PR-8
THE BEET SUGAR INDUSTRY--
THE WATER POLLUTION PROBLEM
AND STATUS OF
WASTE ABATEMENT AND TREATMENT
NCMMSKA
KANSAS
U.S. DEPARTMENT OF THE INTERIOR
Federal Water Pollution Control Administration
South Platte River Basin Project
Denver, Colorado
June 1967
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THE BEET SUGAR INDUSTRY--
THE WATER POLLUTION PROBLEM
AND STATUS OF
WASTE ABATEMENT AND TREATMENT
U.S. DEPARTMENT OF THE INTERIOR
Federal Water Pollution Control Administration
South Platte River Basin Project
Denver, Colorado
June 1967
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TABLE OF CONTENTS
List of Figures iii
List of Tables vii
Acknowledgment viii
Summary ix
I. INTRODUCTION, BACKGROUND, AND DESCRIPTION 1
A. Introduction and Background 1
B. Description of Area 4
1. Geographic Features 4
2. Water Resources and Uses 5
C. Analytical Methods 7
D. Definition of Terms 8
E. Description of Sugar Beet Processing 9
1. History 9
2. Process Operations 10
II. INDUSTRIAL PLANT SURVEYS 14
1. Loveland, Colorado 14
2. Windsor, Colorado 18
3. Greeley, Colorado 21
4. Fort Morgan, Colorado 27
5. Sterling, Colorado 32
6. Ovid, Colorado 36
7. Brighton, Colorado 41
8. Longmont, Colorado 48
9. Eaton, Colorado 53
10. Johnstown, Colorado 57
III. TOTAL POLLUTION LOADS FROM SUGAR BEET MILLS 65
A. Total Factory Waste Loads 65
1. Classification 66
2. Waste Flows 66
3. BOD and COD Loads 68
4. TSS Loads 68
5. Total Alkalinity Loads 69
6. Bacterial Loads 69
7. Summary of Overall Factory Loads 70
B. Waste Loads to the Receiving Stream 71
IV. BACTERIOLOGICAL ASPECTS OF SUGAR BEET PROCESSING WASTES . 78
A. Background on Bacterial Pollution 78
B. Sources of Bacterial Pollution Within the Sugar
Factory 80
C. Effects of Waste Storage upon Bacterial Populations . 84
D. Bacterial Survival 86
E. Fecal Coliform-Streptococci Relationships 88
F. Salmonella Associated with Sugar Beet Wastes 90
G. Criteria for Bacterial Reduction 91
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TABLE OF CONTENTS
(Continued)
V. WASTE ABATEMENT AND TREATMENT IN THE BEET SUGAR
INDUSTRY 93
A. Description of Major Wastes 94
1. Spent Flume Water 94
2. Process Waters 95
3. Lime Mud Slurry 96
4. Steffen Filtrate 97
5. Excess Condenser Waters 97
B. In-Plant Measures 98
1. Handling of Sugar Beets before Reaching
the Factory 98
2. Redesign of the Beet Flume System 98
3. The Value of Process Water 99
4. Handling of Lime Muds 100
5. Steffen Filtrate Conversion 101
6. Condenser Water Desirable in Some Cases 102
7. Reuse and Recovery of Various Flows 102
C. Minimum Waste Abatement and Treatment 103
1. Fine-Mesh Screening 104
2. Grit and Solids Removal by Mechanical Means . . . 105
3. Treatment Lagoons and Ponds 108
4. Aeration Fields Ill
D. Intermediate Waste Abatement and Treatment 112
1. Long-Term Waste Storage 112
2. Mechanically-Aerated Ponds and Lagoons 114
3. Chemical Treatment 115
4. Land Irrigation 116
E. High-Level Waste Abatement and Treatment 117
1. Recirculation-Reuse Systems 117
a. Flume Water Recycle Systems 118
b. Integrated Flume and Condenser Water
Recycle Systems 122
2. Biological Systems 124
a. Activated Sludge 124
b. Trickling Filters 127
c. Anaerobic-Aerobic Lagoons 132
3. Biological-Recirculation Systems 133
F. Other Considerations 134
1. Design, Operation, and Maintenance 135
2. Research 136
Bibliography 138
ii
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LIST OF FIGURES
No. Description Page*
1 General Map of Sugar Beet Study Area 4
2 Process for Beet Sugar-Basic Flow Diagram 12
3 Loveland Sugar Factory, In-Plant Flows, January 1964 14
4 Loveland Sugar Factory, Plant Area, January 1964 14
5 Picture of Loveland Sugar Factory Showing Greeley-Loveland
Canal, Factory Intake Canal, and Seal Tank Discharge 15
6 Windsor Sugar Factory, In-Plant Flows, January 1964 20
7 Windsor Sugar Factory, Plant Area, January 1964 20
8 Picture of Windsor Sugar Factory Showing Accumulated
Wet Pulp in Silo Near End of Campaign 20
9 Picture of Windsor Sugar Factory Showing Lime Mud Slurry
Entering Upper End of Impoundment Pond 20
10 Picture of Windsor Sugar Factory Showing Interior of
Lime Mud Pond 20
11 Picture of Windsor Sugar Factory Showing Continuous
Outflow from Lime Mud Pond 20
12 Picture of Windsor Sugar Factory Showing Liquid Overflow
from Ash Pond 20
13 Picture of Windsor Sugar Factory Showing Total Plant
Wastes Delivered to the Treatment Field 20
14 Greeley Sugar Factory, Plant Area, January 1964 22
15 Picture of Greeley Sugar Factory Showing Raw Water
Supply Pond 23
16 Picture of Greeley Sugar Factory Showing Truck Hopper
on the Beet Flume System 24
*The majority of Figures are given on the page following the above
designated position. In some cases, the pictures are contained
on the page so designated.
111
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LIST OF FIGURES
(Continued)
No. Description Page*
17 Picture of Greeley Sugar Factory Showing Overflow from
Treatment Lagoon to Discharge Drain 24
18 Fort Morgan Sugar Factory, In-Plant Flows, December 1963 27
19 Fort Morgan Sugar Factory, Plant Area, December 1963 27
20 Picture of Fort Morgan Sugar Factory Showing Railroad
Car Receiving Station 28
21 Picture of Fort Morgan Sugar Factory Showing Waste
Treatment Pond No. 2 29
22 Picture of Fort Morgan Sugar Factory Showing Final Over-
flow from Waste Treatment Pond No. 1 Entering Discharge
Drain 29
23 Picture of Fort Morgan Sugar Factory Showing Final Over-
flow from Waste Treatment Pond No. 2 Entering Discharge
Drain 29
24 Sterling Sugar Factory, In-Plant Flows, December 1963 33
25 Sterling Sugar Factory, Plant Area, December 1963 33
26 Picture of Ovid Sugar Factory Showing Lime Mud Storage
Pond 37
27 Ovid Sugar Factory, In-Plant Flows, December 1963 37
28 Ovid Sugar Factory, Plant Area, December 1963 37
29 Picture of Ovid Sugar Factory Showing Side-Dumping of
Sugar Beets into the Truck Hopper 37
30 Picture of Ovid Sugar Factory Showing the Open Discharge
Drain Leading to the South Platte River 37
31 Brighton Sugar Factory, Plant Area, January 1965 41
32 Picture of Brighton Sugar Factory Showing End-Dumping
of Sugar Beets into the Truck Hopper 43
33 Brighton Sugar Factory, Plant Area, 1966-1967 43
IV
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LIST OF FIGURES
(Continued)
No.
34
35
36
Description
Picture of Brighton Sugar Factory Showing Vibrating
Screens on Flume Water Recirculation System
Picture of Brighton Sugar Factory Showing East Leg of
Compartment A in the Recirculation Pond System
Picture of Brighton Sugar Factory Showing South Leg of
Pag(
43
44
Compartment A together with Inner Compartments in the
Recirculation Pond System 44
37 Picture of Brighton Sugar Factory Showing West Leg of
Compartment A in the Recirculation Pond System 44
38 Picture of Brighton Sugar Factory Showing Excess Waste
Storage Pond and Lime Mud Pond 45
39 Longmont Sugar Factory, General Area, November 1965 and
1966 48
40 Picture of Longmont Sugar Factory Showing Factory Water
Supply Canal 49
41 Picture of Longmont Sugar Factory Showing Inlet Area of
Waste Treatment Lagoon 50
42 Picture of Longmont Sugar Factory Showing Lower End of
Waste Treatment Lagoon 50
43 Eaton Sugar Factory, General Area, November 1965 54
44 Picture of Eaton Sugar Factory Showing Sugar Beets
Transferred by Front-Loader from Storage Pile into the
Lateral Flumes 54
45 Picture of Eaton Sugar Factory Showing Discharge Drain
before Entering Eaton Draw 54
46 Material Flow Diagram for the Johnstown, Colorado Sugar
Recovery and MSG Plants 58
47 Johnstown MSG and Sugar Recovery Operations, Plant Area,
August and November 1965 60
48 Picture of Findlay, Ohio Sugar Factory Showing Vibrating
Screens on the Flume and Condenser Water Closed Circuit 105
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LIST OF FIGURES
(Continued)
No. Description
49 Picture of Findlay, Ohio Sugar Factory Showing Dorr
Clarifier on the Flume and Condenser Water Closed
Circuit 107
50 Picture of Fremont, Ohio Sugar Factory Showing Waste
Treatment Lagoon and Influent and Effluent Canals 118
vi
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LIST OF TABLES
No. Description Page
I Loveland Sugar Factory, Summary of In-plant Data,
January 15-23, 1964 17
II Windsor Sugar Factory, Summary of In-plant Data,
January 24-February 1, 1964 22
III Greeley Sugar Factory, Summary of In-plant Data,
January 24-February 1, 1964 26
IV Fort Morgan Sugar Factory, Summary of In-plant Data,
December 7-16, 1963 31
V Sterling Sugar Factory, Summary of In-plant Data,
December 7-16, 1963 35
VI Ovid Sugar Factory, Summary of In-plant Data,
December 7-16, 1963 40
VII Summary of Data for Brighton Sugar Factory and South
Platte River, January 4-8, 1965 46
VIII Brighton Sugar Factory Sampling, January 12-13, 1967 47
IX Summary of Data for Longmont Sugar Factory and St. Vrain
Creek, November 1-5, 1965 and October 31-November 15, 1966 52
X Summary of Data for Eaton Sugar Factory and Eaton Draw,
November 15-19, 1965 56
XI Summary of Data for Johnstown Sugar Recovery-MSG Plants and
Little Thompson River, August 25-28, 1965 and November
1-5, 1965 64
XII Unit Waste Loads for Total Factory Effluents Representing
Nine Sugar Beet Mills in the South Platte River Basin,
1963-1966 67
XIII Status of Waste Treatment and Waste Loads Discharged to
Receiving Streams for the Beet Sugar Industry in the
South Platte River Basin, 1963-1966 75-77
XIV Coliform Bacteria in the Fort Morgan Flume System, 81
December 1963
XV Bacteriological Densities-Particulate Material 83
XVI Bacterial Densities in Sugar Beet Plant Wastes and
Receiving Streams, South Platte River Basin 89
vii
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ACKNOWLEDGMENT
The excellent cooperation by the beet sugar industry, various
State Health Departments, private and public groups, Federal agencies,
and individual investigators, was a major factor in making this report
possible. Recognition is given to the following who contributed in
significant measure to the study. Their assistance is gratefully ac-
knowledged.
The Great Western Sugar Company, particularly management
personnel and plant supervisors for providing access to the
factories, information on process and operation, and much
of the source data used within the report.
The Colorado State Department of Public Health for their
overall interest in the study.
The State Health Departments of California, Iowa, Minnesota,
Montana, Nebraska, Wyoming, and Utah, who provided informa-
tion on sugar process operations within their areas.
The Beet Sugar Development Foundation and indirectly the
British Columbia Research Council, who by virtue of previous
studies, were a source of much valuable information used in
the report.
Various investigators who provided specific information
and their reports of findings in the area of sugar factory
operations and methods of waste abatement and treatment.
viii
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SUMMARY
Primary attention is focused upon the beet sugar industry in the
South Platte River Basin. Beet sugar wastes are the largest source of
pollution within the area. Ten sugar factories are dispersed throughout
the region and affect water quality over 300 miles of Basin streams. This
report comprises five major parts. Section I consists of introduction and
background to the problem, and description of process operations. Section
II gives the results of industrial surveys and status evaluation on each
of the ten factories in the Basin. Section III discusses total factory
waste loads before and after treatment. Section IV describes the bacteri-
ological aspects of sugar beet waste pollution across the country. Sec-
tion V offers a comprehensive review and evaluation of waste abatement and
treatment throughout the industry both in the U.S. and abroad.
In 1955, sugar beets were grown on almost one million acres of
land mostly situated in the Western U.S., by some 60,000 farmers in 22
States. Eighteen sugar companies managed 73 sugar beet factories located
in 16 different States. The basic processes within the mill consist of
diffusion, juice purification, evaporation, crystallization, and recovery
of sugar from molasses. The typical factory operates round-the-clock for
a continuous period of 80 to 160 days during the year.
Detailed study was made of the nine sugar beet mills and of the
Johnstown, Colorado (sugar recovery - Monosodium Glutamate) factory, lo-
cated in the South Platte River Basin. Information was secured on process
and operation, water supply, the beet flume system and waste flume water,
beet pulp, lime mud wastes, the main plant sewer, and available waste
abatement and treatment facilities. Special emphasis is given in these
studies to the source, nature and magnitude of in-plant waste loads to-
gether with various factors governing these loads. The report includes
process description of the Johnstown, Colorado plant which is the only
one of its type in the Western Hemisphere, and a discussion of the closed
flume water recovery system recently installed at the Brighton, Colorado
factory.
Total factory waste loads and flows are defined in terms of unit
process rate, and these loads were investigated with regard to reasons
for change and the increments from particular operations. Total factory
BOD loads varied from a low of 10 pounds per ton. beets processed to a high
of 33 pounds, with the average of 15 pounds for all Basin plants. The ad-
dition of lime mud could be expected to increase normal BOD and COD loads
from a sugar factory by 10-40 percent whereas, if pulp silo drainage is
also added, the basic waste loads could be increased by 50-200 percent.
Total suspended solids loads varied from 22 to 121 pounds per ton beets
processed. Complete lime mud wasting could be expected to increase basic
plant TSS loads from 100-300 percent, whereas pulp silo drainage contrib-
uted a minor portion of the TSS loads. Bacterial loads varied from 0-68
ix
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BQU total coliform bacteria and fecal coliform bacteria from 0-8.4 BQU
per 100 tons beets processed. The studies indicated that pH levels
exceeding 9.0 were particularly destructive to organisms of the coli-
form group.
The survey results showed that lime mud wasting from a Steffen
house factory would add about 5 pounds BOD, 7 pounds COD, 90 pounds TSS
and 45 pounds alkalinity per ton beets processed, to the basic plant loads.
A straight-house factory would approximate one-half to three-fourths of
these respective levels. Pulp silo drainage would add another 16 pounds
BOD and 22 pounds COD to the total plant wastes. The nine sugar process-
ing establishments (excluding Brighton), contributed total factory waste
loads of 175 tons BOD and 780 tons TSS on a daily basis together with
6900 BQU total coliform bacteria. Overall waste reduction by means of
available treatment at the mill sites was only 8 percent for BOD and 58
percent for TSS, whereas total coliform bacteria loads demonstrated a
23 percent overall increase. The big picture of sugar beet waste dis-
posal in the South Platte River Basin strongly implies that much remains
to be done.
Results were collected on the bacteriological aspects of sugar
beet waste pollution from many studies conducted across the country. In-
terpretation and findings are condensed in this report as to the probable
sources of bacteriological pollution within the sugar beet factory, changes
due to waste storage, survival tendencies of bacterial organisms, differ-
entiation between human and animal-caused pollution, pathogens in sugar
beet wastes, and criteria for reducing bacterial pollution. The studies
show that incoming dirt and trash together with the sugar beets represent
the significant sources of bacterial entry to the sugar mill. These bac-
teria are strongly associated with the fertilization of agricultural lands
by means of animal manure, a practice common to the industry. Disregard-
ing recent changes in the South Platte River Basin, the treated factory
effluents contained total coliform densities in the range of 1.6 to 49
million/100 ml and fecal coliform densities between 18,000 and 4.1 million
/100 ml. The serious nature of bacteriological pollution in the Basin
cannot be disputed. Pathogenic Salmonella organisms were found at the
East Grand Forks and Moornead, Minnesota factories and the river waters
below the mills. Similar isolations were also made at the Fremont, Ohio
and Longmont, Colorado plants. These waste effluents are considered sig-
nificantly polluted and definite hazard is involved for human contact.
The waste abatement and treatment section of the report is divided
into description of major wastes, in-plant measures, minimum treatment
(primary treatment or less), intermediate treatment methods, high-levels
of treatment, and other considerations. Description and information from
the literature are given on the major wastes including spent flume waters,
process waters, pulp silo drainage, lime mud slurry, Steffen house fil-
trates, and condenser waters. In-plant measures are considered of great
importance and include the proper handling of sugar beets before reaching
the factory, redesign of the beet flume system particularly dry-handling
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techniques, the value of reusing process waters, handling of lime muds,
Steffen filtrate conversion to usable end-products, disposition of ex-
cess condenser waters, and the reuse and recovery of various flows in
the typical factory.
Methods and procedures of waste abatement and treatment are group-
ed for ease and clarity in presentation rather than giving a rigorous
definition of the system. In this report, high-level treatment is meant
to provide factory waste loads not exceeding 2 pounds BOD and TSS per ton
beets processed.
Primary treatment measures include fine-mesh screening, grit and
solids removal by mechanical means, treatment lagoons and ponds, and
aeration fields. Adequate screening of the waste flows from a typical
factory can remove 10 to 40 tons of coarse wet solids daily which are
reused in the process or sold as animal feed. Mechanical clarifiers
should be preceded by grit removal and screening, and are generally em-
ployed in closed wastewater recycle systems. The large quantities of
accumulated dirt and debris are usually deposited into sludge storage
ponds. Treatment lagoons and ponds have widespread use throughout the
industry but too often their performance is quite poor. Both earthen
lagoons and mechanical clarifiers may cause serious problems without
proper operation and maintenance care. Aeration fields provide reason-
ably good suspended solids removal but little change in organic waste
loads.
Intermediate waste treatment methods include long-term waste stor-
age, mechanically-aerated ponds and lagoons, chemical treatment and the
irrigation of agricultural lands with waste effluents. Extended waste
storage over the winter months at one factory produced almost complete
removal of suspended solids together with 50 percent reduction in organic
material. Laboratory studies on the feasibility of treating sugar beet
wastes in aerated lagoons showed encouraging results and the desirability
of full-scale systems application. Chemical precipitation of waste flume
waters provided 57 percent reduction of the BOD load at a Michigan factory.
The use of sugar factory effluents for irrigating agricultural lands di-
rectly or indirectly, is widely practiced throughout the Western United
States. Examples are cited in the States of California and Texas, and the
South Platte River Basin within the State of Colorado.
High-level waste treatment is sub-divided into recirculation-reuse
systems, biological systems, and biological-recirculation systems. The
complete recycle system has generally proven superior to biological methods
in terms of overall results. A closed flume water recirculation circuit
is described as one with continuous recycling of waste flume waters to-
gether with essential treatment units on the line enabling complete reuse
of such waters. This system is explained for four different factories in-
cluding Fremont, Ohio; Ottawa, Ohio; Fort Garry in Manitoba, Canada; and
Brighton, Colorado. The total discharge load at Fremont was only 0.8-0.9
pounds BOD per ton beets processed, and the levels at Fort Garry were 0.3
XI
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pounds BOD and 0.6 pounds TSS per ton of beets processed. The Brighton
factory with its waste treatment system has achieved better than 90 per-
cent reduction in BOD waste loads compared to previous conditions. Con-
denser waters may be added into the recycle circuit because of economics,
regulation, or the need for heat content. Examples are given of the in-
tegrated flume and condenser water systems at the Findlay, Ohio and
Betteravia, California factories. The total plant waste load ultimately
discharged from the Findlay factory has averaged only 0.1 pounds BOD per
ton beets processed.
Many studies have been performed on the treatment of sugar beet
wastes by biological systems including activated sludge, trickling fil-
ters, and other means. Pilot-plant evaluation of activated sludge treat-
ment at Hereford, Texas has provided reasonably good results. Nitrogen
and phosphorous deficiency in biological waste treatment must be taken
into account. Trickling filter studies undertaken at Hereford, Texas
and many full-scale installations in Great Britain and Western Europe
have shown biologica.1 filters to have real merit in sugar beet waste
treatment. On the other hand, two such installations in the U.S. at
Rupert, Idaho and Lewiston, Utah, have failed in large degree. This is
believed due to gross under-estimation of the processing rate and diffi-
culty in design and selection of treatment units. Neither system was
given the opportunity to develop the full potential of the waste treat-
ment processes.
Anaerobic-aerobic lagoons have been utilized on a pilot-study
basis at Tracy, California for treating sugar beet wastes. The results
are generally encouraging and future improvements will be made in this
system. The Hereford, Texas waste treatment system is typified by two
discrete treatment phases consisting of waste recycling followed by sta-
bilization ponds and disposal of wastes onto agricultural lands. The
Hereford system demonstrated a few problems which presumably will be cor-
rected, but good overall performance has been reported.
The proper design, operation and maintenance of all waste treat-
ment procedures and facilities are considered essential to an effective
waste management program. Awareness of the problem, correct blending of
attitudes, and status recognition are thought to be ingredients necessary
in the program. Many details are mentioned including staffing patterns
requisite to adequate management. Lastly, six areas of research are spec-
ified as valuable to the interests of the beet sugar industry and the
broad needs of waste abatement.
xii
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SECTION I
INTRODUCTION, BACKGROUND, AND DESCRIPTION
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I. INTRODUCTION, BACKGROUND, AND DESCRIPTION
A. INTRODUCTION AND BACKGROUND
This report is of first importance directed to the problems of
sugar beet waste disposal and associated stream pollution found in the
South Platte River Basin. However, broad application to the industry
is found in the particular sections of the report devoted to bacteri-
ological aspects and waste abatement procedures and treatment methods.
The South Platte River Basin Project, of the Federal Water Pollution
Control Administration, Department of the Interior, has conducted
studies on sugar beet waste pollution since December 1963. Part of
the Project's findings in this area has been presented in prior publi-
cations (1, 2, 3). The remainder of data collected over the past three
years is contained herein, and together with previous findings, serves
as a rather complete documentation on the definition of the waste prob-
lem, its nature and magnitude, and potential and probable solutions.
On July 18, 1963 Governor Love of Colorado requested the Secre-
tary of Health, Education, and Welfare to assist the State in determin-
ing the quality of waters and sources of pollution in the South Platte
River Basin within the State of Colorado. The Secretary convened the
First Session of the Conference in the matter of Pollution of the South
Platte River Basin which was held in Denver, Colorado on October 29,
1963 under enforcement provisions of the Federal Water Pollution Control
Act as amended (33 U.S.C. 466g). At this Conference it was established
that a study would be undertaken by facilities of the U.S. Public Health
Service, which is now the Federal Water Pollution Control Administration
in the Department of the Interior. The First Session of the Conference
provided a general review of water quality conditions in the Basin and
referred to the urgent need for information towards clarifying and solv-
ing the existing problems (1).
The South Platte River Basin Project was given the primary re-
sponsibility for assisting the State of Colorado in developing necessary
plans for the control and abatement of pollution in the Basin. This
program is directed to: 1) determine sources of pollution and adverse
effects on water uses; 2) conduct field studies on the condition of
Basin streams; 3) compute necessary waste load reductions for desired
water quality and to recommend commensurate water quality control mea-
sures; and 4) recommend remedial time schedules for pollution abatement
action.
Immediate attention was focused on the sugar beet industry since
it was the largest single source of pollution in the Basin. A coopera-
tive program was formulated with the State and the industry to define
the problem, develop additional knowledge where necessary, and evaluate
ways and means to combat the problems.
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Informal meetings were called at various times for progress eval-
uation and the exchange of information with the State and the industry.
The first major delineation of findings and conclusions was made at the
Second Session of the Conference in the matter of Pollution of the South
Platte River Basin held in Denver, Colorado on April 27-28, 1966. De-
tailed information was presented at the second conference session on the
quality of stream waters in the area of sugar beet processing, the bio-
logical life in the streams, the bacterial pollution, and a recommended
pollution abatement schedule for the industry towards achieving desirable
water quality in the Basin (2).
The recommendations of the Federal report at the second conference
session were submitted to the newly-formed Colorado Water Pollution Con-
trol Commission for implementation. The State authorities were given
sufficient time to study and evaluate the Federal report, and to develop
a program for implementation of remedial measures and time schedules.
The Second Session of the Conference was reconvened on November 10, 1966
(3). This conference session developed certain conclusions and recom-
mendations and those having specific reference to the beet sugar industry
are given as follows:
1) "Pollution of the South Platte River Basin which endangers
health and welfare, caused by municipal and industrial discharges,
is occurring."
2) "All discharges into the South Platte River Basin shall have
adequate remedial or control facilities in full operation by June
30, 1971, so as to comply with water quality standards established
by the Colorado Water Pollution Control Commission as approved by
the Secretary of the Interior."
3) "State and Federal authorities will have progress evaluation
meetings at six-month intervals to determine compliance with the
above requirements."
The water quality standards referred to above are those required
to be set by each of the 50 States before June 30, 1967, under provisions
of the Federal Water Quality Act of 1965, Public Law 89-234. Particu-
lar note must be taken of item 11 contained in the Guidelines for estab-
lishing these Water Quality Standards developed by the FWPCA in May 1966
(4). This item states "the use or uses of the waters concerned, the
water quality criteria to provide for such use or uses, and the plan for
implementing the water quality criteria . . . should encompass any re-
medial program recommended by the Secretary as a result of an enforce-
ment action taken under Section 10 of the Act; and should be revised to
reflect any recommendations resulting as such programs and actions de-
velop."
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Specific recommendations concerning sugar beet waste abatement
were given at the Second Session of the Conference on April 27-28, 1966
(2) These recommendations specify that:
"1) The industry provide treatment of wastes so that the total
5-day BOD load discharged in any one day in the total effluents
entering Basin streams shall not exceed the values given below
for respective plants. Residual wastes may be discharged over
an extended period of the year if necessary.
Brighton - 1100 pounds 5-day BOD per day
Longmont - 1450 "
Loveland 1750
Johnstown - 800 "
Windsor - 1100
Eaton - 1000 "
Greeley - 1100
Fort Morgan - 3000 "
Sterling - 2200 "
Ovid - 2800
"2) There shall be no settleable solids contained in the total
effluents, and that suspended solids loads in these effluents not
exceed the numerical levels prescribed above for 5-day BOD.
"3) Disinfection be provided for each and every waste discharge
so that the receiving stream or waterway directly below each mill
shall not shown an increase of more than 5,000 total coliform
bacteria per 100 ml, and 1,000 fecal coliform per 100 ml, over
corresponding densities upstream of the mill discharge.
"4) Dissolved oxygen in the treated waste effluents not be less
than 2 mg/1 at any time to insure minimum dissolved concentra-
tions of 4.0 mg/1 in the receiving streams or waterways.
"5) There be absence of grease, oil, floating solids, slime or
sludge banks in the receiving streams, or waterways, as a result
of waste discharges from the sugar beet mill.
"6) Waste treatment and control measures and other procedures
shall not cause pollution of the underlying valley-fill aquifiers.
"7) There be no disagreeable odors or other nuisance in the areas
outside of, and immediately adjacent to, the plant sites.
"8) Each sugar beet mill shall conduct continuous monitoring of
the quality of final waste effluents and of each receiving stream
above and below the points of waste discharge to these streams.
Adequate records shall be maintained by each plant on water qual-
ity and shall be reported regularly to the State Water Pollution
Control Agency.
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"9) Final approval of design plans on all waste treatment and
control measures, inspection during and following construction of
facilities, and final joint evaluation (together with the 'indus-
try) of waste treatment and control performance shall be provided
by the State Water Pollution Control Agency."
The above recommendations more or less set the limits of this re-
port. The stream survey and biological sampling results associated with
sugar beet processing are not included herein since such information was
reported upon at the Second Session of the Conference.
Section I of this report consists of introduction and background
to the problem, description of the study area, explanation of analytical
methods and important technical terms, and description of the various
operations within the sugar beet processing plant. Section II gives the
full results of industrial plant surveys and status evaluation for each
of the ten sugar factories in the South Platte River Basin. Section III
discusses the total waste load leaving the factory and the discharge
load entering the receiving stream from the South Platte River Basin
mills. Unit operations are related to magnitude of waste load. Section
IV describes the bacteriological aspects of sugar beet processing wastes
derived from various studies conducted across the country. Section V
offers a comprehensive review and evaluation of current methods for
waste abatement and treatment within the modern sugar factory. Both
published and unpublished information from the United States, Canada,
and foreign countries have been used. Innovations and broad implica-
tions for the future are also examined.
B. DESCRIPTION OF AREA
1. Geographic Features
The study area comprises the South Platte River from the city of
Brighton, some 20 miles below Denver, downstream to the Colorado-Nebraska
Stateline a total distance of 210 miles; St. Vrain Creek from Longmont to
the stream mouth some 23 miles; the Big Thompson River from Loveland to
the stream mouth, 27 miles; and the Cache la Poudre River from Windsor to
below Greeley, about 26 miles. Total stream distance approximates 300
miles. The Brighton, Longmont, Johnstown, Loveland, Windsor, Eaton, and
Greeley sugar factories are located in the Middle, portion of the Basin.
The Fort Morgan, Sterling, and Ovid factories are in the Lower Basin.
The ten mill sites are shown in Figure 1. St. Vrain Creek, the Big
Thompson River, and the Cache la Poudre River are the three largest tri-
butary streams to the South Platte River in the study area.
The lands of the Middle and Lower sectors of the Basin are pri-
marily devoted to farming, with the growing of field and vegetable crops
and cattle raising as the agricultural mainstays. This enterprise is
highly dependent upon extensive irrigation systems which divert large
amounts of surface water from the main-stem South Platte River and vari-
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DIGITALLY
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ous tributary streams. Supplemental agricultural water is received from
numerous wells sunk into the shallow ground-water aquifers along the
river valleys.
In addition to many small farming communities, there are a number
of population centers having great importance in the social-economic
well-being of the Rocky Mountain region. These include Fort Collins -
26,695 persons; Greeley - 26,314; Boulder - 37,718; Sterling - 10,751;
Fort Morgan - 7,379; Brighton - 7,055; Brush - 3,621; and Julesburg -
1,840 (5) .
Commercial trade and some light industry are present mainly in
the larger cities and towns. The Great Western Sugar Company contributes
significantly to the economy of the area.
The region is well-traversed by good roads, rail and airline
routes. Facilities for transporting people, goods, and services are
cons idered exce1lent.
2. Water Resources and Uses
The water resources of the area are in extremely heavy demand.
In fact, water rights greatly exceed the available supplies. Resources
comprise surface waters, ground water, and transmountain diversions.
Agricultural irrigation is the major water use, comprising 90 percent
or more of the total demands from both surface and ground water sources
(1). Large-scale withdrawals continue unabated throughout the year, in
the summer for direct-use irrigation and in the winter for irrigation
water storage. Streamflows are augmented in large degree by return
ground-water inflow from previous agricultural irrigation. Streamflows
are generally lowest in the period from June to September. The secon-
dary period of low flow occurs from October through February. Minimum
conditions occur frequently and at many locations especially below large
diversion systems. Flows less than 20 cubic feet per second (cfs.) are
not uncommon.
At present time, all surface withdrawals for municipal water
supply are situated above sugar beet mill locations. These cities and
towns receive their supplies from the upper watersheds of St. Vrain
Creek, the Big Thompson River, and the Cache la Poudre River. Two major
factors preclude any such use of the lower stream waters. The waters
are grossly polluted with sugar beet wastes, and also are high in sal-
inity content from irrigation return flows and natural sources. Treat-
ment of these waters under the present conditions would involve undue
expense or otherwise could not guarantee a product of sufficient purity.
Many towns in the study area utilize ground water with salinity
content equal or exceeding that in nearby surface waters. The question
is posed whether these surface waters, reasonably free of organic wastes,
could serve as supplementary or alternate sources of municipal water sup-
ply. If salinity loads are decreased in the future, special study of
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these resources would be more than appropriate. Overall benefit-cost
relationships are not properly defined at this time. However, future
populations exerting continuously increasing demand, will alter the
distribution and upgrade the classes of uses to which these waters will
be directed.
Effects of organic wastes on irrigation water use are mitigated
since the seasons do not generally coincide. However, the Johnstown
picture is different where waste discharges occur throughout the year.
Farmers below the Johnstown sugar recovery - MSG plant have reported
serious odor and a high degree of coloration in the irrigation waters.
The situation indicates that the service life of irrigation structures
and appurtenances may be shortened because of undesirable effects of
waste discharges. Major problems are the disagreeable odors and the
undesirable physical appearance of stream and irrigation waters (6).
The fisheries resource below each sugar factory and the city
of Denver has been reduced almost to the point of complete extinction
(6). Only tolerant species are found which include carp, suckers, and
minnows. The potential demand for creating a game fishery in the pres-
ently affected streams of the Basin is very real, and development of
this resource would have important merit. The Colorado Game, Fish and
Parks Department has stated that a desirable fishery could be maintained
in the streams, regardless of the low flows, if only an effective waste
abatement program was established (7). Accordingly, large-scale bene-
fits could be made available to the residents of the Denver Metropolitan
area, the many thousands of tourists in the region, and the general pop-
ulation.
Recreation on a broad spectrum is a very active pursuit within
the State of Colorado and when linked with tourism is ranked as the
State's third largest industry. _As such it contributes in great mea-
sure to the region's economy. In the past, the valley and plains areas
have received much less attention than the mountain region but this pat-
tern is undergoing rapid change. Also the lower areas must be traversed
by tourists and other people in their travel to and from the mountains.
The following points are pertinent to recreational use of the waters in
the Middle and Lower Basin:
1) Large use is made today of the limited recreational facilities,
particularly the facilities located on irrigation water storage
reservoirs.
2) Residual wastes from industry and various municipalities may
have serious adverse effects upon the recreational uses envisioned
for the future Narrows reservoir.
3) The poor physical appearance of affected watercourses with
solids, floating materials, sugar beet chunks, scum, odors, and
other conditions of gross degradation are aesthetically objec-
tionable.
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Brief reference must be made to the insect vector problems of the
Basin. A previous Project document (8) has shown that the Basin area
possesses all the natural features for the large-scale buildup of insect
populations and the associated vectors of disease to man, livestock, and
wildlife. When large amounts of organic material are added to the sys-
tem, in this case from inadequately treated sugar beet wastes and muni-
cipal sewage, all the necessary environmental factors are present both
in time and space. The organic wastes trapped in pools, off-channel
areas, and available as stream bottom sludge deposits greatly enhance
insect production. Many of the various species of mosquitoes and flies
transmit disease or otherwise create serious nuisance. Also, mosquito-
borne encephalitis is present in relatively high degree in the South
Platte River Basin. On this account, maximum effort should be made to
reduce the organic level caused by sewage and industrial wastes. Sugar
beet wastes comprise the majority of this waste load.
The above discussion on present water uses and adverse effects
is not by any means all-inclusive. The prime objective is to provide
greater understanding and recognition of the serious water quality prob-
lem existing within the South Platte River Basin. Even more important,
this situation visualized for the future could be far more serious and
with widening consequences. The Middle Basin together with Metropolitan
Denver are projected as a region with great future growth in people, ma-
terial goods, and services (9). This area and the needs of the large
population will demand far more from its natural resources, including
adequate water quality and quantity to be made available on a large scale.
C. ANALYTICAL METHODS
Except in a few cases where special techniques were found neces-
sary, all laboratory procedures and analyses were undertaken in accord-
ance with "Standard Methods" (10). Special procedures are described in
the following.
Bacteriological testing was based 'upon 5 replicate tubes at each
of 3 significant dilutions to obtain the MPN (Most Probable Number) value.
The total colifocm bacteria determination corresponded to the confirmed
coliform test as given in Standard Methods. The fecal coliform bacteria
determination consisted of a confirmation of the positive presumptive
tubes from the standard coliform analysis using EC broth at 44.5 ± 0.5°C.
with an incubation period of 24 hours (11, 12). Soil samples for bacteri-
ological testing were mixed with buffered distilled water in a weight
ratio of 1 soil: 9 water, in a Waring blender under sterile conditions.
The soil-water mixture was then subjected to the same testing procedure
as for a water sample.
Fecal streptococci were evaluated by direct plate count on KF agar
from an appropriate sample dilution. The incubation period was 48 hours
at a temperature of 35°C (13) . Samples for Salmonella determination were
filtered through a membrane filter and pre-filter, and the filters were
inoculated into various enrichment media, as was the straight sample.
-------
The enrichment media included GN Broth, Hajna, SBG Sulfa Enrichment,
and Tetrathionate Broth Base. The growth on these media was subse-
quently streaked onto selective plating media which consisted of Bis-
muth Sulfite, MacConkey, and SS Agar. Colonies with characteristics
typical of Salmonella-Shigella were picked, purified, and run through
appropriate biochemical tests, followed by serological identification
(14, 15).
A small percentage of the 1963-1964 bacteriological results were
reported as exceeding or being less than a certain number. For ease in
computation, such results were converted into absolute values. Coli-
form densities are given in this report as MPN or Most Probable Number
per 100 ml, and the daily bacterial loads as BQU, or Bacterial Quantity
Units (see Section ID). All data in the report except those for bacteria
and pH are average values. The latter are reported in terms of the med-
ian or geometric mean values. Lastly, the river mileages for various
locations within the study area are derived from the '"River Mileage Index
for the South Platte River Basin" previously published by the Project
(16).
D. DEFINITION OF TERMS
The definition of certain technical terms appearing most fre-
quently or otherwise important in better understanding this report are
given as follows:
Biochemical Oxygen Demand (5-day BOD, BOD) is a measure of the
oxygen demand of sewage and industrial wastes determined by biochemical
techniques. BOD in the stream is a measure of oxygen used by living
organisms in decomposing these wastes.
Bacterial Quantity Unit (BQU) is one measure of the total load
of bacteria passing a given stream location and is particularly useful
in comparing relative loads between stations. The number of BQU's is
derived as the product of flow in cfs and coliform density in MPN/100
ml, divided by 100,000.
Chemical Oxygen Demand (COD) is a measure of the oxygen demand
in sewage and industrial wastes or in the stream, determined by chemical
techniques. A definite relationship between COD and BOD for a specific
waste flow may generally be established from proper laboratory evalua-
tion.
Conductivity is a measure of the ability of water in conducting
an electrical current. In practical terms, it is used for approximating
the salinity or total dissolved solids content of water.
Fecal Coliform Bacteria represent a specific group of microorgan-
isms from the gut of warm-blooded animals. Enumeration yields an index
for that portion of the coliform group which is of fecal origin with a
95-percent level of confidence. Similarly, coliform organisms from other
-------
sources are excluded from the test with about the same level of confi-
dence. As the numbers of fecal coliform increase, the relative proba-
bility of hazard from enteric disease also increases.
MPN is an abbreviation of the phrase "Most Probable Number." The
term MPN derives from bacteriological testing procedures and represents
the number of bacteria most likely to occur in statistical theory under
particular conditions of the test.
£H is a measure of the relative acidity or alkalinity of water.
a pH value of 7.0 indicates a neutral condition, less than 7 a predomi-
nance of acids, and greater than 7 a predominance of alkalis. There is
a 10-fold increase (or decrease) from one pH unit level to the next,
e.g., 10-fold increase in alkalinity from pH 8 to pH 9.
Population Equivalents (P-E.) describe the pollutional effect of
various waste discharges in terms of a corresponding effect of discharg-
ing raw sewage from an equivalent number of human population. Each P.E.
represents the waste contributed by one person in a single day.
Total Coliform Bacteria represent a diverse group of microorgan-
isms whose presence have been classically used as indication of sewage
pollution in water supplies. They are always present in the intestinal
tract of man and other warm-blooded animals and are excreted in large
numbers by fecal wastes. Where such fecal pollution exists, there is
always the possibility of the presence of enteric pathogenic bacteria
and other pathogenic entities. Increasing density of the coliform bac-
teria group is assumed to represent an increase in the quantity of pol-
lution and, therefore, greater hazard. It must be noted under some cir-
cumstances total coliform may be present which are derived from sources
other than fecal excreta.
Total Suspended Solids (TSS) are solids found in wastewater or
in the stream which can be easily removed by filtration. The origin of
suspended matter may be man-made wastes or natural sources such as silt
from erosion.
E. DESCRIPTION OF SUGAR BEET PROCESSING
1. History
The culture of sugar beets is recorded in the earliest periods
of man's history. The beet root is known to have been part of the diet
of the Egyptians during the building of the Great Pyramids. It was
later found as a common food substance throughout the Middle Ages. Ex-
traction of sugar from the beet was first started on a commercial scale
both in Germany and France in the early nineteenth century. Improvement
in the manufacturing process evolved in slow degree until some success
was achieved around the 1850 "s. The earliest sugar beet enterprises in
the United States were established in the 1830's in Pennsylvania, Mass-
achusetts and Michigan, but these plants and many others that followed
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failed in a few years. After many disappointing ventures, the Alvarado,
California sugar beet mill achieved an economic break-through in 1879
and was subsequently described as the first successful operation in the
United States.
The first sugar beet factory in the State of Colorado was estab-
lished in Grand Junction and operated from 1899 to 1943. This was fol-
lowed by Rocky Ford and Sugar City in 1900, and then the factories lo-
cated in the South Flatte River Basin acquired by and built for the Great
Western Sugar Company. The Basin plants were established as follows:
Loveland - 1901, Greeley - 1902, Eaton - 1902, Windsor - 1903, Longmont
- 1903, Sterling - 1905, Fort Morgan - 1906, Brighton - 1917, Johnstown
- 1926, and Ovid - 1926. Factories were also constructed at Fort
Collins, Brush, and Fort Lupton, in 1903, 1906 and 1920 respectively,
but these have been discontinued in recent years (17).
Up to the late 1940*s the economic stability of both the sugar
beet and cane sugar industry fluctuated widely. Tariff reductions on
import of foreign sugar very seriously depressed the domestic sugar econ-
omy throughout its early growth. The sugar industry is now protected
and operates on a quota system established by the Sugar Act of 1948 which
was extended and amended in July 1962. Quotas are exercised on both do-
mestic and foreign sugar and in most cases the administration of this Act
has been favorable to the industry in this country. The domestic sugar
industry at present time provides an annual payroll in excess of 160
million dollars (18).
In 1955, it was reported that sugar beets were grown on almost
one million acres of land, the large majority in the Western United
States, by some 60,000 farmers in 22 States. Sugar from this acreage
accounted for almost one-fourth of the total consumption of sugar in
the country. At that time, there were 18 processing companies operating
73 sugar beet factories in 16 States (19).
2. Process Operations
The various commercial operations required for converting sugar
beets into refined sugar are many, and in some cases relatively complex.
The sugar company in large degree is responsible for the sugar beets
long before these reach the processing plant. The company obtains acre-
age allotments, conducts research on developing beet seed most adaptable
for growing in the local areas, undertakes contracts with the individual
farmers for the proper growing, harvesting, and delivery of sugar beets
to the processing plant, and offers advice and assistance to the farmers
in solving their particular agricultural problems. The company generally
stores the granulated sugar and the various sugar products at the factory
site. Management at this point becomes engaged in arranging and deliver-
ing its products, advertising, product and plant improvement, and other
functions necessary to skillful and competitive merchandising.
10
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The sugar beet plant utilizes a series of physical and chemical
unit operations and processes which over many years of experience has
proven most successful. The prime objectives of the sugar factory are
maximum sugar recovery together with consistently high purity in the
finished products. The incoming beets contain 15-16 percent sugar con-
tent which means about 300 pounds' of refined sugar are extracted from
each ton of raw beets processed. The mill produces a variety of sugar
products including granulated, brown, confectioners, powdered, fondant,
cube, and molded sugars together with various syrups and molasses (17).
