1. Environmental Challenges
Facing Sugar Sector in
Pakistan
By
Talha Usman
M.Sc(Env,Science)

2. Waste produce during sugar
Production:
Mill House Sugar cane
(waste & by product)
Wastewater from bearing house of the mill
contain SS and oil contents also include
washing water used for floor cleaning,which
contain sugar content like Bagasse
Process House Sugar Juice
(waste & by product)
Filter cake generates aggressive effluents
like BOD5,COD,TDS and Molasses

3. Boiler House Bagasses,Furnace
oil
(Waste & by product)
Fly ash, smoke, flue gasses
Cooling pond water and
chemical
(waste & by product)

4. Environmental Solution
It can be classified into three main
categories.
1. In-House improvement options
(Waste reduction at source )
2. Air & Noise Emission control measures
3. Waste water treatment technologies for
NEQS compliance

5. In-House improvement options
( Waste reduction at source)
Flow measurement through flow meter and monitoring at
inlet and out let of each consumer unit at the mill for better
water management practices.
Use of optimum imbibitions rate to save energy in terms of
steam consumption and to reduce organic and hydraulic
load from the process house
Dry cleaning of mill floors with bagasse
Efficient operation of evaporators will reduce waste
disposal problems and enhance sugar recovery.overloading
of evaporators and vacuum pans, boiling at excessive rates,
operating them at incorrect liquid levels,and variation of
vacuum lead to a loss of sugar through condenser water.
Recycling of cooling and condenser water

6. The simple measure of controlling spillover of molasses
can very significantly reduce the organic pollution
content(BOD5) of the wastewater stream.
Segregation of oil from other effluent will allow for the
recovery and reuse of lubricating oil and reduce soil
contamination when wastewater is applied for irrigation.
Controlling the mixing of filter mud with wastewater can
very significantly reduce the organic and inorganic pollution
content of wastewater stream.
Routine inspection of units, particularly pumps, pipes and
other vessels.
Reducing water used for floor sweeping and washing by
recovering water from various mill processes and reusing it
for cleaning purposes.
Detaining filter cloth washing in a holding tank for a short
time before being allowed to mix with other effluents from
the mill will reduce the contamination in the condenser

7. Installation of circular mist eliminators or demisters
constructed of stainless steel in the multiple effect
evaporators can eliminate sugar entry in condenser water.
Bagasse management is of paramount importance in
establishing overall energy efficiency in the mill .steam and
power generation and reduction in fuel oil consumption are
largely dependent on an adequate supply and efficient
utilization of bagasse .Benefits will also result from ensuring
that maximum moisture has been removed before
bagasses is used in the boiler.
As far as air emissions are concerned the first step should
be to set up a system of regular monitoring of stack
emissions with periodic boiler tune ups.this can
considerably increase boiler efficiency and minimization
emissions.
Reduction of the use of Lead sub Acetate(Toxic chemical)

8. Air and Noise Pollution Control
Air Emission Control Methods:
1. Regular monitoring of stack emissions
2. Settling chamber
(These chamber will remove large particulate matters)
3. Wet collectors
(Mostly available in simply spray tower is an
effective method for removing particulate
matters.)
4. Gas Scrubber
5. Electrostatic precipitator

9. Air and Noise Pollution Control
Noise Pollution Control Methods:
1. Sound reduction at source
(using silencers)
2. Interrupting the path of the sound
(using sound barrier)
3. Protecting the recipient
(using Ear muffs,plug)

10. Strategy for wastewater Management
Steps for wastewater minimization:
Arrangement to divert the washing of Lime house and grit
washing to condenser water channel to reclaim both the
water and residual Lime which helps to make up the
condenser water pH.
Collection and recirculation of leakage from pumps glands
Collection of centrifugal house floor washing and pumping
it back to raw juice.
Using sugar contaminated condensate for maceration at
mill house.
Recirculation of all cooling waters.
Reclamation of hot water and vapors from boiler blow

11. Drainage within the plant should not be allowed as this
leads to indiscriminate use of water.
Arrangement for collection of all cooling waters should be
made designed for cascade cooling of water which follow
the recirculation.
Boiler feed water requirement will be met by condensation
from vapors cells, if need be supplemented by the
condensate from pans, the collection system should be
tow ways.
Vapour condensate from vapour line juice heaters is
collected and used in maceration.
The overflow of spray pond and boiler blow downs can be
used for spraying over bagasse and fly ash in dumping
yard to prevent the hazard of fire.
Prepare the Do,s and Don,t for the plant personals.

