O&G and
emulsified O&G measures. These tests will determine the type of
treatment required. Free O&G can be removed by flotation & skimming
using gravity oil separator (GOS). (10)

20. 13
● SURFACTANTS
Surfactants are large organic molecules that are slightly soluble in
water and cause foaming in wastewater treatment plants and in surface
waters into which the wastewater effluent is discharged. Surfactants
tend to collect at the air-water interface. During aeration of wastewater,
these compounds collect on the surface of the air bubbles and thus
create a very stable form. (10)
● Phenols
Phenols in industrial effluent have teratogenic, carcinogenic,
mutagenic effects, they are toxicity and difficult to Bio-degradation. They
will do harm to environment and have been listed in the 129 priority
pollutants. (10)
● Pesticides & agricultural chemicals
Trace organic compounds, such as pesticides, herbicides, and other
agricultural chemicals, are toxic to most life forms and therefore can be
significant contaminants of surface waters.
● Volatile organic compounds (VOCs)
Organic compounds that have a boiling point less than 100C and a
vapor pressure more than 1mm Hg at 25 C are generally considered to be
volatile organic compounds. The release of these compounds in sewers
and at treatment plant is of particular concern with respect to the health of
collection system and treatment plant workers.

21. 14
b) Parameter of organic content
● Biochemical oxygen demand (BOD5)
The most parameter of organic content widely used parameter of
organic applied to wastewater is the 5-day BOD. The BOD5 is usually
exerted by dissolved and colloidal organic matter and imposes a load on
the biological units of the treatment plant. Oxygen must be provided so
that bacteria can grow and oxidized the organic matter. Added BOD5
load, caused by an increase in organic waste, require more bacterial
activity, more oxygen, and greater biological unit capacity for its
treatment. The determination of the BOD5 involves the measurement of
the dissolved oxygen used by microorganisms in the 13 biochemical
oxidations of organic matter. Several dilutions of the wastewater are put
into standard BOD5 bottles with water that has been saturated with
oxygen and contains bacteria. A control bottle is also prepared with only
water and bacteria. The bottles are put into a standard incubator for five
days, hence this is called the “five-day BOD test (BOD5)”. The difference
in oxygen levels between the control bottle and the bottles with oxygen
remaining is used to calculate the BOD5 IN mg/L. (11)
TEST RESULTS ARE USED TO:
1) Determine the approximate quantity of oxygen that will be required
to biologically stabilize the organic matter present.
2) Determine the size of wastewater treatment facilities.
3) Measure the efficiency of some treatment process.
4) Determine compliance with wastewater discharge permits

22. 15
Chemical oxygen demand (COD)
The COD test is used to measure the organic matter in industrial
wastewater that contains compounds that are toxic to biological life. It
oxidizes the reduced compounds in wastewater through a reaction with a
mixture of chromic and sulphuric acid at high temperatures. The COD of
wastewater is, in general, higher than that of the BOD5 because more
compounds can be chemically oxidized than can be biologically oxidized.
For many types of wastewaters, it is possible to correlate COD with
BOD5. This can be very useful because COD can be determined in 3
hours, compared with 5 days for the BOD5. Once the correlation has been
established, COD measurements can be used to good advantage for
treatment-plant control and operation. The ratio of COD to BOD5 is
usually 1.5:2 for industrial wastewater containing biodegradable material
(e.g., food industry). For wastewater with ratios higher than 3, it is
assumed that some oxidized material in the sample is not biodegradable.
No biodegradable material sometimes is called refractory and found
mainly in wastewater from chemical and pulp& paper industries. (12)
● Total organic carbon (TOC)
This method measures the organic carbon existing in wastewater by
injecting a sample of the WW in special device in which the carbon is
oxidized to carbon dioxide is measured and used to quantify the amount
of organic matter in WW. This method is only used for small
concentration of organic matter. (12)

