WATER POLLUTION CONTROL RESEARCH SERIES
12060 DSI 07/71
State-of-Art, Sugarbeet Processing
Waste Treatment
U.S. ENVIRONMENTAL PROTECTION AGENCY
-------
WATER POLLUTION CONTROL RESEARCH! SERIES
The Water Pollution Control Research. Series describes the
results and progress in the control and abatement of pollu-
tion of our Nation's waters. They provide a central source
of information on the research, development, and demon-
stration activities of the Environmental Protection Agency
through inhouse research and grants and contracts with
Federal, State, and local agencies, research institutions,
and industrial organizations.
Inquiries pertaining to the Water Pollution Control Research
Reports should be directed to the Head, Publications Branch,
Research Information Division, R&M, Environmental Protection
Agency, Washington, D.C. 20460.
-------
State-of-Art, Sugar beet Processing Waste Treatment
by
Beet Sugar Development Foundation
P. 0. Box 538
Fort Collins, Colorado 80521
for the
ENVIRONMENTAL PROTECTION AGENCY
Grant #12060 DSI
July, 1971
For sale by the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 - Price $1.25
-------
EPA Review Notice
This report has been reviewed by the Environmental
Protection Agency and approved for publication. Approval
does not signify that the contents necessarily reflect
the views and policies of the Environmental Protection
Agency, nor does mention of trade names or commercial
products constitute endorsement or recommendations for
use.
ii
-------
ABSTRACT
The beet sugar industry in the United States produces annually more
than 3 million tons of sugar from about 25 million tons of beets
grown in 19 states. This paper reports the waste disposal practices
of the 58 beet sugar factories operating in 1968-69 and provides an
estimate of the amount of pollution of streams attributable to these
factories. It is shown that, although stream pollution has been
greatly reduced, the beet industry still discharges to streams 3.15
pounds BOD per ton of beets sliced or a total of about 79 million
pounds annually. Amounts of water used are reported and methods of
re-use of water described. Estimates of total settleable solids are
made; methods of elimination are described. Effectiveness of some
biological treatments are estimated. Needed research is briefly out-
lined. Costs of waste disposal facilities and annual operating
costs are shown for many of the plants. A brief description of the
beet sugar process is furnished. Current practices employed by a
selected group of sugarbeet processing plants in several Western
European countries are also described.
This report was submitted in fulfillment of Grant #12060 DSI under
the sponsorship of the Water Quality Office, Environmental Protection
Agency.
Key words: Sugarbeet waste treatment, state-of-art, BOD discharge,
water consumption, water re-use, treatment costs.
ill
-------
CONTENTS
Section Page
I Conclusions 1
II Recommendations 3
III Introduction 5
IV Manufacturing Process 7
V Water Use in the Beet Sugar Factory 13
Flume or Transport Water 13
Process Water 13
Lime Mud 14
Barometric Condenser Water 14
Steffen Dilution Water 15
Miscellaneous Water Uses 16
VI Flow Diagrams 17
VII Waste Treatment and Disposal 21
Flume Water 21
Barometric Condenser Water 22
Lime Mud 22
Steffen Waste 23
General Wastes 24
VIII Associated Waste Disposal Problems 25
IX Treatment and Discharge of Effluents 27
X Cost of Waste Disposal Facilities 31
XI Laboratory and Pilot Plant Work on Waste Treatment 33
XII Problems Requiring Additional Research and Development 37
XIII Discussion 39
XIV References 43
XV Glossary 51
XVI Appendices 53
-------
FIGURES
1. Type I Water Flow in Beet Sugar Factory 18
2. Type II Water Flow in Beet Sugar Factory 18
3. Type III Water Flow in Beet Sugar Factory 19
4. Type IV Water Flow in Beet Sugar Factory 20
5. Waste Water Scheme - Ameln Factory (Pfeiffer
and Langen) 56
6. Schladen Factory Waste Water Scheme 58
7. Wabern Factory Water Scheme 60
8. Biological Filter Flow for Effluent Treatment,
Ely Factory 64
9. Newark Factory Waste Water Scheme 65
10. Wissington Factory Passveer Oxidation Ditch 66
11. Waste Water Scheme, Ortofta 73
12. Aarberg Factory Water Scheme 74
VI.
-------
TABLES
1. Present and Projected Processing Capacity of Beet Sugar
Factories by States 7
2. The Average Raw Material Requirements and End Products
Produced Per Ton of Beets Processed 10
3. Water Characteristics of the Schladen Factory
(Germany) 59
4. Water Characteristics of the Wabern Factory
(Germany) 61
5. Water Characteristics of the Ely Factory
(Great Britain) 63
6. Water Characteristics of the Newark Factory
(Great Britain) 66
7. Water Characteristics of the Breda Factory
(Netherlands) „ 68
8. Water Characteristics of the Ortofta Factory (Sweden) 72
9. Summary of Factory Capacities and Fresh Water Usage 78
10. Water Use and Re-Use Per Ton Beets 83
11. Waste Discharged to Stream Per Ton of Beets; Cost of
Disposal Facilities 88
12. Beet Sugar Factories Included in This Survey 91
Water Use, Re-Use and Disposal (by Factories) 94
Vll
-------
SECTION I
CONCLUSIONS
The successful production of sugar from sugarbeets dates from about
187U. Many of the original factories were constructed at sites
near small agricultural communities. The growth of these comm-
unities has required the installation of waste treatment, and/or
water conserving systems to remain a welcome partner of each area's
economic structure. The early-day discharge to receiving waters
of between 30 to 40 pounds of BOD,- per ton of beets processed has
been reduced to an average of 3.15 pounds in 1968. Greatest ad-
vancements have taken place in the last 10 years; a number of fac-
tories now recycle much of the process waters. Some factories
do not discharge BOD-containing water.
The technology presently known on the treatment and handling of
sugarbeet process wastes does not provide a single scheme that is
applicable to each and all geographical areas. It has been noted
that each factory is undergoing constant improvement by periodic
additions to existing facilities. The need to reduce or eliminate
the discharge of process waters from the factory premises is re-
cognized by the industry and will be accomplished as technology
and time permit. The progressive development of local and national
water quality standards will influence priority schedules for the
upgrading of treatment systems.
-------
SECTION II
RECOMMENDATIONS
Under the structure of the Federal Sugar Act, the price of sugar
to consumers is controlled through the powers vested in the Secre-
tary of Agriculture. Periodically each year he amends the total
national consumption requirements. Sales quotas to domestic pro-
ducers are adjusted accordingly. This unique method whereby price
of product is controlled, precludes the potential of translating
waste treatment costs to the end product price. This fact modifies
the recommendation of some typical waste treatment systems. It
has been demonstrated, however, that beet wastes are generally
amenable to presently-known treatment practices. It would appear
that appropriate treatment techniques to each separate stream offers
considerable .promise for the future. Otherwise, surge or mixing
lagoons to produce a more uniform waste would provide a waste that
can be digested by either aerobic or anaerobic organisms. Due to
odor problems associated with anaerobic digestion, aerobic approaches
should be given preferable attention. The handling and treatment
of waste lime mud and precipitated flume water solids need addi-
tional research efforts. The land available for discard of these
wastes becomes less and less. The by-product use of these solids
should be explored.
-------
SECTION III
INTRODUCTION
Under the terms of an agreement with the Federal Water Quality
Administration, this report presents data relating to the domestic
and foreign waste treatment technology in the sugarbeet processing
industry and outlines areas requiring further development. This
report includes:
(a) projections of the potential growth of the domestic industry
and its water pollution problems over the next ten years; (b)
details of present treatment practices including hydraulic and organic
loads, plant sizes, removal efficiencies, construction and operating
costs; (c) a discussion of pilot plant work on waste treatment;
and (.d) an analysis of the manufacturing process with a view toward
further in-plant treatment, by-product recovery and water re-use.
The reporting of data on a comparable basis has been complicated
by the diversity of conditions under which the b8 sugarbeet pro-
cessing plants operate. Sugar-processing plants are located from the
near-tropical areas of southern California and Arizona to the
frigid areas of Montana, Minnesota and North Dakota; from the arid
or semi-arid regions of the west to the areas of more abundant
rainfall in the east.
Of the 10 million tons of sugar consumed during 1968 in the United
States, more than three million tons were produced from sugarbeets.
The remainder was produced from mainland cane or supplied from
imported cane raws.
-------
SECTION IV
MANUFACTURING PROCESS
The slicing capacity of the factories shown in Table 1 ranges from
a low of 1,275 to a high of 7,000 tons per day, averaging about
3,250 tons each. Of these factories, 21 also recover sugar from
molasses by the Steffen process and one uses an ion-exchange process.
One company produces sugar from discard beet molasses by a barium
process in a separate plant and recovers monosodium glutamate from
Steffen and barium saccharate filtrates in still another plant.
All factories in this country and abroad use basically the same pro-
cesses. Differences in fresh water use and re-use and in waste loads
result from differences in operating practices and, to a minor
degree, from differences in equipment. Facilities for handling
wastes vary markedly from plant to plant. It will be noted that the
quantity of fresh water taken into plants in different areas varies
greatly. The total water, including re-used water, varies much less.
Most of the water used in a sugarbeet processing plant is used for
condensing vapors from evaporators and pans and for conveying and
washing beets. These uses do not require water of high purity,
hence considerable recirculation is possible. Differences in fresh
water use and in recirculation practices affect the quantity of
wastes discharged from the plant.
Table 1. Present and
Factories by States.
Projected Processing Capacity of Beet-sugar
Number of
State Factories
California
Colorado
Michigan
Idaho
Minnesota
Nebraska
Montana
Ohio
Utah
Wyoming
Washington
Arizona
Iowa
Kansas
Maine
North Dakota
Oregon
Texas
10
10
5
4
4
4
3
3
3
3
2
1
1
1
1
1
1
1
Rated Capacity
(1968)
Tons beet/day
39,800
25,400
10,900
20,000
12,800
9,510
8,720
5,000
6,350
7,200
10,525
4,200
2,400
3,200
4,000
5,000
6,650
6^500
Actual Capacity Projected
(1968) Capacity
Tons beet/day Within 10 yrs
37,825
26,500
10,324
20,169
11,830
9,974
8,450
5,130
5,972
6,817
10,250
4,200
1,881
2,605
4,000
3,915
6,600
6,500
40,000
29,300
11,800
24,950
14,750
10,000
11,450
5,130
6,350
7,550
13,800
4,200
2,400
3,600
4,000
5,000
7,200
6,500
Totals
58
188,155
182,942
207,980
-------
A Knowledge of the sugar production process is essential to an
understanding of the waste disposal problem. A brief description
of the process is provided in sufficient detail to show the app-
roximate quantities of operating materials and supplies, the yields
of salable products and the magnitude of wastes discharged.
The sugar company exercises considerable control of the sugarbeets
long before they are delivered to the factory. It obtains acreage
allotments-*-, develops or selects seed best suited to the area, makes
contracts with growers for the proper growing, harvesting, and delivery
of the beets to the factory or to the receiving stations. It de-
termines when the harvest will commence and, usually, the rate of
harvest—the latter being determined in some instances by the rec-
eiving equipment available and in others, where storage of beets
in piles is impractical, by the slicing capacity of the plant.
Beets in the northern interior sections of the United States are
processed in the fall from late September or early October to
January or even later. In these areas beets are stored in large
piles. Harvesting must be completed before freezing weather sets
in. The harvest in these areas is usually completed early in
November, although some beets may not be dug until considerably later.
The processing period is considerably longer than the period of
harvest, hence beets must be kept in open storage for periods ranging
from 20 to 40 or more days during which time considerable deterior-
ation occurs.
In California and other areas where warmer winter temperatures
prevail, storage of beets in piles is not feasible. The harvest is
carefully regulated in these regions so that beets may be processed
soon after removal from the field. In some of these areas the har-
vesting may be interrupted by winter rains. The plants are closed
until the rainy season ends and harvesting can begin again.
Loss of sugar from beets in storage is serious even under the best
of conditions; therefore, great effort is made to reduce the time
in storage by maintaining maximum slicing rates in the factories
even at some sacrifice in extraction efficiency-
Beets are delivered to the factory by trucks or railroad cars and
stored in large piles or dumped directly into flumes for transport
into the processing plant. The flumes are steel or concrete-lined
channels through which beets are conveyed by a continuous stream
of water.
lAcreage allotments are imposed upon growers by the Federal Government
tor certain years when over-production is to be avoided. Thus, even-
tual marketing of sugar from sugarbeets meets the limits established
by the terms of the Sugar Act.
-------
Water tor the flumes is supplied from the main fresh water tank or
from the evaporator and pan barometric condenser seal tanks. The
flumes are provided with rock catchers which trap and remove stones
and other heavy foreign material from the flow of beets. Trash
catchers remove light material including weeds and loose beet tops.
The beets are lifted from the flume to a beet washer by a beet wheel.
They are discharged from the washer to a roller conveyor where a
final washing is given by means of sprays of clean water under high
pressure. The washed beets are elevated to the slicer station where
they are sliced into thin strips called cossettes and fed into a
continuous diffuser. A mechanism is usually installed in a section
of the belt feeding the diffuser to weigh the beets entering the
process. Washings from the beet washer and sprays are discharged
into the flume. As will be noted later, this flume water consti-
tutes the largest volume of waste and, because of its volume and high
content of suspended and dissolved solids, becomes one of the most
difficult to handle.
The ditfuser is the first step in the beet sugar process. It
extracts sugar and other soluble solids from the cossettes under a
countercurrent flow of water. The liquor containing the sugar and
other soluble solids—called "raw juice"— is drawn off the diffuser
and pumped to the purification stations.
The exhausted cossettes are usually conveyed to pulp presses which
reduce the water content of the pulp to about 80 percent before the
cossettes are fed into a pulp drier. The pulp press water is usually
returned to the diffuser as part of the diffuser supply. A very few
plants do not dry the pulp. The wet pulp in these cases is pumped
over a screen to separate the pulp from the transport water. The
pulp is then discharged to a silo. Drainage from the wet pulp silo
constitutes one of the main sources of BOD in the plant effluent.
A particularly objectionable feature of the pulp silo is the prolonged
period of drainage, often continuing for months after completion of
the beet processing campaign.
The juice from the diffuser containing most of the sugar from the
beets, as well as soluble and colloidal impurities, is pumped to the
first carbonation station. Lime in the form of a slurry of calcium
hydroxide or calcium saccharate (from the Steffen process) is added
and the mixture is gassed with carbon dioxide from the lime kiln to
precipitate the lime. The calcium carbonate thus formed carries with
it suspended impurities in the juice. The lime precipitate is
separated from the mixture by means of thickeners and filters, and
then is pumped to a waste pond. The thin juice, after further treat-
ment with CC>2 , filtration and treatment with sulfur dioxide to
reduce the pH to about 8, is concentrated in multiple-effect evap-
orators to a thick (65 percent solids) juice and then boiled in a
single-effect evaporator (pan) to crystallize sugar. The sugar is
separated by centrifugation from the adhering syrup and dried. The
-------
syrup is concentrated further to yield additional crystalline sugar
and finally, molasses.
The molasses may be sold as such for animal feed or other purposes
or may be desugarized by the Steffen process. In this process the
molasses is diluted, cooled and treated with powdered quick lime to
precipitate the sugar as a saccharate.
The calcium saccharate after separation by filtration from the solu-
tion of molasses impurities is pumped to first carbonation. The
Steffen filtrate may be discharged as a waste or, after precipi-
tation and removal of calcium carbonate, evaporated to a thick
liquor called concentrated Steffen filtrate and dried on beet pulp
or used as a source for salable by-products—monosodium glutamate,
potash fertilizer salts and animal feed.
The raw materials entering the beet sugar process are beets, limestone,
small amounts of sulfur, fuel and water. The products are refined
sugar, dried beet pulp and molasses (See Table 2). The latter, as
indicated previously, may be further processed to yield additional
sugar.
Table 2. The Average Raw Material Requirements and End Products
Produced Per Ton of Clean Beets Processed.
Limestone, tons 0.04
Fuel, coal or gas, BTU 2.5 x 106
Water, intake, gal. 2200
Beet pulp, dry, tons 0.05
Sugar produced, tons 0.13
Molasses, tons 0.05
Waste water, gal. 2100
at Steffen Factories
Molasses worked, tons 0.05
Additional limestone, tons 0.02
Additional sugar produced, tons 0.015
Steffen filtrate, gal. 90
Wide differences in these quantities are experienced at individual
factories, particularly with regard to fresh water intake. Eight
factories withdraw less than 900 gallons per ton of beets sliced
(one, only 215) while eight withdraw 4,000 gallons or more.
10
-------
Within the last 2 decades, two important equipment changes have been
made in United States beet sugar factories which have affected water
usage and quantities of wastes. These are the installations of contin-
uous diffusers and of pulp driers. Although the first continuous
diffuser was installed more than 30 years ago, replacement of the
Roberts (cell-type) diffuser in the United States beet sugar industry
was not completed until two years ago. The first pulp drier was in-
stalled in an American factory over 50 years ago; one factory is still
without one.
The continuous diffuser permits factories to operate with lower draft,
i.e., with lower quantities of diffuser supply water. A further marked
reduction in water required for the diffusion process is accomplished
by the return of pulp press water to the diffuser. With the Roberts
diffuser pulp water and pulp press water were discharged as a waste.
The greatest reduction in fresh water usage, however, has been accom-
plished by the recirculation of flume water and by the re-use, after
cooling, of condenser water. Incentive for these changes has been:
first, the necessity, in some areas, for conserving the limited sourc-
es of fresh water; and second, the advantages of reducing the volume
of wastes to permit use of smaller ponds and other waste treatment
facilities.
11
-------
SECTION V
WATER USE IN THE BEET SUGAR FACTORY
Water is used for six principal purposes: (a) transporting (fluming)
and washing of beets, (b) processing, i.e., extraction of sugar from
beets, (c) transporting solid wastes—lime cake, (d) condensing va-
pors from evaporators and pans and cooling, (e) at Steffen factories,
dilution of molasses, and (f) cleaning of equipment and plant. A
brief description of each usage follows:
Flume or Transport Water
Transport of beets from piles or cars into the factory is invariably
accomplished by means of water flowing in a narrow channel (flume)
which not only provides gentle handling of the fragile beets but
removes much adhering soil. Beets are lifted from the flume to a
washer and then subjected to a final wash by sprays. The combined
flume, washer and spray water constitutes the largest single usage
of water, ranging from 1,200 to 4,000 gallons per ton of beets,
averaging about 2,340. This is not necessarily all new water. In
most factories flume water is recycled, usually after separation of
much of the suspended soil. The flume water carries in addition to
suspended matter, dissolved solids extracted from the beets. The
amount extracted depends largely on the condition of the beets.
Water used for fluming in many factories is water drawn from the
barometric condenser seal tanks. In others fresh water is used,
either alone or as a supplement to condenser water. The use of
warm condenser seal tank water for fluming is necessary in cold
climates to thaw frozen beets.
Process Water
Process water is used to extract sugar from the beet. About 270
gallons of water per ton of beets is used for this purpose. Data
submitted indicate in some instances, considerably more but these
probably include some pulp transport water. Nearly all factories
report 100 percent recycle of pulp water and pulp press water. The
weight of juice drawn from the diffuser amounts to about 125 percent
of the weight of beets entering. The pressed pulp contains about
80 percent moisture. It is easily calculated that make-up water
to the diffuser must be at least 45 percent of the weight of beets.
The total diffuser supply water consisting of make-up and recycle
will therefore range from about 100 to 120 percent of the entering
weight of beets, or equivalent to 240 to 290 gallons per ton of
beets. The make-up water may be drawn from fresh water supplies,
barometric condenser water, condensed water from the heaters, or a
13
-------
combination of these sources. Where condenser waters are cooled and
re-used a build-up of dissolved solids may result, rendering its use
in the diffuser undesirable.
Two factories of the Holly Sugar Corporation do not recycle pulp
water and pulp press water. The Torrington factory has no pulp drier.
Condenser water is used as the sole source of diffuser supply.
Pulp water and pulp silo drainage containing large amounts of organic
matter are discharged as wastes. The Brawley factory has a pulp
drier but does not recycle the pulp water or pulp press water back
to the diffuser. Instead, these waters are discharged to waste ponds.
Both fresh water and condenser water are used as diffuser supply.
The Union Sugar Company factory at Betteravia, California also uses
fresh or condenser water as diffuser supply with no recycle of
pulp press water.
Lime Mud
The precipitate of calcium carbonate containing raw juice impurities
is removed by a rotary vacuum filter which discharges a cake contain-
ing about 50 percent water. It is slurried with water and pumped
to a lime pond. Water used to slurry the lime cake may be fresh water,
condenser water or other in-house hot water. It is desirable to use
minimum amounts of water to avoid filling and overflowing the lime
ponds. The quantities actually used vary from less than ten gallons
per ton of beets to more than 100. Most of the factories use 20
to 60, averaging about 50 gallons per ton of beets. A. Carruthers,
reporting on European practices in this regard, (See appendix)
describes a factory in Switzerland which adds only a small amount of
water to the cake and transports it to a distant pond with compressed
air. American practice has tended, in recent years, toward reduced
use of water in the lime mud slurry. The lime mud, though relative-
ly small in volume, is high in BOD and suspended solids.
Barometric Condenser Water
Cold water in large quantities is required for use in the barometric
condensers of the evaporators and pans. The quality of the water is
not important but since the only source of cold water is the fresh
water from wells or streams it is usually relatively pure. In 20 of
the 58 factories in the United States, condenser water is cooled by
cooling towers or spray ponds and recycled to the condensers.
In 38 of the United States beet sugar factories, spent condenser
water frequently is re-used, principally for fluming beets. In
many of these, condenser water is the only source of flume water.
14
-------
The amount of condenser water used varies from 1,300 to 4,500
gal/ton beets. The average usage is 2,210 gallons per ton of beets
sliced.
In factories where recycling of flume water is practiced, it is
often advantageous to discharge the condenser water direct to streams,
By this expedient a large volume of effluent containing relatively
little BOD by-passes the waste ponds. The BOD in spent condenser
water, however, is not negligible; often amounting to 0.5 pounds per
ton of beets. Usually the temperature is about 50 C and the diss-
olved oxygen content near zero; hence discharge into small-flow
streams sometimes results in the killing of fish. Twenty-six of
the 38 factories that do not recycle condenser water now discharge
all or a considerable part of condenser waters direct to streams.
Steffen Dilution Water
Twenty-one beet sugar factories employ the Steffen process. In this
process, molasses containing about 50 percent sucrose is diluted with
cold fresh water to produce a "solution-for-cooler" containing 5 to
6 percent sucrose. At the six Steffen factories of the Great Western
Sugar Company about 45 percent of the dilution water is replaced by
Steffen waste.
Steffen waste is concentrated at fourteen factories. The concen-
trate (CSF) is mixed with extracted pressed beet pulp and dried.
At the other seven Steffen factories, the Steffen waste is discharged
to shallow ponds where it dries or is lost by seepage.
At the Hamilton City factory of the Holly Sugar Corporation, an ion-
exchange process is used for treating about 75 percent of the syrup
centrifuged from second boiling fillmass, a mixture of mother liquor
and sugar crystals. Regeneration of the ion-exchange resin columns
with acid and with ammonium hydroxide produces wastes somewhat
similar to Steffen waste. Raw water is used for dilution of syrups
in this process and for the regeneration and washing of the columns.
The wastes are separated into two main streams, one of which is dried
on pulp, the other concentrated to produce a nitrogenous fertilizer
product. There is no discharge to streams.
Another special case is the Johnstown molasses plant where molasses
is desugarized by a barium hydroxide process. This operation will be
discussed in greater detail later but it is to be noted that a waste
similar to Steffen waste is produced. It, too, is concentrated and
subsequently used as additive to beet pulp.
15
-------
Miscellaneous Water Uses
Heating and evaporation of juices by steam or vapors result in the
production of quantities of condensed waters ranging from 150 to 200
percent of the weight of beets sliced. The purest of these condensates
are collected and used as boiler feed. Normally, no other water is
used for this purpose. Condensed waters are used for many other
purposes: diffuser supply (in part), press wash, i.e., washing of
lime cake precipitate, centrifugal wash, house hot water (cleaning
evaporators, floors, etc.). Some of the cleaning operations require
the use of acids or caustic soda. The wastes are sent to the main
sewer and general ponds. The flow is intermittent and often results
in sudden changes in the pH of the effluent to ponds. This accounts,
in part, for erratic behavior of waste treatment processes.
16
-------
SECTION VI
FLOW DIAGRAMS
Water uses, re-uses, and disposal vary greatly among the factories,
but may be represented, in general, by the four flow diagrams shown
in Figures 1 to 4. Actually, these four flow diagrams do not repre-
sent, exactly, the water and material flow in any particular factory
but they illustrate four general types of flow. It is not prac-
tical to show in detail all the modifications exhibited by indivi-
dual plants. The arrangements, volumes, and depths of settling ponds
and of waste storage ponds vary greatly among factories.
Type I (Figure 1) represents a water flow once very common in the
United States beet sugar industry but now found only at one plant—
Torrington, Wyoming. Even at this plant, there is some modification.
The type is characterized by the absence of re-use of water in the
plant except for some limited use of condenser water in the beet
flumes. This diagram illustrates the extreme usage of raw water
in a beet processing plant and has been included to show the progress
in water re-use during the past several years.
Type II (Figure 2) represents a water flow now very common in the
industry. In this type all the fresh water is used in the baromet-
ric condensers of evaporators and pans, for miscellaneous cooling,
and at Steffen factories for dilution of molasses. Spent condenser
water is used for fluming and washing beets, for make-up water in the
diffuser and for other purposes. Factories employing this type of
water-flow are equipped with continuous diffusers, pulp screens,
pulp presses, and pulp driers. Pulp press water is returned to the
diffuser. Settling ponds for removing soil from spent flume water
and ponds for collecting lime mud are provided. The overflow from
ponds and any excess condenser water is discharged to streams.
Thirty-one factories use this pattern of water flow.
Type III (Figure 3) represents a flow pattern involving more complete
re-use of water. Fresh water, as in Type II, is used only in evapor-
ator and pan condensers; for some miscellaneous cooling and at Steffen
factories for dilution of molasses. During campaign, flume water
after screening is pumped to settling ponds and, after more or less
complete removal of settleable solids, is returned to the flumes.
Water from the evaporator and pan barometric condensers is used as
make-up water in the diffuser and in the beet washers and sprays.
Pulp water and pulp press water are returned to the diffuser. Lime
mud is pumped to a separate lime pond; the overflow, if any, is dis-
charged to the stream. Most of the condenser water is cooled by
cooling tower or spray pond and recycled to condensers. Steffen waste
is evaporated to concentrated Steffen filtrate. Twenty-three factor-
ies use this pattern of water flow with some modifications.
17
-------
I RAW WATER I
BEET STORAGE
CD
PULP SCREEN I 1
PULP SILO
WET PULP
LIME KILN
SA.CCHARATE__MJL.K_
LIME MUD
MOLASSES
HSTEFFEN
STEFFEN
FILTRATE Ji ,
TO STREAMS
>
i
— —(FLU*
SCREEN
-•-(WASHERS | •—
" PULP
SLICER puLP
r-41 — • f
-------
Figure 3. Type III Water Flow in Beet Sugar Factory.
The amount of water re-use varies greatly among the factories. At the
Torrington factory, the total water usage, including re-use, exceeds
the raw water intake by only 24 percent; at the Hereford, Texas factory
the total usage exceeds intake water by 1,300 percent. Raw water is
severely limited at the Hereford plant, hence great effort is made to
conserve it. At most plants raw water intake constitutes one-third
to one-half of the total usage. At six factories, however, fresh
water constitutes less than 20 percent of the total use.
19
-------
Type IV (Figure 4) represents a completely enclosed pattern of flow,
except that at the end of the operating campaign, ponds are drained
either to streams during spring floods or to municipal sewage treat-
ment plants. Only three factories use this type of water flow.
TO RIVER IN
SPRING
OR
TO CITY SEWAGE
Figure 4. Type IV Water Flow in Beet Sugar Factory.
20
-------
SECTION VII
WASTE TREATMENT AND DISPOSAL
The five principal wastes from the sugar factory are: flume water,
barometric condenser water, lime mud, general wastes (floor washes,
equipment washes, etc.)> and Steffen waste. To these might be added
the sanitary sewer which, however, is usually discharged separately
to municipal sewage plants.