12. All ground water tube wells have meters. Daily recording
and monitoring shall help in reduction of ground water
extraction through effluents generation.
Set up a pit for collecting juice contaminated water to
reduce sugar content in washing and cleaning water.
Monitor and follow up the quality and quantity of pollution
sources to prevent additional polluting effluent.
Precipitation and filtration of flue gas washing water will
regenerate it into a colorless and transparent state. This
regenerated clean water can be reused in the flue gas
washing system.
Training and developing the concept of water conservation
to managers, operators and labors.
Organizing the internal seminar giving opportunity to
express the views to suite the environmental and company

13. Wastewater Treatment Technologies
Solution Technical Characteristics Operational
Characteristics
Lagoon Anaerobic lagoons are BOD5 loading kg/m3? Least
s deep earthen basins used efficient
for high strength organic  BOD5 removal efficiency ?
wastewater with high solid 85-90%
concentration. Energy requirement for
Facultative lagoons are aeration kwh/kg BOD treated ?
earthen basins filled with Moderately efficient
screened or primary Hydraulic detention time ?
effluent in which Very high
stabilization of east is
 mechanical complexity ? low
brought about by a
combination of aerobic, Reactor resilience for power
anaerobic and facultative failure and shock loads ?
bacteria. Moderate to high
Aerobic lagoons are large, By-product ? Nil
shallow earthen basin used for
Land requirement ? large
treatment of wastewater by
natural processes.

14. Solution Technical Characteristics Operational Characteristics
Lagoons Maturation ponds are low On –site environmental impact
rate stabilization ponds –soil infiltration and aerosols
usually designed to provide dispersion
for secondary effluent Man power requirement ?
polishing and seasonal Skilled
nitrification. Frequency of repair &
maintenance ? medium
Tricking Wastewater flows from BOD5 loading kg/m3 ? Least
Filters top to bottom, dispersed efficient
over filter material BOD5 removal efficiency ? 85
(stones,plastic during 90%
which soluble compounds Hydraulic detention time ?
are removed and, to a Most efficient
lesser extent, solids are
Land requirement ? Small
taken up into the biofilm
adhered to the carrier Man power requirement ?
material. Skilled
Mechanical complexity ? Low
By product ? nil

15. Solution Technical Characteristics Operational Characteristics
Upflow The basic idea of this BOD5 loading kg/m3/d ? Very
Anaerobi system is that the flocs of efficient
c Sludge anaerobic bacteria will tend BOD5 removal efficiency ? 80
Blanket to settle under gravity, 90 %
(UASB when applying a moderate Energy requirement for aeration
Reactor up flow velocity of water. In kwh/kg BOD treated ? Most
this way no separate efficient
sedimentation tank is
Hydraulic detention time ? Mos
necessary.
efficient
The waste water passes
Mechanical complexity ? low
the reactor from the bottom
to top. To guarantee By product ? Biogas
sufficient contact between On site environmental impact ?
the incoming wastewater Nil
and the bacteria in the Land requirement ? Small
sludge layer the
Man power requirement ?
wastewater is fed evenly
over the bottom of the Highly skilled
reactor .Further mixing is Frequency of repair &
brought about by the maintenance ? low
production of the gas

16. Solution Technical Characteristics Operational Characteristics
Activated Many variations of BOD5 loading kg/m3/d ? Very
Sludge activated sludge treatment efficient
Treatmen exist, depending on load BOD5 removal efficiency ? 85
t characteristics. Activated 95%
sludge treatment is most Energy requirement for aeration
appropriate for high kwh/kg BOD treated ? Least
organic pollution loads. efficient
Most successfully applied if
Hydraulic detention time ?
hourly flow is low.
Moderately efficient
System consist only of
 mechanical complexity ? High
aeration tank (operated as
fill and draw system ) and Reactor resilience for power
mechanical surface failure ? Low and for shock loads
aerators. Aeration and ? Moderate
sedimentation takes place By product ? Nil
in the same reactor on the On site environmental
following cyclical principle: impacts ? Aerosol dispersion and
feeding and aeration of the
reactor during a certain period, noise
switch off the aeration, followed Land requirement ? Moderate
by settling of the sludge and
Man power requirement ?
discharge of the effluent.
Highly skilled

