A
PRELIMINARY INDUSTRIAL
PROCESS SURVEY
OF THE HAWAII SUGAR INDUSTRY
by
Robert J. Burnry, Sanitary Engineer
and
Charles T. Bourns, Civil Engineer
(A compilation of data collected on individual sugar mills
in Hawaii in 1966 and 1967 for the purpose of planning "The
Hawaii Sugar Industry Waste Study", published June, 1971)
U. S. ENVIRONMENTAL PROTECTION AGENCY
Region IX
San Francisco, California
-------
OtOKELE Mill
N
(CONTROL AREA
McftRYOE MILL
Seal* in Mil..
LOCATION MAP-HAWAII AN ISLANDS
HONOR A A MILL
CONTROL AREA
KAHOOLAWE *
HAWAII SUGAR INDUSTRY WASTE STUDY
AREAS OF SUGAR CANE
CULTIVATION
ENVIRONMENTAL PROTECTION AGENCY
REGION IX
SAN FRANCISCO, CALIFORNIA
c
3J
-------
KILAUEA SUGAR CO.
PACIFIC
OCEAN
ISLAND OF KAUA
HANAPEPE SAY
POIPU BEACH
*-
'GROVE FARM SUGAR co.
NOTE: "W DENOTES A SUGAR MILL
HAWAII SUGAR INDUSTRY WASTE STUDY
LOCATION OF SUGAR MILLS
ISLAND OF KAUAI
ENVIRONMENTAL PROTECTION AGENCY
REGION IX
SAN FRANCISCO, CALIFORNIA
(D
c;
-------
N
PACIFIC
OCEAN
ISLAND OF OAHU
NOTE:
DENOTE I A SUGAR MILL
DIAMOND HEAD
HAWAII SUGAR INDUSTRY WASTE STUDY
LOCATION OF SUGAR MILLS
ISLAND OF OAHU
ENVIRONMENTAL PROTECTION AGENCY
REGION IX
SAN FRANCISCO, CALIFORNIA
tr>
•a
-------
N
PACIFIC
OCEAN
NOTE:
DENOTES A SUGAR MILL
HAWAII SUGAR INDUSTRY WASTE STUDY
LOCATION.OF SUGAR MILLS
ISLAND OF MAUI
ENVIRONMENTAL PROTECTION AGENCY
REGION IX
SAN FRANCISCO, CALIFORNIA
O
c
-------
HAV.'AIIAN SUGAR WASTE STUDY
KILAU3A SUGAR COHPAKI (KAUAl)
Date of Visit
November 28, 1966
Parsnt Company
C. Brewer
Persons Contacted
Noboru Takanura, State Sanitarian; Ernest Smith, Manager; Bob Duncan, Pit. Manager
Operation Rate
18,000 tons of raw sugar over a 10-aonth psriod.
Shifts
24 hours a day, 5 days a week.
Employees
235
Water Supply
•z>"
An average of H£ mgd ('2700 irdllion gallons per year"—seems low) is used. (Another?)
£tBi =igd is used in the mill of which l| ncd is sent back for irrigation. All water
is surface water obtained fron the nearby mountains.
Process Description
Cano is dumped from the trucks over en approximately 6-foot bank where it is then
grab lifted onto a conveyor belt. Some heavier soil is removed in this manner,
and about 30 yards per day are bulldozed out of the aroa. The cane washing operation
consists of spraying the cane with water for dirt removal only; no trash is
mechanically separated fron the cano and no sink-float process is used for rock
and heavy debris removal. This latter step is apparsnt3y not necessary because
there are no rocks in the soil. Washing is conducted vdth two conveyors operated
in series.
-------
- 2 -
Upon cc-ipletion of the washing cycle, tho cane is shredded by one set of knives
and than passes through the first "rollinc nill" or crusher. The cane then passos
through three noro r.ills and the liquid oqaocsed fron each of the last three mills
is sent forward to tho previous mill. Seas vator is added at the last mill. Juice
obtained, frca the first rain (croohor) lo weighed £r.d then has cagnesiuni cod.de added
for i>H neutralization and coagulation. Tha Juice is then heated in juice heaters
usin'p vacor from the pre-evaporator. Final clarification takes place with the "nxid"
going to'a rotating drurc filter whore it is washed and additional sucrose is thereby
removed in the uash water. The and seed crystals; the separation or strike is called the A strike and gives
co-snercial (high-TS.de) sugar and A molasses. The A molasses is then added to the
KL""h»crtdo pan together with more syrup; this leads to a B strike which yields core
cosrnercSal sugar and B molasses. Tho B rcolasseo is placed in the low-grade pan or
evaporator, where after boiling, the «lw-seeA*' (C) strike yields law-credo sugar
and" final icolassas. The final molasses in sold and the low-grade sugar is sent to
the seed evaporating pan for Growth to ceod crystal or back in the process to the
clear Juice before the evaporators. The ttrlkea occur in centrifuges. A total of
S27' .sucrose recovery occurs in the plfjit.
Waste Reduction Measures
SOT.S wish water is sent back to the fislds. Eo other genuine waste treatment exists.
Any surplus bagasse is added to the diachtrgo \ratcr, but this apparently has not
h£-?pencd eir.ce'a new boilor was placed in operation in 1963. Wastes arcj flined
about 2,000 feet to a valley and then continue another 2,000 feet down tho valley
to the sea.
Cjxno Afff at Harvesting
24 months
KorvestlRg Procedxires
?uch Rake
Fo.rtilirsr
300 Iba. of Mitrogen/acre/crop (put on in first 10 months)
iCO Ibs. of P;x>5/acr3/crop at planting
300 Ibs. of KaO/acrc/erop
6,000 Ihg. of Ca?Ji/acre/crop on half the plantation^
Nitrogen is put on as powdersd urea \dth scsio aitsionia.
-------
-3-
Irrf *.*.tic;n Ppoceduroo
1,700 acres
— 1,5CC acrss
i — 1,300 acs-ea
a i3 utsocl as a Witos- corea^t'.tJ.cn insure snd uoas tho "Anjos 2ooci-0-Raiair
wG.c5T ie"c;a overhead boon. Gpz-trlclui: installations cav cheapej- but operating costs
Field Runoff .Chapfcctori jstica
otrccrus carry the runoff.
.v;.:asiiKf — 4 Ibc. /aero/crop; airci-aft -p^
2-.^, ]) — ;> Ibs. /acre/crop; at crop cta^t
D.C.I'-.U. — s]»b apraycd
recrcuric cccfcatc) — u;,z^ iss oc«i iath
L'v.: Crop P.r
is prJLctietsd tidcc bsforo
Hlant p^i'C-JTiisl strivo for a soori burr. bic?usy oi'J t'-io absence of & dctr^shsr.
If tr&ch rcrroval end a hjdroserru.'T.to!? V-JTO aricliia, the coc« vouid bo about
C 500,000.
Tho plant tpptnanUy lus boan "in l.hj 2-^i'1 sisico 19^3.
1.7Sid recLr/Abion is not needed.
The receiving valley nuay bo dawwc cr«J fillc-d if v^.ste treatment is required.
Tnc s&a drift is to the wast.
-------
HAMAIIAH SUGAR WASTE STUDY
LIHU3 FIAKTATICW COMPANY (KAUAI)
Date of Vic.it
November 28, 1966
Parent Coaipaay
Anerican Factors
Persons Contacted
Clinton Childs, Asst. Manager; John R. Lowrie, Factory Supt.j Hoboru Takamura,
State Sanitary Engineer
Or>eration Rate
70,000 tor.s/yr., raw sugar in about 10 months.
Shifts
2k hours a day, 5 days a week.
Employees
990
Water Supply
500 gpm well for domestic use.
20 mgd used in rill.
Total plantation usage ~ not obtained.
Most water is obtained from the nearby mountains.
Process Description
The cane is cleanod at washer located about 3>500 feet fi-om the nd.ll and is then
sluiced to the mill. The cane passes up the conveyor and through primary extractors
and then into a sink-float tank. Firom the sink-float tank, it passes up to a drum
separator and then, depending on siae, passes through trash extractors. The trash
and other solids are trucked ai;ay for land reclamation. The cane then passes to
the mill.
-------
-2-
Tha plant has two rolling mills, called the A and B mill. The mills are apparently
identical. The first press or mill (not to bo confused with the term A or B mill
which means the entire plant section) is called the crusher and this is followed
by three other mills. Liquid extracted from each mill is sent backwards to the
previous mill. Some water is added before each press except the first. Bagasse
frora the last mill is measured by gaarca ray and then burned. Any excess bagasse
apparently has a ready market for fertilizer.
The juice from the first nill is neutralized with lime and then passes through
juice heaters which get their heat froa evaporator vapor. Clarification then occurs
and the juice then passes through 4-stage evaporators (no pre-evaporators). Sugar
production is by standard vacuum pans and centrifugal separators as follows. The
A strike uses just syrup and seed crystalj tha B strike is formed, in high-grade
pans, from about 70^ A molasses and syrup. The low-grade or C strike is formed in
low-grade pans from B aolassoo. Further curing of this molassss takes place in
crystallizors in which crystals are formed by slow stirring and cooling for up to
72 hours. Low-grade sugars, not seeded in the seed pan for making seed crystals
are sent back and added to the A and B strikes. Recovery is 86^-88$.
Waste Reduction Measures
Washing wastes pass through a 150-foot diameter hydroseparator. Detention in the
separator is apparently 4-5 hours. The slurry is about" 24£ solids and is used
for land reclamation. Separator effluent contains about 1500 mg/1 suspended
solids. Much of the separator effluent reaches the sea below the Lihue Airport
main runway.
Cane Age at Harvesting
24 months
Harvesting Procedures
Push Rake
Fertilizer
See attachment.
Irrigation Procedures
460 acres by overhead irrigation — 2g acre inch an application
10,500 acres by furrows — 5-7 acre inches applied
4,000 acres unirrigated
Field Runoff Characteristics
After the reservoirs are filled, the water escapes to the sea in various channels.
-------
-3-
Peaticide Usage
See attachment.
New Crop Procedures
Three ratoons before replanting.
Random Ccnnsnts
The cane washer is located away from the na.ll because of better drainage at the
site.
The effluent ditch is amenable to monitoring.
-------
-t p—i"——
i i , .'
L uL
P. 0. BOX 751 | LIHUE, HAWAII 96766
iir
~3 n r;
^L:JIJ Jviyuu
eg
lilllil
i ! ii
A SUBSIDIARY OF AMFAC INC | HONOLULU, HAWAII
December 2, 1986
Mr. Charles T. Bourns, Chief
Water Quality Activities, Hawaii
Room 428
1481 So. King Street
Honolulu, Hawaii 96814
Dear Mr. Bourns:
As per your verbal request., the following information is submitted giving
amounts of chemicals used for control of weeds ard also amounts of fertilizers
used in the years shown.
WEED CONTROO CHEMIC/.LS
YEAR
1964
1965
1966
AREA
ACRE ROUNDS
44,220
41,438
(est.)35,162
Descriptions of the
TONS
STCA
67.5
134.2
105.0
TONS
DCMU
42.9
16.2
10.4
TO. IS
ATRA2INE
25.2
25.8
41.9
TONS
AMSTRYNE
25.9
16.9
GAL.
AR55
33,957
23,957
30,470
GAL.
PENTA
24,
48,
33,
159
682
050
TONS
DALAPOtf
14.
12.
16.
0
0
6
above-named chemicals:
AMETRYNE - 2-Thiomethyl-4-ethyla.T.ir.o-6-isoproprylanino-s-triazine.
Geigy Agricultural Chemicals Co.
ATRAZINE - 2-chloro-4-ethylamino-6-isopropylamino-s-triazine.
Geigy Agricultural Chemicals Co.
DCMU Diaron (Karmex) - (3s4-dichloro?henyl)-l,l-diT.ethylurea.
E. I. dupont, de Munuers
DALAPOM - 2,2 dichloropropionic acid. Dovrpon (sodium salt)
" Dow Chemical Co.
STCA - sodium salt of trichloroacetic acid.
Dow Chemical Co.; Farber Warka Hoaschst Co.
PSMTA chloropher.ol and/or sodium pent a c'nlorophenato.
Reichold Chemical i Inc.; Monsanto Chemical Co.
AR55 - standard aromatic oil.
-------
Ite. Charles T. Bourns
Page 2
December 2, 1966
All of the weed control in sugar cano in Lihue Plantation is done by means
of chemicals. The present program of control of needs carried out by the planta-
tior -epresents a coooerative effort of experimental testmg of new herbicides
releaseTby the chemical industry and the commercial development by the plantations
after the Federal registration has oeen obtained.
SURFACTANTS - (surface active agents) are used with the herbicides as wetting ^
agents and "sticking agents to aid in spreading the herbicides over the leaves or
the plants to add in retaining them there until tnexamum absorption oy .he plant
has been affected.
DILUTEMTS - used with herbicides, include not only water but also nay include oil,
solvent'sT and emulsions which are used fo? extending the herbicide in the field
mix.
FERTILIZERS
YEAR
1961
1965
1966 (est.)
AREA
ACRE ROUND
,)
31,426
41,081*
35 ,125
TOMS
NITPOGFAT
1,01*0.6
1,418.7
1,111.5
TOIIS
PHOSPHATE
913.2
1,127.2
570.3
TOMS
POTASH
1,501.9 •
1., 804.0
1,240.4
TONS
CALCIUM
^ ^—
27.7
255.3
795.3
TONS
SILICA
212.3
691.2
V«ry truly yours,
THE LIHUE PLANTATION CO., LTD.
i D. T.
JA vice President £ Manager
DTS-DWB:o
-------
HAWAIIAN SUGAR WASTES STUDY
GROVE FAHM COMPANY (KAUAI)
Date of Visit
November 30, 1966
Parent Company
Independent
Persons Contacted
John Van Dreser; Srie Spillner, Administrative Agror.ordst; Don Carswell, Civil
Engineer} Ernie Warner, Field Supt.; Fred Kcbcrt, Factory Supt.j W. M. Moragne, Hgr.
Operating Rats
42,000 tons/year in 9^ months.
Shifts
5 days a week; 24 hours a day.
575
Water Supnly
Water is obtained from both surface and deep wall sources. A supply in excess of
71 lii.qd can be delivered to the plan cation v.ith a ground capacity of 40 lugd also
existing.
Process Description
The cane washer has nearly complete bypass which was constructed three years ago.
The management anticipates that this \rill be used in the not too distant future when
seme form of dry cleaning is in operation.
The cane, after initial unscrambling, pasocs thrcugh & sink-float, tilth the material
removed, being hauled away in a truck also containing trash. The rjatarial is used
for land reclamation. The cans -xiases through standard wet washing and crash
extractors. A minor, but significant, innovation at the plant ia ths placement of
-------
-2-
metal tab at abc a 15° angle \ii\,'.i the chuto above the trash extractors; the tab
causes the cano stalks to bounce over the extractors iMle the trash passes over
them.
The milling consists of knives, a rock crusher, shredder, four standard mills and a
screw press. Mixed juice passes forward from mill to mill with extraction taking -,
place at the crusher and first mill. The screw press consists essentially of a
large •worm gear v/hich forces the cane against a steel barrier and extracts additional
juice from it. All bagasse produced by the mill is burned.
