COLLEGE OF ENGINEERING & DESIGN

Silliman University

A Proposal: Industrial Wastewater Treatment of Sugar

Factory in Negros Island
( A partial fulfillment of the requirements of the subject MEP 214)

Submitted to:
Dr. Jorge Emmanuel
Instructor

Submitted by:
Engr. Harry S. Rodwell Jr.
Engr. Kenneth V. Ramirez
Engr. Francis Robert Demetri C. Quingco

March 20, 2017

CONTENTS
1 Introduction .................................................................................................................. 5

1.1 The History of Sugar in the Philippines ............................................................................. 5

1.2 Definition of Terms ........................................................................................................... 7

1.3 Background on Sugar Cane Production Process ............................................................... 9

2 Objectives.................................................................................................................... 11

3 Statement of the Problem .......................................................................................... 11

4 Scope and Limitations ................................................................................................. 12

5 Review of Related Literature ...................................................................................... 13

5.1 Taxonomical classification .............................................................................................. 13

5.2 Botanical description ...................................................................................................... 13

5.3 Phytochemical profiles of sugarcane .............................................................................. 14

5.4 Sugarcane crop and its various products ........................................................................ 20

5.5 Physicochemical characteristics of waste water............................................................. 21

5.6 Sugar Industry Waste ...................................................................................................... 25

5.7 Reverse Osmosis (RO) ..................................................................................................... 26

5.8 Demineralization ............................................................................................................. 26

6 Methodology ............................................................................................................... 28

7 Results and discussion ................................................................................................ 30

7.1 Waste Water Discharge .................................................................................................. 30

7.2 Water Treatment Plant Options ..................................................................................... 35

8 Timeline of the Study .................................................................................................. 39

9 Conclusion ................................................................................................................... 40

10 Recommendations ...................................................................................................... 40

11 Reference .................................................................................................................... 42

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 12 Appendices .................................................................................................................. 43

12.1 Appendix A (Sedimentation Lagoon of Mill A) ............................................................ 43

12.2 Appendix B (Sugar Factory Flow Chart) ...................................................................... 44

12.3 Appendix C (DENR Standard Table) ............................................................................ 45

12.4 Appendix D (Mill B Sedimentation Lagoon) ............................................................... 49

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 Abstract
Wastewater from sugar industries has been addressed to be a problem for the
locality and has a negative environmental impact to the surroundings. The downside to this
is that most of the equipment used for conventional mills utilizes an enormous amount of
water for cooling, maceration and imbibition. Waste water gets contaminated with oil,
grease, chemicals and various impurities. Before treatment, determination of
physicochemical parameter is an important step for data gathering. Many different types
of techniques in managing waste water are introduced and modified for the purpose, but
depend upon the water quality parameters made by the DENR. The main aim of this
proposal is to assess the environmental impact of the effluents discharged into the
environment and propose an industrial wastewater treatment plant to reduce the pollution
made, minimize the use of water, and meet the water quality parameters when discharged
into the receiving body of water.

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1 INTRODUCTION

The Philippines is mainly an agricultural country with a land area of 30 million hectares,
47 percent of which is agricultural. The total area devoted to agricultural crops is 13 million
hectares distributed among food grains, food crops and non-food crops. Among the crops
grown, rice, coconut and sugarcane are major contributors to biomass energy resources.

Negros Island, currently known as the sugar bowl of the Philippines, has an operational
of 13 mills and producing more than 50% of the whole Philippines sugar production. The
downside to this is that most of the equipment used for conventional mills utilizes an
enormous amount of water for cooling, maceration and imbibition. In addition to the
previous statement, some water gets contaminated with oil, grease, chemicals and various
impurities.

1.1 THE HISTORY OF SUGAR IN THE PHILIPPINES

Cane (Saccharum officinarum) is a tall perennial grass that is widely grown in warm
climates as a source of sugar. Cane grows to a height of two to five meters and has narrow,
corn-like leaves and stalks that are from two to four centimeters thick. The stalks (yellow,
green, purple, or striped, depending of the variety) are composed of short, jointed sections
that contain the sweet, juicy pith. The plant is usually propagated by planting sections of
the stalk in shallow furrows. Most sugarcane varieties mature within a period of twelve to
twenty-four months.