23. 16
c) Inorganic Matter
Several inorganic compounds of wastewater are important in
establishing and controlling wastewater quality. Industrial wastewater has
to be treated for removal of the inorganic constituents that are added in
the use cycle. Concentrations of inorganic constituents also are increased
by the natural evaporation process, which removes some of surface water
and leaves the inorganic substances in the wastewater. (13)
● Alkalinity
Alkalinity in wastewater results from the presence of the hydroxides.
Carbonates, and bicarbonates of elements such as calcium, magnesium,
sodium, potassium, or ammonia. Of these, calcium and magnesium
bicarbonates are most common. Borates, silicates, phosphates, and similar
compounds can also contribute to the alkalinity. The alkalinity in
wastewater helps to resist changes in pH caused by the addition of acids.
The concentration of alkalinity in wastewater is important where chemical
treatment is chemical treatment is to be used, in biological nutrients
removal, and where ammonia is to be removed by air stripping. (13)
 Phosphorous
….phosphorous is also essential to the growth of algae and other
biological organisms. The organically bound phosphorous is an
important constituent of industrial wastewater and sludge. (13)
● PH
The hydrogen ion concentration is an important quality parameter of
wastewater. The concentration range suitable for the existence of most
biological life is quite narrow and critical. Wastewater with an adverse
concentration of hydrogen ions is difficult to treat by biological means,

24. 17
and if the concentration is not altered before discharge, the wastewater
effluent may alter the concentration in the natural waters. (13)
● Nitrogen
Because nitrogen is an essential building block in the synthesis of
protein, nitrogen data will be required to evaluate the turbidity of
wastewater by biological process. Insufficient 16 nitrogen can necessitate
the addition of nitrogen to make the wastewater treatable. Where control
of algal growth in the receiving water is necessary to protect beneficial
uses, removal, or reduction of nitrogen in wastewater prior to discharge
may be desirable. The total nitrogen, as a commonly used parameter,
consists of many numerous compounds such as amines, amino acids, urea,
organic-N, etc. (13)
● Sulphur
Sulphate is reduced biologically under anaerobic conditions to sulfide,
which in turn can combine with hydrogen to form hydrogen sulfide.
Hydrogen sulfide released to the atmosphere above the wastewater in
sewers that are not flowing full tends to accumulate at the crown of the
pipe. The accumulated H2S can then be oxidized biologically to sulfuric
acid, which is corrosive to steel pipes and equipment. (13)

25. 18
● Toxic inorganic compounds
….These are found particularly in metal plating wastewater and
should be removed by pre-treatment at this site of the industry rather
than be mixed with the municipal wastewater. Fluoride, another toxic
anion, is found commonly in wastewater from electronics
manufacturing facilities. Organic compounds present in some
industrial wastewaters are also toxic. Such a copper, lead, silver,
chromium, arsenic, and boron
● Heavy metals
Trace quantities of many metals, such as nickel (Ni), manganese (Mn),
lead(pb), chromium (Cr), cadmium (Cd), zinc (Zn), copper (Cu), iron
(Fe), and mercury (Hg) are important 17 constituents of some industrial
wastewaters. The presence of any of these metals in excessive quantities
will interface with many beneficial uses of the water because of their
toxicity, therefore, it is frequently desirable to measure and control the
concentration of these substances.
2.4 Biological characteristics
Some industries have certain pathogenic organisms like
slaughterhouses others have fungi as starch and yeast factories. Biological
tests on wastewater determine whether pathogenic organisms are present
by testing for certain indicator organisms. Biological information is
needed to assess the degree of treatment of the wastewater before its
discharge to the environment. Total nitrogen is a commonly used
parameter that includes a number of parameters, NH3, NH4-N, NO3-N,
NO2- N, urea, organic N such as amines, amino acids, proteins, etc., and
process chemicals. The presence of these compounds depends on the
production. (14)

26. 19
Chapter 3
Industrial wastewater treatment

27. 20
3. Industrial wastewater treatment
3.1primary.treatment.(physical..treatment)
…….primary treatments in many wastewater treatment facilities in
elsewhere are the most common wastewater treatment processes and
contain many forms of physicochemical processing that may be
categorized into a small number of basic operations called unit operations.
Physicochemical processes in the primary treatments food and
agricultural wastewater generally comprise a set of unit operations that
are intended to remove particulates and other coarse materials from the
wastewater stream prior to the secondary treatment process (mostly
biological process). The removed solids are fed into either aerobic or
anaerobic digesters for further volume reduction. 19 In primary treatment,
only physicochemical processes are used to separate suspended solids and
greases form wastewater. Primary treatment of food and agricultural
wastewater usually include screening, flotation, sedimentation, and
sometimes granular sand filtration that used to separate suspended solids
and greases from wastewater. In a typical wastewater treatment facility
for a food processing plant, wastewater is normally held in a tank for
several hours, allowing the particles to settle to the bottom and the greases
to float to the top. The solids drawn off the bottom and skimmed off the
top receive further treatment as sludge. The clarified wastewater flows on
to the next stage of wastewater treatment. The exact line up and sequence
of unit operations consists of unit operations to remove suspended solids,
oils and elation largely depended on the characteristics of wastewater
streams, objectives of treatment, and local environmental laws.