Flume Water
The physical removal of suspended solids from flume water is the
first treatment step. The amount of soil (dirt tare) varies greatly
from one beet area to another and from season to season. In wet
harvesting seasons the soil adhering to beets may exceed 10 percent
of the weight of beets. In dry favorable harvesting seasons, part-
icularly in areas of light sandy soil, the dirt tare may be only
three or four percent. In any case suspended solids are removed in
part from flume water in settling ponds or by clarifiers. J.
Henry (32) in Belgium estimates dirt tare at about 14 percent on beets,
This is much higher than is found in the United States, possibly be-
cause of greater rain fall and heavier soils in Europe. An important
difference, however, is the much greater use of roller screens at
beet receiving stations in America. Except in unusual seasons and
under unusual conditions, dirt tare at factories in the United States
amounts to five to six percent.
A factory slicing 400,000 tons of beets during a campaign will acc-
umulate 20 to 24 thousand cubic yards of dirt in its settling ponds.
At Nyssa, Oregon, 53,000 cubic yards of dirt were removed from lag-
oons in 1969 after processing 995,000 tons of sugarbeets.
Grit separators are employed by five factories to remove coarser
material from recirculated flume water. Ten factories use convention-
al clarifiers to effect more complete separation of suspended solids
before recirculation of flume water or discharge to ponds. The
clarifier under-flow is pumped to mud ponds.
The flume water is screened to remove beet fragments, tails, etc.,
at all except 8 of the 58 factories. In most cases the flume water
is ponded with the general wastes of the factory. At 12 factories,
milk of lime is added to the flume water as it leaves the screens
or enters ponds. This serves to keep the pH at a level which impedes
bacterial action thus reducing odors. It also acts as a floccula-
ting agent. Where flume water is recycled back to flumes the add-
ition of lime allows the use of smaller settling lagoons in the sys-
tem.
21
-------
Barometric Condenser Water
Condenser and cooling water, in principle, is relatively unchanged
by usage except for an increase in temperature to 50-55°C. Ac-
tually, condenser water always picks up some entrained solids. Pan
condensers are prone to intermittent "shots" of liquor boiled over
at some stage of the boiling cycle.
Data regarding the BOD content of condenser water are limited but
tend to confirm previous findings, namely that sugar lost by en-
trainment amounts to about 1,800 Ib. per day in a plant of 2,500
to 3,000 ton capacity. Suspended solids in the condenser water as
it leaves the seal tank are low.
Re-use of condenser water is common practice thus reducing actual
treatment. Thirty-eight factories use condenser water for fluming
and other in-plant usages; twenty cool and recycle this water back
to condensers. Many factories make some in-plant use of condenser
water and discharge the remainder to streams.
Condenser water picks up ammonia from the evaporating juices, hence
is always alkaline, ranging from 8 to 10 pH but usually less than 9.
While undesirable, the discharge of this mildly alkaline condenser
water into streams has rarely, thus far, met serious objection from
pollution control authorities. A more serious objection to direct
discharge of condenser water is its temperature which may be as high
as 55°C. Where streams are small and sluggish, local temperature
increases in the stream at the point of entry of the condenser
water sometimes results in fish kill.
Lime Mud
The quantity of dry solids in the lime mud discharged by the factory
ranges from about four to a little more than six percent of the weight
of beets. The so-called lime cake discharged from the rotary filters
contains about 50 percent solids but it is slurried with water to ob-
tain a pumpable mixture of 20 to about 36 percent solids, usually
about 25 percent. Treatment consists of shallow ponding.
Fifty-four factories discharge lime mud to separate lime ponds; five
discharge it to the flume or general ponds. Twenty-seven factories
report no overflow from these ponds. Mud transport water at these
factories is lost by seepage or evaporation (in a few instances some
overflow occurs). At five factories overflow from the lime ponds
goes direct to streams; at twenty-two the overflow runs into the flume
or general ponds. At the latter plants, the lime pond effluent is
subjected to the same treatment as the flume and general wastes.
22
-------
The quantity of lime cake retained in ponds is approximately the same
as that of flume sediments—20 to 30 thousand tons a year. Only two
factories now re-burn lime cake for the production of lime—
Manteca and Mendota, California. The Alvarado factory of Holly Sugar
Corporation has been shut down; the lime cake re-burning operation
at Spreckels, California has been discontinued. Re-burning of lime
cake was discontinued because of objections to the dust emitted by
the rotary kiln. Lime cake from the Spreckels factory now is being
shipped to the Mendota factory for re-burning.
Sale of lime cake for agricultural and other usages has not been
notably successful. At only two factories—Tracy, California, and
Toppenish, Washington, has any considerable outside use been made
of it. The rather large store of lime cake at Tracy is being sold
to farmers for use on peat soils at a somewhat faster rate than it
is being produced. At Toppenish, a commercial distributor collects
lime cake from the dry ponds for sale in areas with acid soils.
Cleaning of lime ponds is a continuing, expensive chore at all other
factories. As a general practice, two or more lime ponds are avail-
able at a factory, enabling the operators to have one out of service
each year so it can be dried and dug out.
Steffen Waste
The disposal of Steffen waste has been one of the most perplexing
problems of the beet sugar industry. The solids in the waste consist
principally of sodium and potassium salts and nitrogenous compounds—
betaine and amino acids. The latter, though biodegradable, is not
easily attacked in the usual biological treatment systems. The
Steffen process has not been used in Europe, where it was devel-
oped, partly for this reason. In the United States a number of
Steffen operations have been discontinued partly but not entirely
because of the waste disposal problems.
At 14 of the operating Steffen factories the disposal of the waste
has been satisfactorily accomplished by evaporation and subsequent
use of the concentrated Steffen filtrate. Originally, impetus was
given this procedure by the demand for CSF as a source of monosodium
glutamate (MSG). Five factories of Great Western Sugar Company still
ship CSF to the Johnstown, Colorado, MSG processing plant. The
remaining nine Steffen factories dry the concentrate on beet pulp,
directly. Other processes for the production of MSG have largely
superseded recovery from Steffen waste.
To reduce the cost of evaporating Steffen filtrate considerable
effort is made to keep the concentration of the thin waste as high
as possible without adversely affecting the purity of the saccharate
produced. One method used by The Great Western Sugar Company is the
23
-------
return of cold saccharate filtrate as part of the dilution water.
The volume of thin Steffen waste is thus reduced from about ten
tons per ton of molasses to about six.
Seven Steffen factories do not evaporate the waste. At some fac-
tories it is discharged to the lime ponds; at others to separate
lagoons where it is allowed to evaporate or seep away.
General Wastes
General wastes include floor and equipment washes, filter cloth
wash, and miscellaneous effluents. These wastes are usually dis-
charged to the general ponds together with flume water and overflow,
(if any), from the lime pond.
24
-------
SECTION VIII
ASSOCIATED WASTE DISPOSAL PROBLEMS
The molasses desugarizing plant and the monosodium glutamate recovery
plant at Johnstown, Colorado, while not beet processing plants, are an
integral part of the industry in Colorado and Western Nebraska. These
plants are necessarily included in this survey since their effluents
constitute a part of the pollution of the South Platte River attri-
butable to the beet sugar industry.
The two plants have a common water supply, a common stream and power
plant, and a common waste disposal system.
The molasses desugarizing plant processed daily 230 tons of molasses
received from Great Western Sugar Company beet sugar factories in
Colorado and Nebraska. The MSG plant processes daily 115 tons (dry
solids basis) of molasses residuals from the desugarizing plant and
of concentrated Steffen filtrate from Great Western Sugar Company
Steffen factories.
The gross water intake—both plants—is 4.2 million gallons a day,
3 million of which is pumped from the Little Thompson River, the
remainder is obtained from wells and from the Johnstown city water
system. Most of the raw water is used in barometric condensers in
the two plants. There are two sets of evaporators and four sugar
pans in the molasses plant and two evaporator stations in the MSG
plant. The condenser water is returned to the river containing
considerable BOD, presumably from entrainment.
Water is used extensively in both plants as miscellaneous washes
for regenerating char columns, gas washing, etc. These, including
floor drainage, go to the so-called "treated sewer" which is dis-
charged into two one-acre ponds, 15 feet deep, operating in parallel.
In each of these ponds a 60 HP aerator is mounted, each capable of
delivering about 120 pounds oxygen per hour. The two ponds dis-
charge into a 20-acre pond, 3 feet deep, partitioned to direct the
flow in a tortuous path prior to discharge to the river. It was
confidently predicted by the company engineers that this arrangement
of ponds and aerators would reduce the BOD in the effluent from
the plants to acceptable limits, i.e., to 800 pounds BOD per day.
Present results show almost 2,800 pounds of BOD are being dis-
charged to the Little Thompson River but the results are not conclu-
sive. It is believed that the newly completed installation, when
equilibrium conditions are reached, will reduce the discharge of
BOD to the river to about 1,400 pounds per day.
25
-------
SECTION IX
TREATMENT AND DISCHARGE OF EFFLUENTS
It is difficult to classify the waste treatment at the various fac-
tories since it ranges from little or no treatment to reasonably
complete treatment. Procedures for reduction of BOD differ in prin-
ciple; some companies rely chiefly on anaerobic fermentation in deep
ponds, some on aerobic fermentation in shallow ponds with or without
mechanical aeration.
In the following paragraphs these processes are discussed in some
detail.
Preliminary to any treatment flume water or flume water plus general
wastes are screened at all but eight of the 58 factories. By this
means a large amount of solid organic material is eliminated which
otherwise would settle in ponds to form a bed of slowly decaying
material.
Three types of ponding are in use. The American Crystal Sugar Com-
pany at its four plants in the Red River Valley in Minnesota employs
large ponds capable of holding nearly all the wastes produced during
the campaign. Usually some waste discharge is permitted during the
early part of the campaign, so regulated as to avoid raising the BOD
level of the river above permissible limits and reducing dissolved
oxygen below acceptable limits. After the river freezes over all
discharge of waste to the stream is stopped. All factory effluent
is held until the spring thaw at which time the ponds are emptied
at a carefully regulated rate based on BOD content of the effluent
and the flow of the river.
Discharge of waste at Moorhead, may be at a rate of one million gal-
lons per day, or at one-half million or less when the river is low.
The dissolved oxygen, normally about 8 ppm above the point of dis-
charge diminishes to about 7 ppm below the plant. BOD content of
river water above discharge from ponds is about 3.6 ppm; below as much
as 5.6 ppm. Some reduction in BOD content of the ponded waste takes
place during the long storage period and prior to regulated discharge
to the river, but the reduction in storage is usually not significant.
The Crookston, Minnesota factory discharges its ponded wastes into
the Red Lake River which, in turn, empties into the Red River of the
North near Grand Forks. Discharge is regulated, as at Moorhead, to
maintain favorable conditions in the river at all points downstream,
i.e., a minimum of 5.0 ppm of dissolved oxygen. Records on discharge
of wastes from the Crookston factory between October 3, 1968 and
December 7, 1968 show a total discharge of 362 million gallons of
pond water with an average BOD of 500 ppm plus one million gallons of
27
-------
lime pond overflow with a BOD of 4,500 ppm. This is an average of
24,000 Ibs/day. From December 8 no further discharge was permitted
until the "spring thaw" starting on April 18, 1969. Between this
date and June 6, 1969 about 408 million gallons of pond water and 17
million gallons of lime pond water were discharged. The BOD of the
discharge from the ponds was an average of about 1,050 ppm and 4,400,
respectively for an average daily release of approximately 84,000
Ibs of BOD to the river. The rate of discharge of each of these
effluents was controlled to prevent unfavorable stream conditions
at any time.
Similar control of waste discharges to the river is maintained at the
East Grand Forks, Minnesota and the Drayton, North Dakota factories.
The BOD discharged per ton of beets at these Red River factories of
American Crystal ranges from 3.5 to 14 Ibs but its entry into the
river is spread over a period of six to nine months.
Another type of long-term retention in ponds is exemplified by fac-
tories of the Spreckels Sugar Company. In this type no discharge of
effluents to streams is permitted at any time. The waste is even-
tually dissipated by evaporation and seepage, or in some cases, by
use of the pond water for irrigation. At the Woodland, California
factory the ponds are shallow and cover large areas. Reduction
in BOD content is due to aerobic action primarily. At the other
Spreckels factories, reliance is placed principally on anaerobic
action in relatively deep initial ponds followed by shallow ponds.
These practices appear to be successful. Some odor problem was repor-
ted at the Spreckels (Salinas) plant. Several aerators are in use
and more planned to alleviate this nuisance. There is no detectable
pollution of streams by any of the Spreckels factories.
The Moses Lake factory of the Utah-Idaho Sugar Company also uses a
long-term retention ponding system although the pond area in use is
not large—45 acres. Extensive recirculation of flume and condenser
water permits a very low intake of fresh water—only 580 gallons per
ton of beets, hence a small discharge to ponds. The waste is com-
pletely dissipated by evaporation and seepage.
The Hereford, Texas plant of Holly Sugar Corporation also practices
remarkably complete recirculation of waters with very low intake of
fresh water—215 gallons per ton of beets. Although large areas are
available for ponding of wastes, actually little is used. Ponds for
collection of flume wastes are intermediate in depth—8 feet. There
is no discharge to streams.
The Goodland, Kansas factory of The Great Western Sugar Company, like
the Hereford plant, depends on extensive recirculation and low intake
of fresh water—only 328 gallons per ton of beets—to reduce wastes
to a volume that can be totally contained without discharge to streams
28
-------
Seventeen factories report either no discharge of BOD to streams or
the discharge of quantities less than one pound per ton of beets
sliced.
In general, factories in Montana, Wyoming, Nebraska, and Colorado
report relatively large amounts of BOD per ton of beets discharged to
streams. Notable exceptions are the factories at Longmont, Eaton and
Brighton, Colorado, where remodeling of waste disposal facilities
has been completed. Similar changes at other factories in the South
Platte river valley are planned for the near future.
A calculation based on these figures and on the annual slice rate
of each factory shows that in 1968 all beet sugar factories dis-
charged to streams 82,016,000 pounds BOD. The total tonnage of
beets sliced was 26,071,000. The average pounds BOD per ton of
Beets sliced was, therefore, 3.15. However, 17 factories showed
no discharge of BOD to streams. The remaining 41 factories there-
fore discharged an average of 4.8 pounds BOD per ton of beets sliced.
29
-------
SECTION X
COST OF WASTE DISPOSAL FACILITIES
The annual operating cost includes intercampaign costs of cleaning
ponds and maintenance. The costs reported may not be quite accurate
in some cases due, in part, to the difficulty of separating cleaning
and maintenance costs from the cost of improvements of existing fac-
ilities. The cost of land should not have been included in these
estimates but in a few cases land cost, or some of it, is probably
included. For the most part, these estimates include only the cost
of forming dikes, leveling pond basins, construction of pump houses
and concrete structures, cost of pumps, piping, mechanical separa-
tors, screens, motors, control devices, etc.
Lo'f and Kneese in "The Economics of Water Utilization in the Beet
Sugar Industry" prepared for Resources for the Future, Inc. in 1967,
review waste treatment costs for the beet sugar industry. Their fi-
gures show the same wide range of capital expenditures at various
plants that the present survey shows, namely, from a few thousand
dollars to more than half a million (one reports five million). Also,
annual operating costs vary widely. Some factories report as little
as one thousand dollars—some 30 to 40 thousand.
M
A figure by Lloyd Jensen which has been widely quoted and which Lof
and Kneese mention in their report is 30 million dollars in capital
expenditures for the entire beet sugar industry as the amount nec-
essary to completely eliminate pollution of streams. This means
about one-half million for each factory. Table 11 in the appendix
indicates some plants have accomplished a great deal with much less;
some have accomplished much less with larger amounts.
The ultimate solution of the problem of stream pollution by the beet
sugar industry will probably require the following at each plant:
1. Equipment for screening of wastes to remove beet fragments, leaves
and other organic solid material.
2. Equipment for complete separation of the soil and other matter
suspended in the flumes and general wastes. This may mean mech-
anical equipment or ponds.
3. Areas for the permanent disposal of dirt. About 100 pounds of
dirt per ton of beets sliced must be allowed for. A factory sli-
cing 300,000 tons a year will, in 20 years, require storage space
for about 200,000 cubic yards of soil.
31
-------
SECTION XI
LABORATORY AND PILOT PLANT WORK ON WASTE TREATMENT
A project sponsored by the Beet Sugar Development Foundation, the
"Treatment of Beet Sugar Plant Flume Water" was conducted by the
British Columbia Research Council, University of British Columbia,
Vancouver, B. C. in 1964. A complete report by T. E. Howard and C. C
Walden is available. A summary of their conclusions follows:
1. The report is limited to studies on BOD reduction at four fac-
tories: Billings, Montana; Tracy, California; Moses Lake, Wash-
ington; and Winnipeg, Manitoba.
2. Any build-up in BOD loading, at a mill recycling a constant per-
centage of flume water, occurs in less than one week from the
start of campaign.
3. Beet flume wastes are susceptible to biological oxidation.
4. Using beet muds as a source of inoculum, start-up rates are
slower than desirable, evaluated on a weekly batch-type fermen-
tation. Subsequently, with an established floe, the rates of
BOD removal are entirely adequate to handle high BOD loadings.
In a subsequent report it was found:
1. Biological oxidation was an effective procedure for the reduc-
tion of BOD: 93.1 to 96,8 percent of BOD load was removed by
an active floe.
2. Maximum BOD removal rates were obtained within 96 hours.
In a later report of experiments in which flume wastes from 48 beet
sugar factories were subjected to bio-oxidative treatment, it was
shown that significant BOD reduction was obtained in 72 hours of
aerobic treatment.
The Beet Sugar Development Foundation with support funds from EPA,
(formerly Federal Water Quality Administration) sponsored pilot plant
work on treatment of beet sugar factory wastes at the Tracy plant of
the Holly Sugar Corporation. The essential features of the procedure
followed in these experiments are as follows:
Factory wastes, principally flume water, after screening and removal
of settleable solids by mechanical means, are run into three ponds
in succession; the first pond, about 20 feet deep, operates as an
33
-------
anaerobic fermenter, the second shallower ppnd acts as a faculta-
tive pond, and the third, still shallower and much larger as an
aerobic pond in which algae grow.
Flows in the ponds were carefully controlled, changes in pH and in
BOD content were determined and the numbers and kinds of organisms
present were investigated. Results which in general were satisfac-
tory, have been reported elsewhere. (86)
Substantially this procedure is currently being used for the treat-
ment of wastes at the Manteca, California, plant of the Spreckels
Sugar Company. Some modifications have been made. The results are
apparently satisfactory.
Wider use in the industry has not been made, partly because tempera-
tures during the operating season in many areas are often below
freezing, hence the biological action would not be as satisfactory
as in California—or so it is believed.
A full-scale plant experiment has been conducted in 1967-69 by the
Beet Sugar Development Foundation and the Environmental Protection
Agency at Longmont, Colorado. Reports of these tests are in progress
so only the general plan and results will be discussed here.
Flume water after screening to remove organic debris is run into
channels about 40 feet wide at the top, 12 feet deep and about 600
feet long in which suspended solids are deposited. Milk of lime is
added after the screening operation to improve the settling rate.
The liquid flows from the channel into a secondary pond from which
it is recirculated to the flumes. Make-up water is added by the spray
over the roller conveyor which carries the beets from the beet washer
to the elevator. Any excess water that may build up is drawn off the
secondary pond to a larger and deeper (about 15 feet deep) storage
pond where anaerobic micro-biological action takes place.
The channels where primary settling of muds takes place are arranged
in duplicate so that flow may be directed from one while the other
is being cleaned. The removal of wet mud from these channels during
the operation period proved troublesome.
The installation at Longmont has been closely studied by the Founda-
tion to determine the relation of pH, alkalinity and other factors
on settling rates. The number and kinds of microorganisms have been
investigated as part of the overall study.
Some odor problems have arisen from the storage pond. Aerators have
been installed in the system to reduce odors.
The Amalgamated Sugar Company uses a system similar to this at Nyssa,
Oregon. The channels are arranged in a horseshoe shape around a
34
-------
central secondary pond.
Some studies are being made by individual companies, directed toward
reducing pollution by improved "housekeeping." Also, efforts are
being made to transport lime mud by the use of minimum amounts of
water.
35
-------
SECTION XII
PROBLEMS REQUIRING ADDITIONAL RESEARCH AND DEVELOPMENT
Two of the major problems confronting the industry in connection with
waste disposal are the disposal of muds and the lessening of odors
from ponds and muds. Both of these previously have been referred to.
The use of mechanical separators (hydroseparators, thickeners) allow
the concentration of facilities for separation of soil in a small
area. Cost and maintenance of the equipment represents a consid-
erable outlay. Ultimately the muds so separated must be transported
to permanent storage areas at additional cost.
J. Henry (32) in his survey of the beet factory waste problem in
Europe with particular emphasis on Belgium apparently views the mud
disposal aspect with some pessimism. Mud disposal at a factory neces-
sarily becomes increasingly burdensome with time as the volume builds
up and disposal areas shrink.
The use of large settling ponds permits disposal of muds in their
final storage place with only the requirement that the deposited soil
be lifted to the remaining dikes, thus raising the level of the ponds
higher and higher as time goes on. Veterans in the industry are of-
ten shocked to see, after the passage of several years, the increased
height of pond walls at some factories (Moorhead, for example). Yet
this may be one of the more economical solutions of the problem.
The second exasperating problem of waste disposal at sugar factories
is the matter of odor. When most of the factories were built, i.e.,
prior to 1930, they were located downstream from small towns.
Inevitably, the towns have grown often pressing close to the plant
so that smoke and fly ash from the boiler house and odors from the
ponds become very objectionable. Better combustion in boiler houses
and the conversion from coal to gas fired boilers have lessened the
fly ash problem. The odor nuisance possibly has been made acute by
required efforts to avoid pollution of streams. At factories that
discharge all wastes—mud, lime cake, pulp water, condenser water—
direct to streams diluted with as much water as they could pump,
there was less time for the development of hydrogen sulfide and
putrefactive odors.
37
-------
Ponding, particularly in deep anaerobic ponds, frequently promotes
the growth of sulfur reducing organisms. It has been observed that
careful screening of wastes to remove organic matter which settles
out forming a septic bed on the floor of the pond, lessens the quan-
tity of noxious gases discharged. However, the floe formed during
biological treatment of wastes becomes an unsavory component of the
"reatment ponds promoting the formation of unpleasant odors.
38
-------
SECTION mi
DISCUSSION
The magnitude of the pollution of streams by beet sugar wastes is still
very great, approximately 2,200 gallons containing an average of 3.15
pounds BOD per ton of beets sliced (4.8 pounds if only discharging
factories are used for computation). The total discharge to streams
from the entire beet sugar industry in the United States in 1968 was
about 57 x 109 gallons containing about 82 x 106 pounds BOD. The beet
crop in 1968 was unusually large; possibly a more normal crop to be
expected is 22 million tons instead of 26 million tons.
It should be pointed out that the pollution by beet sugar factories has
been greatly reduced in recent years. Before the advent of contin-
uous diffusers and of pulp driers, the amount of BOD discharged to
streams was about 30 pounds per ton of beets. At Steffen factories
before evaporation of Steffen waste was generally practiced, the BOD
discharge from these factories was 40 pounds per ton of beets. Improved
ponding of general wastes has also contributed to the reduction of
pollution of streams by beet factories.
Much of the beet sugar industry is located in lightly populated areas
of the western part of the United States. Most of this area is semi-
arid. Streams are relatively small, hence, the influx of even rela-
tively small amounts of organic wastes becomes objectionable. The
beet sugar industry is often the only industry of importance in its
area, hence, produces most of the pollution of the area streams.
Under the present Sugar Act, the beet sugar industry is permitted to
increase at a rate of 3 percent a year. Such growth and development
of beet areas and manufacturing facilities will be in new areas as
well as in present beet-growing areas. Some companies anticipate very
large increases at certain factories—some little or no growth.
Increases in slicing rates (and total annual slice) will result in
increased waste disposal problems at some factories—at others, very
little. The pollution problem is recognized by all processors, now,
and is apparently carefully considered when expansions are planned.
The marked tendency toward reduced usage of new (fresh) water by the
re—use of water permits considerable expansion without added waste
disposal facilities.
The present processes available to treat beet sugar factory wastes
have been described in previous sections of this report. Common to
all processes is the requirement for adequate screening of wastes to
remove fragments of beets and other organic matter and facilities,
either mechanical or other, for separation of muds. The method of
handling the clarified or partly clarified liquid wastes may be one of the
39
-------
following: (a) direct discharge to streams during periods of floods
(where this is permitted), (b) anaerobic biological treatment in
deep ponds, followed usually by aerobic action in shallow ponds or
ponds equipped with mechanical aerators, or (c) aerobic fermentation
only. To these should be added biological (trickling) filters; also
the use of waste disposal facilities, jointly with neighboring mun-
icipalities .
The pollution load produced by a factory before any corrective action
is taken is, approximately:
BOD Suspended Solids - Ib/ton beets
Ib/ton beets Soil Lime Cake
Straight houses 30-35 80-250 60-100
Steffen houses 40-45 80-250 100-140
With the use of continuous diffusers, pulp presses, pulp driers and
the complete recirculation of pulp press water, the BOD discharged in
the waste may be reduced by about 17 pounds per ton of beets sliced.
By retaining lime muds in ponds with no overflow, a further reduction
of about six pounds BOD per ton of beets sliced is affected. The
elimination of Steffen waste from the factory effluent by concentra-
tion and disposal as cattle feed reduces the pollution load by about
230 pounds of BOD per ton of molasses worked. The amount of molasses
worked varies considerably but ranges usually between four and six
percent of the weight of beets sliced. The BOD in the Steffen waste
is therefore, ten to eleven pounds per ton of beets.
It is apparent that the BOD in wastes that must be subjected to bio-
logical treatment can be, and is in most U. S. factories, reduced to
that contained in flume water, condenser water and floor washings,
i.e., five to ten pounds per ton of beets. Unfortunately, these quan-
tities are frequently exceeded due to accidental spills in the house or
to the introduction of deteriorated beets into the flumes,
The removal efficiencies of present waste treatment processes are diff-
icult to assess. Adequate BOD determinations are infrequently avail-
able in statistically significant numbers. Exceptions to this are,
of course, the intensive studies (88) made by the EPA (formerly Federal
Water Quality Administration) on pollution in the South Platte River
(June 1967) where the systems of treatment investigated were found com-
pletely inadequate, and the various studies of experimental units con-
ducted by the companies or by the Beet Sugar Development Foundation.
It is reasonably certain, however, that the facilities outlined on
pages 33-34 of this report can be made adequate to reduce stream pollu-
tion to presently acceptable levels. Obviously, those few factories
that contain all their wastes, with no discharges to streams, cause no
direct stream pollution. Contamination of ground waters or even of streams
40
-------
by seepage is perhaps possible.
The cost of construction of adequate waste treatment facilities for
beet sugar factory wastes will vary greatly among factories. An
engineering estimate for each individual factory is beyond the scope
of this report.
Such an estimate must include several items not usually thought of as
waste disposal facilities. Among these are changes in water supply
to re-use water in the plant; changes in means of removal of lime
cake from the factory without dilution, and others. Additional land
may be required at several factories, primarily for disposal of mud
and lime cake. The writer(s) of this report held the opinion that Mr.
Lloyd Jensen's generalization that the cost would be about $500,000
per average factory was possibly high; after this survey we take a
much more pessimistic view, namely, the cost may be considerably
higher—possibly $750,000 at many plants. The annual operating cost
of waste disposal is estimated by us to approach $0.25 per ton of
beets sliced, however, newer installations operate at half or less
that amount. These figures will include power, maintenance and pond
cleaning costs.
Gaps in the technology of beet factory waste disposal, at first glance,
appear to be trivial; it has been demonstrated that beet wastes are
amenable to treatment. As indicated previously, two approaches are
currently being used: anaerobic biological action and aerobic fer-
mentation. The former, according to Tsugita, ej: al. (86) is pro-
bably the most efficient and leads to the most nearly complete stab-
ilization of BOD. It, however, gives rise to objectionable odors
including particularly, the odor of hydrogen sulfide. At many fac-
tories, neighboring residents have protested this annual nuisance.