Magnesium oxide is used for neutralization arid coagulation, and evaporator vapor is
used to heat tho juices before clarification. Five-stage evaporators are used. The
A strike consists of syrup and seed and yields cosmorcial sugar and A molasses.
The B strike consists of A molasses, so:r.3 eyrup, and seed and produces cojinuercial
sugar and B molasses. The C strike consists of 3 nolasses and a footing which consists
of syrup and powdered sugar. The low-grade sugar produced in the C strike is either
boiled in a separate seed strike to produce seed for tho A and 3 strikes, or is
remelted and returned to the A and B atrikes. HJasuecuite from the C strike is passed
through crystallizers for about 90 hours.
Waste Reduction Measures
Water from the mill flows to five settling rsservoirs from which it is used for
irrigation water. The land is in a relatively dry area so irrigation is practiced
r.oat of the- time. When irrigation is not being conducted, the overflow from the
reservoirs passes through three ponding resorvoirc in sories and then reaches the
?a. An excess of Nitrogen exists in tho mill master and cane irrigated with this
.ater grows well, but has low sugar content. Analysis of the settling reservoir
effluent follows:
GROViS FARM COKPAHY. INC.
Analysis of Mill Water:
1. Samples taken at point of entry to field, aftsr settling ponds.(Field K-2)
2. Unfiltered suspension — readings in ppra.
Total
Date Sampled H p v Qa pH
6/3/66 7.8 1.4 20.0 26.90 5.3
8/4/66 10.3 1.-5 15.5 15.40 5.4
8/15/66 13.4 Tr 20.0 17.15 6.0
8/25/66 14.8 Tr 12.5 15-65 5.4
9/6/66 10.2 2.7 18.0 29.85 5.7
9/19/66 * 39.0 1.35 42.0 17.85 6.1
9/30/66 16.12 .11 15.0 15.50 5.1
10/25/66 10.30 1.20 21.9 21.65 5.8
TOTALS 121.92 8.11 164.90 159.95 44.80
AVZSAGS 15.24 1.01 20.49 19.99 5.6
* High TK values were verified.
/O
-------
-3-
Are at Harvesting
23-24 months.
Harvesting Procedures
Push Rakes
275 Ibs. of I;itro£en/acre/crop (Two applications by siachine and tiro by air).
2 50-450 Ibs. of Potash/acre/crop.
200 lbs« of Fhosphorus/acra/crop (1,000 Ibs. in deficient areas).
Nitrogen is applied as a urea, auraoniicr. sulfate, and aranonia mix. All fertilizer
is applied in tho first eight months of growth.
Irrigation Procedures
4,500 acres irrigated.
5,5CO acres unirrifiated.
The plantation is beginning overhead irrigation and cone pressure-irrigation pipe
was observed on new land. The company cccpccto to use more of this in the future be
because it is core challenging to the ucrkers, olininates soae labor, and cor.servcs
rater. The sane yiold of sugar is expactcd. In the unirrigated fields, shallow
furrows are built for drainage.
Field Jfomoff Characteristics
Temporary channels are built after harvesting to carry the runoff to various channels.
Pesticide TJsage
Amatrion — 4 Ibs. /acre/crop
Atrazine — 1.6 Ibs. /acre/crop
DcJapon — 2 Ibs. /acre/crop -f 2 Ibs. aaiatrion/acre/crop
Diuron is used on occasion in place cf acatrion.
2-4-D at 2 Ibs. /acre/crop is used if no danger exists.
!,'ct.- Crop Procedures
Ratooning is done 2-3 tines before planting on the average. In unirrigated land,
ratooning is practiced 1-2 times; in irrigated land, 3-5 tines.
\\
-------
Random Comments
The company is enthusiastic about dry cleaning of cane.
Sixty thousand tons of soil is reclaimed from the reservoirs per year.
Three per cent of the sucrose is lost in liquid washing.
The mill apparently has the best sugar recovery in Hawaii.
Reference: "Water Resources Data for Hawaii and the Pacific Areas,V USGS, 1965
-------
HAUAIIAE SUGAR WASTE STUDY
McBRYDE SUGAR COMPANY (KAUAl)
Date of Visit
December 1, 1966
Parent Cornyvny
Alexander & Ealdvjin
Persons Contacted
Earl Saith, Production Department Head) Mead Xirkpatrick, Irrigation Supt.; Shigeo
Uyeda, Planting & Research Overseer
OperationRate
35,OCX) tons of raw sugar in about 9 months.
Shifts
5 days a week; 2k hours a day.
Sriployoes
358
t/ater Sunoly
Water coiaes primarily fron diversion of the Kar.apeps River and one deep well. Thirty-
five zigd can be supplied if necessary. The Kill uses about 5.5 nigd.
Process Description
'The washing procecQ seems to have t;.-o p^cuiitrities and consists of unrs.volin^ on a carting
carting drum, sink-float separation ::ith the raid SJIQ rocks hauled to a gulch, \rashing,
detrashing viith the trash being thz'Oiai over the cliffs. All bagasse is burned.
Ths rdlline consists of knives, a crusher, a shredder, and three irdlls. KLxed juice
is cycled backward successively, vdth c::ti-e.cticn baking place from the crusher and
first mill. A 60-40 mixture of liaie and jieynesiuu oxice is added to the juice before
heating arid clarification. Lvaporaicr vc.por ia usad to heat the juice. Upon
clarification, the juice passes through S-staga evaporators -jd.th 26 inciies of vacuum
-------
-2-
being reachsd in the last sta^s. Lia A strike consists of syrup, renelt, A molasses
(if good quality), and seed. The 3 strike consists of A molasses, renelt, and syrup
(sometimes). The C strike consists nostly of 3 molasses and is followed by about
70-hour detention in crystallizers. All lev-grade sugar is remelted and sent to
the A and B strikes. Seed production is unusual in this plant because they do not
use ths low-grade su«ar for this purpose. About ono every three cycles, syrup and
A Molasses is added to a high-grade pan and boiled to produce seed. No "seed pan"
exists at the mill and they use tiro high-grade and two low-grade pans. Total recovery
was reported to be 86-8.7$.
Waste Reduction I'sasures
water is pumped to a IOC-foot diameter hydrosenarator, and the effluent from
the separator passes tc a reservoir and is then used for irrigation. Slurry from
the separator is pumped to gulches for filling. If irrigation is not taking place,
and the reservoir ic full, the runoff reaches the &ea. The null water Eakes the
cane grow fast but reduces its sugar content.
Cane Age at Harvesting
2k months
Fertilizer
250 Ibs. of Nitrogen/acre/crop as annonium nitrate and ajrmonia.
125 Ibs. of Phosphorus/acre/crop
260 Ibs. of Potash/acre/crop
Applications are by air or irrigation water.
Irrigation Procedures
5,500 acres of furrow irrigation.
500 acres without furrotre and using portable sprinklers if needed.
Eo real effort seenis to be made to intercept tailwater and a large aiount was
observed to be reaching the sea at one location and severely discoloring it.
Field Runoff Characteristics
Runoff occurs in many places.
Pesticide- Usage
Xs.rr.iex (Diuron) — 10 Ibs ./acre/crop
j-.traaine or Auitrion — 5 Ibs. /acre/crop
Dalipon (Dowpon) — 10 Ibs. /acre/crop
Above are rcaxinuB usage figures.
-------
Uevr Crgn Procedures
An avarass of tvjo ratoons are planted and this depends on harvesting end new varisties.
Random Co,TJients
Trash is duuped over the cliffs '.vhere it decays or is carried away in stores.
The plantation is situated on the last volcanic flow en Kauai and silt is not 50
great a problem during rains.
Tailwater v;as severely discoloring the ocoarj in one location.
Use grooved, concrete blocks for djun structures f.«hich would be very acienable 1.0
vcir conctiiiction.
-------
K/i/jAiiAi; siKJATi WhS'ra S-IUDY
OL05ELS SUCA2 CCS-IPAKI (KAUAl)
Date of Visit
K'ovembor 29, 1966
Parcrt Cor-pgrg
C. Drawer
Persons Contacted
Koboru Takamura, State Sanitarian; Don Ifcrtins Hans Poppinga, Factory Supt.j Dick
Vebbj Factory Engineer, C. Brewer
Ccjgj.ti.on Rate
53j,OCO tons ra-rf sugar in 10 months.
Shifts
6 days a week; 24 hours a day.
240
Water Suonly
/»O cgd total usage when irrigating at a maximum rate.
k mgd is used in the rail (no flow measurement).
Water source is surface water froa the mountains.
Process Dascrintion
Ihe cans washing process incorporates all the standard equipment. The cane first
rassss through a cutting drua and then a sink float. It then passes through washers,
stoolin* dnnia and then to Glts-n Rolls (trach retcvora). The v-aah water passes
through a trash rerover and grit chaater boforo leaving the rill proper. The washeo.
cana thsn passes through a rinser, cotter, c'.irccxior, crusher, and four mills. Water
ecra-'valent to 35?J of the juice ia atldod bo^o« the Last mill and the riixea juice is
cycled step by step back up the sarico of mills. Juice removal is from the first mill
-------
(and cn_-.. .?). 1'ost bagasse io burned but ecr:ie excess is hauled to the shoreline.
Kasnssiuii oxide is added fcr neutralisation, and the juice is then heated and
clarified. Four-stage evaporators are used for concentration with 24 inches of
vacuum occurring in the last stage. The A strike consists of syrup and seed, and
produces A molasses and commercial sugar; the B strike consists of A molasses and
seed (this takes place in high-£rs.do pans), and produces B ^classes and commercial
sugarj the low-^rade (C) strike consists of B colasses and seed slurry. The
Esaocccuile from this strike goes to a crystallizer for about 125 hours when the
slow stirring and cooling produces more low-grade sugar and final molasses. Low-
grade sugar which is not used as aesd is remelttd and ssnt to the evaporators. A
total of about 85% recovery is achieved at the plant.
Waste Reduction Measures
Ths. pl&nt does not have a hydro-separator1,. The wastes pass through detention ponds
for irrigation but not all of the water is uaed for this purpose. Ths wastes enter
the sea through two ditches; one contains slurry from e. detention tank, and ons
contains the pond discharge. Flow in the former ditch is minor, but the waste is
strong.
Cane Age At Harvesting
24 months
flarvcstiir; Procedure
Push Rake
Fertilizer
2GO Ibs. of Hitrogen/acre/year a3 amionlii in the irrigation water.
2CO Ibs. of potash/acre/year in the irritation rater.
100 Ibs. of phosphorus/acre with the seed at planting.
Irrigation Procedures
4,800 acres of land is furrow irrigated. Furrow are at a slope of 0.55& because of
tight soil. Apparently, overhead irrigation is not possible because the water runs
off.
Field Runoff Characteristics
Much of the runoff enters the Hanapcpe 2iver and the V/oimea River.
Pcaticida Usage
TMU — 6 Ibs. /acre/year
/7
-------
_3—
Daliphon — 4 Ibs./acre/year
DCKU — 4 Ibs./acre/year
Atrasine — 5 Ibs./ acrs year
CMU, DCMU, and atrasine are used interchangeably, and the above should not be totaled.
Raw Crop Procedures
No ratooning is practiced. This ia because the soil is fluffy and will not hold
the roots at harvesting.
Handera Comenfaa
Cane from the Robinson Plantation is also ground at the mill.
Tho management would prefer not to use tho vash wtter for irrigation because of the
excessive aracunto of nutrients in it which cause the sugar production in the cane
to fall off.
Currents at tho nd.ll shoreline are generally xrasterly.
It would cost about $100,000 a year bo prr.ip all the mill wastes up to the fields.
Reference: "Major Streams of Kaual and their Utilization," U of H Thesis, I960
Doak Cox of U of H knows a lot about streai=s on Kauai.
-------
HAWAIIAN SUGAR WASTE STUDY
KSXAHA SUGAR COI1PAOT (KAt'Al)
Dato of Visit
Noveisber 29, 1966
Parcit Company
American Factors
Persons Contacted
Koboru Takanrara, State Sanitarian j IV. S. Baldwin, Manager} John Robinson,
Processing Supt.
Operating Rats
51,000 tons raw sugar/year during 8-9 (tenths of operation.
Shifts
24 hows a day, 5 (iajs a week
aanloyeca
Water SunoXy
Water ccraes from the followins courocs (averags uscns shovn):
y.'aimea StreaJE (through a ditch-tunnel cycto^i) — 20 ngd
5bl£ee(?) Streaa(?) — 10 iasd
Ground vater — JU mgd
The sill usos about 10 ingd of the gi'our.d
Process Description
Tho wEshiag opcsration consists initially of a velocity sink float with the wastes
froci this device passing t^irou^h a duality controlled einkilcdt. The cana is
lashed and also passes through e moehenical dotrashsi*. 'Ivaeh ar«d heavier wactes
are dumped on the wasteland.
-------
-I*
-2-
The rilling consists of a shredder, crushers and five cilia with rater equivalent
to Sftj juico voltma added before ths lant ndllj mixed juice is thon cycled forward,
mill by still, to tho firct sd.ll (and cntchcv?) v^oro it is extracted. About 65%
of tho bagasse is burned during operations,, and the renainder on weakendc.
Tho juico is uci^.od, neutralised idtii lir:o, and then heated before clarification.
Concentration takes place in fivc-otaTC evaporators vith 26 inches of vacuum
bdLng rsacked in the last st^o. TI-w A strips consists of syrup and a crystal
siUTi-yj lov-gradc sucar oeed is appA?ontlj not used in this :d.llj tha ctrilse
producec cOKnerclal ou^ar and A rxslao^cs. Tho B otrike consists of A nolasses
and ee'jd. Tlie low-spade strilce ccnaicto mostly of B.a»lacr»es and the ssassecuite
fs-Kt the strike passes to ei-yatallicoFs. All low-grade sugar is rcaelted and
returned to ths svaoorators.
Heduetion
>-.tii(?r enters a oettlins bauin urd tha overflow frou tho basin is used for
irrigation. Little of this overflow apparently rcachss the sea bocauye of low
rainfall in the area. A now settling basin ia being dug to replace tho old one
which filled in two years. Ths Ccucaiiy piano to build a hydrooeparatcr wiien
tha r.sw basin has filled up. Hot ao icuch fertilizer is used in the fields
irrigation waiter, but ccxc is apparently added.
Cera A/*o at Harvesting
23 cunthu
Push Rakes
Fertilizer
In those fields irrigated vdth call crater, the foll.oirdng is added:
1?6 Ibs. Kitrassn/acrc/crcp
191 Ibs. Potcsh/acro/crop
75 Its. Phosphoruo/acreVcrop
In those fields not recoiving zrd.ll t^ter, the following is added:
350 Ibs. of Kitrogcn/acrc/crop
360 Ibs. of Fotach/aerc/cinop
75 Ibs. of Phcsphorus/acro/crcp
Nitrogen is added cs urea or a^conia v.dth tho last application by plane.
-------
-3-
jccdvvres
90 acres by overhead irrigation.
7,300 acres by furrow irrigation.
A clopo of 0.5% is used in tho furious.