28. 21
a) Screening from
…..Wastewater form food processing or postharvest processing may
contain debris, either suspended or floating on the surface. These coarse
solids have to be removed at the very beginning of the wastewater
treatment regimen. Screening of debris is sometimes considered as a
''preliminary'' treatment, not part of primary treatment of wastewater,
however, the distinction is more semantics than anything else. Screening
can be effective in the food industry to reduce the amount of relatively
large solids (0.7 mm or larger) quickly and cheaply in the wastewater. The
simplest type of screen is an inclined flow through type of static screen
with openings of about 1.5 mm to 6 mm for fine screens with opening of
0.2 to 1.5 mm placed after the coarse or fine screens, which can reduce
suspended solids to levels near those achieved by primary clarification
/sedimentation. (15)
Fig. (2,3): show on Mechanical Screen

29. 22
b) Flotation
Flotation is a physical process of removing not only oil and grease,
but also fine and light suspended particulates from wastewater. Flotation
has appeal to food wastewater treatment because this source of
wastewater contains a substantial amount of oil/grease flotation on the
surface. The particulates in wastewater that do not settle well and take too
much time for settling are also good candidates for flotation treatment.
Flotation is achieved by introducing gas (usually air) in the wastewater
stream through either pressure dissolved air in the feed or direct air
diffusers or vacuum. The air bubbles attach themselves to the particulates
causing the particulates and oil to aggregate and rise to the surface where
the particulates are removed by mechanical skimmers. For oil and grease
removal, the emulsified oil grease in wastewater presents a problem for
utilization of flotation technology.(18)
fig (4) show Vacuum Flotation fig (5) show on Air Flotation

30. 23
c) Sedimentation
Sedimentation is the most common physical unit operation in
Wastewater, it is a process by which the suspended solids, which have
higher densities than that of water, are removed from wastewater by the
action of gravity in the bottom of the settling tank or basin (also called a
clarifier) within a reasonable period of time. Sedimentation uses
gravitational force to separate unstable and destabilized suspended solids
from wastewater. It is based on the density difference between the bulk of
the liquid and the solids. Stabilized solids such as colloids can be
destabilized with flocculants. Sedimentation is a very important primary
treatment process, however, also used in the biological treatment, such as
activated sludge and trickling filters for solid removal. The settling
characteristics of the solids are determined by the types of the settling’s
solids and their concentrations. (17)
fig. (6) shows on rectangular basin fig. (7) show on Circular basin

31. 24
d) Flow Equalization
Generally speaking, flow equalization is not a treatment process or
treatment methods, it's a method to improve wastewater treatment
process, where they are physicochemical processes or biological
processes. The purpose of flow equalization is to balance out the process
parameters, such as flow rate, organic loading, and strength of wastewater
streams, PH, and temperature over a 24-hour period. Flow equalization
usually involves construction of large basins to collect and hold
wastewater streams, from which the wastewater is pumped to treatment
facilities at a constant rate. Mixing is usually provided to ensure adequate
equalization in basins. Additionally, these basins also provide some
treatment functions by oxidizing the reduced compounds in the
wastewater and reducing the BOD through air stripping. The mixing may
be achieved by a number of ways: distribution of inlet flow or baffling,
turbine mixing, diffused air aeration, and mechanical aeration. (16)
Fig. (8): show on parallel plate

32. 25
e) Filtration processes
Filtration is often employed in wastewater treatment, with or
without prior treatment by coagulation- flocculation and sedimentation,
for removal of flocks from primary and secondary wastewater treatment
processes, solids remaining in effluents from primary and secondary
wastewater treatment processes, and precipitates from physicochemical
treatment of phosphate from the advanced wastewater treatment stage.
Earlier application of filtration for wastewater treatment borrowed heavily
from design and operational experience with potable water treatment.
Fig. (9): show on sand filter