Besides the continued study of factory scale bio-treatment of wastes,
an economic and engineering study is required to determine the most
practical and economic means of solid waste disposal.
41
-------
SECTION XIV
REFERENCES
1. Anonymous. 1959. The beet sugar story. U. S. Beet Sugar
Assoc. Washington, D. C. 88 p.
2. Anonymous. 1961. Design, operation and success of installations
for the treatment of sugar factory waste waters in the soil.
Zucker. 14: 36, 61.
3. Anonymous. 1964. Stream pollution. A major sugar industry
problem? Sugar y Azucar. 59: 62-64.
4. Barr, W. W. 1962. Lagooning and treatment of waste water.
J. Am. Soc. Sugar Beet Technol. 12: 181-191.
5. Bianucci, G. 1966. Water economy in the sugar industry. Acqua
Industriale. 8: 15-21.
6. Black, H. H. and G. N. McDermott. 1952. Industrial waste guide-
beet sugar. Sewage and Industrial Wastes J. 24: 2, 181.
7- Black, H. H. and R. A. Teft. 1965. Treatment of beet sugar wastes.
Proc. 33rd Am. Conv. Sugar Technol. Assoc. India, Pt. 3: 45-46.
8. Blankenbach, W. W. and W. A. Willison. 1968. Wastewater recircula-
tion as a means of river pollution abatement. J. Am. Soc. Sugar
Beet Technol. 15(5): 396-402.
9. Brandon, T. W. 1947. Waste waters from sugar beet factories—their
treatment and disposal. Intern. Sugar J. 49: 98, 124.
10. Browning, J. E. 1954. Water conservation and process water utiliza-
tion in the beet-sugar industry. Am. Soc. Sugar Beet Technol. Proc.
8(2): 254-257-
11. Carruthers, A., et al. 1960. The composition and treatment of sugar
beet factory waste waters. Presented to the 13th Annual Technical
Conference of the British Sugar Corporation, Ltd. British Sugar
Corporation, Ltd. The Grange, Bramcote. Nottingham, England.
12. Chekurda, A. F. and A. P. Parkhomets. 1967- Principal scheme of
purifying sugar factory waste waters in static reservoirs. Sakhar
Prom. 41: 20-22.
43
-------
13. Christensson, D. G. 1964. Waste waters from a beet factory.
Oxidation of oxygen-demanding-material in a biological (storage) tank.
Socker Handl. I. 20: 43-61.
14. Crane, G. W. 1967. Water re-use in the beet sugar industry.
Effluent and Water Treatment J. 7: 639-644.
15. Czirfusz, M. 1961. Water economy in our (Hungarian) sugar factories.
Cukoripar. 14: 218-223.
16. Daniels, R. M. 1952. Mud and trash handling. Am. Soc. Sugar Beet
Technol. Proc. 7: 765-768.
17. Dazai, M., Y. Yoshida and H. Ono. 1963. Industrial wastes treatment
by activated sludge. 2. Treatment of beet sugar factories' wastes.
Hakko Kyokai (J. Ferment. Assoc. Japan). 21: 20-25.
18. Devillers, P. 1968. Water in the sugar factory. Sucr. Franc.
4: 95-99 and 5: 147-150.
19. Dojlido, J., J. Moraczewski and K. Czyz. 1964. Influence of sugar
factory wastes on the degree of pollution of the Cetynia (river, in
Poland). Gaz. Woda Tech. Sanit. 38: 192-195.
20. Drabek, B. 1962. Effect of the sugar campaign on the purity of the
River Morava. Listy Cukr. 78: 274-276.
21. Edeline, F. and R. van Achter. 1968. Study of seasonal pollution
in a canal. Tribune du Cebedeau. 21: 206-209.
22. Eldridge, E. F. 1942. Industrial waste treatment practice.
McGraw-Hill Book Company, New York, New York.
23. Fleming, G. S. 1952. Treatment and re-use of water in beet sugar
manufacturing. Sewage and Industrial Wastes J. 24: 1382.
24. Force, S. L. 1963. Beet sugar wastes and their treatment: the
Findlay (flume and condenser water) system. Proc. 17th Ind. Waste
Conf. 1962. Publ. in Eng. Bull. Purdue Univ. 47: 116-125.
25. Force, S. L. 1965. The Findlay flume and condenser water system.
J. Am. Soc. Sugar Beet Technol. 13(6): 478.
26. Gajban, C. 1965. Researches on sugar industry waste waters.
1. Efficiency of the system for treating waste waters at Bucecea
sugar factory. 2. Possibilities of reducing the volume and
harmfulness of some waste waters. Ind. Alimentara. 16: 255-264
271, 317-321.
44
-------
27. Gajban, C. 1966. Notes on the uses of adsorbent materials in the
treatment of sugar industry effluents. Ind. Alimentara.
17: 373-375.
28. Gorska, S. and B. Mazur. 1962. Purification station for industrial
waste waters at Ziebice factory (in Poland). Gaz. Cukr. 64: 269-272.
29. Gorska, S. and B. Mazur. 1962. Waste water economy at Werbkowice
sugar factory. Gaz. Cukr. 64: 360-362.
30. Gorska, S. and B. Mazur.' 1966. Collecting reservoir as second
stage in the purification of sugar factory wastes. Gaz. Cukr.
74: 189-190.
31. Helmke, G. 1963. (Return of) pure water to the watercourse.
Z. Zuckerind. 13: 568-569.
32. Henry, J. M. 1963. Problems of waste waters in sugar factories.
Found in Reuse of Water in Industry. International Union of Pure
and Applied Chemistry. Butterworths, London, England.
33. Hiidenheimo, H. 1963. Some views on the handling of raw sugar
factory waste waters, Rakennusinsinoori. 19: 344,346.
34. Hopkins, G. J., J. Neel and F. Nelson. 1956. Evaluation of broad
field disposal of sugar beet wastes. Sewage and Industrial Wastes
J. 28: 1466.
35. Hungerford, E. H. 1954. Factory wastes stabilization by aeration
on large fields. Am. Soc. Sugar Beet Technol. Proc. 8(2): 258.
36, Ichikawa, K., C. G. Golueke and W. J. Oswald. 1968. Bio-treatment
of Steffen house waste. J. Am. Soc. Sugar Beet Technol. 15(2): 125.
37. Jensen, L. T. 1954. Stream pollution abatement legislation. Am.
Soc. Sugar Beet Technol. Proc. 8(2): 260-266.
38. Jensen, L. T. 1955. Recent developments in waste water treatment
by the beet sugar industry. Proceedings of the 10th Industrial
Waste Conf. Purdue Univ. 439, May 9-11.
39. Jensen, L. T. 1965. Sugar. Industrial Wastewater Control. C. F.
Gurnham (ed.) Academic Press, Inc. New York and London.
40. Kalda, D. C. 1958. Treatment of sugar beet wastes by lagooning.
Proceedings of the 13th Industrial Waste Conf. Purdue Univ.
126, May 5-7.
41. Kastner, F. 1961. Recirculation of flume water and wash water in a
sugar factory. (Some theoretical considerations). Listy Cukr.
77: 246-253.
45
-------
42. Kastner, F. 1964. Water economy in East German sugar factories.
Listy Cukr. 80: 150-156.
43. Kastner, F. 1965. Water economy in Czechoslovak sugar factories.
Listy Cukr. 81: 78-83, 111-117.
44. Kastner, F. 1966. Water economy of sugar factories in the new
economic system of control of the national economy. Listy Cukr.
82: 137-145.
45. Keller, A. and H. Huckabay. 1960. Pollution abatement in the sugar
industry of Louisiana. Sewage and Industrial Wastes J. 32: 755.
46. Kralik, U. 1962. Investigations on the effects of beet sugar
industry waste waters on the quality of river waters. Wiss Z.
Karl-Marx Univ. Leipzig, Math.-Naturwiss. Reihe. 11: 159-165.
47. Langen, A. and J. Hoeppner. 1964. Water economy at the Ameln raw
sugar factory after introduction of the Vortair process. Zucker
17: 546-552.
48. Laughlin, J. E. 1966. Waste treatment in a new beet sugar plant.
Water Pollution Abst. 39: No. 1785.
49. Leclerc, E, and F. Edeline. 1960. Sugar factory waste water.
Chromatographic study of organic substances dissolved in decanted
waters. Bull. Mensuel Centre Beige Etude Docum. Eaux, 201-203.
50. Limprich, H. 1961. Limits of water recycling and waste water land
treatment of sugar factories. Z. Zuckerind, 11: 81-85, 135-137,
260-262, and 12: 71-75.
51. Limprich, H. 1961. The position in the biological purification of
sugar factory waste waters. Wasser Luft u. Betrieb. 5: 187-189.
52. Lindrooth, J. E. 1954. Wastewater treatment and waste disposal in
the eastern area. Am. Soc. Sugar Beet Technol. Proc. 8(2): 248.
53. Lochman, V. 1961. Complete return of pulp-press water to Robert
diffusion at Velka Bystrice sugar factory. Listy Cukr. 77: 111-116.
54. Manea, G. I., R. Cojocaru, A. Otahal, I. Birca and C. Gajban. 1966.
Main problems of management and purification of sugar factory
effluents in Roumania. Gospodar. Ap. Meteorol. 11: 141-147.
55. Marini, V. and J. Bickel. 1961. Considerations on the possibilities
of disposal of liquid wastes from sugar factories. Riv. Ital.
d'lgiene. 21: 385-409.
46
-------
56. Mazur, B. 1963. Technico-economic problems of spraying sugar
factory wastes (on fields). Gaz. Cukr. 71: 222-224.
57. Mazur, B. 1963. Irrigation with (beet) sugar industry waste water
as a second stage in purification. (A review). Gaz. Cukr.
71: 127-129.
58. McDill, B. M. 1947. Industrial wastes—beet sugar industry.
Industrial Engng. Chem. 39: 657.
59. McGinnis, R. A. 1951. Beet-sugar technology. Reinhold Publishing
Corporation. New York, New York.
60. Muhlpforte, H. 1962. The present position of waste water disposal
in sugar factories. Wasserwirtschaft-Wassertechnik. 12: 65-70.
61. Nielsen, F. Stanley. 1968. Amalgamated Sugar Company combats
water pollution. Sugar y Azucar. 63(6): 28-31.
62. Norman, Lloyd W., James E. Laughlin and L. 0. Mills. 1965. Waste
water treatment studies at Tracy, California. J. Am. Soc. Sugar
Beet Technol. 13(5): 415-424.
63. Offhaus, K. 1965. Elimination of wastes in sugar factories with
special regard to the situation in Bavaria. Zucker. 18: 539-545.
64. Parkhomenko, A. N. 1964. Irrigation of fields with sugar factory
waste waters. Sakhar Prom. 38: 748-751.
65. Parkhomets, A. P. 1960. Problems of water economy sugar refineries.
Sakhar Prom., 46-53.
66. Peterson, A. T. 1965. Joint treatment of municipal and beet sugar
wastes on high-rate trickling filters. Chronic and Associates,
Consulting Engineers. Boise, Idaho.
67. Phipps, 0. H. 1955. Effluent treatment in the beet sugar industry.
Chemistry and Industry. 40: 1242.
68. Porges, R. and G. J. Hopkins. 1955. Broad field disposal of beet
sugar wastes. Sewage and Industrial Wastes J. 27: 10,1160.
69. Porterfield, J. L. and E. B. Cowan. 1954. Elimination of trash
between flumes and slicers. Am. Soc. Sugar Beet Technol. Proc.
8(2): 213-219.
70. Prochal, P. 1964. Water economy and the possibilites of agricultural
utilization of the wastes of Baworow sugar factory. Gaz. Woda Tech.
Sanit. 38: 271-275.
47
-------
71. Rogers, H. G. and L. H. Smith. 1953. Beet sugar waste lagooning.
Proceedings of the 8th Industrial Waste Conf. Purdue Univ.
136, May 4-6.
72. Sawyer, C. N. 1950. Beet sugar treatment processes. Sewage and
Industrial Wastes J. 22: 221.
73. Schneider, F. 1963. Some aspects of the 1962 (beet) campaign
(in Germany). Zucker. 16: 435-443.
74. Schneider, F., H. P. Hoffman-Walbeck and D. Kollatsch. 1961.
Water balances in sugar factories with regard to the waste water
problem. Zucker. 14: 619-626.
75. Schneider, F., H. P. Hoffman-Walbeck and D. Kollatsch. 1964.
Aerobic decomposition of waste waters. Zucker. 17: 393-399.
76. Schulz-Falkenhain, H. 1963. Biological treatment of wastes from
sugar factories. Zucker. 16: 615-617-
77- Schulz-Falkenhain, H. 1964. Measures of the sugar industry for
maintaining waste waters in a pure state. Zucker. 17: 518-523.
78. Semling, H. V. Jr. 1967. U. S. sugar industry fights water
pollution. Sugar y Azucar. 62: 25-28,44.
79. Shulka, J. P. and B. D. Kapoor. 1962. Examination of the activated
sludge process for the treatment of sugar factory effluents. Proc.
30th Ann. Conv. Sugar Technol. Assoc. India. 122-127.
80. Skalski, K. 1961. Industrial waste water economy in sugar factories
of the German Federal Republic. Gaz. Cukr. 63: 111-115.
81. Skalski, K. 1961. Tendencies in the development of waste water
economy in West German sugar factories. Gaz. Cukr. 63: 177-179.
82. Skalski, K. 1961. What we know about gas-washer waste waters.
Gaz. Cukr. 63: 304-306.
83. Skalski, K. 1962. Changes in (the condition of) by-pass streams
for sugar factory waste waters as a result of modernization of the
waste water economy. Gaz. Cukr. 64: 46-48.
84. Skalski, K. 1966. Conditions and modernization trends in the
economy of water and sugar factory wastes in Poland. Gaz. Cukr.
74: 292-295.
85. Stiltz, W. P- 1955. Vibrating screens in industrial waste water
treatment. Proceedings of the 10th Industrial Waste Conf. Purdue
University. 381, May 9-11.
48
-------
86. Tsugita, Ronald A., William J. Oswald, Robert C. Cooper and Clarence
G. Golueke. 1969. Treatment of sugarbeet flume waste water by
lagooning, a pilot study. J. Am. Soc. Sugar Beet Technol.
15(4): 282-297-
87. U. S. Department of Agriculture Statistical Bulletin No. 244. 1969.
Sugar statistics and related data. Volume II (Revised).
Washington, D. C.
88. U. S. Department of Interior, Fed. Water Pollution Control Adm.,
South Platte River Basin Project. 1967- The beet sugar industry—
the water pollution problem and the status of waste abatement and
treatment. 144 p.
89. Walden, C. C. 1965. Water use, re-use and waste water disposal
practices in the beet sugar industry of the United States and
Canada. British Columbia Research Council. Vancouver. 150 p.
90. Weckel, W. 0. 1948. Pulp press water reclamation. Am. Soc. Sugar
Beet Technol. Proc. 5: 629-634.
91. Willison, W. A. 1966. A report on river pollution abatement by the
Manitoba Sugar Company Ltd., Fort Garry, Winnipeg, Manitoba.
Manitoba Sugar Company Ltd.
92. Wintzell, T. and T. Lauritzson. 1944 and 1945. Return of beet sugar
factory waste water. Sugar. 39: 9-10,26 and 40: 5,28.
93. Zanoni, L. 1963. Purification of sugar factory waste waters. Ind.
Sacc. Ital. 56: 267-274.
49
-------
SECTION ;xy
GLOSSARY
campaign - (French) the period of the year during which the beet
factory makes s*ugar.
cossettes - thin strips of sugarbeet root tissue produced from the
knives of the slicer.
diffuser - an apparatus into which water and cossettes are fed, the
water "dissolving" sugar from the sugarbeet cells.
filtrate - liquid after passing through a filter.
granulator - a rotary drier used to remove free moisture from
sugar crystals prior to packaging or storing.
lime mud - the washed calcium carbonate filter cakes, including
sludges from first and second carbonation.
nonsugar - any material present, aside from water, which is not
a sugar.
pan - a single-effect evaporator used to crystallize sugar.
process water - water which is used in the internal juice streams
from which sugar is ultimately crystallized.
pulp press - a mechanical pressure device which squeezes the
exhausted cossettes (pulp) removing some of the water.
saccharate milk - a slurry of (calcium saccharate) cakes from
the Steffen process.
seal tank - the seal on the bottom of a barometric leg pipe.
slicer - usually a drum on which V-shaped corrugated knives are
mounted. This machine produces the cossettes.
slicing capacity - processing capacity, the number of tons of
sugarbeets a factory is capable of processing in a 24-hour
period of time.
Steffen process - a process of treating molasses tc produce a
precipitate containing sucrose which can then be treated to
release free sucrose in solution.
% on beet - ratio of a quantity to clean beet weight.
51
-------
APPENDICES
53
-------
SELECTED WASTE WATER SCHEMES
IN OPERATION AT SUGARBEET FACTORIES
IN EUROPEAN COUNTRIES AND GREAT BRITAIN1
INTRODUCTION
This section contains information on water schemes and methods of
treatment of waste waters in operation at: (1) German factories—
Ameln, Schladen, Wabern; (2) British factories—Ely, Newark, Wiss-
ington; (3) a Swedish factory—6'rtofta; and (4) a Swiss factory—
Aarberg.
Costs of installing and operating each plant are reported. Estimates
from Belgium have been included and information of a more general na-
ture relating to developments in France and the Netherlands also has
been included.
GERMANY
Nowhere on the Continent have the various problems associated with
waste waters apparently received more attention than at the Ameln
factory of Pfeiffer and Langen. The developments which have taken
place there are fully described and discussed in the papers authored
by Langen and Hoeppner (4) and F. W. Meyer (5).
The first of these papers gives details of the various water cycles
which have been set up and of the storage basins for receiving mud and
water (Figure 5). Settled water from the mud ponds is eventually
stored in a rectangular shaped lagoon, covering 6 acres and holding
at the end of the campaign about 31 million U. S. gallons, before
being fed to an activated sludge plant. The first paper gives de-
tails of the costs of installing and operating the activated sludge
plant supplied by the Lurgi Company, and the second paper amplifies
on the improved performance of the plant.
The quantity of water to be purified corresponds to about 57 percent
of the weight of beets to be processed but it is pointed out that
this amount could be reduced by about 17 percent on beet weight if
the water from the gas washer was not used as a spray to clean the
beets after they emerge from the beet washer. Furthermore, an add-
itional saving of 4 percent on beet weight could be achieved if the
*By A. Carruthers, Director of Research (Retired), British Sugar
Corporation Ltd.
55
-------
6.0
ACRES
3IXI06
GAL
7%
57%-< 1
% means weight
of water to
weight of beets
processed.
5.9 ACRES
18.7 X I06
GAL
LIME
POND
2.4 ACRE/
3.8 XIO6
GAL
2.7 ACRES
5.IXI06 GAL
2.1 ACRES
3.35 XIO6
GAL
0.9
ACRES
L9XI06/
GAL
1020%
OO
430%
BEET TRANSPORT
ASH TRANSPORT
GAS WASHER
CHLORINATOR
BEET LAB
BEET DUMP
534%
8%
LIME
SLUDGE
4%
MIXER
_60%
4%
Figure 5. Waste water scheme - Ameln factory (Pfeiffer and Langen).
capacity of the cooling tower, operating on the condenser water, were
increased by installing forced draft. The latter proposition is not
considered to be economical, and presumably the need for the spray
application on the beets is a reflection of th.e quantity of soil
being delivered to the factory. The yearly rise in level of soil
in the two basins of 2.7 acres and 2.1 acres is said to be 0.5 meter.
At the Ameln factory, unlike the practice adopted at many other fac-
tories on the Continent, lime sludge is not combined with, thickened
mud for discharge to ponds. The sludge, mixed with a very small
quantity of water, is conveyed by a Moyno pump to a basin of 2,4 acres
where it readily dries out in the summer.
56
-------
To the water being returned from the final settling pond (area 0.9
acre) chlorine is added at a dose rate of ISg/m^ which is equivalent
to 15 ppm. It is interesting to note that some factories operating
with closed systems add chlorine to the return water mainly to avoid
an unpleasant sulphide odor at the beet end.
Schneider and Hoffman-Walbeck (8) recommend addition of lime to re-
cycled transport water sufficient to maintain the pH at or above
11.0 since under these conditions bacterial action is greatly inhib-
ited. It is noteworthy that at Ameln, because the capacity of the
lime kiln is limited, lime is not added to the return transport water
although it is recognized that by raising the pH the settling rate
of the mud could be increased. To meet the lime requirement of
0.3 percent CaO on beet would cost $8,000.
The Ameln factory is situated in an area of very productive agri-
cultural land, and since an area of some 30 acres would be required
to permit natural purification (the depth of water not exceeding 1.2
meters), it became economically attractive to examine other alterna-
tives critically. The factory particularly had in mind that if the
polluted waste water could be suitably treated it could then be dis-
charged into a river. In the light of the inevitable tightening of
the regulations in Germany governing the discharge of polluted waters,
Ameln may claim "to have done the necessary homework."
The activated sludge plant consists of an aeration tank, a Bruckner
clarifier and two Vortair aerators each fitted with 15 kw motors and
capable of supplying 3,000 Ibs 02/kw hr. The annual operating cost
is about $60,000. The aeration tank is designed for a throughput
of 4,700 gallons/hour at a BOD level of 2,500 ppm and allows a res-
idence time of 24 hours. The clarifier, made of concrete, is 18 feet
in diameter and has a capacity of about 12,000 gallons.
Running costs of the sludge plant are estimated to be approximately
19£ per m3 of waste water discharged or 7
-------
Over the past 15 years the following measures were achieved at Ameln:
1. The amount of water used was drastically reduced by
establishing closed cycles.
2. Larger storage ponds and lagoons were provided.
3. An activated sludge plant was installed.
Even when these developments were spread out over 15 years the finan-
cial burden on the sugar company was severe. The costs of operating
the activated sludge plant are only a fraction of the total costs re-
sulting from the over-all waste water problem. It is estimated that
the total costs (including amortization) are equivalent to a charge
of 24
-------
Table 3. Water Characteristics of the Schladen factory (Germany).
Name of Company
Annual beet tonnage processed
Average 24-hour tonnage
processed
Gross fresh water intake
gallons/day
Source of fresh water
Treatment of fresh water
Type of diffuser
Quantity of water discharged
to river
1. Surplus condenser water
as well as gas wash water
and blowdown
2. Cooled excess condensate
Quantity of stored water -
gallons
Period of storage - days
BOD discharged - Ibs/ton beet
Nordharzer
330,000
Sucker A. G.
3,200
)6 or 200% on beet
1.6 x 10C
River ui<.er
Gravel filtered
Tower, with return of pulp press water
154% on beet
BOD
16%
BOD
39 x
200
0.05
= 22 ppm
on beet
= 48 ppm
106 = 46% on beet
Flume and beet washer waters are de-sanded in two classifiers and then
mud is allowed to settle in two thickeners, one of 50 and the other of
44 meters diameter and having a depth of 1.5 meters. The overflowing
water passes to a further settling basin having a capacity of almost
2 million gallons.
The thickeners have mechanical scrapers and the mud from them is com-
bined with lime sludge and pumped to the settling area. From the first
basin, water flows to a storage lagoon and there undergoes natural pur-
ification. In August the partially purified water having a BOD of 300
ppm is used to irrigate an adjoining area of land.
The construction costs of waste water facilities at Schladen are given
as $250,000 and annual operating costs at $7,500 including labor.
The water sheme adopted at the Wabern factory is shown in Figure 7.
Condenser water is cooled in a spray pond and 590 percent on beet out
of 600 percent on beet is recycled.
Surplus condenser water and condensate are stored in a basin of 7.8 x
10.6 gallons capacity, and by the early part of the year following the
campaign the combined water has undergone self-purification and is dis-
charged. See Table 4 for details.
59
-------
CONDENSATION FROM
ROTARY FILTER
GAS WASHER
WATER
ELMO PUMPSl
2.5 L/SECT
Figure 7. Wabern Factory Water Scheme.
Transport and beet washer waters are first led to a small thickener
which is fitted with a mechanical scraper (this equipment was made in
the factory). Mud from the thickener is pumped together with lime
sludge to an unused gravel pit.
The water from the thickener flows to a settling basin and is recycled.
The settling basin has to be cleaned out every campaign at a cost of
$10,000. The muddy transport water also carries the regenerant liquors
derived from the Quentin process and has a BOD content of 3,000 ppm.
From the gravel pit the water flows into two ponds where natural pur-
ification occurs and the water gradually evaporates and percolates
away. The three ponds cover an area of about 12.5 acres.
The waste water treatment facilities at Wabern are estimated to have
cost $75,000 and the annual operating costs are $17,500 including labor.
60
-------
Table 4. Water Characteristics of the Wabern Factory (Germany).
Name of Company
Annual beet tonnage processed
Average 24-hour tonnage
processed
Gross fresh water intake
gallons/day
Treatment of fresh water
Source of fresh water
Type of diffuser
Quantity of water discharged
to river - gallons
BOD discharged - Ibs/ton beet
Quantity of stored water -
gallons
Period of storage - days
Actien-Zuckerfabrik Wabern
162,000
1,800
0.7 x 106 or 150% on beet
Gravel filtered
River Schwalm
Tower, with return of pulp press
water
0.54 x 106 or 116% on beet
0.05
16.9 x 106
300 to 400
GREAT BRITAIN
At all factories transport and beet washer waters are re-circulated,
and the amount of water which accumulates varies from as little as
30 percent up to 45 percent on beet. Several methods have been adop-
ted for the disposal of the heavily polluted water remaining after
soil has settled out. Direct discharge to estuaries or to tidal riv-
ers occurs at five factories.
The privilege of being able to discharge heavily polluted water, even
under these circumstances, is always subject to review, and it is in
fact highly probable that in a few years the practice may be changed
at two factories. Anything, therefore, which a factory can do to reduce
the BOD load to the river is worthy of attention.
At one of these factories the water from the main settling basin (loc-
ally known as the "pulp lake" which term savors of the bad old days)
flows through two rather small ponds, each about 150 yards square,
before going to the river. In the first of these ponds four 25 hp
surface aerators were recently installed, and after a lag period during
which a sludge developed, the BOD of the water leaving the pond was
reduced from 1,200 ppm to 350 ppm. Sludge which overflowed from the
aeration pond was trapped in the next pond. This study is continuing.
61
-------
Discharge to rivers (non-tidal) of water purified by trickling fil-
ters occurs at five factories. Provided that they receive a measure
of attention the trickling filters perform satisfactorily and read-
ily produce an effluent suitable for discharge to rivers, even where
one of the requirements is that the BOD shall not exceed 20 ppm. Care
has to be taken, however, to prevent the concentration of suspended
solids in the effluent exceeding the usual limit of 30 ppm, and set-
tling tanks of improved design, which will help in this respect are
being studied.
Discharge to rivers (non-tidal) of water purified by an activated
sludge system occurs at two factories.
The system adopted is that known as the Passveer Ditch and a descrip-
tion of the plant and its performance at the Newark factory is given
later in this report.
Discharge of untreated water direct to municipal sewage plants occurs
at four factories. This is a recent development and in two instances
it has come about through the British Sugar Corporation agreeing to
pay part of the installation costs for new municipal sewage plants. To
one local body the sum paid was $67,200 and to another $75,000, and
in return the two factories concerned are permitted to put their eff-
luents into the sewers without charge provided that on any one day the
load applied does not exceed 300 pounds of BOD. Under this scheme
one factory has discharged 29 million gallons of waste water in one
year.
At two other centers the local authorities have granted permission for
the factories to put their waste waters into the sewers mainly at
night, and for this service they levy a charge which at one factory
has amounted to $115 for about 1 million gallons. It is required
that the pH of the effluent being put into the sewer should be be-
tween six and nine.
Discharge by percolation into chalk occurs at one factory. This
unusual method of disposal is of course carried out with the appro-
val of the local authorities who are satisfied that no contamination
of underground water sources is possible. Water from the Ely factory
storage lagoon is purified through two trickling filters operating
in series (see Table 5); the arrangement of the filters and humus
tanks is shown in Figure 8.
It has also proved worthwhile to have a small aeration pond ahead of
the biological filters. Six pounds/day of diammonium phosphate is
fed into this pond. Approximately ^ ton of lime/day is added to the
waste water before settling, as this amount will regulate the pH at
6.5 to 6.8 of the water returning to the factory.