Sugar mills operate over a 24-hour day and employ from 40 to more
than 400 workers at a single plant. In the northern climes, beet pro-
cessing is generally conducted from late September or early October un-
til January, for a continuous period of 90-120 days. In other respect,
beet processing in California occurs over the summer and fall months and
sometimes for short durations in late spring, approximating 110-160 days
each year.
The Great Western Sugar Company provides a good illustration on
the process flow within the sugar factory together with a detailed ex-
planation of the various operations, both contained in Figure 2. Sup-
plementary information on the major unit operations is given in the
following discussion. Further details on the individual Basin factories
are included in the next section of this report. Many exceptions are
possible on the process line depending upon the particular factory and
sugar company.
The sugar beets are delivered to the individual factories by
truck or railroad car. The beets are stored in large piles on the fac-
tory grounds or enter directly into processing. Large beet piles are
not common in California or other warm climates since the rate of decay
is too great in storage. Sugar beets are removed from the storage piles
or directly from the incoming trucks or railroad cars and placed into
vthe wet hopper of the beet flumes. The flumes-consist of long concrete
channels through which beets are conveyed via a continuous stream of
water to the inside of the factory. Beet chips and tailings, stones
and miscellaneous debris are removed by various devices on the flume
line. The beet flume system may be very extensive or in some mills ex-
tremely limited. A few factories employ belt conveyors for moving the
beets part of the way into the mill. The water supply for the flumes
is received from the main water supply tank, excess condenser water,
recirculated flume water, or other sources.
Inside the plant, the beets are separated from the flume water,
enter a beet wheel and are elevated to a beet washing tank, pass over
a roller-spray table, and are then ready for slicing. Water supply for
washing and spraying in most cases is obtained from the main water supply
tank. The progress of the beets so far has been followed up to the point
of entering the main processing. The basic processes consist of dif-
fusion, juice purification, evaporation, crystallization, and recovery
of sugar from molasses. The auxiliary stages include pulp drying and
11
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concentration of Steffen filtrate. A Steffen house employs a number of
additional operations over and above the straight-house factory and is
designed to extract additional sugar from molasses. The molasses is an
end product from the straight-house factory (17).
The washed beets are sliced into thin strips or cossettes and
passed to the continuous diffuser. A few mills may still employ the old
type diffusion battery consisting of 12 to 14 cells in series arrange-
ment. The diffuser extracts sugar from the cossettes under counter-
current flow of water. In this process, the sugar passes through the
porous membrane of the beet cossettes into the water. The liquor im-
pregnated with sugar is termed "raw juice" which is sent to the purifi-
cation operations.
The exhausted cossettes or wet pulp are transferred to the pulp
presses and the dryer. Otherwise the wet pulp is flumed into a pulp
silo for storage and later use as livestock feed. The pulp is gen-
erally transported to the presses by conveyor belt; if instead water
is used, this is known as pulp transport water and may constitute plant
waste. Liquor extruded from the pulp in pressing is known as pulp press
water and is generally returned to the diffuser; if discarded, this
liquor becomes part of the plant wastes. It is also common terminology
to describe all wastes associated with the handling of pulp as "process
wastes."
Raw juice is limed and carbonated and sent to the Dorr clarifi-
cation system. Non-sugars and undesirable sugars are in large part ab-
sorbed into the precipitated calcium carbonate which settles out in the
thickener-clarifier tanks. A second carbonation removes the last traces
of dissolved lime. The purified liquor from the second carbonation is
termed "thin juice." Sludges from the thickener-clarifier tanks and
second carbonation are filtered. The end filter cake is slurred with
water and sent to waste. This waste is known as lime mud or lime mud
slurry.
The thin juice passes through the multi-effect evaporators under
high-pressure steam, the end result which is to raise the sugar solids
in the juice 'from 10-15 percent up to 55-70 percent. The concentrated
liquor from the evaporators is termed "thick juice." The thick juice
is mixed with remelt sugar and forwarded to the vacuum pans. The solu-
tions are boiled under high vacuum, a supersaturation condition is cre-
ated, the solution is then "shocked" by introducing small quantities of
powdered sugar, and crystals begin to form.
The crystals and the mother liquor, or "massecuite," are passed
from the pans to a mixer, followed by retention in the centrifugals for
spinning off the liquid, the granulator for drying, and then the finish-
ed product is received for packaging and for storage. The remaining
crystallization and separation operations shown in Figure 2 involve the
treatment and recovery of additional sugar from the middle and low-grade
syrups and massecuite.
12
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IGITALLY
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Process for Beet Sugar
It is all-important in beet sugar operations for the technician
to understand the basic flow of the process, step-by-step,
through the factory. The process itself remains virtually the same
from the early days of Great Western at the turn of the century,
but its actual operation differs now with the addition of
newer equipment and controls and with the higher standards for the
finished product. The explantation here traces the basic flow
through the main stages, designated by different colors,
on the diagram on the opposite side. This flow sheet may be
preserved in a three-ring notebook for study and reference
by loosening the staple in the fold at far left.
BEET HANDLING
Trash Removal
DIFFUSION BY
EXTRACTION
The Diffuser
The Pulp
PURIFICATION
& FILTRATION
• Sugar beets are delivered to the sugar factory in trucks or railroad cars. They
are piled on the ground, over flumes, or dumped directly from rail cars into wet
hoppers, where jets of warm water help unload the beets. The beets float into the
factory itself by water in a flume. On the way, they pass through a rock-catcher
or rock-drag for the removal of any rocks, mud or sand, and then through another
section for the'removal of any trash, weeds, or leaves. They then flow into a beet
wheel to be elevated into the beet washer. From the washer, they move across a
roller-spray table for additional washing and removal of trash. The beet elevator
then carries the beets to the top floor of the factory to the picking table. While
moving across the table, the beets undergo a hand search for any more trash or
foreign material. From there, they drop into a hopper above the beet slicers.
• The beets are fed from the hopper into the slicers, where they are cut into long
noodle-like pieces resembling shoestring potatoes. These are called cossettes or
chips. Emerging from the slicers, the cossettes fall on to a conveyor belt to be
carried across a continuous weighing device and then discharged into a chute leading
to the diffuser. Here the sugar is removed from the cossettes by being dissolved in
hot water. The diffuser itself stands on a slope. Water enters the higher end and
flows down the slope, while the cossettes enter the lower end and move upward
through the water by means of scrolls. (Note: The Loveland and Fort Morgan
factories employ diffusers with different mechanical equipment, but operate on
the same principle of diffusion.) The diffuser works continuously to extract sugar
from the cossettes. The process of diffusion uses osmosis, or the passage of sugar
through the porous membrane of the beet cossettes to the water. The sugar solu-
tion leaves the diffuser at the lower end in the form of "raw juice." When the
cossettes reach the upper end—free of most of their sugar—they become beet pulp
and move on to the pulp dryer or the wet pulp silo to be used as livestock feed.
• Upon leaving the diffuser, the raw juice moves through the various stages of
purification and filtration to remove impurities and other non-sugars. It is first
heated in the raw juice heaters. It is then pumped to the first of the two tanks of
the first carbonation station. Here the raw juice is mixed with milk of lime or
saccharate milk. It then moves on to the second tank for treatment by carbon
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First Garb
The Dorr Thickener
Sweetwater
The Pre-Limer System
Second Carb
Third Saturation
EVAPORATION
Thick Juice
CRYSTALLIZATION
& SEPARATION
White Pan
White Centrifugals
The Granulator
dioxide gas (CO2) from the lime kiln. The COa enters the gassing tank under
control to give the juice the proper pH or alkalinity upon leaving the first carb
station.
• Now the carbonated juice flows on to the Dorr thickener at most factories. The
thickener tank acts to settle out the precipitate formed in the juice by milk of lime,
or saccharate milk, and carbon dioxide. This leaves a clear juice to be sent to the
heaters and then on to the second carbonation station. The mud or sludge remain-
ing on the bottom of the thickener goes to the drum filters for washing in order to
recover any other sugar. After this, the mud goes to the sewer. The filtrate and the
wash water from the drum filters now become "sweetwater." It goes either to the
lime house to be mixed with burned lime, or to the Steffen house at factories with
that process; any excess goes back to the first carb tank.
• There is one exception to this flow of the juice at three factories—Greeley,
Windsor and Sterling. These three houses send the raw juice to a pre-liming tank
ahead of first carbonation. There, the juice is mixed directly with milk of lime and
then moves on to first carbonation, where more lime is added and carbonated. Up-
on leaving there, it goes to a direct filtration station, with either Grand Pont or Kelly
filters, instead of to the Dorr thickener. The juice then resumes the normal course
through the drum filters to second carbonation.
• In the second carb tank, the clear juice again mixes with CO-2 gas at a controlled
rate to obtain the proper pH or alkalinity. It then moves on to the second carb
filters for the removal of precipitates formed by the CO2 gas and the lime left
in the juice from first carbonation. This precipitate goes to the sludge tank and
then back to the drum filters for further washing, while the clear juice from the
second filters moves on to the third saturation station.
• In third saturation, the juice mixes with sulphur dioxide (SO2) gas from the
sulphur stove. This gas removes some color-forming materials in the juice that
would eventually appear in the finished sugar, but its main function is the final
adjustment of pH for sugarend liquors. The juice then moves on to the evaporator
supply tank and becomes known now as "thin juice."
• From the supply tank, the thin juice moves through heaters and then to the
evaporation station. This consists of five bodies, or effects, usually horizontal, but
in some factories also vertical. Inside the bodies, steam heat removes excess water
from the thin juice in five successive stages. It concentrates the dry substance in
the juice from a range of 13% to 15% upon entering the first body to 65% to
70% upon leaving the fifth body. In other words, while going through the evapo-
ration station, the thin juice becomes thick juice.
• The thick juice now moves on to the "blow-ups," a tank for mixing the juice
with melted sugar from the sugarend. After heating and filtration, this concentra-
tion becomes known as "standard liquor"—or the purified material for making
crystallized sugar. It goes to the standard liquor storage tank. (In some factories,
the evaporator thick juice goes to the high melter station instead of the blow-ups.
In this flow, the thick juice is used instead of thin juice to dilute and melt the
high raw sugar. It is then sent through the heaters and filters to the standard
liquor storage tank.) In either case, the standard liquor moves on to the white
pan to be boiled and crystallized to a high concentration of sugar called "white
massecuite." This heavy mass then drops into the white mixer.
• From the mixer, the white massecuite drops into the white centrifugal machines.
Here, the spinning action of the centrifugals separates the sugar crystals from
the liquor containing sugar syrups and impurities. The crystals remaining in
the centrifugal basket undergo further spinning for washing and some drying. The
spun sugar then drops to a conveyor to be moved up to the granulator for further
drying and cooling. The finished sugar then passes over screen sifters and moves
on to the bulk sugar bins for storage or to the warehouse for packaging. This
completes the "straight-line" flow of the process from sugar beets to beet sugar—
but other "side-line" processes still remain to recover more of the sugar from
the beet.
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Lower Purity Syrups
Hi-Raw Sugar Cycle
Lo-Raw Sugar Cycle
The Crystal! izers
The White Side • The "white side" of the sugarend comprises only the first stage in the complete
crystallization and separation process—that is, the white pan and white centrifugals
handle the material with the highest purity and the greatest yield. Other sugar—
along with important by-products—still remain in the syrups and wash-water spun
off by the white centrifugals. These must be re-crystallized in the sugarend.
• There is the "hi-green" syrup. It is spun off by the white centrifugals before
the application of hi-wash water on the massecuite. There is also the "hi-wash"
spun off by the white machines during the actual washing period. The hi-wash
usually flows to the hi-melter and then on to the blow-up tank to enrich the
mixture. Meantime, the hi-green goes to its storage tank and then to the hi-raw
pan. There, much like on the white side, the syrup is boiled down to a high
concentration, until the sugar crystallizes. It then drops into the hi-raw mixer.
From there, it goes to the hi-raw centrifugals, where the spinning action again
separates the crystals from other sugar and impurities in the liquor. It is also
washed to increase its purity. From the centrifugals, the hi-raw crystals go back
to the process, instead of to final product storage. Hi-raw sugar moves to the hi-
melter to be mixed with the high wash and also thin juice at a controlled brix
or concentration. This hi-melter mixture flows back to the blow-up tank to be
mixed with thick juice, where it re-enters the process as standard liquor on the
white side.
0 There is also the "machine syrup" spun off by the hi-raw centrifugals. It goes
to the machine syrup storage tank on the pan floor and then to the lo-raw pan.
Here again, boiling crystallizes the sugar in the mass. But instead of going directly
from the pan to the centrifugal machines, the lo-raw massecuite drops to the
crystallizers for cooling and further crystallization over a period ranging from 20
to 40 hours. With this completed, the lo-raw mass goes to the lo-raw mixer and
then to the lo-raw centrifugal. Once again, the spinning action separates the
crystals from the liquor. The lo-raw sugar goes to the lo-melter, with thin juice
added there, and then on to the lo-melter storage tank for use in the hi-raw pan
or in some cases the lo-raw pan again. The lo-melter can also be sent to the
The Melters blow-ups to be mixed with the hi-melter and re-enter the process with the
standard liquor, or it can also be sent back to the first carb station to be mixed in
with the raw juice. (Some factories operate with only one melter. In this case,
the melted sugar from the lo-raw centrifugals goes with the melted sugar from
the hi-melter to mix with the thick juice to form the standard liquor.) The crystal-
lization and separation cycles end with the "lo-green" or molasses spun off by
the lo-raw centrifugals.
Molasses e At a non-Steffen house, this molasses will be shipped by rail tank car to a
nearby factory with the Steffen process. At a factory with a Steffen house, however,
this same sugarend molasses is shipped to the Johnstown sugar factory for further
processing. All our Steffen factories, with the exception of Billings, work 100%
non-Steffen molasses in the Steffen process. The Billings factory works half of
its own molasses in the Steffen house with the other half coming from the Lovell
factory.
STEFFEN PROCESS • The Steffen process employs' a different method to extract more sugar from the
molasses left over at the end of the regular sugar factory process. At present, six
Great Western factories operate Steffen houses—Loveland, Longmont, Fort Morgan,
Scottsbluff, Gering and Billings. The process begins with burned lime from the
factory lime kiln. The lime goes through a crusher and then to a Raymond mill,
where it is pulverized. The powdered lime then moves to the Steffen cooler tanks
Cooler Solution to be mixed in measured amounts with a "cooler solution." This solution is made
up in the for-cooler tank with non-Steffen molasses mixed with water and recycled
cold filtrate from the Steffen process itself. In the cooler tanks, the powdered lime
combines with the sugar in the molasses solution to form tri-calcium saccharate.
The precipitate of this mixture in the coolers moves to the cold drum filters for
washing. The cold saccharate cake from the filters goes on to the saccharate mixing
tank to be diluted with sweetwater from the regular factory process. Meanwhile,
-------
Filtration
Saccharate Milk
CSF Process •
CSF Carbonation
THE LIME KILN
Milk of Lime
C02 Gas
THE PULP DRYER
Pulp Presses
Dryer Drums
Pellet Mills
STEAM & POWER
Coal & Gas
the cold filtrate from the cold drum filters goes through a heater and then to the
hot Steffen Dorr thickener tank, where the precipitate or the hot saccharate cake
settles out. It is then sent to the hot Steffen filters. From there, the hot cake goes
to the saccharate tank to be mixed with sweetwater and the cold saccharate cake
from the Steffen process. The saccharate milk in the tank then flows back to the
first carb station to enter the regular factory process flow. There remains the
filtrate from the Dorr thickener and the hot drum filters. It goes to the process
for making CSF—concentrated Steffen filtrate. About 40 percent of the cold
saccharate filtrate returns to the for-cooler tank of the Steffen cycle. In three of
the Steffen houses, the cake from the hot Dorr thickener goes back to the for-cooler
tank, instead of the hot drum filter, to make up part of the Steffen cooler solution.
The CSF process, for making concentrated Steffen filtrate, takes the filtrate from
the hot Dorr thickener and the hot drum filters. It first passes through the flash
cooler and then on to the hydrolysis tank to be retained for about 40 hours. From
there, the filtrate flows to a carbonation tank to be mixed with CO2 gas from the
lime kiln. It is carbonated to about 7pH. The filtrate then goes to the CSF Dorr
thickener tank for the removal of the sludge formed by carbonation. This sludge
goes to the drum filters, where the filtrate is retained in the process and the mud
discarded. Meanwhile, the clear liquor from the CSF Dorr thickener goes on through
heaters and then to the CSF evaporators. With the removal of water, the Steffen
filtrate becomes concentrated and goes to storage tanks. It is then shipped by rail
tank cars to the Johnstown MSG Plant, in Colorado, for the extraction of mono-
sodium glutamate, a flavor-enhancer for many foods.
• The lime kiln supplies burned lime and CO2 gas for both the regular factory
process and the Steffen process. Both products result from the burning of limestone
with coke in controlled amounts in the kiln. There is one exception, at the Fort
Morgan factory, where the kiln operates automatically on natural gas fuel without
the use of coke. For the regular factory process, the burned lime goes to the slacker
to be mixed with sweetwater. This produces milk of lime for use in first carbona-
tion. For the Steffen process, the burned lime goes through a crusher and then
a Raymond mill. The powdered lime then moves on to the Steffen cooler to be
mixed with water, molasses and recycled filtrate to form the Steffen cooler solution.
The CO2 gas from the lime kiln enters the regular factory process at both first and
second carbonation and also goes to the carbonation tank in the CSF process.
• There are pulp drying operations at most Great Western sugar factories. A direct
by-product of the sugar process, dried or pelleted beet pulp provides highly nutri-
tious feed for livestock. The operation begins with the exhausted cossettes or chips
emerging from the upper end of the diffuser in the sugar factory. This pulp, still
wet, moves to the dryer house on belts or through pipelines to the pulp presses.
The mechanical squeezing action of the presses reduces the moisture of the pulp
to about 80%. At this time, the protein content of the pressed pulp may be in-
creased from about 8% to 13% by adding a liquid protein concentrate (LPC)
from the Johnstown MSG Plant. The pressed pulp then enters the dryer drums,
fired by either coal or natural gas, where the furnaces reduce the moisture content
from 80% to about 5% or 10%. Now in dried form, the pulp moves on conveyors
to bulk storage in the pulp warehouse or to the pellet mills. Under the compac-
tion of the pellet mills, the pulp emerges in a hardened form for easier handling.
It then goes to bulk storage in the pulp warehouse. Both dried and pelleted pulp
may also be sacked, depending on the facilities at the factory. If there is no pulp
dryer at the factory, the wet pulp goes to an open silo to be stored until trucked
away in wet form for stock feed.
• Almost all of the processing operations in the sugar factory depend upon the
steam boilerhouse and electric generators for power. A critical factor in economical
processing, the steam boilers may be fired either by coal or by natural gas, depend-
ing on the equipment at each factory. Steam furnishes the supply of heat required
for many process operations, and also passes through turbo-generators to provide
electrical power to move machinery. Some electrical power may also be purchased
locally.
-------
Three main types of waste are produced from the concentration
steps of the process. The first consists of spillage, leakage, etc.
which escapes to the floor drains. This type waste may actually occur
anywhere in the plant. The second waste is the result of cleaning and
reconditioning the evaporators, pans, and other equipment. The third
waste consists of the excess condenser water and condensates from the
multiple-effect evaporators and vacuum pans not reused within the plant.
Condenser waters receive organic load by virtue of material becoming
entrained in the vapors and being carried over into the condenser system.
The Steffen process found only in a Steffen house factory re-
ceives molasses, and employs a two-stage lime precipitation of sugar
(from the molasses) giving cold and hot saccharate cakes off the filters.
A mixture of the cold and hot saccharate sludges is slurried and re-
turned as the liming agent in the first carbonation stage of raw juice
purification.
The CSF (concentrated Steffen filtrate) process also associated
with Steffen house operations is a procedure for concentrating the fil-
trate essentially from the hot sacrharate filter cake described above,
for eventual reuse. The CSF product in the South Platte River Basin is
shipped to the Johnstown, Colorado sugar recovery-MSG factory, described
in the next section of this report. The final sludges resulting from
the CSF process are believed to be mixed in with lime mud for disposal.
The CSF evaporator condensates are wasted to the plant sewer. Results
collected by the Project show that this condensate compares in strength
to that received from straight-house operations but comprises only 5-8
percent of the straight-house volume.
Pulp pressing and drying operations produce a nutritional feed
for livestock. The dried pulp contains 5-10 percent moisture and may be
additionally fortified with liquid protein concentrate. The product may
be pelletalized for easier handling and appeal, and is sold in bulk or
packaged form.
13
-------
SECTION II
INDUSTRIAL PLANT SURVEYS
-------
II. INDUSTRIAL PLANT SURVEYS
This section of the report provides evaluation of the industrial
waste picture at each of the nine sugar beet mills and the Johnstown,
Colorado (sugar recovery - MSG) chemical operations, all located in the
South Platte River Basin. Detailed information is given on the source,
nature and magnitude of in-plant waste loads and associated factors.
Studies were conducted at the Loveland, Windsor, and Greeley sugar pro-
cessing factories in January 1964; the Fort Morgan, Sterling, and Ovid
factories in December 1963; the Brighton factory in January 1965; and
the Longmont, Eaton, and Johnstown plants in November 1965. The evalu-
ations are dependent upon conditions that were present at the time of
particular surveys. However, additional comments are included at the
end of each plant report describing recent changes incorporated by the
company together with future plans.
1. Loveland, Colorado
Process and Operation
The Loveland sugar factory, the oldest plant in the South Platte
River Basin, was established in 1902. A modernization program was in-
itiated in 1947 which included installation of the chain-type diffuser.
During the 1963-1964 campaign, Loveland processed an average of 3,500
tons of beets per day. The plant included a Steffen house operation
receiving molasses from the Eaton and Windsor mills; the average rate
of molasses over the period of survey was 180 tons per day.
All incoming sugar beets were received in railroad cars, and
overhead water used for thawing frozen beets directly in the cars. The
plant had full pulp-pressing and drying facilities with full recircula-
tion of press waters to the diffuser. The exhausted pulp was conveyed
to the pulp presses by means of a scroll and there was no transport
water. The relative locations of sampling points for the Loveland fac-
tory survey are shown in Figures 3 and 4.
Plant Water Supply
The large majority of plant water supply was obtained from Lake
Loveland via the Loveland-Greeley Canal, and this water was sampled at
Station 71. A steel pipe carried the water to a cistern where it was
then pumped to an elevated main water supply tank within the factory.
Overflow from the main supply tank returned to the cistern. City water
at the rate of 1.5 cfs was used for diffuser makeup and cooling in the
barometric condenser on the cold Oliver filters. Total factory water
consumption approximated 18 cfs.
14
-------
WATER
SUPPLY
1
MAIN
WATER
SUPPLY
PUMP
CISTERN
TO
TREATMENT
FIELD
WASTE
LIME
MUD
•VAPOR
*-, OVERHEAD
WATER
WET HOPPER
FLOOR
WASHINGS
741
75
DECANTATION
TANK
BEET
WHEEL
PUMP
_2
BEET WASHER
I
i
MAIN SEWER
LOVELAND SUGAR FACTORY
IN-PLANT FLOWS
JANUARY 1964
FIGURE 3
-------
LOVELAND BEET
SUGAR FACTORY
CISEAL TANK SPILLAGE
DAM
.OVELAND
"GREELEY
CANAL
SEEPAGE FROM
BOYD LAKE
76
TREATMENT FIELD
MIIIIIM
1
1
f
77 a 79
TO BIG THOMPSON
LOVELAND SUGAR FACTORY
PLANT AREA
JANUARY 1964
RIVER
FIGURE 4
-------
Condenser Water
Main supply tank water furnished needs of the barometric con-
densers which in turn discharged to a seal tank. Seal tank overflow was
separately discharged into the Loveland-Greeley Canal downstream of the
point of canal water intake as shown by Figures 4 and 5. The Loveland-
Greeley Canal terminated at Boyd Lake near Loveland.
Figure 5.
Loveland sugar factory; 1-18-67.
Loveland-Greeley Canal in foreground with
diversion dam at extreme left, plant water
intake canal at center of picture, and seal
tank spillage discharging to Loveland-Greeley
Canal at lower right corner.
Beet Flume System and Waste Flume Water
The wet hopper at the beginning of the flume system received
water from two sources. The seal tank supplied the total needs of
overhead spray water, and the decantation tank provided continuous un-
derflow to the wet hopper. The latter source consisted of recirculated
flume water pumped at the rate of 1500 to 3000 gpm over a vibrating
screen into the decantation tank mixed together with seal tank water.
Details are shown in Figure 3. The primary purpose of the decantation
tank was to separate sand and tailings from the water. Sand from the
bottom of the tank was flushed to the main sewer and screened tailings
were sent to the pulp presses. Overflow from the decantation tank dis-
charged to the main sewer. In-plant sampling of the Loveland beet flume
system included: a) seal tank water at Station 73 added to the decanta-
tion tank; b) the recirculated flume water over the vibrating screen at
Station 74, and; c) the mixed contents of the decantation tank at Station
75. The quality of water obtained at Station 74 represented the charac-
teristics of waste flume water ahead of the beet washer.
15
-------
Main Plant Sewer
The main plant sewer received waste flume water, beet washer ef-
fluent, roller spray table washings, decantation tank overflow and under-
flow, floor washings, CSF condensates, seal tank overflow, waste lime
mud, and miscellaneous. Flows to the main sewer are illustrated in Fig-
ure 3. Grab samples were taken at a manhole on the main sewer and des-
ignated as Station 72; composite samples collected at this same point
during the day shift (6-8 hours) were designated as Station 78. These
stations are shown in Figure 4.
The ashes resulting from coal burning were removed from the boil-
er room by flushing with condenser water into one of two ash ponds. Fre-
quent overflow from the ash ponds also entered the main plant sewer.
Sanitary wastes from the plant discharged separately to the municipal
sewers of the city of Loveland. Waste from the boilout and cleaning of
evaporators and vacuum pans, consisting of scale residue and small quan-
tities of hydrochloric acid and caustic soda, likewise were released to
the main plant sewer.
The 24-inch main sewer crossed under the Loveland"Greeley Canal
and discharged into an open drain which carried the wastes to a treat-
ment area located approximately 1.5 miles east of the mill site.
Waste Treatment
The treatment (aeration) field utilized during the 1963-1964 cam-
paign is shown by Figure 4. The first or primary cell covered 92 acres
in area, and the secondary cell 41 acres. The waste flowed through the
first unit in numerous shallow channels, one to five inches in depth,
was collected by three culverts at the lower end of the field and passed
to the second unit. Liquid depth in the second unit was somewhat great-
er, ranging from a few inches to about two-feet. The waste discharged
from the treatment field through a rectangular weir into a collection
ditch leading to the Big Thompson River. Grab samples obtained at the
treatment field outlet were designated as Station 77; composite samples
collected at the same point over the daytime period (6-8 hours) were
designated as Station 79.
Subsequent to 1964, the company slightly modified the treatment
field. An earthen dike was constructed across the width of the first
cell dividing this unit into two sections. The present treatment scheme
consists of three areas receiving the waste flow in series arrangement.
At the end of processing campaign, the residual waste volume
trapped within the lower pond is entirely drained to the river by re-
moval of the outfall weir device. This practice may also be followed
at the other sugar factories to facilitate cleaning of treatment units
before the next campaign.
16
-------
TABLE I
LOVELAND SUGAR FACTORY
SUMMARY OF IN-PLANT DATA
January 15-23, 1964
Sta.
No.
71
73
74
75
74
72
78
76
77
79
Flow (cfs) No.
Meas- Esti- of
ured mated Samples
7
21
21
21
21
18 21
18 7
14
19.1 14
6
BOD COD
niE/1 % ma/1 %
2 11
450
49
1080
90
1010
110
1080
100
1080
680 (1100)
100
1050
80
800
(510) (1250)
Total
Suspended
Solids
ma/1 %
12
50
6
2000
90
1740
120
2000
90
1830
(730)
230
4150
20
860
(530)
Volatile
Suspended
Solids
mg/1 %
3
170
5
310
80
250
120
310
130
390
(130)
120
470
20
110
(80)
Total
Alka-
linity
me/1 1.
75
120
87
150
130
200
80
150
400
600
(330)
440
2660
20
540
(480)
Conduc-
tivity
umhos
290
305
440
435
440
650
480
720
555
550
pH
7.9
8.7
7.4
7.6
7.4
8.6
8.7
10.1
10.4
10.5
Temp.
°C
2.5
50.9
28.0
28.4
28.0
35 1
20.6
10.5
Confirmed
Coli. Bact.
MFN/100 ml 7.
1,650
0
32
7,850,000
90
6,760,000
120
7,850,000
90
7,150,000
0
44,000
5_
2,700
Fecal
Coli Bact.
MPN/100 ml \
430
5_
20
403,000
100
398,000
100
403,000
360
1,440,000
0
100
590
Station Description
Canal Water Intake
Seal Tank Water
Waste Flume Water
Flume Inlet Water
Waste Flume Water
MH Grabs
MH Composites
Treatment Field Inlet
Treatment Field Effluent
Grabs
Treatment Field Effluent
Composites
NOTE:
% - Remaining between stages
Values in parenthesis not used in calculating percent remaining between stages.
-------
Presentation and Discussion of Sampling Data
The average values of data collected from the Loveland survey are
given in Table I. A key feature of the table is the percent remaining
of selected waste variables between consecutive stages of process and
treatment. These values are shown underscored in the table.
Between the point of canal water intake at Station 71 and the
seal tank water at Station 73, there was reasonable increase in COD and
Volatile Suspended Solids (VSS) concentrations likely caused by condenser
carryover. Bacterial organisms were almost completely eliminated in the
seal tank water due to high water temperatures.
Waste concentrations increased many fold from the canal water in-
take at Station 71 to near the beet flume outlet as reflected by Station
74. Discarded flume water was the major waste load from the plant.
Main sewer waste at Stations 72-78 compared to the waste flume water
showed no increase in COD concentration, a four-fold increase in alka-
linity presumably due to entry of lime mud, and an increase in the fecal
coliform bacteria numbers.
The wastes entering the treatment field (Station 76) compared to
that leaving the factory (Stations 72-78) showed a two-fold increase in
TSS, a four-fold increase in total alkalinity, and a significant rise in
pH value. The full explanation for these changes cannot be given al-
though lime mud was suspected. Relatively low levels of coliform bac-
teria apparent in the total wastes entering and leaving the treatment
field definitely were attributed to high alkalinity and pH levels.
The treatment field was estimated in January 1964 as providing
an average waste detention time of only 37 hours over the entire 133
acres of treatment surface. Treatment results show that COD and BOD
concentrations were reduced in the order of 20 to 25 percent, and TSS,
VSS, and alkalinity levels were decreased approximately 80 percent.
Recent Operational Changes
Modifications made in the treatment field during 1965 and 1966
are described above. The factory has also experienced some increase in
processing rate; an average of 3680 tons beets per day was reported
during the 1966-1967 campaign.
2. Windsor, Colorado
Process and Operation
The 1966-1967 campaign was the last season of operation at the
Windsor sugar factory. Construction of a new plant at Goodland, Kansas,
and other management considerations lead to the closing of this factory
in January 1967. Survey results for Windsor must necessarily relate to
conditions existing prior to shutdown.
18
-------
The Windsor sugar factory over the 1963-1964 campaign received
an average of 2,200 tons beets per day. Straight-house operations in-
cluded a continuous diffuser, and molasses was generally shipped to the
Loveland Steffen house.
Part of the incoming sugar beets were received by truck and piled
in the yard; the remainder entered in railroad cars via a highline system.
The railroad tracks were elevated to provide for beet storage below the
tracks and the beets were brought into the plant by lateral flumes. Beets
in the factory yard were transferred to the lateral flumes by an end-
loader .
The Windsor factory produced wet pulp exclusively which was stored
within a pulp silo. Lime mud was placed in a large pond however, produc-
ing continuous overflow. The relative locations of sampling points for
the Windsor plant are shown by Figures 6 and 7.
Plant Water Supply
The large majority of plant water supply was obtained via canal
from Lake Windsor, and this rate of supply approximated 12 cfs. Around
1.5 cfs of city water was employed directly for diffuser makeup. Canal
water supply was impounded on the mill property and sampled at Station
81. "Excess" water from the impoundment bypassed and flowed into the
main waste drain as illustrated by Figure 7.
Beet Flume System and Waste Flume Water
Overflow from the main water tank together with seal tank water
supplied the lateral flumes in the beet receiving area. If the seal
tanks overflowed, this volume entered the beginning of the main plant
sewer following the beet washer and roller spray table. No recircula-
tion was provided in the Windsor flume system.
Beet Pulp and Pulp Silo
The exhausted wet pulp was transported from the diffuser to the
pulp silo by means of diffuser water. The pulp passed through a fanger
screen elevated above the silo. Screen water discharged to the main
waste drain, and the pulp deposited and stored in the silo as shown by
Figures 6 and 8. Pulp silo underdrainage was collected, screened, and
subsequently pumped to the lime mud pond. It was intended that part of
the acidity in the pulp silo drainage would be neutralized in the lime
mud pond.
Lime Mud Waste
Lime mud slurry was pumped to a large pond as illustrated by
Figures 9 and 10. Pulp silo underdrainage also entered the pond as
mentioned above. Only a small portion of the basin was used for effec-
tive waste settling. The continuous outflow from the far end of the
19
-------
pond containing large quantities of suspended and dissolved waste ma-
terial discharged to the main waste drain as shown in Figure 11.
Ashes
The burning of coal for heat and power in the Windsor factory
produced ashes requiring disposal. The ashes were flumed into a pond
with the heavier solids settling to the bottom. Continuous overflow
from the ash pond was released into the excess water bypass canal prior
to joining the main plant drain. This separate discharge is shown in
Figure 12. Ashes accumulated in the pond at the end of campaign were
reported to be used by the State Department of Highways for winter road
maintenance.
Main Plant Sewer
The main sewer immediately after leaving the factory converted
into an open drain. Station 82 established at the beginning of the open
drain represented the characteristics of the main plant sewer wastes
plus the fanger screen water from the pulp silo. The main sewer re-
ceived waste flume water, seal tank overflow, floor washings, sanitary
sewage and miscellaneous. Sanitary sewage was diverted from the main
plant sewer to the municipal facilities in 1965.
Main Plant Drain
The main plant drain collected and transported the total plant
wastes to a treatment area located about one mile south of the factory
site. The main drain was sampled both at Stations 83 and 84, shown in
Figure 7. Station 83 included the main plant sewer wastes plus the
fanger screen water originating from the pulp silo, ash pond overflow,
excess water bypass, and the outflow from the lime mud pond which in
turn contained some part of the pulp silo drainage previously intro-
duced to the lime pond. Station 84 represented the total plant wastes
immediately before treatment.
Waste Treatment
The treatment (aeration) field in place during the 1963-1964
processing campaign is illustrated by Figure 7. The waste flowed down
the field in numerous shallow furrows or channels. A corrugated steel
weir was placed across the mid-point of the field to reduce short-cir-
cuiting. The influent waste canal and upper section of the treatment
field are shown in Figure 13. The effluent from the treatment field
was sampled in the discharge ditch leading to the Cache la Poudre River;
grab samples were designated as Station 85 and composite samples as
Station 86.
20
-------
BEET
SHEDS
RAIL
SYSTEM
BEET
WHEEL
BEET WASHER
VAPOR
WET PULP
LIME MUD
TO POND
t
FLOOR
WASHINGS
l_L£t
FANGER
SCREEN
PULP
PULP SILO
^SANITARY SEWER
82
MAIN SEWER
WINDSOR SUGAR FACTORY
IN-PLANT FLOWS
JANUARY 1964
'TO LIME
MUD POND
TO TREATMENT FIELD
FIGURE 6
-------
CANAL FROM
LAKE WINDSOR
RESCREENED
PULP SILO
DRAINAGE
J
f
LIME MUD
POND
MAIN
WASTE
DRAIN
TREATMENT
FIELD
Ass
_A
a as
CACHE LA POUDRE RIVER
WINDSOR SUGAR FACTORY
PLANT AREA
JANUARY 1964
FIGURE 7
-------
Figure 8.
Windsor sugar factory;
1-5-67
Wet pulp accumulated in
pulp silo, near end of
campaign. Note fanger
screen at top center of
picture.
Figure 9.
Windsor sugar factory;
1-5-67
Lime mud slurry entering
upper end of impoundment
pond.
o
Figure 10.
Windsor sugar factory;
1-5-67
Interior of lime mud
pond. Lower end of pond
and discharge are in the
far background.
-------
Figure 11.
Windsor sugar factory;
1-5-67
Continuous outflow from lime
mud pond into main plant drain.
Drain was flowing from right
to left.
Figure 12.
Windsor sugar factory;
1-5-67
Liquid overflow from ash
pond to the excess water
bypass canal.
O
Figure 13.
Windsor sugar factory;
1-5-67
Total plant wastes delivered
in concrete channel to upper
end of treatment field. Part
of the wastes were bypassed
around the upper field as shown
on right side of picture. Note
pattern of waste flow down the
field towards the river located
at tree-line.
-------
Presentation and Discussion of Sampling Data
The average values of data collected from the Windsor survey are
given in Table II. The percents remaining of selected waste variables
between consecutive stages of process and treatment are also described
in the table.
The canal water supply to the plant at Station 81 was shown to
be of relatively good quality. Waste concentrations increased in very
large measure between the point of canal water intake at Station 81 and
the main sewer leaving the plant at Station 82. Main sewer wastes ex-
hibited COD and TSS levels of 1360 and 3270 mg/1 respectively. Total
and fecal coliform bacteria densities were 2,630,000 and 48,800 per 100
ml respectively. Waste flume water and fanger screen water constituted
the major waste loads.
Between Station 82 and Station 83 the excess water inflow served
to reduce waste concentrations, followed by lime pond discharge which
conversely increased the waste levels. The net effects caused substan-
tially no change in COD, TSS, VSS, and alkalinity concentrations between
the two stations. On the other hand, coliform bacteria levels increased
four to five-fold over the numbers found in the main sewer.
Waste concentrations remained at essentially the same high levels
from Station 83 to the point of entry into the treatment field except
for a further increase in total coliform bacteria. On the basis of
waste strength, the treatment field reduced the waste level as follows:
10 to 15 percent in COD, approximately one-half of the total and vola-
tile suspended solids, one-third of the alkalinity, and two-thirds of
the coliform numbers. The dissolved oxygen level in the effluent was
only 0.6 mg/1. The aeration field provided only minimum treatment of
processing wastes before final disposal into the river.
Recent Operational Changes
The transfer of domestic sewage from the main plant sewer to the
city facilities was completed in 1965. The significant change was the
final and complete shutdown of Windsor in January 1967.
3. Greeley, Colorado
Process and Operation
The Greeley sugar factory was a straight-house operation having
a continuous diffuser and complete pulp drying facilities. During the
1963-1964 campaign the Greeley establishment processed an average of
2,200 tons beets per day. Molasses from the process was shipped to the
Longmont and Loveland mills.
21
-------
TABLE II
WINDSOR SUGAR FACTORY
SUMMARY OF IN-PLANT DATA
January 24-February 1, 1964
Sta.
No.
81
82
83
84
85
86
Flow (cfs) No.
Meas- Esti- of
ured mated Samples
7
21
21
12 4 14
14
7
Total
Suspended
BOD COD Solids
me/1 % me/1 % me/1 %
6 31 15
1360 3270
120 80
1660 2770
100 90
1740 2610
90 40
1480 1060
1,110 (1670) (1120)
Volatile
Suspended
Solids
me/1 %
7
630
80
480
100
470
50
220
(230)
Total
Alka-
linity
ma/I %
270
1750
100
1720
100
1650
60.
1080
(1190)
Conduc-
tivity
umhos
1710
1530
1790
1790
1920
1760
Confirmed Fecal
Temp. Coll. Bact. Coll. Bact. DO Station
pH °C MPN/100 ml % MPN/100 ml % mR/1 Description
8.2 2.2 94 32 Canal Water Intake
9.2 20.7 2,630,000 48,800 Main Sewer
390 480
8.4 17.5 10,200,000 234,000 Drain below Lime
170 2P. Pond
8.3 17.1 17,800,000 165,000 Inlet to Aeration
40 30 Field
7.9 9.1 6,620,000 52,100 0.6 Effluent from Aera-
tion Field Grabs
7.8 Effluent from Aera-
tion Field
Composites
NOTE:
% - Remaining between stages.
Values in parenthesis not used in calculating percent remaining between stages.
-------
DIVERSION
FROM RIVER
WATER
SUPPLY
LIME MUD
WASTE TO
POND
GREELEY BEET
SUGAR FACTORY
LAGOON
M Ml
GREELEY SUGAR FACTORY
PLANT AREA
JANUARY 1964
FIGURE 14
-------
In 1963-1964, all incoming beets to the plant were received by
railroad cars and a highline system. The large majority of beets is now
delivered by truck. Trucked beets are dumped into a wet hopper and the
beets are flumed a short distance into the factory. Remaining beets are
conveyed to the plant through a considerably longer flume. Lime mud was
stored in a large pond with no reported overflow. The relative loca-
tions of sampling points for the Greeley plant are shown in Figure 14.
Plant Water Supply
The principal source of plant water supply was the Cache la Poudre
River. River waters were diverted into a small pond on the mill prop-
erty. The pond also received inflow from a city storm sewer. In January
1964 the diversion, although located upstream of the city sewage treatment
plant, probably received some raw municipal sewage bypassed around the
treatment facility and into the factory canal. The point of river water
intake is now believed located above all sewage discharges of major con-
sequence in Greeley. River water was used predominantly in beet fluming.
Supplemental water supply was obtained from the city of Greeley and a
single company well and directed to diffuser makeup and the washing of
sugar.
River water usage approximated 10 to 12 cfs, and total factory
consumption around 13 to 16 cfs. The river water in January 1964 was
of extremely poor quality, reflecting gross pollution. The intake from
the water supply pond to the factory was designated as sampling Station
91 as shown in Figure 14. A picture of the water supply pond is illus-
trated by Figure 15.
Figure 15.
Greeley sugar factory; 1-6-67.
Water supply pond principally receiving in-
flow from the Cache la Poudre River. Grease
and scum on pond water surface. Note munic-
ipal sewage treatment plant in right background
23
-------
Figure 16.
Greeley sugar factory;
1-6-67
Wet hopper for receiving
trucked beets. The flume
at bottom of hopper con-
veyed beets into the plant
Figure 17.
Greeley sugar factory; 1-6-67
Overflow from lagoon into discharge
drain. Drain was flowing from right
to left. Backup wastes in drain
above point of overflow.
-------
Beet Flume System and Waste Flume Water
Water received from the main supply tank and seal tanks furnished
the needs of the beet flume system. No recirculation was provided in
the circuit. The wet truck hopper recently installed at the Greeley
plant is shown in Figure 16.
Beet Pulp
The exhausted pulp leaving the diffuser is now transported to the
pulp presses via scroll and there is no transport water. All pulp is
sent to the dryer, and press waters are returned and reused in the dif-
fuser. The pulp dryer was first placed in operation during the 1963-
1964 campaign. The break-in period for the dryer coincided with the
field survey and at that time some wet pulp was discharged to the pulp
silo. Tailings from the beet washer and roller spray table were also
discarded to the silo, but are now combined with the pressed pulp and
subsequently converted into dry pulp pellets.
Pulp silo drainage which separately discharged to the Cache la
Poudre River during the January 1964 survey was considered to be tem-
porary and therefore not sampled.
Lime Mud Waste
Lime mud slurry was pumped to a storage pond directly across the
river from the sugar factory. No overflow was reported to the river al-
though some indirect seepage may have occurred.