33. 26
3.2 Secondary Treatment "Chemical Treatment"
3.2.a) Chemical Pre-treatment
● Neutralization
Industrial wastewaters often contain acidic or alkaline components
which require neutralization before discharge or treatment. For
wastewater discharged to receiving waters, a pH between 6 and 9 is
frequently specified by regulatory |agencies. For wastewater entering
biological treatment processes, the pH should be maintained between
6.5 and 8.0 for optimum growth of the microorganisms. Aerobic
biological processes generate CO, which also affects the pH of the
system. Spent acid, especially sulfuric acid, constitutes the majority of
plant wastewater requiring neutralization. Lime is the most widely used
alkaline material for neutralization acid wastes because of its low cost.
The solid lime, however, maybe slows to react and may form insoluble
precipitates such as CaSO4.Sodium carbonate (soda ash), sodium
hydroxide, and ammonia react faster with acids than lime but they are
more expensive. Alkaline wastewaters are F12 usually neutralized with
sulfuric acid or with waste acids from other operations. A flue gas can
also be used to neutralize alkaline wastes since the CO, in flue gas
forms carbonic acid when contacted with water. (19)
● Oxidation/Reduction
Oxidants are used in wastewater treatment as a first step in the
removal of heavy metals to oxidize organics or as a last step in a
treatment process, to oxidize odoriferous compounds such as hydrogen
sulphide or to oxidize inorganics such as cyanide and for disinfection.

34. 27
● Coagulation
it takes place in rapid mix, or flash mix basins they are very rapid, the
primary function of rapid mix basin is to disperse the coagulant so that it
contacts all of the wastewater. Two theories have been advanced to
explain basic mechanisms involved in the stability and instability of
colloid systems.
Chemical theory assumes that colloids are aggregates of definite chemical
structural units, it occurs because of specific chemical reactions between
colloidal particles and the chemical coagulant added. Physical theory
proposes that reduction of forces tending to keep colloids apart occurs
through the reduction of electrostatic forces, such as the zeta potential
good coagulation, flocculation and sedimentation is difficult to obtain in
wastewater treatment. (19)
● Flocculation
The purpose of flocculation is to form aggregates or flocs from the
finely divided matter. The flocculation of wastewater by mechanical or
air agitation may be worthy of consideration when it is desired to (19)
:
 Increase the removal of suspended solids and BOD5 in primary
settling facilities.
 Condition wastewater containing certain industrial wastes
 Improve the performance of secondary settling tanks, especially
the activated sludge

35. 28
Fig. (10) show on Coagulation & Flocculation Process
3.2.b) chemical precipitation
Chemical precipitation in wastewater treatment involves the addition of
chemicals it alters the physical state of dissolved and suspended solids and
facilities their removal by sedimentation. The degree of clarification obtained
depends on the quantity of chemical used and care with which the process is
controlled. From80 to 90 percentof the total suspended matter, 50 to 80 percent
of the BOND5 and 80 to 90 percent of bacteria can be removed by chemical
precipitation. (19)

36. 29
3.3 Tertiary Treatment (Biological Treatment)
3.3.1 Biological wastewater treatment
Often associated with secondary wastewater and intends to treat the
dissolved and colloidal organics after primary treatment. The goal of all
biological wastewater treatment system is to coagulate and remove or
reduce the non-settling organics solids and dissolved organic load from
the effluents by using microbial communities to degrade the organic load
through biochemical reactions. Biological wastewater treatment is
generally a major part of secondary treatment design wastewater and
characterized by reduction of the communities to degrade the organic load
through biochemical reactions and reduction of oxygen demand of
influent wastewater to a given level of purification. The microorganisms
responsible for reducing the organic maters and consequently the oxygen
demand of inorganic wastewater is classified based on the way in which
they utilize oxygen: aerobic (need oxygen for their metabolism),
anaerobic (thrive in the absence oxygen), or facultative (can live with
oxygen and live without it through their metabolisms). Aerobic biological
treatment dominates secondary wastewater treatment scenes and is
performed in the presence of oxygen by aerobic microorganisms
(principally bacteria) that metabolize the organic matter in the
wastewater. Anaerobic processes sometimes are also used in the
secondary biological treatment of wastewater. Anaerobic processes
employed to treat high-strength wastewater, such as high-strength food
processing wastewater streams when the prospect of difficulty associated
with oxygen supply to the reactor and large biomass produced in an
aerobic process is deemed uneconomical.