In the Philippines, the ideal physical conditions for growing sugarcane are found in
Negros Occidental, Negros Oriental, Pampanga, Batangas, Laguna, Tarlac, and Iloilo. Thus,

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these are the leading sugar producing provinces of the country. Early Spanish chronicles
contain details of cane propagation. After the settlement of Manila by the Spaniards in
1572, sugarcanes were planted increasingly in Bulacan, Cebu, Iloilo, Laguna, and
Pampanga. Negros and Pampanga have, since then, dominated the country's sugar
industry.

The primitive system of extracting juice from cane consisted of exerting pressure
on a hand or foot-lever against a fixed wooden surface. This technique was later improved
by crushing cane between two upright wooden rollers using human power. With the arrival
of Chinese immigrants in the Philippines during the early decades of the Spanish
Occupation, stone cylinders replaced the wooden rollers, and carabaos were used to
operate these crude extractors. Muscovado, or unrefined sugar, and molasses because
important commercial trade items, but sugarcane juice was also fermented into wine, as in
the famous basi of northern Luzon provinces. Steam power, from imported machinery and
equipment, later replaced human and animal power in the milling processes. Centrifugal
mills were eventually installed.

Sugar production increased steadily from then on, interrupted only by the
Philippine Revolution that did considerable damage to the industry. By the first decade of
the twentieth century and the start of American colonial rule, however, the sugar industry
had recovered and, in fact, had started modernizing.

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1.2 DEFINITION OF TERMS

The following terms is used in this paper:

Bagasse - the fibrous residue of sugar cane which remains after the crushing operation.

Boiling - the evaporation of moisture from the juice at temperatures of between 90 and 116ºC.

Brix - the term “degrees Brix” (or more usually ºBrix) is the sugar 'technologists' measure of the
concentration of dissolved solids in solution.

Clarification - removal of impurities from the juice.

Extraction - the removal of juice from the cane by crushing.

Factory - this term is used throughout to indicate a sugar processing plant regardless of its type,
processing capacity or physical size.

Massecuite - the concentrated cane juice obtained after boiling, also known as rab or final syrup.

Molasses - a syrup by-product from the manufacture of sugar, containing sucrose, invert sugars,
moisture, ash and other insoluble matter.

Open Pan (OP) - describes sugar produced by boiling juice in open pans at atmospheric pressure.

OPS Open Pan Sulphitation (OPS) - is a method for production of white granular sugar.

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Recovery - the proportion of sugar produced by weight of cane processed, usually expressed as
a percentage. For example, 10% recovery means that for every 100kg of cane processed 10kg of
sugar is produced.

Strike - the removal of massecuite from the boiling operation at the required concentration.

Sucrose - an organic chemical of the carbohydrate family, found in the sap of most green plants.
Ordinary white crystal sugar is almost (99.9%) pure sucrose while some of the non-crystalline
sugars may contain less.

TCD – or known to be (Tonnes of Cane per Day), refers to the amount of cane a processing plant
crushes each day and not the amount of sugar produced.

VP – or known to be (Vacuum Pan Vacuum), describes a technology used to boil or evaporate

the sugar cane juice.

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1.3 BACKGROUND ON SUGAR CANE PRODUCTION PROCESS

The basic process is to crush sugar cane to extract the juice. The crushing process
must break up the hard nodes of the cane and flatten the stems. The juice is collected,
filtered and sometimes treated and then boiled to drive off the excess water. The dried
cane residue (bagasse) is often used as fuel for this process.

Extraction
The cane is first shredded then crushed using hydraulically loaded 3, 4 or 5-mill
tandems. The major difference between this and OPS roll mills is that water is sprayed
onto the bagasse before the final mill and diluted juice is recirculated to the previous
mills. This system, known as imbibition, helps to wash out more of the sucrose with the
juice. Typically, extraction rates of 75% of the available juice are common. A schematic
diagram is provided in (Appendix A) to illustrate the process of milling sugar cane.

Clarification
Clarification is carried out by lime sulphitation, similar to that used in Open Pan
Sulphitation (OPS), but here it is a continuous rather than a batch process.

Evaporation

The major difference between the VP and OPS technology is the method of
evaporating or boiling the juice. Instead of in open pans the juice is boiled under vacuum,
to about 70º Brix, inside closed vessels or 'effects'. Low pressure steam is used to boil the
juice which circulates through tubes within a closed vessel. The vapor driven off passes into
a second similar vessel, where it is used to heat more juice. To maintain suitable
temperature differentials for heat transfer to occur, a partial vacuum is applied to each
vessel, effectively lowering the boiling temperature of the juice.