62
-------
Table 5. Water Characteristics of the Ely Factory (Great Britain)
Name of company British Sugar Corporation Ltd.
Typical dates of campaign September 21 to February 1
Annual beet tonnage processed 500,000
Average 24-hour tonnage
processed 4,100
Source of fresh water River Ouse
Treatment of fresh water None
Type of diffuser 1 RT with return of pulp press water
Volume of effluent discharged/
tons of beet sliced 110 gallons
Concentration of BOD in
effluent discharged <20 ppm
Quantity of water discharged/
day Minimum 12,000 gallons
Maximum 400,000 gallons
Period of storage - days Up to 300
The polluted water which accumulates from total re-use of flume and wash
waters is purified through two trickling filters which today would cost
$110,000. The annual operating charges are $10,000.
Water from the Newark factory storage lagoon is purified by an activ-
ated sludge biological process carried out in a Passveer Ditch. The
process is described in Table 6. The water scheme at the Newark fac-
tory is shown in Figure 9. The layout of a large Passveer Ditch in-
stalled at the Wissington factory is shown in Figure 10.
At Newark milk of lime is added to the water leaving the clarifier—
a sufficient amount is added to maintain the pH at about 6.0 to 7.0,
and chlorine is added to the water returning to the factory.
In 1957 0. H. Phipps estimated the annual cost to the British Sugar
Corporation, which was then converting from partial re-use to complete
re-use of waste waters, at about $600,000. This estimate covered the
costs for the whole of the 18 factories most of which had already gone
over to partial re-use.
At the Newark factory flume and waste waters are recycled and the pol-
luted water which accumulates is purified by an activated sludge pro-
cess. Condenser water is recycled after passing through a cooling tow-
er.
The costs of installing the necessary equipment during the last few
years were as follows:
63
-------
o
CENTRIFUGAL PUMP
FLOW METER
VALVE
20 ACRE
WATER STORAGE TANK
FLOW USING NO. I AS PRIMARY FILTER
A,B,C,0,E,F,G,H,I9J
FLOW USING N0.2 AS PRIMARY FILTER
L,G,H,l,M,N,B,C,Daj
MIXING
TANKS
Figure 8. Biological Filter Flow for Effluent Treatment, Ely Factory.
64
-------
Dorr Oliver Clarifier (120 feet diameter)
Drag screen, stone catcher, pipeliners,
pumps, tank for recirculation of water
in tare house
Passveer Oxidation Ditch
Chlorinator
Cooling tower
$65,300
49,000
47,800
1,600
24.000
$187,700
SETTLING POND
15 ACRES
w/////////,
1/4" SCREEN
DREDGER
STORAGE OF
PURIFIED WATER
Figure 9. Newark Factory Waste Water Scheme,
65
-------
Table 6. Water Characteristics of the Newark Factory (Great Britain)
Name of company
Typical dates of campaign
Annual beet tonnage processed
Average 24-hour tonnage
processed
Source of fresh water
Treatment of fresh water
Type of diffuser
Volume of effluent dis-
charged/ton beets sliced
Concentration of BOD in
effluent discharged
Quantity of water discharged/
day
Quantity of stored water -
gallons
Period of storage - days
BOD discharged - Ibs/day
British Sugar Corporation Ltd.
September 26 to February 1
230,000
1,850
River Trent
None
Battery, operated with return of
diffusion and pulp press waters
117 gallons
20 ppm
Average 168,000 gallons
27 x 106
300
4
3'X8' TNO ROTOR
330'
3'X8' TNO ROTOR
-428
VENTUR1 TROUGH
, FOR SLUDGE RECIRCULATION
*R
PUMP METER
HOUSE
-on
Figure 10. Wissington factory Passveer oxidation ditch.
66
-------
A Passveer Oxidation Ditch has been installed at the Wissington Fac-
tory at a total cost of $96,000 which includes rotors, pumps, meters,
pump house, piping, lining of ditch with 0.03 inch thick Butyl rub-
ber sheeting and building of banks. The normal water level in the
ditch will be 5 feet and the capacity at that level will be 772,000
gallons, i.e. approximately three times as great as that of the ditch
at Newark. The slice is to increase from 3,000 tons/day to 7,000
tons/day over the next 3 years.
NETHERLANDS
Information relating to the Netherlands was supplied by Ir. R.
Vletter whose company, N. V. Central Suiker Maatschappij processes
at six factories 38 percent of the sugarbeets grown in the Nether-
lands .
At the present time no statutory regulations exist governing the ab-
straction of water or the discharge of polluted waters, but it is
anticipated that by 1971 industry and local authorities will be sub-
ject to new legislation. In all probability levies will be imposed
dependent upon the pollution load being discharged into National
Waters, i.e. rivers or large canals, and the degree of pollution will
not be assessed on BOD, but on determinations of COD and nitrogen.
The population equivalent is to be calculated on the basis:
p.e. = COD + 4.57N (in mg/1)
180
At the Breda factory, for which limited information on water usage
is reported (see Table 7), the water flowing out from the one large
settling basin has up to now been discharged without treatment into
the River Mark. The settled mud is excavated yearly and used to fill
up a large pit left from sand workings.
For the 1969-70 campaign a Bruckner thickener or clarifier has been
installed at a cost of $415,000, which includes the necessary ser-
vices for the return of water from the thickener.
Beet transport and washer waters will pass over a vibrating screen,
(4 mm apertures) then to a Baum and Schreiber Classifier for the sep-
aration of stones and tails and finally to another vibrating screen.
The muddy water will then go to the Bruckner thickener (72 m dia-
meter—capacity 235,800 gallons), and from there the mud will be
pumped to a lagoon. The settled water will be aerated using four
floating Simcar Aerators, each of 50 hp. This study is to be car-
ried out in conjunction with the government authorities. During
these trials the authorities have agreed that press pulp water and
diffusion water can be discharged directly to the river, a practice
67
-------
Table 7. Water characteristics of the Breda factory (Netherlands).
Annual beet tonnage processed
Average 24-hour tonnage pro-
cessed
Type of diffuser
Daily water intake
1,000 gallons/day
Condenser water
Flume + beet washer water
Period of storage
Quantity of water discharged-
gallons (up to 1969)
BOD discharged - Ibs/ton beet
350,000
4,500
Battery - 2. At present pulp press
water and diffusion water are dis-
carded, but in 1970 continuous
diffusers will be installed and
then pulp press water will be re-
turned to the diffuser.
9,000 + 800 for the diffusers
Re-used for beet flumes and then
discharged
At present discharged to one large
30-acre basin; depth 26 feet.
Several months in all but gradually
discharged to the River Mark.
3,800/ton beets
6.7
which will be discontinued when a continuous diffuser is operative
in the 1970-71 campaign.
It is proposed to add lime to the water coming from the thickener
to adjust the pH to 8.0. Chlorine will be added to the water which
is returned to the factory.
During the 1969-70 campaign Mr. de Vletter hopes to study in some
detail the loss of sugar from beets during washing, using various
designs of agitators in the washers. At the factory of Sass van
Gent a new beet washer has been installed, and since this has been
specially designed to meet the factory capacity, its performance
will be examined carefully.
BELGIUM
J. Henry of the Raffinerie Tirlemontoise put forward estimates of
costs for a 4,800 ton/day factory in Belgium as follows:
a. Capital cost for:
1. Condenser water cooling tower
2. Flume and wash waters clarification,
etc.
$200,000
100,000
68
-------
b. Annual maintenance for:
1. Condenser system 1,000
2. Flume and wash waters system 70,000
c. Annual operating costs:
1. Power and chemicals 70,000
FRANCE
Inquiries addressed to Mr. P. Devillers and to Mr. J. Genotelle
failed to elicit information on waste water matters for particular
sugarbeet factories in France, but information of general interest
was made available. Legislation is now operative in France which
will require all French sugarbeet factories to take appropriate
action to re-use waters and to avoid putting waste waters into rivers
or other natural waters.
Mr. P. Devillers, Head of the Technical Services of the Syndicat Nat-
ional des Fabricants de Sucre, has pointed out in an article in
Sucrerie Francaise that charges are to be levied (1) for water ab-
stracted which will vary according to region and may range from 0
to 2<: per M3, and (2) for pollution which may cost from $8 to $12
per ton of BOD. Mr. Devillers estimated that a factory processing
3,000 tons of beets/day could be liable to levies amounting to be-
tween $25,000 and $40,000 per campaign; for the French sugarbeet
industry as a whole the annual charge might amount to more than
$2,300,000. However, the industry is offered financial incentives
to take the action that is necessary to avoid the penalties: the
authorities are prepared to meet 50 percent of the costs of instal-
ling equipment which will both minimize water usage and also pre-
vent the discharge of polluted effluents. This would apply only to
certain installations and would not apply, for instance, to a cooling
tower.
In his article Devillers lists costs for particular items which may
have to be provided by, for example, a 3,000 ton/day factory:
Cooling of condenser water $ 44,000
Mud thickener of clarifier 230,000
Pumping mud to lagoons over 2 km 41,000
Pumping lime cake 800 M 10,000
Even if the factory already had a clarifier it could nevertheless be
faced with an expenditure of the order of $95,000.
It would seem that there are sugar factories in France which still
discharge diffusion and press waters, and this practice will obvious-
ly have to be stopped. In some years French factories may have an
average dirt tare as high as 50 to 70 percent, and it is pointed out
69
-------
that this situation could be improved either by encouraging cleaning
on the field or by returning soil to growers at the time of delivery.
It would appear to be permissible for some French factories to put
settled flume and beet washer waters on land which is permeable and
has a structure such that natural purification will occur during seep-
age. Under these special conditions satisfactory results are said to
be obtained with water having an average level of BOD of 600 ppm. It
is calculated that the operation will apply to the land an amount of
potassium equivalent to about 1 ton of potassium per acre per campaign.
In principle, prefectorial authorization is necessary to dispose of
the water in this way.
SWEDEN
Information relating to Sweden was supplied by Civ. Ing. 0. Wiklund,
The Research Department of the Swedish Sugar Company, ArlAv, Sweden.
A central authority, Statens Naturvard-Sverk or State Board for the
Preservation of Nature, administers laws which were formulated as
recently as 1967 and became effective in July, 1969. These laws
require that sugarbeet factories, as well as industry, generally must
have permission to abstract and dispose of water. Permission, when
granted, is subject to review after four years, and in the interim
period factories are required to meet whatever costs may be neces-
sary to bring about improvements in their usage and disposal of water.
All of the Swedish sugar factories have continuous diffusers. Two
of them, Kopingebro and Jordberga, are sufficiently near to the coast
so that after settlement of soil in lagoons they can discharge surplus
water into the sea.
Ortofta for which details are reported is not in such a situation and
therefore it has established closed cycles for transport and beet wash
waters, and it recycles condenser water. The quantity of water accumu-
lated is about 87 percent on beet. This high proportion is in accord
with the BOD of the surplus water being about 1,300 ppm. The main
course of entry into the factory, apart from that brought in with the
beet, is through the cooling systems, and part of the water from the
cooling tower passes into the transport water having been used to
spray the beets after they emerge from the washer. No chlorine is
added to the water going to the cooling tower, but in amounts which
range from 213g to 77g/ton beet at Ortofta and Kopingebro, respec-
tively, chlorine is added to the water returning to the factory from
the Passavant Thickener.
After separation of sand and mud, the surplus water is stored in two
ponds occupying an area of about 19 acres. The depth of water in these
ponds is about 15.5 feet so that they are highly anaerobic. From
these deep ponds the water passes into three shallow aeration ponds
70
-------
(3.3 feet deep), where through spraying and by the action of surface
aerators, the BOD is brought down to about 45 ppm, at which level
discharge to the river is permissible.
The Research Department of the Swedish Sugar Company has carried out
extensive studies on waste waters with a pilot scale activated sludge
system, and the results are to be found in work reported by Wiklund,
et al. (11). Confirming the experiences of Ameln it was found to be
beneficial to add to factory waste waters ammonium salts and disodium
phosphate (Na2 HPO^ ). No Swedish factory has yet installed an acti-
vated sludge plant. Mr. Wiklund expressed considerable interest in a
paper, "The Anaerobic Filter for Waste Treatment", presented by J.C.
Young and P. L. McCarty of Stanford University Civil Engineering De-
partment to the 22nd Conference (1967) on Industrial Waste. When
a rock-filled bed, similar to an aerobic trickling filter was fed
from below, the Stanford investigators obtained good removal of or-
ganic matter and an effluent practically free from suspended solids.
To obtain an effluent free from sludge is an attractive aim, but it
must be pointed out that if the anaerobic process were applied to
sugarbeet factory waste waters, very appreciable quantities of sul-
phide would be formed by the reduction of sulphate.
At the Ortofta factory, water from the three mud ponds, each of which
is filled in turn, passes to a large lagoon where anaerobic condi-
tions prevail. (See Table 8), Finally, 98 percent elimination of
BOD is accomplished by aeration through spraying and through mechan-
ical agitation in three shallow ponds.
A schematic representation of the waste water system is attached
(Figure 11). By agreement with a farmer soil from the mud ponds is
pumped to a meadow for ultimate reclamation.
Condenser water is cooled by forced ventilation in a tower. A por-
tion of the condenser water is used as a spray on the beets coming
from the washer, and this passes into the beet transport water.
Lime sludge is conveyed without addition of water by means of a pump
and air injection applied intermittently into the pipeline carrying
the thickened mud.
At the Ortofta Factory the estimated cost of converting to re-use
of waste water was given as $600,000 with annual operating costs as
$9,000.
SWITZERLAND
Information on the scheme shown in Figure 12 was kindly supplied by
the Aarberg factory manager, Civ. el. Ing. P- Reichen.
71
-------
Table 8. Water Characteristics of the 6'rtofta Factory (Sweden).
Name of company
Typical dates of campaign
Annual beet tonnage processed
Average 24-hour tonnage
processed
Source of fresh water
Gross fresh water intake
1,000 gallons/day
Treatment before use
Type of diffuser
Estimated cost of waste water
treatment facilities
Annual operating costs
Volume of effluent discharged/
ton beet sliced
Amount of BOD discharged/
ton beet sliced
Concentration of BOD in
effluent discharged
Volume of waste water stored -
gallons
Length of storage
Period of discharge
Volume of water discharged/day
Svenska Sockerfabriks AB
October 2 to December 23
409,800 metric tons
5,080 _metric tons
River Kavlinge
786
None
2 DDS continuous types with total
recycling of pulp press water
$600,000
$ 9,000
233 gallons
0.088 pounds
45 ppm
91.7 x 105
Approximately 260 days
112 days, i.e. from late May to
September
851,500 gallons
The Aarberg factory has an average daily slice of 2,880 tons and pro-
cesses about 250,000 tons beet per campaign. Dirt tare averages be-
tween 10 and 12 percent but may at times reach 40 percent.
Transport and wash waters are fed into a rectangular shaped von Roll
(Swiss) clarifier having two sections through which water flows in
parallel. The clarifier has a capacity of 325,000 gallons and cost
the equivalent of $150,000 which included all concrete work, machin-
ery, pumps and a control building.
Flume and beet washer waters are screened to separate small pieces
of beet, and mud is separated in a Passavant clarifier. Before re-
turn to the factory, chlorine is added to the water.
72
-------
FROM FACTORY
CHLORINE
THICKENER
SAND
POND
2.84 ACRES
3
1.76 ACRES
I.84ACRES
fl 9 ACRFS
WASTE WATER SCHEME. b'RTOFTA
STORAGE
AERATION
BASINS
AREA
ACRES
19
1.4
4.0
1.7
DEPTH
FEET
15.5
3.5
3.5
3.5
VOLUME
I06 GAL
93.6
1.5
4.2
1.8
Figure 11. Waste Water Scheme, Ortofta.
The settled mud is pushed to one end of the clarifier from where it is
transferred to a bunker. Here it is mixed with lime sludge (which is
transferred from the rotary filters without water addition), and to-
gether the soil and sludge are pumped at a rate of about 30,000 gallons/
hour through a pipe of 150 mm diameter to mud ponds 1.5 to 2.5 km dis-
tant from the factory.
The addition of the lime cake together with a small amount of lime
maintains the water in the clarifier at a pH of 11 to 12. The lime
which is used is simply that which accompanies the sand and very fine
waste lime that are separated from the milk of lime after it leaves
the slaker. The overflow from the clarifier goes to a basin of
208,000 gallons capacity, and from these it is pumped back to the
flume and wash water systems. The BOD of the water builds up to about
1,800 ppm, but because the pH is always kept at a high level, no un-
pleasant smell develops. De-scaling of pumps is necessary from time
to time.
73
-------
.CONDENSER
Figure 12. Aarberg Factory Water Scheme.
Aarberg factory is situated in a region where land is scarce and what
is available is very expensive, and under these circumstances the fac-
tory cannot store its waste water on a large scale. Fortunately the
owners of land situated 1.5 to 2.5 km from the factory are prepared to
allow soil to be deposited on certain areas provided that these are
subsequently drained and quickly rendered suitable for reclamation for
agricultural purposes. It is interesting to note that the subsoil in
the pond areas is gravel, and after the factory had dug out the ponds
for the reception of soil, it was obliged to line them with clay so as
to avoid the possibility of contaminating the supplies of domestic
water which are pumped from wells nearby-
Water free from soil is pumped from the settling ponds to an activated
sludge plant where it undergoes substantial purification (at times as
much as 96 to 98 percent of the BOD is removed), and after separation
of sludge, the treated water is piped about 0.5 km to another activated
sludge plant belonging to the communities of Aarberg and Lyss. Here
the water together with local sewage is purified and rendered suitable
for discharge into the river, the Alte Aare. Having contributed the
substantial sum of $296,000 toward the cost of the municipal plant,
the sugar factory pays only a nominal charge for the privilege of
putting its final effluent into the sewage treatment plant.
74
-------
The activated sludge plant belonging to the factory cost $342,000 and
is comprised of three concrete basins, two for aerators and one for
clarification by settling. The largest aeration basin, measuring 13.5
x 104 x 2 meters, is fitted with seven Lurgi Vortair aerators, each
capable of introducing about 1 ton of oxygen per day into the water.
Sludge and water pass from the large aerating basin to a similar ba-
sin in parallel with the first and containing four Vortair aerators.
From here water and sludge pass to a settling basin measuring 8 x
43 x 2 meters and having a central channel in the bottom from where
the excess sludge which settles out is pumped away to the soil ponds.
Provision is also made for sludge to be returned to the aeration ba-
sins. Purified water which overflows from the clarifier is conveyed
to the municipal sewage treatment plant. It is aimed to reduce the
BOD of the water in the factory plant to about the level of normal
domestic waste, but even if at times this is not achieved, neverthe-
less, the municipal plant has the necessary capacity.
Additions of diammonium phosphate and urea are made to the ingoing
waste water at the factory plant since these are found to enhance the
activity of the sludge. The need for phosphate and for nitrogen in
activated sludge systems has frequently been observed, and it is also
common experience that active sludge is rather slow to develop in
sugar factory waste waters. This difficulty has been overcome at
Aarberg by starting the plant about a week before the beginning of
the campaign, the aeration basins having been filled with a dilute
solution made from between 8 and 10 tons of molasses.
SUMMARY
It is evident that some sugarbeet factories have succeeded when work-
ing with a closed system in reducing the quantity of waste water that
has to be stored to between 30 percent and 40 percent on beet. To
do this they have adopted certain measures which include:
1. Recycling of flume and beet washer water after separation of soil.
2. Recycling of condenser water through a cooling tower.
3. Returning pulp press water to the diffuser and using hot conden-
sate, preferably after neutralizing with acid as make-up water
for diffusion.
4. Transporting lime sludge out of the factory without addition of
water to the lime cake.
5. Returning to the river, from which the factory receives its water,
all uncontaminated cooling water as, for example, that used for
turbines, pumps, etc.
If a factory slices 200,000 tons of beets and stores a quantity of
waste water equivalent to 30 percent on beet, then it will require
a lagoon covering about 15 acres if the depth of water is not to be
75
-------
more than 3 to 4 feet; this being the condition under which natural
purification of the water will proceed most rapidly.
It has been established at factories in England and Germany that
sugarbeet factory waste water can be purified satisfactorily by bio-
logical processes carried out either on trickling filters or by
aeration in the presence of activated sludge. The resultant efflu-
ent, having a BOD of 20 ppm or less, is suitable for discharge to
rivers or other natural sources of water.
Evidence obtained from different countries confirms that to treat
waste water by either of the biological digestion processes is costly,
and for financial as well as operational reasons it seems to be worth-
while for a factory to seek permission to feed its waste water, either
with or without partial purification, into a public sewage plant.
An approach by the factory to the municipality seems most likely to
succeed at a time when the latter is contemplating installing a new
plant, and the factory offers to defray a substantial part of the cost.
Under these conditions the factory may be given the right to feed its
waste into the public sewer without further charge.
When it is possible to store a relatively large volume of water having
a low concentration of BOD, then purification can be carried out satis-
factorily, as at Ortofta, simply by energetic aeration.
Where no storage space is available, then the system of aeration foll-
owed by discharge of the effluent to a municipal sewage plant, as dev-
eloped at Aarberg, is a practice worthy of consideration.
76
-------
REFERENCES
1. Crane, G. W. 1968. The conservation of water and final treatment
of effluent. Proc. of the 19th Technical Conference of the British
Sugar Corporation Limited.
2. Devillers, P. 1968. Sucrerie Francaise. 4:95.
3. Eau et Industrie. 1969. Ministry of Industry Paris, March 17-
4. Langen, Arnold and Hoeppner, J. 1964. Distribution of waters of
the Ameln raw sugar factory and the introduction of the Vortair
process. Zucker. 17:546.
5. Meyer, F. W. 1968. Purification of waste water by means of acti-
vated sludge. Zucker. 21:338.
6. Re-use of water in industry. International Union of Pure and App-
lied Chemistry. Butterworths, London, W.C.2.
7. Schneider, F. 1968. Technologie des zuckers. M. & H. Schaper, 3.
Hannover 26, Germany.
8. Schneider, F., Hoffman-Walbeck, H. P. and Killatsch, D. 1961.
Zucker. 14:619.
9. Schneider F. and Hoffman-Walbeck, H. P. 1968. Zucker. 14:396.
10. Seine Normandie. Secretariat due bulletin de liaison. 10-12
rue du Capitaine. Menard, 75, Paris 15, France.
11. Wiklund, 0., Bladh, P- 0. and Hink, G. 1965. Socker. 13:1.
77
-------
00
TABLE 9
Summary of Factory Capacities and Fresh Water Usage
Factory
Betteravia,
California
Brawley,
California
Clarksburg,
California
Hamilton City,
California
Manteca,
California
Mendota,
California
Santa Ana ,
California
Spreckels ,
California
Tracy,
California
Woodland,
California
Brighton,
Colorado
Slicing Molasses
ton/day ton/day
4,800
6,500
3,000
-t
1,875 -J-
4,000
3,900 220
1,851 96
6,000 350
2,600 123
3,300 180
2,178
Gross3
Water
Intake
GPDxlO3
3,954
3,900
8,000
4,773
6,300
4,132
2,270
9,505
3,500
6,900
4,070
Beet
Flumes
0
0
3070
1,980
0
1,100
0
150
2,500
0
0
Barometric
Condensers
2,246
2,800
4,500
587
1,750
2,500
2.0002
3,310
some
6,900
3,872
Dif fuser
Supply
1,420
860
0
138
150
0
0
0
250
?
0
Lime Steffen
Mud (Dil.) Other
0 - 288
240
0 - 430
75 - 2,06s1
175
30 370 132
702 2002
0 700 ?
150 600
0 ?
198
Ion-Exchange
2Estimated by Author
3cross water intake does not always total the sum of individual uses
since condenser water is considered fresh water at some factories.
-------
TABLE 9 (continued)
vo
Factory
Delta,
Colorado
Eaton,
Colorado
Fort Morgan,
Colorado
Greeley,
Colorado
Longmont ,
Colorado
Loveland ,
Colorado
Ovid,
Colorado
Rocky Ford,
Colorado
Sterling,
Colorado
Bay City,
Michigan
Caro,
Michigan
Carrollton,
Michigan
Slicing Molasses
ton/day ton/day
1,500 50
2,000
3,632 187
2,145
3,307 189
3,688 190
2,617
3,024 94
2,435
3,500
1,835
1,814
Gross
Water
Intake
GPDxlO3
6,000
3,268
12,000
6,050
11,000
13,070
11,692
8,000
6,100
8,200
4,450
4,600
Beet
Flumes
0
0
7,990
0
0
0
4,864
800
1,525
3,000
1,700
1,650
Barometric
Condensers
3,000
3,116
2,203
5,121
9,000
11,000
5,820
5,818
4,179
5,000
2,400
2,600
Diffuser
Supply
360
0
194
0
432
670
812
800
151
0
250
250
Lime
Mud
1
152
272
202
216
710
58
240
62
0
100
100
Steffen
(Dil.) Other
120
-
249
727
432
432 258
-
342
183
200
- -
-
-------
TABLE $ (continued)
oo
o
Factory
Croswell,
Michigan
Sebewaing,
Michigan
Idaho Falls,
Idaho
Mini-Cassia,
Idaho
Nampa ,
Idaho
Twin Falls,
Idaho
Chaska,
Minnesota
Crookston,
Minnesota
East Grand Forks,
Minnesota
Moorhead,
Minnesota
Bayard,
Nebraska
Gering,
Nebraska
Slicing
ton /day
1,275
1,900
4,200
6,545
4,824
4,594
2,000
3,494
2,750
3,585
2,174
2,250
Gross
Water
Molasses Intake
ton/ day GPDxlO3
3.2504
4,000
125 3,600
8,640
8,640
226 10,800
4,000
5,800
5,000
4,328
8,290
100 5,000
Beet
Flumes
75
1,200
0
0
0
0
0
0
500
0
0
2,500
Barometric
Condensers
3,000
2,450
2,542
7,780
7,776
9,720
3,500
5,800
4,500
4,328
6,500
2,476
Dif fuser
Supply
0
250
648
0
0
0
0
0
0
0
0
Lime
Mud
150
100
86
0
0
36
0
0
0
3
1
Steffen
(Dil.) Other
25
-
180 144
570
764
270 810
464
0 0
0
-
-
13
+ ?ump capacity. Actual flow approximately 1800 gpm.
-------
TABLE 9 (continued)
oo
i
Factory
Mitchell,
Nebraska
Scottsbluff ,
Nebraska
Billings,
Montana
Hardin ,
Montana
Sidney,
Montana
Find lay ,
Ohio
Fremont,
Ohio
Ottawa,
Ohio
Garland ,
Utah
Lewis ton,
Utah
West Jordan,
Utah
Lovell,
Wyoming
Torrington,
Wyoming
Slicing Molasses
ton/day ton/day
2,184
3,366 175
4,250 180
1,700
2,500
1,500
1,980
1,700
2,550 110
1,822 98
1,600
2,183
3,034 139
Gross
Water
Intake
GPDxlO3
8,500
12,000
18,000
4,000
6,867
570
8,650
2,000
8,712
4,640
7,200
5,000
7,630
Beet
Flumes
0
2,500
10,000
0
0
0
0
0
0
0
?
2,248
2,290
Barometric
Condensers
6,500
7,750
3,000
4,000
6,867
520
8,600
2,000
8,014
4,435
7,000
1,552
3,816
Diffuser
Supply
-
0
170
0
0
50
50
0
288
0
?