37. 30
3.3.1.1 Aerobic biological treatment
a) Activated sludge Processes
Activated sludge is a secondary treatment process in which
wastewater has normally received primary sedimentation is allowed to
flow through the aeration tank or " reactor " where aerobic bacterial
culture is maintained in suspension. The reactor contents are referred to
as the " mixed liquor " The aerobic environment in the reactor is achieved
by the use of diffused or mechanical aeration, which also serves to
maintain the mixed liquor in a completely mixed regime. After a specified
period of time, the mixture of new cells and old cells is passed into a
settling tank, where the cells are separated from the treated wastewater. A
portion of the settled cells is recycled to maintain the desired
concentration of organisms in the reactor, and a portion is wasted. The
portion wasted corresponds to the new growth of cell tissue, associated
with a particular wastewater. The major types of activated sludge
treatment processes used for secondary treatment are: Conventional
Activated Sludge with variation of the conventional systems, Extended
Aeration. Tod Sludge and variation of the conventional.
b) Conventional Activated Sludge
The conventional activated sludge system contains a tank for
wastewater aeration followed by a settler and a solid recycle line. The
wastewater flows through under constant aeration in the presence of
activated sludge and exits at the end of the tank after 4-8 hours of
residence time. As the flow passes through the tank, the high oxygen
demand gradually will decrease. The oxygen concentration in the reactor
should be 0.5-2 mg / l throughout, where values over 2 mg / l are
considered lost energy. Most conventional plants use tapered aeration to

38. 31
adjust the air rate along the reactor length to satisfy the local oxygen
demand.
Fig. (11): show on Conventional Activated Sludge
3.3.1.2. Extended Aeration
This is the modified form of a conventional activated sludge process
in which the production of Excess sludge is minimized by oxidation and
an increase in residence time, i.e., through the larger size of the aeration
tank. The retention time is extended to 1-2 days, which results in a very
low net yield of sludge due to its consumption by endogenous respiration.
The main advantage of the extended aeration system is in having the
minimum of sludge handling facilities as compared with other
conventional activated sludge processes. The sludge in extended aeration
effluents is very light, of non - degradable nature, and settles with

39. 32
difficulty. Therefore, settling tanks are provided with a longer retention
time of approximately 4 hours versus 2 hours for the conventional
treatment process.
3.3.1.3. Sequential Batch Reactor " SBR
Sequential Batch Reactor (SBR) is a fill - and - draw activated - sludge
treatment system. The unit processes involved in the SBR and conventional
activated - sludge systems are identical. Aeration and sedimentation /
clarification are carried out in both systems. However, there is one important
difference. In conventional plants, the processes are carried out simultaneously
in separate tanks, whereas in SBR operation the processes are carried out
sequentially in the same tank. (20) All SBR systems have five steps that are
carried out in sequence as follows: 1) Fill 2) React (aeration), 3) settle
(sedimentation / clarification), 4) Draw (decant) 5) Idle in that there is no need
for a return activated. (20)
Fig. (12): show on Sequential Batch Reactor biological treatment

40. 33
3.3.1.4 Trickling Filter " BiologicalAir Filters "
The concept of a trickling filter grew from the use of contactfilters, which
were watertight basins filled with broken stones. In operation, the contact bed
was filled with wastewater from the top, and the wastewater was allowed to
contact the media for a short time. The bed was then drained and allowed to rest
before the cycle was repeated; a typical cycle required 12 hours (6 hours for
operation and hours of resting).
Fig. (13,14): show on Trickling Filter "Biological Air Filters " biological
treatment”