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 It is common for four vessels to be used in series, each subjected to a progressively
higher vacuum. This system is capital-intensive but is highly energy efficient and more
importantly boils the juice at progressively lower temperatures from 103 to 50ºC, reducing
the effects of inversion, minimizing discoloration and enhancing the formation of sugar
crystals.

Final boiling to over 95º Brix takes place under vacuum in a single vessel, known
as the vacuum pan, which is designed to handle the viscous massecuite. During this stage
crystallization begins in a controlled manner, enabling the maximum yield of crystals to
be developed before the massecuite is transferred to the crystallizers.

Bagasse is used to fuel highly efficient high-pressure steam boilers. The high-
pressure steam is used to generate electricity to meet the VP plant's needs and the low-
pressure exhaust steam is then used to boil the juice in the vacuum pans. A schematic
diagram is provided in (Appendix A) of this paper to illustrate how bagasse from the last
mill is transferred to the boiler as biomass fuel for the factory.

Crystallization
The massecuite is cooled and the crystallization process completed using large
vessels that stir the massecuite continually for up to 48 hours.

Centrifuging
Takes place on a batch basis using large centrifuges similar in design and operation
to those used in the OPS process.

Drying and packaging

Drying is carried out at low temperatures using rotary or fluidized bed driers.

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2 OBJECTIVES

The objective of this proposal is to assess the environmental impact of the effluents
discharged into the environment, this also includes:

 determining the physicochemical characteristics of wastewater

 determining the usage and classification
 assessing the present data with DENR standards
 determining the significant effluent quality parameters
 conducting on-site investigations and surveys of wastewater
 recommendations of a wastewater treatment plant design
 providing a financial analysis of the wastewater treatment plant

3 STATEMENT OF THE PROBLEM

Sugarcane is highly abundant in the Negros Island, during the milling season the
industries produce wastewater that come from cleaning sugarcane, and cleaning the
industry premises and the outside surroundings. The wastewater is discharged continuously
throughout the milling season coming from a canal in the factory going to the creeks/rivers,
and is then discharged to the nearby bay. The build-up of these effluents in the canals and
creeks causes a serious environmental impact, such as relatively dark and yellowish effluent
that emits foul and strong odor, sludge build-up on the canals and creeks. Due to this fact,
there have been numerous numbers of complaints from agricultural land owners and local
communities nearby the creeks/rivers coming from the factory, including local inhabitants
living nearby the factory.

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4 SCOPE AND LIMITATIONS

The study on the proposal focuses on reducing the level for total coliform, Fecal Coliform,
E. coli, total dissolved solids (TDS), bio-chemical oxygen demand (BOD) and chemical oxygen
demand (COD) values using an industrial wastewater treatment plant. The method most suitable
is by the method of reverse osmosis. Moreover, multiple tube fermentation technique has been
used as the test method in gathering the data as well as review of related literature to support
the details.

The study is only limited to the amount of data gathered due to high confidentiality
matters, and the data only made available will only be assessed in relation to the water quality
parameter guidelines by the DENR. Other parameters stated in the administrative order shall not
be assessed or made comparison due to the unavailability of the data.

The study will also be focusing on 2 mills situated in Negros Oriental. Due to
confidentiality and to avoid confusion, 1st mill will be referred to as “MILL A” and 2nd Mill will be
referred to as “MILL B”.

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5 REVIEW OF RELATED LITERATURE

5.1 TAXONOMICAL CLASSIFICATION

Table no. 1: Table of Taxonomical Classification of Sugarcane

Kingdom Plantae
Order Poales
Family Poaceae
Subfamily Panicoideae
Tribe Andropogoneae
Genus Saccharum
Species S. officinarum

5.2 BOTANICAL DESCRIPTION

Saccharum officinarum is a perennial plant that grows in clumps consisting of
several strong unbranched stems. A network of rhizomes forms under the soil, which
sends up secondary shoots near the parent plant. The stems vary in color being green,
pinkish or purple and can reach 5 cm (16 ft.) in height. They are jointed, nodes being
present at the bases of the alternate leaves. The internodes contain a fibrous white pith,
immersed in sugary sap. The elongated, linear, green leaves have thick midribs and saw-
toothed edges that grow to a length of about 30 to 60 cm (12 to 24 inches) and width of
5 cm (2.0 inches). The terminal inflorescence is a panicle up to 60 cm (24 inches) long, a
pinkish plume that is broadest at the base and tapering toward the top.