Field 3.anoff Charactsristico
A large portion of tho plantation lands arc located in an old sarah area below
soa levol. Aa a raault, several panpins stations exist through vhich the seepage
is diechar^edj and the stem runoff also enters the sea through theee sites. A
total of five outlets exist.
Pesticide Usage
DC;-5U — 4 Iba./awe/crop (pure elraar.t)
2-4-D — ttvuaatitios not tawwn
.taatrion — 4 Iba. /acre/crop
Now Crop Procedures.
Eatoons seen to cutyield the plant crops or. this plantation, and they strive
for at least thrco ratoon crops.
Cornenta
The State otms the plantation lana.
Socie boilers are always running to onpply po'.rcr to the drainase pusups.
Tho drainage ?-osps -i&yo observed, to be diochcr£jin£ -.Kiter of very hich sediasnt
bacause of a trenching operation which woo takins place at the tis:o.
-------
HAWAIIAN SUGAR WASTE STUDY
UAIALUA AGRICULTURAL COKPAOT (OAHU)
Date of Visit
January 19, 1967
Parent Cocoan?
Castle & Cooke
Persons Contacted
Frederick Gross, Civil Engineer; James Honke, Crushing Plant Supt.j Masa Uehara,
Cultivation Supt.; George Teraraoto, State Health Dept.
Operating Hate
74,000 tons of raw sugar in 8 months.
Shifts
5 days a week; 24 hours a day.
Employees
662
••Jater Supplj
Surface and ground water are used for irrigation. The majority of the surface
vater is impounded in the 2,400,000,000 gallon capacity Wahlava Reservoir. About
15 000 n£ of ground water is used per year and about 14,000 ing of surface water
is'used per year. The plant uses 10 mgd of ground water of which 7 ragd is used
for cane washing. An additional 7,500 gpa of brackish ground water is used for
cooling in the boilers.
Process Description
The cane initially.passes over a "tumbling" conveyor for unscrambling, and primary
extractor with spray for initial trash reascval. The cane then passes through a
velocity sink float, cascade spray, stool drums, and twin banks of Olsen Rolls for
final trash removal. It is expected that all trash will be burned in the upcoming
season.
.22-
-------
-2-
liilling consists of cutting, crushing in a two-roll crusher, and extraction in ;.
five-throe -roll nills. A shredder exists between the first two mills. All
bagasse is burned.
In the boiling house, the juice is weighed, limed, clarified, and concentrated in
five-stage evaporators. The plant has five c ..v-vacuum pans, two high-grade, tiro
low-grade, and one seed pan; one low-grade pan is also used for seed. The A or
high-grade strike contains syrup, high-grade seed, A molasses, and renielt.1. The
plant apparently has no other high-grade strike (the only plant to have this
feature). The low-grade strike contains A nclasses and seed. Massecuite from
the low-grade strike is processed in crystallizers for about 24 hours. All low-
grade sugar is renelted and sent back to the high-grade strikes.
Waste Reduction Measures
The plant has a hydroseparator which receives the washing wastes and filter mud.
The separator demensions are about 120' dianeter by ?' average depth. Effluent
is either pumped to nearby low fields or lifted through 4,400 feet of pipe and a
total head of 100 feet to higher fields. Slurry is pumped to diked-in areas
for land improvement. In 1966, almost £0-aore feei of soil was obtained from the
separator. If the separator breaks down, the effluent goes to two, snail deten-
tion ponds; if their capacity is exceeded, it was stated that the plant would
then shut down.
Cane Age at Harvesting
24 months.
Harvesting Procedures
Push rakes.
Fertilizer
Nitrogen — 310 Ibs/acre/crop (as N) mostly as MHj in the irrigation water.
Phosphorus — 0-200 Ibs/acre/crop (as P20O with an average of 150 Ibs.
Potash — 340 Ibs/acre/crop (as K£0) mostly as KC1 in irrigation water.
Irrigation Procedures
The plantation has about 10,000 acres of irrigated land and 1,000 acres of
unirrigated land. The general irrigation practice is a herringbone pattern
with the tailwater ending up in the low spots in the fields. This EiniMzes
the chances of tailwater reaching any streams or the sea.
2.3
-------
-3-
Peaticide Usage
Pre-eaergencer 5-6 Ibs/acre atrazine or anatrion.
Posteaergence: Hand spray of Dowpon, DCIIU, or 2-4-D
Crop Procedures
One to two ratoons and a plant, but the plantation is developing a system of
planting and ratooning the same field.
-------
HAWAIIAN SUGAR WASTE STUDY
KAHUKU SUGAR COMPANY (OAHU)
Date of Visit
February 23, 1967
Parent Company
Alexander & Baldwin
Persons Contacted;
C. D. Christophersen, Manager
Operating Rate
20,000 to 22,000 tons/year.
Shifts
5 days a week; 24 hours a day; 9 months a year.
Employees
223
Water Supply
The majority of water is obtained from subterranean sources. About 11.5
billion gallons per year of ground water is used. The plant uses about
7,000 gpm.
Process Description
The cane is initially crashed as it passes over carding drums and then drops
to a velocity sink-float. It then passes through a cascade washer, carding
drums, and Olsen rolls. Trash and rocks are trucked to land-fill areas.
The milling process consists of a crusher, shredder, and three mills. Juice
is withdrawn from the crusher and first two dills. About 20 per cent of the
bagasse is used for fill.
-------
-2-
In the boiling house, the juice is weighed, neutralized with MgO, heated,
clarified, «nd evaporated in five-stage evaporators. Sugar production is
done using a high-grade seed pan, low-grade seed pan, low-grade pan, and two
high-grade p..ns. The high-grade seed pan contains syrup, A molasses, powdered
sugar, and reraelt. The low-grade seed pan consists of powdered sugar and B
molc-sses. The A strike consists of high-grade seed, syrup, and reraelt. The
B strike consists of A molasses, and high-grade seed. The C strike consists
of low-grade seed and B molasses. Low-gr-de taassecuite is processed in
crystallizers for about seventy yours.
Waste Production Measures
Waste water goes to a sedimentation basin with the basin overflow being used
for irrigation if needed, or is pumped to the sea.
Cane Age at Harvesting
24 months
Harvesting Procedures
Push rakes
Fertilizer
Nitrogen -« 240 Ibs/acre/crop (as N) - urea mostly
Phosphates « 160 Ibs/acre/crop (as P2°«^
Potash — 310 Ibs/acre/crop (as ^0)
Irrigation Procedures
4,400 acres total — about 10 per cent is ur.irrigated; furrow irrigation is
practiced in irrigated areas.
Field Runoff Characteristics
About 30 small gulches and culverts carry the runoff and excess tailwater to
the sea. Two gulches have continuous flow.
Pesticide Usage
Pentachloro Phenol -- 3 Ibs/acre/crop
Dowpon — 3 Ibs/acre/crop
21,
-------
-3-
Pesticide Usage (cont'd)
DCMU —1.5 Ibs/acre/crop
Amatrion — 5 Ibs/acre/crop
New Crop Procedures
Plant and two ratoons
-------
SUC-AP. WAS23 STUDY
CAHU GU3AR CGffiAnY (03)
Pate of Viait
November 1^, 1966
Persons Contacted
Louis Herschler, Bigineer — Lab oad Water Ec
Reider Peterson, Boiling House Superintendent
Operation. Rate
75,000 tons of raw sugar per year. Sugar is produced in 8-10 months, followed
by a twaonth overhaul.
gbifta
5 days a veekj 2b hours a day
.Ewployoeg
698; 119 in nill
Voter
An average of 80 Egd of ground rater is uc2d fcr irrigation and Edll processing.
Approximately 18 Egd of this ie used in the mill. An additional 35"^ tuffd of
vindvard vater is brou,sht to the plantation ti-rc'c^h the Waiahole uater tunnel
built in 1913-1916. Kien xmter is not ncadsfi, the vindvard vater IB diverted to
the original receiving Etrecms.
Process Iteecriutioa
After being uolcsded from the cane hauler, the cane passes through a mechanical
cysten that rolls the cane over to a ccsvoycr belt vfcile simultaneously elloving
heavy dirt and stones to be separated frca the cane by gravity. She cane is then
subject to henvy washing operations in vfaich approximately 1^ n?gd of vater is
sprayed on the cone to rinso off the ctlhcrin;; coil and light trash. Additional
amounts of trash are also rerscvaii by Eecisanical separators, de vssh vater then
passes through 36 cyclone separatoro vliich resovr soliCo by eeutrifUQal action.
Taps exist on both sides of the separators and the volume of vater passing through
-------
- a -
Is alco recorded tfaicii vcald Bicplify sToiiss operations. It was stated that
about 65$ of the solids ore removed in 'c'-ie separators (85$ are removed in hyfiro-
soprrstorc). The clurry ic parcel to K^ipio Peninsula where it is placed behind
diked areas. ApprortEctely 50 acres of lovlcad on t!ie peninsula arc reclaimed
each year in thic Banner; fiept^ of rcclciscd lead is one to two feet. Effluent
frca the separators ie also piped to the SSZ.Q peninsula and used for Irrigation.
!Eie actual sugar production process begins rliea the stalks leave the waoher and
are crushed to the extent the,t the juice is rcnoved. She remaining material
(bagasse) ic ell burscd for power prcSuetioa. 'Sac ceue Juice is neutralized from
p3 of 5.5 to 7.6 uitfc. line slurry. Evs juice is then heated to 212° (boiling
point io ebcut 216°) and then pocccs through c fiaol clarifier vfcsre any regaining
cud ia removed. The Juice then paoccc tl^rou.^ five stage vacuim evaporators (or
diet illation) Tfeere It loses 80^S of its vzter content. At this point, the Juice,
or syrup, is in a cc.turc.tcd condition end passes to devices called vacuum pans in
i-ftich finely paw2erecl cusar crystals arc sctLcfij t'ae ousar then cryfitsllizes on
theee csall nuclei! end larger crystals crc fortcd. She crystals are separated
frca the liquor on centrifuges ccd tUc rav cuc^r is then e3iippca to the oainlaud.
Eie rcratining liquor (colasoco) is alco ocat to the icainlacd after cugar crystal-
lization has been completed. Several cycles of crystallization are conducted
before the liquor ic esbaustcd.
Process voter la used in the foilouira causer. Khen the water IB reaoved frees
the ground, it io first used for ccclias ^ur^oacs in the poirer house. T&e \»ter
thce pccces to tlic vacuim evaporate ; vlxoro it is again used for condensation.
'J3ie cajority of the \atcr then Is • 3 to rztih the cane while cone is used for
various enell ucee such as a potcL rater
Daring and for signif leant periods cftcr c rr.in, -;£icncver irrigation is not taking
place, the nill efflucut pascss through a rooorvoir 023d ultlnately to Pearl Harbor.
Boring periods of heavy runoff, the efriacst ic probably naeJted by other Eaterial
enteriBs the receivias water; several dr^'3 cTtcr the rain, this Ksy not be the
case.
All of the following vsastes ultinctely cad vro in the irrigation system on Vaipio
Peninsula: car.e x-zshijfvs vastes, cusar profiucticm equipment clean up, sanitary
vaetes from the nill and City of Waipc&u.
tofiuetloa J
All vashins wastes pass tlaroush Krcba ccntrifVG5l sepaxators. All effluent is
used for irrigation purposes If irrl,3C.tioa is required.
-------
On? .fee at
20-24 nonths.
Standard Push-Rate harvesting in tfflich the crop Is broken off at the ground follovlns
burning .
JjgtjLfta.ti.cai i
J!brrt lends are irrigated by the furrow cethosl. Paot experience using overhead
irrigation apparently resulted in reduced cuscr yields.
Ratooniug is practiced for 3 or k cyclers 3 ncv plsntlnss are then conducted.
To be furnished.
Field Runoff
She irrigation furro-r»s bscono draiaa^e ^iitcns :rtt.h the nosoff vator ultiicately
reaching local receiviHS vatero. Several conversence points exist in uhich
for field runoff sey be carried on.
B CoraontB
!ir. Herschler stated that accordins to hlo ccsnutatioao, one-tenth of ea inch of
torpcoil is lost each year through hsrventins
fields app«rently ere subject to destructive erosion for 1-2 month period
following harvesting.
-------
HAW;.. ,..d SUGAR WASTE STUDY
Btt PLANTATION COMPANY
Date of Visit
November 22, 1966
Persons Contacted
Edward Bryan, Manager
Frank Wiley, Executive Assistant
Operation Rate
60,000 tons of raw sugar per year. Sugar is produced in 9-10 months, followed by
an overhaul.
Shifts .
5 days a weak; 24 hours a day
Employees
About 700; 65 in the mill
Vfater Supply
An average of 150 mgd is used at peak operation; up to 10 mgd is used in the mill.
All water used Is artesian or cap-rock water.
Process Description
After being unloaded from the cane haulers, the cane ie cleared in the following
manner. The cane, after leaving the transport conveyor, is lifted in an "unscranbling11
conveyor i-rtiich increases in slope as it progresses. The cane is unscrambled or
disentangled as it tumbles backwards, on the conveyor. Heavy rocks and metal also
tumble down to the bottom of the bslt where they are removed and trucked av/ay. The
cane then falls into a sink and float, rock separator in which a mixture of cane,
dirt and water exists of sufficient density to cause the cane to rise to the surface
and the heavier rock and solids to settle to the bottom for removal. The density
of the mixture is checked periodically and more or less slurry vrater is added in
proportion to the observed density. The cane is then skinaned off and thrown on a
cascade washing conveyor in which water is sprayed on the cane to reraove adhering
dirt particles. The cane then is sorted out by size in "combing rolls" and falls
-------
- 2 -
down to mechanical trash extractors in which the leaves and trash are pulled from
the rest of the cane.
Tho actual milling begins when the cano is shredded and enters a series of six
rollers. Juice squeezed out of tho first major set passes into a nixed juice tank
after filtration and passes on to the next production step. Filtrate is returned
to the rollers and hot water is added before the last roller. Juice and water from
tha last roller is pumped back to tho third last roller, and Juice from the second
last roller is punped back to the fourth last roller, etc. Bagasse from the last
roller is burned for power production.
The juice, following extraction, is vraighed and then has lime added for neutrali-
zation and coagulation. The juice is than heated to 212° by exhaust steam and
passes to a clarifier. Five-stage evaporators then extract water from the juice with
26 inches of vacuum existing in the last evaporator. The syrup, which is just
below saturation, then enters a high grads vacuum pan where "seed" sugar is added
and the ndxture is boiled under vacuum and controlled temperature and feed rate.
Tho crystals then grow to the proper size and the mixture of crystals and liquor
Onassecuite) are then separated in what is called the "first or syrup strike." The
remaining liquid, molasses, is then returned to an evaporator, more fre«*h syrup is
added, and the process is repeated with an "A strike" resulting. Some A strike
molasses and syrup forms a B strike, and A and B molasses and syrup form a C strike.
The latter strikes occur in low grade vacuur. pans and the boiling time is increased
for each strike. Additional crystallization takes place in mechanical crystallissers
in C strike.