0
0
Lime
Mud
215
5
110
0
0
-
0
0
86
0
56
200
190
Steffen
(Dil.) Other
9
240
128
-
-
-
-
-
180 144
0 490
144
-
19
-------
TABLE 9 (continued)
oo
to
Factory
Worland ,
Wyoming
Toppenish,
Washington
Moses Lake,
Washington
Chandler,
Arizona
Mason City,
Iowa
Goodland,
Kansas
Easton,
Maine
Dray ton,
North Dakota
Nyssa,
Oregon
Hereford,
Texas
Slicing Molasses
ton/day ton/day
1,600 76
3,800
6,450 225
4,000
1,881
2,609
4,0005
3,915
6,605 204
6,493
Gross
Water
Intake
GPDxlO3
7,500
8,640
3,715
1,883
7,340
853
2,000
8,794
14,400
1,400
Beet
Flumes
4,000
0
0
0
1720
0
500
0
0
0
Barometric
Condensers
2,000
7,906
2,225
1,250
5,370
811
1,200
8,500
11,520
some
niffuser
Supply
500
518
922
0
0
0
300
0
0
0
Lime Steffen
Mud (Dil . )
100 100
0
86 324
33
250
0
0
0
357
some
Other
800
216
158
-
-
42
-
294
2,523
—
Estimated from incomplete oral report
-------
CO
u>
TABLE 10
Water use and Re-Use Per Ton Beets
Factory
Betteravia,
California
Brawley ,
California
Clarksburg,
California
Hamilton City,
California
Manteca,
California
Mendota,
California
Santa Ana,
California
Spreckels,
California
Tracy,
California
Woodland,
California
Raw Water
Intake
Gal/Ton
Beets
850
600
2,666
2,540
1,600
1,060
1,220
1,600
1,350
2,100
Gross Water Use, Gallons Per Ton Beets
Fluming
1,430
1,810
2,440
2,060
1,500
2,560
X
1,100
1,000
1,300
Condensers
and
Cooling
2,080
1,270
1,500
2,760
1,250
2,000
X
3,000
2,120
2,100
Dif fuser
Supply
190
223
3331
539
240
250
X
295
270
240
Lime
Mud
32
76
7
40
44
18
X
47
60
X X
Steffen
Dilution
-
-
-
I.IOO1
-
95
X
120
231
124?3
Total
3,732
3,379
4,228
5,339
3,034
4,925
X^
4,562
3,680
2,800
Ion-exchange regeneration omitted from total.
"X" entry indicates information was not supplied.
3 "?" indicates the entry is questioned and was not verified.
-------
TABLE 10(continued)
oo
Factory
Brighton,
Colorado
Delta,
Colorado
Eaton,
Colorado
Fort Morgan,
Colorado
Greeley ,
Colorado
Longmont ,
Colorado
Loveland ,
Colorado
Ovid,
Colorado
Rocky Ford,
Colorado
Sterling,
Colorado
Bay City,
Michigan
Caro,
Michigan
Carrollton,
Michigan
Croswell,
Michigan
Raw Water
Intake
Gal/Ton
Beets
1,870
4,000
1,620
3,300
2,800
3,300
3,560
4,090
2,640
2,540
2,350
2,420
2,480
2,500
Pluming
2,640
2,000
2,525
2,200
2,390
2,500
2,620
3,350
2,640
2,880
1,720
3,270
3,170
2,500
Gross Water
Condensers
and
Cooling
3,100
2,000
2,160
1,100?
1,720
2,720
3,040
2,220
2,000
1,720
1,430
1,310
1,430
2,360
Use, Gallons
Dif fuser
Supply
290
240
284
190
240
260
360
284
300?
238
510
408
344
300
Per Ton Beets
Lime Steffen
Mud Dilution
90
66 80
76
80 70
100
65 130
190 117
20
80 114
20
X
50
110
120
Total
6,120
4,400
5,045
3,660?
4,450
5,545
6,327
5,870
5,134
4,800
3,660
4,978
5,054
5,280
-------
TABLE LO (continued)
no
ui
Factory
Sebewaing,
Michigan
Idaho Falls,
Idaho
Mini-Cassia,
Idaho
Nampa,
Idaho
Twin Falls,
Idaho
Chaska,
Minnesota
Crookston,
Minnesota
East Grand Forks,
Minnesota
Moorhead ,
Minnesota
Bayard ,
Nebraska
Gering,
Nebraska
Mitchell,
Nebraska
Scottsbluff ,
Nebraska
Raw Water
Intake
Gal/Ton
Beets
2,1003
860
1,320
1,800
2,350
2,000
1,650
1,890
1,210
1,800
2,220
3,900
3,600
Pluming
2,610?
1,710
1,320
1,790
1,300
1,500
1,888
1,640
1,220
2,760
2,210
2,000
1,500
Gross Water
Condensers
and
Cooling
2,000?
2,230
2,215
1,610
2,320
1,750
1,660
1,820
1,210
3,000
1,100?
3,000
2,300
Use, Gallons Per Ton Beets
Diffuser
Supply
300?
223
170
300?
225
240
220?
290
290
240
240
220
330
Lime
Mud
50?
20
51
50
63
27
9
4
54
2
__
100
16
Steffen
Dilution Total
4,960?
43 4,226
3,700
3,750
57? 3,965
3,527
3,777
3,754
2,774
6,000
6 4,316
5,400
72 4,218
-------
TABLE 10 (continued)
oo
Factory
Billings ,
Montana
Hardin,
Montana
Sidney ,
Montana
Findlay,
Ohio
Fremont ,
Ohio
Ottawa,
Ohio
Garland,
Utah
Lewis ton,
Utah
West Jordan,
Utah
Lovell,
Wyoming
Torrington,
Wyoming
Worland,
Wyoming
Toppenish,
Washington
Raw Water
Intake
Gal/Ton
Beets
4,200
2,360
2,750
380
4,300
1,180
3,400
2,530
4,400
2,300
2,500
4,690
2,280
Pluming
2,825
2,060
2,650
4,000
3,530
1,170
2,820
4,410
4,500
1,630
1,480
3,800
2,084
Gross Water
Condensers
and
Cooling
2,360
2,750
4,500
4,340
2,250
3,400
2,270
4,400
2,170
1,270
1,900
2,080
Use, Gallons
Diffuser
Supply
220
324
288
170
160?
254
239
945
305
296
470
3804
Per Ton Beets
Lime Steffen
Mud Dilution
30 30?
60
50?
20
20
7
130 70
X 220
70
100
63 6
60 60
23
Total
4,804
5,740
9,690
8,150
3,600
6,604
7,140
9,915
4,215
3,115
6,290
4,567
Includes pulp transport water.
-------
TABLE 10 (continued)
oo
Factory
Moses Lake,
Washington
Chandler,
Arizona
Mason City,
Iowa
Goodland,
Kansas
Easton,
Maine 2
Dray ton,
North Dakota
Nyssa
Oregon
Hereford,
Texas
Raw Water
Intake
Gal/Ton
Beets
580
470
3,900
328
500
2,250
2,190
215
Gross Water Use, Gallons Per Ton Beets
Fluming
2,340
1,650
4,440
4,500
X
2,440
2,180
1,330
Condensers
and
Cooling
2,000
2,060
2,855
3,320
X
2,170
1,750
1,375
Diffuser
Supply
201
190
314
263
X
197?
210
300?
Lime
Mud
13
8
13
55
X
63
58
X
Steffen
Dilution Total
50 4,604
3,908
7,622
8,738
X
4,870
54 4,252
3,000
-------
CO
CO
TABLE 11
Waste Discharged to Stream Per Ton of Beets; Cost of Disposal Facilities
Factory
Betteravia, California ( pulp
operation, Sinton and Brown)
Betteravia, California
Brawley , California
Clarksburg, California
Hamilton City, California
Manteca, California
Mendota, California
Santa Ana, California
Spreckels, California
Tracy, California
Woodland, California
Brighton, Colorado
Delta, Colorado
Eaton, Colorado
Fort Morgan, Colorado
Greeley, Colorado
Longmont, Colorado
Loveland, Colorado
Loveland, Colorado (planned 1970)
Ovid, Colorado
Effluent
Per Ton
Gallons
-
0
373
1,099
0
0
0
0
0
1,260
0
0
400
760
2,200
2,400
890
2,660
-
3,450
to Streams
Beets Sliced
Lb. BOD
8.0 est.
0
0.6
2.2
0
0
0
0
0
0.5
0
0
5.0
-
5.0
3,1
0.3
3.1
0.5
5.0
Waste
Capital
Cost
$
-
250,000
250,000
-
200,000
250,000
-
700,000
-
200,000
300,000
63,700
160,000
150,000
182,000
260,000
-
500,000
100,000
Disposal Facilities
Annual
Operating Cost
$
—
1,000
?
_
20,000
20,000
_
15,000
-
15,000
54,000
13,000
26,000
3,500
10,000
40,000
_
50,000
3. 00
-------
TABLE 11 (continued)
oo
Factory
Ovid, Colorado (planned 1970)
Rocky Ford, Colorado
Sterling, Colorado
Bay City, Michigan
Caro , Michigan
Carrollton, Michigan
Croswell, Michigan
Sebewaing
Idaho Falls, Idaho
Mini-Cassia, Idaho
Nampa , Idaho
Twin Falls, Idaho
Chaska, Minnesota
Crookston, Minnesota
East Grand Forks, Minnesota
Moorhead, Minnesota
Bayard, Nebraska
Gering, Nebraska
Mitchell, Nebraska
Scottsbluff, Nebraska
Scottsbluff, Nebraska (planned 1970)
Effluent
Per Ton
Gallons
?
2,330
2,415
1,140
2,300
1,800
2,500
2,000 est.
1,900
0
1,610
2,185
0
658
1,800
741
2,890
2,220
500
1,367
-
to Streams
Beets Sliced
Lb, BOD
low
-
6.0
1.0
4.0
3.5
4.0
3.5 est.
4.0
0
3.2
15.6
0
6.3
5.0
3.5
5.0
5.0
4.3
7.0
2.0
Waste
Total
Cost
$ 250,000
200,000
-
150,000
-
150,000
—
100,000
200,000
689,000
650,000
70,000
250,000
300,000
500,000
-
37,000
52,000
30,000
40,000
?
Disposal Facilities
Annual
Operating Cost
$ 25,000
?
1,500
15,000
-
15,000
—
est. 5,000 est.
3,000
20,000
20,000
2,000
12,000
25,000
50,000
-
4,350
5,000
3,300
3,000
?
-------
TABLE 11(continued)
Factory
Billings, Montana
Hardin, Montana
Sidney, Montana
Findlay, Ohio
Fremont , Ohio
Ottawa, Ohio
Garland, Utah
Lewis ton, Utah
West Jordan, Utah
Lovell, Wyoming
Torrington, Wyoming
Worland, Wyoming
Toppenish, Washington
Moses Lake, Washington
Chandler, Arizona
Mason City, Iowa
Goodland, Kansas
Easton, Maine
Dray ton, North Dakota
Nyssa, Oregon
Hereford, Texas
Effluent
Per Ton
Gallons
2,600
1,750
2,758
0
4,200
1,500
3,350
1,756
4,235
2,010
1,483
0
1,906
0
0
3,396
0
little
2,000
1,730
0
to Streams
Beets Sliced
Lb. BOD
7.0
2.6
7.7
0
2.5
1.1
4.0
3.0
4.0
9.0
3.8
0
4.0
0
0
6.9
0
little
.14.0
5.7
0
Waste Disposal
Total
Cost
$ 40,000
10,000
67,000
300,000
450,000
-
125,000
162,000
250,000
57,000
-
-
200,000
300,000
450,000
150,000
448,000
5,000,000
-
338,000
1-2 million
Facilities
Annual
Operating Cost
$ 3,000
5,000
3,500
30,000
35,000
20,000+
1,000
5,000
1,000
?
-
-
3,000
2,000
20,000
25,000
21,000
100,000
-
40,000
7
-------
TABLE 12
Beet Sugar Factories Included In This Survey
1. The Amalgamated Sugar Company
First Security Bank Building
P. 0. Box 1520
Ogden, Utah 84402
Factories at: Mini-Cassia, Idaho (Rupert)
Nampa, Idaho
Twin Falls, Idaho
Nyssa, Oregon
Lewiston, Utah
2. American Crystal Sugar Company
Boston Building
Denver, Colorado 80202
Factories at: Clarksburg, California
Rocky Ford, Colorado
Mason City, Iowa
Chaska, Minnesota
Crookston, Minnesota
East Grand Forks, Minnesota
Moorhead, Minnesota
Drayton, North Dakota
3. Buckeye Sugars, Inc.
Ottawa, Ohio 45875
Factory at: Ottawa, Ohio
4. The Great Western Sugar Company
Sugar Building
P. 0. Box 5308
Denver, Colorado 80217
Factories at: Brighton, Colorado
Eaton, Colorado
Fort Morgan, Colorado
Greeley, Colorado
Johnstown, Colorado - Molasses Plant
Johnstown, Colorado - Monosodium Glutamate Plant
Longmont, Colorado
Loveland, Colorado
91
-------
TABLE 12 (continued)
Ovid, Colorado
Sterling, Colorado
Goodland, Kansas (Kemp)
Billings, Montana
Bayard, Nebraska
Gering, Nebraska
Mitchell, Nebraska
Scottsbluff, Nebraska
Lovell, Wyoming
5. Holly Sugar Corporation
Holly Sugar Building
P. 0. Box 1052
Colorado Springs, Colorado 80901
Factories at: Brawley, California (Carlton)
Hamilton City, California
Santa Ana, California (Dyer)
Tracy, California
Delta, Colorado
Hardin, Montana
S i dney, Montana
Hereford, Texas (Shoup)
Torrington, Wyoming
Worland, Wyoming
6. Michigan Sugar Company
Second National Bank Building
P. 0. Box 1091
Saginaw, Michigan 48606
Factories at: Caro, Michigan
Carrollton, Michigan
Croswell, Michigan
Seb ewaing, Michigan
7. Monitor Sugar Company
2600 South Euclid Avenue
Bay City, Michigan 48706
Factory at: Bay City, Michigan
92
-------
TABLE 12 (continued)
8. Northern Ohio Sugar Company
(wholly owned subsidiary of The Great Western Sugar Company)
Sugar Building
Denver, Colorado 80217
(operating offices - Fremont, Ohio)
Factories at: Findlay, Ohio
Fremont, Ohio
9. Spreckels Sugar Company
Two Pine Street
San Francisco, California 94111
Factories at: Chandler, Arizona
Manteca, California
Mendota, California
Spreckels, California
Woodland, California
10. Union Sugar, Consolidated Foods Corporation
230 California Street
San Francisco, California 94111
Factory at: Betteravia, California
11. Utah-Idaho Sugar Company
200 Beneficial Life Building
47 West South Temple (P. 0. Box 2010)
Salt Lake City, Utah 84110
Factories at: Idaho Falls, Idaho
Garland, Utah
West Jordan, Utah
Moses Lake, Washington
Toppenish, Washington
93
-------
WATER USE. RE-USE AND DISPOSAL
The Amalgamated Sugar Company at Lewiston, Utah
A. Beets sliced, tons/day:—1822; Molasses worked, tons/day:—98; Gross raw water intake:—4640
x 103 (US gal/day); Source: Bear River—100%.
B. Flow sneet type II. Modifications: Steffen waste to separate lagoon. All wastes held until
spring. Some reduction in BOD. Controlled discharge during high river flows.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
Steffen Dilution
Miscellaneous
Water Re-Use
0
4150
0
0
0
490
Recycled
3600
0
435
Barometric
Flumes Condenser
4435
Diffuser
Supply
288
Lime
Steffen Mud
X
220
D. Waste Treatment
1. Flume and general waste screened, discharge not direct, to holding facilities (one pond—
20 acres, 10 ft. deep), 70 days retention, then to river during high water flow in the
spring. BOD in waste to river 370-910 ppm. Sanitary sewer to septic tank.
2. Lime mud discharged to ponds (one pond—5.18 acres), overflow discharged direct but volume
controlled.
3. Condenser water to flumes. Discharged direct—none.
Note: Steffen waste to separate pond. Held until BOD is reduced and discharged when river
is high.
Comment: Volume flume water discharged to river 3.2 x 10 gal/day. BOD in waste discharged
550 Ib/day.
-------
10
WATER USE, RE-USE AND DISPOSAL
The Amalgamated Sugar Company at Rupert, Idaho
A. Beets sliced, tons/day:—6545; Total campaign:—799400; Gross water intake:—8650 (GPD x 103);
Source: Wells and drainage ditch (creek); Water Treatment: 90% given "boiler water" treat-
ment,
B. Flow sheet type IV. Modifications: Excess condenser water to stream, otherwise completely
enclosed system. Very elaborate settling system. No discharge to stream.
C. In-Plant Water Flows (GPD x 103) .
Raw Water Use
Flumes
Condensers
Diffuser Supply
Lime Mud
0
7780
0
0
Recycled Flumes
8210
7200 4750
690
Water Re-Use
Barometric Diffuser Lime
Condenser Supply Steffen Mud
430
Steffen Dilution - -
Gas Washer
570
D. Waste Treatment
1. Flume water screened, then hydroseparator (2- 22' diam.) underflow to mud pond (6.9 acres -
6 ft. deep), one day retention; overflow to clarifier - 130' diam. by 12' deep, clear over-
flow to second holding basin - 130' diam. x 12' deep which is supply to fluming system.
Completely enclosed system. Milk of lime added before hydroseparator - about 19 tons
CaO/day.
2. Condenser water cooled in tower (5000 gal/min.); 2800 GPM to pan condensers, remainder
to creek. Temperature 30° C. Makeup water pumped from creek.
3. Lime mud to separate pond, 26 acres, no overflow; hence no BOD to creek.
Note: Sanitary sewer to septic tank.
-------
WATER USE, RE-USE AND DISPOSAL
Ch
The Amalgamated Sugar Company at Twin Falls , Idaho
A. Beets sliced, tons/day: — 4594; Molasses worked, tons/day: — 226; Gross water intake: — 10800 x
10^ (US gal/day); Source: One well, river, 5% of water treated — Nalco.
B. *'±ow sheet type
river — no ponds
C. In-Plant Water
Raw Water
Flumes
Condensers
Diffuser Supply
Lime Mud
Steffen Dilution
Miscellaneous
II. Modifications: Many. Flume water and general wastes
Steffen waste
Flows (GPD x 103
Use
0
9720
0
0
270
810
evaporated.
).
Water Re-Use
Barometric Diffuser
Recycled Flumes Condensers Supply
0
0 5910 537
537
0
0
screened, then to
Lime
Steffen Mud
288
Waste Treatment
1. Flume and general waste: screened, discharged direct to river—no ponds. Volume of waste
10.8 million gal/day, BOD content 72,400 Ibs/day.
2. Lime mud to pond, one. Overflow of settled liquor direct to river - 302,000 gal/day. BOD
content unknown.
3. Condenser water to flumes, beet washers, sprays and dilution lime mud.
4. Pulp and pulp press water completely recycled to diffuser.
5. Steffen waste evaporated and dried on pulp 100%.
6. Floor drainage to main sewer (432,000) gal/day), main sewer to general waste.
7. Sanitary sewer to septic tank.
Comments: Total effluent 2185 gal/ton beets. BOD in effluent - 15.6 Ib/ton beets. Future
plans: Recycle of flume water. Improve ponds - 80% reduction in waste discharge
expected.
-------
WATER USE. RE-USE AND DISPOSAL
The Amalgamated Sugar Company at Nampa, Idaho
A. Beets sliced, tons/day:—4824; Non-Steffen; Gross raw water intake:—8640 (GPD x
Source; Nine wells - no treatment.
B. Flow sheet type II. Modifications: Flume and general wastes after screening to hydro-
separator, then to City Sewage Plant. All fluid wastes to City Treatment Plant. No Steffen.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
0
7776
0
0
Recycled
0
0
1100(D
Water Re-Use
Barometric Diffuser
Flumes Condensers Supply
0
6192 340(D
Lime
Steffen Mud
0
-
-
-
Steffen Dilution
Miscellaneous
764
-
') Estimated by editor
D. Waste Treatment
1. Flume and general waste screened, discharged to hydroseparator; mud to mud pond, 33.2
acres; clear liquor 240 x 103 GPD to Nampa City Treatment Plant. (BOD to City Plant
225 ppm, BOD from City Plant 7 to 20 ppm) City sewage plant discharge to Indian Creek.
2. Condenser water (7776 gal x 10^ /day) discharged to flumes and miscellaneous.
3. Sanitary sewer to septic tank. Discharge is chlorinated; then to creek.
4. Lime mud to mud pond with flume mud. Overflow to city treatment plant.
5. Pulp and pulp press water 100% recycled.
Special: Plant will be doubled in slicing capacity for 1969-70—9600 tons. Will store part
of thick juice for processing in intercampaign also planned. Recycle of overflow from
mud pond to flumes.
Note: Nampa city charges for waste treatment based on volume, BOD and suspended solids content.
-------
i-D
00
A.
B.
C.
WATER USE. RE-USE AND DISPOSAL
The Amalgamated Sugar Company at Nyssa, Oregon
Beets sliced, tons/day:—6605; Molasses worked, tons/day:—204; Gross water intake:—14400
(GPD x 103); Source: River, no treatment.
Flow sheet type III. Modifications: No cooling and recycling of condenser water. Excess
discharged to stream.
In-Plant Water Flows (GPD x 103).
Raw Water Use
Water Re-Use
Barometric Diffuser Lime
Recycled Flumes Condenser Supply Steffen Mud
Flumes
Condensers
Diffuser Supply
Lime Mud
Steffen Dilution
Miscellaneous
(includes gas washer)
0
11520
0
0
357
2523
8640
0 1440
668
720
D.
Special
Waste Treatment
1. Flume and general waste screened, discharged to two ponds, 45 A total x 10' deep, reten-
tion 7 hours, recycled. Ca(OH)2 added after screening (1 ton CaO/1000 ton beets), pH
about 11. Odor thus minimized.
Condenser water (excess) discharged to river @ 40° C. (about 7200 GPD). BOD 14 to 19 ppm.
Lime mud discharged to lime pond (one-27 A) - all effluent contained.
Steffen waste - 100% evaporated.
Pulp and pulp water returned to diffuser.
Floor drainage (432 x 103 GPD) to main sewer to river. Discharge to river (total) about
170 ppm BOD; pH 7.9 - 9.5. Flow of river - low, ca 4000 GPM.
Quentin (MgO) process ion exchange, some back wash to sewer.
Sanitary sewage to Nyssa City Sewage Plant.
6 to 10% increase in slicing planned. Increased waste sewer pump capacity 53,000 cu.
yd. soil removed annually from ponds - cost about $0.50/cu. yd. Cost of waste treat-
ment facilities $338,000, annual cost $40,000.
-------
WATER USE. RE-USE AND DISPOSAL
American Crystal Sugar Company at Clarksburg, California
A. Beets sliced, tons/day:—3000; Non-Steffen; Gross water intake:—8000 (GPD x 103 ); Source:
Wells - 576, River - 7424; Pre-treatment: 15% of water treated with chlorine and lime.
B. Flow sheet type III. Modifications: No Steffen. Condenser water is not cooled and
recycled.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use Water Re-Use
Flumes
Condensers
Diffuser Supply
Lime Mud
Other
3070
4500
0
0
430
Recycled
4320
0
1000
Barometric Diffuser
Flumes Condenser Supply
1080 X
Lime
Steffen Mud
21
D. Waste Treatment
1. Flume and general wastes screened. Discharged to holding ponds, two, total 12 acres.
Depth 4 ft. Retention 1.25 days. Discharged to river 8000 GPD x 103. BOD in waste dis-
charged 6481 Ib/day.
2. Condenser water (3400 x 103 GPD) discharged to river (Sacramento) @ 50° C.
3. Lime mud ponded - 3 ponds - 12 acres total. No overflow.
4. Gas washer water from well to river. Volume 58 x 10 GPD.
5. Sanitary sewer to septic tank, overflow chlorinated.
Special: New ponds, new screens. Will screen and settle in ponds all flume water (6 acres),
Recycle settled. Overflow 5700 GPM, spring 1970. Big problem - disposal of
lime cake.
6. Pulp pumped % mile to North American Dryer - Transport and pulp press water returned to
diffuser.
-------
o
o
WATER USE, RE-USE AND DISPOSAL
American Crystal Sugar Company at Rocky Ford, Colorado
A. Beets sliced, tons/day:—3024; Total Campaign:—435407: Molasses worked, tons/day:—94; Total
campaign: —13509; Gross water intake:—8000 (GPD x 103 ); Source: Wells and artificial lake
drawing water from Arkansas River - pre-treatment: Nalco #128, 3 ppm.
B. Flow sheet type II. Modifications: Many. Raw water, in part, to flumes, diffuser, lime mud,
Lime pond - no overflow. Steffen waste to pond - no overflow.
C. In-Plant Water Flows (GPD x 103 ).
Raw Water Use Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
Steffen
800
5818
800
240
342
Barometric
Recycled Flumes Condensers
0
0 X
Yes
Diffuser
Supply
X
Lime
Steffen Mud
Waste Water Treatment
1. Flume and general wastes not screened. Discharged direct - 8000 GPD x 103. BOD in
waste - 6000 to 8000 Ib/day.
2. Lime mud to one pond, 20 acres, no overflow.
3. Condenser water to flumes.
4. Pulp and pulp press water recycled to battery 100%.
5. Steffen waste to pond; disposed by evaporation (some seepage).
6. Sanitary sewage to city lagoons.
Comments: Cost of waste treatment facilities $200,000. No future increase in slicing antici-
pated. Estimated pounds BOD discharged to stream per ton beets not known. Volume
waste discharged per ton beets sliced, ca 2330 gal.
-------
WATER USE, RE-USE AND DISPOSAL
American Crystal Sugar Company at Chaska, Minnesota
A. Beets sliced, tons/day:—2000; Non-Steffen; Gross water intake:—4000 (GPD x 10^); Source:
Minnesota River and Springs: Pre-treatment: 100% with Nalco 918; Cost of treatment: $4500/
year.
B. Flow sheet type III. Modifications: No Steffen. Condenser water direct to river (no cooling)
C. In-Plant Water Flows (GPD x 103 ).
Raw Water Use Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
Other
0
3500
0
36
464
Recycled Flumes
3000
325
Barometric Diffuser
Condensers Supply
150
Lime
Steffen Mud
0
D. Waste Treatment
1. Flume and general wastes screened, then to one mud pond, 12 A, 8 to 10 ft. deep. Recycle
(100%) back to factory water clarifier. Mud to mud pond. Lime added after screening.
2. Lime mud discharged to lime pond, 10 A. Overflow to general pond, 54 x 103 GPD.
3. Condenser water discharged direct to river, 3000 x 103 GPD. Temperature 25-40° C.
4. Gas washer from raw and clarified water. Discharged to clarifier, 75 x 103 GPD. Acid
washes to lime pond. Sanitary sewer to city sewage treatment plant.
5. Pulp and pulp press water completely recycled - makeup with condenser water.
Special: Expect 10% increase in slicing. Will recycle condenser water; dewater sludge from
clarifier. Estimated cost present waste treatment system $250,000; operating cost
$12,000/year.
-------
WATER USE. RE-USE AND DISPOSAL
American Crystal Sugar Company at Moorhead, Minnesota
A. Beets sliced, tons/day:- — 3585; Long campaign:—644,000 tons beets; Gross water intake:—4328
(GPD x 103 j; Source: River, pre-treated with Nalco #918.
B. Flow sheet type II. Modifications: No Steffen. Excess condenser water to ponds or river (no
cooling). Wastes ponded and discharged according to river flow.
C. In-Plant Water Flows (GPD x 10-).
Raw Water Use Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
0
4328
0
0
Recycled
1100
100%
Flumes
3265
Barometric
Condensers
Diffuser
Supply
650
Lime
Steffen Mud
196
Waste Treatment
1. Flume and general waste not screened. Discharge to four ponds, total area 183 acres, depth
9 feet. Discharge to river depends on river flow. Discharge usually about 10^ C-PD
(only half that in mid-July, 1969). Some odor problem during long storage. 941 gallons
effluent discharged per ton beets, 3.5 Ib. BOD in effluent per ton beets (16,412 Ib. BOD
per day equivalent to 4.6 Ib/ton beets. About 1 Ib. BOD/ton lost in storage).
2. Lime mud discharged to pond, 34 acres. No overflow. Waste held until beginning next
campaign - discharged with general waste.
3. Pulp and pulp press water - 100% recycled to diffuser.
4. Condenser water (excess - 217 x 10^ GPD) discharged direct to river @ 45° C.
5. Sanitary sewer to city sewer system.
1300-1400 ton increased slicing during next ten years. Waste treatment will include aeration,
closed loop, recycling, clarifying. With proposed changes, discharge of wastes to stream will
be greatly reduced.
-------
WATER USE. RE-USE AND DISPOSAL
American Crystal Sugar Company at Crookston, Minnesota
A. Beets sliced, tons/day:—3494; Total campaign:—646000; Gross water intake:—5800 (GPD x 103);
Source: Red Lake River, no treatment.