17. End-of-pipe Treatment in sugar mills
Combination of Lagoons in Sequence
(Anaerobic,Facultative and Maturation)
Preliminary design and costing of this option?for a mill generating
6,000 - 7,000mg/l BOD5 ? Suggests that to achieve of 90%
removal efficiency the lagoons system would require a total
surface area of 120 hectares, a total volume of 1.5 million cubic
meters,and a total retention time 216 days.The exorbitant level of
retention time, land requirement and high cost of lining make this
inadvisable for local sugar mills. However, unlined lagoons,
though pose serious threat to ground water quality, can also be
taken into consideration after careful analysis of environmental
condition around the mill.

18. End-of-pipe Treatment in sugar mills
Combined Treatment System Comprising of a
UASB Reactor and an Activated Sludge System
When used alone, the activated sludge system has a high
operational cost because of the energy required for aeration.
Combining it with a UASB Reactor significantly reduces this cost.
The UASB Reactor can remove about 80 - 90 % BOD5;in
addition, a by-product of the process is methane which can then
be used as a source of energy for the boiler. After passing
through the UASB Reactor, the effluent can passed through the
Activated Sludge System for treatment of remaining BOD5. The
combined system will achieve the same pollutant removal
efficiency as the Activated Sludge System but at lower cost. This
combined system will bring the present BOD5 and suspended
solids level near or below the NEQS.Such a system will require
around 1,500 - 3,000 square meters of land and its annual
operation and maintenance expenditure would be approximately
10% of its total cost .with in–house improvement USAB reactor
as single treatment can be applied.

19. Health Risks
Bagasses dust, fly ash and high noise levels (reaching up to
109dB)are particularly health irritant.Excessive exposure to
fly ash and bagasse dust may cause irritation to
eyes,asthma,and other respiratory diseases including
bagassosis(a lung disease caused by inhalation of bagasse
dust)Dust prone areas ,including cane preparation and the
boiler house, should be carefully monitored. Nuisance dust
levels should be controlled properly.Dermatitis or skin
disease is a major health complaint resulting from chemical
burns,and contact with lime and sugar.Toxic gasses
including sulfur dioxide,caustic fumes are released at
various stages of the process and are health hazards.Flue
gas which is produce by the combustion of bagasse cause
a visual nuisance and have serious health concern.These
problems are particularly high in boilers due to not equipped
with scrubbing or cyclone systems.

20. ISO 14001
A set of environmental management
requirements for environmental
management systems.The purpose of this
standard is to help all kinds of organizations
to protect the environment, to prevent
pollution, and to improve their overall
environmental performance.

21. Components of ISO 14001
Environmental policy
Planning
Implementation
Monitoring and evaluation
Review

22. Requirements for ISO 14001
Certification
Existence of EMS
Effective operation of EMS for at least
three month
Internal audit conducting capacity should
exist in the company
Environmental training has been imparted
to its employees
Documents are maintained
Management review has been conducted

23. ISO 9001 & ISO 14001 will help
you:
Promote & Enhance your business &
marketing efforts
Increase income revenues
Keep your customers happy & satisfied.

24. By having ISO 9001 & 14001
Certification,you gain:
Reduced liabilities & added protection
Extended management & operation tools,
including those to reduce “non quality” costs.
Improved control, to manage internal and
external
activities.
Improved quality for products and services.
Improved supply schedules for products and
services.
A better feeling caused by better managed
environmental care.

25. Environmental Management
Systems:
It is set of policy measures, management
actions, operating procedures,
documentation and record keeping,defined
responsibilities and accountabilities of
personals within an organization to address
its environmental issues.

26. Concept of EMS
Management review
Env, consequences of operation
Environmental policy
Set objective for Env,performance
Action planning
To achieve objective
Implementation
To monitor performance against these objectives
Corrective action
For continue improvement

27. Environmental Management
Systems Benefits
The benefits of an EMS and registration of the
EMS to ISO 14000 are organized into these
categories:
Increased profits
Operations
Marketing
Regulatory Compliance
Social Status