Waate Reduction Ifaasurca
All cane washing wastes pass through a hydroseparator built in 1949- Slurry from
the separator is used to reclaim 20-30 acre feet of land a year, and the effluent
is used for irrigation. The clarifier is 120 feet in diametervith a bottom sloping
toward the middle. Mr. Wiley estir.ia.ted the detention time to be two hours at
maximum flow of 10 mgd. Depth varies but serins to bo more than ten feet in the
center. Floating material goes out with the effluent to the fields.
Cane Age at Harvesting
About 24 months
Harvesting Procedures
Push rake
Fertilizer
350-400 Ibs. of Nitrogen (as ammonia solution) per cere (per crop?). 350-400 Ibs.
-------
-3 -
of potash (as a slurry) per acre. Phosphates are only needed on 15% of the land—
no figures. Host fertilizer is added to the irrigation v/ater.
Irrigation Procedures
8,000 acres are furrow irrigated. 1,200 acres by overhead irrigation.
Irrigation water apparently varies from 340 to 1350 mg/1 chlorides so an excess
anount of water is needed on the plantation for leaching. Mr. Bryan stated that
the overhead irrigation "approaches" furrow irrigation. Problems of overhead
cited were leaf damage and salt deposition on the foilage.
Field Runoff Characteristics
No tailwater runoff apparently exists and stonn flow is absorbed by the very porous
soil to a great extent, but not entirely.
Pesticide Usage
See attachment.
New Crop Procedures
Ratooning is practiced four tiries on the average.
Random Comments
Harvesting is not practiced in wet periods because it overloads the washing
equipment.
600-700 gm of juice is extracted when ths mill is operating.
Flow measurements in the rail! vrould not be difficult because of existing weir
slots as irell as pump rating curves.
Most drainage streams contain water from above the plantation but one may exist
in which only field drainage occurs.
-------
I
EWA PLANTATION COMPANY
APPROXIMATE TOTAL AMOUNTS OF PESTICIDES APPLIED PER YEAR
HERBICIDES
Pentachlorophenol -~ 133,000 ibs. 7"
2,4-D 15,000 "
Atrazine 26,500 "
Arcctryne • 15,000 "
Diuron 11,000 "
F-90 Surfactant 15,000 "
Dowpon 23,500 "
INSECTICIDES
Baytex 160 Ibs.
FUNGICIDES
Phenyl Mercuric Acetate (10%) 800 gals.
WHLiyk
11-22-66
-------
IJAtfAHAK SUGAR WASTE STUDY
UAILU10J SUGAR CCl-2»A2flr (KAUI)
Of Visit
DecAv.ber 7,
C. Jrcwor
tS Jen ut.at s.A
''illiiin ..liaoro, HSPA; IVaicsr lix^uin, Aoou* LCT.J Packard 3r.vith, Pit. UupL.j Samuel Goc,
3 Late iii^itarlcin.
35,000 tons of raw a-A^ar In about '} raontho
5 '-:v>'a a week; ?J* hoxxrs a day.
3L2
!£' necrioci, 15 rr^ ci' grourid water can bc» crppliod to oupplenent the surface supply ^rfiich
ia obtained fron the hi Us, AT avorar.o cf about 33 Jr-C«i of curfaco v«ater visa uucd
l'/C5. Four tsgii is used in the ndll -.•.•hon it is operating.
'v>cesq Descriptjon
cana ciaansr at tho clll is esswtJally tvo cloanore with on 3 built on ten of the
o-rhor. Gere of the procosses, &e n rusulxi, aro unorthodox if ccr-warod to 1,hc rilla vioitod
u\:- to tide point. The cane first enters J cc.r
-------
-2-
where the trar.p cane is nickec un .i4-.:l rcl.u:rc;''. Ih-j rocks are trucked away. The cane,
afte:- rock removal, is washed and than proceeds to tho ndll.
The rilling consists of cutting end crusliir.ij followed ty compression in four sills. Water
is> added before the last mill and tho rixcd juices are cycled forward one still at & tine.
"i^r.-ictio-a of the juice takns p3s.ce at the crusher and first and second rills. All bagasse
is burned. Tho .iuice is liiccc.1 end hc.'itsd i.lth vapor froa tho pre-evaporator, and then
Fiasco irivO vha i/re-cyajiorator sjvi a four-ata^e evaporator. Final vacua: is 26 inches.
The plan- haa fcvo hl^n anc! tvo low-^ra^c vacuir.1 p^ns. The A ctriks conr,i&ts of syrap and
psr-olt^ CMC' prortuces A irolaancs ard C3r.,:ieroial aii^ar. Tho B atrikc conuis'-G of s;Tup,
re.'ij.Tt;, ; vi A :a>lt.saoo arid j-x>aciiicc;.3 D ^.ulacccc :'.r/J cocijorcial sugar. The C strike consists
of A and 1 !ccla:o3s es well a:; 30.-.C cyrup, and yiclda fir.c.1 ir.olassec and lovf~^rads cu^ar.
All lew ^TTJla ?.'jj;ar ic rcncltait ur.d aUcio'I tc who A «jid D strikes. In the pasit, SOL.O low-
:;radc su^jr -.ia^ used for sei:d but the plant aupwintondciit stated that, thoy i.Tuit the
tc crystallize on its O'.RI fron the auj-w-otturatcd lifjucr. l::jcn aslced if the crystal
'./OU.IA* -/ji-y becuaio of this, he jtulc.. wl'.-L .ryct of tho crystals appear at tho SSL-IS
xr.d oha'i siost of the late arriving ci*ysbals catch up because of increased cx-rface
' .'act? :lgri«ctipn, rGasurus
ilis j.-ill hiis a hj'd:-05op
-------
Fiald ntmof f Chnractezlsiics
Runoff enters numerous drainage ditchcu end
The problem of excess tallwator g.ppapently does not exiat oa the plantation.
F& st 1 eld Q
The following applications are always avade clui-ing the first year of ths* crop:
Application Ho. 1 (by air) ~~ 4 lbs./aoi»e (active ingredient) of DCKU, Atraaine, or
Application !'o. 2 (by air or harjdi) — 2 lbs./acra of Atrasaaincs or Aauitrion.
Application Ko. 3 (by hand) — 5 gal3x>ns/aci-o of CADE v-ihich ia an activated ciiesoL oil
has a horbicifie effect.
K&-f Crop Procadu?o&.
Hatooning is practiced twice before replanting .
ftnndorr . Ccrf:r.ent.s
When no rdtrogon is addets to the '««aoh water ci-cpss they get yellow.
The plantation has a severe rock problem, bocaaoe their cane ic on a wash aLLuvivcn soil below th<
West I^ui &ountaiR3; th« rocks extend 300 fest bslow the sirfacec A dry cLeanixi^ process
apparently be difficult because of ths exccisciro azsounts of rocks present.
The Bill produced tho third beat sugar in tho islands based on color, eiae, filterability,
and ether similar factors..
-------
HftKKlI/iS SUCAX WftSSE STUDY
H. C. & S. - PAIA KILL crusher, in tijo tru© eenso of
-------
the word, exists at the pleat. Mater ic added before the last Bill, and the saixed
.Juice ie cycled backwards one niU at a tics. Juice reisoval is froa the first xd.ll
is burned, or if an excess exists, it is dumped.
Tha juice is then weighed, lined, heated, clarified, and then passes through a
pre-svfcporator and three-stafio evaporator. Tha plant lias two high-grade pans.
ono toww-pade pan, ead t:« seed pans. A detailed description of the sygarsraaking
process was given, and tho following write-ups contain csich wore detail than nraHoua
write-ups and is to bs considered sjoro technically accurate. Seed pans ara operated
iisdopcadently e&d. have syrup added to thcsa vhich is then boiled down tocupcr-
aaturatlon; finely pondered sufiar grains are then added and the sdxtare is then
boiled SJC^G ROTO while core syrap (sucroso) is adciod; this is continued until the
crystals ara of tho dcsiroci Bir,e. The A strike takes place in a hlgh-srade pan
and DjTup and ocsae water is initially added to the pen or tank; this is thoa
boiled doi-ai to tjupersaturation^ and at this rolnt, the tank is at about 2& of
cap.-.cityj seed is then added £vtx* the seed rcn in a volra» of about 2^, of the
capacity of tho pan (the pan is than about half full), and r-iore syrup is added as
tne crystals crow so at the Mass of tho actual eteU», the pan is ideany at caoacity
iao B strike takec place in a high-spade pza and A s^lasaes; reaelt, and occasioaally
SJTUO ie initially added; tiiie cdx&ta?c is boiled to eupersaturation, and at this
point occupies about 2S? oS the pan»s capacity; seed is than added iroa the seed
pan in a votoua of about, 253 or tho ca-acity or tto '»n, and aore r.oiass'-s and
re..;olt is then added as tho crystals grow until ideally, tho pan is full uiicn the
crystal* &?e at the desired sise. The C strike t^ea place in low-srade n=»ns and
D glasses and EC^O resaelt is initially ed*Zsa soeeda up the process. If
larger capacities were available, it would bu possible to grow' the sugars fpoa their
ovjn nucleii es is doae at V&ilaku Gugar CcciTsany. All low^grado sa&r ie rorelted
and added to the A, B, and C strips. J Other sdlla uso some loi^-crade sugar as crystal
in the eeed
te I
tail effluent passes to a hydrosersarator ^;dth a ciia:i.Gter of 120 feet and en average
depth of about 12 feet. The effluent rsnsses to a reaervoip where it is used for °
irrlcation. When it is not needed for i«£catlon, the reeervoir effluer.t enters
liilwa Qalch, t-Meh ultimately enters the oea. S;;cess scuntain :«ater is also ^ener-
ajJy in the (julch et this tise, and a dilution of 3:1 is strived for. Apcrcadsately
670 acros of cane reeeive oill water- for ijwisation, and 320 of those acres receive
no other mtor. Slurry is used, for load
Harvootin? .Procodures
Push Rclco
-------
-3
Nitrogen — 335 Ibo. /acre/crop (as S) in Irrigation viator*
Potash — 150 Ibs. /acre/crop (as K^O) in irrisaiic-n water oa about 17^ of tho crop land ••>:
only.
Phosphorous — 200 IJSS./SLGXK/CPQV (as PgOg) in irrigation »jater oa about £$ of the crop
loud only.
So^e nitrogen is added to tho cans receiving sill tiater at first because it needs &or®
during the first year (but gets too Eruch during tho second
Irri a
All 30, (XX) acres of cano land arc irrdgafcsd by furrow irrigation -with tha exception
of 430 acres of car,erisKmtal overhead irrigation. The overhead, irrigation apparently
saves ^ater* eivos equal suga?' pccduction but caxisss soae meclianical problesas,
FieLhmoff
Several gulchos catch the ruaoff . 'rho picntafcica does not have an excess *J3ter end
as a result, tailtster is intercepted in i&&g ditches and sent to lower fieldsj apparently
tailwator runoff is no problem*
gesticido Usage
3 Ibs. (active }/a$re/srecr en 11,000 acres by air.
)/a '
Aratrion «— 4 3i>s. (active )/acrc/yea3? on r-enjining' acrea^ by air.
In addition, an additional 35 gJirtons; of asatsica -clx (.0? Ibs. acatrion/gallon) are
added by hand*
One plant and twa rateoas,
H.C* & S* is the largest privately otaaed- plantation in tho world.
4o
-------
K-. i.II.\K S'.MAP.
K.C. f: s. - . ;-"tjf.?:
i.fi cf ''!.-.j I
:: -.bur r., li
.i".lLft.i :.:.••*«;, Promotion Dcpt. IIo-c;: :va:.I .-.-c>t.v-. .•^r-LcjilLir-al Sup'-.; TaJcazo Inouye.
'.ill :••.;,-.
\CCO to.: 3 cf rev. su;ii- iii 9
vlays & wjekj 2;,» liours a day.
:co :-:.c. •' a., rcii, .-an
'.'ha irJll uaos about U>,000 &;.: oi' vriuch about 11,000 gpea oix) uaed to clean the cane.
Faa B.C. £ H., ?t±a Z'JLll for"r.orc dc'o
: rocerg nc-crvA^M
Tin cine p^^aco u:irour,h a carvii:-!^ d^iufi i't-r uiiscrj^bliis** colliir rollc for uotriuriing, juti
ti.sfi ;v?.-i.cu «!coi:j,h i t'unaitj L>.'.:i!x ricc.L. tclio'.i.Xj thic, the ctne io v^uhod ar-d thon
T:.SUCS over cOscn ix»lls Tor acJLtdoiiul t;M3:'. v^.:.ru,slicu. --.11 T.rcah it; screened off and
to tlic TacV-Ja viith the rocics.
7r>& ^l^'-t /...c u'o iclaullcal cdili:ri^ Jiv.x5..j •jcur.i^^.l^.j oi' .aUvoy, »t crushcrr, siireu
.7)u fou.- nillj. ..Lttir is w~-w
-------
•VI—
of fcu.-itata cvi-.Toratoro. Su^ i-j produced in fiva high-grade pans and three low-grade
.-ans. The .. strike is jnade up of syrup,, rcsr.clt, arxi a shock seed with tha najorlty of
tha £ur;ar .'i-cloil foraed frcr. thcj syrup t-.f\.sr a. c.iock seeding. The B strike ic s-.ade up
of A r .classes and rcr.clt. Ti-:c C strike is rado up of E nols.ssas . All lov-^rada siigar is
rcrfcuTOod to the A. and 3 r-trlic. C o^^i.1,:3 aascecuito is rotaiJicd in cryatallieers for
?0->0
TVo r311 .1.0 .i 10.:-r-:.5-. (I.'.a. j!x_~ hi'di^svr-iratoi^ T^ic Hdrurctor «sf fluent is sonl to a
roscr/cir :,:-.ur:1. /.'wut. 1,1CO acres of casw ii; iT-ri^a^cd with sill -.salor of -.rftLch
1U -cr:.i; ...jt c-^2;' -cLll •„•;?. '-•:.-. r.lvjnv -.- 'J-^i :*or l.-J^.:. re \cc-Vi tio;i. It t,-.lcc3 about 9-1C
tc:^ of r.i] .1-ir-.-i-£ii:;;ci C.JT.L- to -;cl cr.c t.:.i el G^.TJ? vrhilo it takas 7.6 tons of otter
caivj to /oi. -*r.s con of su/jir.
Ape a.t_ tl
Goo H.C. L 5., r^ii Mill.
c:c-o li.C. & :3., ?aia Kin.
S33 H.C. i 3., Paia Jill.
Tr?i;: at. '. on rrcc aclur ;c 3
Soo II. C. & S., PiJ.a Kill.
jPIald Runoff CS
Oeo H. C. & 5., Paia J3L11.
Goe H. C. t C., Fnia I'J.11.
;. . : v
&so H. C. & S., Paia Kill.
a Co!-icrto
Tho roceivinj gulch alao rsceivoj overflew froai a low-cost houoin^ oxidation pond, as v«ll
as several septic tenhs.
-------
HAWAIIAN SUGAR WAST3 STUDY
PIOS3SH KILL COHP/.NT (KAUI)
Date of Vir.it
December 9, 1966
Fey a ors Cc"it:.ctc^
Frank yartin, Pit. .Engineer; John Seiiaer, lixr.ger; Kidco Idehara, Processing Engineer;
Bob 3orfc-lci, Agricultural Supt.