41. 34
3.4 Anaerobic Biological Treatment.
Anaerobic Contact Process Some industrial wastes that are high in
BOD, can be stabilized very efficiently by anaerobic treatment. In the
anaerobic contact process, untreated wastes are mixed with recycled
sludge and then digested in a reactor sealed off from the entry of air. After
digestion, the mixture is separated in a clarifier or vacuum flotation unit,
and the supernatant is discharged as effluent, usually for further treatment.
Settled anaerobic sludge is then recycled to seed the incoming wastewater.
The disadvantages and advantages of the anaerobic treatment as compared
to aerobic treatment that the slow growth rates required a relatively long
detention time in the digester for adequate waste stabilization to occur.
Most of the organic waste is converted to methane gas, which is
combustible and therefore a useful end product. The high temperature
necessary to achieve adequate treatment are often listed as disadvantages
of the anaerobic treatment process; however, high temperature is
necessary only when sufficiently long mean cell - residence time cannot
be obtained at nominal temperatures.
Fig. (15): show on Anaerobic Biological Treatment

42. 35
5. Conclusion
 From reviewing study, there were many conclusions:
 The physicochemical value of the sugar industry effluent is very
high which cross the standard limit.
 It should be facing this problem due to their effects on the ecology
system.
 Physio-chemical and biological methods are generally used to treat
the sugar industries’ effluent.
 The treated effluent of sugar industries is well balanced in chemicals
if it is diluted with other fresh water and can be used for irrigation
purpose.
 Effluents which are released from sugar industry after treatment
may be utilized for industrial processing again.
 No industrial development can be expected without any adverse
impact on environment and sustainable development would only be
possible if the adverse effects are minimized through strict
maintenance and control measures

43. 36
6. References:
1. Hammer, M.J. and Hammer Jr, M.J. (2011), “Water and Wastewater
Technology”, (7th edition), Prentice-Hall, USA,pp159.
2. Metcalf & Eddy, Inc. (2002). Wastewater Engineering - Treatment and
Reuse (4Th edition). McGraw-Hill, New York,pp243.
3. Qasim, S.R. (1998). Wastewater Treatment Plants: Planning, Design &
Operation (2nd edition). CRC Press, Sweden,pp283.
4. Tebbutt, T.H.Y. (1998). Principles of Water Quality Control (5th
edition). Butterworth-Heinemann,Britain,pp154.
5. Viessman, W. and Hammer, M.J. (1998). Water Supply and Pollution
Control (6th edition). Prentice-Hall, United kingdom,pp78.
6. Czysz W. and Schneider W., (1989) Wastewater Technology: Origin,
Collection, Treatment and Analysis of Wastewater, Springer - Verlag
Berlin Heidelberg, New York, pp103-10
7. Wrang & Howard, (2004) " Hand book of Industrial and Hazardous
Wastes Treatment " USA, pp96-97.
9.Csuros M., Csuros C. (1999). Microbiological Examination of Water
and Wastewater. Boca Raton, Florida, USA: CRC Press, 324 pp.
10.Industrial & Hazardous. )1991(Waste Treatment, Nelson Leonard
Nemerow , Van Nostrand Reinhold, New York,pp325.

44. 37
11.M.A. Mullkk, )1976(Wastewater Treatment Processes in the Middle
East, Water Pollution Control Federation, Washington, D.C.pp 23
12. Metcalf & Eddy, )1991(Wastewater Engineering, Treatment
Disposal & Reuse, Third Edition, United States American,pp748.
13. Nelson Leonard Nemerow,)1991( Industrial and Hazardous Waste
Treatment, Van Nostrand Reinhold, New York,pp472.
14. Nancy Riikonen, )1992(Industrial Wastewater Source Control, Mc
Graw - Hill Publications Co. New York,635.
15. Vincent Cavaseno,)1980( .Industrial Wastewater & Solid Waste
Engineering,.
16. Russell L. Culp, )1978(Handbook of Advanced Wastewater
Treatment, Second Edition, Van Nostrand Reinhold Environmental
Engineering Series. New York,pp89.
18. Ralph L. Stephenson, )1998(The industrial Wastewater Systems
Handbook, Lewis Publishers, New York,pp213.
19. W.W. Eckenfelder, )1970( Water Pollution Control, The Pemberton
Press, Jenkins Publishing Company, New York.
20. NPDES Compliance Inspection Manual,) ,1994(, United States
Environmental Protection Agency, Office of Environmental and
Compliance Assurance September.
21. Environics Management of Environmental Systems,
(2001)Environmental Inspection Procedures Manual. September.
22. Barron B., Rosenbaum M., Balcerzak P., Angenent L. (2010). A
Curriculum for High School Science Education. Microbial Fuel Cells: A
living Battery. Cornell University, p.89