Ashes
The burning of coal for power and heat within the plant produced
ashes which were slurried to the ash pond. Overflow from the pond dis-
charged directly into the river. Manpower limitation did not permit the
sampling of this waste during the January 1964 survey. This waste flow
still exists at the Greeley factory.
Main Plant Sewer
The main sewer after leaving the factory was enclosed for some
distance and then converted to an open flume before reaching the treat-
ment lagoon. Station 92 was established at the beginning of the open
section. The main sewer carried the total plant wastes exclusive of
lime mud and ash pond overflow. Sanitary sewage from the plant separ-
ately discharged to the municipal sewers.
Waste Treatment
Main plant sewer wastes flowed into a treatment lagoon located
directly east of the factory. In January 1964 the facility operated as
a lagoon with liquid depths in the pond from one to three feet. Dye
24
-------
tracer studies showed an average waste detention time in the pond of 200
minutes; short-circuiting started at 115 minutes and delayed flow per-
sisted up to 240 minutes. Because of odors created by the lagoon, the
company over the last two campaigns has instead operated the facility as
a treatment field similar to the Loveland and Windsor installations. A
rectangular weir regulated the outflow from the lagoon. This effluent
was designated as Station 93 for grab samples, and Station 94 for com-
posite samples.
Discharge Drain to River
The wastes from the treatment lagoon were released into a dis-
charge drain as shown by Figures 14 and 17, which in turn emptied to the
Cache la Poudre River. Dye studies indicated an average waste detention
in the drain of approximately 10 minutes. The drain was sampled near
its mouth at Station 95. Results indicated a poor degree of waste treat-
ment in the lagoon. Additional waste load was believed added to the
drainway from adjacent feed-lots, particularly during times of surface
runoff.
Presentation and Discussion of Sampling Data
The average values of data collected from the Greeley survey are
given in Table III.
As mentioned previously, the water received from the river for
factory supply was of poor quality. The plant intake at Station 91 con-
tained 270 mg/1 BOD, 500 mg/1 COD, only 2.1 mg/1 dissolved oxygen, and
very high levels of total and fecal coliform bacteria. The waters ob-
tained by the other sugar factories were of far better quality.
There was a many fold increase in waste concentrations from the
point of factory water intake to the main sewer at Station 92. The BOD
and TSS levels in the total wastes entering the treatment field were
1,010 and 1,300 mg/1, respectively. Total and fecal coliform densities
approximated 11.0 million and 0.53 million MPN per 100 ml respectively.
The waste flume water contributed a major part of the increase in waste
load.
A single pass through the treatment lagoon in January 1964 pro-
vided marginal reduction of waste levels, reflected by sampling results
obtained at Stations 93 and 94. Waste reductions were in the order of
10-15 percent for BOD and COD, 75 to 90 percent for TSS and VSS, 25 per-
cent in alkalinity, and 70 to 80 percent in coliform densities. Ef-
fluent waste concentrations remained high. The decrease in pH value
from 8.2 to 6.9 indicated anaerobic conditions in the pond, substanti-
ated by an abundance of free hydrogen sulfide in the vicinity of the
pond. The aeration field in present use by the company is believed even
less effective in waste treatment compared to the previous lagoon.
25
-------
TABLE III
GREELEY SUGAR FACTORY
SUMMARY OF IN-PLANT DATA
January 24-February 1, 1964
Total Volatile Total
Flow (cfs) No. Suspended Suspended Alka- Conduc- Confirmed
Sta. Meas- Esti- of BOD COD Solids Solids linity tivity Temp. Coll. Bact.
No. ured mated Samples me/1 % me/1 % mg/1 % me/I % mg/1 % umhos pH °C MPN/100 ml
Fecal
Coll. Bact. DO Station
MPN/100 ml % me/1 Description
91
7 270 500 142 100 400 1690 7.S 2.6 4,700,000 80,700 2.1 Plant Water Intake
370 280 920 260 200 230 650 from Pond
92 7.9
14 1010 1400 1300 260 810 1610 8.2 21.9 11,000,000 529,000 Main Sewer
85 85 10 25. 70 30 20
93 6.0
14
1210 120
-64
590 1770 6.9 12.5 3,060,000
103,000
Treatment Lagoon
Effluent Grabs
94
7 860 (1230) (130) (71) (580) 1690 7.0
100 90 80 100 100
190
Treatment Lagoon
160 Effluent Composites
95 9.0
850 1100
93
63
590 1760 7.0 12.5 5,690,000
162,000
Drainage Drain at
Mouth
NOTE:
% - Remaining between stages.
Values in parenthesis not used in calculating percent remaining between stages.
-------
There was no significant change in concentration of waste within
the discharge drain before final disposal to the river.
Recent Operational Changes
Changes which have been previously mentioned include the majority
of incoming beets now being received by truck rather than railroad car,
full pulp drying capacity with elimination of pulp silo drainage, and
the conversion of the treatment lagoon into an aeration field.
4. Fort Morgan, Colorado
Process and Operation
The Fort Morgan factory was one of the largest sugar beet process-
ing plants in the South Platte River Basin. Operations included a Steffen
house receiving molasses from the Ovid and Sterling mills. The Fort Mor-
gan plant had a continuous chain diffuser and full pulp-drying capacity.
During the 1963-1964 campaign, the average rate of processing was about
3,000 tons beets per day, but has since increased to around 3,250 tons
beets per day. Approximately 25,000 acres of farmland, almost entirely
within Colorado, were devoted to the growing of sugar beets required by
the Fort Morgan factory in the 1966-1967 campaign.
The Fort Morgan mill received about 70 percent of incoming beets
by railroad car and the remainder by truck. Beets from the railroad cars
were deposited directly into the wet hopper. Trucked beets and those
piled in the yard were elevated over and into the wet hopper via belt
conveyor. One purpose of the conveyor was to reduce dirt and debris on
the beets entering the flume system.
The plant pressed and dried all pulp for the production of dry
pulp pellets. Exhausted pulp from the diffuser was transferred to the
presses via scroll and there was no transport water. The pulp press
waters returned to the diffuser.
The average amount of molasses worked during the 1963-1964 cam-
paign approximated 145 tons per day and this increased to 161 tons per
day over the 1966-1967 season. The residual filtrates in the Steffen
house were hydrolyzed and evaporated to produce concentrated Steffen
filtrate, otherwise known as CSF. The CSF represented raw material
necessary in the Johnstown, Colorado sugar recovery operations.
The relative locations of sampling points for the Fort Morgan
factory are shown in Figures 18 and 19.
Plant Water Supply
Water supply for the factory was obtained from the South Platte
River via the Fort Morgan Canal at the rate of 35 to 40 cfs, and de-
livered to a small pond on the mill property. Samples collected from
27
-------
VAPOR
MULTIPLE EFFECT CSF
EVAPORATOR
COMBINED
SAMPLE
WASTE
LIME
MUD
1
i
ROCK
CATCHER
MAIN SEWER
FORT MORGAN SUGAR FACTORY
IN-PLANT FLOWS
DECEMBER 1963
I I I
TO WASTE
LAGOONS
FIGURE 18
-------
(EXCESS WATER) DISCHARGE DRAIN
FORT MORGAN
BEET SUGAR
FACTORY
26
WASTE
LAGOON
NO. I
FORT MORGAN CANAL
J
r
FORT MORGAN SUGAR FACTORY
PLANT AREA
DECEMBER 1963
FIGURE 19
-------
the lake were designated as Station 21. Pond water was pumped to the
main water supply tank located inside the Fort Morgan factory. Over-
flow or excess water from the lake flowed into a discharge drain which
circuited around the company waste treatment lagoons and subsequently
returned to the River. Small amounts of city water were also essential
in plant operations. Total water use within the factory approximated
13 to 15 cfs.
Beet Flume System and Waste Flume Water
Both overhead spray water and underflow water to the wet hopper
on the beet flume system were derived from the seal tanks and main water
supply tank, as shown in Figure 18. This source of water was sampled at
Station 29. The amounts of water in the beet flume system were limited
by this factory, and the seal tank water not required in fluming over-
flowed to the main plant sewer following the beet washer. During colder
weather the frozen beets in the railroad cars were soaked and thawed
with hot overhead water as shown in Figure 20.
Figure 20.
Fort Morgan sugar factory; 1-20-67.
Hot overhead water applied to frozen sugar
beets received in railroad cars. Thawed
beets were deposited into the wet hopper
located directly below the overhead water
station.
Additional sampling was conducted at both ends of the beet flume,
Representative soil portions taken from the belt conveyor moving the
beets into the wet hopper were designated as Station 27. Wastewater at
the tail end of the flume was described as Station 22.
CSF_Condensa,t_es
The combined flow of the condensate lines from the quintuple
effect CSF evaporators was designated as Station 28. This type waste
28
-------
was sampled only at the Fort Morgan factory. The condensates were dis-
posed of to the main plant sewer.
Main Plant Sewer
The main plant sewer received waste flume water (which included
beet washer and roller spray table wastes), the main water supply and
seal tank overflows, waste lime mud, CSF condensates, floor washings, and
miscellaneous. Sanitary sewage separately discharged to the municipal
sewers. Miscellaneous wastes in part comprised the boilout of evapora-
tors and vacuum pans. Evaporators were cleaned with acid followed by
caustic, then flushed and rinsed. Evaporator bodies Nos. 1 and 2 were
cleaned only at the end of campaign. However, bodies Nos. 3, 4, and 5
as an aggregate received boilout on the average of once every two weeks.
Vacuum pans were cleaned with a chemical compound known as SR-10 mixed
with water. The boilout schedule was described as every 32-hours for
the white pans and once-a-month for the raw pans. The Fort Morgan plant
relied entirely on natural gas to provide power and heat, and consequent-
ly no ashes were produced.
Total factory wastes were sampled on the main sewer line outside
and adjacent to the plant. Grab samples were described as Station 23
and composite samples during the day shift (6-8 hours) as Station 24,
shown in Figure 18. Total wastes then flowed in a closed line to the
waste treatment lagoons maintained by the company adjacent to the South
Platte River.
Waste Treatment
Waste treatment facilities at the Fort Morgan sugar factory con-
sisted of two shallow waste lagoons. Overflows from the lagoons were
released on a continuous basis to the (excess water) drain previously
described and shown in Figure 19. The total contents of the discharge
drain emptied to the S_uth Platte River a short distance below the ponds.
Cell No. 1 received the total wastes directly from the factory,
covered about 20 acres and overflowed both to the discharge drain and
to cell No. 2. The secondary pond received only part of the total
wastes previously entering cell No. 1, covered about 15 acres and had
a separate overflow to the discharge ditch. The ponds were cleaned
only when absolutely necessary after three or more consecutive cam-
paigns. As a result, liquid operating depths were minimal in the ponds,
ranging from 1-2 inches up to a maximum of about 2 feet. There was con-
siderable weed growth and short-circuiting of waste flow through the
ponds. An observation taken of the east side of pond No. 2 is given by
Figure 21.
The December 1963 survey provided separate sampling of the final
overflows from the two waste treatment ponds. The effluent from cell
No. 1 was described as Station 25, and that from cell No. 2 as Station
30. Recent pictures of these two outflows are shown respectively in
29
-------
Figure 21.
Fort Morgan sugar factory;
1-20-67
View of the east portion of
waste treatment pond No. 2.
Waste flow was towards the
observer and then to the
right. Note dense weed
growth, and solids deposi-
tion extending to pond sur-
face at center of picture.
Figure 22.
Fort Morgan sugar factory;
1-20-67
Final overflow from waste treat-
ment pond No. 1 entering dis-
charge drain. Flow in drain was
from left to right. Note signifi-
cant change in color between excess
water above and mixed waste flow
below.
Figure 23.
Fort Morgan sugar factory;
1-20-67
Final overflow from waste
treatment pond No. 2 enter-
ing discharge drain.
-------
Figures 22 and 23. Some of the lagooned wastes probably reached the
drain by indirect seepage. Additional sampling was taken at the end
of the discharge drain after it received the waste effluents from the
two waste treatment ponds and this point was designated as Station 26.
Presentation and Discussion of Sampling Data
The average values of data collected from the Fort Morgan survey
are given in Table IV.
The pond water intake at Station 21, and the mixture of seal tank
and main water supply tank waters at Station 29 serving as flume inlet
water, were both of relatively good quality. High water temperatures
at Station 29 reflected the seal tank water derived from the evaporators
and vacuum pans.
The waste flume water at Station 22 compared to the flume inlet
water at Station 29 showed substantial increase in waste load due to beet
fluming and washing operations. This waste was particularly high in
suspended solids content and coliform bacteria densities. The addition
of waste lime mud, CSF condensates, and other inflows between Station
22 and Stations 23-24 caused appreciable and further increase in COD,
TSS, VSS, and alkalinity concentrations in the total wastes. The pH
value also increased from 8.4 to 9.1. The entry of waste lime mud into
the main plant sewer was reflected in TSS and alkalinity levels of 5,020
and 1,900 mg/1 respectively at Station 24.
The primary lagoon even with serious short-circuiting and minimum
operating depths effected moderate reduction in waste concentrations
shown by the results collected at Station 25. BOD and COD levels were
lowered about 20 percent, and total and volatile suspended solids con-
centrations about 60 percent. It is believed that waste treatment
within the ponds could be far more effective if greater care were taken
in cleaning and overall management of the treatment facility. Results
on the effluent from the secondary pond were considered relatively un-
important during the survey because of the small discharge flow present
at that time.
Chemical waste concentrations of the total flow at the end of the
discharge drain corresponding to Station 26 were lower than in the pri-
mary lagoon effluent because of considerable dilution offered by the ex-
cess water arriving from above the mill site. Coliform bacteria densi-
ties at the end of the drain reflected better sampling conditions and
likely were more representative of plant waste effects than results ob-
tained directly from the lagoon effluents.
Recent Operational Changes
There have been no significant changes in the Fort Morgan waste
picture since the December 1963 survey.
30
-------
TABLE IV
FORT MORGAN SUGAR FACTORY
SUMMARY OF IN-PLANT DATA
December 7-16, 1963
Sta.
No.
21
29
22
23
24
25
30
26
28
Flow (cfs) No.
Me as- Esti- of
ured mated Samples
5
20
29
13.4 9
13.4 20
12.0 6
3
36.2 6
30
BOD COD
ma/1 % mB/1 %
3 25
47
440
150
480 (810)
640
80 80
380 510
(140) (230)
30 30
115 165
57 132
Total
Suspended
Solids
IMS/1 %
9
9
1690
300
(3940)
5020
40
2010
(31)
20
440
42
Volatile
Suspended
Solids
me/1 %
3
3
230
260
(490)
600
40
240
(20)
J25
61
4
Total
Alka-
linity
ms/1 %
275
293
400
470
(2240)
1900
19.
890
(460)
50
445
246
Conduc-
tivity
umhos
1480
1380
1400
1285
1270
1380
1340
1380
210
pH
8.1
8.5
8.4
9.1
9.1
8.5
8.0
8.2
9.7
Temp.
°C
0.3
31.2
25.6
26.1
18.5
6.3
5.0
60.5
Confirmed
Coll. Bact. •
MPN/100 ml %
870
2,300
4,500,000
70
3,200,000
30
1,000,000
(270,000)
160
1,600,000
Fecal
Coll. Bact.
MPN/100 ml %
80
70
43,000
70
30,000
60
18,000
(3,200)
70
13,000
Station
Description
Main Water Supply
Flume Inlet Water
Waste Flume Water
MH Composites
MH Grabs
Primary Lagoon Effluent
Grabs
Secondary Lagoon Efflu-
ent Grabs
Discharge Drain near
Mouth
CSF Condensate
NOTE:
% - Remaining between stages.
Values in parenthesis not used in calculating percent remaining between stages.
-------
5. Sterling, Colorado
Process and Operation
The Sterling sugar factory was a straight-house operation with a
continuous diffuser and produced wet pulp exclusively. Molasses was
shipped to the Fort Morgan mill. The processing rate during the 1963-
1964 campaign was 2,200 tons beets per day, but has since increased to
2,390 tons beets per day.
In previous campaigns, all incoming sugar beets were received by
railroad car and deposited directly into the flume. Approximately one-
third of the total beets are now delivered by truck. Beets are side-
dumped from the truck into a dry hopper. The dry hopper subsequently
connects to the original flume system for transport of beets into the
plant.
The Sterling factory stored wet pulp in a large silo. Lime mud
previously discharged in 1963-1964 to the main sewer is now separately
impounded. The mill utilized nautral gas for power and heat production
thereby eliminating the handling of ashes. The relative locations of
sampling points for the Sterling survey are shown in Figures 24 and 25.
Plant Water Supply
The large majority of plant water supply was obtained from the
South Platte River via the Sterling No. 1 Canal and a factory supply
canal. The factory canal received an excess of water to prevent ice
formation during freezing weather. Some well water was also added to
the canal. Canal water was diverted into a supply pond on the mill
property and the excess water remained in the canal bypassing around
the main factory as represented in Figure 25. Pond waters were pumped
to the main water supply tank within the plant. This supply was sampled
at Station 31. Other water was received.from the city of Sterling at
the rate of 1 cfs for diffuser makeup. Total water use by the factory
approximated 10 to 12 cfs.
Beet Flume System and Waste Flume Water
Railroad cars with incoming beets were hauled to a prescribed
location on the tracks, dosed with overhead water if necessary, and
the beets dumped directly into the wet hopper and flume system for
transport into the plant. The flume was completely washed out several
times a day between periods of unloading the cars. The total flume
system at Sterling was far less extensive than one associated with a
system of beet sheds.
Various sources of water for the beet flume included fanger
screen water returned from the pulp silo and reused as overhead water
for the wet hopper; overflow from the main water supply and seal tanks
serving as underflow to the flume inlet and the influent to the rock
32
-------
catcher; and the main water supply tank serving the beet washer.
The Sterling mill also recirculated the drainage from the tail-
ings discarded at the roller spray table. Tailings were screened on an
A-frame and the drainage returned to the wet hopper at the front end of
the flume system as shown in Figure 24.
Waste flume water was sampled at Station 34 and included all
wastes to the flume except beet washer waters.
Beet Pulp and Pulp Silo
The exhausted wet pulp from the diffuser was transported to the
open pulp silo by means of spent diffuser water. The pulp was placed on-
to a fanger screen elevated above the silo and the solids deposited into
the silo. The fanger screen water returned for use as overhead water to
the wet hopper. Excess fanger screen water not used in the flume dis-
charged via a supply tank to the main plant sewer.
Underdrainage from the pulp silo was separately collected and
pumped to a second or stationary screen over the silo. Solids collect-
ed on the screen were redeposited in the silo and the screen waters in
this case were released to the discharge drain.
The Sterling mill is expected to complete the construction of
full pulp pressing and drying facilities to be ready for the 1967-1968
campaign. These facilities will provide for the complete elimination
of wet pulp and the pulp silo operation. Pulp press waters will be en-
tirely reused in the diffuser.
Lime Mud Waste
Commencing with the 1964-1965 campaign, the lime mud was removed
from the main plant sewer and transported to a newly-constructed lime
mud storage pond located north of the main discharge drain near Station
35. No overflow has been reported or observed from the storage pond.
Main Plant Sewer
The main plant sewer immediately after leaving the factory con-
verted into a short run of open steel flume and then to the discharge
drain. This line was sampled in the open flume section at Station 36,
and the various wastes included were waste flume water, lime mud waste,
sanitary sewage, floor washings, and miscellaneous. Boilout of the
evaporators and vacuum pans contributed part of the miscellaneous wastes.
On the average, one evaporator and one vacuum pan were cleaned every
two weeks.
33
-------
VAPOR
DISCHARGED
at-
32 a 33
WET PULP FROM
DIFFUSER
DRAINAGE RETURN
PULP
DRAINAGE
DRAIN 36
STERLING SUGAR FACTORY
IN-PLANT FLOWS
DECEMBER 1963
FIGURE 24
-------
STERLING BEET
SUGAR FACTORY
MAIN
SEWER 32833
[Bj
.DISCHARGE DRA
tj WATER SUPPLY
WATER SUPPLY
POND
EXCESS WATER
0AM
FACTORY SUPPLY
(IRRIGATION) CANAL
WELL FIELD
STERLING SUGAR FACTORY
PLANT AREA
DECEMBER 1963
FIGURE 25
-------
Discharge Drain
The discharge drain carried the total factory wastes. Waste flows
additive to Station 36 consisted of fanger screen water originating from
the pulp silo and not used as overhead water, together with screened un-
derdrainage also from the pulp silo. A city storm sewer entered this
section of the drain but did not flow, at least during the period of the
survey. Grab samples taken on the discharge drain were described as
Station 32; composite samples collected at the same point over the 6-8
hour daytime shift were designated as Station 33.
The discharge drain downstream of Stations 32-33 was joined by
the excess canal water bypass from the site of the water supply pond as
shown in Figure 25. Total plant wastes combined with the excess water
and were carried in a continuation of the discharge drain about 0.7
miles before final disposal to the South Platte River. The discharge
drain was further sampled near its end at Station 35. Dye studies
showed that time of waste flow from Station 36 on the main plant sewer
to Station 35 near the River was only about 35 minutes.
Waste Treatment
The Sterling factory during the December 1963 survey had no treat-
ment facilities for any part of its plant wastes.
Presentation and Discussion of Sampling Data
Average values of the data received from the Sterling survey are
presented in Table V. The results indicated the plant water intake at
Station 31 was of relatively good quality, low in organics, suspended
solids, and bacterial content. The waters near the end of the beet
flume at Station 34 reflected heavy waste loads with significantly high
levels of COD, suspended solids, and total and fecal coliform bacteria.
Increases from Station 31 to Station 34 were as follows: COD from 20
to 710 mg/1, TSS from 37 to 2,780 mg/1, total coliform bacteria from
382 to 1,090,000 organisms per 100 ml, and fecal coliform bacteria from
50 to 103,000 organisms per 100 ml.
Inflows of beet washer water, lime mud, floor washings and san-
itary sewage to the main sewer between Station 34 and Station 36, caused
further rise in the waste concentrations. Total suspended solids and
alkalinity levels increased another 40 and 60 percent respectively.
The third increment of waste flows to the plant drain included
the pulp screen water and underdrainage from the pulp silo entering be-
tween Station 36 and Stations 32-33. Waste concentration increases were
100 percent in COD, 60 percent in alkalinity, and many fold in coliform
bacteria between the two sampling locations. Total coliform bacteria
density expanded from 1,090,000 to 20,400,000 per 100 ml, and fecal coli-
form bacteria from 87,800 to 313,000 per 100 ml.
34
-------
TABLE V
STERLING SUGAR FACTORY
SUMMARY OF IN-PLANT DATA
December 7-16, 1963
Sta.
No.
31
34
Flow (cfa) No.
Meas- Esti- of BOD
ured mated Samples me/1 %
7 2
28
Total Volatile Total
Suspended Suspended Alka-
COD
mg/1 %
20
710
SolLds
tne/1 %
37
2780
Solids linity
me/1
5
480
% me/1 %
280
460
Conduc-
tivity
umhos
1700
1680
Confirmed Fecal
Temp.
pH °C
7.9 4.5
7.9 22.2
Coll. Bact. Coll. Bact.
MPN/100 ml
382
1,090,000
% MPN/100 ml %
50
103,500
Station
Description
Water Supply
Pond
Waste Flume Water
36
32 9.3
33
35
9.0
6.5 18
8
10
870
100 140 130 160
670 3980 620 710 1640
200 90 90 160
(1310) (4220) (660) (1400) 1620
100 80
8.6 22.1 1,090,000 87,800
1900 360
8.1
1350 3470 570 1100 1840 8.2 18.7 20,400,000 313,000
50 50 50 50 100 80
10 410 690 1950 280 1100 1790 8.0 12.5 17,100,000 251,000
80
Main Plant Sewer
Discharge Drain
Composites
Discharge Drain Grabs
Discharge Drain near
River
NOTE:
% - Remaining between stages.
Values in parenthesis not used in calculating percent remaining between stages.
-------
Total plant wastes after mixing with excess water flow showed
about 50 percent reduction in chemical waste concentrations at Station
35, compared to the previous station. This indicated a volume ratio
of total plant wastes: excess water of approximately 1:1 within the dis-
charge drain. However, coliform densities were reduced only 20 percent
after the addition of excess water. Aftergrowth of bacterial organisms
was probable within the open discharge ditch leading to the River.
Recent Operational Changes
Significant improvements since December 1963 and those planned
for the near future, are changing the waste picture at the Sterling mill.
Receiving of beets by truck and the installation of a truck hopper may
have caused some reduction over the unit waste load and volume experi-
enced in December 1963. However, a greater volume of beets noted in the
1966-1967 campaign has probably offset this reduction.
The lime storage pond completed in the summer of 1964 has removed
the lime mud from the main waste discharge and should be effective if
underdrainage is precluded from entering the River. The completion of
pulp pressing and drying facilities at the Sterling mill ahead of the
1967-1968 campaign will eliminate the large pollutional loads associated
with the pulp silo and this action represents one important step towards
successful pollution abatement by the company.
6. Ovid, Colorado
Process and Operation
The Ovid sugar factory was a straight-house operation with a con-
tinuous diffuser and partial facilities for pulp drying. In 1963-1964
dry pulp was produced from 1800 tons beets per day and the remainder was
pressed and disposed of. The Ovid establishment, during the 1963-1964
campaign, processed an average of 2,800 tons beets per day; this has re-
mained fairly constant in subsequent campaigns. Molasses from the pro-
cess was generally shipped to the Fort Morgan mill.
During the plant survey all beets were delivered by railroad car;
beets were either stored in beet sheds, or deposited directly into the
wet hopper. Daytime operations consisted of dumping beets directly into
the flume. At night, beets were moved from the beet sheds into the fac-
tory by means of lateral flumes. The Ovid factory now receives a sub-
stantial part of its incoming beets by truck and has eliminated the beet
sheds and the lateral flumes. Storage of beets in the yard, rather than
in sheds, has reduced the deterioration of sugar beets upon standing.
Lime mud was handled separately and stored in a large pond as
shown in Figure 26. No overflow was reported or apparent from the lime
pond. The mill utilized natural gas for power and heat thereby elimi-
36
-------
nating ashes. The relative locations of sampling points for the Ovid
factory survey are shown in Figures 27 and 28.
Figure 26.
Ovid sugar factory; 1-10-67.
Lime mud storage pond approximately three-
quarters full.
Plant Water Supply
The large majority of plant water was obtained from the South
Platte River via the Peterson Canal, transported down Lodgepole Creek
and withdrawn at the factory site. Five company wells supplemented
this supply. Raw water was received into the main water supply tank
within the factory and sampled at Station 41. A sixth well, on occa-
sion, provided water directly to the beet flume. Total water use by
the Ovid mill approximated 12 to 15 cfs.
Beet Flume System and Waste Flume Water
Discounting the lateral flumes which have been abandoned along
with the beet sheds, the present flume system may be described as rela-
tively short, transporting beets into the plant from both the railroad
car and truck receiving areas. Beets are dumped from the railroad cars
directly into the original flume. Trucked beets are stored in the yard
or side-dumped into a truck hopper located immediately adjacent to the
railroad car receiving station. A new flume section underlying the
truck hopper connects to the original flume. Truck unloading at Ovid
is illustrated by Figure 29.
Recent observations were made at both the Ovid and Brighton mills
regarding the manner in which beets were dumped from the truck into the
hopper. The Brighton mill was served by trucks with greater capacity,
a longer load platform, and provisions for end-unloading. It was con-
cluded that side-unloading produces a much higher degree of cutting,
splitting and abrading of beets in the hopper. The vertical drop from
the truck into the hopper and design of the hopper appear quite impor-
37
-------
PUMP WATER
PUMK SUPPLY
FROM CRYSTALLIZER
JACKETS AND SEAL TANK
FLOOR WASHINGS
SEPTIC TANK
M.H. NO. I
DISCHARGED a 43
NORTH
M.H.
SCREENED ROLLER
SPRAY TABLE
WATER
BEET WASHER
SUMP
I
BEET
WHEEL
IPUMP
TO SOUTH
PLATTE RIVER
4*
SAND ONE
WELL
BEET FLUME
RCCK
CATCHER
OVID SUGAR FACTORY
IN-PLANT FLOWS
DECEMBER 1963
FIGURE 27
-------
'LODGEPOLE
CREEK
WATER
SUPPLY
OVID BEET
SUGAR FACTORY
LIME
i MUD POND
NORTH M.H.
MAIN
SEWER
42843
M.H. NO. I
DISCHARGE
DRAIN
SOUTH PLATTE RIVER
OVID SUGAR FACTORY
PLANT AREA
DECEMBER 1963
FIGURE 26
-------
Figure 29.
Ovid sugar factory;
1-10-67
Side-dump of sugar beets
into the truck hopper at
the truck receiving
station.
Figure 30.
Ovid sugar factory;
1-10-67
Drop section in the open
discharge drain leading
to the South Platte River.
-------
tant in reducing wear and tear on the beets and the amount of sugar and
other materials eventually lost to the flume water. Waste load would
be proportionately affected.
At the Ovid factory, flume inlet water was supplied from the main
water supply and seal tanks, and an intermittent well supply. The rock
catcher installed in the flume system received return flume water from
the pump ahead of the beet washer. Water supply for the beet washer was
provided from three sources—drainage from the tailings screen on the
spray table, the main water supply line, and return from the crystall-
izers and seal tanks.
The waste flume water before entering the closed main sewer pass-
ed through a small sump for removal of gross settleable solids. The sump
was intended to provide protection of the solids recovery pump on the
roller spray table. A sand line drained the sump and discharged to
Lodgepole Creek. This was sampled at Station 45 as shown in Figures 27
and 28. Outside the main plant Station 44 was taken to represent waste
flume water, although additional wastes were undoubtedly present at this
point.
Beet Pulp
In December 1963, drying facilities were available only for about
two-thirds of the pulp produced. The remaining pulp was pressed and de-
posited into a pit for eventual use as cattle feed. Drainage from the
pulp pit discharged to an absorption ditch from which there was no sur-
face overflow.
Today, all pulp is reported to be pressed and dried at the Ovid
plant. However, Ovid is the last mill in the Basin using wet transport
of pulp to the presses . Although transport water is recirculated in
the pulp carrier system, some portion is probably wasted to the main
sewer.
Main Plant Sewer
The main sewer was sampled at Stations 42-43 as shown in Figure
27, and included waste flume water, floor washings, effluent from the
septic tank receiving domestic sewage, and miscellaneous wastes. Grab
samples taken on *-he main sewer were described as Station 43; composite
samples collected at the same point over the daytime shift (6-8 hours)
were designated as Station 42. Miscellaneous wastes included boilout
material from evaporators and vacuum pans. On the average, one pan was
cleaned every 12 hours, and one evaporator each week. The main plant
sewer eventually converted into an open discharge drain leading to the
South Platte River as shown in Figure 30.
38
-------
Waste Treatment
The impoundment of lime mud and disposal of pressed pulp drainage
onto the ground represented the only forms of waste treatment employed
by the Ovid sugar mill in December 1963.
Presentation and Discussion of Sampling Data
The average values of data collected from the Ovid mill survey are
given in Table VI.
The quality of raw water intake at Station 41 was shown quite sat-
isfactory for factory needs. As expected, concentrations of measured
waste variables at the Ovid mill increased many times between the point
of water intake and the end of the beet flume system (Station 44). From
Station 41 to Station 44, increases were as follows: COD from 25 to 640
mg/1; TSS from 78 to 1,300 mg/1; VSS from 9 to 270 mg/1; total coliform
bacteria from 7,700 to 9,800,000 organisms per 100 ml; and fecal coliform
bacteria from 227 to 159,000 organisms per 100 ml. The spent flume water
represented a major waste load from the Ovid factory.
The sand lime discharge at Station 45 and the spent flume water
at Station 44 were found to be essentially one and the same waste. The
sump in the flume system did not appear to provide any real degree of
protection for the solids recovery pump on the roller spray table, and
furthermore had no benefit whatsoever in pollution control.
Floor washings, sanitary sewage and miscellaneous plant inflows
did not cause appreciable change in waste concentration between Station
44 at the end of the waste flume and Stations 42-43 on the main sewer.
However, concentrations remained quite high and these were associated
with a greater waste flow and loading at the downstream location.
Recent Operational Changes
The truck receiving station installed at the Ovid factory may
have caused slight reduction over the unit waste volume and load ex-
perienced in December 1963. The new system should require less water
compared to the old lateral flumes and the elimination of some overhead
water. Additional pulp drying capacity completed in summer 1964 has
precluded handling of pressed pulp and the waste drainage associated
with this pulp.
The sugar company at present time is negotiating with the town
of Ovid for construction of municipal waste treatment facilities on a
cost-share basis. Under this arrangement, all domestic sewage from
the mill would be diverted from the factory drain to the sewage treat-
ment plant.
39
-------
TABLE VI
OVID SUGAR FACTORY
SUMMARY OF IN-PLANT DATA
December 7-16, 1963
Total Volatile Total
Flow (cfs) No. Suspended Suspended Alka- Conduc- Confirmed Fecal
Sta. Meas- Esti- of BOD COD Solids Solids linity tivity Temp. Coll. Bact. Coll. Bact. Station
No. ured mated Samples mg/1 7. me/1 % mg/1 % me/1 % me/1 % umhos pH °C MPN/100 ml % MFN/100 ml % Description
41
44
42 12.6
43 13.1
45
7 5 25 78 9 290 1630 7.8 7.1 7,700 227 Main Water Supply
28 640 1300 270 420 1550 8.2 23.4 9,800,000 159,000 North MH
100 110 90 170 100 MQ
8 500 (990) (2290) (340) (1050) 1540 8.5 MH No. 1 Composites
28 610 1440 250 710 1910 8.6 23.5 9,480,000 177,000 MH No. 1 Grabs
26 746 1216 226 323 1592 7.8 22.8 18,700,000 362,000 Sand Line
NOTE:
% - Remaining between stages.
Values in parenthesis not used in calculating percent remaining between stages.
-------
7. Brighton, Colorado
Process and Operation
The Brighton sugar factory was a straight-house operation with a
continuous diffuser and complete facilities for drying pulp. Wet pulp
was carried to the presses by conveyor belt and the press waters en-
tirely reused in the diffuser. Molasses was shipped to the Longmont
sugar mill for further sugar recovery. The Brighton establishment em-
ployed 70 to 75 persons on a permanent basis and 375 additional persons
during the campaign. The rate of processing averaged 2400 tons beets
per day over the 1964-1965 campaign.
Incoming sugar beets to the mill were received both by railroad
car and truck. Approximately 80 percent of total beets were brought in
from Kansas by railroad car. The remaining beets originated from Colo-
rado; three-fourths of these beets being received by truck and one-fourth
by railroad car. The beets in the railroad cars were deposited directly
into the wet hopper of the flume system. The trucks unloaded to the beet
piles or to the truck hopper. The truck hopper in turn was tied into the
original beet flume system. The railroad car and truck hopper flumes
subsequently combined into one header flume which transported the beets
inside the factory.
Lime mud was separately handled and stored in a holding pond with
no reported overflow. Ashes were flumed to an ash pit area and the li-
quid percolated into the ground. The relative locations of sampling
points employed for Brighton plant survey of January 1965 are illustrat-
ed in Figure 31.
Significant changes were incorporated in the waste abatement and
treatment system at the Brighton sugar factory in the summer of 1966.
These improvements are described later.
Plant Water Supply
In January 1965, the factory received water supply from the McCann
Canal, the South Platte River, the city of Brighton, and three company
wells. Water was diverted from the South Platte River and McCann Canal
into a supply pond and then pumped to the factory. Fond supply was util-
ized in the beet flume system and occasionally in the' diffuser. The
three wells operating on a 24-hour basis provided for needs of the dif-
fuser. Municipal water was employed only for domestic purposes. Pond
and well supplies at that time were rated at about 10-12 cfs, and 2 cfs
respectively. The pond and well supplies to the mill were sampled during
the January 1965 survey and designated as Stations 101 and 100, as shown
in Figure 31.
The waste handling and abatement system starting in October 1966
caused decrease in plant water use. Withdrawal from the water supply
pond is now believed in the range of 7-8 cfs, and the wells provide about
2.0-2.5 cfs.
41
-------
BRIGHTON
SUGAR
FACTORY
^\ x\
v*
o
PLANT
WELLS
STATION IOO
HIGHWAY 85
104
DAM
WASTE
TREATMENT
LAGOON
ACCESS DITCH TO / FROM
SOUTH PLATTE RIVER
SOUTH PLATTE RIVER
,103
BRIGHTON SUGAR FACTORY
PLANT AREA
JANUARY, 1965
FIGURE 31
-------
Beet Flume System and Waste Flume Water
In January 1965, all incoming beets were delivered by railroad
car, dosed with overhead spray water, and deposited directly into the
wet hopper of the flume system. The truck hopper was not used during
the January 1965 survey. The truck hopper, when in operation, was
served by a secondary flume as shown in Figure 32. The apparent ad-
vantages of end-unloading trucks over side-unloading have been mentioned
previously.
About 40 percent of the waste flume water was recirculated in the
beet flume system in January 1965. The new waste handling scheme in
effect as of October 1966 provides now for 100 percent return of waste
flume water.
Lime Mud Waste
Lime mud slurry was pumped to a separate 5-acre holding pond lo-
cated next to the South Platte River. An overflow line available from
the pond to the River could be used infrequently. It is known that an
accidental discharge of lime mud to the River occurred in December 1966
following a break in the pond walls. The duration and extent of this
spill were not documented.
Ashes
The residual ashes from coal-burning at the Brighton plant were
flumed by condenser water into an ash pit. A high rate of percolation
precluded any surface water overflow from this site. Some questions
have been raised about the possibility of ground-water contamination
in the vicinity of the ash pit, but evidence for this condition has not
been found.
Main Plant Sewer and Old Waste Treatment System
In January 1965, all wastes from the Brighton sugar factory ex-
cluding lime mud, ashes, and domestic sewage were collected into the
main plant sewer and then carried either to a waste treatment lagoon, or
directly into the McCann Canal for disposal as depicted in Figure 31.
Domestic sewage from the mill discharged to the municipal sewers. The
industrial wastes in the McCann Canal were directed to the South Flatte
River via a discharge drain a short distance below the mill. The waste-
water in the discharge drain was sampled at Station 102. The treatment
lagoon covered approximately 10 acres in area and varied in depth from a
few inches up to 3 feet. The lagoon was greatly limited in volume and,
as a result, provisions were available for frequent waste releases to
both the McCann Canal and the South Platte River. Overflow structures
were located on the north and east sides of the pond. The remaining
pond contents were disposed of by evaporation, percolation and under-
drainage to the River, or direct spillage to the River following the
not infrequent breaks in the pond walls. Waste treatment prior to
42
-------
October 1966 was considered far from adequate. The January 1965 waste
survey of course did not reflect the later changes made at the Brighton
mill, but did offer a basis of comparison upon which these changes
could be evaluated.
Presentation and Discussion of Sampling Data
The average values of data collected from the Brighton survey of
January 1965 are given in Table VII. The results at Stations 100 and
101 indicated the well and pond water supplies were both of reasonably
good quality. Bacterial densities, particularly fecal streptococci, in
the pond supply were, however, somewhat higher than expected. The dis-
charge drain at Station 102 was comprised entirely of factory wastes
being released to McCann Canal. This wastewater was extremely high in
organic material, suspended solids and bacterial content, and very low
in available oxygen. During the January 1965 study at least some part
of the main sewer wastes from the factory were believed retained in the
waste treatment lagoon. Therefore, the discharge drain did not repre-
sent all, but rather some portion of the total factory wastes. These
results may or may not have reflected the minimum waste loads discharged
by the Brighton mill to the South Platte River over the 1964-1965 cam-
paign.
The South Platte River reaching Brighton, Colorado, in 1965 and
previous years was in essence an open sewer receiving heavy waste loads
from Denver and other communities. This condition was verified by re-
sults from Station 103 immediately above Brighton. The sugar mill op-
erations in January 1965 caused further severe degradation of the River
reflected by sampling results below the mill at Station 104. Over this
three and one-half miles of River, BOD increased from 77 to 112 mg/1,
TSS-from 122 to 391 mg/1, total coliform bacteria from 3.3 to 4.6 million
per 100 ml, and fecal coliform from 0.79 to 1.7 million per 100 ml.
Also, dissolved oxygen decreased from 3.1 to 1.6 mg/1. Most, if not all
the change, was attributed to the Brighton sugar factory waste effluents.
The new waste handling system at the Brighton sugar factory and recent
completion of the Metropolitan Denver Sewage Disposal District No. 1
treatment facilities, are two major factors leading to the present re-
covery of the South Platte River in and below Metropolitan Denver.
New Waste Treatment System
The waste handling system recently installed at the Brighton mill
essentially provides for the recirculation, treatment, and complete re-
use of waste flume waters within the factory. The basic units consist
of a pump station for directing flume water to and from the treatment
basins, two vibrating screens for removing waste solids and debris, and
three ponds in series for treating and maintaining a proper flow balance
within the circuit. Some condenser water is bled into the circuit but
the majority is discharged to a spray pond with subsequent overflow to
the South Platte River. Excess water built up in the flume water cir-
cuit and spillage are transferred to a 10-acre storage pond. The
43
-------
Figure 32.
Brighton sugar factory; 1-12-67
End-dumping of sugar beets into the
truck hopper at the truck receiving
station.
Figure 34.
Brighton sugar factory; 12-28-66
Dual vibrating screens removing
tailings from waste flume water
before entering the recirculation
basins.
-------
PLANT
WELLS
RECIRCULATION PONDS
BRIGHTON
SUGAR
FACTORY
SOUTH PLATTE RIVER
BRIGHTON SUGAR FACTORY
PLANT AREA
1966 - 1967
FIGURE 33
-------
Brighton system initiated in October 1966 is illustrated by Figure 33.
This system is described in detail since it is believed a forerunner
of treatment facilities to be made available at many sugar mills in
the not too distant future.
Waste flume water at the Brighton plant includes the beet washer
and spray table effluents, floor drainage and miscellaneous wastes.
Lime mud, ashes, and sanitary sewage are separately disposed of as be-
fore. The main plant sewer wastes drain to the pump station and are
lifted over the vibrating screens having 1/8 by 5/8-inch openings and
the screened waters enter the recirculation treatment basins. The
screens together with the solids removed are shown in Figure 34. These
solids, amounting to about 30 tons per day (wet), are sold to local
farmers at $2 per ton and used as livestock feed.
The three recirculation basins cover a total area of 6 acres in-
cluding dikes, and the maximum capacity before filling with solids was
approximately 6 million gallons. Compartment A is the largest of the
three ponds, and the wastes are circulated in a horseshoe-shaped circuit.
The east, south, and west loops of compartment A are shown respectively
in Figures 35, 36, and 37. The wastewater then flows consecutively
through the inner compartments B and C, shown by Figure 33, is col-
lected and returned to the pump station. The stabilized wastewater is
entirely reused as water supply to the wet hopper below the railroad
car receiving station, and also for the beet washer.
The recirculation chambers are designed for solids settling and
therein lies a problem. The Brighton system was not equipped for auto-
matic removal of solids and the solids level builds up rapidly, causing
considerable reduction in the effective settling volume. Prior to mid-
January 1967, the accumulated solids have been removed only one time
(by dragline) and deposited on the dikes surrounding the outer recir-
culation pond. Scum and floatable solids on the pond surface may create
other difficulties such as reduction of surface aeration, odor, etc.
Compartment A is provided with a safety or overflow which can discharge
directly into the McCann Canal. There was no indication of overflow
during the 1966-1967 campaign.
Substantial quantities of various chemicals are added to the re-
circulation treatment ponds to counteract low pH levels and odorous con-
ditions. Chemical requirements for the duration of the 1966-1967 cam-
paign were estimated in the order of 19 tons caustic soda, 1000 tons of
lime as CaC03, and HTH (chlorine) added intermittently at the rate of
25 pounds per day. Also, 73 tons of coke were necessary in converting
limestone into usable lime in the form of CaO. Odors appear more criti-
cal within the pump station rather than the ponds but have presented no
large problems to date.