63,000 tons of raw susar in about nine ronths.
Shifts
5 days a week; 24 hours a day.
700
'.rr.ter Supply
Total capability is 50 nigd oi' surface .-.-atci- and 50 nyd of ground vater. The mill uses
r;,OCO gpsr. vdth 4,000 gpir. being used for cooling and wash water and 4,000 £p:.. for cooling
only. Additional amounts of irrigation '. ater are brought through tht plant for cooling.
\
Trocess Ue3cri>:tion
Tiie cane is unscrambled in &. caixiing c'rur- and than passes through a density sink float.
".'ashing t.-.kes place as the cane passes over flovrer rolls and trash is then removed ir. collar
rolls. Rocks and trash are hauled s.-;ay to fill.
The Pioneer 15111 has an entirely different and nev; method of juice extraction ao Jollov.-s.
The cane is first cut and then passes t!urouc'n c. "buster" which is a hc^rner Kill ahrodd^r;
followins this is a "fiberizcr" ::hich is a aiiidlar device but crushes the cane further.
The cane looks like stringy bagasse at this point.. It is then di schar&ed Jnto the
diffuser in which ,tho cane lies at a depth of about cja feet. The diffuser io a large
turntable i.hich rc\rolvc3 the cane £t a r-tt, of cr.r fj&ci'&r hour. '..Tiile the cux- ia
rsvolvins around frcn the point in v.v.ich it has boon added to the point in which it \.111
be extracted, water is passed through itj the vater is first added to tho top of^cane
just before thy cane is reeved, wvl o.f1.or trickling thiough the cane n-at, the '..\it3r is
picked up at the bottom and cycled up and forward and then allowed to flov through the
cane again. Looking down at the process, the c&na revolves around in a clockvdscs direction
-------
-2-
vrhile th« vrater is cycled back in a counterclockwise direction. Thn water passes
throus'n thn CEJIC a total of 17 times and the extraction is actually by solution. When
the cano haa ccnpleted the revolution and is approaching tho point of entry, it is lifted
out by a vrora c62^ system and is then passed through a screw press where raost of the
remaining water is squeezed out. Tliij water is clarified and then added to the initial
water paasins through the carie. The watcq after passing through the cane 17 tines, has
rev.ovod most of tho sugar and co:r.prioos the rdjced juice. .".11 bagasse is burned.
Aftsr leaving ths diffuse?, \,hc. .jl^nl !u".y a coTii'cntional process. Ko clarification of
the juice is r.osdcd a.c the shredded cane acts as a. filter. The Juice passes through
heaters an;' rcu^-yc^s :-ve.;jora'uoa>i . Ae pla-it Iv.s t*.;o high grade, 2 low grade and one
seed pan. The /. strike consists of syrup a.i:i seed liquor containing the number of crystals
desired. The B strikes consist of K uiolatsses and seed, and the C stoikss consist of B
molnssea. The seecl pan contains syrup boiled ccvni to super-saturation and powdered
corim-ci-l &ajjc.r C.D a lucloii source. ?Iie iuO'uU'ita bakea out of the seoa pcin for the other
strikoj -Jvipeins on th^ nufubar or de*-olo?Jir<; -jryBbLls desired. The C aacsecuite is added
to cryatiloisers Tor 72 hours and til lovj-^r.-^lt: j^gs.?- goes to the A and B strikes.
Taste Reduction Keasures
Tha cane vodh va\,er goes to one of tiro parallel settling lagoons of about
dspt.i. It takes aoou-i five to dxv.-eeke to fill one lagoon and then the other larpoa is
tru-owtt into eervice wliile the Ilrnt one is drsri^ed. The effluent froa tho pona(s) io
ussJ for irrigation Uiu-ing the day shift but ii added to tho sea during the night and
when irrigation is not taking place. If the lift pump for tho waste breaks dov.-n, the
vrajh water passes under the Lahaina Shopping Center and enters the sea off of Lahaina.
The vrater not used for cane washing is used for irrigation or passes to Kahooa. Stream
\Mch enters the sea on the north side of Lahaina. About 1,000 acres of cane is
irrigated uith the v;ash water.
Csne Afle at Harvesting;
23-24 months.
ISarveatint: Procedvires
Push rakes are not uaed; grab liaxvesters are us-sd vrhich shear the car.c off at the ground
and lift it up. The purpose of these is to lessen the number of rocks entering the plant.
Fertilizer
llitrogen — 350-.WG l*>s- ( as K) acre/crop e.a RHj ir. the irrigation vrater or as urea by air.
Potash — 0-500 las. (as I<20) acre/crop by air.
Phoapliate — 0-4GO ibs. (as PaOs) acre/crop by aj.r.
About 350 Ibs. llitrogen are added per acre of vach vrater irrigated crop.
Irrigation Procedures
All land is irrigated.
I-'urrov; irrigation — 9,100 acres
Overhead irrigation — 280 acres
The overhead irrigation is experimental and apparently, "at best is equal to furrow
irrigation" .
-------
-3-
Ficld Runoff Characterisl/ico
T2.Hi/c.ter occasionally enters various ravineo but apparently rarely enters the sea with
the, posuibly exception being Hor.okowai Stroar.i.
Pesticide Uoa,-»c
1st Application — k Ibo., DCIAi (.autiva) by air/aero.
2nd Application — >.2 Iba., A^atrion or AiriLino t;r air/acre.
3rc i.pplicacica — 4 Ibs., .'j.i
No'-f Crop rracedurcs
'i'hrea ratccnu ai:d a plant.
i:; Cc-'ij;.sr.ts
R-^-cval in the detention ponds is "marginal .•'
P-£cLSce is longer and stringier becaurid ol the process.
7}:e extraction process involves the principle of solution rather than diffusion.
The plant water cor.es from the ground and can contain up to 300 3g/l of chlorides.
The plant has 83|^ overall recovery of sugar.
-------
HAWAII/IK SUGAR UASTS STUDY
KOHALA SUGAR COMPANY (HAWAII)
Date of Visit
December 19, 1966
Parent Company
Castle & Cooke, Inc.
Persons Contacted
Frank Gomes, Asst. Mgr.j Ray Giannini, Pit. Sup£.
Operating Rate
50,000 tons of raw sugar in 10-11 months
Shifts
5 days a week; 24 hours a day plus 15-20 overtime days.
Employees
576
'.teter Supply
Ground water and surface water, llill consumption is 8.8 mgd of ground water
with 8.65 msd used for washing. About 30 ngd (average) of surface water is used
for irrigation, and the maximum ground water capacity is about 23 ragd including
a recently completed 3 mgd nill.
Process Description
Ths cane is first conveyed to a carding drun for unscrambling and then passes
through buapinc rolls for dirt reuoval, a velocity sink float with the stones being
dumped in a* nearby gulch, a cascading washer, stool dru.r.s and Olsen Roll detrashers.
The trash is flumed away with the wash uater.
Killing consists of cutting with two sets of knives, a threo-roll crusher, and
five additional rills. Juice extracted from the fifth rill is addfcd to the second
Td.ll; juice extracted frcr. the third and fourth nill* goes to the first mill, and
.liiice from the crusher and the first and second rd.ll is drawn off and sent to the
boiling house.
-------
-2-
In the boiling house, the juice is neighed, limed, heated, clarified, and passca
through ?ive-ftace evaporation. The plant has four high-grade vacuum pans and
™ low-grade pans plus a waller pan. No seed pans are used The A strike
S=a r:^^
is rer.elted and sent to the A strike.
Tjaste Reduction Measures
wastes enter a gulch alongside of the mill throutfi two flumes, Excess
about 25^1so enters the gulch. Apparently, the solids •"u.aOate in
baaso aou .
the rulch vith the water seeping out to the sea. Every year or ao, the mat of
organic Material breaks loose "like a spring ice break up" and moves out to the sea.
Cane Are At Harvesting
21-30 months with a 23£ month average.
Harvesting Procedures
Push rakes.
Fertilizer " '
Nitrogen — 175-300 Ibs . /acre/crop (as- II) as NH3 mostly by all methods.
Potash — 0-300 Ibs. /acre/crop (as KsO)
Phosphates -- 0-300 Ibs. /acre/crop (as P205)
Irrigation Procedures
4,800 acres are irrigated primarily by overhead irrigation.
8^200 acres are unirrigated.
Field Runoff Characteristics
Tha taiHrater from the approximately 800 acres of furrow irrigation rarety reach
the ocean. The plantation has numerous drainage gulches.
Pesticide Usage
Pre-eciereence — DCI-OJ and Atrasine - 2.5 Ibs. /acre.
Postencrgar.ee — Dowpon and DCIIU - up to 10 Ibs. /acre.
Kuron (C1-3J) — Used to kiU passion vine.
-------
,3
/ y.iA
-3-
New Crop Procedures
Plant and tvro ratoons.
Random Conmenta
The company plans to test a prototype harvester to cut the cane which does not
have the transportation mer.haaism of other similar cutters.
Irrigated fields only require Nitrogen.
The plantation soil is some of the oldest on Hawaii and is, therefore, less rocky.
A constant pumpage of water enters the plant, but it nay be augmented with
irrigation water when very dirty cane is being processed.
The plant gets 84-86/S recovery.
Reference
Gilnore Sugar Manual
-------
•^ ic-4
HAWAIIAN SUGAR V/AST-; STUOY ,..;„.
HONOKAA SUGAR COMPANY (HArfAll) „
i; r- r
Date of Visit .. . >.
r
December 14, 1966
Parent Company
Theo. H. Davles & Cor.pany, Ltd., owns the majority of the stock.
Persons Contacted
Anthony Tovea, Sanitarian; Horace Kawamura, .-jamtanan; Richard Fraser, Manager;
Yasu Kawawaki, Field Supt.
Operating Rate
30,000-40,000 tons of raw sugar in 9-10 months, Jooending on rainfall.
Shifts
5 days a week; 24 hours a day.
Snployees
303
Water Supply
All of the water is surface- water froir the H^waia«tn Irrigation Company. The mill
uses about 9.25 mgd of whinh G nifld is uiod for wasn >:ater. The remaining water is
used for irrigation. Flow into the pJant is monitored by the LJSGS .
Process Description
The cane is unscrambled in carding dnura and then passes over a "primary extractor"
(detrasher). The plant has a density sink float which follows, and the cane is then
washed and paaoed over Olsen Roll trash extractors. Rocks from the sink float are
used in roai'. construct.) on.
After washing, the cane passes through knives, a rock cruoher, and f /e .-aiils.
Water is added before the last mill and the mixed juice is recycled forward one
mill at a time. Apparently, some juice is withdrawn .'or the boiler-thcos*: from
every mill(?). Any bagasse which is not burned is filmed to the sea.
i
-------
- 2 -
Lime is added after weighing in the boiling house, and the juice is then heated,
clarified, and passed through four-stage evaporation. The plant has two low-grade
vacuum pans, two high-grade vacuum pans, and one seed nan. All boiling house
personnel were on vacation and 5>u#fir production information was not available.
Waste Reduction Measures
None. All wash water, trash, and excess bagasse is 1'Iumed to the sea. Some bagasse
is sold to experimental feed lots, however.
Cane Age at Harvesting
23r! months (average)
Harvesting Procedures
Push rake or HSPA cut harvester. This device cuts the cane at the ground level
and loads it in an attached carrier and dun'ns it in a pile when the carrier is full.
The cutter works with wet or dry cane, ann is less detrimental to ratooning. It
doas not work too well on slopes, and rocks ruin the blades.
v-tillzer
Nitrogen — 2kG lbs./acre (an N) as urea by hand ar.c mechanical means.
Potash — 425 lbs./acre (as K20) by hciiid and mechanical means; application varies widely.
Phosphorus — liO lbs./acre (as P-JJ$) - (NH^PO/. (See attachment)
Irrigation Procedures
1,600 acres a year by overhead irrigation during the first summer only with Hanawai
Target Master sprinklers.
Total acreage — 9,000 acres.
Fit- Id Runoff Chirac teri stirs
Many gulches exist on tne plantation. Diversion ditches have been built with the
assistance of the USSCS, and flood water damage is minimal.
Pesticide Usage
DCMU — 6 lbs./acre (average) (active)
Atrazine — J> lbs./acre
Dalipon — 7.J> lbs./acre
Certain fields do not get some chemicals.
-------
-3-
Hew Crop Procedure.-;
Two ratoons and a plant.
Random Comments
The plantation has the most severe terrain of all plantations of the islands.
The ground is too porous for furrov, irrigation.
Mill effluent passes at very high velocity through a reinforced concrete ditch.
Otto Van Der Srug (USGS - Hilo) is familiar with the measurement of very high velocity
w&
Filter mud leaves the rill in a separate concrete ditch at lower flow it will
probably settle out behind any weir-like obstruction. If the flow is 'low enough
it may be estimated by timing. euwwgn,
The mill achieved 86.^ recovery in 1966.
The ocean floor slopes off at about 1:1 off of the mil, and this is apparentlv
true of all of the Hanakua Coast. "
Currents at the mill are apparently always to the northwust.
A buoy exists off of the mill, and its location is known. Triangulation stations
also exist at the mill shoreline.
57
-------
O-'-it; '
Date of Visit
December 15, 1966
Parent Company
Theo. H. Davis & Company, Ltd.
Person Contacted
Leon Thevenin, Manager
Operating Rate
28,000-35,000 tons raw sugar in 10 aonths.
Shifts
i days a week; 24 hours a day.
Employees
288
VJater Supply
HAWAIIAN SUGAR WASTE STUDY .,x
' '
t*t\
HAMAKUA MILL COMPANY (KAWAIf)
' i*"-r
2,200 gpm of ground water is usod in the;raill and for domestic water. Almost all
of this is used ultimately for wash water. An additional 1.25 mgd of surface water
is obtained from Waipio Ditch Water through the Hawaiian Irrigation Company. This
water is used for irrigation or cane washing in wet periods
Process Description
The cane initially passes through a carding drum and then stool drum aetrashera.
It then passes through a velocity sink float with the stray stalks being pulled
froa the sink-float effluent in another separator. Rocks are dumped in a gulch.
The cane then is washed and passes through Olsen Roll detrashers. '
The milling process consists of kniving, crushing and mining in four mills. Water
is added before the last mill and juices are cycled forward. Apparently a common
trough exists below the four mills so mixed juice is actually drawn off from all
Mis. Only about 7556 of the bagasse is burned because of furnace capacity; some
additional power is bought during milling.
-------
- 2 -
Boiling house procedures consist of liming, heating, clarification, and four-stage
evaporation. The plant has two high-grade pans, one low-grade pan, and one seed
pan. The seed pan contents consist of syrup and powdered sugar. The A strike
consists of syrup and seed-pan seed. The B strike consists of syrup, A molasses,
remelt, and seed-pan seed. The lo*r-grade strike consists of B molasses, and
reaelted low-grade sugar (with crystals); the low-grade massecuite is processed
in cryatallizera for up to three days. The low-grade sugar is sent to the B strike
as true remelt or to the low-grade strike.