45. 38
23. Clauwaert P., Van der Ha D., Boon N., Verbeken K., Verhaege M.,
Rabacy K .. Verstraete W. (2007). Open air bio cathode enables
effective electricity generation with microbial fuel cells, Environmental
Science and Technology. 41 (21, 7564-7569
24. Energy - Saving Wastewater Treatment: Taking a Sequencing Batch
Reactor as an Example. Biotechnology and Bioengineering, 108 (6),
1260-1267.
25. Flodman, A., (2002 ) . Air emissions of methane, nitrous oxide and
ammonia when storing dewatered sewage sludge. Master Thesis.
Swedish University of Agricultural Sciences , Uppsala , Sweden , 53p.
26. Lefebvre O. , Al - Mamun A. , Ng H.Y. ( 2008 ) . A microbial fuel
cell equipped with a bio cathode for organic removal and denitrification
. Water Science & Technology , 58 ( 4 ) , 881-885 .
27. Mathuriyal A.S., Sharma V.N. (2010) . Treatment of Brewery
Wastewater and Production of Electricity through Microbial Fuel Cell
Technology. International Journal of Biotechnology and Biochemistry ,
6 (1 ) , 71-80 .

46. 39
.

47. 40
‫الملخص‬
‫ومع‬ .‫مصر‬ ‫في‬ ‫االقتصادية‬ ‫التنمية‬ ‫في‬ ‫مهمة‬ ‫مكانة‬ ‫السكر‬ ‫صناعة‬ ‫تحتل‬
،‫ذلك‬
‫مي‬ ‫فإن‬
‫اه‬
‫السكر‬ ‫مصانع‬ ‫تنتج‬ .‫التلوث‬ ‫عبء‬ ‫من‬ ‫عالية‬ ‫درجة‬ ‫تتحمل‬ ‫الصناعات‬ ‫هذه‬ ‫عن‬ ‫الناتجة‬ ‫الصرف‬
‫حوالي‬ ‫مصر‬ ‫في‬
1000
‫البنجر‬ ‫أو‬ ‫السكر‬ ‫قصب‬ ‫من‬ ‫واحد‬ ‫لطن‬ ‫الصحي‬ ‫الصرف‬ ‫مياه‬ ‫من‬ ‫لتر‬
‫صناعة‬ ‫من‬ ‫العادمة‬ ‫المياه‬ ‫تشكل‬ .‫المطحون‬
،‫السكر‬
‫دون‬ ‫تصريفها‬ ‫تم‬ ‫إذا‬
،‫معالجة‬
‫تلوث‬ ‫مشاكل‬
‫من‬ ‫كل‬ ‫في‬
.‫والبرية‬ ‫المائية‬ ‫البيئية‬ ‫النظم‬
‫نسبة‬ ‫الرتفاع‬ ‫ا‬ً‫نظر‬
،‫التلوث‬
‫تؤثر‬ ‫التي‬ ‫ا‬ً‫ث‬‫تلو‬ ‫األكثر‬ ‫الصناعات‬ ‫من‬ ‫السكر‬ ‫صناعة‬ ‫تعتبر‬
‫المهام‬ ‫من‬ ‫معالجتها‬ ‫وتعتبر‬ ‫معقدة‬ ‫خصائص‬ ‫السكر‬ ‫صناعة‬ ‫من‬ ‫الصرف‬ ‫مياه‬ ‫تحمل‬ .‫بيئتنا‬ ‫على‬