The spikelets are born on side branches and are about 3 mm (0.12 inches) long
and are concealed in tufts of long, silky hair. The fruits are dry and each one contains a

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 single seed. Sugarcane harvesting typically occurs before the plant flowers, as the
flowering process causes a reduction in sugar content.

5.3 PHYTOCHEMICAL PROFILES OF SUGARCANE

Sugarcane wax is a whitish to dark-yellowish powdery deposit on the surface of
stalks and leaves of S. officinarum, which appears as a cuticle layer. It is necessary to
consider sugarcane wax when reviewing the phytochemical profile of S. officinarum
because of its widespread industrial application, and cosmetic and pharmaceutical
interest. It is a potential substitute for the expensive carnauba wax. The amount of wax
in sugarcane ranges between 0.1 and 0.3%, depending upon its variety.

Sugarcane wax is used as a commercial source of long chain fatty alcohols, acids,
esters, aldehydes, and ketones. Policosanols and D-003 along with some steroids and
terpenoids have also been identified and isolated from sugarcane wax. Policosanols are a
mixture of long chain primary aliphatic alcohols (1 - 8) ranging from 2.5 - 80%. Octacosanol
(1) constitutes 50 - 80% of the total policosanoles. Other major pharmacologically active
components of sugarcane wax are long chain aliphatic fatty acids (9 - 18) present at lower
concentrations. The mixture of these acids is known as D-003 as shown in Figure 1.

Figure no. 1: Chemistry of sugarcane wax: (a) Long chain saturated fatty alcohols (b) Long chain
saturated fatty acids present in D-003

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 Although fatty acid and fatty alcohol are reported as major constituents
[18,19,20,21,22] various phytosterols (19 - 22), steroids (23 - 28), and higher terpenoids
(29 - 30) have also been reported in sugarcane wax [23,24], all of which can be seen in
Figure 2.

Figure no. 2: Chemistry of sugarcane wax: (a) Simple phytosterols; (b) Ketosteroids; (c) Hydroxyketosteroids; (d)
Higher terpenoids

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 Furthermore, to understand the phytochemistry of jaggery (non-centrifugal
sugar), brown sugar, and molasses, it is necessary to explain the phytochemical profile of
sugarcane juice. Sugarcane juice is obtained by grinding the sugarcane culms. Basically, it
comprises of 70 - 75% water, 13 - 15% sucrose, and 10 - 15% fiber. Before 1971, it was
assumed that the color of juice might be due to the presence of plant pigments. In 1971,
several color components from sugarcane juice have been identified, with chlorogenic
acid (31), cinnamic acid (32), and flavones being some of them. Sugarcane juice was then
extensively studied for their flavonoid content. The analysis of phenolic compounds from
sugarcane juice showed the presence of phenolic acids such as hydroxycinnamic acid (33),
sinapic acid (34), and caffeic acid (35), along with flavones such as apigenin (36), luteolin
(37), and tricin (38) as shown in Figure 3.

Figure no. 3: Phenolic compounds identified from sugarcane juice (a) Phenolic acids; (b) Flavones

Among the flavones, tricin derivatives accounted for the highest concentration.
Extensive chromatographic and spectroscopic studies indicated the presence of various -
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 O- and -C- glycosides of the above-mentioned flavones, and 3947 were identified.
Illustrations of such are on Figure 4.
Figure no. 4: Flavone glycosides identified from sugarcane juice (39 – 47) and from sugarcane leaves (39, 40, 46,
and 47)

Four new minor flavones swertisin (48), tricin-7-O-neohesperoside-4’-O-rhamnoside (49),

tricin-7-O-methylglucuronate-4’-O-rhamnoside (50), and tricin-7-O-methylglucuronide (51) were
isolated and identified from sugarcane juice. In addition, some novel acylated flavone glycosides,
such as, tricin-7-O-β-(6’-methoxycinnamic)-glucoside (52), luteolin-8-C-rhamnosyl glucoside (53),

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and tricin-4’-O-(erthroguaicylglyceryl)-ether (54) were isolated, along with orientin (47), from
sugarcane juice, all shown in Figure 5.

Figure no. 5: New Flavone glycosides identified from sugarcane juice (48 - 52) and from sugarcane leaves (53, 54)

Brown sugars are also used commercially in Brazil for its nutraceutical value and
other biological activities. Liquid chromatography-mass spectrometry (LC-MS) analysis of
aqueous and dichloromethane extracts of brown sugars confirmed the presence of various
phenolic acids (59 - 63). In addition to phenolic acids, eight major volatile constituents (64
- 70) were also discovered to be present in brown sugars in Figure 6.