Wasto Reduction Measures
None. All wash water, trash, and bagasse enters the sea.
Cane Age at Harvesting
23-27 months depending on elevations.
far-vesting Procedures
About 80% of the cane is harvested by "combines" or "9R harvesters." The cane is
cat and conveyed backward to a storage bin which is an integral part of the device.
"hen the bin is full, the machine unloads it on one spot where it is later grab
jaded to trucks. Another name for the device is the Duncan Cutter. About 2C# of
the cane is harvested by push rakes.
Fertilizer
Ritrogen — 275 Ibs/acre (as N)
Phosphate — 125-250 Ibs./acre (as P205)
Potash — 450 Ibs./acre (as XaO)
Calcium — 1,000 Ibs./acre on acid land only
Irrigation Procedures
Two thousand acres of Land are irrigated in the summer, if needed, with overhead
irrigation using aluminun pipe.
A total of 7,800 acres is harvested.
Field Runoff Characteristics
Numerous gulches receive the water.
-------
Pesticide Usage
A pento chloro phenol-diesel oil mixture is used in addition to the following:
2-4-D — 2 Ibs./acre
Dowpon — 8 Ibs./acre
DCMU — 60 Ibs./acre (maximum)
Atrazine — 6.5 Ibs./acre (maximum)
New Crop Procedures
About, three ratoons are practiced before pjanting because of the gentler action of
the harvesting machines.
Random Comments
The plantation has the "most sophisticated machines" in the State for harvesting,
and cost $90,COO each. It costs about $0.40 a ton to harvest cane by push rake
and $1.00 a ton by the harvesters, but increased sugar recovery because of less
cane damage apparently makes up for it.
The plant achieves 86/6 recovery.
Three inches of rain in a relatively short period is needed for any runoff to
occur.
Reference — 10th Congress of International Society of Sugar Cane Technologists —
Honolulu — report containing all data on every mill.
Waste vater is flumed in a concrete ditch, and the volume of water does vary over
a long period of time depending on the weather.
-------
r\ \1
HAWAII*:: SUGAR WASTE STUDY
- • f" •• A J. ^
PAAUHAU SUGAR COMPANY (HAWAII)
Date of Visit
December 14, 1966
Parent Company
C. Brewer
Persons Contacted
Jay Sasan, Field Supt.; Howard Plahy, Factory Supt.; Jack Roey, Industrial Engineer;
Charles Street, Manager
Operating Rate
24,000 tons of raw sugar in 10 months.
ifta
5 days a week; 24 hours a day.
Employees
194
Water Supply
Water is obtained from the Hawaiian Irrigation Company.
Irrigation water — 8.4 mgd wheUer us,o.ig the Crater or not.
Kill water — 5.25 ngd; about 3£ mjd fcr wash water.
Process Description
The cane passes through a carding drum for unscraabling, receives a first wash,
passes over pipe rolls for initial tr&ah removal, and then Olsen Rolls for additional
trash removal. Additional washing also takes place before and at the detrashing
process. All trash goes to the sea.
Milling consists of knives, a Krajewski Crusher, and four ailla wiU. water added
before the lasfc miU. Juice is sent to the boiling house froa the crusher ana first
*so mills. About 5-405? of the bagasse formed is flumed to the sea.
-------
- 2 -
The juice is weighed, limed, heated, clarified, anc passed through four-siage
evaporators in the boiling house. The plant has two high-Crade pans, one low-grade
pan. and a seed pan. The seed pan contains low-grade sugar and syrup. The A
strike is made up of syrup, seed from the seed pan, some A molasses, and remelt.
The B strike is made up of seed, A molasses, and possibly some syrup. The low-
grade strike is made up of A and 5 molasseo, and some seed from the seed pan. The
low-grade uassecuite is orocessed in crystallizers for 24-30 hours and the low-
grade sugar is used in the seed pan or as remelt in the A strike.
Waste Reduction Measures
None. All unwanted material is fluked to the sea.
Cane Age at Harvesting
24-25 months.
Harvesting Procedures
"V" cutters and push rakeo.
Fertilizer
Nitrogen — 288 Ibs./acre (as N) as urea applied mechanically and by air.
Potash — 350 Ibs./acre (as K20) applied mechanically and by air.
Phosphates — 296 Ibs./acre (as ^2°^ applied mechanically only.
irrigation Procedures (includes private growers)
1.400 acres irrigated by overhead.
4:500 unirrigated. Irrigation has been practiced for 40 years, but by the furrow
method in the past — high soil porosity was one reason for switching to overhead.
Field Runoff Characteristics
Ten gulches.
Pesticide Usage
Plant Crop: DCMU —2.5 Ibs./acre Amatrion — 4.8 Ibs./acre
Atrazine — 2.4 Ibs./acre Dowpon — 5 lbs./acre
Ratoon Crop: DCMU — 4.8 Ibs./acre /u-natricn — 0.8 Ibs./acre
Atrazine ^~ 5.6.1bs.'/acre Dowpon — 4 Ibs./acre
-------
- 3 -
New Crop Procedures
Two ratoons and a plant.
Random Comments
Wash water can be estimated (1($ accuracy) by the pumps; the pumps run steadily
so the flow should be the same.
All wash water leaves the plant in a concrete ditch with constant velocity and
depth.
-------
HAWAIIAN SUGAR WASTE STUDY &»./•-•.*••-, *•- .
l>tj,
LAUPAHOEHOE SUGAR COMPANY (HAWAII) .,/,-•
Date of Visit
December 15, 1966
Parent Company
Theo. H. Davies & Company, Ltd.
Persons Contracted
Robert Bruce, Manager
Operating Rate
47,COO tons (maximum) of raw sugar in 10 months.
•Shifts
5 days a week; 2k hours a day.
Enployees
453
Water Supply
No irrigation is practiced. A constant pucpage of 5.7 mgd of ground water is
supplied to the mill which is ultimately used as g*»«sd- water.
••«••• )ij
Process Description
The cane initially passes through carding drums for unscramoling, collor rolls for
detrashing, and a velocity sink float for rock removal. Sink-float effluent passes
through a "short" separator for stray cans retrieval. Rocks are hauled to a gulch.
The cane is then washed and passed through Olsen Roll detrashers.
The milling consists of kniving, crushing, and passage through four mills. Water
is added at the last mill and the mixed juice is cycled forward, with the juice
being drawn off from the crusher ar.3 first mill. Bagasse is mostly all burned.
-------
- 2 -
The juice after extraction is weighed, limed, heate-1, clarified, and passed
through four-stage evaporation. The mud from the clarifier, after rinsing on a
vacuum filter, is added to the waste water. The nlant has three higtt-grade pans,
two low-grade pans, and a seed pan. The seed pan has syrup and a granular sugar
slurry added to it. The A strike has syrup, remelt, ana seed froir. the seed pan
added to it. The B strike has « molasses, some syrup, and seed from the seed pan
added to it. The low-grade strike nas B molasses, reirelt, an<1 seed from the seed
pan added to it. Low-grace massecuite is added to crystaliizers for up c.o 50
hours. All low-grade sugar goes to the A strike and low-grade strike.
Waste Reduction Measures
None. All wash water and trash enters the sea. Any future surplus bagasse will
also be flumed to the sea. At present bagasse production and consumption are
about equal.
Cane Age at Harvesting
22-30 months depending on elevation.
Harvesting Procedures
bout 75? of the cane is harvested by cutter transport (9R harvester). The
remainder is harvested by push rake or "V" cutter.
Fertilizer
Nitrogen — 325 Ibs./acre (average, as N) as urea by mechanical means, air, and hand.
Potash — 540 Ibs./acre (as K20, average)
Phosphates — 300 Ibs./acre (as P205)
CaC03 — 1,500 Ibs./acre on acid soil during planting.
Irrigation Procedures
All 10,300 acres of land are not irrigated.
Field Runoff Characteristics
Numerous gulches exist.
Pesticide Usage
Pro-emergence: 2-4-D — 2 Ibs./acre; atrazine or DCMU — 2.5 Ibs./acre
Postemergence: Dowpon — 6.5 Ibs./acre; DCMU — 3.2 Ibs./acre
"napsack spray: About 2 Ibs., atrazine and L. Ibs., dowpon
-------
- 3 -
New Crop Procedures
An average of a plant and two ratcons.
Random Comments
The mill was formerly known as Kaiwiki Sugar Company.
A dry cleaner will be built at the plant to work in parallel with the wet cleaner;
it will be operated in late 1967 or 1968.
The currents at the mill generally go to the northwest, but they have been observed
to travel to the southeast.
-------
HAWAIIAN SUGAR WASTE STUDY
PEPEEKEO SUGAR COMPANY, NORTH PLANT (HAWAII)
Date of Visit
December 16, 1966
Parent Company
C. Brewer
Persons Contacted
Herbert Gomez, Manager; Toru Yugawa, Process Engineer
Operating Rate
29,000 tons of raw sugar in 10 months.
shifts
5 days a week; 24 hours a day.
Employees
See south plant.
Water Supply
J Process water is surface water obtained froip several streams. The plant uses about
6,000 gpm of which 4,000 gem is used in wash water.
Process Description
The olant is located in the low T.outh of a gulch and cane is flumed down to it
from' the truck unloading station up or. the bluff. Upon entering the mill, it passes
through a relatively small cleaning process consisting of pipe roll detrashers and
a spray washing. Trash and flume water enter the sea.
In the mill room, the cane is cut by knives and then passes through a three-roll
crusher and three standard mills. Water is added at the last mill and recycled
forward. Juice is drawn off from the crusher and first mill. About 10-15£ of the
\gasse is flumed to the sea.
fef
-------
- 2 - '
The juice is limed, heated, clarified with the mud washed and filtered in VACU-.UE
filters, and then passes through four-stage evaporation. The plant has two high-
grade and two low-grade vacuum pans with high-grade ar.d low-grade seed made, when
needed, in the high and low-grade pans respectively. High-grade oeed is made
from syrup and powdered sugar (fondar.t sugar). The low-grade seed is made from
B molasses and powdered sugar. The A strike is made from syrup, high-grade seed,
and remelt (low-grade sugar); the D strike is made froa A molasses, syrup, and
high-grade seed. The low-grade strike is made from B molasses, and low-grade
seed; tho low-grade massecuite is processed in crystallizers for 50-60 hours. All
low-grade sugar is remelted and sent back to the A strike.
Waste Reduction Measures
None. Wash water, trash, and excess bagasse is flumed to the sea.
Agricultural Information
See south plant write-up.
Random Comments
"he mill was formerly the Hakalau Sugar Company.
"> 7 I
cl <*<•> i- 'r t
The location of the plant is subject to tsunami action, and the plant was devs*ted
in the 19^6 tidal wave.
Operations of the Pepeekeo Sugar Company may be confined to the south plant in
the future.
Discolored water was noticed off of the mill even though the mill had closed on
November 19, 1966.
The plant is located below a highway trestle.
-------
HAWAII SUGAR WASTE STUDY
PEPEEKBO SUGAR COMPANY, SOUTH PLANT (HAWAII)
Date of Visit
December 13, 196t-
Parent Company
C. Brewer
Persons Contacted
Herbert COM.. Manager; Melvin Tnonpson, A..I. Supt.; Horace Kawarcura, Sanitarian
Operating Rate
30,000 tons of raw sugar in 10 months
'lifts
5 days a week; 21* hours a clay.
Employees
/
.--
I .. - \J
Water Supplg
The mill uses about 6,000 gpm of water from nearby streams of which 4,000 gpn
used to wash the cane.
Process Description
unscram
. The trash is flurned to the r-ea while rocks are hauled away.
The cane is unscrambled in a carding drun *ro then is washed and detrashea by
Si
The juice is then neutralized with lime, h«Ua,
-------
S'"1-
o .,*^'S
-2 - ,
High-grade seed is made from syrup and low-grade sugar in the seed pan. An A
strike is prepared from syrup and high-grade seed and all of the molassus is
used in a B strike with more high-grade seed. The molasses from this strike is
used with powdered sugar to make low grade seed. Another A strike is then prepared
from syrup and high-grade seed and half of the molasses from this strike is used
in a B-l strike with high-grade seed and syrup. Tho B-l molasses is all uaeo in
a B-2 strike with high grade seed and syrup and all of the B-4 molasses is used
for the low-grade strike. The B-l and B-2 strike procedures are then repeated with
the remaining half of the A strike molasses. The low grade strike consists of the
B-2 molasses and low-grade seed. Low-grade massecuite is processed in crystallizers
for 36 hours. All low-grade sugar not used as seed in the high-grade seed pan is
remelted and added to the A strikes.
Waste Reduction Measures
None. All wash water, excess bagasse, and trash enter the sea.
\
Cane Age at Harvesting
22-24 months.
Harvesting Procedures
"V" cutter with 3056 of the cane picked up with a pick-up transport and 70% removed
by buggy.
Fertilizer
Nitrogen — 350-400 Ibs./acre/crop (as N) as urea by air or mechanical application.
Potash — 450 Ibs./acre/crop (as K^O) by mechanical application or air.
Phosphate — 400 Ibs./acre/crop (as P^)>) by air or mechanical application.
Irrigation Procedures
N/A
Field Runoff Characteristics
Diversion ditches are built in the fields and the fields have small furrows
initially, but these are eliniinated After a few months. The soil is very porous
and only heavy rains apparently cause runoff.
Pesticide Usage
Pre-emergence: Atrazine — U Ibs./acre: DCMU — *£ Ibs./acre
Postemergence: Dalipon — A Ibs./acre
-------
Hew Crop Procedures
One plant and two ratoons.
Random Comments
The 3ea around the mill was observed to be turbid for about 2,000 feet, probably
because of sludge deposits since the mill was not operating.
-------
HAWAII SUGAR WASTE STUDY
MAUNA KEA SUGAR COMPANY, NORTH PLANT (HAWAII)
Date of Visit
December 13, 1966
Parent Company
C. Brewer ~"
Persona Contacted
Horace Kawamura, State Sanitarian; Bill Silver, Pltn. Supt.j A. Larsen,
Production Supt.(?)
Operating Rate
33,000 tons of raw sugar in 10-11 months.
hifts
5 days a week, 24 hours a day.
Employees
See south plant.
Water Supply
Nine mgd in mill of which 3 mgd is used for cleaning. Another 9-12 ngd is used
for fluming (and cleaning) the cane. All water used is surface water.
Process Description
The cane is dumped initially in an 1800 ton storage pit. The mill grinds
considerable amounts of private cane and the purpose of the pit is to stockpile
the coaapany or the private cane while the other is being processed. The cane
is unscrambled in a carding drum and then has the trash removed in a series of
pipe rolls and Olsen Rolls. All trash and rocks are flumed directly to the
sea. The cane is then flumed about 500 feet to the mill. Additional cleaning
of the cane occurs in this flume. Additional trash removal occurs at the end
of the flume with another series of Olsen Rolls.
-------
•» 2 ••
Milling consists of cutting, pulverising, crushing, and passage through four mills.
Water is added before the last mill and cycled forward. Juice is withdrawn from
the crusher and first two mills. Excess bagasse is flucied to the sea at the
rate of 35 tons a day if a generator is not being used and 10 tons a day if it
is being used.