B. Flow sheet type II. Modifications: No Steffen. Excess condenser water to river. Wastes
ponded, controlled discharge after ice breaks up according to river flow.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
Water Re-Use
0
5800
0
0
Recycled Flumes
1100
5500
386
Barometric
Condensers
Diffuser
Supply
386
Lime
Steffen Mud
300
D. Waste Treatment
1. Flume and general waste screened, discharged to two ponds, total area 146 acres, depth 14
ft. Retention variable. Discharged to Red Lake River until river freezes - remainder af-
ter spring thaws. Controlled discharge to maintain dissolved oxygen down stream in river
of 5 ppm and no deleterious effect on domestic water supplies. October 3-December 7, 1968,
362 x 106 gallons containing 500 ppm BOD discharged; April 18-June 6, 1969, discharges as
follows: Totalgal x 1C6 May GPD x 106 BOD
North Pond 291.4 " 15.0 850
South Pond 116.8 15.2 1580
Lime Pond 17.0 0.5 4400
2. Lime mud to two ponds, 12 acres.
3. Condenser water excess, 1500 GPD x 1Q3 discharged to river @ 45° C.
4. Other wastes to general ponds.
5. Pulp and pulp press water 100% recycled to diffuser.
E. Special Information: No increase in slicing over 5000 tons/day expected. Planned: A clarifier,
screens, recycle of beet flume water. Cost of present waste water facilities $500,000. Annual
operating costs $25,000. Waste effluent to river - gal/ton beets 1220; BOD, Ib/ton beets 8.8.
-------
WATER USE. RE-USE AND DISPOSAL
American Crystal Sugar Company at East Grand Forks, Minnesota
A. Beets sliced, tons/day:—2750; Gross water intake:—5000 (GPD x 1Q3 ); Source: Red River - all
treated with 2 ppm phosphate - cost $2500/year.
B. Flow sheet type II. Modifications: No Steffen. Wastes ponded (no screening). Controlled
discharge after ice breaks up, during floods.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
500
4500
0
0
Recycled
400
Flumes
4000
Barometric
Condensers
Diffuser
Supply
400
Lime
Steffen Mud
12
Waste Treatment
1. Flume and general wastes not screened. Discharged to one pond, 155 acres in 11 bays.
Retention time 11 days. Discharged to Red River of the North. Volume discharged (GPD
x lO^) 4500 average. BOD in waste discharged 8250 Ib/day. Discharge regulated to
avoiu high BOD concentrations in river. Effluent at start about 1000 ppm BOD, in July,
1969, 640 ppm. Typical samples from river:
DO - ppm BOD - ppm
Above outfall 8.0 2.6
Below outfall 8.4 5.6
2% miles below 4.4 3.4
28 miles below 8.1 2.2
2. Lime mud discharged to three ponds, 5 acres. No overflow discharge. In spring about
2000 - 3000 Ib/day BOD discharged.
3. Condenser water to flumes.
4. Sanitary sewer to City Sewage Plant.
Comments: Main pond contains floor drainage. Waste line runs two miles underground to
river. Impossible to empty pond rapidly during river flood.
-------
WATER USE, RE-USE AND DISPOSAL
American Crystal Sugar Company at Drayton, North Dakota
A. Beets sliced, tons/day:—3915; Total sliced, campaign:—688721; Gross water intake:—8794
(GPD x 103); Source: River - 2% of water from City of Drayton. Treated with 2 ppm PO^.
B. Flow sheet type III. Modifications: No Steffen. Condenser water not cooled and recycled.
Wastes ponded, controlled discharge to river during floods in spring.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use
Flumes
Condenser and Cooling
Diffuser Supply
Lime Mud
Other
Water Re-Use
0
8500
0
0
294
Recycled
870
370
Barometric
Flumes Condenser
7800*
Diffuser
Supply
398
Lime
Steffen Mud
246
o Includes 1000 to beet washer and sprays.
Ul
D. Waste Treatment
1. Flume and general waste screened. Discharged to two ponds, 250 acres total, 16 ft. deep,
7 days retention until freeze-up, then until ice break-up in river (spring). Discharged
to Red River, 5490 GPD x 103 in fall, 31,667 in spring-summer, regulated according to
river conditions. Total wastes discharged to river 2000 gal/ton of beets, BOD in discharge
14/ton.
2. Lime mud to one pond, 60 acres, overflow discharged to general ponds.
3. Other wastes, floor drainage 5 x 103 GPD, BOD 210 Ib/day (sugars 300 Ib). Gas washer
to main sewer.
4. Pulp and pulp press water 100% recycled.
E. Suspended solids 100% removed in lagoons, 10% of BOD reduced. No increase in plant capacity
expected. No change in waste disposal planned. Sanitary sewage to Drayton city lagoon
(estimated BOD 64 Ib/day). No odor problem.
-------
o
CTl
WATER USE, RE-USE AND DISPOSAL
American Crystal Sugar Company at Mason City, Iowa
A. Beets sliced, tons/day:—1881; Non-Steffen; Gross water intake:—7340 (GPD x 103 ); Source:
Wells - 860, River - 6480 (Winnebago River).
B. Flow sheet type II. Modifications: No Steffen. Flume and general waste not screeeed, re-
cycled back to flumes. Excess held 190 days, then discharged to river. No discharge from
lime pond. Excess condenser discharged to river.
C. In-Plant Water Flows (GPD x 203) .
Raw Water Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
1720
5370
250
Recycled Flumes
7150
225
Water
Re-Use
Barometric Diffuser
Condenser Supply
365
Lime
oteffen Mud
D. Waste Treatment
1. Flumes and general waste not screened. Ca(OH)« added, discharged to three holding ponds -
85 acres total. Retention 3 to 282 days. Then discharged to river. Volume 1036 average
(193 day period). BOD in waste discharged 8991 Ib/day. Some odor problem.
2. Lime mud ponded, one pond - 38 acres, overflow not discharged. Volume 98 x 103 GPD.
BOD in waste to pond 3680 Ib/day.
3. Condenser water. Excess discharged to river @ 33° C. average, 5000 x 103 GPD. BOD 61
ppm average.
4. Pulp and pulp press water recycled to diffuser.
5. 638 gallons ponded water plus 2658 gallons condenser water per ton of beets, discharged to
stream. About 6.89 Ibs BOD to stream per ton of beets sliced.
Special: Future increase in slicing, ca 10%. Expect to effect closed loop waste treatment.
Waste discharged to river, regulated over period of about ten months to insure positive
oxygen balance.
-------
WATER USE. RE-USE AND DISPOSAL
Buckeye Sugars, Inc. at Ottawa, Ohio
A. Beets sliced, tons/day:—1600-1700; Total campaign:—220,000; Gross water intake:—2,000
(GPD x 1Q3 ;; Source: Blanchard River (settling pond to remove settleable solids).
B. Flow sheeu type III. Modifications: No Steffen. Mechanical clarifier for flume water, thence
to ponds - 120 days retention. Controlled discharge.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
0
2000
0
0
Recycled
1440
3560
100%
Flumes
460
Barometric
Condenser
3560
Diffuser
Supply
72
Lime
Steffen Mud
D. Waste Treatment
1. Flume and general waste screened, lime added (pH 9) to clarifier, mud to ponds, sedimenta-
tion pond, 3 acres, to main holding pond, 8 acres, 12 ft. banks, to recycle. Then to Blan-
chard River; 120 day retention in ponds.
2. Lime mud to two ponds, 5 acres, 5 ft. deep, overflow to 8 acre holding pond. Two 7% HP
aerators in holding pond to control odor and reduce BOD.
3. Pulp and pulp press water recycled to diffuser - 100%.
4. 110 gal waste discharged/ton beets and 0.14 lb BOD/ton beets.
5. Condenser water recycled through spray pond, 6 acres.
6. Sanitary sewer to city sewage plant.
7. Gas washer, source, condensers, discharged to flumes.
8. Floor drains to main sewer to holding pond.
E. Comments: Sodium nitrate and copper sulfate added to settling pond. 23 x 10^ gal waste
accumulates during campaign - controlled discharge afterward. No increase in slicing contem-
plated. Future plans: all waste waters, after screening and settling, will go to new city
sewage treatment plant when completed in 1970 or 1971. Cost of cleaning lagoons $1.00 per cu.
yd., $20,000 annually. City will charge $12,000 annually. Estimated future cost of waste
disposal $0.16/ton beets.
-------
o
oo
WATER USE. RE-USE AND DISPOSAL
The Great Western Sugar Company at Loveland, Colorado
A. Beets sliced, tons/day:—3688; Total campaign:—399000; Molasses worked, tons/day:—190; Total
campaign:—20300; Gross water intake:—13070 (GPD x 103 ); Source: Lake Loveland (from Big
Thompson River) - 13,000; from city - 70. City water filtered and chlorinated.
B. Flow sheet type II. Modifications: Condenser water to flumes, excess to streams. All other
water usage from raw water. Steffen waste evaporated,
C. In-Plant Water Flows (GPD x 103) .
Raw Water Use Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
Steffen Dilution
Miscellaneous
0
11000
670
710
432
258
Barometric
Recycled Flumes Condensers
0
9670
670
45%
Diffuser
Supply
670
Lime
Steffen Mud
Waste Treatment
1. Flume and general waste not screened. Discharged to three ponds, total 119 acres, 1 ft.
deep. Retention 4 days. Discharged to Big Thompson River - 9670 GPD x 103. At times
overflow from Boyd Lake runs through ponds, up to 5000 GPD x 103. When this happens,
DO in effluent rises to 7 ppm.
2. Lime mud 500 GPD x 10.3 runs into flume water ponds.
3. Condenser water: 928 GPD x 103 direct to Boyd Lake; remainder to flumes.
4. Steffen waste evaporated.
5. Other factory wastes to main ponds. Total volume - 135 x 103 GPD.
6. Pulp and pulp press water recycled.
Comments; No planned increase in slicing. Will install 100% flume water recirculation and
separate lime pond. Cost of waste water system $1,000,000. Annual cost $50,000.
-------
WATER USE, RE-USE AND DISPOSAL
The Great Western Sugar Company at Greeley, Colorado
A. Beets sliced, tons/day:—2145; Total campaign:—219000; Gross water intake:—6050* (GPD x 103);
Source: Wells - 806, Cache la Poudre - 4315, City storm sewer - 1939; 11% filtered and
chlorinated.
B. Flow sheet type II. Modifications: No Steffen. Raw water to lime mud to lime pond. No
general ponds - all discharge to long winding ditch - 5900 ft. to stream.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
0
5121
0
202
Recycled
2560
258
Water Re-Use
Barometric
Flumes Condenser
1800
Diffuser
Supply
258
Lime
Steffen Mud
o
>J3 D. Waste Treatment
1. Flume and general waste screened, discharged through a winding ditch - 15 ft. wide by 6 ft.
deep, 5900 ft. long to Poudre River. Area of ditch 3.7 acres. Retention time 5^s hours.
Volume 6050 GPD x 103. BOD in discharge, 3 Ib/ton beets.
2. Lime mud to pond, 4.6 acres. No overflow - seeps away.
3. Condenser water excess discharged to ditch with flume water to Poudre River. Volume 3700.
4. All other factory wastes to main sewer to flume water ditch. Volume 200.
5. Sanitary sewer to city sewage treatment.
6. Pulp and pulp press water 100% recycled to diffuser.
7. Effluent discharged 2400 gal/ton beets. BOD in effluent, 3.12 Ib/ton beets.
E. Comments: No increase in slicing planned. Holding ponds and total recycling of flume water
planned. Also, cooling and recirculation of condenser water. Will need additional water. BOD
will be reduced to 0.4 Ib/ton. Cost of present waste treatment $182,000. Annual operating cost
$10,000.
Does not equal tabulated raw water use due to other non-process uses of water.
-------
WATER USE, RE-USE AND DISPOSAL
The Great Western Sugar Company at Eaton. Colorado
A. Beets sliced, tons/day:--2000; Total campaign: —217140; Gross water intake:—3268 (GPD x 1()3);
Source: Wells - 3100, City - 140. Pre-treatment: main water Nalco #128, cost $2400/year.
B. Flow sheet type II. Modifications: No Steffen. Raw water to lime mud - lime pond.
C. In-Plant Water Flows (GPD x
Raw Water Use Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
0
3116
0
152
Recycled Flumes
5050
3116
280
Barometric
Condenser
Diffuser
Supply
288
Lime
Steffen Mud
Waste Treatment
1. Flume and general waste screened and pumped to two mud ponds, 0.35 acres each, used
alternately (10 ft. deep), one settling surge pond (0.4 acres x 4 ft. deep). Ion exchange
regenerants to chemical pond (1.3 acres) - no discharge. Seepage, zero BOD to stream.
2. Condenser water to spray pond. Two wells (1500 GPM each) pumped to cool water. Overflows
to 6 mile ditch to Poudre River.
3. Lime mud ponded. One pond, ca 6 acres. Overflow to seep ditch. No discharge to river.
4. Sanitary sewage to city sewer system.
5. Other wastes: gas washer water, source wells - discharged to seep ditch.
Comments: Milk of lime added to flume water after screening pulp and pulp press water recycled
to diffuser. No increase in slicing anticipated. No change in waste treatment. Cost of waste
treatment facility $160,000. Operating cost $26,000 per year. Effluent to stream per ton
beets - 760 gal.
-------
WATER USE. RE-USE AND DISPOSAL
The Great Western Sugar Company at Longmont, Colorado
A. Beets sliced, tons/day:—3307; Total campaign:—378000; Molasses worked, tons/day:—189; Total
campaign:—21620; Gross water intake:—11000* (GPD x 103 ); Source: St. Vrain River - 10,000,
City - 970; City water filtered and chlorinated.
B. Flow sheet type III. Modifications: Raw water to diffuser make-up and to lime mud - to lime
pond. No discharge - seepage. Condenser water direct to streams.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use Water Re-Use
Barometric Diffuser Lime
Recycled Flumes Condensers Supply Steffen Mud
Flumes 0 3597 (4660)
Condensers and Cooling 9000
Diffuser Supply 432 432
Lime Mud 216
Steffen Dilution 432
D. Waste Treatment
1. Flume and general waste screened; 3600 recycled direct to flumes; 4660 limed, thence to
mud lagoon (a) or (b) 0.276 acres, 10 ft. deep to (b) surge pond 1.79 acres, thence to
flumes, or excess to (c) anaerobic pond 1.61 acres, 15 ft. deep. Latter held until BOD
is reduced to 100 ppm before discharge. Normally no discharge to stream. Some odor in
(c); corrected by two 25 HP aerators. Pond, therefore, not altogether anaerobic.
2. Condenser water direct to stream.
3. Lime mud to pond, 22 acres, supernatant evaporates or seeps - no discharge.
4. Steffen waste evaporated.
5. Sanitary sewage to septic tank and leach field.
6, Gas washer water, source, raw water discharged to intake pond.
E. Comment: Cost of waste facilities $260,000. Annual operating cost $40,000; 890 gal (condenser
water only) discharged per ton beets, BOD to stream 0.35 Ib/ton of beets.
*Does not equal tabulated raw water use due to other non-process uses of water.
-------
WATER USE, RE-USE AND DISPOSAL
The Great Western Sugar Company at Sterling, Colorado
A. Beets sliced, tons/day:—2435; Total campaign:—290000; Gross water intake:—6100 (GPD x 103) ;
Source: River - 5100, City - 1000, Wells (in emergency, as river frozen). Pre-treatment Nalco
918. Cost $1500/year.
B. Flow sheet type II. Modifications: No Steffen. Flume water and general wastes direct to
stream (no ponds). Lime mud to ponds - no overflow. Condenser water excess direct to river.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use Water Re-Use
Barometric Diffuser Lime
Recycled Flume Condensers Supply Steffen Mud
Flume 1525 1403
Condensers and Cooling 4179 0 4179
Diffuser Supply 151 __ 154
Lime Mud 62
M Miscellaneous 183
I— ' '
ISJ
D. Waste Treatment
1. Flumes and general waste not screened. Discharged direct to South Platte River through 3/4
mile ditch - 5612 GPD x 1Q3, containing 13,500 Ib BOD per day.
2. Lime mud to pond, 4.4 acres. Overflow is not discharged but pond close to river; perhaps
seepage.
3. Condenser water discharged direct to river, 4117 GPD x 103 3 45° C.
4. Other wastes - 70,000 gal/day. BOD not known, discharged to river.
5. Sanitary sewer to Sterling Sewage Treatment System.
6. Pulp press water 100% recycled.
7. Present operating costs of waste water handling about $1500 per year.
E. Comments: No increase in slicing anticipated. Planned (1970-71) changes in waste treatment:
flume water recirculation system with ponds - $250,000; annual operating costs $25,000.
Estimated volume effluent per ton of beets 2415; BOD 5.6 Ib/ton beets.
-------
U)
WATER USE. RE-USE AND DISPOSAL
The Great Western Sugar Company at Brighton, Colorado
A. Beets sliced, tons/day:—2178; Total campaign:—278000; Gross water intake:—4070 (GPD x 103);
Source: Wells - 864, River - 3136, City - 70. Water intake screened, treated with Nalco.
Cost $4000/year.
B. Flow sheet type III. Modifications: Raw water to lime mud - to lime pond. No discharge.
Excess condenser water - very little - direct to ditch, to river. Practically no BOD to stream.
C. In-Plant Water Flows (GPD x 103)u
Raw Water Use
Flumes
Condenser and Cooling
Diffuser Supply
Lime Mud
0
3872
198
Recycled
5750
3740
360
Water Re-Use
Barometric
Flumes Condensers
Diffuser
Supply
305
Lime
Steffen Mud
D. Waste Treatment
1. Flume and general waste screened; to mud pond (a) 0.253 acres, to (b) suge pond 1.77 acres,
recycled to flumes or to (c) when build-up occurs, 17.1 acres. No discharge from (c) - seeps
or evaporates.
2. Condenser water to spray pond, recirculates to condensers. Additional water added to lower
temperature - overflow to ditch and South Platte River. New plans include more sprays to
lower temperature.
3. Lime mud to lime pond, 4 acres, overflow seeps away or evaporates. No BOD discharged.
4. Sanitary sewage to city sewage system.
5. Milk of lime added to flume water after processing.
6. Pulp and pulp press water recycled to diffuser.
E. Comments; Cost of facility $300,000. Annual operating cost $54,000.
-------
WATER USE, RE-USE AND DISPOSAL
The Great Western Sugar Company at Fort Morgan, Colorado
A. Beets sliced, tons/day:—3632; Total campaign:—453433; Molasses worked, tons/day:—187; Total
campaign:—23390; Gross water intake:—12000* (GPD x 103); Source: South Platte River.
B. Flow sheet type II. Modifications: Raw water to flumes to diffuser make-up and lime mud.
Flume and general wastes not screened - to ponds - to river. 85% Steffen waste evaporated.
C. In-Plant Water Flows (GPD x 1C3).
Raw Water Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
Steffen Dilution
7990
2203
194
272
249
Recycled
0
0
483
0
0
Water Re-Use
Barometric Diffuser
Flumes Condensers Supply
Lime
Steffen Mud
D. Waste Treatment
1, Flume and general waste not screened. Discharged to two ponds, 2% acres each, 3 ft. deep,
retention 3 hours. Thence to river. Volume 12,000 GPD x 103, 20,000 Ib. BOD per day.
2. Lime mud to one pond, 10 acres, overflow to river - 272 GPD x 103. BOD included in general
waste.
3. Condenser water discharged direct. Volume 4000 GPD x 103, temperature 30° C.
4. Steffen waste evaporated - 85% of total. Remainder to main sewer.
5. Other wastes - floor drainage, gas washer water, chemical washes discharged to main sewer.
6. Sanitary sewer to city sewer plant.
7. Pulp and pulp press water 100% recycled.
E. Comments: Slicing to be increased 2400 tons between 1969 and 1979. Waste treatment to include
flume water recirculation. Cost $250,000. Operating cost $25,000 per year (estimated). Cost
of present facilities $150,000, $3500 per year. Effluent discharge 2200 gal per ton beets,
containing 5 Ib BOD per ton beets.
Does not equal tabulated raw water use due to other non-process uses of water.
-------
WATER USE, RE-USE AND DISPOSAL
The Great Western Sugar Company at Billings, Montana
A. Beets sliced, tons/day: — 4250; Total campaign: — 595000; Molasses worked, tons/day: — 180; Total
campaign: — 25200; Gross water intake:-- 18000*
B. Flow sheet type II.
denser water reused
C. In-Plant Water Flows
Raw Water Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
Steffen Dilution
Modifications: Raw water
in flumes. Steffen waste
(GPD x 103).
Recycled
10000 0
3000 0
170 756
110
128
(GPD x lO3 ); Source: Yellowstone River.
for all purposes, except 1250 x 10.3 GPD
to lime pond until 1968-69; evaporated in
Water Re-Use
Barometric Diffuser
Flumes Condensers Supply Steffen
1250
con-
1969-70
Lime
Mud
0
I—
£ D. Waste Treatment
1. Flume and general waste screened: 2000 discharged to pond (in 1968) - 3 basins, 1/3 acre each;
two used at same time. Then to long channel - 6 passes, 1000 ft. each by 35 ft. wide. New,
one additional pond 1400 ft. long x 60 ft. wide. Discharges to Yeager ditch and to river.
Cost cleaning channels and ponds during and after campaign about $13,000. BOD entering
system 770 ppm, leaving about 700 ppm ( no change). Later (December) BOD 300 ppm. Settle-
able solids reduced from 4000, average to 125 ppm. Volume effluent 8-10 million gal/day
from ponds - some bypassed. Total perhaps 11 million.
2. Lime mud to one pond, 40 acres. No overflow.
3. Condenser water - 1420 GPD x 103 discharged to river at 55° C.
4. Steffen waste evaporated in 1969 - previously to lime pond.
5. Other wastes to sewer.
6. Sanitary sewer to city plant.
E. Comment: Volume effluent about 2600 gal per ton beets - about 7 Ib. BOD per ton beets.
&
Does not equal tabulated raw water use due to other non-process uses of water.
-------
WATER USE, RE-USE AND DISPOSAL
The Great Western Sugar Company at Lovell, Wyoming
A . Beets sliced, tons/day:—2183; Total campaign:—310000; Gross water intake:—5000* (GPD x
10 3 ); Source: Shoshone River.
B. Flow sheet type II. Modifications: No Steffen. Raw water to flumes. Flume water screened,
then to river, no general settling ponds. Lime mud to ponds - no discharge.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
2248
1552
0
200
Recycled
432
Flumes
1312
Barometric
Condensers
Diffuser
Supply
240
Lime
Steffen Mud
0
D. Waste Treatment
1. Flumes and general waste screened (1969) - 3 vibrating screens, then direct to river—4424,
no ponds.
2. Lime mud to pond, 29 acres. No overflow - evaporation and seepage.
3. Condenser water discharged direct to river - 1312.
4. Other wastes: gas washer water 100; floor drainage 72; boil outs - all to sewer and river.
5. Sanitary sewage to city plant.
E. Comments: Cost of present waste treatment facilities $57,000; operating costs not available
(but considerable). Effluent to stream 2010 gal per ton beets. BOD to streams not available
(author's estimate 8-10 Ibs per ton beets). No increase in slicing planned.
&
Does not equal tabulated raw water use due to other non-process uses of water.
-------
WATER USE, RE-USE AND DISPOSAL
The Great Western Sugar Company, Scottsbluff, Nebraska
A. Beets sliced, tons/day:—3366; Total campaign:—336860; Molasses worked, tons/day:—175; Total
campaign:—16600; Gross water intake:—12000* (GPD x 1C3 )\ Source: Wells - 2400, Winter Creek -
9600. Pre-treatment: Nalco #519 to 70% of flow.
B. Flow sheet type II. Modifications: In 1968-69, pulp to silo, in 1969-70 to dryer (II). Flume
and general wastes not screened but to ponds, then river. Steffen waste evaporated.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
Steffen Dilution
2500
7750
5
240
Recycled
0
0
1203
Water Re-Use
Barometric
Flumes Condensers
7500
Diffuser
Supply
1023
Lime
Steffen Mud
D. Waste Treatment
1. Flumes and general wastes not screened, to ponds, three in use each year, 100 acres, 6 ft.
deep, thence to North Platte River. Volume (Nebraska State measurements) 4450; 23,500 Ib
BOD, per day.
2. Lime mud to ponds, overflow to general ponds. Volume 4.5 GPD x IC^. BOD unknown.
3. Condenser water - 1572 discharged to general ponds, remainder (except 1023) to flumes,
thence to ponds and river.
4. Steffen waste - 100% evaporated.
5. Other wastes, including sanitary sewer, to general ponds.
6. Pulp and pulp press water recycled to diffuser. Pulp dryer installed in summer 1969; hence
no pulp silo drainage in 1969-70 campaign.
E. Comments; Flow figures not consistent. Their estimate of effluent per ton beets sliced 1367
gal; 7 Ib BOD per ton sliced. Probably considerable seepage to river. Proposed changes ex-
pected to reduce BOD to 2 Ib/ton.
*Does not equal tabulated raw water use due to other non-process uses of water.
-------
WATER USE, RE-USE AND DISPOSAL
The Great Western Sugar Company at Gering, Nebraska
A. Beets sliced, tons/day:—2250; Total campaign:—240000; Molasses worked, tons/day:—100;
Total campaign: —12000; Gross water intake: — 5000 (GPD x 103 ); Source: Winter Creek.
B. Flow sheet type II. Modifications: Raw water to flumes. Lime pond has no discharge. Steffen
waste evaporated. Condenser water to flumes - no recycle.
C. In-Plant Water Flows (GPD x 103) .
Raw Water Use Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
Steffen Dilution
Barometric
Recycled Flumes Condensers
2500
2476 2476
22
1
13
Diffuser
Supply
0.5
Lime
Steffen Mud
Waste Treatment
1. Flume and general wastes screened and discharged to two ponds, 3 acres each. Retention time
2 hours. Discharged, 5000, to North Platte River. BOD in effluent 12,000 Ib/day.
2. Lime mud discharged to pond, 5 acres. No overflow - seeps.
3. Condenser water discharged direct - 2476 @ 35° C.
4. Steffen waste 100% evaporated.
5. Other wastes all to main sewer, i.e., to general wastes.
6. Pulp and pulp press water all recycled to diffuser.
Comments: No increase in slicing planned. Flume water settling basin constructed in 1969 to
remove settleable solids. Estimated cost of treatment facilities $52,000; annual costs $5,000.
Effluent discharged per ton beets 2220 gal. BOD 5.0 Ib/ton beets. No flume water recircula-
tion planned. Note: Check made 10-29-69—BOD per day 11,000, suspended solids in effluent
830 ppm.
-------
WATER USE. RE-USE AND DISPOSAL
The Great Western Sugar Company at Bayard, Nebraska
A. Beets sliced, tons/day:-•-2174; Total campaign:—216037; Gross water intake:—8290* (GPD x 1P3);
Source: River - pre-treatment to 90%. Nalco #918. Cost $1800 per year.
B. Flow sheet type II. Modifications: No Steffen. Flume and general waste not screened, run to
four general ponds, thence to river. Lime mud to general ponds.
C. In-Plant Water Flows (GPD x 1C3).
>£>
Raw Water Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
Recycled
0
6500
0 285
3
Water Re-Use
Barometric
Flumes Condensers
6000
Diffuser
Supply
233
Lime
Steffen Mud
D. Waste Treatment
1. Flume and general waste not screened. To ponds (four), total 120 acres, 4 ft. deep.
Discharged to North Platte River. Volume effluent 6300, BOD 1100 Ib/day (State of Nebraska
measurement).
Lime mud to general ponds (four), 120 acres. Volume 13 GPD x
Condenser water excess above in-plant re-use about 1200 to general ponds, temperature 55° C.
Other wastes all, including sanitary sewer, to main ponds, 120 acres.
Pulp and pulp press water recycled to diffuser.
Comments: This factory and a few others of Great Western Sugar Company drip Nalco 674 into
wastes— 1% Ib per day—to mask odors. Forty-day increase in campaign for 1969-70 campaign.
No changes in waste treatment planned. Cost of waste treatment facilities $37,000. Operating
costs $4350 per year. Volume effluent 2890 gal per ton beets. BOD estimated 5 Ib per ton beets,
Does not equal tabulated raw water use due to other non-process uses of water.