Excess condenser waters from the plant are cooled and recondi-
tioned within a spray pond which overflows to a discharge drain to the
South Platte River. Although appearance of this drain was not good,
44
-------
Figure 35.
Brighton sugar factory;
12-28-66
East leg of Compartment A
in the recirculation pond
system. Main factory shown
at upper right of picture.
Figure 36.
Brighton sugar factory;
12-28-66
South leg of Compartment A
in the recirculation pond
system in foreground. Inner
Compartments B and C shown
in upper left and right sides
of picture, respectively.
Figure 37.
Brighton sugar factory;
1-12-67
West leg of Compartment A in
the recirculation pond system.
Note heavy scum layer on pond
surface and safety or overflow
structure at lower left hand
corner of picture.
-------
the waters were found reasonably low in waste content, indicated by
later results. The rate of condenser water discharge to the River is
believed around 6-10 cfs.
The 10-acre pond used as a treatment lagoon prior to October
1966 has now been converted into a storage pond for holding excess
volume from the flume water recirculation circuit, together with spills
and accidental discharges. Liquid depths probably range from a few
inches up to 4 or so feet in the pond. Two undesirable features under-
lie this part of the system. First, the pump used for transfer of
waste material to the storage pond is undersized and improperly main-
tained, causing waste drainage into McCann Canal. Second, the rate
of percolation from the storage pond into the South Platte River is
believed significant, probably resulting in appreciable waste load
introduced to the River via this means. Furthermore, the overflow
device from the north side of the pond continues to exist and may
cause additional discharge to the River. The storage pond and the
adjacent lime pond are illustrated by Figure 38.
Figure 38.
Brighton sugar factory; 1-12-67.
Storage pond at center, and lime mud pond at
left. Inlet to storage pond shown entering
from right side of picture. Note bridge
crossing South Platte River in center background.
Both on October 21 and November 12, 1966, the single pump for
transferring waste flume water from the sugar factory to the recircu-
lation treatment ponds became inoperative. Consequently this waste
volume was diverted to the pump station serving the storage pond. This
second pump was unable to handle the large volume and one-half or more
of the waste was thereby released to McCann Canal and eventually to the
South Platte River. The waste flume pump was down 48 hours on the first
occasion and 12 hours on the second. Since that time, the company has
installed a second flume water transfer pump.
45
-------
TABLE VII
SUMMARY OF DATA FOR
BRIGHTON SUGAR FACTORY
AND SOUTH PLATTE RIVER
January 4-8, 1965
Sta.
No.
100
101
102
103
104
Flow (cfs) No.
Meas- Esti- of BOD COD
ured mated Samples rag/1 mg/1
22 16
(Grabs)
11 4 4 17
(Grabs)
4.9 10 935
(Grabs)
105 7 77 97
(Grabs)
115 7 112 151
(Grabs)
Total
Suspended
Solids
ma/1
6
17
2,040
122
391
Volatile
Suspended
Solids
mg/1
5
11
390
75
134
Total
Alka- Conduc-
linity tivity Temp.
mg/1 umhos °C
Sugar Mill
279 1520 26.8
310 1350 4.3
1510 25.4
South Flatte River
290 1260 5.4
310 1370 5.5
Dis-
solved Confirmed Fecal Fecal
Oxygen Coll. Bact. Coll. Bact. Strep. Station
PH ma/I MPN/100 ml MPN/100 ml No./lOO ml Description
7.6 --- <3 <3 --- Well water
7.9 11.3 12,000 2,300 11,000 Water sup-
ply pond
7.0 1.0 19,500,000 4,100,000 11,000,000 Discharge
drain to
So. Platte
River after
receiving
McCann Ca-
nal wastes.
7.7 3.1 3,300,000 790,000 260,000 At State
Hwy. 7
bridge,
Brighton
7.6 1.6 4,600,000 1,700,000 1,600,000 At Watten-
burg Road
bridge, N.
of Brighton
-------
The sugar company is preparing an evaluation report of the
Brighton waste handling system. The company has collected analytical
data on various waste characteristics within the system, the spray
pond, McCann Canal and the South Platte River above and below the
Brighton factory. Unfortunately these results were not available to
the Project at the time of this writing. However, the Project in
January 1967 did collect a few samples in the area of the spray pond
and drainage ditch; sampling stations are shown in Figure 33.
The January 1967 data are presented in Table VIII, but must be
considered as preliminary to the sugar company report:
TABLE VIII
BRIGHTON SUGAR FACTORY SAMPLING
January 12-13, 1967
Number
Sta. of BOD
No. Samples mg/1
Total
Suspended
Solids
mg/1
Confirmed Fecal
Temp Coli.Bact. Coli.Bact. Station
°C MPN/100 ml MPN/100 ml Description
105
106
107
10
41
22
32
2.8 3,950
22.0 12,000
23.0 9,450
170 McCann Canal
above spray
pond.
7 Spray pond
overflow to
discharge
drain.
4 Discharge
drain flow
into South
Platte River,
The Brighton system, patterned after the Fremont and Findlay, Ohio
sugar plants, operates on the basic principle of minimizing excess waste-
water in the recirculation circuit as much as possible. The company es-
timated the capital cost of the Brighton system (excluding cost of land
which was already available) around $160,000. At this stage of evalua-
tion, the system would appear to have performed quite well and with a
high degree of success in removing the serious pollution acknowledged in
January 1965. The present picture would seem to indicate better than 90
percent reduction in waste loads compared to the previous period.
The company has indicated future improvements to be made in the
Brighton system as follows: a) enlargement of compartment A; b) enlarge-
ment of the spray pond together with additional sprays provided; and
c) levelling of the storage pond with provision for greater capacity.
47
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8. Longmont, Colorado
Process and Operation
The Longmont factory compared in size and complexity to the Love-
land and Fort Morgan mills. The Longmont installation included a
Steffen house with a continuous diffuser and complete pulp-drying fac-
ilities. Wet pulp was carried to the presses by conveyor belt with press
waters entirely reused in the diffuser. Molasses was received from the
Brighton and Greeley mills; the average input was 186 tons per day over
the 1965-1966 campaign. Residual material in the Steffen house was hy-
drolyzed and evaporated to produce CSF, eventually shipped to the Johns-
town, Colorado recovery operations. The Longmont factory processed an
average of 3570 tons sugar beets per day during the 1965-1966 campaign.
The plant received about 90 percent of raw sugar beets by rail-
road car and the remaining 10 percent by truck. Approximately 72 per-
cent of the incoming beets originated from Colorado, 20 percent from
Kansas, and 8 percent from Texas. Beets received by railroad car were
dosed with overhead water when necessary, and deposited directly into
the wet hopper and beet flume system. Trucked beets were stored in the
factory yard for later retrieval.
An extensive waste survey was conducted at the Longmont plant in
November 1965. At that time lime mud wastes were separately impounded,
but there was no other treatment of factory wastes. A follow-up study
conducted in November 1966 reflected changes following the construction
of a treatment lagoon for total plant wastes. The results of both
studies are given in this report. The relative locations of sampling
points are given in Figure 39.
Plant Water Supply
Factory water supply was obtained from St. Vrain Creek together
with relatively small amounts from the city of Longmont. Intake from
the stream approximated 18 to 20 cfs, and the city supply directed to
diffuser makeup and other special needs was in the order of 1 cfs.
During the campaign, the complete flow of St. Vrain Creek was diverted
into a factory water supply canal. Essential water for the factory
was stored in a supply pond and the excess water returned to St. Vrain
Creek as shown in Figure 39. Effluents from the city of Longmont sewage
treatment plant were disposed of either into the factory water supply
canal, as illustrated in Figure 40, or otherwise to St. Vrain Creek.
The water intake line from the supply pond into the factory was sampled
in 1965 at Station 110.
Beet Flume System and Waste Flume Water
Two separate flumes, one serving the railroad car receiving sta-
tion and the other for the beet piles in the yard, combined into a single
system for transporting the beets into the factory. Beets were trans-
48
-------
X A X X X
LONGMONT
LONGMONT
BEET SUGAR
FACTORY
BOULDER
114 CREEK
(1965)
WASTE
LAGOON
IN 1966
LONGMONT
STP
EFFLUENT
WATER
SUPPLY
POND
DISCHARGE
DRAIN
COUNTY
LINE
ROAD
EARTHEN
DAM
FEED
LOT
LONGMONT SUGAR FACTORY
GENERAL AREA
NOVEMBER 1965 AND 1966
FIGURE 39
-------
ferred from the piles into the flume by an end-loader. Flume inlet water
was derived from the main water supply and seal tanks. No recirculation
was provided in the Longmont flume system.
Figure 40.
Longmont sugar factory; 1-18-67.
Factory water supply canal receiving St. Vrain
Creek waters. Note Longmont sewage treatment
plant effluents entering canal from left side.
Lime Mud Waste
Lime mud slurry was pumped to a separate holding pond with no
reported overflow. However, in November 1966, Project personnel found
a line from the lime mud pond leading to the open ditch above the waste
lagoon. The company declared this was a case of accidental discharge;
nevertheless this line has neither been removed nor permanently sealed.
Ashes
Ashes resulting from coal-burning at the Longmont sugar factory
were flumed with main supply tank water to an ash pit with no reported
overflow. The high rate of percolation evidently precluded any surface
runoff.
Main Plant Sewer and Open Ditch
The main plant sewer was sampled adjacent to the factory and des-
ignated as Station 111. With the exception of lime mud, the main sewer
received all plant wastes plus domestic sewage. The main sewer convert-
ed into an open ditch some distance from the factory, and total plant
wastes carried to the treatment lagoon constructed in 1966.
49
-------
Waste Treatment
Total plant wastes were passed through a waste treatment lagoon
covering approximately 14 acres in area. Continuous overflow from the
lagoon was released to the discharge drain and then to St. Vrain Creek.
The influent and effluent ends of the lagoon were recently observed
as shown in Figures 41 and 42. The waste flowed in rapid fashion
through the upper half of the basin, whereas the lower end was clogged
with solids thereby resulting in short-circuiting and incomplete treat-
ment. This means of treatment at best must be considered only a stop-
gap measure.
Discharge Drain to Receiving Stream
The discharge drain leading to St. Vrain Creek was sampled at
Station 112 in 1965, and at Station 115 during 1966. Since the early
survey was prior to the treatment lagoon, results at Station 112 re-
flected conditions of no waste treatment. Data at Station 115 reflect-
ed changes with the treatment lagoon in place.
St. Vrain Creek
Both the 1965 and 1966 surveys included sampling of St. Vrain
Creek at Station 113 immediately above the Longmont discharge drain as
shown by Figure 39. St. Vrain Creek was also sampled below the sugar
mill at Station 114 in 1965, and at Station 116 in 1966. These two
stations were approximately 4 miles below the factory discharge drain.
St. Vrain Creek through the Longmont area was affected by other
factors upstream of the sugar mill. The Longmont sewage plant provided
reasonable secondary waste treatment except for high bacterial densities
in their effluents. Important waste loads into St. Vrain Creek were
also contributed by the Kuner Empson cannery, a municipal storm sewer
south of the cannery, and the Ludlow Cattle Company feedlot.
Presentation and Discussion of Sampling Data
The average values of data collected during both the 1965 and
1966 surveys for Longmont are given in Table IX. Two important obser-
vations must be made prior to a data interpretation. First, in Novem-
ber 1965, the samples collected on the main plant sewer at Station 111
were judged to be not truly representative, and therefore the results
were discounted. Secondly, in November 1966, sampling at Station 115
was believed to reflect, in part, lime mud being released from the lime
pond eventually passing through the waste treatment lagoon.
With reference to Table IX, the factory water intake (Station
110) was found to be of fair quality. Dissolved oxygen, suspended
solids and mineral content were satisfactory, but BOD and bacterial
content definitely indicated the presence of upstream wastes.
50
-------
Figure 41.
Longmont sugar factory;
11-15-66
Inlet area of waste treatment
lagoon. Note heavy weed growth,
and channeling of waste flow.
Figure 42.
Longmont sugar factory;
11-15-66
Lower end of waste treatment
lagoon and overflow structure.
Poor solids separation, septic
and odorous conditions were
experienced at this sifce.
-------
The total wastes from the Longmont sugar factory represented a
very large waste load imposed on St. Vrain Creek. The waste strength
was lower in comparison to the other mills because of the large volume
of water used. The 1965 data at Station 112 prior in time to the waste
lagoon showed the total plant wastes with 320 mg/1 BOD, 1750 mg/1 TSS,
a temperature of 39.2°C, pH of 8.3, 2.3 mg/1 dissolved oxygen, and tot-
al and fecal coliform bacteria respectively of 490,000 and 17,500 organ-
isms per 100 ml.
The completion of the waste treatment lagoon in 1966 appears to
have produced mixed results on the total wastes subsequently released
to the stream (Station 115). Suspended solids and temperature were
significantly lowered, but dissolved organic and bacterial content re-
mained the same or even increased. The drop in pH level from 8.3 to
7.5 was attributed to anaerobic decomposition in the treatment lagoon.
Although dissolved oxygen was not taken in 1966, all indications pointed
to septicity in the treated wastes; and there was good reason to expect
odors in the general area of the lagoon. The increase in coliform bac-
teria or aftergrowth was believed due to favorable environmental condi-
tions within the treatment lagoon. Retention was too short to produce
bacterial reductions. Total wastes discharged to St. Vrain Creek in
1966 showed 340 mg/1 BOD, 470 mg/1 TSS, and total and fecal coliform
bacteria respectively of 4,600,000 and 515,000 organisms per 100 ml.
St. Vrain Creek above the Longmont factory (Station 113) was of
fair to poor quality. The average flow was 25 cfs in 1965 and approxi-
mately 6 cfs in 1966. In 1965, the stream contained 9 mg/1 BOD, 8.3
mg/1 dissolved oxygen, and total and fecal coliform bacteria respective-
ly of 790,000 and 71,500 organisms per 100 ml. In 1966, values were as
follows: 20 mg/1 BOD, 2.5 mg/1 dissolved oxygen, and total and fecal
coliform bacteria respectively of 3,300,000 and 330,000 organisms per
100 ml. Clearly, the water quality situation above the Longmont fac-
tory was not a good one and was severely restricted by the lack of dilu-
tion water in the stream system. The ability of the sugar company to
completely dry up the natural watercourse below the factory intake canal
was rather surprising.
Below the sugar factory (Stations 114 and 116), St. Vrain Creek
waters were of exceptionally poor quality. The stream contained high
organic, suspended solids and bacterial loads, and lack of sufficient
dissolved oxygen. In 1966, Station 116 on St. Vrain Creek showed waste
levels of 107 mg/1 BOD, 95 mg/1 TSS, 2.2 million total coliform per 100
ml, and a complete absence of dissolved oxygen in the stream.
Acceptable stream water quality through the Longmont area can
only be achieved in the future by greatly reducing waste loads not only
from the sugar factory but other sources as well. Also, a water resources
management plan for protection of all present and future needs must be
provided. This management plan for achieving desirable water quality
will probably require additional stream flows to be made available
throughout the system.
51
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TABLE IX
SUMMARY OF DATA FOR
LONGMONT SUGAR FACTORY
AND ST. VRAIN CREEK
November 1-5, 1965 and
October 31 - November 15, 1966
Total Volatile Total Dis-
Flow (cfs) No. Suspended Suspended Alka- Conduc- solved Confirmed Fecal Fecal
Sta Meas- Esti- of BOD COD Solids Solids linity tivity Temp. Oxygen Coll. Bact. Coll. Bact. Strep. Station
No. Period ured mated Samples mg/1 me/1 mg/1 me/1 mg/1 umhos °C pH mg/1 MPN/100 ml MPN/100 ml No./lOO ml Description
110 1965 --- 19 6 12 20 18
(Grabs)
111 " 20.5 --- 4 290 390 990
(24-hr. Composites)
112 " 21.0 --- 14 320 420 1750
(Grabs)
Sugar Mill
12 240 1350 8.7 8.1 9.0 41,000
181
250 1280
8.8 ---
250 228 1370 39.2 8.3 2.3 490,000
2,300 7,200 Intake from water
supply pond
Main plant sewer
17,500 6,350,000 Discharge drain
115 1966
4 340 525
(Grabs)
470
119 310 1520 28.5 7.5 --- 4,600,000
515,000
Discharge drain
113 1965 25.2
114
46.2
10 9 19 18
(Grabs)
10 42 74 450
(Grabs)
St. Vrain Creek
11 229 1360 10.4 8.1 83 790,000
102 270 1600 15.0 7.8 0.7 490,000
71,500 22,000 Imm. above sugar
factory discharge
drain
94,500 1,100,000 Below factory and
above Boulder Cr.
113 1966
116
63 20 81 25
(Grabs)
3 107 240 95
(Grabs)
20 243 1510 13.0 7.8 2.5 3,300,000 330,000
42 247 1750 16.8 7.7 0.0 2,200,000 130,000
Imm. above sugar
factory discharge
drain
Below factory and
below Boulder Cr.
-------
Recent Operational Changes
A major change in waste abatement is planned for the Longmont
sugar factory. The company, in 1968, will construct a waste recir-
culation system followed by anaerobic and/or aerobic polishing ponds.
The project will be supported in part by Demonstration Grant funds of
the Federal Water Pollution Control Administration. There is overall
optimism that this system will solve most if not all the waste problems
presently experienced at the Longmont mill.
9. Eaton, Colorado
Process and Operation
The Eaton sugar factory was a straight-house operation with a
continuous diffuser, and complete pulp drying facilities. It must be
noted that the pulp dryer was installed in the summer of 1966 follow-
ing the waste survey of November 1965. Therefore, the survey reflected
prior conditions of wet pulp handling and storage. The Eaton mill pro-
cessed an average of 2135 tons beets per day during the 1965-1966 cam-
paign. Molasses was shipped to the Loveland factory.
Over the 1965-1966 campaign, the mill received sugar beets both
by railroad car and truck. Beets were unloaded from the railroad cars
directly into the flume. Trucked beets were stored in the factory yard;
beets were retrieved from the piles by means of lateral flumes. Sugar
beets are now totally received by truck. Lime mud was separately stored
in a large pond with no reported or apparent overflow. The relative lo-
cations of sampling points for the Eaton survey both at the plant and on
the receiving stream are shown in Figure 43.
Plant Water Supply
The large majority of plant water supply was obtained from com-
pany wells. Well water was delivered to a spray pond. The pond also
received condenser water from the plant and some flow from Eaton Draw.
The spray pond served to cool and recondition the condenser waters be-
fore their reuse in the factory. Mixed waters were then transferred to
the main water supply tank within the factory. Water for domestic needs
was received from the city and amounted to about 400,000 gallons per
month. Total plant water use at the time of survey approximated 5 cfs.
Beet Flume System and Waste Flume Water
Most of the incoming sugar beets are now unloaded from trucks
directly into a truck hopper. Beets are moved from the storage piles
by front loaders into the lateral flumes as shown by Figure 44. The
truck hopper joins the original flume system immediately adjacent to
the main factory.
53
-------
The beet flume received water from the main water supply and seal
tanks. The plant employed 20-25 percent recirculation of waste flume
water following the beet washer and roller spray table, back to the
flume inlet.
Beet Pulp and Pulp Silo
Drainage from the wet pulp silo existing at the time of survey
entered the plant discharge drain. Fanger screen water from the silo
returned to the beet flume. The pulp silo drainage was independently
sampled at Station 121 as shown in Figure 43.
Under present operation, wet pulp and the pulp silo have been
eliminated. The exhausted pulp from the diffuser is conveyed to the
press via scroll without transport water, and the press waters are
entirely reused in the diffuser.
Ashes
The burning of coal for power and heat within the Eaton mill
produced ashes which were carried by condenser water to a ponded area
located adjacent to the plant discharge drain. No overflow was re-
ported but the possiblity of underdrainage could not be excluded.
Main Plant Sewer and Discharge Drain
The main plant sewer converted into an open discharge drain after
leaving the factory. The main sewer received all plant wastes excluding
the lime mud, pulp silo drainage, and sanitary sewage. Domestic wastes
discharged to the municipal sewer.
The discharge drain was sampled in November 1965 at two loca-
tions. Station 120 was located close to the factory. Station 122
was situated at the end of the drain below the pulp silo drainage
line, and immediately before the total plant wastes entered Eaton
Draw. The discharge drain is shown in Figure 45.
Waste Treatment
The only waste treatment provided by the Eaton mill in November
1965 was the separate handling and storage of lime mud. The water con-
servation practices within the plant of condenser water reuse, recircu-
lation of waste flume water, and close regulation of the well water
supply undoubtedly served in some degree towards reducing waste volumes
and possibly waste loads. However, these procedures were not, per se,
waste treatment measures.
Eaton Draw
Eaton Draw, originating north of Eaton and extending south five
miles to the Cache la Poudre River, served as the waste receiving stream
54
-------
EATON BEET
SUGAR FACTORY
MA|N.
-— . 120
SEWER
EATON STORM ^
^^^g^^TZ^^^^^^^^^^^^^^^^^^^
SEWER
126
124
EATON STP
EFFLUENT
CACHE LA POUPRE RIVER
GREELEY
EATON SUGAR FACTORY
GENERAL AREA
NOVEMBER, 1965
FIGURE 43
-------
Figure 44.
Eaton sugar factory; 1-6-67
Sugar beets being transferred by
front-loader from storage pile
into the lateral flumes. Note
abandoned high-line system.
Figure 45.
Eaton sugar factory; 1-6-67
Discharge drain from Eaton mill
before entering Eaton Draw. Ash
pond shown in right background.
-------
in the area. Eaton Draw was also used during the summertime to convey
irrigation water within certain sections. In addition to the sugar fac-
tory effluents, Eaton Draw received various wastes from the municipal
sewage treatment plant in Eaton, a storm sewer in the town, two feedlots
south of Eaton, and other agricultural enterprises. The November 1965
survey included sampling of the Eaton storm sewer at Station 126, the
municipal sewage treatment plant effluents at Station 127, and four
points on Eaton Draw as follows: Station 123 immediately above the
sugar factory spray pond, Station 124 below the sugar factory discharge,
Station 125 adjacent to the Cache la Poudre No. 1 irrigation canal, and
Station 64 at the mouth of Eaton Draw. These stations are shown in Fig-
ure 43.
Presentation and Discussion of Sampling Data
Average values of data received from the Eaton survey are given
in Table X.
The on-site survey data for the Eaton sugar mill were represent-
ed by Stations 120, 121, and 122. The main sewer flows at Station 120
were relatively high in waste concentration commensurate with a low
water use within the plant. Suspended solids levels averaged 3020 mg/1.
Pulp silo drainage at Station 121, although of limited volume, was very
high in waste strength and acidic in nature. The BOD level was greater
than 7200 mg/1, and COD approximated 11,600 mg/1. Bacterial densities
were surprisingly high considering the low pH levels. Pulp silo drain-
age contributed about 40 percent of the BOD and COD loads found in the
plant discharge drain. Total plant wastes at Station 122 showed 860
mg/1 BOD, 1430 mg/1 COD, 3320 mg/1 TSS, a temperature of 35.3°C (96°F),
only 0.3 mg/1 dissolved oxygen, total coliform bacteria of 33,000,000
per 100 ml, and fecal coliform bacteria of 640,000 per 100 ml.
Eaton Draw was sampled at Stations 123, 124, 125, and 64. The
flow data indicated that Eaton Draw in large part consisted of sugar
factory effluents and the remainder_ originated from the Eaton storm
sewer and municipal sewage treatment plant. Eaton Draw may be described
as a conveyance means for disposing large amounts of organic and solid
waste material into the Cache la Poudre River at Greeley.
The small flow of water in the upper end of Eaton Draw at Station
123 was somewhat high in mineral content but otherwise of fair quality.
The stream at Station 124 below the Eaton sugar factory strongly re-
flected the waste discharge from the mill. Waste concentrations in the
Draw were only slightly lower than found in the total wastewater leaving
the factory and the dissolved oxygen level of 0.3 mg/1 indicated near
septic conditions.
Inadequately treated wastes from the community of Eaton served to
augment severe conditions in the Draw. Agricultural enterprises in the
area besides the sugar beet mill may have intensified the waste picture.
Station 125, located four miles from the mouth of Eaton Draw, and Sta-
55
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TABLE X
SUMMARY OF DATA FOR
EATON SUGAR FACTORY
AND EATON DRAW
November 15-19, 1965
Sta.
No
120
121
122
123
124
125
64
Flow
Meas-
ured
4.37
0.11
4.48
0 50
5.14
5 39
5 68
(cfs) No
Esti- of BOD
4 560
(Composites)
15 > 7200
(Grabs)
15 860
10 <15
(Grabs)
10 > 580
(Grabs)
15 700
(Grabs)
10 >580
(Grabs)
COD
ms/1
980
11,600
1,430
56
860
930
760
Total
Suspended
Solids
HIR/1
3020
340
3320
104
3150
2480
2400
Volatile
Suspended
Solids
mR/1
610
250
630
32
820
520
540
Total
Alka-
linity
mg/l
388
...
350
350
360
340
430
Dis-
Conduc- solved
tivity
umhos
Sugar
2170
2500
1800
Eaton
1560
2040
2000
1980
Temp . Oxygen
°C PH mR/1
Mill
7.9
35.5 4.2
35.3 6 8 0.3
Draw
22.1 8.2 6.4
31.6 7 0 0.3
23.7 6.9 0.0
17.7 7.5 0.0
Confirmed — /
Coll. Bact.
MPN/100 ml
3,300,000
33,000,000
7,450
29,000,000
94,500,000
330,000,000
Fecal
Coll. Bact
MPN/100 ml
250,000 $1
640,000 -1
410 -1
380,000 -1
3,650,000 -1
4,900,000 -1
Station Description
Main plant sewer
Pulp silo drainage
Total plant wastes, discharge
drain at mouth
Imm. above spray pond
Below sugar mill at Galeton
Road
Near Cache la Poudre No. 1 Canal
At mouth
Eaton Storm Sewer
126
0.23
5 49
(Grabs)
85
322
85
1570
Eaton STP
127
0 44
15 100
(Grabs)
118
99
53
470
2580
11.8 7.8
Effluent
14.6 7 7
23,000,000
15,000,000
30,000
5,950,000 £/
Near Galeton Road
a/ Median Fecal Strep density was 57,000,000 per 100 ml.
b_/ Median Fecal Strep density was 62,000,000 per 100 ml.
cj Median Fecal Strep density was 15,000 per 100 ml.
d_/ Median Fecal Strep density was 63,000,000 per 100 ml.
e/ Median Fecal Strep density was 137,500,000 per 100 ml.
^/ Median Fecal Strep density was 150,500,000 per 100 ml.
£/ Median Fecal Strep density was 1,100,000 per 100 ml.
-------
tion 64 at the mouth, more or less showed the same waste pattern as
directly below Eaton. The BOD and solids levels remained very high and
dissolved oxygen was completely absent at these two stations. Total
and fecal coliform bacteria continued to increase throughout the entire
distance from Eaton to Greeley. Eaton Draw at Greeley contained 330
million total coliform and 4.9 million fecal coliform bacteria per 100
ml. Bacterial regrowth undoubtedly occurred, aided by a favorable en-
vironment and the presence of large amounts of inadequately treated wastes.
Recent Operational Changes
There has been considerable change at the Eaton factory since the
time of the November 1965 survey. Complete pulp-drying facilities and
elimination of the pulp silo with associated drainage represents an im-
portant first step in waste abatement at the Eaton mill. In-plant water
conservation practices have served in some degree to reduce the waste
problems. More important, these practices should minimize the costs of
extensive waste treatment required in the future. Management indicates
that the Eaton sugar factory will install a waste treatment system sim-
ilar to the Brighton mill.
10. Johnstown, Colorado
Process and Operation
The Johnstown, Colorado operations comprised two separate plants
--the sugar recovery house and the MSG (monosodium glutamate) establish-
ment. The two plants, although distinct, were more or less dependent on
each other. The following information on process description for the
Johnstown factory has been derived from McGinnis on "Beet Sugar Tech-
nology" (17) and from correspondence with the sugar company.
The Sugar Recovery House originally built in 1926, employs the
barium saccharate process for final extraction of sugar from discard mo-
lasses. The molasses is received from five Steffen houses. The Johnstown
plant is the only one of its type in the Western Hemisphere. The proce-
dures within the barium plant are similar in many respects to those in a
conventional Steffen house. Major differences however are the use of
barium hydrate in place of calcium oxide and the economic necessity of
recovering and reusing the barium salt in maximum degree. The barium
saccharate process is much more specific than the Steffen process to-
wards eliminating raffinose, and undesirable sugar, together with other
impurities. The barium plant was ideally suited for the South Platte
River Basin because the discard molasses produced over the Rocky Mountain
region contains relatively large amounts of raffinose.
The barium saccharate process at Johnstown is divided into two
main operations: the regeneration of barium carbonate, and the precipita-
tion of sugar from discard molasses by barium hydrate. A schematic show-
ing the major operations at the barium plant is given by the upper half
of Figure 46.
57
-------
The barium regeneration cycle is started with witherite (natural-
ly occurring barium hydrate) and sand (silica) in the ratio of 3:1, the
mixture being fed to a rotary kiln. Carbon dioxide is driven off and a
clinker remains. The clinker is fed with water to a ball mill and in
this operation approximately two-thirds of the BaO is leached from the
clinker into the water; the solids residue consists of BaO'Si02- The
effluent from the ball mill is then sent to a series of thickener tanks.
The liquid overflow from the tanks is collected and cooled to produce
barium hydrate slurry. The slurry is filtered; the crystals are saved
and the filtrate and wash which also contain BaO are returned to the
ball mill.
The used barium carbonate from the sugar house is mixed with the
sludge (BaO'Si02) recovered from the thickener tanks (to which barium
sulfate is added to make up losses) and this slurry is filtered. The
filter cake constitutes the basic feed to the rotary kiln and the re-
generation cycle is renewed. Barium hydroxide may also be added to the
kiln to make up barium losses in the circuit.
In the sugar recovery operations, discard molasses is mixed with
barium hydrate liquid and heated to about 80°C before entering a series
of precipitation tanks. Approximately 200 tons of molasses are handled
over the 24-hour day. Barium saccharate sludge is produced, filtered,
and washed; the filter cake is saved, and the filtrate and wash mixture
are collected, carbonated, and filtered. From the second filter the bar-
ium carbonate cake is returned to the kiln house, and the filtrate in
this case is specially treated for the recovery of stock-feed additives
and fertilizer salts.
The washed barium saccharate cake from the first filter is mixed
with sweetwater, carbonated, and then re-filtered. The thin juice re-
sulting from these operations is subsequently processed for sucrose
recovery more or less using the same procedures as a straight-house
sugar factory. Final or "A" molasses may be sold as stock-feed addi-
tive, or treated in subsequent steps for the separate recovery of raf-
finose.
The MSG Manufacturing Plant was originally built in 1954 to pro-
vide further recovery of valuable materials remaining in the final waste
effluents from the Steffen houses and the barium saccharate plant.
The severe stream pollution problems caused by the Steffen house resi-
dues necessitated the extensive waste abatement and recovery operations
undertaken by the sugar companies in the 1950's. This action still con-
tinues in certain parts of the country.
The Johnstown MSG plant, one of very few in the United States, is
ideally suited to the conditions and supply of raw materials found in
the South Platte River Basin. Although the market price for MSG is re-
ported to have fallen in recent years, the Johnstown MSG operation is
essential to the functioning of the sugar company and to its overall
economics. This plant probably represents the largest single source of
58
-------
BARIUM
MOLASSES FROM
OXIDE
i '
STEFFENS HOUSE
i *
1 MIXING
1 fr\
1
| FILTR/
i
WASTE
CO
CSF
* '
H20 |!
1 »
HI ION *^ C AR BON A 1 ION ^" FILTERS — ^ FILTER CAKE
JBAC03 1
' * i BAROMETRIC
1
P ULltKb '
1 r
VACUUM PANS
^
i^^~^^~ i "A"
CJh rrMTRirnr.rc>. 1 M ^- MnnirrT
ttNIKII-Ulito | uri| ft0erc. »• MAMKLI
1 1
_...,,... 1 noiro juoHn .. A ni/i-j
BARIUM PI ANT 1 E MARKCT
Hzso4 MS6 PLANT
i
PRE COAT FILTER
—I SALT SEPARATION |
| PRE COAT FILTER |
MARKET |
EVAPORATOR
NAOH
H2S04
LPC
CRYSTAL
SEPARATOR
I , H.
JTIONj—'
PRECIPITATE
SOLUTION
| SALT SEPARATION |—»^ CRYSTALLIZER |
POTASH
MOTHER
^LIQUOR
SEPARATION
MARKET \
CARBON
PURIFIED
GLUTAMIC
iiAClD
MSG
MARKET
SOLUTION
NAOH
MATERIAL FLOW DIAGRAM FOR
THE JOHNSTOWN, COLORADO SUGAR
RECOVERY AND MSG PLANTS
FIGURE 46
-------
MSG in the United States, producing in the order of 5 million pounds
annually.
The MSG establishment utilizes CJF (concentrated Johnstown fil-
trate) and CSF (concentrated Steffen filtrate) as the two primary raw
materials in the feed ratio of 3:2 CJF to CSF. The CJF represents the
exhausted material from the Johnstown barium plant. Five Steffen houses
supply CSF to Johnstown, including Loveland, Longmont and Fort Morgan
located in the South Platte River Basin, and Gering and Scottsbluff,
Nebraska. These five factories also provide the discard molasses for
the Johnstown barium plant. Storage of raw material at the five Steffen
houses and at Johnstown enable year-round operation of the barium and
MSG plants.
The manufacture of MSG is essentially the recovery of glutamic
acid from glutamine, both amino acids. Production is complex and exact-
ing. A schematic of major units operations at the Johnstown MSG plant
is given by the lower half of Figure 46. The CSF and CJF mixture is
filtered and concentrated, and within these operations potash salts are
separated from the mixture. The potash salts are sold as fertilizer
ingredients. The desalted mixture is allowed to set and crystallize.
A liquid protein concentrate known as LPC is withdrawn at this stage to
be later used as an additive to dried beet pulp as cattle feed. The
process stream is next hydrolyzed with caustic soda for conversion into
L-glutamic acid. Sulfuric acid is added until the isoelectric point of
glutamic acid is reached at approximately pH 3.2. The mixture is then
cooled and the separation of glutamic acid crystals occurs. The mother
liquor is reboiled and returned to the process for additional crystal
recovery. The crystals are purified in a solution of caustic soda, de-
colorized, concentrated, and re-crystallized. The final crystals are
further separated, dried, and packed.
The waste studies at the Johnstown, Colorado operations antici-
pated the presence of a complex process effluent which indeed was found.
The relative locations of sampling points for two surveys, one conduct-
ed in August 1965 and a second in November 1965, are illustrated in Fig-
ure 47.
Plant Water Supply
Sources of plant water supply included the Little Thompson River,
the Hillsboro Canal, municipal water from Johnstown, and a series of
company wells. Average water demand according to company records is
given as follows:
59
-------
Source Summer (May - Sept) Winter
Little Thompson River (direct) 7.6 cfs
Hillsboro Canal — 6.3 cfs
Municipal Supply 0.7 cfs 0.7 cfs
Company Wells 1.2 cfs 0.6 cfs
Total 9.5 cfs 7.6 cfs
Waste Collection System and Treatment for All Johnstown Operations
As implied in previous discussion, the Johnstown, Colorado oper-
ations did not receive or process sugar beets as such; consequently there
were no flume waters or lime mud wastes. The wastes from both the bari-
um and MSG plants were collected into two systems, designated by the com-
pany as the "clean water" sewer and the "dirty water" sewer. The clean
water system, which was a misnomer, received various waste flows reported
as relatively unpolluted, and these were discharged directly to the
Little Thompson River without treatment. The remaining plant wastes
within the dirty water system flowed into a waste treatment lagoon with
continuous overflow also to the Little Thompson River. Both systems are
shown in Figure 47.
Many improvements were reported to have been made in the Johns-
town waste collection system during the summer of 1965. These changes
supposedly consisted of segregating weak and strong wastes respectively
to the clean water system and the dirty water system. The pre-coat fil-
ter material originating in the MSG plant was also removed from the dirty
water system, and thereafter disposed of by incineration. The August
and November 1965 surveys were intended to show the before and after con-
ditions, reflecting such changes.
The clean water sewer contained the following waste streams ac-
cording to the company records:
Effluent Stream Average Daily Flow (cfs)
MSG pan cooler
Juice evaporator
CGA, PGA - Carbon cooler
A, B, C, D pan condensers
Nash pumps
Sulfuric acid cooling water
MSG cooling water
CJF cooling water
LPC cooling water
Total 1.82 cfs
The clean water collection system was sampled during November
1965 in the open drainway south of the main plants and below the diver-
sion box to the treatment lagoon. This location was designated as
Station 130.
60
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JOHNSTOWN
MS6 AND
SUGAR
RECOVERY
FACTORIES
JOHNSTOWN MSG AND
SUGAR RECOVERY OPERATIONS
PLANT AREA
AUGUST AND NOVEMBER, 1965
FIGURE 47
-------
The dirty water sewer conveyed the remainder of the plant wastes
to the treatment lagoon and according to company records consisted of
the following flows:
Effluent Stream Average Daily Flow (cfs)
MSG crude evaporator 1.05
MSG pan heater 0.02
Sweetwater evaporator 0.87
BaO crystallizer wastewater 0.13
Gas scrubber 0.28
BaO crystallizer cooler 0.13
Moore filters 0.16
Floor drains
Sanitary sewage
Total 2.64 cfs
In November 1965, both incoming and outgoing wastes from the
treatment lagoon were sampled respectively at Stations 131 and 132.
The waste treatment lagoon at Johnstown covered 15-20 acres,
varied in depth from a few inches to 18-20 inches, and was divided into
three compartments as shown by Figure 47. The dirty water collection
system was split at a diversion box into two flows which entered the
first compartment on two sides. The flow continued through the second
and third chambers to the overflow structure and then to the Little
Thompson River. Waste detention time in the lagoon approximated 1-2
days. According to the company, the lagoon had not been cleaned over
recent years, undoubtedly causing serious reduction in treatment effi-
ciency.
Little Thompson River
The August 1965 study comprised sampling of the Little Thompson
River at two locations shown in Figure 47. Station 133 approximately
one mile above the sugar company provided background conditions on the
Johnstown operations. Station 134 about 0.2 miles below the treatment
lagoon effluent and 0.5 miles below the clean sewer discharge indicated
the stream water quality changes resulting from the Johnstown industrial
operations. These two river stations were re-sampled concurrent with
the in-plant survey conducted in November 1965.
Presentation and Discussion of Sampling Data
The average values of data collected from both the August and
November 1965 studies in the Johnstown area are given in Table XI.
61
-------
The sugar plant results were rather surprising in many aspects.
First of all, the aggregate wastes in the clean water sewer (Station
130) were found in November 1965 to be considerably stronger in strength
compared to the dirty water sewer. The clean water line showed average
waste values of 510 mg/1 BOD, 438 mg/1 TSS, 0.9 mg/1 dissolved oxygen,
temperature of near 40°C, and relatively low coliform bacteria. The com-
pany had previously sampled this line early in 1965, and at that time re-
ported a BOD waste load of 6100 pounds per day. Following the plant
changes made during the summer 1965, the November 1965 results were ex-
pected to show improvements in the clean water sewer. However, this was
not the case with the BOD load increasing to 7700 pounds per day. The
company said that the clean water sewer in November contained used con-
denser water with slight waste loads. It was clear that the company
picture did not coincide with the results of the November 1965 survey.
Some part of the clean water flows may have been transferred to the
lagoon after November; nevertheless the total waste loads to the receiv-
ing stream would have remained at their former high level due to the
poor waste removals experienced in the treatment lagoon.
The dirty water line entering the lagoon at Station 131 repre-
sented a waste stream with 282 mg/1 BOD, 53 mg/1 TSS, dissolved oxygen
of 0.5 mg/1, temperature of 35°C, a pH of 4.6, and moderate levels of
coliform bacteria. The company reported for early 1965 the dirty water
sewer was rated at 7800 pounds BOD per day, whereas the November 1965
study showed a decrease to 4100 pounds per day. The low pH level of
this waste would appear to have reduced biological activity within the
initial stages of lagoon treatment.
The results on the waste overflow from the lagoon at Station 132
indicated a surprising recovery of pH to near neutral levels, but on the
other hand there was a remarkable proliferation of coliform bacteria.
Total and fecal coliform increased 220 and 160-fold respectively from
pond inlet to outlet. Inhibitory effects, if present in the incoming
wastes, would seem to have been removed by mixing and dilution with the
existing pond contents. Undoubtedly, the environmental conditions were
extremely favorable for bacterial growth. The presence of sanitary
sewage in the lagoon may have contributed to the observed bacterial
response.
The treatment lagoon was found almost completely ineffective for
waste reduction. The effluents contained 264 mg/1 BOD indicating only
10 percent BOD removal together with a complete absence of dissolved
oxygen and very high coliform bacteria densities.
The effects of the Johnstown factory effluents on the Little
Thompson River were pronounced and severe. The very large increases
of organic BOD and bacteria content in the stream together with the
lowering of dissolved oxygen were particularly significant. BOD values
above to below Johnstown were increased from 9 to 60 mg/1 in August
1965; and from 3 to 36 mg/1 in November 1965. The bacteriological data
specially showed that in-plant changes of summer 1965, rather than im-
62
-------
proving the waste picture, in fact created more serious conditions.
During the earlier survey, total and fecal coliform bacteria were
raised 17 and 10-fold respectively in the stream. The later survey
showed increases of 300 and 18-fold respectively. Representative val-
ues of total coliform within the Little Thompson River below the fac-
tory were in the range of 1.0 to 4.0 million organisms per 100 ml.
Dissolved oxygen in the stream was lowered from 9.1 to 7.2 mg/1
in November 1965, and from 7.1 to 3.2 mg/1 during August 1965, from
above to directly below the Johnstown operations. Other August 1965
data not shown in Table XI but included in Project files showed that
dissolved oxygen three miles below the factory ranged from 0.0 to 2.0
mg/1 with an average content of only 0.9 mg/1.
The composite effluents from the Johnstown factory were high in
complex organic materials and bacterial content. Disposal of this
wastewater into the Little Thompson River was shown to produce severe
stream degradation and limitation of the various water uses. Extensive
waste abatement and treatment should be initiated at the Johnstown fac-
tory without further delay.
Recent Operational Changes
Over the past year, the sugar company through the Beet Sugar
Development Foundation has employed the consulting services of the
British Columbia Research Council. Study has been directed to the
Johnstown waste problems and development of adequate treatment pro-
cedures. From these studies a pilot plant will be started in late
spring 1967 for treating part of the Johnstown factory wastes. The
installation will probably comprise an aerated lagoon with recircula-
tion of activated sludge. It is hoped this program will provide a new
course of action in regard to waste pollution problems at Johnstown.
63
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TABLE XI
SUMMARY OF DATA FOR
JOHNSTOWN SUGAR RECOVERY-MSG PLAMTS
AND LITTLE THOMPSON RIVER
August: 25-28, 1965 and
November 1-5, 1965
Sea.
No.
130
131
132
Flow (cfs) No.