The juice is limed in the boiling house, heated, and clarified. It then passes
through four-stage evaporation. The plant has four vacuum pans: a high-grade,
a high-grade-seed, a low-grade, and a low-grade-seed. The high-grade-seed pan
contains low-grade sugar and syrup. The A strike contains syrup and high-grade
seed. The B strike contains high-grade seed and A molasses, and sometimes B
molasses. The plant's C strike is considered a high-grade strike and contains
A and B molasses and high-grade soed. The low-grade seed pan contains syrup
and B molasses with powdered sugar added as a nucleii source. The low-grade
strike contains the C molasses and low-grade seed and the mixture is placed
in a crystallizer for 32 hours. Tho low-grade sugar *s used as high-grade
seed or is remelted and added to the strikes. The sugar is separated from the
molasses in standard centrifuges.
Waste Reduction Measures
None. All excess bagasse, wash water, and trash enters the sea.
,ane Age at Harvesting
See south plant.
Harvesting Procedures
See south plant.
Fertilizer
See south plant.
Irrigation Procedures
See south plant.
Field Runoff Characteristics
See south plant.
Pesticide Usage
ee south plant.
67
-------
- 3 -
Key Crop Procedures
See south plant.
Random Comments
About 25% of the cane ground at the mill is grown by small farmers.
Considerable discoloration existed in the waters around the mill, probably
from sludge deposits in the surf zone.
Four separate flumes are used for the various waste disposal procedures.
About 200-650 tons of trash/day enter the sea.
The mill was formerly the Onomea Sugar Company.
-------
10
HAWAII SUGAR WASTE STUDY "*
Jl/I
MAUNA KEA SUGAR COMPANY, SOUTH PLANT (HAWAII)
Date of Visit
December 13, 1966
Parent Company
C. Brewer and Company, Ltd.
Persons Contacted
Horace Kawamura, State Sanitarian; Martin Black, Manager(?); Bin Silver
Plant Supt.j John Ellison, Process Engineer
Operating Rate
32,000 tons of raw sugar in 10-11 months.
Lfts
5 days a week, 2k hours a day.
Employees
546
Water Supply
Irrigation is not practiced; about 8-9 ngd is used in the mill of which about
4 mgd (2,500 gpm) is used to wash cane. The viator is all surface water from
nearby streams.
Process Description
The cane passes initially througn a carding drum (for unscrambling) and then to
pipe and Olsen Roll detrashers. Washing also takes place. The trash is severe
from the wash water and hauled away to lava land for future pasture usage.
Killing consists of cutting, shredding, crushing, and milling in four mills
Water is added before the last mill and the mixed juice is cycled forward one
mill at time. The juice is drawn off of the crusher and first two mills. Most
'>agasse is burned and the surplus is used to spread on the wasteland.
. .
" '
-------
- 2 -
In the boiling house, the juice is lined, boated, clarified in a Dorr Clarifier,
and the mud is filtered for sugar extraction. The juice then passes through
four-stage evaporators followed by three evaporating pans, consisting of one
high-grade, one low-grade, and a seed pan. The A strike contains syrup and low-
grade sugar; the B strike contains syrup and A molasses (the A molasses apparently
has enough crystal nucleii in it). The C strike at this plant is still considered
a high-grade strike and contains syrup and B molasses. The low-grade strike
consists of some A molasses and a shock seed of powdered sugar; all low-grade
sugar is used in the high-grade strikes. Low-grade massecuite is placed in
crystallizers for about 20 hours.
•
Waste Reduction Measures
All nill water enters the sea directly; excess bagasse and trash is trucked away.
Cane A/ge at Harvesting
22-24 months.
Harvesting Procedures
The cane is first cut with a "V" cutter and is then picked up with a "pick-up
transport" which is essentially a irobile conveyer belt with a conveying compart-
ment attached. When fullj'fentire device travels to the edge of the field and
dumps its load. These devices cut down on the dirt and rock content of the cane
and are designed for unirrigated fields.
Fertilizer
Nitrogen — 400 Ibs. (as N)/acre/crop as urea.
Potash — 600 Ibs. (as K20)/acre/crop.
Phosphorus — 400 Ibs. (as ?205)/acre/crop.
CaC03 — Up to 1,500 Ibs./acre for acid soil.
Irrigation Procedures
N/A
Field Runoff Characteristics
No real furrows are present in the fields but ditches are constructed to prevent
a washing effect.
70
-------
fl/nt/K-A-~
Pesticide Usage
TCA — 8 Ibs./acre/crop
Dalipon — 3 Ibs./acre/crop
Atrazine — k Ibs./acre/crop - pre-emergence application
DCMU — 2 Ibs./acre/crop
New Crop Procedures
Planting and two ratoons.
Random Comments
The mill was formerly known as the Hilo Sugar Company.
The mill achieves 85$ sugar recovery.
Discharge from the mill is inside Hilo Harbor and very close to the City of
Hilo. This is apparently why the bagasse and trash is hauled away.
-------
HAWAIIAN SUGAR WASTES STUDY
PUMA SUGAR COMPANY (HAWAII)
Date of Visit
December 21, 1966
Parent Company
American Factors, Ltd.
Persons Contacted
William Boiake, Manager; William Fairchild, Pit. Supt.
Operating Rate
52,000 tons of raw sugar in about 10 months.
Shifts
5 days a week; 24 hours a day.
Bnployees
410
Water Supply
All plant water is ground water artf is noed at s. rate of 1-2 mgd. A combination
of puir.ps is used, and during dry periods, the water table drops and pump-age is less.
Process Description
The clearing plant is quite extensive and consists of e. carding drum, initial wash,
sifter pipes for debris removal, a velocity sink float, cascade washer, stool druits,
Olsen and Collar Ron detrashers, and a final wash. Trash is fluined to a separate
area and rock is also deposited on tho land.
The mill initially consists of two sets of knives and a two-roll crusher which is
followed by a "sand bath"; in this bath, the crushed cane passes through a juice
bath which operates on the sarao principal as a velocity sink float; scall rock and
i7-girt- are removed in this manner. The cane then passes through a shredder and four
mills. Water is added before the last nill and tho rdxed juice is cycled forward
72.
-------
ono will at a time. Juice for the boiling house is withdrawn from tho first
two ndlls while the juice fron the crushsr is added to the sand bath; some additional
juice is required in the sand bath as tho cane washing action carries away more
juice than the crusher supplies. About 15-20£ of the bagasse is flumed to waste ;
land or sold for mulch.
The boiling house processing consists of weighing, lining, heating, clarification
with the filter roud entering the wash water, and evaporation in four-stage
evaporators. The plant has two high-grade pans with one used for seed and two low-
grade pans with one also used for seed. The high-grade seed consists of syrup
and powdered raw sugar and the low-grade seed consists of syrup, remelt, and
powdered raw sugar. The A strike consists of syrup, high-grade seed and renelt.
The B strike consists of A molasses, remelt (raybe) and high-grade seed. -The lou-
grade strike consists of B ir.olasaes and low-^rade seed. The low-grade inassecuite
is processed in crystallizers for about 4S hours, and all low-grade sugar is
renelted for the A and B strikes as well as the seed pans on occasion.
Uaate Reduction Measures
The plant has a hydroseparator with water surface diameter of about 135 feet and .
an average depth of about 11 feet. Uith the use of the hydroseparator, about 14 '
ngd is recirculated to the cane washer. The effluent goes to waste land where it
disappears into the ground. The slurry and filter aiud are pumped to diked areas
where land reclamation takes place. Trash and bagasse are fluned to another
waste area where it accumulates.
Cane Age at Harvesting
24,27, or 30 months depending on elevation. Highest elevation cultivated is about
2500 feet.
Harvesting Procedures
Grab harvesters.
Fertilizers
Plant crop: Nitrogen — 298 Ibs./acre as H
Phosphate — 233 Ibs./acre as
Potash — 400 Ibs./acre as KsO
CaO — 1123 Ibs./acre
Ratoon crop: Same except only 63 Ibs./acre of CaO. These figures do not apply to
private growers.
Irrigation Procedures
All 12,000 acres are unirrigated.
73
-------
Field Runoff Characteristics
The land is flat, porous, and full of lava tubes. A six- or seven-inch rain
probably does not reach the sea except through maybe a gulch.
Pesticide Usage
Harvested field — 41 lha./acre(?) OI" various types. "
Cultivated field — 18 lbs./acre(?) of various types.
These figures do not apply to private growers.
New Crop Procedures
Plant and two ratooris.
Random Conyienta
llauka soil is relatively good but the irakai soil is rfelatively new lava.
About 800 acres of cane field was lost in a I960 volcanic eruption.
A.bout 40£ of the cane ground by the nill is harvested, hauled, and ground for
private growers.
The company plans to put in a boiler which vail be designed to burn all trash and
bagasse.
The plantation soil is black.
-------
HAWAIIAN SUGAR WASTE STUDY
HAWAIIAN AGRICULTURAL C01IP'"" (HAWAII)
Date of Visit
December 20, 1966
Parent Company
C. Brewer and Company, Ltd.
Persons Contacted
Paul R. Tate, Manager
Operating Rate
46,000 tons of raw sugar in about 10^ months.
Shifts
24 hours a dayj 5^ days a week.
Employees
326
Water Supply
Ground water for the factory — 4.5nigd
Surface water — 1.5 sngd average
Process Description
The washing process consists of unscrambling in a carding drum, initial wash, Sap
rolls for debris removal, one set Olsen Rolls for detrashing {£#/^fi^Sash is
uncontrolled density, cascade washer, and four banks of Olsen Rolls. All trasn is
^ssed througha cutting nachine before being fluncd from the plant.
The milling consists of two sets of knives a two-roll crusher
bagasse enters the "wash water ilurae.
-------
-2-
The boiling process consists of weighing, lining, heating, clarification with the
filter mud being added to the wash water flune, and five-stage evaporation. The
'plant "has four evaporating pans and one seed pan. The seed pan contains syrup, and
low-grade sugar as a nucleii source. The A strike consists of syrup, ronolt,
and seed fron the seed pan. The B strike consists of A molasses and seed from the
seed pan. The low-grade strike consists of B nolasses and powered coariercial
sugar. Low-grade ir-assecuito is processed in crystalizzers for about 50 hours. All
low-grade sugar goes to the seed pan or as rerelt in the A strike.
Waste Reduction Measures
All uLant wastes go to a disposal ditch which empties into diked areas on several
thousand acres of old lava flou.' None of the liquid apparently reacnos the sea.
The trash is chopped up before leaving the rrlll to facilitate flow and aid in
decomposition. About 100 acres a year of land have been reclaimed for future use
by this method.
Cane Age At Harvesting
29-43 nonths with cane grown up to 3300 feet.
Harvesting Procedures .
Push rakes.
Fertilizer
Fertilizer is added up to 12-14 months before harvesting — see attachment.
Irrigation Procedures
All 10,600 acres are not irrigated.
Field Runoff Characteristics
Erosion is a problem at the plantation and is controlled by 75 miles of 2$ drainage
ditches and by a slowly developing strip crop program.
Pesticide Usage
See attachment. Applications given are only during the first year and therefore
are applied on about 3600 acres.
New Crop Procedures
An average of12-2^ ratoons are cultivated.
-------
-3-
Randon Consents
The soil on half the plantation is "Pahala Ash" which is dust from Kilauea Volcano.
The remainder of the plantation is rocky and of lava origin.
The plantation was the first to put in soil conservation measures.
The soils are soft and fragile and easily eroded.
The soil is extremely abrasive and requires the plant to replace the rolling mills
every three months and to use armor plate in the cane washer.
Good burns are impossible because of the moisture and altitude of the plantation.
•77
-------
~^_.r_. 3££<*L.z_i_ "ii.""'
.•1>E«lOO.COVERED WOW
_COST CENTER .A**-*:
-------
"PERIOD COVE«D FROM
| f-tt/i-il
CUVtKtU I-KVM . tv T- ;
W'i/JTv/v^ «/
-------
HA'TAIIAI! SUGAR I/AST." STUDY
HUTCHIKSOiJ SUGAR COIZIM.Y (IIA'/AII)
Date of Visit
December 20, 1966
Parent Corcoany
C. Brewar and Company, Ltd.
Persons Contacted
Georre Ko, State Sanitarian; BiU Caso, Field Supt.; Bruce ilcCall, How
Supt.j Iwao Yoneraitsu, Crop Control Supt.
Operating Rate
30,000v- tons of raw sugar in 11 months.
Shj f ts
6 days a week; 24 hours a day.
Employees
247
V.':
foter S
'Several11 rjd of surface water ia tapped =nd ecnc. to the county ty tho
Scr.c siirfacs wator is used for boiler vaLur, sjcd washing, equipment waahir.-, etc.;
approximately 0.1 ngd ia used for this. The JTOUT.U i:ater pur.parjo is brackia^ end
is used for cane washing at a rate of about 7 s-d depending on the pumping head which
depends on the tides.
rrocess Peacriotjon
The cane passes through a cardan:? drur.;, velocity sink float, with the rocka being
duv.pcd en the land, a cascade washer a.id Olson da trashing rolls vrith the trash
entering the v/aste trash-^/ater flu-iio.
llillins consists of cutting by ;-/.-:o sets of l^iivco, a three-roll cryshor, and three
aills. \.'ater is added at the last rill and is recycled forward ont rill at a time.
Juice for the boiling houso io dravm off fror. the crusher and first mill. About
202 of the bagasse enters th& sea.
-------
-2-
t
In the boiling house, the juice is weighed, li:scd, heated, clarified, and con-
centrated in five-stage evaporators. I'.ad frcm the filters £oes to the \nuh watsr ditch.
The plant has two high-grade and two low-grade pans. The A strike consists of s;-rup,
A iro lasses, recelt, and powdered coirr.arcial su^ar. The B strike conoiuts of syrup,-
A molasses, and powdered corj.ercial susar. Tha lou-grs.de strike consists of syrup,
B molasses, and po\;ciered cocmercial STi.'jar. The lew-grade massecuite is maintained
in crystallizers for 50-60 hours. All lov-^rade susar is rernelted and sent to the
A strike.
Waste Reduction Measures
Kone. All trash, wash water, and bagasse enters the sea.
Cane Are at Harvesting
26-36 months; cane is grown up to the 2400-foot elevation.
Harvesting Procedures
Push rakes.
Fertilizer
Nitrogen — 350-450 Ibs./acre/crop (as H) as rany forms and by all methods of
application.
Potash — 450-600 Ibs./acre/crop as KoO by all rcathods of application.
Phosphates — 0-450 Ibs./acra/crop as P20$ by nechanieal application.
The fertilisers are applied until about 14 rronths before harvesting.
Irrigation Procedures
8,500 acres are all unirri^abeci.
Field Runoff Characteristics
Erosion is a serious problem and the Company practices ditching, contouring, and
strip croppinc. Those methods '.rare init:at.ei in 1953- Additional reads are
required by the strip cropping prccecuro. The lands have 1:1 slopes in spots.
Pesticide Usa^o
Pre-er.ergence — Amatrion, Atrasine, DCIU, C'l1 at 10-12 Ibs./acre/crop.