-------
WATER USE, RE-USE AND DISPOSAL
The Great Western Sugar Company at Mitchell, Nebraska
A. Beets sliced, tons/day:—2184; Total campaign:—229274; Gross water intake:—8500* (GPD x 103) ;
Source: Wells - 1500, Spotted Yellowtail Creek - 7000. Pre-treatment 85% with Nalco 918.
Cost $1100/year.
B. Flow sheet type II, Modifications: No Steffen. Flume and general wastes not screened, run to
ponds, thence to river. Lime mud to flume ponds.
C. In-Plant Water Flows (GPD x K3).
Flumes
Raw Water Use
Condensers and Cooling
Dif fuser
Lime Mud
Supply
0
6500
215
Recycled
0
2400
Water Re-Use
Barometric
Flumes Condensers
4250
Diffuser
Supply
0
Lime
Steffen Mud
o D. Waste Treatment
1. Flumes and general wastes not screened. To ponds, one with five sections, 88 acres, total.
Depth 6 ft. Days retention - 80. Discharged to North Platte River 1050 (State of Nebraska
measurement, 14,077 Ib BOD per day). Pond adjacent river. Probable seepage.
2. Lime mud combined with flume water in 88 acre pond.
3. Condenser water - 2000 discharged direct, 4250 as flume water, all to pond. Temperature
55° C.
4. Other wastes, including sanitary sewer, approximately 151 GPD x 1C'3 to pond.
5. Pulp and pulp press water 100% recycled.
E. Comments: Ten percent increased annual slice planned. Cost of present waste disposal facili-
ities $30,000. Annual operating cost $3300. Estimated BOD discharged per ton of beets 4.3 Ibs,
Volume effluent 500 gal. per ton beets (appears low).
Does not equal tabulated raw water use due to other non-process uses of water.
-------
WATER USE. RE-USE AMD DISPOSAL
The Great Western Sugar Company at Ovid, Colorado
A. Beets sliced, tons/day:—2617; Total campaign:—290000: Gross water intake:—11692* (GPD x 103);
Source: Wells 100% (river - standby).
B. Flow sheet type II. Modifications: Raw water to flumes, condensers, diffuser supply, lime mud.
Flume and general waste screened - no ponds, thence to river. No Steffen.
C. In-Plant Water Flows (GPD x 1C3).
Raw Water Use Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
4864
5820
812
58
Recycle
0
360
Flumes
3900
Barometric
Condensers
Diffuser
Supply
Lime
Steffen Mud
D. Waste Treatment
1. Flume and general waste screened, discharged direct to river (no ponds), 10,350, BOD unknown
2. Lime mud to pond - 1. Overflow discharged to river - 28.
3. Condenser water - 5820 discharged direct to river @ 45° C.
4. Sanitary sewer to city sewer system.
5. Pulp and pulp press water 100% recycled to diffuser.
6. Other wastes - to general waste.
E. Comments: No increase in slicing planned. Flume water recirculation system will be installed.
Cost $250,000. Annual operating cost $25,000 estimated. Cost of present waste facilities
$100,000. Annual operating cost $3,000. Effluent discharged 3450 gal. per ton beets sliced.
BOD in effluent 5 Ib/ton beets (estimated).
Does not equal tabulated raw water use due to other non-process uses of water.
-------
WATER USE. RE-USE AND DISPOSAL
The Great Western Sugar Company at Goodland, Kansas
A. Beets sliced, tons/day:—2609; Total campaign:—355800; Gross water intake:—853 (GPD x 103);
Source: 3 wells. Water treated with Nalco 918 - 50 Ib/day. Cost of treating facilities $2500.
Operating costs $600 per year.
B. Flow sheet type III. Modification: No Steffen. Discharges from pond, including lime pond,
recycled or excess to anaerobic pond. No discharge to streams.
C. In-Plant Water Flows (GPD x 103)•
Raw Water Use Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
Miscellaneous
0
811
0
0
42
Barometric
Recycled Flumes Condensers
11645
7900 155
255
Diffuser
Supply
267
Lime
Steffen Mud
144
NJ
D. Waste Treatment
1. Flume and general waste screened, to ponds "A" or "B", each 0.6 acres, to "C", 1.0 acre;
2100 recycled from screen to flumes; 9545 recycled from ponds to flume; 11 discharged by
evaporation and seepage; 144 excess to anaerobic pond "E", 2.48 acres, no discharge to
stream.
2. Lime mud all to lime pond "E", 12.1 acres. Water from lime mud to evaporation and seepage.
No discharge to streams.
3. Condenser water to spray pond, 0.65 acres, cooled and recycled, from 70° to 25° C.
4. Floor drainage to main sewer to ponds, 217 GPD x 103 - 2430 ppm BOD, 3090 ppm sugar (high).
5. Gas washer to flume ponds - 12.
6. Sanitary sewer to stabilization pond, 2.48 acres.
7. Pulp press water 100% recycled; make-up water (diffuser) 217 - new water.
E. Comments: Plant capacity will be increased 1000 tons beets per day. No change in waste treat-
ment. Cost of waste facilities $448,000. Annual operating cost $21,000.
-------
ro
u>
A.
B.
C.
WATER USE. RE-USE AND DISPOSAL
Holly Sugar Corporation at Hamilton City, California
Beets sliced, tons/day:—1875; Total campaign:—270000; Ion-Exchange Treatment of 75% of machine
syrup (High Green); Gross water intake:—4773 (GPD x 103 ); Source: Wells.
Flow sheet type III. Modifications: Ion-exchange treatment of high green. Raw water make-up
to diffuser. No Steffen.
In-Plant Water Flows (GPD x 1C3).
Raw Water Use
Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
Ion- Exchange
1980
587
138
2068
Barometric
Recycled Flumes Condensers
3160 1884
163
Diffuser
Supply
138
Lime
Mud
0
75
Ion-
Exchange
D. Waste Treatment
1. Flumes and general wastes screened, to one pond, 55 acres, 15 ft. deep, 20 days retention.
No discharge.
2. Lime mud to one pond, size ?. Overflow - 10 - to general pond.
3. Condenser water to tower cooler and recycled.
4. Pulp and pulp press water 100% recycled to diffuser.
5. Ion-Exchange regenerants in part evaporated for fertilizer. First strip to pulp dryer,
dilute wash to pond (main). (Owing to plant difficulty, some waste (acid) presently going
to lime flume). Some complaints about odor.
E. Comments: No effluent discharged to streams. Expect to increase annual slicing to about
370,000 tons in next few years. No change in waste treatment planned.
-------
WATER USE. RE-USE AND DISPOSAL
Holly Sugar Corporation at Santa Ana, California
A. Beets sliced, tons/day:—1851; Total campaign:—405088; Molasses worked, tons/day:—96;
Total campaign:—21126; Gross water intake:—2270 (GPD x 103 ); Source: Wells.
B. Flow sheet type III. Modifications: Raw water transport of lime mud. Waste discharge to
District Sanitary Plant. Steffen waste to ponds.
C. In-Plant Water Flows (GPD x 103) •
Raw Water Use Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
Steffen Dilution
X
-
X
X
Barometric
Recycled Flumes Condensers
Yes
X
X
Diffuser
Supply
X
Lime
Steffen Mud
N)
*>. D. Waste Treatment
1. Flumes and general waste screened, to three ponds, seven days retention, to Orange County
Sanitation District, two million gallons per day.
2. Lime mud to ponds (two), overflow to general ponds.
3. Condenser water to tower cooler, recycled (in part), cooled to 32° C.
4. Steffen waste to ponds (not evaporated).
5. Other wastes to sewer, to ponds.
6. Sanitary sewer to sanitary district plant.
7. Pulp press water 100% recycled to diffuser.
E. Comments: Effluent discharged to streams - zero per ton of beets; BOD zero. All plant eff-
luent is screened, passed through a flocculator, a clarifier, cooled by aeration, discharged
to district sanitation district - 2 million gallons per day.
-------
WATER USE, RE-USE AND DISPOSAL
Holly Sugar Corporation at Worland, Wyoming
A. Beets sliced, tons/day:—1600; Total campaign:—214667; Molasses worked, tons/day:—76;
Total campaign:—10177; Gross water intake:—7500 (GPD x 103 ); Source: Bighorn River.
B. Flow sheet type II. Modifications: Pulp drier with 100% recycle of pulp press water. Steffen
waste to lime pond. Condenser water only to river. All other wastes ponded. No discharge.
Ponds dry in intercampaign.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use Water Re-Use
Barometric Diffuser Lime
Recycled Flumes Condensers Supply Steffen Mud
Flumes 4000
Condensers and Cooling 2000 0 0 0 0 0_
Diffuser Supply 500 250
Lime Mud 100
Steffen Dilution 100
N)
ui Miscellaneous 800
D. Waste Treatment
1. Flume and general wastes screened, to ponds, 5, average 180. Retention 160 days. Ultim-
ately dries up. No discharge to river.
2. Lime mud to ponds - 6 units, no discard.
3. Condensed waters discharged direct to Bighorn River.
4. Steffen waste to lime ponds. No discharge.
5. Pulp and pulp press water recycled.
E. Comments: Increase of 20% in slicing anticipated. Effluent discharged per ton beets - 0.
-------
WATER USE. RE-USE AND DISPOSAL
Holly Sugar Corporation at Sidney, Montana
A. Beets sliced, tons/day:—2500; Total campaign:—400000; Gross water intake:—6867 (GPD
x 103 ); Source: Yellowstone River via ditch to pond to factory.
B. Flow sheet type II. Modifications: No Steffen. Overflow from lime pond to general (flume
water) ponds, thence to stream.
C. In-Plant Water Flows (GPD x 103).
Flumes
Raw Water Use
Condensers and Cooling
Diffuser
Lime Mud
Supply
0
6867
0
0
Water Re-Use
Barometric Diffuser
Recycled Flumes Condensers Supply
6627 240
480
Lime
Steffen Mud
0
D. Waste Treatment
1. Flumes and general wastes screened, discharged to two ponds, 8.3 acres, 7 ft. deep. Reten-
tion 1.5 days. Discharged via canal to river - 6627 GPD x 103 , 18,300 Ibs BOD/day.
2. Lime mud to ponds (one in use), 712,000 cu. ft. Overflow - 95 GPD x 1C3 to general ponds.
3. No condenser water - discharged direct.
4. Other wastes: floor drainage - 10, containing 8,000 Ibs "sugar" per day; gas washer water
8; and chemical washes to lagoons. Sanitary sewer - 4.5 - to Sidney sanitation system.
5, Pulp press water 100% recycled.
E. Comments: Cost of present waste facilities $67,000. Annual cost $3,500. Beet slicing will
ultimately be increased 1700 tons per day. Waste treatment will also include more complete
re-use of waste water in closed system. Effluent discharged to stream: 2758 gal/ton beets;
BOD - 7.8 Ibs/ton.
-------
WATER USE. RE-USE AND DISPOSAL
Holly Sugar Corporation at Torrington, Wyoming
A. Beets sliced, tons/day:—3034; Total campaign:—330180; Molasses worked, tons/day:—139; Total
campaign:—15121; Gross water intake:—7630 (GPD x 10^ ;,; Source: North Platte River, some
wells. Pre-treatment with Nalco balls. Cost $3700 per year.
B. Flow sheet type I. Modifications: Lime mud to lime pond, little overflow to river. Steffen
filtrate 20% evaporated, remainder to lime pond. Waste is screened before discharge to river.
Pulp water to separate lagoon,_then to river.
C. In-Plant Water Flows (GPD x
Raw Water Use
Flumes
Condensers and Cooling
2290
3816
Water Re-Use
Barometric
Recycled Flumes Condensers
—
2930
Diffuser
Supply
887
Lime
Steffen Mud
0
Diffuser Supply
Lime Mud
Steffen Dilution
190
19
—
D. Waste Treatment
1. Flume and general waste screened (40 mesh), then to North Platte River. No recycle of flume
water.
2. Lime mud to three ponds, 12 acres, no overflow, loss by seepage and evaporation.
3. Pulp silo drainage (no dryer) to lagoon, 50 acres, 1365 GPD x 10^.
4. Steffen waste to lime ponds, 80%, evaporation, 20%.
5. Condenser water - 1527 discharged direct @ 41° C.
6. Other waste: floor drains - 200, 15,000 Ib BOD per day; gas washer - 300; chemical washes
including pans and evaporation - 16,700 Ib BOD per day. All to main sewer and river.
7. Sanitary sewer to septic tank. Effluent to lime ponds.
E. Comments; Effluent (1483 gallons) discharged per ton beets. BOD in effluent 4-10 Ib per ton
beets.
Does not equal tabulated raw water use due to other non-process uses of water.
-------
WATER USE, RE-USE AND DISPOSAL
Holly Sugar Corporation at Hardin, Montana
A. Beets sliced, tons/day:—1700; Total campaign:—275000; Gross water intake:—4000 (GPD x 1C3);
Source: Bighorn River, settled briefly, only. Cost $20,000 for reservoir and pumps, $10,000
annually for maintenance.
B. Flow sheet type III. Modifications: No Steffen.
C. In-Plant Water Flows (GPD x IP3).
Raw Water Use
Water Re-Use
Barometric Diffuser Lime
Recycled Flumes Condensers Supply Steffen Mud
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
0
4000
0
0
0-25%
1000 3500
300
220 100
M D. Waste Treatment
K3
co 1. Flumes and general waste screened, all to four ponds, depth 7 ft., 2 days retention.
Discharged - 3000 - to river, containing 45,000 Ib BOD per day.
2. Lime mud to one pond, 6 acres. No overflow. Ponds empty after campaign by seepage and
evaporation.
3. Condenser water to spray pond - 1000. None discharged to stream direct.
4. Other wastes: floor and miscellaneous drainage - 300 - to general ponds, containing 800-
1000 Ib sugar per day; gas washer (raw water - 150) to ponds; chemical wastes (little) to
ponds. Little BOD.
5. Sanitary sewage to lime ponds.
6. Pulp and pulp press water 100% recycled.
E. Comments: Plan to increase slicing to 3000 tons per day. Will construct more settling lagoons
for flume water and recirculate back to flumes. Cost of waste facilities (present) $10,000.
Annual cost, including removing mud from lagoons, $5,000. Effluent discharged per ton beets
sliced - 1800 gal; 26 Ib BOD per ton beets. Proposed changes will reduce BOD to 3 Ib/ton beets,
-------
WATER USE. RE-USE AND DISPOSAL
Holly Sugar Corporation at Delta, Colorado
A. Beets sliced, tons/day:—1500; Total campaign:—215000: Molasses worked, tons/day:—50; Total
campaign:—6000; Gross water intake:—6000* (GPD x 1Q3 ); Source: Gunnison River, principally.
City water, some.
B. Flow sheet type III. Modifications: Condenser waters to flumes. No flume recycle. Raw
water to diffuser.
C. In-Plant Water Flows (GPD x 1C3).
Raw Water Use Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
Steffen Dilution
0
3000
360
1
120
Barometric
Recycled Flumes Condensers
0 3000
360
Diffuser Lime
Supply Steffen Mud
1
VD
D. Waste Treatment
1. Flume and general waste screened, discharged to two ponds, 7 acres, 4 ft. deep.
2. Lime mud to ponds (one) - overflow to stream.
3. Condenser water discharged direct.
4. Steffen waste evaporated.
5. Other wastes: floor drains - 10,000 gal/day to ponds. Chemical wastes to ponds. Sanitary
sewage to city plant.
6. Pulp and pulp press water recycled.
E. Comments: Slicing will be increased 400 ton/day. Flocculator, clarifier and new lagoon will
be installed. Cost of system $63,000. Annual operating cost $13,000.
*Does not equal tabulated raw water use due to other non-process uses of water.
-------
OJ
o
A.
B.
C.
WATER USE, RE-USE AND DISPOSAL
Holly Sugar Corporation at Tracy, California
Beets sliced, tons/day:—2600; Total annually:—600000; Molasses worked, tons/day:—123;
Total annually:—27919; Gross water intake: (GPD x 103 ) From canal - 2500 (c), From wells -
1000 (w).
Flow sheet type III. Modifications: Raw water make-up for diffuser. Raw water to flumes with
no recirculation. Raw water to lime mud.
In-Plant Water Flows (GPD x 103).
Raw Water Use
Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
Steffen Dilution
(c)
(w)
(w)
(w)
Recycled
2500
X 5500
250 450
150
600
Barometric Diffuser Lime
Flumes Condensers Supply Steffen Mud
some
D. Waste Treatment
1. Flumes and general wastes not screened - 2750 to six ponds, 30 acres, 4 ft. deep. (Actua-
lly used 4 passes only - short retention time). Discharged to "old" river (0.0 ppm DO, 450
ppm BOD).
2. Lime mud to pond, about 2 acres. Overflow - 150 - to general ponds.
3. Condenser water cooled in tower, recycled in part.
4. Steffen waste evaporated nearly 100%.
5. Other wastes: gas washer (from cooling tower) to flumes, 200. Sanitary sewer to septic
tank. All other to general waste.
6. Pulp water 90% recycled to diffuser, 10% to general waste.
E. Comments^ Slicing will be increased to 4000 tons/day; 90 ft. diam. clarifier to handle 7400
GPM flume water and new 10-mesh vibrating screen—all in next year or two. Effluent now dis-
charged to stream: 1260 gal/ton beets. BOD in effluent to stream: 4-5 Ib/ton beets.
-------
A.
B.
C.
WATER USE. RE-USE AND DISPOSAL
Holly Sugar Corporation at Brawley (Carlton), California
Beets sliced, tons/day:—6500; Total campaign:—650000; Gross water intake:—3900 (GPD x 1C3);
Source: All American Canal (Colorado River).
Flow sheet type III. Modifications: No return of pulp water to diffuser. No Steffen.
In-Plant Water Flows (GPD x 103).
Raw Water Use
Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
0
2800
860
240
Recycled
9700
5250
Flumes
400
Barometric
Condensers
Diffuser
Supply
590
Lime
Steffen Mud
250
D. Waste Treatment
4.
5.
Note:
Flumes and general waste screened, to four ponds, 1040 acres
tion. Discharge (2220)
BOD per day to stream.
Lime mud to six ponds, 16 acres
pond overflow - 4000 Ibs/day.
Condenser water to spray tower, (5250) cooled, recycled, 64° C.
sewer. Gas washer 1800 (raw water) discharged to flume ponds.
Sanitary sewer to septic tank. Effluent to general pond.
Pulp and pulp press water to main sewer, to general ponds.
Flume water, after screening, sent to mechanical clarifier, then to ponds.
4.5 ft. deep, 75 days reten-
Sea. Carries 3520 Ibs
to drain canal, to Alamo River, to Salton
Overflow to general pond (see 1 above). BOD in lime
Other wastes to main
E. Comments: Planned soon to recycle water from settling pond to beet washer and flumes. Cost
of present waste treatment facilities $250,000. Operating costs $1,000 per year. Effluent
discharged to stream - 373 gal/ton beets; BOD 0.6 Ibs/ton beets, (their estimates). Low
figures due to large pond and long retention at high, average temperature—80-90° F.
-------
WATER USE, RE-USE AND DISPOSAL
Holly Sugar Corporation at Hereford, Texas
A. Beets sliced, tons/day:—6493; Total campaign:—899000; Gross water intake:—1400* (GPD x 1Q3);
Source: Wells, some raw water treated - ion-exchange and softener.
B. Flow sheet type III. Modifications: Raw water (some) to condensers and to diffuser. Note
sparing use of raw water. No Steffen.
C. In-Plant Water Flows (GPD x 10^).
Raw Water Use Water Re-Use
Flumes
0
Recycled
8600
Flumes
Barometric
Condensers
Diffuser
Supply
Steffen
Lime
Mud
Condensers and Cooling some 8600 1740 120
Diffuser Supply 100%
Lime Mud X
D. Waste Treatment
1. Flume and general waste screened, to 11 ponds, depth 8 ft. Days retention, total. No
discharge. Clarifier - 100 ft. diam. to separate sand and dirt. Rubber lime pumps. They
have 11 interconnected ponds - total area about 160 acres, but use only 3 ponds.
2. Lime mud to lime pond (lime pond and sludge pond) about 17 acres. No discharge.
3. Condenser water recycled through tower cooler. No discharge.
4. Sanitary sewer to septic tank.
5. Recycled portion of flume water screened and mud separated by mechanical clarifier (see
D.I.).
6. Pulp and pulp press water 100% recycled to diffuser.
E. Comments: Holding ponds not cleaned (yet) - 100,000 cu. yds. in sludge ponds. Effluent
discharged per ton beets sliced - 0. BOD discharged per ton beets - 0. No estimate given as
to cost of waste treatment (author: $1 million, plus).
Make up for losses to mud, evaporation and seepage.
-------
WATER USE, RE-USE AND DISPOSAL
Maine Sugar Industries, Inc. at Easton, Maine
CO
u>
A. Beets sliced, tons/day:—4000; Total campaign:— ca 350000; Gross raw water intake:—2000
(GPD x 103).
B. Flows sheet type II.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use
Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
500
1200
300
0
Recycled
Yes
Yes
Yes
Flumes
150
Barometric
Condensers
Diffuser
Supply
Lime
Steffen Mud
Flume to clarifier, etc.
Some used to thaw frozen beet cars, thence to
D. Waste Treatment (No report submitted. Meager information by telephone)
1. Flume and general waste screened, to ponds, originally two, now five; recycled to flumes.
Have auxiliary mud pond. Elaborate system.
2. Condenser water to spray pond and recycled.
flumes.
3. Diffuser supply: Pulp press water recycled, make-up with raw water.
4. Lime mud: Cake from drum filters puddled with little water, pumped (blown) to mud pond -
no overflow.
5. Floor drainage (hose-down) to waste system. Sanitary sewage to septic tank.
E. Comments: Apparently little effluent or BOD to streams. Cost of waste treatment plant
estimated at $5 million plus. This includes ponds, covered water storage, dump trucks, cranes
(clam), piping, pumps, etc. Little odor problem, some at primary mud pond. Special problems:
rocks to be separated and hauled away; freezing conditions. An integrated system - difficult
to separate waste disposal from beet handling and water supply systems. Cost of operation
(waste disposal) about $100,000 annually (their estimate). This plant processes raws from off-
shore. Also handles potatoes, hence more involved than the usual beet-house. An unusual fea-
ture: chlorination of small effluent flow.
-------
WATER USE. RE-USE AND DISPOSAL
Michigan Sugar Company at Caro, Michigan
A. Beets sliced, tons/day: —1835; Total campaign:—280000; Gross water intake:—4450 (GPD x 103);
Source: Cass River.
B. Flow sheet type II. Modifications: Raw water to flumes and diffuser together with recycle.
Also raw water to lime mud. No Steffen.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use Water Re-Use
Barometric Diffuser Lime
Recycled Flumes Condensers Supply Steffen Mud
Flumes 1700 4300
Condensers and Cooling 2400 0 0 250
Diffuser Supply 250 250
Lime Mud 100
D. Waste Treatment
1. Flume and general waste screened, to settling pond (small) then to storage pond, 50 acres,
6 ft. deep. Retention - duration of campaign. Controlled outlet to Cass River; 76 Ibs
BOD/cu. ft./sec flow of river (state rules). When river is low none is discharged. Lime
added to discharge from screen to hold pH at 12. Stops odors.
2. Lime mud ponded in two ponds, 8 acres total. No discharge.
3. Condenser water - 2150 discharged direct @ 45° C. (Temperature stream 9° C.)
4. Floor drains - 20 - to main sewer (to general ponds), 1500 Ibs BOD per day. Gas washer to
flumes. Chemical washes to main sewer.
5. Sanitary sewer to city sewage system.
6. Pulp and pulp press water recycled. (BMA tower diffuser)
E. Comments: Anticipate 20% increase in annual slice. Pollution problem will increase by 10%.
Effluent per ton beets sliced 2300 gal.; BOD - 4 Ibs per ton. Note: Stored wastes can be
released during spring floods at a rate not exceeding 1% of river flow.
-------
WATER USE. RE-USE AND DISPOSAL
Michigan Sugar Company at Croswell, Michigan
A. Beets sliced, tons/day:—1275; Total campaign:—208000; Gross water intake:—3250 (GPD x 103);
Source: Black River. Nalco #918 added to water at factory. Cost about $2000 per year.
B. Flow sheet type II. Modifications: No Steffen. Raw water to sprays (flumes) and lime mud.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
Miscellaneous
75
3000
0
150
25
Barometric
Recycled Flumes Condensers
2800
350
200
Diffuser
Supply
175
Lime
Steffen Mud
D. Waste Treatment
1. Flume and general waste screened, to holding ponds - (1) grit collector; mud to mud pond,
3 acres. Overflow to pond No. 2, 8 acres. Turbid overflow 0.8 mile to five ponds, 25 acres,
to another pond near river, thence to Black River. Controlled flow, i.e., 5 Ibs BOD/cu. ft.
per second flow up river. Black River empties into St. Claire River.
2. Lime mud to ponds (2); overflow - 150 to general pond, containing 1500 Ibs BOD/day.
3. Condenser water discharged direct - 1700+ (GPD x 103). Temperature 40° C.
4. Other wastes: 35-40 GPD x 103 containing 1000 Ibs BOD per day discharged to general ponds.
Also sanitary sewer, 10 GPD x 103 containing 50 Ibs BOD/day to general ponds.
5. Pulp press water recycled 100%.
E. Comments: 2500 gal effluent discharged per ton beets; 4 Ibs BOD per ton beets.
-------
WATER USE. RE-USE AND DISPOSAL
Michigan Sugar Company at Sebewaing, Michigan
A. Beets sliced, tons/day: —1900; Total campaign:—about 300000; Gross water intake:—ca 4000
(GPD x 103).
B. Flow sheet type II. Modifications: Some raw water to flumes, diffuser and lime mud.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use Water Re-Use
Barometric Diffuser Lime
Recycled Flumes Condensers Supply Steffen Mud
Flumes 1200 4000
Condensers and Cooling 2450
Diffuser Supply 250 100%
Lime Mud 100
Note: Questionnaire not returned. Above data rough estimate from information on visit.
M
U>
CT\ D. Waste Treatment
1. Flumes and general waste screened, to clarifier, part recycled to flumes. Mud to mud pond.
Overflow to recycle. Lime added before discharge to ponds (odor control). pH 8.5. Six
ponds: #1-5.5 acres, #2-11.7 acres, #3-^-33 acres, #4-17.5 acres, #5-8.5 acres, #6-12.5 acres.
Flow from #1 to #6 to ditch and the bay. Flow from #2-#3,#5,#6 may be diverted individually
to ditch. Flow to bay controlled carefully. Must be no fish kill. When ice forms, flow
to bay is stopped.
2. Lime mud to lime ponds: #1-33 acres or #2-5.9 acres. Overflow (supernatant) to settling
pond #3-33 acres.
3. Pulp press water 100% recycled.
E. Comment: While there is no BOD standard, determinations are made regularly. Some odor problem.
-------
WATER USE. RE-USE AND DISPOSAL
Michigan Sugar Company at Carrollton (Saginaw), Michigan
A. Beets sliced, tons/day:—1814; Total campaign:—293000; Gross water intake:—4600 (GPD x 103).
Source: Saginaw River. Water treated with Nalco #918 at cold water tank. Cost $1650 per year.
B. Flow sheet type II. Modifications: Raw water to flume, diffuser supply and lime mud. Conden-
ser water (86%) discharged direct. No Steffen.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
Water Re-Use
1650
2600
250
100
Recycled Flumes
3860
-
125
-
Barometric
Condensers
Diffuser
Supply
250
Lime
Steffen Mud
100
D. Waste Treatment
1. Flumes and general waste screened, to four ponds, 20 acres, 3-8 ft. deep. Retention 2 to
100 days. Discharged to river 1000 GPD x 103, containing 6000 BOD/day.
2. Lime mud to one pond, 17 acres. Overflow - 100 GPD x 103, to general ponds containing
2000 Ibs BOD/day.
3. Condenser water - 2250 GPD x 103 discharged direct to river @ 45° C. BOD in condenser
water 60 ppm.
4. Other wastes: Floor drainage - 20 GPD x 103 containing 1000 BOD per day to main sewer
(general ponds); gas washer water to river (50 GPD x 103 ); chemical washes to ponds.
5. Sanitary sewer to city sewer system.
6. Pulp and pulp press water 100% recycled.
E. Comments: 30% increase in annual slice expected. Will provide, in future, complete recircu-
lation of flume water. Also aerators for holding ponds. Note: Cost of cleaning mud and lime
ponds per year $20,000. Lime added to flume pond to control odor. Effluent discharged 1800
gallons per ton beets; 3.5 Ibs BOD/ton beets. Will be reduced 50% when planned changes are
made.