Meas- Estl- of BOD COD
Period ured maced Samples me/1 me/1
Nov., 2.8 15 510 560
1965 (Grabs)
11 2.9 15 282
(Grabs')
2.9 15 264
(Grabs)
Total
Suspended
Solids
mg/l
438
53
30
Volatile
Suspended
Solids
mg/1
63
24
28
Total
Alka-
linity
mR/1
Sugar
250
(low)
280
Conduc-
tivity Temp.
umhos °C pH
Plants
1580 39.7 8.6
1690 34.9 4.6
1380 12.5 7.8
Dis-
solved
Oxygen
me/1
0.9
0.5
0.0
Confirmed Fecal Fecal
Coll. Bact. Coll. Bact. Strep. Station
MPN/100 ml MPN/100 ml No./lOO ml Description
13,000 4,900 160,000 "Clean Water"
sewer below the
diversion box on
the dirty water
line
225,000 59,500 7,800 "Dirty Water"
sewer inlet to
lagoon
49,000,000 950,000 3,600 Lagoon effluent
to river
Little Thompson River
133
134
133
134
Aug., 42 8 <9 23
1965 (Grabs)
41 8 60
(Grabs)
Nov., 44 10 3 12
1965 (Grabs)
62 10 36 38
(Grabs)
345
379
82
79
36
34
19
19
300
300
270
275
2660 18.4 8.0
2570 20.8 8.0
2550 8.9 8.2
2400 10.6 8.2
7.1
3.2
9.1
7.2
59,500 5,950 10,300 County road bridge
1 mi. directly
S. Johnstown
1,045,000 56,000 County road bridge
0.2 mi. below
sugar factory
lagoon effluent
13,000 3,600 1,650 County road bridge
1 mi. directly
S. Johnstown
3,950,000 63,500 26,200 County road bridge
0.2 mi. below
sugar factory
lagoon effluent
-------
SECTION III
TOTAL POLLUTION LOADS FROM SUGAR BEET MILLS
-------
Ill. TOTAL POLLUTION LOADS FROM SUGAR BEET MILLS
This section of the report focuses on the total waste loads orig-
inating from the ten sugar factories in the South Platte River Basin.
Evaluation is provided on the waste loads leaving the factory and second-
ly, on the loads actually discharged to the receiving stream after avail-
able treatment, if any.
The total waste load directly from the factory as found in the
main sewer or discharge drain is significant in two respects:
1) The waste material represents that portion which has not
been eliminated by factory operations.
2) The total plant waste load before general treatment estab-
lishes a level of comparison between various factories with
their particular operations. The information contained in this
section of the report is intended to supplement the 1952 Indus-
trial Waste Guide for the Beet Sugar Industry (20) describing
typical wastes expected from sugar beet mills.
Knowledge of the waste load entering the receiving stream is
important in at least three respects:
1) To determine the physical, chemical and biological responses
of the river in relation to these loads.
2) To determine the adverse effect and impairment of stream
waters for legitimate and beneficial uses.
3) To assess waste load reductions and control measures neces-
sary to achieve the desired stream water quality objectives.
A. TOTAL FACTORY WASTE LOADS
The picture of total plant waste loads from factories in the
South Platte River Basin has been developed in large part from data
previously included in Tables I - XI of this report. The factory dis-
charges are described in terms of unit waste loads predicated on the
basis of a single ton of raw sugar beets received for processing.
Major emphasis is centered on the following: a) summary table giving
the unit waste flow and load characteristics for each of nine sugar
beet processing establishements; b) important factors and the reasons
for change in unit waste loads, and; c) waste load from particular
unit operations. It must be recognized that conditions in the South
Platte River Basin may be somewhat different compared to other areas
of the country.
Some adverse comments have been expressed on the timing of the
in-plant surve'ys, particularly for the months of December and January
65
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during which certain studies were conducted. Severe cold-weather was
reported to be associated with a higher percentage of frozen beets.
These conditions were reported responsible for greater operational dif-
ficulty and higher waste loads. Although low temperatures such as ex-
perienced in the January 1964 studies undoubtedly did reflect higher
waste loads, nevertheless, these conditions and others were believed
representative and typical for the study area. Plant studies were also
conducted in November and December. Weather was an important, but not
an overriding factor.
Plant waste loads from the nine sugar beet mills in the South
Platte River Basin are summarized in Table XII. The data array at
first glance gives the impression of wide variation in values, but
suitable explanation is given in the subsequent discussion.
1. Classification
Waste loads are arrayed in Table XII with respect to particular
unit operations at the sugar mills. The Greeley, Ovid and Brighton
factories excluded lime mud waste from the main sewer and, additionally,
did not have pulp silo drainage. The Loveland and Fort Morgan factory
had no pulp silo drainage; however they discharged the total lime mud
to the main sewer. The Sterling and Windsor mills added both pulp silo
drainage and lime mud to the waste drainage system. Eaton and Longmont
did not conveniently fit any of above three categories. The Eaton fac-
tory was atypical of the general group because of its high degree of
in-plant water conservation; however pulp silo drainage was discharged.
The Longmont installation, although possessing lime mud holding facil-
ities, was releasing part of the lime mud to the drain; no pulp silo
drainage was present. The Longmont plant was grouped with Loveland and
Fort Morgan on the basis of lime mud wasting.
One important point must be made clear regarding lime mud. The
Steffen houses which included Loveland, Fort Morgan and Longmont may be
expected to use nearly twice the amount of lime within the process com-
pared to the straight-house factories. Lime mud slurry from a Steffen
house factory is also about 50 percent higher in waste strength (19).
2. Waste Flows
Wastewater volumes from the factories were believed to represent
90 percent or more of total plant water use. The various mills in Table
XII may be categorized as low, medium, and high water-using establish-
ments using the study area as baseline. Minimum wastewater volumes were
reflected at the Greeley plant and particularly the Eaton plant by re-
strictions, imposed or otherwise, in securing available water supply.
The Loveland, Windsor, and Longmont mills had relatively free access to
surface waters in the Middle Basin resulting in above average water con-
sumption. Steffen house operations included at the Loveland and Longmont
mills may have accounted in part for the higher water use. The three
sugar factories of the Lower Basin including Fort Morgan, Sterling and
66
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TABLE XII
UNIT WASTE LOADS FOR TOTAL FACTORY EFFLUENTS
REPRESENTING NINE SUGAR BEET MILLS IN THE
SOUTH PLATTE RIVER BASIN
1963 - 1966
Greeley
Station No. 92
Waste Flow (gals/ton) 2300
BOD (Ibs/ton) \^
COD (Ibs/ton) 17-/
TSS (Ibs/ton) 25
Total Alkalinity 16
(Ibs/ton)
-/
Total Coli. Bacteria 23^'
(BQU/100 tons)
Fecal Coli. Bacteria 1.6^.'
(BQU/100 tons)
Ovid Brighton
42-43 102
3000
12 10^
15
36 22^7
18
44 40—
OH o /, d /
. O O.'l —
Longmont
112
3700
10
13
55
7
3
0
Love land
76
3300
19
29
115
74
0
0
Fort
Morgan
23-24
2900
12
15
121
46
14
0
Sterling
32-33
2700
20
30
78
25
85
1.3
Windsor
83
3600
33
50
84
52
58
1.3
Eaton
122
1400
10
16
38
4
69
1.3
Aver age -2'
Values
2950
15
22
67
32
33
1.4
a/ Excludes wastes disposed of by separate means and not appearing in the main plant sewer.
waste loads before general treatment.
b/ Weighted in respect to production rate.
£/ Adjusted for waste load in the plant water intake.
d/ Probable minimum values.
These values reflected
-------
Ovid were classed in the intermediate range. The Lower Basin plants
probably experienced a small degree of difficulty in obtaining water
since the available supply in this region is largely dependent upon
return irrigation flows from upstream areas. Results from other parts
of the country certainly do indicate that the South Platte River Basin
factories could greatly reduce water consumption, if desired. In turn,
minimum wastewater volumes would promise less problems in waste handling
and lower costs in future treatment.
3. BOD and COD Loads
Table XII shows that BOD waste load varied from a low of 10
pounds per ton of beets observed at three mills—Brighton, Longmont,
and Eaton, to a high of 33 pounds at the Windsor mill. The average
for the nine plants was 15 pounds BOD per ton beets processed. The
COD loads were more or less proportional to BOD, and varied from 13 to
50 pounds per ton beets.
Pulp silo drainage, in particular, and lime mud waste were de-
termined to be major factors contributing to the magnitude of organic
(BOD and COD) waste load from a sugar factory. Field observations
further indicated that the quantity of pulp silo drainage would in-
cre'ase throughout the season related to the total accumulation and the
age of wet solids in the silo.
The BOD and COD waste loads showed progressive increase across
Table XII which were correlated with increasing amounts of pulp silo
drainage and lime mud wastes from the various mills. The Eaton mill was
an exception, and the waste load associated with pulp silo drainage in
this case was believed on the low side. This waste load was low only
because the survey data was collected early in the campaign when there
was a minimum accumulation of wet solids and drainage in the pulp silo.
The data in Table XII show that the addition of lime mud may be expected
to increase the normal BOD and COD loads from a sugar factory by 10 to
40 percent. If pulp silo drainage is also added, basic waste loads
could be increased from 50 percent up to 200 percent.
4. TSS Loads
Total suspended solids loads varied from a minimum of 22 pounds
per ton of beets at the Brighton mill to a maximum of 121 pounds ob-
served at the Fort Morgan mill. Lime mud wasting was the predominating
factor contributing to high suspended solids loads in the factory efflu-
ents. The four plants which provided for separate handling and disposal
of lime mud slurry--Greeley, Ovid, Brighton, and Eaton, experienced the
least TSS loads. TSS levels for these plants ranged from 22 to 38 pounds
per ton beets with an average of 30 pounds TSS. The remaining five fac-
tories demonstrated TSS waste loads in the range of 55 to 121 pounds solids,
with an average of 91 pounds solids. Pulp silo drainage was believed to
contribute a minor portion of the TSS load.
68
-------
The Loveland and Fort Morgan mills with entire wasting of lime
mud together with relatively large amounts of lime generally expected
from Steffen houses, typified extremely high levels of TSS. These
loads were respectively 115 and 121 pounds TSS per ton beets processed.
The survey data indicated that complete lime mud wasting may be ex-
pected to increase basic plant TSS loads from 100 up to 300 percent.
This increase would undoubtedly be greater for a Steffen house com-
pared to a straight-house factory.
5. Total Alkalinity Loads
The total alkalinity within sugar factory wastes varied from
the low of 4 pounds per ton beets observed at the Eaton mill to a max-
imum of 74 pounds at the Loveland mill. Lime mud wastes greatly in-
creased the alkalinity loads, which would be more significant for a
Steffen house factory. The Greeley, Ovid and Eaton plants without
lime mud wasting demonstrated a level of 4-18 pounds total alkalinity
per ton beets processed. The other five plants (excluding Brighton)
averaged 41 pounds alkalinity. These alkalinity values were not ad-
justed for loads in the plant water supply.
Pulp silo drainage when mixed with total plant wastes served
in partially neutralizing excess alkalinity, particularly that portion
contributed by lime mud. Alkalinity levels were very high at Loveland
and Fort Morgan where the lime was completely discharged and the ab-
sence of pulp silo drainage precluded any neutralization. The combin-
ing of the two wastes at both Windsor and Sterling caused some reduction
in alkalinity loads at these mills. Greeley, Ovid, and Brighton dis-
charged neither waste. The Eaton mill represented the case where lime
mud was absent and the pulp silo drainage served to almost completely
neutralize all the available alkalinity. The Longmont situation with
low alkalinity levels unfortunately could not be explained on the basis
of known information.
6. Bacterial Loads
The bacterial loads shown in Table XII varied from 0 to 68 BQU
of total coliform bacteria discharged per 100 tons beets, and fecal
coliform bacteria from 0 to 8.4 BQU. Six of the nine factories contain-
ed very high levels of coliform bacteria in the effluent wastes. For
comparative purposes, the raw sewage discharged by a human population
of 1,000 persons would be expected to contain around 15-30 BQU of total
coliform bacteria and 5-20 BQU of fecal coliforms.
The various sugar mills may be categorized as low, medium, and
high bacterial load-producing plants. The three factories at Longmont,
Loveland and Fort Morgan demonstrated relatively low bacterial loads
because of lime mud wasting contributing to very high pH levels in the
total plant wastes. The field surveys showed that pH levels exceeding
9.0 were particularly destructive to organisms of the coliform group.
The alkaline environment may include other factors associated with, but
69
-------
incidental to lime mud, causing the destruction of bacterial organisms.
Love land factory wastes were in the pH range of 10.1 to 10.5, and the
Fort Morgan effluents approximated a pH value of 9.1. The flows from
both factories were highly alkaline. The Longmont plant discharges
were in the pH range of 8.3 to 9.1 during the survey, although higher
pH levels were believed present at other times.
Windsor, Sterling, and Eaton discharged pulp silo drainage which
appeared to offer the most favorable conditions for bacterial growth.
The silo drainage from the Eaton mill with a pH level of only 4.2 was
found to contain 3.3 million total coliform and 0.25 million fecal coli-
form/100 ml. No inhibitory effects could be demonstrated after the pulp
drainage was mixed with total plant wastes. The drainage would also con-
tain a wide variety of substrate material suitable for bacterial propa-
gation. The Windsor, Sterling and Eaton factories all with pulp silo
drainage, experienced the maximum bacterial loads.
Greeley, Ovid and Brighton, with neither lime mud nor pulp drain-
age, demonstrated intermediate, but nevertheless fairly high bacterial
loads. The proportion of fecal to total coliform was notably high at
the Brighton mill but a full explanation for this occurence cannot be
given.
The reader is informed that Section IV of this report contains
detailed information on the overall nature and consequences of bacterial
pollution caused by sugar beet processing wastes. Special emphasis is
given to the in-plant sources, changes due to waste storage, pathogenic
association, survival trends, and effective measures towards bacterial
reduction. Such information is considered essential to a full under-
standing of the bacterial problems inherent to sugar beet processing.
7. Summary of Overall Factory Loads
The Industrial Waste Guide for Beet Sugar (20) published in 1952
gave extensive review of the waste problems which existed in the industry
through the 1940's and early 1950's. However, since that time, many mod-
ifications have been made in equipment, practices and procedures. The
Industrial Waste Guide contributed valuable information on the character-
istics, volumes and unit loads associated with various waste streams in
the sugar factory. Major waste effluents at that time included flume
water, pulp screenwater, pulp press water, pulp silo drainage, lime cake
slurry, barometric condenser water, and Steffen filtrate.
The present studies must necessarily update some of the informa-
tion given in the Industrial Waste Guide. One of the more important
changes within the industry has been the increase in water reuse and
recovery. Future conditions may dictate almost complete reuse of waste-
water resulting in little or no effluent to the receiving stream. The
large majority of present-day sugar factories have virtually eliminated
70
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the pulp press and pulp screen waters. It is also important to note
that all Steffen filtrate in the South Platte River Basin is shipped
to the Johnstown chemical operations; this waste, per se, is not a
problem over the area.
Basic waste loads are defined in this report as those originating
from waste flume water, excess condenser water and minor sources; lime
mud wastes and pulp silo drainage are excluded. In Table XII basic waste
loads are found to approximate 10 pounds BOD, 14 pounds COD, 28 pounds
suspended solids, and 17 pounds alkalinity, per ton beets processed.
This BOD load is about double that given by the Industrial Waste Guide and
presumably reflects miscellaneous wastes not accounted for in the original
studies and/or different operating conditions encountered in the South
Platte surveys.
Lime mud waste and pulp silo drainage cause significant increase
in factory waste load far beyond the basic levels. Therefore, unit
waste loads are developed from the information in Table XII specifically
for lime mud and pulp drainage. Predicated upon this data collection,
it is determined that lime mud from a Steffen house factory would con-
tribute about 5 pounds BOD, 7 pounds COD, 90 pounds TSS, and 45 pounds
alkalinity per ton of beets processed. A straight-house operation
would approximate from one-half to three-fourths of these respective
loads. Pulp silo drainage would be expected to add another 16 pounds
BOD, 22 pounds COD, and minor amounts of TSS to the total plant load.
Unit BOD loads are in fair agreement with those previously given in
the Industrial Waste Guide, whereas COD, TSS and alkalinity loads repre-
sent new values not found in the original Guide.
B. WASTE LOADS TO THE RECEIVING STREAM
The pollutant waste material entering the receiving stream rep-
resents the total plant waste load less the portion removed by avail-
able on-site treatment. Excluding the new Brighton system, the various
sugar mills in the South Platte River Basin provided only minimum treat-
ment, with the large majority of total plant waste loads then reaching
the stream.
Waste treatment consisted of aeration fields at the Loveland and
Windsor factories, and shallow lagoons at the Greeley, Fort Morgan,
Brighton, Longmont, and Johnstown factories. The Sterling, Ovid and
Eaton mills provided essentially no waste treatment. Waste removal var-
ied from zero efficiency to the equivalent of primary treatment. The
status of waste treatment is summarized for each factory in Table XIII,
giving the treatment method, waste loads before and after treatment, and
nature of the final discharge to the receiving stream. Discussion of
the results received from individual mills over the 1963-1966 seasons
is given by the following:
71
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The Loveland aeration field covered an extensive area of 133
acres- Suspended solids and alkalinity removals were reasonably good,
but soluble organic wastes were reduced only in minimum degree. The
facility provided less than equivalent primary treatment, and waste
concentrations within the final effluents remained at high levels.
The merits of maintaining an extensive treatment area may be seriously
questioned in view of results obtained. Recent modifications made at
Loveland have not changed the overall picture. Twenty percent reduc-
tion in BOD, and discharge loads of 26 tons BOD and 44 tons TSS daily
are definitely not compatible with the water quality needs of the area.
The Windsor plant was rated highest of all mills in terms of
organic BOD load discharged to the receiving stream. The aeration
field at Windsor was found less effective than Loveland, producing
only 0-10 percent removal of BOD and 60 percent reduction of TSS. The
wastewater entering the Cache la Poudre River contained in the order
of 1100 mg/1 BOD, 1060 mg/1 TSS, and 6.6 million total coliform bac-
teria/100 ml.
The Greeley factory in January 1964 maintained a small, shallow
lagoon for waste treatment. This facility afforded reasonably good
removal of TSS, but virtually no change in the organic waste loads re-
leased to the receiving stream. Severe odor problems were associated
with the lagoon operation and the installation was converted to an
aeration field in 1965. Present waste removals are likely to be even
less promising than before.
The Fort Morgan operations consisted of two shallow lagoons
which functioned singularly or in series. As in the case of other fac-
tories, the treatment facilities received little or no attention. The
waste treatment lagoons were nearly filled with solids negating effec-
tive treatment. Considering the lack of supervision and maintenance,
the BOD and TSS removals of 35 and 75 percent respectively were rather
surprising. Heavy lime mud loads added to the ponds were responsible
in part. Bacterial levels were effectively lowered within the ponds
by an alkaline environment, but these loads showed rapid increase in
the receiving stream and bacterial aftergrowth was suspected. Waste
loads imposed on the South Platte River were quite high, approximating
11 tons BOD and 43 tons TSS discharged daily.
At both the Sterling and Ovid factories, total plant wastes were
released directly without change into the South Platte River. The or-
ganic BOD, TSS and bacterial loads from the two mills contributed heavi-
ly to water quality degradation of the lower South Platte River. The
Sterling mill was rated highest of all mills in terms of TSS and total
coliform bacteria loads discharged to the receiving stream. The serious
nature of final effluents from Sterling and Ovid is evident from the
waste concentrations shown in Table XIII. Combined waste loads from the
two factories were 38 tons BOD, 54 tons COD, and 136 tons TSS contributed
daily to the South Platte River, together with 3100 BQU total coliform
bacteria and 52 BQU fecal coliform bacteria. Records clearly show that
72
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these plants have been responsible for significant pollution of the
South Platte River at the Colorado-Nebraska StatPline which has been
occurring for many previous years.
The Brighton plant was evaluated in January 1965 based only on
the waste loads to the receiving stream; total factory loads were not
known. At that time, the shallow waste lagoon would seem to have pro-
vided an order of treatment similar to Greeley for that portion of the
wastewater being retained in the pond. The majority of factory wastes
were discharged to the River without treatment. Daily BOD and TSS loads
were 12 tons and 27 tons respectively. The bacterial loads were ex-
tremely high particularly in terms of fecal coliform bacteria.
Longmont factory wastes in November 1966 were retained in a
shallow lagoon approximating 14 acres in area. Waste retention was
severely limited by solids filling, extensive weed growth and uneven-
ness of the pond bottom. Furthermore, anaerobic conditions likely
prevailed at the lower end of the lagoon and within the final effluents.
The Longmont situation was similar to Fort Morgan in that the majority
of suspended solids were settled in the lagoon but appreciable amounts
which could otherwise be removed by effective treatment were permitted
access to the receiving stream. Longmont experienced virtually no re-
duction in organic waste material and furthermore the environment was
extremely favorable to increasing bacterial densities in the final ef-
fluents. Future treatment measures envisioned for Longmont, if success-
ful, would effect tremendous improvement in the water quality of St.
Vrain Creek.
The Eaton sugar mill provided no waste treatment and the total
plant wastes caused severe pollution not only in Eaton Draw but also
in the lower Cache la Poudre River through the Greeley area. Eaton
waste loads approximated 10 tons BOD and 40 tons TSS on a daily basis
together with 1480 BQU total coliform bacteria and 29 BQU fecal coli-
forms. Waste concentrations were quite high. About one-third of the
BOD. load has since been removed due to elimination of the pulp silo
with its associated drainage. However, there still remains a great
need for extensive waste treatment facilities.
The Johnstown operations made certain in-plant changes during
the summer of 1965 designed to decrease waste loads placed upon the
Little Thompson River. However, appropriate studies showed only minor
differences resulting from such changes. Both the clean and dirty
water collection systems carried heavy waste loads. Wastes in the
clean water sewer received no treatment before final discharge and
contained daily loads of 3.8 tons BOD and 3.3 tons TSS together with
a dissolved oxygen level of only 0.9 mg/1. The contents of the dirty
water sewer were passed through a shallow lagoon providing limited re-
tention and little or no waste treatment. Organic waste loads were
essentially unchanged in the pond and, of equal importance, very large
bacterial increases were observed in the final effluents to the re-
ceiving stream. Near septic conditions also occurred within the lagoon
73
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system associated with poor treatment efficiency. The Johnstown waste
treatment facilities appeared to serve no useful purpose in view of the
performance record.
The nine sugar establishments (excluding Brighton) possessed tot-
al factory waste loads of 175 tons BOD and 780 tons TSS on a daily basis
together with 6900 BQU total coliform bacteria. Total waste loads reach-
ing the stream after general treatment from these same nine plants ap-
proximated 161 tons BOD and 330 tons TSS daily, with 8450 BQU total coli-
form bacteria. Adding Brighton, the total loads reaching the stream were
about 10 percent greater. Overall waste reductions by means of treat-
ment were only 8 percent for BOD and 58 percent for total suspended sol-
ids. On the other hand, total coliform bacteria loads actually increased
23 percent associated with the available treatment measures. This re-
versal in bacterial loads was largely attributed to the picture obtained
at the Johnstown and Longraont establishments. It is realized that the
closure of the Windsor mill in 1967 has altered the above analysis.
The overall picture of sugar beet waste disposal in the South
Platte River Basin strongly illustrates that much remains to be done.
The sugar company has taken the first steps towards a major waste abate-
ment program sorely needed in the Basin. However, such a program to be
truly effective will also require imaginative and bold thinking, proper
resources, and a keen and discerning attitude on the part of industry to
complete the task clearly at hand.
74
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TABLE XIII
STATUS OF WASTE TREATMENT AND WASTE
LOADS DISCHARGED TO RECEIVING STREAMS
FOR THE BEET SUGAR INDUSTRY IN THE
SOUTH PLATTE RIVER BASIN
1963 - 1966
Factory
Loveland
Windsor
Greeley
Fort Morgan
BOD-
COD-
TSS-
Alk.
Tot.
Fee.
BOD-
COD-
TSS-
Alk.
Tot.
Fee.
BOD-
COD-
TSS-
Alk.
Tot.
Fee.
BOD-
COD-
TSS-
Alk.
Tot.
Fee.
Total Plant Loads
Before General
Treatment
33 Tons/Day
51 Tons/Day
201 Tons/Day
129 Tons/Day
Coll.- 0 BQU
Coll.- 0 BQU
37 Tons/Day
55 Tons /Day
93 Tons/Day
57 Tons /Day
Coll.- 1280 BQU
Coll.- 29 BQU
16 Tons/Day-^
19 Tons/Day^'
28 Tons/Day
17 Tons /Day
Coll.- 505 BQU5/
Coll.- 35 BQU£'
17 Tons /Day
23 Tons/Day
181 Tons/Day
69 Tons /Day
Coll.- 430 BQU
Coll.- 4 BQU
Type
Treatment
Loads
Out
% Removal
Aeration
Fields
BOD-
COD-
TSS-
Alk.
Tot.
Fee.
Aeration
Fields
BOD-
COD-
TSS-
Alk.
Tot.
Fee.
26 Tons/Day
41 Tons /Day
44 Tons /Day
28 Tons /Day
Coll.- 0 BQU
Coll.- 0 BQU
20
20
80
80
--
--
37 Tons/Day
49 Tons /Day
35 Tons /Day
36 Tons /Day
Coll.- 820 BQU
Coll.- 6 BQU
0-10
10
60
35
35
80
Shallow
Lagoon
BOD-
COD -
TSS-
Alk.
Tot.
Fee.
15 Tons/Days'
16 Tons /Day*/
2 T/>ns/Day
14 Tons/Day
Coll.- 140 BQU£/
Coll.- 8 BQUS/
5-10
15
95
20
50
75
Shallow
Lagoons
and
Dilution
BOD-
COD-
TSS-
Alk.
Tot.
Fee.
11 Tons /Day
16 Tons /Day
43 Tons/Day
27 Tons/Day-'
Coll.- 580 BQU
Coll.- 5 BQU
35
30
75
60
0
0
Characteristics of Waste
Discharge to Receiving Stream
Receiving Total Coll form
Stream BOD TSS Bacteria
mg/1 mg/1 MPN/100 ml
Big Thompson 510 860 2,700
River
Cache la Poudre 1,110 1,060 6,620,000
River
Cache la Poudre 850 93 5,690,000
River
South Platte 115 440 1,600,000
River
a/ Adjusted for loads in the plant water intake.
b/ Adjusted for loads in the discharge drain above the treatment lagoons.
-------
TABLE XIII (Cont.)
- STATUS OF WASTE TREATMENT AND WASTE LOADS DISCHARGED TO RECEIVING STREAMS
FOR THE BEET SUGAR INDUSTRY IN THE SOUTH PLATTE RIVER BASIN 1963 - 1966
Factory
Sterling
Ovid
BOD-
COD-
TSS-
Alk.
Tot.
Fee.
BOD-
COD-
TSS-
Alk.
Total Plant Loads
Before General
Treatment
21 Tons/Day
33 Tons /Day
86 Tons/Day
27 Tons/Day
Coll.- 1870 BQU
Coll.- 29 BQU
17 Tons/Day
21 Tons /Day
SO Tons/Day
25 Tons/Day
Treatment
Type
Loads
Out
% Removal
Dilution
only
Same as loads before
general treatment
None
None
Same as loads before
general treatment
None
Receiving
Stream
South Platte
River
South Platte
River
Characteristics of Waste
Discharge to Receiving Stream
Total Col i form
BOD TSS Bacteria
mg/1 mg/1 KPN/ 100 ml
410 1,950
500 1,440
17,100,000
9,480,000
Tot. Coll.- 1220 BQU
Fee. Coll.- 23 BQU
Brighton
Shallow
Lagoon
BOD-
TSS-
Tot. Coli
Fee. Coli
12 Tons/Day£/
27 Tons/Day£/
- 955 BQU£'
- 200 BQU£/
Undefined
Longmont —
Eaton
BOD-
COD-
TSS-
Alk.-
Tot. Coli.
Fee. Coli.
BOD-
COD -
TSS-
Alk.-
Tot. Coli.
Fee. Coli.
18 Tons/Day
24 Tons /Day
99 Tons/Day
13 Tons/Day
-105 BQU
4 BQU
10 Tons /Day
17 Tons/Day
40 Tons/Day
4 Tons /Day
- 1480 BQU
29 BQU
Shallow
Lagoon
BOD-
COD -
TSS-
Alk.-
Tot. Coll
Fee. Coli
18 Tons/Day
28 Tons/Day
25 Tons /Day
17 Tons/Day
.- 920 BQU
.- 105 BQU
0-10
0-10
75
0
Large Incr.
Large Incr.
South Platte
River
St. Vrain
Creek
935 2,040
340 470
19,500,000
4,600,000
In-Plant
water con-
servation,
but no
treatment
Same as loads before
general treatment
None
Eaton Draw
860 3,320
33,000,000
c/ Probable minimum values.
d/ Total plant loads before general treatment determined in 1965 before treatment lagoon was provided.
the lagoon was built. Characteristics of waste discharge given for the 1966 campaign.
Loads after treatment determined in 1966 after
-------
TABLE XIII (Cent.)
STATUS OF WASTE TREATMENT AND WASTE LOADS DISCHARGED TO RECEIVING STREAMS
FOR THE BEET SUGAR INDUSTRY IN THE SOUTH PLATTE RIVER BASIN 1963 - 1966
Factory
Johnstown —
(2 Plants)
Total Plant Loads
Before General
Treatment
BOD- 6.1 Tons/Day
TSS- 3.7 Tons/Day
Alk.- 1.9 Tons/Day
Tot. Coll.- 7 BQU
Fee. Coll.- 2 BQU
Treament
Type
Loads
Out
% Removal
Shallow
Lagoon for
Dirty
Water Col-
lection
System;
no trmt.
for Clean
Water Col-
lection
System.
BOD- 5.9 Tons /Day
TSS- 3.5 Tons /Day
Alk.- 4.1 Tons /Day
Tot. Coll.- 1420 BQU
Fee. Coll.- 28 BQU
0
5
100% Incr.
V. Large Incr.
V. Large Incr.
Characteristics of Waste
Discharge to Receiving Stream
Receiving Total Coliform
Stream BOD TSS Bacteria
mg/1 mg/1 MPN/100 ml
Little Thompson Clean
River 510
Dirty
264
Water System
438 13,000
Water System after Lagoon
30 49,000,000
e/ Waste loads represent combined values for clean and dirty water collection systems.
-------
SECTION IV
BACTERIOLOGICAL ASPECTS OF
SUGAR BEET PROCESSING WASTES
-------
IV. BACTERIOLOGICAL ASPECTS OF SUGAR BEET PROCESSING WASTES
The large numbers of total coliform, fecal coliform, and fecal
streptococci bacteria in sugar beet wastes has been a matter of serious
concern for some time. Extensive bacterial studies were undertaken by
the U.S. Public Health Service in 1961-1963 on the North Platte River
in Wyoming and Nebraska below five sugar beet mills from Torrington,
Wyoming to Bayard, Nebraska. Laboratory investigations were carried
out from late 1963 through 1966 by the FWPCA facilities associated with
the Sanitary Engineering Center in Cincinnati, Ohio. The Cincinnati
staff also conducted special studies from January-May 1965 on the waste
treatment ponds of the Fremont and Findlay, Ohio sugar mills. Labora-
tory and field studies of the South Platte River Basin Project have
been undertaken since late 1963 at each of the ten sugar factories in
the Basin. Additional surveys were undertaken in November 1964 and
again in October 1965 by the U.S. Public Health Service (now the FWPCA
facilities) of four sugar beet mills in Minnesota and North Dakota on
the Red River of the North.
The available data focuses on the probable sources of bacteri-
ological pollution within the sugar beet factory, changes due to waste
storage, importance of pathogens in sugar beet wastes, survival tenden-
cies of bacterial organisms, differentiation between human and animal-
caused pollution, and lastly, criteria for reducing or eliminating
bacterial pollution. The following discussion is primarily derived
from the studies listed above, with special reference given to the South
Platte River Basin.
A. BACKGROUND ON BACTERIAL POLLUTION
Coliform bacteria universally occur in sanitary sewage. With
few exceptions, these bacteria are not harmful and have been used by
regulatory agencies for many decades as an indicator of the probable
presence of pathogenic organisms. Objections have been made to the use
of total coliform densities in that their origin is not exclusively from
fecal sources. While this is true, the Eschericia species comprising
part of the total coliform group is derived exclusively from human or an-
imal excreta and its presence is evidence of fecal contamination. A
second indicator group, the fecal coliform bacteria, is almost exclu-
sively derived from the guts of warm-blooded animals and man. In the
past 2-3 years, the fecal streptococci group has been accepted and used
as a third indicator of warm-blooded animal and man pollution. This
group is not known to multiply in surface waters and rarely occurs on
uncontaminated surface soil or vegetables.
Salmonella is a genus of bacteria pathogenic to man and to warm-
blooded animals. These pathogens are discharged from the intestines of
infected man and animals. Because of disease-producing capabilities,
their presence in receiving waters constitutes a health hazard through
78
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indirect or direct contact with these waters. Recent techniques now
make possible the isolation of Salmonella even at extremely low con-
centrations .
The relationship between fecal coliform and fecal streptococci
numbers provides further indication of the origin of fecal pollution.
Ratios of fecal coliform to fecal streptococci that are greater than 2:1
generally indicate that pollution was primarily derived from domestic
sewage. Ratios less than 1:1 indicate that the majority of pollution
originated from the wastes of warm-blooded animals other than man (21).
More recent interpretation suggests that source delineation may be more
exacting if the ratios are either in excess of 4:1, or less than 0.6:1
(22).
The North Platte River in the area of five sugar beet process-
ing plants was found to contain large numbers of total coliform, fecal
coliform, and fecal streptococci bacteria. In 1962 the control station
above the first sugar mill showed average concentrations as follows:
60/100 ml total coliform, 30/100 ml fecal coliform, and 90/100 ml fecal
streptococci. Within the stretch of river from Torrington, Wyoming to
Bayard, Nebraska, the bacterial values increased to maximum levels of
219,000/100 ml total coliform, 81,600/100 ml fecal coliform, and
2,250,000/100 ml fecal streptococci. These large increases were as-
cribed to inadequately treated municipal wastes, but particularly sugar
beet wastes discharged to the river. Suggested water quality control
measures for the North Platte River were directed to protection of pre-
sent interests together with future provisions for municipal and indus-
trial water supply, recreation and fishing (23, 24, 25).
The initial plans of the South Platte River Basin Project, rec-
ognizing the North Platte River study and the fact that ten sugar fac-
tories were operating in the study area, thereby called for extensive
bacteriological analyses. The Project over the period 1963-1966 deter-
mined that extremely high levels of bacteriological pollution were in-
deed present in all Basin waterways downstream of sugar beet factories.
These findings were presented at the Second Session of the Conference in
the matter of Pollution of the South Platte River Basin (2). Of great
importance, the Conference established that bacterial levels over most
the area tremendously exceeded the recommended limits for desired water
quality.
The report to the Conference stated that St. Vrain Creek below
the Longmont sugar mill contained total coliform bacteria in the range
of 490,000 to 790,000/100 ml and fecal coliform from 23,000 to 94,500/100
ml. The Little Thompson River above the Johnstown operations experienced
13,000/100 ml total coliform and 3,600/100 ml fecal coliform, whereas the
downstream values were increased to 3,950,000/100 ml and 63,500/100 ml
respectively. Bacterial densities in the Cache la Poudre River were
1,100/100 ml total coliform and 490/100 ml fecal coliform for the control
station above Windsor. On the same river below the Windsor, Eaton, and
Greeley sugar mills, values were in the range of 220,000 to 11,000,000
/100 ml total coliform, and 3,300 to 790,000/100 ml fecal coliform. Last-
79
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ly, on the lower South Platte River from Fort Morgan to the Colorado-
Nebraska Stateline, background levels approximated 490 and 80/100 ml
for total and fecal coliform respectively, whereas below three sugar
mills in this area, maximum values were 2,300,000/100 ml and 45,000
/100 ml respectively. There is no doubt that sugar beet wastes contain
very high bacteria numbers and cause serious pollution of the receiving
waterways.
B. SOURCES OF BACTERIAL POLLUTION WITHIN THE SUGAR FACTORY
Special studies have been directed to determining the specific
sources and causes of bacterial pollution introduced to the sugar pro-
cessing plant. These investigations were undertaken at four factories
including Torrington, Wyoming (North Platte), Fort Morgan, Colorado
(South Platte), and Crookston and East Grand Forks, Minnesota (Red River
of the North).
The Torrington, Wyoming study indicated that bacterial growth in
the beet flume approached optimum conditions when water temperatures
approximated 33-35°C and pH levels were 7.0-7.5. Furthermore, the var-
ious nutrients present in sugar beet wastes were thought to sustain or
even contribute to the bacterial growth. The investigation concluded
that total coliform organisms within the flume water and the main sewer
system were substantially derived from the soils on the incoming sugar
beets. On the other hand, fecal coliform bacteria were believed to orig-
inate from the incoming soils, but multiplication was also probable in
the flume system itself.
The Fort Morgan, Colorado mill was sampled by the South Platte
River Basin Project in December 1963, and the various operations are
described in Section II of this report. All incoming sugar beets were
retrieved from the piles. The soils associated with the beets before
entering the wet hopper were sampled and designated as Station 27. A
relatively constant water flow was maintained in the flume system and
the. detention time was calculated as 5 minutes, although pockets of
stagnant water were likely present. The water supply for the wet hopper
consisted of overflow from the main water supply tank mixed together
with seal tank water, and this supply was designated as Station 29.
Finally, the wastewater leaving the flume system (after the beet washer)
was designated as Station 22.
It was assumed that each gram of total suspended solids in the
flume outlet was equivalent to one gram of dry soil previously intro-
duced to the wet hopper at Station 27. The average temperature and pH
of the flume inlet waters were 31.2°C and 8.5 respectively, whereas the
flume outlet waters averaged 25.6°C with a pH of 8.4. Accounting of
the soil and coliform bacteria entering and leaving the Fort Morgan
flume system is given by Table XIV.
80
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TABLE XIV
COLIFORM BACTERIA IN THE FORT MORGAN FLUME SYSTEM
December 1963
TSS in Flume Outlet at Station 22 (mg/1) 1,690
1. Total Coliform Bacteria
a. In soil at Station 27 (MPN/gram) 3,300,000
b. In flume water, equivalent to the numbers
found on incoming soil, assuming no bac-
terial growth within flume (MPN/100 ml) 575,000
c. In the flume inlet waters at Station 29
(MPN/100 ml) 2.300
d. Total input (MPN/100 ml) 577,300
e. Observed in the flume outlet waters at
Station 22 (MPN/100 ml) 4,500,000
f. Observed Ratio Increase of Total
Coliforms (Outlet:Inlet) 8:1
2. Fecal Coliform Bacteria
a. In soil at Station 27 (MPN/gram) 4
b. In flume water, equivalent to the numbers
found on incoming soil, assuming no bac-
terial growth within flume (MPN/100 ml) 1
c. In the flume inlet waters at Station 29
(MPN/100 ml) 69_
d. Total input (MPN/100 ml) 70
e. Observed in the flume outlet waters at
Station 22 (MPN/100 ml) 43,000
f. Observed Ratio Increase of Fecal Coliforms
(Outlet:Inlet) 600:1
81
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Analytical techniques, although the best available for the Fort
Morgan study, did not provide full recovery of coliform bacteria from
the soils; hence coliform values in MPN/gram soil were likely on the
low side. Regardless of this factor, the majority of total coliforms
would seem to have originated from the incoming soils rather than the
flume water supply. The reverse appeared true for the fecal coliform
organisms. Very large increases in coliform organisms were apparent
within the flume system. The study concluded that incoming soils at-
tached to the beets represented a significant source of bacterial entry
to the sugar mill. Bacteria on the soils were associated with the fer-
tilization of agricultural lands by animal manure, a practice common in
the industry. Bacteria growth in the flume system was enhanced by the
extremely favorable environment, including an abundance of nutrients,
proper temperatures, stagnant pockets and availability of fixed surfaces.
Studies were carried out at the Crooks ton and East Grand Forks,
Minnesota factories during October 1965 using improved analytical pro-
cedures to provide better delineation of the bacterial sources. Table
XV shown below has been taken from the Red River of the North report
indicating the bacterial densities found on the raw sugar beets and as-
sociated dirt, trash and fertilizers.
Total coliform results given in Table XV show that the dirt from
freshly unloaded beets contained 490,000 organisms/gram. Somewhat sur-
prising were the very high total coliforms on the sliced beets, and even
higher densities on the beet trash removed from the flume. These levels
were respectively 13,000,000 and 17,200,000 total coliform/gram material.
Surface peelings of the beets taken from freshly stored piles indicated
a total coliform density of 2,800,000/gram. These bacterial levels on
the material entering the flume were said to account for the excessive
total coliform bacteria found in the flume and wash waters at both
Minnesota plants. A bacterial balance on the system was not attempted.
The sources of fecal coliforms were somewhat more difficult to
ascertain in the Red River of the North study. The only materials
yielding significant fecal coliform were the sliced beets after washing
and the beet trash. It was indicated that growths adhering to the sides
of the flume and wash tank may have been responsible in part for fecal
coliform bacteria in the circuit. High fecal streptococcus counts ob-
served on the soils, the sliced beets, beet trash, and the beet surface
peelings were said to account for the excessive streptococci densities
in the flume waters. These investigations considerably improved upon
and even changed some of the interpretations made available in the ear-
lier Fort Morgan, Colorado study.
82
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TABLE XV
BACTERIOLOGICAL DENSITIES - PARTICULATE MATERIAL ^
Bacterial Count Per Gram
Description Total Fecal Fecal
Coliform Coliform Streptococci
Beet dirt ^/ 490,000 10.9 2,200
Sliced beets 13,000,000 172,000 580,000
Beet trash £/ 17,200,000 49,000 3,800,000
Beet surface peelings 2,780,000 <0.2 5,200
Wet beet field soil 94 1.3 150
Dry beet field soil 0.9 <0.2 210
Beet fertilizer (artificial)-A <0.2 <0.2 1.4
Beet fertilizer (artificial)-B <0.2 <0.2 0.2
Beet fertilizer (artificial)-C <0.2 <0.2 <0.2
a/ Taken from the Proceedings of the Conference in the matter of Pollu-
tion of the Interstate Waters of the Red River of the North; North
Dakota-Minnesota (26).
b_/ Composite scraped from 10-15 freshly unloaded beets.
_c/ Stalks and weed material recovered from flume.
Exploratory studies at the Taft Sanitary Engineering Center in
Cincinnati, Ohio have provided additional information on bacterial sources.
The acquired data showed that sugar beets in the field, with respect to
both the beet surfaces and the soil adjacent to the root area, may be-
come contaminated with fecal organisms from irrigation water, animal, and
/or rodent excreta. Wildlife populations may also be contributing fac-
tors. Whereas chemical fertilizers contributed little, animal manure used
for fertilization was found to be an important source of fecal coliforms
and the associated enteric pathogens which entered the sugar mill on con-
taminated soils or beets. The persistence of such organisms through field
cultivation up to harvesting was influenced by many factors, such as,
moisture content, exposure to sunlight, pH level, and available nutrients
retained in. the fecal pellets (27) .
Sugar beets stored in large piles at the plant site or in outlying
areas such as railroad sidings may be exposed to rodent activity and add-
itional pollution from new truck or railroad car unloadings. Rainfall
may assist the spread of existing contamination. A preponderance of fe-
cal streptococci over fecal coliforms has been found in beet piles. All
streptococci examined were identified as Streptococcus fecalis. These
findings strongly indicated the presence of rodent or storm water pollu-
tion. Within the factory, river water used for fluming and washing pur-
poses may represent another source of fecal coliforms. These bacteria
were found generally originating from domestic waste discharges upstream
(27).
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C. EFFECTS OF WASTE STORAGE UPON BACTERIAL POPULATIONS
Wastewater storage is currently employed by industry as a treat-
ment means to reduce organic and solids waste loads together with bac-
terial loads. The available data resolves itself into the conditions
expected from long-term storage vs. limited or no waste holding.
During the Red River of the North survey extensive bacteriologi-
cal data was collected on the waste holding pond at the East Grand Forks
factory. The holding facility was a flow-through type, consisting of
eleven bays in series providing a waste detention time of about 32 days.
Samples were collected at various locations in the pond, the respective
detention time was determined for the waste corresponding to each sample,
and bacterial concentration-time curves were developed.