Postercergence — Dowpon, 2-4-D, 2-4-5T, TCA at fc-10 Ibs./acre/crop.
.»
-------
-3-
New Crop Procedures
Ratoorvins is practiced seven to eight tinies. This is possible because of soil
conditions which seen; to hold the roots.
Random Convents
The plantation is 25% pre-Mauna Loa soil and the remainder is Manna Loa rocky loas.
The strip cropping is fairly well organized and apparently is not a great burden
on the plantation.
Sone new wells for plant use are being drilled.
Some cooling water and ash water enter the wash-vrater ditch.
-------
3 February 1967
Mr. Robert G. Dodge
Master on Water Quality Standards
State Department of Public Health
Honolulu, Hawaii
Dear Mr. Dodge:
Subject: Statement on Sugar Factory Wastewater Treatment
My name is Michael T. McGovern. I am a registered Civil
Engineer in the States of Hawaii and California. My experience has
principally been in the fields of sanitary and hydraulic engineering.
In presenting this statement, I am representing the Hawaiian Sugar
Planters' Association Water Pollution Committee and no other repre-
sentation should be inferred.
In previous public hearings OP. water quality standards, the
question of treatment of plantation waszewaters was raised by the Master
and others. This statement is intended to clarify some aspects of tech-
nology and economics in this regard and to help substantiate previous
and future testimony alluding to "prohibitive" or "burdensome" costs
for treatment of plantation wastewater.
For the purposes of this statement, I will define the term
"treatment" as the processing of wastewaters by mechanical, hydraulic,
and/or chemical means such that their quality is improved sufficiently
" for beneficial uses or to meet receiving water quality standards.
It is assumed that the necessary quality is that which, upon -
-------
Mr. Robert G. Dodge
Page 2
3 February 1967
ocean or stream disposal of the treated wastewaters, will meet "Class B»
standards as defined by the Master subsequent to the Kauai hearings.
The sugar plantations in Hawaii have two broad categories of
wastewaters which are of concern; factory wastewater and irrigation tall.-
water. The following computations and cost estimates are concerned with
only the first -- factory wastewater -- although certain comparisons
will be made between both in summary.
The qualities most generally recognized as offensive in these
wastewaters are turbidity and apparent color. These qualities, when
present in a discharge to ocean receiving waters, can be offensive to
esthetic senses. It would be naive to say that these wastewaters do not
contain other substances or characteristics which may, to some degree,
affect receiving water quality. It is my opinion, however, that with
regard to ocean disposal, these'other substances and characteristics
have little significance. (A table listing results of several analyses
of factory wastewaters appear as Appendix A of this statement.)
Wastewater treatment as considered herein, then, will be for
removal of turbidity and color. Turbidity in this case is caused by
the presence of suspended solids in the water. These suspended solids
are of both organic and inorganic nature but principally inorganic --
that is, soil particles predominantly of a colloidal size range. (Appen-
dix B to this statement shows the relationship of suspended solids to
turbidity.) Although color is associated with the presence of dissolved
organic matter by sanitary definition, apparent color here is due pri-
marily to the high concentrations of very finely-divided colloidal soil
particles.
-------
Mr. Robert G. Dodge
Page 3
3 February 1967
The treatment methods normally associated with removal of
suspended solids are plain sedimentation and chemical coagulation with
sedimentation. Domestic water treatment practice usually includes sand
filters to further remove traces of turbidity as well as increase bac-
teriological purification, however, this is not considered here.
Previous testimony at these hearings has indicated that plain
)
sedimentation in ponds has little effect on turbidity irregardless of
length of detention. These ponds do achieve partial removal of the
settleable portion of suspended solids but, due to the colloidal nature
of much of the solids in the wastewater, the ponds cannot be completely
"effective in this regard.
A simple hydro-separator or similar gravity settling device
appears to be effective to a limited degree, but it should be emphasized
•
that turbidity and thus apparent'color does not change much with consid-
erable reduction in solids. A comparison of several dilutions of factory
wastewater is attached as Appendix C.
In order to achieve full effectiveness -- that is to discharge
to the ocean relatively clear water which will not, in the Master's words,
"be visible at any time in the water" -- it would be necessary to use
chemical coagulants and coagulant aids in conjunction with sedimentation.
A schematic diagram of this process is attached as Appendix D.
Many coagulants have been used successfully in wastewater
treatment practice. Most notably are aluminum sulfate, ferric chloride,
ferric and ferrous sulfate, sodium aluminate, and magnesium sulfate.
The widest use has been that of aluminum sulfate, more generally known
-------
Mr. Robert G. Dodge
Page 4
3 February 1967
as alum. Recently, a wide range of polymeric substances have come into
use and these are generally known as poly-electrolytes. These may be
cationic, anionic, or non-ionic in charge. Cationic, that is, positively
charged, poly-electrolytes normally are used as primary coagulants while
anionic and non-ionic poly-electrolytes usually function to aid coagula-
tion and settling processes when used in conjunction with a primary .
coagulant.
Coagulant aids are used to develop larger floes and thus accel-
erate the settling action. These chemicals usually are sodium carbonate
(soda-ash) or one of the anionic or non-ionic polymers. Quantities are
usually small and their application depends so radically upon the char-
acteristics of the specific water that further consideration is not
given to them here.
To illustrate the magnitude of the treatment requirements and
costs that would be required by a plantation to remove colloidal turbid-
ity and color from wastewater, the following information is presented.
These computations are based on a wastewater flow of sevenjillion.jallons
per day, an_approximate average.JElog from the sugar factories in Hawaii,
having a suspended JoU£sj:oj^ei^^^^^^ or °-79
percent by weight. The results of several analyses^ofjactory waste-
waters have shown this suspended solids concentration^to be about_ayer-
age.
It is estimated that the alum dosage required to effectively
coagulate this wastewater would be 200j>arts per, million or about one-
half gram per gallon. For a flow of seven million gallons per day, this
-------
Mr. Robert G. Dodge
Page 5
3 February 1967
would amount to 11,690 pounds or nearly 6 tons of chemicals per day.
At a cost of seven cents per pound, the cost of chemical coagulant alone
becomes $818 per day or about $164.000 per normal grinding season. p<*-/wl'••'-w^( »
Experience at some wastewater treatment plants on the West . /^ ^ A'
Coast indicates that some of the new cationic^poly-electrolytes can be
affectively applied at the rate of about five pounds jer ton of dry
solids removed. A flow of seven million gallons per day containing
7,900 parts per million of suspended solids has a dry solids load of
231 tons per day. At five pounds per ton, 1155 pounds of this coagulant - , /, '
would be required each day. At an estimated cost of $1.15 per j?ound, .t^ueJ £*>'
chemical costs would run to nearly $1330 per day or $266,000 per grinding
season.
Although unit alum cost is about six hundredths the unit cost
~of a poly-electrolyte, more than ten times as much chemical is needed.
I would expect a more detailed study to show the higher cost of the
poly-electrolyte being balanced by Jihe lower cost of^transportation,
storage, handling, and feeding.
CapjLtaLcosts of treatment facilities and equipment are esti-
mated as follows:
Chemical Storage Building $ 5,000
Chemical Feed Equipment 15,000
Rapid Mixing Basin 2,000
Rapid Mixing Equipment 7,000
Flocculator-Clarifier (2 Units) 350,000
Sludge Draw-Off Piping 1,000
Sludge Pumps 10i000
TOTAL $ 390,000
This figure includes only treatment facilities and takes no
-------
Mr. Robert G. Dodge
Page 6
3 February 1967
notice of the necessary disposal of the 231 tons of solids each day.
These would be discharged in slurry form at about six percent solids by
weight for a total of about 925 thousand gallons or about 4,570 cubic llV^
, A
yards per day. £- '
Assuming the sludge can be dried in 30 days by spreading in
six-inch layers, this would require more than 170 acres of sludge stor-
age area.
A most conservative assumption is that this land is available
by gravity flow from the treatment unit and no sludge pumping is necessary
other than withdrawal from the clarifier. This assumption borders on the
unreasonable, but the problem of land availability becomes too complex
for a typical situation as described here to have meaning.
Assuming that the sludge storage area can be prepared at $650
per acre, capital costs for this phase would be $110,000.
Amortization of the total capital cost of $500,000, assuming
an interest rate of six percent over a facility life of 15 years, would
correspond to an annual cost of $51,500._
Annual maintenance and operation costs of this treatment
facility can be estimated as follows:
Labor (1 nan/day @ $7,000/yr.) $ 7,000
Power (300 HP installed capacity) 16,000 ^
Trucks (4 Units for sludge hauling) 48,800 —"' •
Bulldozer and Scraper 14,700
Loader 7.000
TOTAL $ 93,500 ^
0
These annual and equivalent annual costs can be summarized as ^<* \
£ollows!
-------
Mr. Robert C. Dodge
Page 7
3 February 1967
Capital Investment $ 51,500
Operation and Maintenance 93,500
Chemicals 266.000
TOTAL ANNUAL COSTS $ 411,000
A similar example using a wastewater flow of 19 million gallons
per day, which is about the maximum encountered at any sugar factory in
the state, and using the maximum suspended solids figure from Appendix
A of 25,375 mg/1 would show total annual costs to be in excess of
$3,000,000. This cost would be required of the larger plantations if
receiving water quality standards are absolute and temporary discharge
of partially turbid water during overload periods is not allowable.
On the other hand, using minimum figures for flow and solids
concentration (4 mgd, 1,320 mg/1), costs could, in rare instances, be
as low as $70,000 annually.
Each of these instances are somewhat unlikely, but it is A
reasonable to expect that costs would range from $250,000 to over ' Q /**..
.- — II 111 m-M. • - « •• " "W>«. p.J - i_ -fi*__. . . - ta ~ . --*r .••••II I • i §
r*~
$1,000,000 annually depending upon the size of the plantation and the '''
wastewater flow. Based, again, upon an average solids concentration
of 7,900 mg/1, these cost figures are equivalent to $295 per million
gallons treated or about $9 per ton of dry solids removed.
This has been a brief outline of the magnitude of treating
wastewater discharged from a sugar factory. Furtherjrefinement^ could
be made to these estimages,_but it is my judgment that such refinement
would have the effect of increasing, not decreasing, the costs.
The problems of similarly treating irrigation tailwater com-
pound several times those of treating factory wastewater. The locations
-------
Mr. Robert G. Dodge
Page 8
3 February 1967
of tailwater discharge are many and widely spaced over the plantation
and pumping and conveying to a central treatment plant would be necess-
ary. Moreover, flows are extremely variable and suspended solids load
would be equally as variable.
I hope that this statement will help to clarify some points
brought out in previous testimony by the sugar plantations and will pro-
vide a frame of reference regarding wastewater treatment for the Master.
Very truly yours,
Michael T. McGovern, P. E.
Registered Civil Engineer
(Hawaii) No. 1818
MTM:hkh
4 Attachments
1. Appendix A
2. Appendix B
3. Appendix C
4. Appendix 0
-------
APPENDIX A
Temperature
Hydrogen Ion (pH)
Turbidity
SctLlcablc Solids
Suspended Solids
Volatile
Fixed
B.O.D. (5 Day - 20
C)
Chlorides (Cl)
Phosphates (PO^)
Organic Nitrogen (N)
Nitrates (N03>
Nitrites (N02)
From Ten Sugar
^
i'7 ,•'
•. „ •
Factories
CANE" CLEANER FLOWS
UNITS
°c
Units
Units
Ml/L
Mg/L
o
7.
7.
Mjj/L_
Mg/L
Mg/L
Mg/L
Mg/L
No.
8
8
8
8
8
8
8
8
4
4
4
4
4
J11X.,
37.5
6.84
7,350
73
17,390
58.5
80.7
Ia370_
27.0
<0.2
25.0
1.3
0.1
Min.
22.0
5.45
283
8.5
1,627
19.3
41.5
173
7.5
£.0.2
2.0
<0.5
< 0.1
Avg.
29.7
6.25
2,056
32
7,436
34.0
66.0
559
13.6
< 0.2
14.1
c 0.7
< 0.1
COMBINED WASTE FLOWS
No.
6
6
6
6
6
6
6
6
6
6
6
6
6
Max.
37.0
7.34
5,450
98
25,375
40.1
75.7
1,534
950
4.0.2
105
1.3
0.1
Min.
29.5
4.96
300
4.0
1,320
24.3
59.9
264
10
< 0. 1
5.0
0.4
<0.1
Avg.
32.4
6.04
2,198
42
7,908
31.4
68.6
976
171
< 0.2
27.2
< 0.7
<. 0.1
z
o
16 January 1967
M. T. .McGovern, P.E.
-------
: ,
r-
-..._
:
I .:-• .
^
/o
o &
T
tl±t±.t
V7"crj'.7
t
/
3±ttS±BI
. ' i .' J ." !—' .
^4-pT-'P4-r-
.:_'"Tri±t"
/; ~i.0rrGiar/Qn-'.j.*.O'/fJ«*r
rri:rr-xi:r":d-i ^
/.
_._ ^.._
- . L •- :- :...!_!-L..i-I...!-]-_)_
T! T 1 ' : • . i i j i : i i i i
-l-i-4 -- .-•• -t-i-- -r-r-:-t"\—,"-,~
.
-:-!- J_i.;_
- •
;;rr±b ?.""..-.'•:-.
,_ j |. ._' , !.._._ _. t
• ! I . .^^ :
E Combined Factory
-• •
o Car,* Cleaning Plant
A A(I Discharge Except
' Cleanin
-;- "
\-H-r-;--rj ---••;- ;-}-:.: 1 :-:;
"5.o ::.::
f IOOO Units)
- L:cDid:
:jTn±H"i:!:i:-.=;:4R;:.
SUSPENDED soups -l::d
'*«'From results of 24 ancr(y£CS of
- from. /o
', P.&.
.._•_•_ j^i j—_.
APPENDIX B
-------
APPENDIX C
Various Dilutions of Factory Wa.stewater
(Equivalent to percent solids removal)
0
nil
DILUTION (
25 50 75
90 100
I
Samples in^nediately following rapid mixing.
percent distilled water.
Dilution is in
*,
LABORATORY ANALYSIS 0? SAMPLES
'ater content) , 7»
1
0
8,120
6,120
7
25
5,875
4,560
6
50
4,012
2,950
5
75
1,862
1,616
4
90
716
569
3
Suspended Solids, mg/1
Turbidity, units
True Color, units
(Sample from Papaikou Factory, Mauna Kea Sugar Company, Inc., Hilo;
17 January 1967, 9:15 A.M.; taken at cane cleaning plant wastewater
outfall flume.)
APPENDIX C
-------
Chemical
Truck*
CHEMICAL
Vs..
I
I
SUQAfi I
25
O
fi
I
Conveyor —-'J
Dry S!uc?g<5 /o Land
Disposal by
/G January
, RE.
f&PIQ
L-0\'
> > J • I
c\'J"A'v;'/'.-„: ^
ft
J
G/UO'ge Piping . . .:
V PurnpS -
1
•FLOCCULAJ-lON BASIN
Flocculating
'SLLJOQ&
J
OUPS FZ-MOVA
sy CQA&ULA r/cav- -^o-'/sfA r/o/v
------- |