-------
WATER USE. RE-USE AND DISPOSAL
Monitor Sugar Company at Bay City, Michigan
A. Beets sliced, tons/day:—3500; Total campaign:—400-500000; Gross water intake: —8200 (GPD
x 103 ;; Source: Saginaw River.
B. Flow sheet type II. Modifications: Raw water to flumes. No Steffen. Excess condenser water
discharged direct.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
Miscellaneous
3000
5000
0
0
200
Barometric
Recycled Flumes Condensers
2000
0 800
800
Diffuser
Supply
1000
Lime
Steffen Mud
oo D. Waste Treatment
1. Flumes and general wastes screened (excellent), to holding facilities: 1 aerated lagoon
4.5 acres, 1 settling - 1 acre, 12 ft. deep. Discharged to river - 4000; BOD in waste
5-10,000 Ibs per day.
2. Lime mud to four ponds, total area 15 acres. No overflow.
3. Condenser water, remainder discharged direct to river.
4. Pulp and pulp press water 100% recycled.
5. Other wastes: To main sewer and general ponds except acid washes which go to lime pond.
E. Comments: Aeration pond equipped with four 60 HP floating aerators. Nominal capacity 480
Ibs 02 per hour. State limitation on discharge to stream - 3550 Ib BOD/day; settleable solids
35 ppm. This requirement is being met. Effluent per ton beets 1140 gal; BOD (maximum)
1 Ib/ton.
-------
WATER USE. RE-USE AND DISPOSAL
Northern Ohio Sugar Company (GWS Co.) at Fremont, Ohio
A. Beets sliced, tons/day:—1980; Total campaign:—320000; Gross water intake:—8650 from river
(GPD x 103).
B. Flow sheet type II. Modifications: No Steffen. Ponds emptied when river is high. Condenser
water to spray pond before discharge to river.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
0
8600
50
Recycled Flumes
7000
130
Barometric
Condensers
Diffuser
Supply
150
Lime
Steffen Mud
Lime Mud
D. Waste Treatment
1. Flumes and general wastes screened; to five settling channels, one holding pond, 2 acres.
Retention time 12 hours, recycled 100%. Pond emptied in spring when river (Sandusky) is
high at about 700 per day. BOD in this water in spring 7600 Ib/day.
2. Lime mud discharged to one pond, 3 acres. Overflow (small) to general ponds.
3. Condenser water to spray pond for cooling and discharge, 8400 to river. Note: Previously,
high temperature at discharge caused fish kill.
4. Other wastes: floor drainage 50; gas washer water 90; chemical washes all to flume water
ponds.
5. Sanitary sewer to city sewage plant.
6. Pulp and pulp press water 100% recycled to diffuser.
E. Comments: Annual slice will be increased about 100,000 tons. Changes in waste treatment
planned include: discharge from ponds to city sewage system. Also recycle condenser water
after cooling. Cost of present waste treatment facilities $450,000. Annual operating costs
$35,000. Volume effluent to stream 4200 gal/ton beets; 2.5 Ib BOD/ton beets. Note: Five tons
CaO per day added to flume water system to control odor. Cost of cleaning channels $0.50 per
cu. yd.
-------
WATER USE, RE-USE AND DISPOSAL
Northern Ohio Sugar Company (GWS Co. ) at Findlay, Ohio
A. Beets sliced, tons/day: —1500; Total campaign:—245000; Gross water intake:—570 (GPD x 103);
Source: 4 wells, but use only 2.
B. Flow sheet type IV. Modifications: None, completely closed system. Ponds ultimately emptied
into City Sewage Plant.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use
Flumes
Condensers and Cooling
Diffuser Supply
Water Re-Use
Barometric Diffuser
Recycled Flumes Condensers Supply
6000
520 6800 6620 6800
50 250
Lime
Steffen Mud
30
Lime Mud
D. Waste Treatment
1. Flume and general waste screened, to three ponds, 5 acres, 4-6 ft. deep. Retention 1.5
days. Recycled to flumes. Ponds discharged to city sewage plant in spring - after BOD
has been reduced - naturally, 60 GPD x 103 excess to city sewage. BOD to city sewer,
average 10,000 Ib/day.
2. Lime mud to lime pond, 2 acres. Overflow 30 to general ponds.
3. Condenser water to spray pond, cooled, returned to cold water tank.
4. Other wastes: floor drainage 50; gas washer water 90; chemical washes - all to flume pond.
5. Sanitary sewer to city sewage plant.
6. Pulp and pulp press water - 100% recycled.
E. Comment: Caustic soda added to flume water to hold pH up and to avoid odor. Cost of waste
treatment facilities $300,000. Annual costs $30,000. No increase in slicing planned for
future. Will install separate flume and condenser water systems. No effluent and no BOD
discharged to streams. Accumulate yearly 11 x 10.6 gal. excess water, also 110,000 cu. ft. mud,
-------
WATER USE. RE-USE AND DISPOSAL
Spreckels Sugar Company at Spreckels (Salinas), California
A. Beets sliced, tons/day:—6000; Total annually:—900000; Molasses worked, tons/day:—350; Total
annually:—50000; Gross water intake:—9505* (GPD x 103); Source: Wells. Phosphate added to
about 90%. Lime and resin treatment for that used in liquid sugar. Cost $2,000 - plant, $9,000
annually.
B. Flow sheet type III. Modifications: None.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
(1) 150
3310
Barometric
Recycled Flumes Condensers
6000
10500 500
1050
Diffuser
Supply
720
Lime
Steffen Mud
280
Lime Mud
Steffen
(2) 700
D. Waste Treatment
1. Flume and general waste screened, to 11 ponds, 147 acres, 2-16 ft. deep. Only 500 to hold-
ing pond. Retained until all evaporated or percolated. No discharge.
2. Lime mud to ponds (6), 32 acres. Overflow—150— to general ponds.
3. Condenser water copied by tower and recycled - 3310 to ponds.
4. Steffen waste evaporated.
5. All other wastes, about 7000 to ponds, estimated BOD 4300 Ib/day.
6. Pulp water 100% recycled.
E. Comments: Cost of facilities $700,000. Operating costs $15,000. Increase of 25% in annual
slice expected.
Does not equal tabulated raw water use. The difference is primarily due to make up for water
to muds, evaporation and seepage.
-------
WATER USE, RE-USE AND DISPOSAL
Spreckels Sugar Company at Manteca, California
A. Beets sliced, tons/day:—4000; Total annually:—900000; Gross water intake:—6300* (GPD x 103);
Source: Wells. Treatment of hot lime and soda to 2%% of total water.
B. Flow sheet type III. Modifications: Raw water to diffuser supply and to lime mud. No Steffen.
No effluent to streams, only to ponds and irrigation.
C. In-Plant Water Flows (GPD x 1C3)-
Raw Water Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
0
1750
150
175
Recycled
4500
4700
800
Water Re-Use
Barometric
Flumes Condensers
1600 (1)
Diffuser
Supply
500
Lime
Steffen Mud
180
(1) Beet washer and sprays
D. Waste Treatment
1. Flume and general x^astes screened, to 15 ponds, 62 acres, 5-14 ft. deep. Retention 90 days.
Discharged to irrigation - 4200 containing 5300 Ibs BOD/day.
2. Lime mud to 8 ponds, 12 acres. Overflow - 290 to general ponds.
3. Condenser water to tower cooler and recycled.
4. Other wastes: floor drainage - 400 - containing 12,000 Ibs sugar per day and chemical washes
to general ponds. Gas washer water - 1000 - to lime pond and beet washer system.
5. Sanitary sewage to septic tank and ponds.
6. Pulp press water all recycled.
E. Comments: Oswald waste treatment, modified: from mud pond - anaerobic - aerobic (algae). Ten
percent increase in annual slicing anticipated. Will add aerators to pond system. Cost of
waste disposal system $200,000. Operating cost $20,000 per year. Effluent discharged to
stream—none.
Does not equal tabulated raw water use. The difference is primarily due to make up for water
to muds, evaporation and seepage.
-------
WATER USE. RE-USE AND DISPOSAL
Spreckels Sugar Company at Woodland, California
A. Beets sliced, tons/day:—3300; Total annually:—650000; Molasses worked, tons/day:—180;
Total annually:—35000; Gross water intake:—6900 (GPD x 103 ); Pre-treatment: 90% with
polyphosphate.
B. Flow sheet type III. Modifications: None.
C. In-Plant Water Flows (GPD x 103 ).
Raw Water Use Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
0
6900
0
Recycled
4100
6000
500
0
Barometric
Flumes Condensers
800 6000
Diffuser
Supply
300
Lime
Steffen Mud
Steffen Dilution
u> D. Waste Treatment
1. Flume and general waste screened, to 13 ponds, 442 acres (only half in use), 3 ft. deep.
Retention 0-120 days. No discharge (evaporation and seepage).
2. Lime mud ponded, 11 acres, no overflow.
3. Condenser water cooled in tower and recycled.
4. Steffen waste all evaporated.
5. Other wastes: Floor drainage 2000 GPD containing 2000 Ibs sugar, and chemical washes to
main sewer; sanitary sewer to septic tank.
E. Comments: No effluent to streams. Replacement cost of waste treatment facilities $200,000,
operating costs $15,000 per year.
-------
WATER USE, RE-USE AND DISPOSAL
Spreckels Sugar Company at Mendota, California
A. Beets sliced, tons/day:—3900; Total annually:—900000; Molasses worked, tons/day:—220; Total
annually:—45000; Gross water intake:—4132 (GPD x 103 ); Source: Wells. 2% treated with lime
and resin for liquid sugar only. Cost $20,000 for plant, $2,500 per year.
B. Flow sheet type II. Modifications: Some raw water to flumes and to lime mud. Steffen waste
to shallow ponds with no outlet (they dry up).
C. In-Plant Water Flows (GPD x 103).
Raw Water Flows
Flumes
Condensers and Cooling
DIffuser Supply
Lime Mud
Steffen
Miscellaneous
1100
2500
0
30
370
132
Recycled
9000
7000
530
Water Re-Use
Barometric Diffuser
Flumes Condensers Supply
1100 450
Lime
Steffen Mud
40
D. Waste Treatment
1. Flumes and general wastes screened, to nine ponds, total 160 acres, 4 ft. deep. Retention
time - total. No discharge.
2. Lime mud to three ponds, 12 acres - 150 GPD x 103 - overflow to general ponds.
3. Condenser water to tower cooler and recycled.
4. Steffen waste to ponds (10), used alternately, total 47 acres. No discharge, loss by
evaporation and seepage.
5. Other wastes: Floor drainage - 320 GPD x 103 containing 3500 Ibs sugar per day to general
ponds. Gas washer water - 350 GPD x 103 to waste water. Also chemical wastes. Sanitary
sewer to septic tank.
E. Comments: Three of nine flume ponds, 24 acres, are sediment ponds. Cost of waste facilities
$250,000, operating $20,000 per year. Effluent discharged per ton of beets - zero.
-------
WATER USE. RE-USE AND DISPOSAL
Spreckels Sugar Company at Chandler, Arizona
A. Beets sliced, tons/day:—4000; Total annually:—650000; Gross water intake:—1883* (GPD x 103);
Source: Wells, Treatment: one and one-half percent with lime and resin. Cost: $20,000
plant; $2,000 annual operation.
B. Flow sheet type III. Modifications: No Steffen. Raw water to lime mud - to lime pond with no
overflow. No overflow from general ponds.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
0
1250
0
33
Recycled
6000
8000
750
Water Re-Use
Barometric Diffuser
Flumes Condensers Supply
760
Lime
Steffen Mud
D. Waste Treatment
1. Flumes and general waste screened, to 7 ponds, 81 acres, 3-10 ft. deep. Retention - total.
No discharge.
2. Lime mud to one pond, 3 acres. No overflow.
3. Condenser water to tower cooler, recycled. No direct discharge.
4. Pulp and pulp press water recycled to diffuser.
5. Other wastes: 240,000 gal/day containing 2200 Ib BOD per day; to main sewer and ponds; gas
washer water 190,000 gal; chemical washes to waste ponds. Sanitary sewer to septic tank.
E. Comments: Flume and general wastes: mud pond - aeration and circulation - digester - matura-
tion ponds. Cost of waste disposal: Plant $450,000, Operation $20,000 per year. Additional
aeration planned.
Does not equal tabulated raw water use. The difference is primarily due to make up for water
to muds, evaporation and seepage.
-------
WATER USE, RE-USE AND DISPOSAL
Utah-Idaho Sugar Company at Garland, Utah
A. Beets sliced, tons/day:—2550; Total campaign:—315000; Molasses worked, tons/day:—110; Total
campaign:—13000; Gross water intake:—8712 (GPD x 103 ) ; Source: River - 8640, Other - 72.
Nalco softening; cost $1500/year.
B. Flow sheet type III. Modifications: Many. Raw water to diffus'er as make-up. Condenser water
discharged direct to river.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use Water Re-Use
Barometric Diffuser Lime
Recycled Flumes Condensers Supply Steffen Mud
Flumes
Condenser and Cooling
Diffuser Supply
Lime Mud
Steffen Dilution
Miscellaneous
0
8014
288
86
180
144
7200
0
648
-
-
86
-
D. Waste Treatment
1. Flumes and general wastes screened, to one desilting pond, 2.7 acres, 2 ft. deep. Retention
time 6 days, recirculated to flumes. Enclosed system.
2. Lime mud to lime pond (1), 8.4 acres. Overflow to river. Actually most disappears by
evaporation and seepage.
3. Condenser water - 8554 discharged direct to Malad River @ 55° C.
4. Steffen waste 100% evaporated CSF.
5. Other wastes: Gas washer water to flumes; others to main sewer (ponds). Sanitary sewer to
city sewage plant.
E. Comments: No changes planned. Effluent discharged - 3350 gal per ton of beets. BOD discharged
4 Ib/ton.
-------
WATER USE, RE-USE AND DISPOSAL
Union Sugar Company at Betteravia, California
A. Beets sliced, tons/day:—4500-4800; Total annually:—1,106,000; Gross water intake:—3954
(GPD x 103 ); Source: Wells - pretreated (a) 98% with sodium hexameta phosphate, (b) 2%
with zeolite softener. Cost of pretreatment: Initial $4500, annual cost: $19,700.
B. Flow sheet type III. Modifications: Raw water to diffuser supply (total) and miscellaneous.
Pulp press water discharged to ocean by pulp drier contractor. No Steffen. No discharge from
settling ponds or lime pond.
C. In-Plant Water Flows (GPD x 1C3).
Raw Water Use Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
Other
0
2246
1420
0
288
Barometric
Recycled Flumes Condensers
6432
9072 6864
No
Diffuser
Supply
1420
Lime
Mud
144
Pulp
Trans pt
664
Waste Treatment
1. Flume and general waste screened, to 3 ponds, 47 acres, 6 ft. deep, 10 days retention.
Closed system - no discharge to stream.
2. Lime mud discharged to four ponds (used alternately) - 8,4,4, 6.4 acres. Overflow dis-
charged direct - 144 GPD x 103.
3. Condenser water to spray pond - 9360 GPD x 1C3.
4. Other wastes: Floor drainage - 144; gas washer - 28; to main sewer. Chemical washes to
lime pond. Sanitary sewer to septic tanks.
5. Pulp transported to Sinton and Brown dryer (200 yds.). Transport water recycled to Union
Sugar pond system; press water discharges principally to ocean.
Comments: Annual accumulation of 6500 tons dirt. No discharge of effluent to stream - see 5
above. BOD in: pulp press water to ocean by Sinton and Brown, probably 10-12 Ibs per ton beets
(estimated by author).
-------
WATER USE, RE-USE AND DISPOSAL
Utah-Idaho Sugar Company at Idaho Falls, Idaho
A. Beets sliced, tons/day:—4200; Total annually:—595000; Molasses worked, tons/day:—125; Total
annually:—21000; Gross water intake:—3600 (GPD x 103 ); Source: Wells. Treatment - Nalco
to prevent scaling. Cost $500 per year.
B. Flow sheet type III. Modifications: Raw water to diffuser and lime mud. No overflow from lime
pond. Full flume recirculation is planned for future.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
Steffen Dilution
Miscellaneous
0
2542
648
86
180
144
Barometric
Recycled Flumes Condensers
4320
5760 9360
936
Diffuser Lime
Supply Steffen Mud
00
D. Waste Treatment
1. Flume and general wastes screened, 4320 recycled, 3600 discharged direct to Snake River.
BOD in waste to river - 16,000 Ibs per day.
2. Lime mud to one pond, 6 acres. No overflow, no discharge.
3. Condenser water recycled through tower cooler to house. No discharge direct to stream.
4. Steffen waste 100% evaporated CSF.
5. Other wastes: Floor drainage - 14.4 GPD x 1C3 containing 69 Ib BOD per day to sewer.
Chemical washes to lime pond. Sanitary sewer - 200 GPD x 1C3 ,' 34 Ib BOD per day to septic
tank and drain field.
E. Comments: After screening, mud partly removed by mechanical clarifier, partly by ponds.
Increase of 16% in slicing planned. Cost of waste system $200,000. Annual cost $2000. Eff-
luent to stream - 818 gal/ton beets. BOD 4 Ib per ton.
-------
WATER USE. RE-USE AND DISPOSAL
Utah-Idaho Sugar Company at West Jordan, Utah
A. Beets sliced, tons/day:—1600; Total campaign:—180000; Gross water intake:—7200 (GPD 103);
Source: Wells - 1440, Jordan River, Nalco treatment for scaling control. Cost $1200/year.
B. Flow sheet type II. Modifications: No Steffen. Lime pond - no discharge.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
Miscellaneous
7000
56
144
Barometric
Recycled Flumes Condensers
0
6700
1512
Diffuser
Supply
230
Lime
Steffen Mud
56
D. Waste Treatment
1. Flume and general waste screened, to one desilting pond, 2 acres, 2 ft. deep, 2 hours
retention, to Bingham Creek to Jordan River - 7200 GPD x 1C3, containing 6800 Ib BOD/day.
2. Lime mud to pond, 40 acres. No discharge.
3. Condenser water used in-plant flows. No direct discharge.
4. Other wastes: Floor drainage - 11,000 GPD (52 Ibs BOD/day) to general wastes; gas washer
water - 216,000 GPD to wastes. Chemical washes to lime pond. Sanitary sewer to city sew-
age plant (288,000 GPD - 28 Ibs BOD/day).
5. Pulp press water recycled to diffuser.
E. Comments; Cost of waste plant $250,000. Annual operating cost $1,000. Effluent discharged
to streams - 4325 gal/ton beets. BOD per ton - 4.0.
-------
WATER USE. RE-USE AND DISPOSAL
Utah-Idaho Sugar Company at Toppenish, Washington
A. Beets sliced, tons/day:—3800; Total campaign:—495000; Gross water intake:—8640 (GPD x 1C3);
Source: Wells. Nalco softening. $1500 per year.
B. Flow sheet type II. Modifications: No Steffen. Raw water to diffuser supply. No discharge
from lime ponds or general ponds (seepage and evaporation). Condenser water direct to river.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use
Water Re-Use
Ul
o
Flumes
Condenser and Cooling
Diffuser Supply
Lime Mud
Other
0
7906
518
0
216
Barometric
Recycled Flumes Condensers
7920
0 576
1440
Diffuser Lime
Supply Steffen Mud
86
Waste Treatment
1. Flume and general wastes screened, to one pond, 20 acres, 1 ft. deep. No discharge.
Seepage and evaporation.
Lime mud to one pond, 20 acres. No overflow. Seepage and evaporation.
Condenser water - 7244 discharged direct to river @ temperature of 50° C.
Chemical washes to lime pond; sanitary sewer to septic tank - sewer.
Other wastes to main sewer.
Pulp water 100% recycled.
Comments: Cost of waste system $200,000. Annual operating costs $3000.
1906 gal. per ton beets, 4 Ibs BOD per ton beets.
Effluent discharged -
-------
Ul
WATER USE. RE-USE AND DISPOSAL
Utah-Idaho Sugar Company at Moses Lake, Washington
A. Beets sliced, tons/day:—6450; Total annually:—900000; Molasses worked, tons/day:—225; Total
annually:—38500; Gross water intake:—3715 (GPD x 103 ); Source: Wells.
B. Flow sheet type III. Modifications: Raw Water to diffuser make-up and lime mud. No discharge
to stream. Seepage and evaporation. U-l has 1200 acres land - use only 600 acres.
C. In-Plant Water Flows (GPD x 103).
Raw Water Use
Water Re-Use
Flumes
Condensers and Cooling
Diffuser Supply
Lime Mud
Steffen Dilution
Miscellaneous
0
2225
922
86
324
158
Barometric
Recycled Flumes Condenser
12009
10080 2880
1380
Diffuser Lime
Supply Steffen Mud
Waste Treatment
1. Flumes and general waste screened, to clarifier, to pond, 45 acres, 3 ft. deep. Recycled
to flume. No discharge, seepage and evaporation.
2. Lime mud to one pond, 39 acres, no overflow.
3. Condenser water to three "Marley" cooling towers. Cools to about 20° C. - to main water
tank (with well water).
4. Pulp and pulp press water recycled to diffuser.
5. Steffen waste all evaporated, added to beet pulp drier.
6. Other wastes: Floor drains - 14 GPD x 103 - BOD 69 Ib. per day, to sewer; gas washer to
sewer ponds (144 GPD x 103); chemical washes to lime pond; sanitary sewer to septic tank
and drain field.
Comments: Increase of 60% in slice planned. Cost of waste plant $300,000, operating costs
$2000. Effluent to stream per ton beets - zero. BOD to stream - zero.
-------
QUESTIONNAIRE
State-of-Art, Sugarbeet Processing Waste Treatment
for the
Federal Water Quality Administration
Section A. General
1. Company Name
2. Location of Plant
(City and State)
3. Typical dates of campaign, from to
4. Annual beet tonnage processed
Average 24-hour beet tonnage processed
If plant includes Steffen process:
Annual tonnage of molasses processed
Average tonnage molasses processed in 24 hours
Section B. Water Use (See Note)
1. Gross fresh water intake (1,000 gal/day)
2. Source of fresh (raw) water (1,000 gal/day) _
Wells River or lake Other
3. Is water treated before use? No Yes
(If yes, what percent of total is treated?)
What types of treatment are provided:
Estimated replacement cost of facilities to treat water before
use: $
Estimated annual operating cost of water treatment prior to
use in the factory: $
Section C. Inplant Water Flows
1. Raw water use (1,000 gal/day):
a. To flumes direct
b. To barometric condensers and cooling
c. To diffuser supply
d. To lime mud
e. To Steffen (dilution)
f. Other
Flume water (1,000 gal/day) :
a. Total flow
b. Recycled ^_^
c. Discharged direct
d. Discharged to ponds
Note: Data for 1968 campaign or latest completed campaign,
15?
-------
Section C. Inplant Water Flows (continued)
3. Barometric condenser and cooling water (1,000 gal/day)
a. Total flow
b. Cooled and recycled
c. To flumes
To beet washers and sprays
To diffuser supply
To lime mud
g. Discharged direct
h. Other
Pulp and pulp press water (1,000 gal/day):
a. Total flow
b. Recycled to diffuser
c. Discharged to wastes
d. Other (explain)
Section D. Waste Treatment
1. Flume and general waste:
Screened - Yes No
Discharged direct
To holding facilities:
Number of ponds
Acreage
Depth
Days retention
Discharged to
Volume discharged (1,000 gal/day)
BOD in waste discharged (Ibs/day)
Lime mud:
Discharged direct - Yes No
Ponded - Yes No
Size and number of ponds
Overflow discharged - Yes No
Direct Volume (1,000 gal/day)
To general ponds
BOD in waste discharged (Ibs/day)
Condenser water:
Discharged direct - Yes No
If condenser water is recycled, how is it cooled?
Tower Spray pond
Volume discharged (1,000 gal/day)
Temperature
Steffen waste:
Discharged direct - Yes No
To ponds - Yes No
Evaporated - Yes No
(If yes, what percentage of total
153
-------
Section D. Waste Treatment (continued)
5. Other wastes:
a. Floor drainage:
Discharged to main sewer - Yes No
Estimated average volume (1,000 gal/day) _
Estimated average BOD Ibs/day
Ibs sugar/day
b. Gas washer discharge:
Source of gas washer water
Discharged to
Estimated volume (1,000 gal/day)
c. Chemical washes:
Boilout of pans and evaporators, discharged to
Estimated BOD (Ibs/day)
Acid wash of filters, discharged to
Estimated BOD (Ibs/day)
d. Sanitary Sewer:
Estimated volume (1,000 gal/day)
Discharged to ..
Estimated BOD (Ibs/day)
6. Details:
a. If flume and beet washer water are recycled, or partly
recycled, what treatment, if any, is provided for the
recycled portion: Screened mud separated by
mechanical clarifiers by settling ponds
other
Please show by sketch or diagram special features of
treating system, including approximate dimensions or
capacities.
b. Is pulp and pulp press water completely recycled to
diffuser?
If not, what disposition is made of the excess?
c. Are flume and general wastes treated in whole or in part
by a biological system or process - Yes No
(If yes, show by sketch essential features; estimate
effectiveness.)
d. If a completely closed system, including integration with
the condenser water system, is used (as in Findlay, Ohio),
please estimate the quantity of surplus waste which
accumulates annually.
Section E. Special Information
1. What increase in annual slice of beets is anticipated during the
period 1969 to 1979?
2. What changes in waste treatment are anticipated during the
period?
3. Will an anticipated increase in the beet operations increase the
water pollution problems and, if so, by how much?
154
-------
Section E. Special Information (continued)
4. Please estimate construction costs of waste water treatment
facilities - $ Annual operating costs $_
5. With existing waste disposal facilities, how many gallons of
effluent is discharged to streams per ton of beets sliced?
How many pounds BOD per ton of beets sliced - (Your best
estimate is requested) .
How much can these quantities be reduced by contemplated changes
in waste disposal facilities?
Section F. Remarks and Comments
155
-------
1
•Accession Number
w
5
n Subject Field Si. Group
05D
SELECTED WATER RESOURCES
ABSTRACTS
INPUT TRANSACTION FORM
<->rganizafion ' ~~~
Beet Sugar Development Foundation, P.O. Box 538 Fort Collins, Colorado 20521
Title
State-Of-Art, Sugarbeet Processing Waste Treatment
1Q Author(s)
.Fischer, James A.
Hungerford, Edgar H.
16
21
Project Designation
EPA, WQO Contract 12060 DSI
07/71
Note
N/A
22
Citation
N/A
23
Descriptors (Starred First)
Wastewater Treatment-*, Wastewater Quality Control-*, Water Reuse-*, Reclaimed
Water, Pollution Abatement, Treatment Facilities-*, Industrial Waste
Treatment^,
25
Identifiers (Starred First)
Sugarbeet waste treatment-*, SB Waste Treatment Technology State-of-the-Art-*,
Water Consumption*, Treatment Costs-*
27
Abstract
The beet sugar industry in the United States produces annually more than 3 million
tons of sugar from about 25 million tons of beets grown in 19 states. This paper
reports the waste disposal practices of the 58 beet sugar factories operating in
1968-69 and provides an estimate of the amount of pollution of streams attributable
to these factories. It is shown that, although stream pollution has been greatly
reduced, the beet industry still discharges to streams 3.15 pounds BOD per ton of
beets sliced or a total of about 79 million pounds annually. Amounts of water used
are reported and methods of re-use of water described. Estimates of total
settleable solids are made; methods of elimination are described. Effectiveness of
some biological treatments are estimated. Needed research is briefly outlined.
Costs of waste disposal facilities and annual operating costs are shown for many of
the plants. A brief description of the beet sugar process is furnished. Current
practices employed by a selected group of^sugarbeet processing plants in several
Western European countries are also described.
/16s'rac'or Fischer, James A.
In
Development Foundation Fort Collins, Colorado
WR:I02 (REV. JULY 1969)
WRSIC
DOCUMENT, TO: WATER RESOURCES SCIENTIFIC INFORMATION CENTER
U.S. DEPARTMENT OF THE INTERIOR
WASHINGTON, D. C. 20240
* GPO: I97O—3B9-930
------- |