Total coliform bacteria in transit through the East Grand Forks
pond increased from an influent value of 12.3 million/100 ml up to 50.3
million/100 ml after 6.3 days. From this point, there was steady die-
away in total coliforms and the final effluents after 32 days waste re-
tention contained 350,000 organisms per 100 ml, or 97 percent reduction
in the original coliform numbers. The fecal types did not proliferate
but instead decreased throughout the pond. From an influent value of
1.5 million/100 ml, the final effluents contained 1,400 fecal coliforms
/100 ml representing a 99 percent reduction in the original numbers.
The fecal streptococcus densities declined rapidly throughout the pond
compared to the coliform organisms, and influent and effluent values
were 840,000 and 400/100 ml respectively, representing a 99.5 percent
reduction after 32 days of waste storage (26).
The Red River of the North report described the bacterial die-
away rates within the East Grand Forks pond-as extraordinarily slow and
attributed this to a high level of nutrients. Not only were the fecal
coliforms sustained over a relatively long period, but there was also
early-stage multiplication in the total numbers of coliform bacteria (26).
Detailed bacteriological studies were conducted on the waste
handling-treatment systems of both the Fremont and Findlay, Ohio sugar
factories during the first five months of 1965 (28). The Fremont plant
employed a waste holding lagoon as an integral unit of a closed flume
water recycle system. The Findlay plant had a closed flume and condenser
water recycle system with mechanical settling, lime mud pond, sludge pond,
spray pond, and excess water pond, all integrated into the circuit. The
reader is referred to Section V, E 1 and 2 of this report for full des-
cription of the Fremont and Findlay systems. At both factories, the
wastes retained in the ponds after the close of campaign (occurring
around mid-January) represented accumulated wastewater under conditions
of long-term storage.
Three locations in the Fremont wastewater lagoon showed total and
fecal coliform densities on January 20 approximating 2,000 organisms/100
ml. During storage, total coliform increased to levels of 0.2 - 0.9
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million/100 ml on February 10. After this time, the total numbers of
coliform demonstrated a gradual die-away with values in the order of
2,000 - 8,000/100 ml on April 7, which was 2 days before the pond was
emptied into high flows within the receiving stream. Fecal coliform
bacteria in the pond varied from about 100 to 10,000/100 ml over the
period of waste storage. The die-away trend in fecal coliforms was
very gradual with values of 50-300/100 ml recorded on April 7. Over-
all coliform reductions were only partially encouraging, primarily due
to relatively low initial counts. Wastewater temperatures during winter
storage at Fremont were in the range of 0-10°C (28).
Bacterial data considered most important at the Findlay installa-
tion were received from the spray pond and the excess water pond. The
observation was made that bacterial densities in the Findlay system were
many times higher than Fremont, aided by sludge pond overflow into the
Findlay circuit. Wastes were retained until the end of May and the
role of temperature was quite important over this period. Wastewater
temperatures decreased sharply in mid-January and remained at 0-2°C un-
til April 7. Thereafter, temperatures increased rapidly reaching 24°C
on May 26.
The spray pond effluent showed both total and fecal coliform
bacteria in the range of 10-40 million/100 ml from mid-January until
February 3. Die-away rates were very gradual throughout February and
March with total and fecal coliforms around 3 million/100 ml on March
28. Coincident with rising temperatures, the bacterial densities rapid-
ly decreased to minimum levels on April 28. On this date, total coli-
forms were 500/100 ml and fecal coliforms were 90/100 ml. Surprising
enough, this was followed in May by significant increases in both total
and fecal coliform. Final values of 150,000 total coliform and 2,000
fecal coliform/100 ml were reached on May 26. Considerable bacterial
reduction was obtained up to the end of April but this was partly offset
by bacterial regrowth during May.
The excess water pond effluent showed more or less a bacterial
pattern similar to the spray pond up to the end of March. At that
point, total coliforms stabilized around 40,000-300,000/100 ml, whereas
fecal coliforms steadily decreased until a level of about 1,000/100 ml
was reached on May 26. Only the fecal coliform reduction was considered
satisfactory at Findlay (28).
The Red River of the North survey found that holding facilities
of the Crookston. Minnesota plant provided a waste detention of 11 days
prior to discharge. The influent to the holding pond contained 5.3
million total coliform/100 ml, and 1.7 million fecal coliform/100 ml,
whereas the fecal streptococci were too numerous to count. Total coli-
form densities in the effluent averaged 37 million/100 ml, and fecal
coliform were 12.5 million/100 ml. As illustrated by previous results
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from the East Grand Forks mill, the Crookston time of storage was about
optimum for producing peak levels of coliform bacteria. Since no re-
duction in bacterial loads was obtained, this situation may be described
as a reversal effect.
The merits of waste treatment upon bacterial loads originating
from the ten sugar factories in the South Platte River Basin were pre-
viously tabulated in Table XIII. Three establishments were without
waste treatment facilities and adequate data was not received at a fourth
plant. The remaining six factories utilized shallow lagoons or aeration
fields for waste treatment with detention times varying from a few hours
up to 1.5 days. The Loveland factory wastes contained very low bacterial
densities attributed to a highly alkaline environment. Treatment at the
Windsor and Greeley factories caused apparent bacterial removals of 35-80
percent. On the other hand, Fort Morgan factory wastes experienced no
appreciable reduction in bacterial numbers through treatment, and results
from the two remaining factories at Longmont and Johnstown were even more
discouraging. Total and fecal coliforms increased many fold in passing
through the waste treatment lagoons at both Longmont and Johnstown.
Discounting recent changes in the South Platte River Basin, the
treated factory wastes generally contained total coliform densities in
the range of 1.6 to 49 million/100 ml. Corresponding fecal coliform
densities were between 18,000 and 4.1 million/100 ml. The serious na-
ture of bacteriological pollution in the South Platte River Basin cannot
be disputed. In summary, it is foreseen that only long-term storage of
sugar beet wastes may possibly reduce the bacterial densities to satis-
factory levels. In contrast, limited waste retention may create large
increases in coliform, streptococci and pathogenic organisms. Other
waste treatment methods should be sought for greater efficiency in bac-
terial removal.
D. BACTERIAL SURVIVAL
Sugar beets are known to be a complex mixture of various carbohy-
drates including pectin, pentosans, cellulose, purines, and related com-
pounds such as betaine and urea together with vitamins. The conversion
of these organic components to waste causes large problems in sugar beet
process treatment and disposal. These nutrients retard the normal die-
away of bacterial organisms both within the treatment system and the
receiving stream. The longer survival time and possible regrowth of
bacteria in the stream negate in part the reduction of bacterial loads
by natural assimilative means. The information given below indicates
the persistence of bacterial organisms within the treatment system.
Representative wastewater samples were taken in October 1965 at
various in-plant locations at the Crookston and East Grand Forks sugar
factories, as well as the influent and effluent of the holding ponds
from these two factories plus the Moorhead factory. The samples, after
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collection, were sterilized and reinoculated with known quantities of
fecal coliform, fecal streptococci, and Salmonella of the typhimurium
series. The reconstituted samples received incubation for periods up
to 14 days at or near the temperature of collection (26).
Fecal coliform concentrations in the water supplies showed some
initial decrease, then remained relatively constant through the third
day, followed by a gradual rate of die-away. Fourteen percent and 6
percent of the original fecal coliform were remaining after 7 days in
the two separate water supplies. An initial period of acclimatization,
the lag phase, and the gradual die-away were likely caused by a favor-
able nutrient level. Fecal streptococci in the water supplies exhibited
an immediate adaptability and increased numbers in the first day or two,
then a gradually accelerating die-away until the densities were virtually
nil on the seventh day. Salmonella showed near the same pattern as fecal
streptococci but demonstrated a greater resistance to die-away from the
fourth day on. The Salmonella densities were approximately 2 percent of
the initial concentrations after 7 days.
Fecal coliforms in the flume waters were reduced to insignificant
quantities after one day. Fecal streptococci showed a gradually acceler-
ating die-away in flume waters until the densities were approximately
2-3 percent of the initial concentrations after 3 days. For Crookston,
Salmonella numbers increased 56 percent over original numbers on the
first day followed by rapid die-away. At East Grand Forks, the Sal-
monella experienced an initial die-away, followed by an increase, then
a very slow die-away with 5 percent of the original numbers remaining
after 14 days. The results of the beet washer waters indicated that add-
ed nutrients greatly encouraged the multiplication and survival of Sal-
monella in the plant wastes. The holding pond effluents showed that fe-
cal coliform die-away was most rapid of the three bacterial groups with
negligible quantities remaining after 14 days. Salmonella had a rapid
initial die-away but after 3 days the concentrations declined slowly.
At Crookston and East Grand Forks, the 14-day Salmonella concentrations
were respectively 5 percent and 0.5 percent of the original numbers.
The fecal streptococci exhibited the slowest die-away rate with signifi-
cant concentrations as high as 34 percent remaining after 7 days (26).
The above study conducted in vitro will not precisely duplicate
conditions in the field. Nevertheless, the results provide a sound
basis for predicting bacterial survival trends in sugar beet processing
wastes. From the available information, there is no reason to believe
that enteric pathogens in general are less persistent and have shorter
survival times than indicator organisms. This extends the time and dis-
tance required both in the treatment system and the receiving stream for
recovery to non-hazardous levels. It must therefore be concluded that
a health hazard is involved whenever the presence of inadequately treat-
ed sugar beet wastes are associated with the use of receiving waters.
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E. FECAL COLIFORM - STREPTOCOCCI RELATIONSHIPS
The relationship between numerical levels of fecal coliforms
and fecal streptococci within various wastewaters serves to describe
the nature of the waste and its major contributing sources. A pre-
ponderance of fecal coliforms with a FC/FS ratio greater than 4 in-
dicates the presence of domestic wastes including laundry wastes and
food refuse. A dominance of fecal streptococci bacteria with a FC/FS
ratio less than 0.6 indicates pollution derived from livestock and
dairy animals such as found on farm-feedlots and stockyards or from
storm-water runoff. Further separation of sources can be made by
studying the distribution of fecal streptococci strains present within
the wastewater (21, 22, 27). These differentiation principles were
employed with good success in the South Platte River Basin area.
Typical bacterial densities in the wastes from four sugar fac-
tories and the receiving stream above and below these locations are
given in Table XVI. Although total coliform densities were quite im-
portant, particular emphasis is placed upon the fecal coliform and
fecal streptococci values. These levels were quite high with the pos-
sible exception of the clean water sewer at the Johnstown factory.
The bacterial quality of stream waters closely reflected the discharge
from the factory. The Johnstown establishment was quite unlike the
other sugar mills in that it received discard molasses and concentrated
Steffen filtrate rather than raw sugar beets.
The ratios of fecal coliform to fecal streptococci contained in
the final waste discharges from the Brighton, Longmont, and Eaton plants
were respectively 0.37, 0.003, and 0.01. There was no doubt for these
three plants that bacterial pollution was primarily and originally de-
rived from the fecal excreta of animals rather than humans. The bac-
terial picture at Johnstown, because of the nature of operations, dem-
onstrated a different picture with a high FC/FS ratio obtained on the
dirty water sewer and a low ratio on the clean water system. The clean
water sewer was reported to be primarily associated with the sugar house
operations rather than the MSG process. The relatively low fecal coli-
form counts may also have been caused by temperature sensitivity to par-
ticular unit operations. However, the full explanation for the Johns-
town results was not available.
The River waters above Brighton in January 1965 were known to
contain large volumes of inadequately treated municipal sewage origi-
nating from Metropolitan Denver. The stream was heavily polluted and
showed a FC/FS ratio of 3.0 indicative of upstream waste sources. Down-
stream of the Brighton sugar factory, this ratio decreased to 1.0, gov-
erned by the large numbers and preponderance of fecal strep discharged
from the Brighton mill at that time. At Longmont, the relative numbers
of fecal coliform and fecal strep changed drastically in the river from
above to below the Longmont sugar mill. Again a predominance of strep-
tococci caused a shift in the FC/FS ratio of 3.3 upstream to 0.09 down-
stream. The stream below the Eaton sugar mill experienced a 930-fold
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TABLE XVI
BACTERIAL DENSITIES IN
SUGAR BEET PLANT WASTES AND RECEIVING STREAMS
SOUTH PLATTE RIVER BASIN
Factory Date
Description
Total Coli.
(MPN/100 ml)
Fecal Coli. Fecal Strep.
(MPN/100 ml) (No./100 ml)
Brighton 1-65
Longmont 11-65
Eaton 11-65
Johnstown 11-65
Factory discharge
to river
River above plant
River below plant
Factory discharge
to river
River above plant
River below plant
19,500,000
3,300,000
4,600,000
490,000
790,000
490,000
Factory discharge
to stream 33,000,000
Stream above plant 7,450
Stream below plant 29,000,000
"tlean water sewer"
discharge to river
Dirty water sewer
after lagoon
treatment
River above plant
River below plant
13,000
49,000,000
13,000
3,950,000
4,100,000
790,000
1,700,000
17,500
71,500
94,500
640,000
410
380,000
4,900
950,000
3,600
63,500
11,000,000
260,000
1,600,000
6,350,000
22,000
1,100,000
62,000,000
15,000
63,000,000
160,000
3,600
1,650
26,200
increase in fecal coliforms and a 4200-fold increase in fecal strep, pro-
ducing a FC/FS ratio of 0.006. This was the least ratio found at any lo-
cation in the South Platte River Basin. The relative effects upon the
river of fecal coliform and fecal streptococci from the two waste dis-
charges at Johnstown appeared to be counterbalancing. This factor, how-
ever, did not mitigate the severe degradation in bacterial quality below
the Johnstown factory.
In November 1965 the South Platte River Basin Project also conduct-
ed special tests on the Eaton factory effluent and the town of Eaton sew-
age treatment plant effluent in order to identify and differentiate special
groups of fecal streptococci present in the two wastes. The treated muni-
cipal sewage showed 38 percent of the streptococci were of the enterococcus
group which were of human origin, 26 percent were of the strep bovis
species and 22 percent of the strep equinis group, both associated with
animal origin, and 14 percent were undefined. The municipal sewage may
have contained some additions of food processing and related industrial
wastes. On the other hand, the sugar beet wastes contained entirely strep
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bovis. The strep bovis group is strongly associated with cattle and
other domestic animal feces. Other investigators have shown that the
excreta from cows contains 63 percent or more strep bovis together with
other streptococci species (21). It was thereby concluded that animal
manure commonly used in the South Platte River Basin for fertilization
of sugar beets very likely transmitted large numbers of fecal micro-
organisms to the processing plant, carried in by the raw sugar beets.
These organisms subsequently appeared in the waste processing effluents
and then in the Basin streams.
F. SALMONELLA ASSOCIATED WITH SUGAR BEET WASTES
The recovery of pathogenic organisms associated with sugar beet
wastes, specifically Salmonella, has been verified in the Red River of
the North study, the Fremont and Findlay plant surveys, and also in
the South Platte River Basin investigations.
At the East Grand Forks factory, Salmonella were not isolated in
the influent wastes to the holding pond but were found within the treat-
ment basin. These wastewaters were reported to be significantly con-
taminated with pathogenic organisms representing a health hazard to any-
one coming in contact with such. Attempts to recover Salmonella from
the influent and effluent of the Crooks ton holding pond did not prove
successful. However, similar attempts on the Moorhead factory effluent
were positive for Salmonella. Successful recoveries were also made in
the river below the Fargo, North Dakota and Moorahead, Minnesota munici-
pal and industrial waste discharges whereas, significantly, no Salmonella
was isolated upstream. The Red River of the North report emphasized that
nutrients added by processing of sugar beets promoted the growth and mul-
tiplication of Salmonella within the factory wastes. Furthermore,
the study recommended that these nutrients should be reduced or elimi-
nated as soon as possible (26).
During the bacteriological sampling program at Fremont, Ohio pos-
itive recovery of Salmonella was made on the treatment lagoon effluent
on April 9, 1965, the day on which the pond contents were emptied to the
river. The pathogens had evidently survived the long period of winter
waste storage (28).
The South Platte River Basin Project on January 20, 1967 collect-
ed a single sample of the treatment lagoon effluent at the Longmont,
Colorado sugar factory. The lagoon effluent was again sampled on Jan-
uary 25, at which time the wastewaters leaving the main factory at
Longmont (ahead of treatment) were also sampled. Eleven Salmonella
cultures were recovered from the three samples and identified as four
serotypes. The wastewater of January 20 showed the presence of Sal-
monella san diego; the plant effluent of January 25 contained Salmonella
tennessee and Salmonella san diego; and the pond effluent of January 25
showed both Salmonella cubana and Salmonella thompson.
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The Longmont results confirmed the presence of potentially patho-
genic Salmonella within the wastes direct from the sugar mill and in the
treatment pond overflows. These effluents were considered severely pol-
luted with definite hazard involved for human contact. A similar hazard
was implied for the receiving stream.
Research in the general area of pathogenesis shows that there has
been a gradual rise in the occurrence of non-typhoid Salmonellosis across
the United States within recent years. Over 900 serotypes, including
the four mentioned above, have been isolated from man, domestic and wild
animals, and their environments, and nearly all have been implicated in
human disease. The Salmonella serotypes in large majority have been
identified as non-host specific and spread from man to man, animal to
man, and from animal products to man, either directly or through inter-
mediate contaminated material (29, 30).
G. CRITERIA FOR BACTERIAL REDUCTION
Guidelines for the necessary reduction of bacterial loads within
sugar beet processing effluents were recommended at the Conference on
interstate pollution of the Red Riyer of the North in September 1965,
and at the Second Session of the Conference on the intrastate pollution
of the South Platte River in Colorado, April 1966 (2, 26).
For protection of the various water uses on the Red River of the
North, including municipal water supply, fish and other aquatic life,
in both the States of Minnesota and North Dakota, certain criteria were
outlined at the Conference. With respect to bacterial loads from the
domestic and industrial sources including the four sugar factories, the
Minnesota and Federal conferees recommended that these waste discharges
not contain total coliform densities in excess of 5,000/100 ml. The
North Dakota conferees recommended that such discharges not cause total
coliform densities in the river, after mixing, to exceed the level of
5,000/100 ml. The Moorhead and Crookston factories were to provide con-
trolled waste discharge which would likely require complete storage of
wastes over the processing campaign. No industrial plants were permitted
to discharge process wastes under ice cover. Furthermore, the Minnesota
and Federal conferees recommended that the regulatory agencies allow 5
years to accomplish removal of nutrients from the various municipal and
industrial waste discharges, where delays in development of effective
removal processes indicated that such time was necessary. The North
Dakota conferees recommended that 5 years be allowed to accomplish re-
moval of nutrients from the various waste discharges if by that time a
feasible method of nutrient removal was developed (26).
The Conference on the South Platte River recommended certain mea-
sures on bacterial waste control in accordance with overall remedial and
control facilities to be made available for the entire Basin by June 30,
1971. Specifically for the ten sugar factories, disinfection or equiva-
lent means were to be provided for each waste effluent so that the re-
ceiving stream or waterway directly below each mill not show an increase
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of more than 5,000 total coliform bacteria/100 ml, and no more than
1,000 fecal coliform/100 ml over the corresponding densities upstream
of the mill discharge. Each mill was advised to conduct continuous
monitoring of the quality of final waste effluents and of each re-
ceiving stream below the points of waste discharge, and to maintain
adequate records of such. This study assumed that high-level waste
treatment would be provided by each mill in the future and would serve
to remove the nutrient loads. Only then would disinfection or equiva-
lent means provide for the necessary destruction of the residual bac-
terial organisms.
Alternative measures and differing philosophies have undoubtedly
been used and expressed with regard to bacterial waste control in other
parts of the country. In all cases, control procedures and regulations
must be linked both to a proper and full recognition of the problem and
the explicit needs of the given area.
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SECTION V
WASTE ABATEMENT AND TREATMENT
IN THE BEET SUGAR INDUSTRY
-------
V. WASTE ABATEMENT AND TREATMENT IN THE BEET SUGAR INDUSTRY
The need for overall review and evaluation of waste abatement and
treatment within the beet sugar industry is of considerable importance
today. The Industrial Waste Guide for Beet Sugar (20) published some 15
years ago, was the latest report giving a summary status of waste condi-
tions throughout the industry. Although the Waste Guide was excellent
in many respects, there has been much change over the intervening years.
Modifications have occurred in the basic process, handling of raw ma-
terials and products, methodology, conversion of old wastes into useful
by-products, changing attitudes on water and air pollution, new and im-
proved treatment schemes, and also the formulation of new problems.
Whereas the preceding sections of this report emphasized the pre-
vailing conditions in the South Platte River Basin, the discussion on
waste abatement and treatment is orientated to the nationwide picture.
This information is based in very large part upon the available litera-
ture and to a lesser extent upon the author's personal experience with
sugar beet mills particularly but not exclusively in the South Platte
area. Heavy reliance is placed upon materials received from the British
Columbia Research Council, Vancouver, Canada. This group has performed
various research work for the Beet Sugar Development Foundation. The
industry must be commended for its interest in such studies. Of great
importance, the data are derived from many areas, and therefore have
widespread and representative application to the entire industry.
The sugar industry is considered to be a principal contributor to
pollution of the Nation's waterways because of large amounts of organic
wastes being discharged. The concentration of sugar factories in certain
areas has undoubtedly enlarged this reputation. Also, the urban popula-
tion has expanded its zone of influence into semi-rural and rural areas.
This has lead to a greater awareness of land and water resources by
larger numbers of people. Unfortunately, it has also resulted in con-
flict where the waters were previously used for industrial and agricul-
tural waste disposal. For example, the sugar beet factories in the South
Platte River region account for 15 percent of the total establishments
in the United States but however, occupy only 0.4 percent of the Nation's
land area.
Sugar beet processing plants may be grouped into four geographi-
cal areas of the United States: 1) the west and north central U.S.;
2) the Red River region particularly the States of North Dakota and
Minnesota; 3) the general Great Lakes area and; 4) the State of
California. Sugar beets are processed in modern factories in Canada,
Great Britain, Western Europe, Poland, the Soviet Union, and other
countries. In all there are some 800 beet sugar factories in Europe
and North America. Information gathered from foreign experience has
been added to this report.
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A wide variety of interests and skills are represented and
affected by industry action including the sugar companies, the farmers,
seed manufacturers, farm equipment manufacturers, irrigation companies
and districts, migratory labor, product wholesalers and retailers, resi-
dent groups, and local, regional, State and Federal Government. The
industry in the past ten years has made reasonable progress in most
areas towards the elimination of processing effluents and serious pol-
lution problems. Nevertheless, the present-day demand for improved
water quality will mean acceleration of this program to be required
of industry.
This report reviews and explores the techniques of recent appli-
cation and those under current study for successful handling of waste
problems. Abatement and treatment methods were found in most cases to
comprise particular systems which were a combination of measures best
suited to the individual factory. Not all the examples in the litera-
ture could be cited. This part of the report is subdivided into the
following sections: description of major wastes, in-plant measures,
minimum treatment (primary treatment or less), intermediate treatment,
high levels of treatment, and other considerations.
A. DESCRIPTION OF MAJOR WASTES
The most important wastes from sugar beet processing are the
spent flume waters; the process waters including pulp transport and
pulp press waters, and pulp silo drainage; lime mud cake (slurry);
Steffen house filtrate; and the excess condenser waters. These wastes
resulting from a sugar beet factory, are discussed below:
1. Spent Flume Water
Flume water is used to convey the beets hydraulically from the
railroad car or truck unloading area or from the beet piling areas,
into the main factory. The beets are floated in shallow, concrete
flumes. The flume waters after passing the beet wheel receive beet
washing and spray table overflows. This mixture is generally described
as spent flume water.
Information was compiled by the British Columbia Research Council
on the flume waters of many factories both in the U.S. and Canada. This
study included mills varying from a high degree of flume water recircu-
lation to once-through systems. The BOD levels ranged from 115 to 1525
mg/1 with an average of 565 mg/1. The suspended solids content averaged
210 mg/1, with a low of 127 mg/1 and high of 4500 mg/1. European ex-
perience has indicated BOD values from 150 to 250 mg/1; furthermore, the
average BOD level varied from year to year. In the United States these
BOD values have most frequently ranged from 200-500 mg/1. A number of
investigators have also commented upon the increasing BOD in the flume
waters as the season progresses. Increases were attributed to frozen
beets or deterioration due to poor or prolonged storage conditions.
Consequently the BOD may increase 3-fold when handling frozen beets.
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During fluming, large quantities of dirt are removed from the in-
coming sugar beets, ranging from 7 percent of the beet weight during dry
seasons up to 20 percent during wet seasons; average tare was 10-15 per-
cent. Another study indicated that a typical factory may receive around
40,000 tons incoming dirt over the average campaign. Flume water gen-
erally accounted for two-thirds to 80 percent of total plant water con-
sumption and resulting wastewater volume.
The Industrial Waste Guide described unit waste values for flume
water of 2600 gallons and 4.5 pounds BOD per ton beets processed. A
value cited from the European literature was 5.0 pounds BOD. Previous
studies in Minnesota showed that the average pounds of BOD per ton beets
varied from 2.0-4.4 at the beginning of the season up to 9.2-10.3 near
the end of campaign. The suspended solids loads averaged about 7.0
pounds over the same season.
Very high bacterial densities are common within waste flume water,
the consequences of which were described in Section IV of this report.
Depending upon particular in-plant measures, flume water volume and
strength may vary greatly. At present time, flume water is the most
complex waste disposal problem remaining in the industry (19, 20, 30,
31, 32, 33, 34, 35).
2. Process Waters
Process waters consist of the drainings from exhausted wet pulp
after diffusion. Continuous diffusers are in common use today facili-
tating the use of closed or nearly-closed process water systems. If
water means are employed for conveying wet pulp to the presses, the
residual water volume is known as pulp transport or pulp screen water.
Many factories provide belt conveyors for moving wet pulp to the presses
thereby eliminating this potential waste. The liquors extruded in the
pressing of pulp are termed pulp press waters which should be returned
to the diffuser. Pulp transport and press waters represent relatively
low volume but high strength wastes.
The British Columbia Research Council from a study of 59 mills
showed that process waters averaged 2960 mg/1 in 5-day BOD with a range
from 800 to 7000 mg/1. Suspended solids averaged 860 mg/1 with a range
from 530 to 1800 mg/1. The Industrial Waste Guide described the process
waste loads associated with a continuous diffuser as approximating 580
gallons and 5.6 pounds BOD per ton beets. The industry after many years
of experimentation has proved that these waters can be completely reused
in the process, with profitable sugar recovery and considerable reduction
in stream pollution.
One other form of process wastewater is the drainage accruing
from wet pulp in the pulp silo. Fortunately, there are less than 12 fac-
tories across the country without pulp press and pulp drying facilities.
These plants produce wet rather than dry pulp as the end product. Pulp
silo drainage is acidic in nature and exceptionally high in dissolved
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organic content. The Industrial Waste Guide indicated that pulp silo
drainage had unit waste values of 210 gallons and 12.3 pounds BOD per
ton beets processed. The studies in the South Flatte River Basin
showed pulp silo drainage contributed 16 pounds BOD and 22 pounds COD
to the total plant load per ton beets processed. Considering the ex-
cellent market for dry pulp together with additional sugar recovery,
all wet pulp silos in the U.S. 'should be phased-out in the near future
(17, 18, 20, 31, 36, 37).
3. Lime Mud Slurry
Hydrated lime is added to the beet juice as a purifying agent
and then precipitated by carbon dioxide. The calcium carbonate sludge
with impurities removed from the juice is vacuum filtered, slurried
with water, and this mixture is known as lime mud waste. Steffen
house factories use nearly double the quantity of lime employed in
straight-house operations, and the lime cake slurry was reported as
about 50 percent higher in strength. Sludges from the CSF process and
boilouts from the cleaning of evaporators and vacuum pans may also be
mixed together with the lime muds in waste disposal. Lime cake gen-
erated from juice purification operations amounts to 1.5-3.0 percent
of the weight of beets worked in U.S. practice, and about 5.0 percent
in European practice. The large difference between U.S. and European
values was not explained. A factory handling 150,000 tons of beets
over the season could produce 3000-4000 tons lime cake. The weight
of slurry would be considerably greater.
Lime sludge is predominately alkaline with extremely high organic
and solids content, and as such represents a serious disposal problem.
Besides calcium carbonate, the sludge includes nitrogen pectins, album-
inoids and significant sugars. Study of 59 mills in the U.S. and Canada
showed lime mud slurries to have an average BOD of 6,370 mg/1 with a
range of 1,060 to 27,800 mg/1 BOD. The suspended solids content of
these slurries averaged 229,000 mg/1 with a range from 143,000 to 357,000
mg/1 TSS. The amounts of water added to the filter cake varied greatly
and were mainly responsible for the wide range demonstrated in BOD and
TSS values. Nearly all the dry solids were in the suspended form. The
British Columbia Research Council reported that lime mud was ponded sep-
arately or together with other plant wastes at 55 of the 59 mills. How-
ever, it is well known that many of these factories actually discharge
lime mud direct to the receiving stream.
The Industrial Waste Guide indicated that lime mud slurry would
be expected to have unit waste values of 210 gallons and 6.5 pounds BOD
per ton beets processed. From experiences in Europe and Great Britain,
both lower and higher BOD values have been reported. The data obtained
from three Steffen house factories in the South Platte River Basin show-
ed average unit waste values approximating 5 pounds BOD, 7 pounds COD,
90 pounds TSS, and 45 pounds alkalinity per ton beets processed (17, 19,
20, 31, 34, 35, 38).
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4. Steffen Filtrate
Steffen filtrate originates from the filtering of saccharate
cake in the precipitation of lime-treated diluted molasses in the Steffen
house. The Steffen filtrate through the 1940's represented the most dam-
aging waste product from the sugar factory. The filtrates are highly
alkaline with a pH level around 11, and 3-5 percent organic solids. The
Industrial Waste Guide described Steffen filtrate as containing around
10,500 tng/1 BOD, 25,000 to 40,000 mg/1 total solids, and 100 to 700 mg/1
TSS. Unit waste values were 2650 gallons (11 tons) and 231 pounds BOD
per ton molasses (expressed as 50 percent sucrose). Steffen filtrate
produced in the South Platte River Basin was entirely converted to CSF
(concentrated Steffen filtrate) and reused. Steffen filtrate conversion
is discussed later in the report (20, 31).
5. Excess Condenser Waters
Vacuum is created on the multiple-effect evaporators and across
the vacuum pans by a barometric condenser system. Steam and vapors
from the fifth-effect of the multiple-effect evaporator and from the
vacuum pans are condensed by direct contact with the waters passing
through the barometric condensers. The degree of contamination in the
barometric condenser waters depends upon the liquid entrainment in the
vapors passing over from the fifth-effect. In the evaporator system,
condensates from the first effect are relatively pure in quality. Sub-
sequent condensates are affected in higher degree due to entrainment of
liquid in the vapors passing from one effect to the next. Condensates
are largely if not totally reused in the factory but some may be wasted.
The CSF evaporators are likewise included in this picture. In most
mills the condenser and cooling water systems are the principal sources
of water supply for the beet flumes.
The British Columbia Research Council study on various factories
reported an average BOD for excess condenser waters of 43 mg/1 with a
range of 25 to 130 mg/1 BOD. Suspended solids averaged 67 mg/1 with a
range from 0 to 100 mg/1 TSS. Experience indicates that accidents,
shock loads, etc., cause heavy entrainment of the vapors and these con-
ditions are reflected in the waste lines. Based upon U.S. and European
practices, the best control procedures will lower the condenser BOD to
15-30 mg/1. The Industrial Waste Guide attributed 0.7 pounds BOD per
ton beets to the barometric condenser waters. The South Platte River
Basin studies showed that the CSF condensates could be expected to create
additional waste load, amounting to 0.7 pounds BOD for each ton of mo-
lasses worked.
Condenser waters may be reused within the plant, discharged
directly, passed through cooling towers before entering the receiving
stream, or may be continuously recycled and reused in an integrated
flume and condenser water recovery system (17, 20, 31, 34, 38, 39).
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B. IN-PLANT MEASURES
1. Handling of Sugar Beets Before Reaching the Factory
Although handling of the beets in the field and enroute to the
factory are not part of in-plant operations, these procedures are
directly related to factory waste disposal problems and therefore war-
rant close attention. The two major items of importance are the dirt
and bacteria brought in with the beets. The sugar company, however,
generally considers the condition, sugar content and purity of the
beets to be of highest concern.
The farm soil may theoretically be removed either by the farmer
or by the company. Universal practice calls for the company to assume
this responsibility. In consequence, the dirt and associated trash
become part of the plant waste system and may eventually enter the
stream. Some tare is removed by shaking and screening prior to pro-
cess, and returned to the delivery trucks. However, the large majority
of dirt enters directly into the mill. This condition has stemmed
from the increasing trend toward mechanization on the farm. Jensen
(18) reported that beet roots were originally loosened from the ground
by a lifting machine and the field workers removed most of the dirt by
shaking and then they cut off the leaves. The discard material there-
upon remained in the field. In the U.S., because of high costs and
labor scarcity, more mechanical harvesting became necessary. In turn,
mechanical harvesting was responsible for much more soil adhering to
the beets as well as the unwanted leaves and trash.
Large quantities of bacteria in sugar factory effluents were
first suspected, and are now known as originating with the incoming
sugar beets. Animal manures applied in raising crops have been estab-
lished as the major source of bacterial release within the sugar beet
factory.
The future of waste abatement would suggest a much needed change
in bringing sugar beets to the factory. The removal of soil, leaves,
and trash at the farm would provide the mill with the cleanest possible
raw product and solve many of the present problems. Late-season irriga-
tion and wet-field harvesting, although advantageous at times to the
farmer, contribute to increased waste treatment or stream pollution by
the factory. Many if not all sugar companies possess adequate leverage
to require that proper measures be taken by the farmers. Dry removal
techniques are highly desirable although harvesting costs would undoubt-
edly rise. However, if extensive factory waste treatment is to be re-
lied upon for removing these materials, the results will not only be
more costly but also less efficient.
2. Redesign of the Beet Flume System
The hydraulic fluming method of transporting beets into the fac-
tory was developed by German technicians in 1879. The flume system
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replaced the then conventional means of handling beets by small cars,
conveyor belts, and even wheelbarrows. The'basic system has been modi-
fied many times, but in view of major attention being given to waste-
water problems it should be re-examined once again. Hydraulic fluming
from the standpoint of the company offers an effective and easy means
of transporting and cleaning the beets| and thawing frozen material. One
disadvantage is the loss of sugar to the flume waters. In pollution
abatement, the waste flume waters represent a formidable problem.
Deterioration of the sugar beets within storage can be minimized
by maintaining proper conditions in the stockpiles and reducing storage
time as much as possible. More care should be given to preventing dam-
age and breakage of the beets and in this regard, the mechanical equip-
ment and handling procedures for loading and unloading could be consid-
erably improved. These measures are highly important for reducing waste
loads in the beet flume. The reuse of beet flume waters is the best
means available at this time for eliminating this waste and will be dis-
cussed later. Major emphasis herein is given to the basic flume system.
In recent years, many factories have reduced beet storage facil-
ities and also have shortened their flume system, integrated with truck
delivery and a truck hopper installation on the line. Other factories
have provided belt conveyors for transporting beets at least part of the
way into the plant. Minimum contact time of the sugar beets with the
flume water and dry handling procedures whenever possible, serve to re-
duce the waste loads imposed upon the beet flume system.] The Bay City,
Michigan factory stored its beets on a large concrete slab, and the beets
were moved by front loader and truck, and deposited into an extremely
short flume directly ahead of the beet washer. The elimination of flumes
from the piling area, dry handling with mechanical equipment, and very
short contact time of beets with the flume water were all responsive to
significant waste load reduction in the Bay City flume system.
The next step possibly indicated for the future is the completely
dry handling of beets until they reach the washer. The British Columbia
Research Council suggested that the beets may receive mechanical shaking
or scrubbing for removing most of the dirt and solids followed by high
pressure jets at the washing table. The jets would provide maximum wash-
ing with minimum water contact. It was cautioned that these techniques
could be of serious disadvantage in colder climates where flume waters
promote necessary warming and thawing of sugar beets. However, hot ex-
haust gases and steam generally available at the factory may be adapt-
able for satisfying even this requirement. Otherwise, recycling and
treatment of waste flume waters are the long-range alternatives (17,
31, 34).
3. The Value of Process Water
The reuse of process waters has been one of the exemplary areas
of waste elimination by the industry. The favorable economics in pro-
ducing dry pulp for a ready market and additional sugar recovery have
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contributed in large degree to this change. Problems still exist where
wet pulp remains or the process system has not been closed, but prog-
ress is continuing.
Pulp transport water has been eliminated in many factories by
the belt conveyor means of moving exhausted pulp to the presses. Trans-
ition plants should provide for continuous recycling and/or reuse of
transport waters within the diffuser until such time as a belt conveyor
system can be installed. A few factories with full pulp pressing and
drying facilities continue to discharge press waters to the drain rather
than reusing these waters, and this practice should be discontinued as
soon as possible. It must be noted that process waters may be reused
for a variety of in-plant needs although general practice favors return
to the diffuser.
Wet pulp produced exclusively by a few remaining factories is
associated with pulp screen waters and pulp silo drainage both of which
are strong pollutional wastes. Successful waste control measures call
for complete elimination of the wet pulp system or extensive treatment
of these liquors. Over the past two years, the last four plants with
wet pulp in the South Platte River Basin have abandoned this system.
Three mills converted to pulp drying, whereas the other mill discontin-
ued operations (17, 31, 36, 37, 40, 41, 42).
4. Handling of Lime Muds
Calcium carbonate sludges are generated from juice purifying
and other operations within the beet sugar factory. Lime cake is re-
covered from the vacuum filters at approximately 50 percent moisture
content. Universal practice in the United States consists of adding
various quantities of water to the lime cake thereby producing a slurry,
easily removed from the plant. A number of factories in Europe, Great
Britain, and the Canada and Dominion mill located in Chatham, Ontario,
employ dry means of disposal. It is believed one or two plants in the
U.S. over past years have attempted dry removal-but data on recent op-
erations were not available.
Disposal of lime mud slurry has represented a continuing problem
in the industry. Direct discharge of this waste to the receiving'stream
still occurs at many factories. The large majority of plants impound
the lime mud slurry in large storage ponds, but 'very often continuous
overflow is permitted from the ponds. Lime mud drainage is extremely
detrimental to the receiving stream and every effort should be made to
prohibit any such discharge. The same principle applies to the ground-
water aquifer where any use whatsoever is made of these waters. A dis-
turbing feature in the literature advocates waste disposal by percola-
tion means whenever possible. Construction not only of lime mud ponds
but other waste holding facilities purposely located over the permeable
aquifer or directly adjacent to surface streams, indicates less than
desirable action towards protecting these water resources. Factories
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in the U.S. commonly use a single storage pond for lime mud whereas
European practices employ separate ponding of the settled solids and
the supernatant. ' Problems of fermentation and noxious odors have been
associated with the long-term holding of lime mud wastes.
Previous reports emphasize that the concept of slurrying an al-
ready semi-dry filter cake for the purpose of pumping must be considered
intrinsically wrong. Besides creating pollution, the lime-water mixture
represents a large volume of difficult-to-separate material, with con-
siderable problems still remaining in its ultimate disposal. It is ser-
iously questioned if any liquid waste discharge should arise from these
operations. The lime cake off the filters should be collected directly
and disposed of onto an enclosed land area, to and from which all drain-
age is excluded. If the mill insists on slurrying and ponding, there
should be no overflow or percolation to the nearby surface stream and
the ground-water aquifer.
Acidic soils have been{upgraded by adding lime mud. European
studies have shown that one ton of lime filter cake contains about 7
pounds organic nitrogen, 13 pounds phosphoric acid, 2 pounds potassium,
and 440 pounds organic matter. At Tirlemont, Belgium, the lime cake was
dried in a kiln, pulverized, and optimum moisture content for land
spreading was maintained around 17 percent. Both in the U.S. and other
countries, studies have been directed to the reuse of burnt lime resi-
due within the factory and in the manufacture of cement and related
products. These methods, whether profitable or not, must be balanced
against future waste abatement and treatment costs that can be expect-
ed at the factory (17, 18, 19, 31, 34, 43).
I
5. Steffen Filtrate Conversion
Excluding a few factories, the Steffen filtrate is not considered
a major waste today. The filtrates resulting from the double precipi-
tation of hot and, cold saccharates in the Steffen factory are generally
converted to CSF (concentrated Steffen filtrate) and used in the manufac-
ture of MSG (Monosodium Glutamate). The CSF is otherwise added to animal
feeds.
The British Columbia Research Council in 1964-1965 reported that
13 of 19 Steffen houses produced CSF as an end product. The Johnstown,
.Colorado plant is believed to be the only facility in the industry
manufacturing MSG directly from the filtrate. The CSF is high in pro-
tein content and a valuable additive to animal feeds when used in mod-
eration. A number of mills introduce CSF into the pressed pulp prior
to drying. Some plants also recycle part of the Steffen filtrate for
reuse as Steffen dilution water. Remaining wastes from the Steffen
house include CSF condensates and sludges, both previously mentioned.
There are no other known uses for Steffen filtrate. Seven or
eight of the above Steffen houses released part or all of the filtrate
into the lime mud storage ponds or the general waste ponding system.
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Only one factory located in Montana was reported to be discharging Stef-
fen filtrate directly into the receiving stream (17, 18, 20, 31, 43).
6. Condenser Waters Desirable in Some Cases
Most sugar factories must reuse their condenser waters and con-
densates to conserve hot water supply. These waters are directed to
the boilers, diffuser makeup, main tank supply, the beet flumes, lime
mud and ash slurrying, and miscellaneous needs. Entrainment of organic
matter in the vapors before condensation requires careful control of
particular unit operations. The excess condenser waters representing
water buildup in the factory are handled in a manner reflecting com-
pany policy and regulatory provisions. Many persons in industry be-
lieve that condenser water should not be classed as waste. Compared
to other effluents, condenser waters are relatively low in organic and
suspended solids content. Condenser waters are detrimental to the re-
ceiving stream by virtue of their high temperature and almost complete
absence of dissolved oxygen.
Where water supply is adequate and regulations permit, the con-
denser waters are discharged directly to the receiving stream after
one pass through the condenser system. In other regions, the waters
must be first passed through cooling towers or the pH level modified
before entry to the stream. With direct discharge, the BOD content
should not exceed 20-30 mg/1. BOD levels have been reported in excess
of 100 mg/1, which definitely should not be tolerated with continuous
operation. It is important to consider whether the factory must oper-
ate within the limits of a specified effluent quality or allowable waste
load to the stream. The literature has indicated that increasing popu-
lation pressures around sugar beet processing sites may result in more
stringent regulations where the release of any waste in the future over
20 mg/1 BOD may be prohibited.
A European writer has suggested that since condenser waters con-
tain only 2 percent of the factory waste load, the installation of ex-
pensive cooling towers is not justified for these waters. Cost of the
cooling system was described as greater than that required in reusing
process effluents or storing lime sludge, and it was therefore implied
that the latter wastes should receive prior attention (17, 31, 34, 43).
The highest degree of control is represented by recycling the
condenser waters in a separate system or within a joint recirculation
system together with flume waters. Both methods are discussed later
in the report.
7. Reuse and Recovery of Various Flows
In addition to previously mentioned practices, certain other
procedures are important towards water reuse and waste recovery. The
continuous diffuser which has largely replaced multiple diffusion cells,
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has created flexibility in process water reuse and significantly reduced
the volume of such waters outside the diffuser. Process water return to
the continuous diffuser requires careful control and in some cases, in-
termediate treatment of these waters. Although some decrease in process-
ing rate may be experienced, this is offset by increased recovery gains
in both sugar and pulp.