‫استخدامه‬ ‫إعادة‬ ‫وكذلك‬ ‫معالجتها‬ ‫حيث‬ ‫من‬ ‫البيئة‬ ‫لمهندسي‬ ‫الصعبة‬
‫اللون‬ .‫ا‬
،‫البني‬
‫الحر‬ ‫درجة‬
‫ارة‬
،‫المرتفعة‬
‫الحموضة‬ ‫درجة‬
،‫المنخفضة‬
‫الكيميائى‬ ‫الكود‬
،‫المرتفع‬
‫الطلب‬
‫األوكسجين‬
‫الب‬
‫يولوجي‬
،‫العالي‬
‫الصلبة‬ ‫المواد‬
،‫الذائبة‬
‫العضوية‬ ‫وغير‬ ‫العضوية‬ ‫المواد‬ ‫من‬ ‫الزائدة‬ ‫والنسبة‬ ‫الرائحة‬ ‫مشاكل‬
،‫الذائبة‬
‫الصناعية‬ ‫السكر‬ ‫لمخلفات‬ ‫المميزة‬ ‫السمات‬ ‫وهي‬
‫تصريفها‬ ‫تم‬ ‫إذا‬ ‫السائلة‬ ‫النفايات‬ ‫هذه‬ .
‫دون‬
،‫معالجة‬
‫االقتصادية‬ ‫المعالجة‬ ‫تعتبر‬ .‫والبرية‬ ‫البحرية‬ ‫البيئية‬ ‫النظم‬ ‫من‬ ‫لكل‬ ‫مشاكل‬ ‫تطرح‬ ‫فإنها‬
.‫صعبة‬ ‫مهمة‬ ‫للسكر‬ ‫الصناعية‬ ‫للنفايات‬ ‫التكلفة‬ ‫حيث‬ ‫من‬ ‫والفعالة‬
،‫لذلك‬
‫معاي‬ ‫لتلبية‬ ‫التكلفة‬ ‫حيث‬ ‫من‬ ‫وفعالة‬ ‫مناسبة‬ ‫طريقة‬ ‫تضمين‬ ‫فإن‬
‫الت‬ ‫ير‬
‫هو‬ ‫فريغ‬
‫التقنيات‬ ‫مختلف‬ ‫عن‬ ‫وموجزة‬ ‫موجزة‬ ‫لمحة‬ ‫الدراسة‬ ‫هذه‬ ‫تقدم‬ .‫للوقت‬ ‫ا‬ً‫م‬‫تما‬ ‫المطلوبة‬ ‫الحاجة‬
‫للسكر‬ ‫الصناعية‬ ‫المخلفات‬ ‫معالجة‬ ‫في‬ ‫المستخدمة‬ ‫المتقدمة‬
‫عملية‬
‫المعالجة‬
‫الصناعي‬ ‫الصرف‬ ‫محطة‬ ‫داخل‬ ‫تتم‬
‫على‬
:‫مرحلتين‬
1
.
‫اولية‬ ‫معالجة‬
‫الفيزيائية‬ ‫بالطرق‬ ‫الحجم‬ ‫كبيرة‬ ‫الملوثات‬ ‫من‬ ‫التخلص‬ ‫يتم‬ ‫وفيها‬
‫والكيميائية‬
.
2
‫ثانويه‬ ‫معالجه‬.
‫المواد‬ ‫من‬ ‫التخلص‬ ‫يتم‬ ‫وفيها‬
‫العضوية‬
‫الموجودة‬
‫المياه‬ ‫في‬
‫ال‬ ‫معالجة‬ ‫طريق‬ ‫عن‬
‫هوائية‬
‫ومعالجة‬
‫هوائية‬
‫وهذا‬
‫هذا‬ ‫عنه‬ ‫يتحدث‬ ‫ما‬
‫المشروع‬

48. 41
‫بكالوريوس‬ ‫مشروع‬
‫السكر‬ ‫صناعة‬ ‫من‬ ‫الناتجة‬ ‫الصرف‬ ‫مياه‬ ‫تدوير‬ ‫إعادة‬
‫الطالب‬ ‫اعداد‬
‫حسن‬ ‫مجدي‬ ‫محمد‬
‫الرابع‬ ‫المستوي‬
‫التكاملية‬ ‫والصناعات‬ ‫السكر‬ ‫صناعة‬ ‫تكنولوجيا‬ ‫كلية‬
‫اشراف‬ ‫تحت‬
‫النقيب‬ ‫عاطف‬ ‫د‬.‫أ‬
‫كلية‬
‫الهندسة‬
-
‫مشرف‬
‫التكاملية‬ ‫والصناعات‬ ‫السكر‬ ‫صناعة‬ ‫تكنولوجيا‬ ‫بكلية‬ ‫الهندسية‬ ‫الشعبة‬
‫أ‬
‫سيوط‬
2022