At least one sugar factory uses process water for molasses dilu-
tion in the Steffen house, or washing the lime cake filters. Waste flume
water is partly reused at many plants within the wet hopper of the beet
flume system. Under strict regulatory control, the various water use
patterns evolve into closed systems, the more important of which are the
process water closed circuit, the flume water recirculation system, and
the condenser and flume water recycling circuit. Treatment is generally
required in the closed system ranging from simple chlorination up to ex-
tensive biological oxidation. A high degree of factory water reuse is
intrinsic with the flume and condenser water recirculation systems. The
British Columbia Research Council in its study of 59 mills has classed
the various mills into five basic types corresponding to the degree of
in-plant water reuse. The Council's report gave flow diagrams for the
major types and described the numerous modifications possible in the
basic flow patterns.
Trash collectors, traps, screens, and other recovery devices
should be placed at all major waste collection points within the factory.
Proper design, installation, and maintenance of these appurtenances are
essential for adequate performance. Coarse materials in particular
should be removed by mechanical means rather than by biological oxida-
tion. Control is necessary not only over routine wastes but also in
regard to spills, leakage and inadvertent releases to the floor drains.
A modern waste control program implies the best operation of equipment,
a high level of job skill and performance, and true awareness of the to-
tal picture (17, 18, 31, 32, 34, 40, 41).
C. MINIMUM WASTE ABATEMENT AND TREATMENT
It is difficult to define in many cases what is meant by minimum,
intermediate or high-level waste abatement and treatment. Attempts to
classify various forms of treatment into a singular category may be
questioned. The particular format was chosen for ease and clarity in
presentation rather than giving a rigorous definition of the system.
Minimum or primary treatment is considered a means of removing most of
the settleable and suspended matter. High-level treatment implies ex-
tensive measures for removing dissolved organic matter together with
other undesirable waste constituents. Biological oxidation units as
such may or may not be used in high-level treatment of sugar beet wastes.
In this report, high-level treatment is meant to provide factory waste
loads not exceeding 2 pounds BOD and TSS per ton of beets processed.
Intermediate treatment represents a compromise between the low and high
treatment levels.
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1. Fine-Mesh Screening
The screening operation is a preliminary step in waste treatment
intended to reduce waste loads placed upon subsequent treatment units.
Adequate screening of the waste flows from a typical factory may remove
from 10 to 40 tons of coarse wet solids daily. The recovered screen-
ings may be shredded and introduced into the pressed pulp going to the
dryer, or sold directly to the farmers for use as animal feed. When
the material contains a large portion of beet slices or chips, it may
be returned to the diffuser. Both vibrating and rotary type screens
are used in waste treatment; industry experience gives preference to
the vibrating screen. In screening technology, the term "mesh" is
synonymous with the number of screen openings per linear inch. Screens
are commonly designated by the space between wires and the wire dia-
meter, both expressed in inches, such as 1/4" -0.135. Screens may also
be equipped with mechanical and hydraulic devices to give more effi-
cient solids removal from the screen cloth. Industry applications are
described as follows.
The Brighton, Colorado factory provided dual vibrating screens
having l/8x5/8-inch slotted openings, as the first unit within its flume
water recirculation system. The screens removed about 30 tons wet sol-
ids daily which were sold directly to local farmers for use as stock
feed. The Fort Garry plant in Manitoba, Canada installed a screening
station ahead of its clarifier integrated within a closed flume water
system. The station has been equipped with a travelling water screen
in series with four 4x8-foot vibrating screens operating in parallel.
The Findlay, Ohio sugar mill has three vibrating screens installed in
parallel which are preceded by a liquid cyclone for removal of heavy
grit and solids. The Findlay screens, each 5xl2-foot, are illustrated
in Figure 48. The grit-solids separator and screen station were an
essential part of the closed flume and condenser water system at Find-
lay. The main objective of the screens was to remove light solids,
beet tops and other organic debris from the circuit. These materials
were utilized for animal feed, green fertilizer and other needs.
The Torrington, Wyoming factory discharged its waste flume water
through two 6-foot long rotary screens in parallel, before final dis-
posal to the river. The screenings from the rotating drums were pumped
to a vibrating screen for further de-watering and the wet solids loaded
into farmers' trucks. The modern factory at Hereford, Texas screened
and settled the wastewater within its 5000 gpm flume water recycling
system. The screening station consisted of four vibrating 20-mesh deck
screens into which the total flow was manually divided. The screens
were considered vital in maintaining the flume waters as fresh as pos-
sible and removing solids which would be otherwise deposited in the
lime mud and stabilization ponds. Peak flows caused some overloading
of the screens which could be remedied by additional screening capac-
ity. The Hereford study emphasized for best efficiency, the screens
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should receive uniform flow over the entire width of cloth and further-
more, incoming velocities should be as low as possible (6, 17, 28, 31,
32, 38, 39, 43, 44).
Figure 48.
Findlay, Ohio sugar factory; 12-9-65.
Three vibrating screens in parallel,
treating waste flume and condenser
waters in the closed circuit.
2. Grit and Solids Removal by Mechanical Means
Mechanical clarifiers preceded by grit removal and/or fine
screening, are generally used in closed wastewater recycle systems.
In other cases, the wastewater may be screened and settled and even
subjected to chemical flocculation, then discharged to the receiving
stream. Mechanical settling units usually imply a high degree of water
reuse in the factory. Natural ponds are used in lieu of mechanical
units where the percentage return is less. The objective is to remove
as much dirt, soil and other solids as possible, particularly critical
in the closed system.
The Garland, Utah factory was the only mill in the U.S. with-
out some reuse being made of the clarifier effluent. The Bay City,
Michigan plant provided for grit separation of spent flume waters, fol-
lowed by chemical flocculation and partial return of the treated waters.
This installation is discussed later under chemical treatment. The
Croswell, Caro and Sebewaing factories in Michigan passed their waste
flume waters through a grit chamber before release to long-term stor-
age ponds.
Mechanical settling of wastewater is relatively important in
both the U.S. and Canada. The Dyer, California factory treated a mix-
ture of flume water, process water and Steffen waste by screening to-
gether with a thickener and mechanical clarifier. The settled sludges
were sent to a series of mud ponds, and the pond and clarifier super-
natants were used primarily for crop irrigation. The Moses Lake,
Washington mill passed its flume water through a mechanical clarifier
and the supernatants from both the clarifier and sludge ponds were
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used for irrigation or disposed of into percolation basins. At Carlton,
California, screened flume waters were received into a thickener and
clarifier followed by three treatment ponds totalling 70 acres, and a
final pond of 35 acres. Total waste retention in the system was 8-10
weeks. The literature indicated that considerable anaerobic action oc-
curred within the Carlton ponds. The Dyer, Moses Lake, and Carlton
factories all reused flume water within the plant. The Alvarado, Cali-
fornia mill discharged a mixture of flume water and Steffen waste
through a thickener and clarifier system. Settled sludges were trans-
ferred to a series of mud ponds and part of the clarifier supernatant
was returned to the beet flumes. Treated effluents were released into
a marshy lowlands area but in the future will be retained in shallow
evaporation ponds.
The mechanical clarifier merits careful attention particularly
when flows are recirculated. It is important that sludge underflows
and floatable scum and grease be removed quickly, preferably on a con-
tinuous basis. If waste detention times are excessive, organic fer-
mentation may occur in the tank resulting in organic acid and hydrogen
sulfide buildup. Chlorination may be used to retard such action. In
any case, efficient screening is essential ahead of the settling tank.
The literature indicated that clarifiers with detention times from 30
to 120 minutes will produce minimum odor compared to settling ponds.
With continuous wastewater recirculation, dissolved organic material
may increase to rather high levels, and it is sometimes difficult to
maintain fresh conditions. European experience suggested a compromise
between the amount of water recirculated and the quantity of clean water
continuously added to the circuit.
Previously, in Belgium, many factories provided for flume water
settling within Dorr clarifiers or large natural basins in order to
comply with an effluent standard of 0.5 ml/1 settleable solids. In
recent years, the regulations have become more restrictive and today
most factories recycle and reuse the waters after settling. The pres-
ent picture shows that waste flows enter the mechanical clarifier with
settleable solids of 30-125 ml/1, and the final waters contain 0.3-1.0
ml/1 settleable material. Intensive recirculation requires fermentation
control by chlorine and lime additions. Fine clay particles which do
not readily settle must be removed by chemical flocculation in the pH
range 10.5-11.5. Shock doses of lime not only retard fermentation but
serve to raise the pH level necessary in flocculation. Following chem-
ical treatment, the pH level must be modified to below 8.5 to permit
final effluent disposal.
Experience in Great Britain has indicated that flume waters with
about 20,000 mg/1 TSS were reduced to around 200-400 mg/1 TSS by means
of special settling tanks or large lagoons. Two types of circular tanks
both with hopper bottoms were reported in use. One was divided radially
into 8-10 compartments receiving flow in series whereas the second type
had no inter-partitions. Sludges of 25-30 percent solids were disposed
of to large lagoons and the supernatants therefrom were returned to the
factory.
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Three factories, the Findlay, Ohio and Hereford, Texas plants in
the U.S., and the Fort Garry establishment in Winnipeg, Canada, placed
heavy reliance upon the mechanical settling unit as an integral part of
their flume and condenser water recirculation systems. The Fort Garry
factory added milk of lime to the screened flume waters prior to settling.
Consequently the pH level was maintained around 11.8-12.0, which provided
rapid settling together with fermentation control. The sludges were de-
livered to a mud pond with supernatant return to the clarifier, and the
clarifier effluent was reused in the beet flumes. Recent changes in the
Fort Garry system have included: 1) modification of the feed well in
the settling tank to achieve better performance; 2) small amounts of
defoaming oil added to the clarifier to reduce foam buildup; 3) alter-
nating use of the sludge and water lines to and from the mud ponds to
mitigate lime deposits in the circuit; and 4) speed reduction on the
mud pumps to prolong pump life. At Findlay, Ohio, combined flume and
condenser waters after grit separation and screening were divided be-
tween two Dorr clarifiers each 63'-8" in diameter by 12-foot deep. The
Dorr units were rated at 2450 gpm with an average waste detention time
of 67.5 minutes. One such unit is shown by Figure 49. Sludges were
deposited into a sludge pond, and the pond supernatant returned to the
circuit.
Figure 49.
Findlay, Ohio sugar factory; 12-9-65.
One of the two Dorr clarifiers treating
screened flume and condenser waters in
the closed circuit. Note excess water
pond in background.
The flume and condenser water recycling system at the Hereford,
Texas factory was designed for continuous bleedoff and the waste efflu-
ents from the circuit received biological treatment. All recycle waters
were screened and settled. Screened waters were received into a single
clarifier (100-foot in diameter by 8-foot deep) equipped with an indus-
trial thickener mechanism to handle heavy mud loads, particularly from
wet harvests. At the average rate of 5000 gpm, the settler provided
1.5 hours waste detention with an overflow of 1000 gallons/sq.ft./day.
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The resulting sludges were pumped to a mud storage pond. Some difficulty
was experienced with fine colloidal clays and peaking flows in the cir-
cuit. Although quicklime, slaked lime and spent lime slurry have all
shown the ability to assist clay removal, further improvement was desired.
The British Columbia Research Council, although reporting favor-
able results with mechanical and pond settling, made clear the point that
soil disposal will be an ever-continuing problem. They suggested that
soil buildup within the factory could be eliminated only by physical
transport in the opposite direction. In the future, it is possible that
the beet farmer may be required to retrieve sludge solids from the system
equivalent to his incoming tare (6, 17, 31, 32, 34-, 38, 39) .
3. Treatment Lagoons and Ponds
Waste treatment lagoons and ponds have widespread use in the beet
sugar industry particularly in the United States. Their function is
similar to that provided by mechanical settling, although less care is
generally given in design, operation and maintenance with the consequence
that treatment performance is often lower than expected. The lack of op-
erating data on this method of treatment is somewhat surprising consider-
ing the current application within the industry. Waste detention times
in the earthen ponds generally range from 24 to 48 hours. The upper lim-
it is suggested for minimizing noxious odors associated with organic fer-
mentation. The following discussion primarily relates to the handling
and treatment of waste flume and condenser waters, with only brief ref-
erence being made to lime mud and other wastes.
Jensen has stated that the lagoon system using single or multiple
basins has been the most common means of treating sugar beet wastewaters
(18). These systems must be shallow and flowing in order to avoid the
nuisances of hydrogen sulfide gas. From his experiences on the Conti-
nent, Henry (34) favored settling ponds for reasons of economy and also
suggested the following principles in relation to these ponds. First
of all, the wastewater should enter the unit with minimum velocity and
circulate evenly but quickly without interference to settling. Second-
ly, large ponds are advised in order to minimize dike construction and
thirdly, ponds should be levelled and grass and weeds removed on a fre-
quent schedule. The removal of solids from the ponds was reported by
many factories as uneconomical; solids are placed on the dike walls
causing buildup of the dikes. Eventually the 'pond together with valu-
able land are abandoned. Studies have been conducted in Belgium using
ponds in series and square arrangement, and the alternation of basins
from one campaign to the next. Other studies in Great Britain have in-
dicated that the ideal shape for a settling pond may be a rectangle 5-6
times long as wide providing a flow-through velocity of about 0.8 fpm.
The British investigations also suggested that small ponds were advan-
tageous in the event of dike rupture since less waste material would
accidentally enter the receiving stream.
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The odor problem becomes very important when waste treatment
lagoons or ponds are used for beet sugar processing wastes. Oxygen
deficiency in the pond and various forms of anaerobic bacteria origi-
nating with the soils and the sugar beets give ready opportunity for
organic and inorganic reduction. The conversion of sulfates into hy-
drogen sulfide is particularly critical. Observations at the Greeley,
Colorado mill in January 1964 indicated severe odor problems associ-
ated with the then present waste treatment lagoon. The pond provided
about 17 hours detention of total factory wastes spread over a few
acres, 1-2 feet deep. Survey personnel noted extremely foul odors
around the lagoon and study showed that the settled effluents were
nearly devoid of oxygen and' contained around 27 mg/1 dissolved sul-
fide. Sulfide if present in surface water used for drinking purposes
may cause severe odor and taste problems with the minimum detectable
level being around 0.05 mg/1 hydrogen sulfide. The threshold value of
hydrogen sulfide for industrial water use ranges from 0.2 to 1.0 mg/l;
whereas sensitive fish species may tolerate no more than 0.5 to 1.0
mg/1 sulfide in water. The South Platte River Basin studies of January
1965 illustrated that sulfide was limited at all river stations except
for the single location below the Greeley, Colorado sugar mill, where
the average level was recorded as 0.63 mg/1.
British studies have shown that sugar beet waste samples if
stored in the laboratory for 3-4 weeks may contain up to 7 mg/1 sulfide
whereas little or none should be present in a properly operated waste
treatment system. Other information was offered on odor suppression by
dichlorophen, bacterial inhibition by means of chromium compounds or
copper sulfate, and supplying available oxygen by sodium nitrate.
Phenolics were measured in the beet sugar wastes from the Greeley,
Colorado mill in January 1964 but were determined as causing no problems
in respect to water uses. However, the possibility of phenols or simi-
lar taste and odor compounds present in beet sugar wastes cannot be dis-
counted. A city located on the Red River of the North has reported re-
cent taste and odor problems in their municipal water supply possibly
attributed to release of sugar beet wastes from upstream holding ponds.
Field studies will be conducted during early 1968 on the water quality
conditions in the affected area (28).
The British Columbia Research Council, reporting on 59 factories
in the U.S. and Canada, described 16 mills ai having pond systems with
5 days or less detention, two mills with intermediate waste detention of
6-20 days, and 8 mills with long-term waste storage. The ponds with
limited retention served essentially as settling basins. Of the 16 fac-
tories in the first category, 8 mills handled flume waters only, whereas
the remaining 8 mills mixed other wastes together with the flume waters.
Of this same group, 13 mills discharged the total pond effluents direct-
ly to the receiving stream, whereas 3 mills recirculated some part of
the treated water for factory reuse. The Council suggested that waste
settling could be readily accomplished in ponds with 1-3 days detention.
Mechanical clarifiers were recommended where strict limitations would be
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placed upon the use of lagoons or ponds. In the U.S., shallow lagoons
are preferred to deep ponds and operating depths are generally in the
range of 3-5 feet. However, in actual practice, the ponds will rapidly
fill with solids and effective settling depths will range between a few
inches up to 1-2 feet. Settling ponds frequently are located on porous
soil or immediately adjacent to the surface stream. In such cases there
should be no contamination of the ground-water aquifer, and indirect
seepage to the stream must be accounted for in assessing the total fac-
tory waste load placed upon that stream.
Previous information is given in Section II of this report on
the waste treatment lagoons at the Greeley, Fort Morgan, Longmont, and
Johnstown factories, all located in the South Platte River Basin. Dem-
onstrated waste removals were considered as ranging from fair to very
poor. Overall BOD and COD reductions were about 10 and 20 percent re-
spectively. Excluding Johnstown with very poor performance, suspended
solids removals varied from 75-95 percent whereas bacterial reductions
were between 0-75 percent. Pictures of the waste treatment lagoons op-
erating at the Fort Morgan and Longmont mills are also shown in Section
II of the report. In the case of all four factories, large quantities
of waste material were subsequently discharged to the receiving stream.
An industrial waste survey was conducted in 1956 at the Belle
Fourche factory in South Dakota. Waste flume water was passed through
three ponds in series covering a total of 16 acres, with an average
liquid depth around 3 feet, and a total waste detention time approxima-
ting 3 days. Overall reductions in BOD and TSS waste loads, taking into
account both evaporation and seepage, amounted to 20 and 95 percent re-
spectively. Waste concentrations were reduced in less degree. Further-
more, very high coliform bacteria numbers were remaining in the lagoon
effluents.
Two sugar mills in Great Britain were compared on the basis of
one mill (Factory A) discharging settled pond water directly to the
river, and the second mill (Factory B) being required to settle and
completely recycle all campaign waters. The settling pond at Factory
A showed a high rate of percolation and overall waste reductions as
follows: BOD - 30 to 70 percent; TSS - 87 to 96 percent; and settle-
able solids - 92 to 100 percent. Factory B employed its pond system
over consecutive seasons with virtually no opportunity for soil removal,
and waste concentrations in the pond were high as expected in a complete
recycle system. Although appreciable purification occurred in the re-
cycle system, volatile acids consisting predominately of acetic and
propionic acids were present in significant amounts, and up to 140 mg/1
total nitrogen was also found in the closed circuit. Factory B is dis-
cussed in this section of the report not by virtue of representing min-
imum treatment, but because it could be directly compared with Facto'ry A.
Lime mud ponds are associated with primary treatment in the sense
of removing suspended solids from the waste treatment system. All fac-
tories in the U.S. release lime mud in the form of a slurry, which in
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the majority of cases is stored or at least partially separated by
means of lime mud ponds. A typical sugar factory may employ one or
more lime mud ponds varying in depth from 2 to 10 feet, and on oc-
casion other wastes may be added together with the lime muds. De-
posits from a given campaign are generally scraped from the pond
bottom and added onto the dike walls. Active fermentation may start
near the end of campaign and is accelerated by the warmer tempera-
tures occurring through spring and summer. This problem is solved
from the standpoint of the factory if it is permitted to discharge
the pond contents during high river flow, or otherwise. High rates
of percolation are favored by the industry in locating the ponds al-
though this may readily lead to other serious problems previously
described. The various difficulties in storing lime mud slurry such
as the viscous nature of the waste, land and construction costs, odor
conditions and many others, would seem to offer strong reasons for
converting to a dry system of handling and disposal (6, 17, 18, 31,
32, 34, 43, 45, 46, 47).
4. Aeration Fields
In many ways, the term "aeration field," referred to and used
for waste treatment within the industry, is a misnomer. The aeration
fields in the South Platte River Basin and presumably at other loca-
tions, consist of spreading the waste effluents over large land areas.
The fields support little or no vegetation, and the wastes trickle down
the field in numerous, shallow channels to be collected and disposed of
at the far end. Because of short-circuiting, the wastes cover only a
small portion of the field. Although the majority of suspended solids
can be removed, there is little or no apparent benefit in aeration.
The aeration field covers an expansive area yet provides the equivalent
of less than primary treatment.
The history of the aeration field in the U.S. started with studies
conducted at the Loveland, Colorado mill in 1951. Full-scale facilities
were constructed at the Bayard, Nebraska factory during 1952 and evalu-
ation studies were carried out over the 1952-1953 campaign. It must be
mentioned in first place that the Bayard aeration field was inherently
different and apparently more effective than the installations which were
to follow. The combined Bayard factory wastes were delivered to a 3500
by 1750-foot area of fairly level contour. Although native buffalo grass
was present, only part of the field was described as a grassland filter
compared to earlier such installations in Europe. Waste channeling was
reported quite evident at Bayard and nearly 50 percent of the waste vol-
ume disappeared by downward percolation before reaching the end of the
field.
The 1952-1953 survey results for Bayard showed that incoming
flows with 483 mg/1 BOD were reduced to 158 mg/1 in the aeration field
effluents providing 67 percent BOD removal. Corresponding values of
suspended solids were 5215 mg/1 and 63 mg/1 giving 99 percent apparent
TSS reduction. Likewise total coliform bacteria numbers were reduced
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89 percent. Although algal and fungal growths were abundant, the dis-
solved oxygen was quite low in the field. Average waste detention ap-
proximated 14 hours and the results indicated that odor production was
at a minimum. The evaluation report while describing the merits of the
system also made certain recommendations for improved treatment includ-
ing the necessary correction of operational and maintenance problems and
levelling of the aeration field.
There were no other reports apparent in the literature besides
Bayard giving information on aeration fields within the industry. In
actual practice, aeration fields were used at two factories in the
South Platte River Basin during the 1963-1964 campaign and later at a
third factory. These facilities included Loveland, Greeley and Windsor,
the operations of which are fully described in Section II of this report.
Most important, it was observed that the treatment facilities at the
three Colorado mills did not embody many of the favorable characteristics
of the Bayard installation and, furthermore the aeration fields in Colo-
rado were beset with numerous operational and maintenance problems.
Loveland with 133 acres of treatment achieved 20 percent removal of
waste BOD and COD, and 80 percent reduction in TSS. The Windsor plant
experienced the following waste reductions: BOD - 0 to 10 percent; COD
- 10 percent; TSS - 60 percent; and coliform bacteria - 35 to 80 percent.
Performance data was not collected at the Greeley location. The South
Platte River Basin studies concluded that aeration fields, as they are
maintained today, could not by any means satisfy the water quality cri-
teria recommended for the Basin (6, 18, 19, 48).
D. INTERMEDIATE WASTE ABATEMENT AND TREATMENT
Intermediate waste treatment in the beet sugar industry is divid-
ed into four areas of interest: long-term waste storage, aerated ponds
or lagoons, chemical treatment, and direct reuse in crop irrigation. In
some cases, these methods may provide a lesser degree of waste removal
than factories previously included under primary treatment. The disposal
of processing effluents to irrigation use is classed as intermediate
treatment because only certain wastes may be used for this purpose and
the practice is generally limited to a few weeks or months of the year.
1. Long-Term Waste Storage
Long-term holding is generally associated with a prescribed degree
of waste stabilization after which time the wastes are released, most
often under controlled conditions. The literature has stated that this
means of treatment has been employed with only limited knowledge of the
factors contributing to purification and the degree of purification real-
ized during storage.
The first extensive study of long-term waste storage was carried
out at the Moorhead, Minnesota factory over 1949-1951. At this plant,
waste flume waters together with pulp press waters were released into
two 12-foot deep lagoons identical in capacity, with a total area of 81
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acres and total volume of 335 million gallons. A third lagoon, 3-foot
deep covering 50 acres and providing 50 million gallons capacity, was
maintained in reserve until late in the campaign. It is noted that to-
tal campaign wastewater volume was 422 million gallons in 1950. Per-
missive discharge from the ponds started in early spring following severe
winter conditions and considerable ice cover over the ponds. The study
showed that waste treatment during the campaign itself was caused large-
ly by settling of suspended matter within the ponds. Over this period,
BOD reductions ranged from 48 to 58 percent and suspended solids removal
was about 97 percent. After the campaign the stored waters underwent no
further decrease in waste loads. This reaction was attributed to com-
plete cessation of biological activity within the ponds under freezing
water conditions. The study concluded that long-term waste storage even
in cold climates, would provide effective removal of suspended solids,
and additionally remove about one-half of the BOD loads.
Later study was undertaken in 1964-1965 in the Red River of the
North which included not only the Moorhead, Minnesota factory (above)
but also the East Grand Forks and Crookston factories in Minnesota.
Both Moorhead and East Grand Forks were reported to have facilities
for long-term waste storage. Discharge was controlled according to the
amount of flow, dissolved oxygen and BOD in the receiving stream, and
was permitted prior to and following ice cover on the river. The study
results showed in November 1964 that the Moorhead pond effluents con-
tained 449 mg/1 BOD, 163 mg/1 TSS, and median values of 1.5 million to-
tal coliform bacteria and 1.25 million fecal coliforms per 100 ml. The
East Grand Forks factory demonstrated final effluent values of 164 mg/1
BOD, 54 mg/1 TSS, 22,100 total coliform/100 ml, and 1,720 fecal coliform
/100 ml. Waste removal efficiencies could not be determined because of
the nature of the survey. The Red River of the North study concluded
that the ponding systems performed reasonably well. It recommended how-
ever, that strict limits be set on the controlled amounts of waste dis-
charge from the Moorhead and Crookston factories in addition to neces-
sary bacterial reductions on the East Grand Forks effluents. Specific
discussion on bacteriological findings from the Red River of the North
investigations are given previously in Section IV of this report.
At least seven other mills were reported as providing long-term
waste holding. Four factories in California exercising a high degree
of recycling and with favorable evaporation and seepage conditions were
able to retain all wastes in the ponding systems without resulting dis-
charge. These installations were characterized by the use of many inter-
connected ponds generally in series, specifically designed for settling,
fermentation, evaporation or seepage. The various ponds ranged from 2
to 10-feet in depth, and covered a minimum of 35 acres at one site up
to several hundred acres found at another. The shallow ponds were
aerobic whereas the deeper basins were designed for controlled fermen-
tation. The settling ponds and the initial anaerobic ponds in some cases
were covered by a heavy proteinaceous scum layer and the fermentation
ponds at times produced serious odors. The British Columbia Research
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Council has remarked that increasing duration of the campaign in Cali-
fornia has intensified difficulties in using the present ponds for waste
treatment and disposal. Also, in other areas, long-term waste storage
extended through the spring months has been associated with intense
odors.
The Caro, Croswell and Sebewaing mills in Michigan utilized deep
anaerobic ponds for waste storage during the wintertime followed by
discharge to high river flows in spring. Condenser waters were released
directly and continuously to the receiving stream at all three mills.
Special attention is given to the fact that both Caro and Croswell were
required to add lime to the ponds in attempts to maintain neutral pH
conditions (18, 20, 26, 31, 33).
2. Mechanically-Aerated Ponds and Lagoons
No beet sugar factory is known at present time to be using me-
chanically-aerated lagoons or ponds for waste treatment. The Fort
Garry mill in Manitoba, Canada for a short time during the 1964 campaign
recirculated its pond effluent over an aeration deck attempting to in-
crease the oxygen content of the wastewaters. The Fort Garry results
however were not conclusive and the factory subsequently converted to
a closed flume water recycle system.
Recent information obtained from the current pilot-scale treat-
ment studies at Tracy, California indicated mechanical aeration to be
initiated in the future. The Tracy study has been investigating the
anaerobic-faculative-aerobic lagooning system for treating sugar beet
wastes. This treatment system, to be described later in the report, en-
visions that four low-head propeller pumps will be installed at a single
location in the aerobic pond to provide mixing and to supplement the
oxygen input from algal growths. The pumps will be operated intermit-
tently, each with a capacity of 12,000 gpm and generating flow veloci-
ties in the pond from 0.25 to 1.0 fps.
Laboratory studies have been conducted by the British Columbia
Research Council to determine the feasibility of aerated lagoons in
treating waste flume waters from the sugar factory. The investigation
was intended to provide data on optimum load conditions, time required
in startup relative to the beginning of campaign, and adaptability of
the aerated lagoon to intermittent operation and temperature change.
The studies were initiated on the basis of activated sludge treatment
with moderate lagoon retention and controlled through-put and storage
of sludge. The tests comprised 6 runs under 48-hour aeration with and
without activated sludge being added from a nearby sewage treatment
plant. Two runs (1 and 6) consisted simply of 48-hour aeration. The
other runs (2 through 5) were successive using the settled floe from
the preceding 48-hour period. The waste flume water was obtained from
a factory with a high degree of recycle and initial BOD values ranging
from 821 to 1121 mg/1.
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The results of the laboratory tests showed that runs 2-5 (after
settling) produced residual BOD values from 30-140 mg/1 whereas, corre-
sponding values in runs 1 and 6 were significantly higher because time
was too short for full development of an active floe. The batch system
was found to achieve an effluent BOD less than 50 mg/1 only if sub-
strate limiting conditions were maintained.
The report on the laboratory studies reached the following con-
clusions:
1) Biological oxidation using an active floe could offer effec-
tive BOD reductions in the range of 93 to 97 percent.
2) Whereas the batch studies attained maximum BOD removal rates
within 96 hours, a full-scale installation would require less time,
3) Within a large and properly compartmented full-scale lagoon,
there would be progressive decrease in BOD toward the discharge
end. Also, controlled sludge entry and removal would provide the
most desirable ratio of substrate to active floe.
4) Chemical flocculation could be used to improve the quality of
lagoon effluents when necessary, most probably at the start of
campaign or with peak loads on the system.
The above studies were conducted with the Johnstown, Colorado fac-
tory wastes in mind and this factory is expected in the near future to
construct a pilot-plant along the lines of the above study. Because this
method of treatment has achieved reasonably good success in respect to
municipal wastes and various industrial wastes, there is strong belief
that it will apply equally well in treating sugar processing effluents.
The proposed Johnstown system should provide interesting results (31, 40,
41, 43, 49, 50, 51, 52).
3. Chemical Treatment
The various uses of chemical agents in the process cycle and for
minimizing odor have already been touched upon in preceding sections of
this report. Although chemical additives are in fact used throughout the
sugar factory, this discussion is limited to chemical flocculation as a
unit operation employed in waste treatment.
The foremost example of waste treatment by chemical precipitation
is the Bay City, Michigan factory. At this plant, waste flume waters
were received into a grit separator for removal of heavy solids followed
by chemical flocculation, with 40 percent of the treated waters being
returned to the beet flume and the remainder discharging to the river.
Separan-AP-30, a commercial flocculating reagent, was used at a concen-
tration of 0.1 mg/1. The sludges from both the grit separator and the
flocculation basin were directed to sludge ponds with return of super-
natants to the grit chamber. The Bay City factory utilized dry handling
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techniques in moving the sugar beets from the piles to the wet hopper re-
sulting in minimum waste loads to the flume system. The average BOD
level in the flume waters before treatment was 223 mg/1. Treatment re-
sults showed that the chemical flocculation system was quite effective--
with 90 percent removal of suspended solids, and final BOD levels from
70 to 130 mg/1. The treated flume waters showed a 57 percent reduction
in BOD content with a residual waste load of 0.86 pounds BOD per ton
beets processed. Other factory wastes not accounted for in the total
waste balance included the continuous discharge of excess condenser
waters and some overflow from the lime mud ponds both reaching the river.
The British Columbia Research Council has given preliminary at-
tention to chemical flocculation as a polishing means following activated
sludge treatment. The results indicated that straight flume waters were
unaffected by separan plus alum. However, the effluents from the aera-
tion units were measurably improved by adding lime or lime together with
separan. The European literature has referred to calcium oxide for im-
proving waste settling from 80-85 percent to a level of 97-98 percent.
Other flocculating agents also considered in the past have been the alu-
minum and iron salts (31, 50, 53).
4. Land Irrigation
Sugar beet processing wastes are applied directly to agricultural
lands when the processing campaign coincides with the growing season,
notably true in the warmer climates particularly the State of California.
Over much of the remaining Western U.S., the wastewaters are generally
stored in off-stream reservoirs until irrigation commences the following
spring. A high degree of water reuse in the water-short areas of the
Western U.S. predominately for agricultural irrigation is strongly re-
inforced by Western water law, and comprises the way of life in this
part of the country. Wastewater whether derived from a city, industrial
plant or previous irrigation is subsequently reused for downstream irri-
gation interests.
Irrigation in general does not require as high a water quality as
other needs, and in most cases the limits have not been established with
a high degree of certainty. This report simply describes the widespread
practice of using wastewater for crop irrigation as it exists today, and
implies neither justification nor disapproval. However, the implications
within the system should be clearly understood, particularly the bacteri-
ological aspects. Considering the overall picture, sugar beet effluents
in most agricultural areas should receive a reasonably high degree of
treatment.
Information reported for the State of California indicated that
five factories were releasing part of their waste effluents for irriga-
tion. The Dyer mill discharged Steffen filtrate together with other
plant wastes into a general ponding system, the overflow being used for
crop irrigation or otherwise diverted to the plant sewer. The Tracy
establishment discharged its combined plant wastes to irrigation when-
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ever feasible or used the San Joaquin River for final disposal. The
Santa Ana, Mendota and Alvarado plants were known to provide some part
of their wastes for irrigation; however Alvarado has discontinued its
practice of irrigating duck feeding grounds. Waste discharge regula-
tions are relatively comprehensive and the California factories gen-
erally exercise a high degree of waste control and treatment. One reg-
ulation stipulates there shall be no pollution or water quality impair-
ment of the ground-water aquifer resulting from waste handling and treat-
ment measures.
The situation in the South Platte River Basin was described in
part by a letter of June 30, 1965 from the sugar company to the State
of Colorado. The company made the comment that practically all surface
river waters below its ten mills were believed used by the sugar fac-
tories or for irrigation purposes. The position was taken that these
wastes were more beneficial than harmful when used for irrigation and it
was further reported that the factories returned more water to the
streams than used. This letter has been taken to illustrate the impor-
tance placed upon irrigation in the West. Although the statement was
true in context and reflected the company policy in 1965, it did not
take into account many particulars or the importance of other water uses
both present and future. Since that time, the company has instituted
a number of waste improvements and given strong indication of so con-
tinuing in the future.
Further reference is made to the Hereford, Texas factory having
a waste treatment system designed to provide reclaimed water for irri-
gating 400 acres of company lands upon which milo and sugar beet crops
were grown. Also, certain literature from abroad has described various
factories in Poland and Russia as extensively reusing flume and process
waters for land irrigation (6, 31, 32, 40, 41, 43, 54, 55).
E. HIGH-LEVEL WASTE ABATEMENT AND TREATMENT
A system of methods and operations which may provide a high de-
gree of waste control and treatment within the sugar factory is ambig-
uous in three ways. First of all, it is difficult to describe. Second-
ly, the system will vary greatly from plant to plant, and thirdly, the
various procedures cannot be conveniently categorized. For purposes of
this report, less emphasis has been placed upon modifications and vari-
ations, and waste treatment has been simply divided as to recirculation-
reuse systems, biological systems, and biological-recirculation systems.
1. Recirculation-Reuse Systems
The closed or nearly-closed wastewater recirculation system rep-
resents the apex of rigorous waste control and treatment. The complete
recycle system has generally proved superior to biological methods in
terms of overall results.
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a. Flume Water Recycle Systems
A closed flume water recirculation circuit is described as one
with continuous recycling of waste flume waters together with essential
treatment units on the line enabling complete reuse of such waters.
This system is definitely known to be in operation at three factories:
Fremont, Ohio; Fort Garry in Manitoba, Canada; and Brighton, Colorado.
The same system is under construction or recently completed at Moses
Lake, Idaho; Toppenish, Washington; Chaska, Minnesota, and possibly
others. The Ottawa, Ohio mill previously employed this procedure but
has since converted to an integrated flume and condenser water closed
circuit.
The Fremont, Ohio factory installed its closed flume water cir-
cuit during the 1950"s. The Fremont factory was a straight-house oper-
ation receiving about 1800 tons beets per day, with pulp drying and re-
turn of press waters to the diffuser, and the separate ponding of lime
muds. The beets were carried to the flumes via belt conveyor and then
flumed a short distance into the mill. The spent flume waters flowed
into a 9-acre shallow lagoon, received treatment in the pond, and re-
turned for complete reuse in the beet flumes. Although details were
not available, the installation included waste screening. The Fremont
waste treatment wotks were considered relatively simple and a partial
view of the system is shown in Figure 50. The picture shows heavy foam
buildup along the length of the incoming canal which undoubtedly created
certain problems.
Figure 50.
Fremont, Ohio sugar factory; 12-9-65.
Overhead view of the Fremont lagoon with
center dike. Inflow at bottom left enter-
ing pond from top left. Outflow canal
from pond shown at right flowing toward
observer for return to the beet flumes.
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Operational data on the Fremont system showed that lime addi-
tions were necessary in the waste lagoon to minimize fermentation which
occurred mostly during the start of campaign and again in late spring.
There were many homes located 1000-feet or less downwind of the pond,
but most likely major complaints if any, were due to the fly-ash prob-
lem observed around the plant. The flume waters remaining after cam-
paign were stored in the lagoon and subsequently discharged to high
streamflows during the spring. The stored wastewaters were reported
to contain around 0.2 pounds BOD per ton beets processed, at their time
of release. The excess condenser waters at Fremont were permitted free
and continuous discharge to the river. These waters contained around
45 mg/1 BOD, with a waste load estimate of 0.6-0.7 pounds BOD per ton
beets processed. The total factory waste load of around 0.8-0.9 pounds
BOD per ton beets was remarkably low in view of the simplified waste
treatment system.
The Ottawa, Ohio factory utilized a closed flume water recycle
system through the 1964-1965 campaign. The procedure at that time con-
sisted of passing flume water through a grit chamber only, with complete
return of the waters to the beet flumes. The grit sludge was directed
to a 2-acre pond followed by overflow into two 8-acre ponds. The three
mud ponds were drained to the adjacent stream at times of high flow.
Pulp press waters were completely returned to the diffuser, but excess
condenser waters together with overflow from the lime mud basins were
released to the stream. Discounting the last feature, the Ottawa in-
stallation because of its uniqueness is deserving of attention. Unfor-
tunately, no further information could be obtained on the past system
or the new integrated flume and condenser water system believed to have
been recently installed at Ottawa.
The sugar plant at Fort Garry in Manitoba, Canada was a straight-
house operation receiving 3,000 tons beets per day with pulp drying and
process waters being returned to the diffuser. The spent flume waters
were recycled in a closed circuit consisting of a screen station, a Dorr
clarifier, and a 12-acre pond receiving sludges from the clarifier. Op-
eration of the screen station and Dorr unit is previously described in
Sections V C 1 and 2 of this report, and will not be repeated here.
Supernatant from the sludge pond was returned to the clarifier, and the
treated waters leaving the settling tank were cycled for reuse in the
beet flumes. Some condenser water was necessary in the flume water cir-
cuit to prevent freezing in the system. Excess condenser water averag-
ing 27 mg/1 BOD and 50 mg/1 TSS, discharged freely to the river. Septic
tank effluents also entered the receiving stream. Lime mud slurry was
stored in a large lagoon from which there was no reported overflow.
The Fort Garry plant considered the closed flume water system to
have demonstrated satisfactory performance in terms of both normal oper-
ation and necessary maintenance care. The BOD content of the recircu-
lated flume waters increased somewhat more than expected to levels of
7,000 mg/1 BOD, but routine lime additions were successful in maintain-
ing freshness in the circuit. The system encountered other problems
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during its first campaign in 1965 as previously described, and these
were corrected. Prior to the closed system, the Fort Garry plant was
discharging total waste loads to the receiving stream in the order of
7.4 pounds BOD and 1.7 pounds TSS per ton beets processed. The closed
flume water system in 1965 reduced total factory waste loads to 0.3
pounds BOD and 0.6 pounds TSS per ton beets processed, excluding resid-
ual wastes from the circuit stored at the end of campaign.
The Brighton, Colorado factory was a straight-house operation
receiving about 2400 tons beets per day with full pulp drying facilities
and return of press waters to the diffuser. Lime mud was stored in a
separate holding pond with generally no discharge. The Brighton waste
treatment system is fully described in Section II of this report and
therefore only a brief summary is given in the following. The Brighton
flume water recirculation circuit was more elaborate than both the
Fremont and Fort Garry plants.
The Brighton system consisted essentially of a pumping station,
fine-mesh screening station, and three ponds in series for solids settling
and reconditioning the waters for their return to the beet flumes. The
ponds covered a total area of 6 acres comprising an outer horseshoe-shaped
basin and two inner basins. Excess condenser water was released to a
spray pond and then to the South Platte River. A reserve treatment lagoon
of approximately 12 acres was employed for the collection and storage of
excess wastewater from the closed circuit together with accidental spills.
During the 1966-1967 Brighton campaign, undue fermentation was
present in the closed circuit and strong counter-measures were taken. To-
tal chemicals added to the system over the campaign included 19 tons of
caustic soda, 1000 tons of lime as CaC03, and small, intermittent doses of
HTH (chlorine). There was substantial solids settling within the ponds,
pointing once again to the desirability of reducing the incoming soil and
dirt to the factory. Analytical results are not yet available from the
sugar company concerning the Brighton system. However, preliminary in-
formation has indicated better than 90 percent reduction in BOD waste
loads compared to previous conditions, and the overall system performance
has been most encouraging.
British studies on comparing two factories, one with and the other
without a closed wastewater system, are previously described in Section
V C 3 of this report. In reference to Factory B equipped with a Dorr
clarifier and settling pond in the closed circuit, pH conditions were
maintained between 5.6-6.9. The levels of BOD and volatile acid (as
acetic) increased respectively to 9-12,000 mg/1 and 5-6,000 mg/1, but
surprisingly enough the waste concentrations did not show much increase
after the first few weeks of campaign. In other words, irrespective of
new waste additions, a constant waste load was sustained in the system.
It must be presumed under these conditions that fermentation was control-
led by chemical means.
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Henry (34), in his report of European practices, referred to a
sugar factory with recycling of flume and condenser waters in a closed
system, and compared the new to the previous conditions. Henry comment-
ed that (now) the "polluting matter discharged is not reduced proportion-
ately, since recirculation concentrates the polluting agents in a small
volume of water. Recycling ... is aimed more at making good water
shortages than at reducing the pollution of the river." Nevertheless,
Wintzell has estimated that pollution in 1953 (for this same factory)
had been reduced by 81 percent compared with 1939. Further reference
was made by Henry to the British situation where he stated "although
the water authorities enforce the recirculation of water from barometric
condensers, the pollution position grows worse."
The principles stressed by Henry certainly merit close scrutiny,
but the impressions given above, particularly when taken in context
with the remainder of his report, appear somewhat pessimistic. However,
a difference does indeed exist between a system with less than 100 per-
cent recycle described by Henry, compared to the full recycle system.
The Fremont, Fort Garry and Brighton factories all employing 100 percent
recirculation, provided very encouraging results. It is noted that the
addition of condenser water into the circuit probably requires more op-
erational care and diligence. Henry further mentioned that flume water
after extensive recirculation may reach up to 2,000-3,000 mg/1 BOD and
1,000 mg/1 TSS. Besides fermentation, he remarked that recycling could
have the secondary effect of accumulating saponins leading to excessive
foaming and problems in fluming. This condition was previously observed
at the Fremont, Ohio factory.
The British Columbia Research Council described British mills as
employing intensive reuse and treatment practices, with screening and
settling of flume waters and complete recirculation in some cases. Un-
der these conditions, the BOD level reached up to 2,000 mg/1, coagulation
was used to improve solids settling, and fermentation was controlled by
10 mg/1 chlorine addition. Condenser waters at certain mills were re-
cycled in a separate circuit with a cooling tower or less desirably a
spray pond, and these waters could attain BOD levels up to 1,000 mg/1.
With condenser waters, 3 mg/1 chlorine was used to retard fermentation.
Additional study by the British Columbia Research Council indi-
cated although flume water recycling would reduce water consumption and
size of waste treatment facilities, the total waste load in the circuit
would not be appreciably lowered until 100 percent recycle was attained.
Equilibrium must be reached where the soluble material level in the
waters equals that in the sugar beets and minimum diffusion exchange
occurs. This condition may be approached when the recycle waters con-
tain 2-3,000 mg/1 BOD, but in other cases the BOD level may be higher.
For proper operation of a closed system, effective screening and settling
are considered essential, and coagulants, alkalis and chlorine additions
may also be found beneficial and even necessary (6, 31, 34, 39, 40, 43,
47).
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b. Integrated Flume and Condenser Water Recycle Systems
Much has already been said on condenser water within the flume
water recycling system and it is difficult in many cases to consider
the two on separate bases. Two examples are given below of the integrat-
ed systems at Findlay, Ohio and Betteravia, California, followed by dis-
cussion of the system. Many factories in Great Britain and Europe em-
ploy the integrated system in whole or part, because of economics, reg-
ulation, or the need for heat content in the circuit.
The Findlay, Ohio factory was a straight-house operation receiving
about 1700 tons beets per day. The pulp was dried with press waters being
returned to the diffuser, and lime mud slurry was stored in a separate la-
goon. The Findlay system installed in 1956 had as its basic^ components
a screen station, mechanical settling tanks, sludge pond, spray pond, lime
pond, excess water storage pond, and a distribution line leading from the
excess water pond back into the factory. The various pond areas were as
follows: sludge pond - 6 acres; lime pond - 5.5 acres; spray pond - 1.4
acres; and excess water basin - 1.1 acres. Sludges from the clarifiers
were pumped to the mud pond, and supernatant overflows from both the mud
pond and the lime pond entered into the spray pond. It may therefore be
seen that the system in reality contained more than flume and condenser
waters. The total capacity of the system was about 9.5 million gallons.
Reclaimed waters were pumped from the excess water pond to the factory
main water supply tank which in turn served the beet flumes, beet washer,
roller spray table, the condenser system, and for slurrying of lime mud.
Previous information in Sections V C 1 and 2 of this report gives detailed
description on the screen station and Dorr clarifiers found at the Findlay
plant.
An important element of the Findlay system was an arrangement be-
tween the company and the city whereby excess wastes from the integrated
closed circuit could be disposed of to the municipal sewage treatment
plant. A surcharge was levied for this service and company policy there-
fore was directed towards minimizing the frequency, amounts and particu-
larly the strength of the wastewaters so discharged. Wastes stored after
the close of campaign could also be disposed of in similar manner. Plant
observations indicated that minimum odor has been associated with the
industrial waste treatment facilities. Lime mud in the circuit has creat-
ed certain problems particularly clogging of the lines in the plant con-
denser system; effective lime settling is essential. The various basins
were reported to be cleaned once each year with the exception of the lime
pond which received more frequent attention. The company estimated the
capital costs of the waste treatment system at $253,000.
Within the Findlay system itself, BOD and TSS levels showed wide
variation. During October and November, the BOD value was around'700
mg/1. Near the end of campaign in January the BOD and TSS levels ap-
proximated 2,600 mg/1 and 1,800 mg/1 respectively. The BOD content of
the wastes under storage conditions decreased to around 700 mg/1 in mid-
March, and decreased further to 70-200 mg/1 BOD when the wastes were held
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until June. The total amounts of waste pumped to the municipal sewage
treatment plant during and after campaign have ranged from a high of
5.2 million gallons down to no volume. The city received no revenues
in 1963-1964, whereas $746 was received over the 1962-1963 season.
The total plant waste load ultimately discharged from the Findlay fac-
tory over the 1956-1964 period has averaged only 0.1 pounds BOD for
each ton of sugar beets processed. This residual waste level is re-
markably low and reflects considerable merit upon the factory and its
waste treatment methods.
Lastly, the Findlay system has been examined by Force (38) for
possible improvement. Two areas were indicated to be of particular
significance:
1) Separate flume and condenser water recycling systems would
serve to reduce the high flume water temperatures existing dur-
ing October. A spray pond would be desirable on the condenser
water circuit. In colder weather, the two systems could be com-
bined, taking advantage of the heat content then desired within
the flume waters.
2) The lime pond overflow should probably be eliminated from
the circuit because of the many problems caused by high solids.
Similar exclusion of sludge pond overflow would aid the circuit,
although to a lesser extent.
The Betteravia, California factory was a straight-house operation
processing about 4500 tons beets per day. A portion of the condenser
water was used for lime mud slurrying and for diffuser makeup, and the
excess was directed to the beet flumes. The spent flume waters were
discharged into a 3-pond system, received treatment, and recycled back
to the factory for reuse in the condenser system and the beet flumes.
In essence, the Betteravia system was an integrated flume and condenser
water closed circuit, however rigid control was lacking on other plant
wastes. Even though pulp drying facilities were available, press waters,
rather than being used in the diffuser were wasted to the lime mud pond.
The lime pond in turn had continuous overflow to the receiving stream.
Improvements could be easily undertaken at the Betteravia mill.
The merits of an integrated recycle system compared to separate
flume water recirculation will depend upon conditions at the particular
factory. With the typical integrated circuit, excess water buildup
approximating 60 gallons per ton of beets processed may be expected dur-
ing the campaign. Percolation and evaporation may reduce this volume.
The British Columbia Research Council estimated that a 4000 ton per day
factory may accumulate 32 million gallons of concentrated wastewater by
the end of campaign. The excess water buildup must not only be continu-
ously removed from the integrated circuit but furthermore, proper storage
facilities must be provided during and following campaign and the accumu-
lated volume eventually disposed of. If this wastewater was treated by
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trickling filtration on a continuous basis as the case at two British
mills, the accumulated volume may be reduced to 7-10 million gallons.
Alternate solutions are flume water recycling with separate discharge
of condenser water, dry methods of conveying beets into the plant, or
a combination of various measures, in-plant and treatment, to achieve
desired waste load reductions (31, 34, 38, 43, 47).
2. Biological Systems
Many studies have been performed on the treatment of sugar beet
wastes by biological means, including activated sludge, trickling fil-
ters, and other methods. In many cases, results have been obtained well
beyond the pilot-plant stage, and full-scale trickling filters in par-
ticular, have proven successful in Great Britain and Europe. The sugar
beet industry in the U.S. has conducted waste treatment research with
emphasis on basic studies and new methods. However, the results already
available in the literature should not be discounted. More information
is needed on the adaptability of present biological methods to sugar
beet wastes; pilot-plant and full-scale studies in this direction would
be more than appropriate.
a. Activated Sludge
Three series of laboratory studies were conducted by the British
Columbia Research Council to determine the feasibility of activated
sludge in treating sugar beet wastes. One series was intended to pro-
vide projection data for aerated lagoons, the results of which are pre-
viously given in Section V D 2 of this report. The treatment units were
maintained at a temperature of 71 ± 0.5°F. Of major importance was the
conclusion that activated sludge could effectively reduce the organic
load in waste flume waters by 93 to 97 percent. The maximum time re-
quired in fully adapting the floe to the substrate was less than 96 hours.
A second series of tests obtained on laboratory activated sludge
units showed that bio-oxidation of sugar beet wastes was successful and
initial BOD values of 135-2,000 mg/1 could be lowered to 0-50 mg/1 within
20-30 hours. Temperature was controlled at 73 ± 2°F. The third study
consisted of aerating a single flume water sample received from each of
48 factories using 72-hour activated sludge treatment. Despite the limi-
tations of the experiment, these results were also encouraging and showed
residual BOD values below 100 tag/1 for all but 10 mills. Of these ten,
six mills had initial BOD values in the range of 1028-2709 mg/1 BOD.
Better control of the system and full adaption of the activated floe
would have provided even lower residual BOD. It was concluded that flume
waters from all the mills were definitely amenable to bio-oxidation by
activated sludge.
The waste treatment system at the Hereford, Texas factory was
evaluated with respect to present capacity and possible future needs. In
this regard both activated sludge and trickling filtration were studied
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as potential means of pre-treatment superimposed upon the existing system.
The experiments were conducted on the composite plant wastes before en-
tering the existing waste stabilization ponds. The majority of these
wastes originated as bleedoff from the flume water recycle system within
the factory. It is noted that the Hereford recycle system was not a
closed one. Only about 85 percent of the waters were recirculated in
the system and the bleedoff was replaced by fresh water. The plant
wastes were not precisely defined although BOD values were probably in
the range of 650-800 mg/1 and COD around 1,000-1,200 mg/1. The existing
facilities at Hereford are described in more detail later in this re-
port.
The bench-scale activated sludge experiments at Hereford provided
data on COD removal as a function of COD loading, unit rate of COD re-
moval as a function of COD concentration, oxygen transfer rates for the
wastewater, and other operational factors. Within the range of 0.5-7.5
pounds COD/pound MLVS/day, the COD removals approximated 85 percent.
The MLVS refers to the mixed liquor volatile solids, the level of which
is directly related to amounts of active biological life in the system.
COD removal as a function of concentration indicated a straight-line re-
lationship within the range of testing. At 100 mg/1 COD, the removal
was 1.2 pounds COD/pound MLVS/day; and at 500 mg/1, 8.0 pounds COD were
removed/pound MLVS/day. The oxygen uptake rate at 23°C. for the waste-
water was 3.30/hr. compared to 6.95/hr. for distilled water, giving an
uptake ratio of 0.475.
The activated sludge studies were significant in other respects.
A strong tendency was noted toward the predominance of few bacterial
species in the system. Sphaerotilis was present in relatively large
numbers whereas protoza were nearly absent. Species imbalance was
associated with high loadings and also occurred when the volatile sol-
ids level decreased below 1500 mg/1. Furthermore, the system was con-
ducive to appreciable "washout" of bacteria. The observations gave no
guarantee that filamentous forms might take over the system but on the
other hand, offered no assurance that they might not. Although the
rate of organic removal was high, the system tendency to lose species
balance and settleability was not encouraging. The Hereford study in
summary, showed the activated sludge system could produce good organic
removals, but was rather easily upset. A system loading of 1 pound
COD/pound MLVS/day with 3000-4000 mg/1 MLVS was suggested. The diffi-
culty at Hereford was that activated sludge would give too high an
efficiency, when in fact, only pre-treatment was desired.
Nitrogen and phosphorous deficiency in biological waste treat-
ment has been associated with various industrial effluents, and sugar
beet waste appears to be one of these. Proper nutrients are necessary
to support the growth and propagation of biological life within the
system. Bacteria which are part of the system require about 12 percent
nitrogen and 0.5 percent phosphorous in their makeup. Sawyer (56) in ref-
erence to biological systems has recommended a BOD:nitrogen ratio of
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17:1 with a maximum of 32:1. The recommended BOD:phosphorous ratio was
90:1 with a maximum of 150:1. If nitrogen and phosphorous are lacking,
the biological system and its treatment performance may suffer greatly.
The Hereford, Texas factory recognized the need for nutrient
supplement by installing a nutrient feed station in its waste treatment
system. The Hereford report emphasized that "no phase of Holly's
(sugar company) biological treatment program is more important than
proper nutrient supply." The nutrient feed station as part of the exist-
ing treatment facilities would also serve activated sludge or trickling
filter units to be added in the future. Plant management has provided
nomographs which describe the proper rate of ammonium nitrate and triple
super phosphate that must be added to the wastewater depending upon its
flow rate and COD concentration.
The nutrient requirements given above have direct and meaningful
application to all biological systems whether activated sludge, trick-
ling filters, stabilization ponds, aerated lagoons, and other. With
this in mind, the South Platte River Basin Project collected special
data in January 1964 from the Loveland and Greeley, Colorado factories,
and these results are given as follows:
5-Day Org. N N03 Tot. P BOD: BOD:
BOD as N as N as P04 N P
Factory Site mg/1 mg/1 mg/1 mg/1 Ratio Ratio
Loveland, total plant wastes 609 0.1 0.1 7.5 3,050 250
Loveland, aeration field
effluent 490 0.1 0.1 4.7 2,450 320
Greeley, main sewer wastes 0.0 0.0 11.2 V. High 230 (est.)
Greeley, lagoon effluent 772 0.2 — 6.1 — 390
The data array on Loveland and Greeley showed that the general
nitrogen level was considerably lower than phosphorous. However, both
nitrogen and phosphorous were relatively low in respect to BOD. Undoubt-
edly, the Loveland and Greeley effluents would require nutrient supple-
ments for successful biological treatment.
Laboratory activated sludge units were also used in Great Britain,
in this case for treating wastewaters received from a factory settling
pond. Aeration periods varied from 6-24 hours, and operations were se-
quential consisting of aeration, settling, disposal of the supernatant,
adding wastewater to the previously settled floe, and then repeating the
process. The first three runs using aeration times of 6-17 hours pro-
vided BOD reductions of 48-83 percent; the active floe may not have been
fully adapted in these runs. Five other runs using aeration times of
18-24 hours produced BOD reductions in the range of 89-95 percent. In-
itial BOD values in the above tests were around 400 mg/1. The report
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concluded that further studies would be undertaken to evaluate the acti-
vated sludge process as an alternative means to the trickling filter sys-
tem in current use at British factories (6, 31, 32, 47, 49, 50, 56).
b. Trickling Filters
Trickling filters have found wide favor at a number of sugar fac-
tories in Great Britain and Western Europe. In the U.S., only two in-
stallations of this type are known to have been constructed. Consider-
ation is given to past treatment results derived from laboratory and
pilot-plant studies followed by the experience gained from full-scale
facilities.
Pilot-plant studies were conducted at the Hereford, Texas factory
to determine the feasiblity of trickling filters as a pre-treatment mea-
sure for the existing system. The installation consisted of a 30-foot
high by 3-foot diameter tower filled with plastic media. No recircula-
tion was provided since the filter was intended only as a roughening
unit. The wastewaters were screened and settled prior to treatment, and
the dosing rates were between 1 and 2 gpm/sq. ft. filter surface. The
various tests gave a performance curve relating COD removal to the applied
COD loading.
The results of the Hereford trickling filter experiments showed
that 60 percent COD reduction was obtained with an applied load of 210
pounds COD/1000 cu. ft./day, whereas 33 percent COD removal was received
at 750 pounds COD/1000 cu. ft./day. Preliminary design stipulated that
the filter should remove about one-third of the applied load of 17,000
pounds BOD per day. It was noted that caustic dumps were troublesome
during the study and caused some adverse effects upon the filter. The
study concluded that the system would eventually stabilize at a higher
performance level permitting about 50 percent increase in load with the
same removal efficiencies shown above. The first cost of a full-scale
filter was estimated at $125,000 with annual operating and maintenance
costs approximating $1500. Hereford preferred trickling filters over
activated sludge because the unit demonstrated more stable performance
and the operating skills were less demanding.
Phipps (35) in Great Britain has suggested that trickling filters
offer a logical means of treating the accumulated wastewaters resulting
from, the integrated flume and condenser water recycling system. The
wastewater would be stored over the campaign in a large pond and drawn
off for treatment at a relatively slow rate throughout the year. The
average factory would probably require storage capacity of 20-30 million
gallons. Phipps preferred a shallow rather than deep pond to take ad-
vantage of wind mixing and aeration. Research was conducted in this
regard using a 20-acre lagoon and a percolating filter of 60-foot dia-
meter by 6-foot deep. Wastes were diluted with .river water when neces-
sary giving an initial BOD of about 200 mg/1 onto the filter. The
monthly volume applied to the filter over 9 consecutive months of oper-
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ation varied from 0.6 to 6 million gallons. Filter inflow ranged from
17 to 230 mg/1 BOD content and the outflow from 7 to 71 mg/1 BOD. The
results showed when waste concentrations were reasonably high, the filter
system produced BOD reductions from 70 to 90 percent.
A pilot-plant installation receiving municipal sewage from the
city of Nampa, Idaho, together with processing wastes from the Nampa sugar
mill was the subject of extensive study in December 1963. In general,
about 20 percent of the total wastes from the factory after settling were
admixed with the municipal wastes. The combined wastes approximating 2
MGD were treated on two filters each 130-foot in diameter by 4-foot deep
connected in series and employing principles of high-rate recirculation.
The filters were preceded and followed by primary and secondary settling.
The sugar beet wastes before mixing demonstrated a varying strength of
275 to 625 mg/1 BOD, with an average of 400 mg/1 BOD. The hydraulic
loading onto the filters was about 38 MGAD and filter recirculation ra-
tios were between 1.7 and 5.0. Near the end of study, the treatment
plant was receiving straight sugar beet wastes with no adverse effects.
Results of the Nampa investigation showed that sugar beet wastes
were highly amenable to treatment over a wide range of loading onto the
filters. The first-stage filter was safely loaded up to 4.5-5.0 pounds
5-day BOD/yd. filter/day including recirculation, and produced 65-70
percent BOD removal. First-stage efficiencies were based on the un-
settled filter effluent. The second-stage filter loaded up to 2.0-2.5
pounds BOD/yd.3 filter/day including recirculation, produced 65 percent
BOD removal. Second-stage efficiencies were based on the effluent after
secondary settling. Overall waste removal averaged 95 percent and the
final effluents were presumed in the range of 15-30 mg/1 BOD.
Over the last 2 weeks of study, the Nampa pilot-plant received
straight sugar beet wastes at filter loads of 2.0-2.5 pounds BOD/yd.^
filter/day including recirculation. Although BOD reductions remained
h.igh, the test period was considered too short in predicting the long-
range effects of straight wastes on filter performance, particularly
at the higher loadings. Although nutrient needs were not determined,
phosphoric acid was continuously added to the process.
The high waste removals at the Nampa pilot-plant were apparently
aided by high waste temperatures (95°F. or more), absence of inhibitory
substances, the process design, size gradation of the filter providing
a relatively high surface area, and the presence of municipal wastes.
It must be concluded from the study results that the two-stage filter
system in many respects would provide superior performance over a single-
stage installation. The major objectives of the Nampa experiments were
to demonstrate overall effectiveness and predict design and operating
criteria for the new municipal treatment plant proposed at Nampa, Idaho.
The current status of these new facilities is not known to the author.
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The full-scale waste treatment system at the Bardney factory in
Great Britain consisted of a single filter operating either at low or
high-rate application and receiving settled factory wastewater. Flume
waters were taken from a settling-storage pond and diluted with river
water prior to filter dosing. The pond effluents varied in BOD concen-
tration from 1239 mg/1 in March decreasing to around 38 mg/1 in October.
The report on the Bardney factory provided monthly data on filter op-
eration extending from January to December.
The Bardney results indicated that the wastewater temperature
varied from 3-21°C. and filter loadings ranged from 0.07 to 0.77 pounds
BOD/yd.3 filter/day with the average load around 0.4 pounds BOD. During
the year 1955 the total waste volume receiving treatment was 38 million
gallons. BOD reductions varied from 55-97 percent, with removal levels
of 83 percent or higher occurring in 9 of the 12 months. Final effluent
BOD values were not reported but apparently were in the area of 20 mg/1.
Other pertinent information was given in the British reports re-
ferring both to low and high-rate trickling filters. One reference was
made to studies conducted by the Water Pollution Control Laboratory in
Great Britain where it was shown that properly operated filters could
consistently produce effluents with less than 20 mg/1 BOD when the in-
itial levels were between 105 and 180 mg/1. A second reference suggest-
ed that in starting up a filter, domestic sewage should be applied to-
gether with the industrial wastes, to reduce the time required for full
filter adaption. Primary and secondary settling were considered essen-
tial, and it was further recommended that for every 100 mg/1 BOD, the
wastewater should contain a phosphorous equivalent not less than 1 mg/1.
A third reference was made to Russian experiences where strong wastes
of 4000-5000 mg/1 BOD have been directly applied at low rates to a
three-stage filter system giving 75-85 percent waste reduction.
In the United States, there have been two full-scale trickling
filter plants specifically constructed for the treatment of sugar beet
wastes. In both cases, however, treatment performance has been most
disappointing. The following discussion relates the experiences at the
Rupert, Idaho and Lewiston, Utah sugar factories.
At Rupert, Idaho, a more or less conventional trickling filter
plant was completed in the summer of 1965 to provide treatment of wastes
expected from the Rupert factory the following campaign. Lime mud slurry
was separately impounded and all other factory wastes which comprised es-
sentially the flume and condenser waters were directed to treatment. De-
sign and operating criteria for the Rupert plant were believed derived
from the pilot studies previously undertaken in 1963 at Nampa, Idaho.
The Rupert facility consisted of a screen station with six vibrating
screens in parallel, twin hydro-separators also arranged in parallel,
followed by a primary settling tank, a single high-rate trickling filter,
secondary settling tank, and a Kessener brush aerator installed on the
effluent discharge canal. The hydro-separators with 20 minutes waste
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detention provided for removal of the heavier solids, and flows in ex-
cess of 5500 gpm through the separators were returned to the beet flumes.
From the separators, the wastewater entered the primary clarifier ap-
proximately 120-foot in diameter, 10-foot in depth, and having a waste
detention of about 2.5 hours. Unfortunately the treatment plant was
grossly overloaded and only 3000 gpm of settled wastewater was subsequent-
ly applied to the trickling filter; the remaining 2500 gpm was discharged
to the receiving stream. Sludges from both the separators and primary
settler were pumped to a storage pond. The trickling filter approximated
200-foot in diameter, 10-foot in depth, and contained slag material of
2-6 inch size, however not uniformly distributed within the filter. The
recirculation ratio was about 3:1 for this single-stage filter. Filter
effluent was then received into the secondary clarifier, which appeared
similar to the primary tank in size, and the final effluent was released
to the stream.
The $450,000 treatment plant at Rupert failed completely in terms
of providing a high level of waste removal. It is of paramount importance
that the apparent and possible causes of failure should be thoroughly ex-
amined. Although in retrospect many reasons may be given, the major
causes would seem to have been gross under-estimation of the processing
rate and difficulty toward design and selection of treatment units. The
design plans called for 3500 tons beets per day to be processed by the
Rupert factory however during the very first campaign the average pro-
cessing rate actually amounted to 6500 tons per day. Even further in-
crease was expected for the next campaign—up to 7000 tons beets per day.
Treatment plant overload was inescapable and drastic. Going back to the
Nampa pilot studies, it was stated at that time that "provision of a
second-stage filter ... is necessary for two reasons: 1) during the
periods of high loading rates and high strength incoming wastes, the first-
stage filter operating alone, will not produce an acceptable effluent and
2) the process apparently undergoes a cyclic unloading . . . (and) is
therefore necessary to have a second filter in operation to pick up the
load from the first-stage filter when this cyclic unloading sequence
occurs." Provision of a second filter at Rupert would have helped the
situation.
Although firm data were not available concerning Rupert, it was
estimated the hydraulic load onto the trickling filter approximated 25
MGAD and the waste load was in the order of 7 to 12 pounds BOD/yd.-* filter
/day including recirculation. These applied filter loads were extremely
high. Besides poor distribution of media, there was little or no visible
biological growth on the surface of the filter. Of great importance, the
steam and water vapor forming over the filter during cold weather retarded
air downdraft tending to suffocate the bed. Provisions for inducing air
undercurrents through the side and bottom of the bed possibly would have
alleviated this condition. Furthermore, a skimming device preferably auto-
matic, was greatly desired on the primary settler to remove the substantial
accumulation of scum and grease present. Information obtained for Rupert
indicated that the treatment plant was providing around 30-40 percent BOD
removal for that portion of the sugar beet wastes receiving treatment.
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The various conditions described above were observed principally during
the 1965-1966 season and do not retlect changes since that time.
The second trickling filter was located at Lewiston, Utah, and as
in the case of Rupert, innumerable problems and difficulties were experi-
enced. Although the available information is somewhat incomplete, the
Lewiston trickling filter was constructed around 1961 and intended for
treating and recycling waste flume water from the Lewiston sugar mill.
During the off-season the filter received various wastes from the fac-
tory holding pond.
The Lewiston facility consisted of a screen station, grit chamber,
a mechanically-operated clarifier 90-foot in diameter by 10-foot deep,
followed by a single filter 120-foot in diameter by 5-foot deep. Two and
one-half hours waste detention was provided in the primary settler and
part of the filter effluent could be returned to the clarifier. The
treatment system was reported in 1963 to have three major defects. First,
the overflow weir on the clarifier was above the side wall and the water
surface was completely exposed to wind and weather action. Serious
deficiencies in the trickling filter included a poor underdrainage sys-
tem and improper media conditions. The underdrainage system experienced
frequent flooding and required additional pumping capacity. The filter
rock varied greatly in size from less than 2-inches to beyond 9-inches
but even more important it was reported that trucks had been driven onto
the filter in the process of placing the media. Compaction of the media
and damage to the underdrains were thereby suspected. The reduction of
media 'interspace would serve to minimize air circulation through the
filter and retard biological growths. The Lewiston factory wastes were
also indicated as nutrient deficient which may have caused even further
difficulty in treatment.
The Lewiston filter was initiated too late in the 1961 season to
develop adequate biological growth. The filter was re-activated in March
1962 using holding pond wastes. The results collected over March-May
1962 showed 0-30 percent BOD reduction with hydraulic and organic loads
(including recirculation) of 4.7 MGAD and 6 pounds BOD/yd.^ filter/day
respectively. Wastewater temperatures varied from 8-14°C. during April
1962. Through June 1962, the BOD removal increased to 40-60 percent
with the applied filter loads around 3.5 pounds BOD/yd.-Vday• When the
next campaign began on October 10, the filter was in very poor condition
and major attention was devoted to re-establishing suitable biological
growth. Through November 1962, the treatment plant provided BOD reduc-
tion in the range of 10-50 percent.
The advantages of two-stage filtration over single-stage were not
present at both Rupert and Lewiston. The absence of a secondary clari-
fier at Lewiston in similar fashion was considered detrimental to satis-
factory biological treatment. The Lewiston and Rupert plants were com-
parable in the respect that neither system was given the opportunity to
develop the full potential of the waste treatment processes. These re-
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suits were certainly not representative of good treatment performance
expected from trickling filters (6, 28, 31, 32, 34, 35, 47, 57, 58).
c. Anaerobic-Aerobic Lagoons
Pilot-plant studies have been continuing at the Tracy, California
factory since June 1965, applying the anaerobic-facultative-aerobic la-
goon system in treatment of sugar beet wastes. The installation consist-
ed of three ponds in series receiving part of the factory waste flume
water plus some septic tank drainage. These wastes were settled prior
to entering the ponds. Detention times varied from about 10-25 days in
the anaerobic pond, 10-30 days for the facultative pond, and 10-20 days
in the aerobic or algal pond. Over the first two years of study, the
anaerobic, facultative and aerobic ponds were used respectively as the
first, second and third units in series, but this sequence will be re-
arranged in future work. The major objectives of the study were to
demonstrate the waste removal efficiencies of the system and to mini-
mize odor in connection with this means of treatment. The system was
evaluated with respect to varying feed rates and recirculation ratios
upon organic waste removal, and the degree of odor control and micro-
bial growth associated with the operations.
The most useful results were those received in September-November,
1966. During this period, influent BOD values generally ranged from
1200-1650 mg/1. In the first experimental run, the recirculation:feed
ratio was 1:1, and the applied organic loadings were 1235 pounds BOD
/acre/day on the anaerobic pond, 831 pounds BOD on the facultative pond,
and 660 pounds BOD on the aerobic pond. Pond depths in this and the
following runs were 15, 7, and 3-foot respectively for the anaerobic,
facultative and aerobic units. The conditions of the first run repre-
sented an overall waste detention period of about 35 days and provided
70 percent BOD removal and 38 percent COD removal. The BOD concentra-
tions from inflow to outflow were reduced from approximately 1200 mg/1
to 350 mg/1. In the third run, there was no recirculation of treated
waters, and the applied loadings were 1640 pounds BOD/acre/day on the
anaerobic pond, 448 pounds BOD on the facultative pond, and 317 pounds
BOD on the algal pond. Overall waste detention time was 70 days which
provided 93 percent BOD removal and 77 percent COD removal. Correspond-
ingly, the BOD concentrations were reduced from about 1650 mg/1 down to
170 mg/1. The studies also included the enumeration of algae, purple
sulfur bacteria, coliform and fecal streptococci bacteria present with-
in the system. Efficient removals were achieved in regard to both coli-
forms and fecal streptococci organisms.
The investigators believed that the Tracy system with suitable
modifications would demonstrate future improvements in waste removal
efficiency. The previous work showed that the majority of waste re-
duction had occurred within the anaerobic pond whereas the other two
ponds contributed only in minor degree. The low efficiencies in the
facultative and aerobic ponds were attributed to a lack of algal growth
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which in turn was caused by heavy loading, improper mixing, or toxic
elements that were present in the waste. Provisions will be made in
future studies to overcome these difficulties and achieve full effec-
tiveness in all three phases of the system. Nutrient additions may be
made if necessary. The industry has commented that the system perform-
ed well with a marked reduction in odor. Lastly, it must be recognized
this means of treatment may have definite limitations in cold climates,
and additional studies will be necessary to prove its application to
other regions of the country (40, 51, 52).
3. Biological-Recirculation Systems
The wastewater treatment system at the Hereford, Texas factory
comprised two discrete treatment phases. The Hereford installation
employed waste recycling, collection of all wastes, then followed by
biological treatment. It must be noted that the Findlay, Ohio waste
treatment facilities previously classed in this report under the re-
circulation-reuse system used similar treatment means, however in the
case of Findlay all units were integrated into a single circuit. The
Hereford system was inherently different from the various other treat-
ment schemes. The Hereford plant has been referred to on earlier occa-
sions within this report.
The one-million dollar waste treatment system was constructed
simultaneously with the 24-million dollar Hereford factory. The expect-
ed rate of processing was 6000 tons beets per day. The treatment mea-
sures were intended to preclude any wastewater from entering the re-
ceiving stream. The Hereford system consisted basically of a flume
and condenser water circuit with about 85 percent recycle, stabilization-
evaporation ponds covering about 160 acres, and final disposal of waste-
water onto company-owned agricultural lands. The flume and condenser
water circuit served by a screen station, mechanical clarifier and sludge
storage pond, is previously described in Sections V C 2 and V E 2 a of
this report. Remaining process wastes from the factory were released
to the lime mud pond. Overflows from the lime and sludge ponds were
collected together with bleedoff from the flume circuit into a catch
basin. This collection basin also received septic tank drainage
and was fed nutrient supplements. The total contents of the catch basin
were subsequently pumped to the series of stabilization ponds. The
waste system was designed on the basis on 1000 gpm total plant waste-
water, comprised of 725 gpm flume and condenser water bleedoff, 120 gpm
sludge pond overflow, 145 gpm lime pond overflow, and 5 gpm each of boil-
er blowdown and septic tank drainage. Design plans called for composite
plant wastes to contain around 660 mg/1 BOD and 1000 mg/1 COD.
The Hereford, Texas interests also included feedlot operations
adjacent to the factory. Lagoons were provided to withstand a 3-inch
runoff and effluent pumps were available for displacing routine feedlot
wastes and runoff to the stabilization ponds. The six stabilization-
evaporation ponds in series could retain up to 7-foot of wastewater which
was twice the volume expected from the beet sugar processing campaign.
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Although analytical results for the Hereford system were not found
in the literature, general information was made available. Odors have
been experienced from the main sewer line leading to the stabilization
ponds and from the feedlot lagoons. The flume and condenser water cir-
cuit also demonstrated a tendency towards turning sour. The Hereford
report commented that the wastewater recycle circuit was surely not
intended as a biological treatment unit but nevertheless this reaction
did occur. With the lack of aeration facilities, anaerobic conditions
could be expected, resulting in the buildup of disagreeable by-products.
Three corrective measures were proposed for the recycle circuit: 1) kill-
ing of the bacteria by chlorine or other chemical agents; 2) distressing
the bacteria by adding lime or some metallic biocide; and 3) aerating the
circuit by continuous blowdown or other means.
In regard to the main sewer and lagoons, air injection was suggest-
ed directly into the sewer to minimize odors enroute to the stabilization
ponds. The feedlot runoff in the lagoons became septic about the second
or third day, turning gray or black and then generating considerable odor.
Prompt drawdown of these liquors was indicated as essential in overcoming
this problem.
The six stabilization-evaporation ponds could be operated a number
of different ways, series or parallel. The most feasible schemes were
six-stage independent operation, three-stage control using cell pairs, or
two-stage control. Operating depths in the above cases apparently ranged
from 2 to 7-foot. Possible odors from the sludge and lime mud ponds could
be minimized by maximum drawdown of the supernatants or adding copper sul-
fate or chromium reagents to the waste inflow (32, 40).
F. OTHER CONSIDERATIONS
Waste control and abatement implies certain action to be necessari-
ly undertaken by industry. The British Columbia Research Council in its
report to the Beet Sugar Development Foundation stated that "a broad spec-
trum of water reuse and waste disposal practices (exists) throughout indi-
vidual mills of the beet sugar processing industry in North America.
Utilizing the experience of mills in other geographic areas, those mills
employing a lesser degree of pollution control at the present time may
base future measures, as they become necessary on the experience of other
mills. The time and place at which specific action is required, with re-
gard to a specific mill and specific beet sugar processing wastes, will
vary considerably. Answers are evident for many situations whereas some
remain to be resolved."
Regarding the approach by industry, it must be noted however, the
necessary measures undertaken too often are those which precisely match
the minimum requirements expected by the regulatory agency, or in other
cases, a lesser degree of control corresponding to the level understood
to be tolerated by that agency. The greatest progress would seem to be
in the area of those measures intended to return a profit or reach a
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"break-even" position. Indeed this should be the case, which further
emphasizes that in-plant measures are probably more effective than waste
treatment in contributing to a successful waste management program.
Recognition by industry of the essential nature and overall consequences
of water pollution would guarantee protection not only for present water
uses but also future uses and our natural water resources.
1. Design; Operation, and Maintenance
A successful waste management program implies that there be a
reasonably high level of proficiency in all aspects of design, operation,
and maintenance, both within and without the sugar factory. Concerning
this issue, awareness of the waste problem and a blending of positive
attitudes are essential. A situation should be created whereby the
necessary measures are made available and then used in attaining the
highest level of waste control on a day-in day-out basis. Also it is
important that much greater status recognition be given to the entire
area of waste abatement.
Most industry, and sugar beet processing is no exception, par-
takes in waste abatement. On design of waste control measures much
has been done by the beet sugar industry, but also much remains. Too
great a reliance is sometimes placed upon standardized treatment units.
It is suggested that a qualified industrial waste engineer be attached
to the permanent staff of the sugar processing company and be given
ample opportunity to support the design in its entirety. The engineer,
whether in the consulting or staff position, should be well-versed in
the area of assignment, have some degree of vested interest in the pro-
ject, supervise if necessary, and follow-through on all essential ele-
ments leading up to and beyond job completion.
The company must provide realistic estimates on factory operation
for proper planning and design of treatment works. The criteria or
guidelines should be reasonable in all cases. Items should not be de-
leted or units undersized unless there is certainty that no decrease in
waste treatment performance will thereby result. By-pass structures
should be designed to serve only in true emergency and the plans should
call for intercepting various spills and unintentional waste discharges
and returning these to the waste treatment system. Excess capacity is
important and should be incorporated into the treatment units. Proper
compaction and construction of treatment lagoons and holding ponds but
particularly of the surrounding walls are necessary. If construction
criteria are lacking for earthen structures, it is suggested that the
criteria for storage ponds in the uranium milling industry may be used.
Many more aspects of proper design could be elaborated upon but are not
feasible within the scope of this report.
Once the waste control and treatment facilities are in place,
the operation and maintenance of these facilities are all important.
Each and every device and procedure intended for waste abatement should
be given a status of importance near equal to the process operations.
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Experience indicates too often the waste treatment system is relegated
to the background and made to function almost solely on its own capa-
bilities. Only when major trouble develops, will it then receive at-
tention. A new philosophy is needed not only in the industrial waste
field but also in regard to municipal wastes, which would upgrade waste
treatment to the level of a precise and professional enterprise. This
concept is thought both desirable and possible by many authorities.
Also since industrial wastes are created by industry and presumably,
the manpower of the regulatory agencies will never be sufficient to
assess the efficiency of each and every industrial treatment installa-
tion, the latter task in very large part ultimately must become the
responsibility of industry.
The sugar beet companies and each mill having extensive control
and treatment facilities, should have an adequate staff whose services
would be devoted to the design, operation and maintenance of these facil-
ities. Possibly some time would be available for research. A qualified
industrial waste engineer could be expected in charge of activities.
There may be some flexibility in numbers of supporting personnel and it
is presumed that supplementary forces would be provided as needed.
The importance of administrative control and plant records was
emphasized in relation to the wastewater control program at Hereford,
Texas. Without proper administration it was pointed out that the pro-
gram must suffer serious shortcomings. Therefore, a logical division
of responsibility and organized approach were found necessary. The
Hereford report did not offer any detailed thinking in this regard how-
ever mentioned general duties of the Superintendent, Chief Mechanic and
Chief Chemist that would fall under this program. These thoughts lead
to the concept of a successful program requiring that lines of authority
and responsibility be fully delineated and that each and every person
clearly understand his explicit role. The Hereford report also recog-
nized the importance of plant records and a prescribed format of data
gathering and recording was considered essential to the program.
The many improvements that are possible in operation and mainte-
nance of waste control and treatment facilities cannot be satisfactorily
covered in the present feport, but it is hoped that other groups may ex-
pand upon this thinking in future studies. In final analysis, no amount
of money devoted to treatment is worthwhile unless proper logic and care
have been used throughout the design and construction phases and further-
more, these facilities are operated and maintained in a truly satisfactory
manner (31, 32) .
2. Research
Concerning research, it is true quite often too much can be said,
and at other times not enough. From the known information, it is more
than clear that all sugar beet wastes can be adequately treated by the
technical means available. The problem remaining is one of economics.
The conjecture that certain wastes cannot be treated and must await fur-
136
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ther research would not appear justified except in the economic sense.
However additional research cannot be disputed in view of improvements
needed both in process and treatment and also in minimizing overall
costs. Other forms of competitive waste treatment may be found in the
future, but most likely these forms will represent modifications of
existing treatment methods.
Research is necessary to secure the highest economies and to
deliver an even better product to the receiving stream. The British
Columbia Research Council has been performing continuous research work
for the Beet Sugar Development Foundation. Applied research is being
carried out at Tracy, California, similar studies will start soon at
Longmont, Colorado, and undoubtedly there are other investigations in
progress. All this represents an important step in the right direction.
Again, much more can be done, and the pertinent suggestions previously
given by the British Columbia Research Council would constitute a spring-
board by evaluating and converting the best suggestions into actual prac-
tice.
Worthwhile and challenging research could be performed in the
specific areas of: 1) dry-disposal of lime cake; 2) transporting the
beets to the factory by dry-handling techniques; 3) eliminating waste
loads from flume waters by treatment or, even more important, by not
permitting these loads to come initially into contact with the waters;
4) new and improved in-plant waste control measures; 5) the best means
of handling excess condenser waters; and 6) modified forms of biological
treatment which may be truly adaptable to sugar beet wastes, particular-
ly spent flume waters. Activated sludge, trickling filters, aerated la-
goons, and other methods should be studied in detail to fully determine
their legitimate role in sugar beet waste treatment.
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Bibliography
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46. "Treatment of Sugar Beet Wastes by Lagooning," Kalda, D.C., Proceed-
ings of the Thirteenth Industrial Waste Conference, 126, Purdue
University, Lafayette, Indiana, May 5-7, 1958.
47. "The Composition and Treatment of Sugar Beet Factory Waste Waters,"
Carruthers, A., et. al., Paper presented to the Thirteenth Annual
Technical Conference of the British Sugar Corporation, Ltd., The
Research Laboratories, British Sugar Corporation Ltd., The Grange,
Bramcote, Nottingham England, May, 1960.
48. "Broad Field Disposal of Beet Sugar Wastes," Porges, R., and Hopkins,
G.J., Sewage and Industrial Wastes Journal, 27, 10, 1160, October, 1955.
49. "Treatment of Beet Sugar Flume Water - Project Report 64-117-B," Pre-
pared for the Beet Sugar Development Foundation, British Columbia
Research Council, University of British Columbia, Vancouver 8, Canada,
December, 1964.
50. "Rate Studies for BOD Removal in Beet Pluming Water - Progress Report
No. 3," Prepared for the Beet Sugar Development Foundation, British
Columbia Research Council, Vancouver 8, Canada, June, 1965.
51. Papers on Demonstration Grant Application No. WPD 93-01 on "Facul-
tative and Algae Ponds for Treating Beet Sugar Wastes," Proposed by
the Beet Sugar Development Foundation and submitted to the Department
of Health, Education, and Welfare, Fall, 1964.
52. "Progress Report II - Facultative and Algae Ponds for Treating Beet
Sugar Wastes, June 1, 1966-December 1, 1966," Studies conducted by
the Beet Sugar Development Foundation at Tracy, California under
Demonstration Grant WPD 93-01(Rl), U.S. Department of Health, Educa-
tion, and Welfare, Public Health Service (now the U.S. Department of
the Interior, Federal Water Pollution Control Administration),
December, 1966.
53. "Sewage Treatment," Imhoff, K. and Fair, G.M., Second Edition, John
Wiley and Sons Publishers, New York, N.Y., 1956.
54. Correspondence with various Regional Water Pollution Control Boards
of the State of California, Information obtained for the South Platte
River Basin Project, Denver, Colorado, by the Southwest River Basin
Office, Department of the Interior, Federal Water Pollution Control
Administration, San Francisco, California, 1964-1965.
142
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55. Letter from the Great Western Sugar Company, Denver, Colorado, to
the Colorado State Department of Public Health, June 30, 1965.
56. "Bacterial Nutrition and Synthesis," Sawyer, C.N., included in
"Biological Treatment of Sewage and Industrial Wastes, Volume I,"
Reinhold Publishing Corporation, New York, N.Y., 1956.
57. Personal and written communication with the Idaho Department of
Health, Boise, Idaho, 1965-1966.
58. "Joint Treatment of Municipal and Beet Sugar Wastes on High-Rate
Trickling Filters," Peterson, A.T., Chronic and Associates, Con-
sulting Engineers, Boise, Idaho, Report received by South Platte
River Basin Project on May 18, 1965.
Other Informative References
59. "Treatment and Re-Use of Water in Beet Sugar Manufacturing," Fleming,
G.S., Sewage and Industrial Wastes Journal, 24, 1382, 1952.
60. "Industrial Wastes-Beet Sugar Industry," McDill, B.M., Industrial
Engng. Chem., 39, 657, 1947.
61. "Waste Waters from Beet Sugar Factories-Their Treatment and Dis-
posal," Brandon, T.W., Intern. Sugar Journal, 49, 98 and 124, 1947.
62. "Evaluation of Broad Field Disposal of Sugar Beet Wastes," Hopkins,
G.J. et. al., Sewage and Industrial Wastes Journal, 28, 1466, 1956.
63. "Design, Operation and Success of Installations for the Treatment of
Sugar Factory Waste Waters in the Soil," Zucker, 14, 36 and 61, 1961;
see also Water Pollution Abstracts, 35, 281, 1962.
64. "Waste Disposal Problems at the Great Western Sugar Plants in Colorado,"
Colorado State Department of Public Health, Division of Engineering and
Sanitation, Water Pollution Control Section, 4 pp., January, 1965.
65. "Investigation of Sugar Beet Pollution in the Cache la Poudre River,"
Tanner, H.A., Colorado Game and Fish Department Cooperating Quarterly
Report, I, 23-37, 1954.
66. "Cooperation Between Industry and Regulatory Agencies in Water Pollu-
tion Control," Formo, H.G., Paper presented at the Intennountain Work-
shop on Water Pollution, Conducted by the Manufacturing Chemists'
Association, Inc., at Denver, Colorado, October 28, 1965.
143
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67. "A Brief History of Beet Sugar/' Ziegler, W.H., Paper presented at
the Holly Sugar Corporation Sales Conference, Colorado Springs,
Colorado, November 12, 1951.
68. "The Manufacture of Beet Sugar," Daniels, R.M., Paper issued by the
Holly Sugar Corporation.
69. "Beet Sugar Treatment Processes," Sawyer, C.N., Sewage and Industrial
Wastes Journal, 22, 221, February, 1950.
144 GPO 937 ~822
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