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Figure no. 6: Chemical constituents of brown sugar (a) Benzoic acid derivatives; (b) Cinnamic acid
derivatives; (c) Volatile constituents

Polyphenolic compounds in various sugarcane products indicated that

molasses are the richest source of phenolic acids as compared to clear juices and
syrup.

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5.4 SUGARCANE CROP AND ITS VARIOUS PRODUCTS
Sugarcane crop is cultivated to produce sugar, but the processing of sugarcane
yields various valuable products such as bagasse, brown sugar, molasses, syrup, and
jaggery, along with sugar (table sugar). The processing of sugarcane in a large-scale
industry to produce sugar is shown in Figure 7.

Figure no. 7: Flowchart diagram for Processing of sugarcane products

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5.5 PHYSICOCHEMICAL CHARACTERISTICS OF WASTE WATER

Color

Color is a qualitative characteristic that can be used to assess the general condition
of wastewater. Wastewater that is light brown in color is less than 6 h old, while a light-
to-medium grey color is characteristic of wastewaters that have undergone some degree
of decomposition or that have been in the collection system for some time. Lastly, if the
color is dark grey or black, the wastewater is typically septic, having undergone extensive
bacterial decomposition under anaerobic conditions. The blackening of wastewater is
often due to the formation of various sulphides, particularly ferrous sulphide. This results
when hydrogen sulphide produced under anaerobic conditions combines with divalent
metal, such as iron, which may be present. In the present investigation, the color of the
untreated effluent was dark yellow. Similar studies by different authors found that the
color was dark brownish black, yellow, and reddish yellow. Color is very important factor
for the aquatic life for making food from sun-rays. This photosynthetic activity reduced
due to dark coloration affects other parameters such temperature D.O. and B.O.D.

Odor
From the available data, it was observed that untreated SIWW have fishery odor
Unpleasant odors in food industry wastewater are usually caused by gases produced by
anaerobic decomposition of organic matter. The most common odor causing compound
is hydrogen sulphide whose characteristic odor is that of rotten eggs. Sulphur is required
in the synthesis of proteins and is released into the degradation process. Under anaerobic
conditions, sulphate is reduced biologically to sulphide which can further combine with
hydrogen forming hydrogen sulphide. This gas is readily soluble in water, colorless and
inflammable, but also toxic. Although hydrogen sulphide is the most common gas formed
during the anaerobic decomposition of organic matter when considering odors, other

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 volatile compounds, such as indole, skatole and mercaptans, may cause odors far more
unpleasant than H2S.

Some other gases, such as carbon dioxide resulting from the decomposition of
organic matter or nitrogen dissolved from the atmosphere, are also responsible for odor.
The control of odors has become more important in the designing and operating of
wastewater collection, treatment and disposal plants. Odors are the foremost concern of
the public in wastewater treatment processes. Quite often, the psychological stress
caused by odors is far more important than the harm they do to the health of humans.

Temperature
Temperature is basically important for its effect on certain chemical and biological
radiations taking place in water for organism and inhabiting aquatic media. It was
observed that temperature of the untreated effluent was recorded as 40 °C, and that of
the treated effluent was recorded as 30 °C, respectively. The temperature of the discharge
should not exceed 35 °C since high temperature many produce softening of bituminous
joints. The rise in temperature accelerated the chemical reaction in oxygen.

pH Level

pH is the value expressed as the negative logarithm of the hydrogen ion

concentration. Its range was give between 0 to 14, if the value is 7 means neutral less
than 7 being acidic and above 7 being basic or alkaline. The wide narration in the pH value
of effluent can affect the rate of biological reaction and survival of various
microorganisms. The presence or absence of various ionic special can have direct relation
with pH of the effluent. Subsequently, such effluent can influence the quality of soil. In
the present investigation, the pH value of the untreated effluents was 5.5 and treated
effluent was 7.2, respectively.

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Dissolved oxygen

It is one of the most important parameters in water quality assessment. Dissolved

oxygen is an index of physical and biological processes in water. The aquatic ecosystem is
depending totally on dissolved oxygen, various biochemical changes and its effects on
metabolic activities of microorganism. The solubility of atmospheric oxygen in freshwater
ranges from 14.6 mg/L at 0° to about 7.0 mg/L at 35° less than one atmospheric pressure,
since it is a poorly suitable gas, its solubility directly varies with the atmospheric pressure at
any given temperature.

Total solids
The term solid refers to the matter either filterable or unfilterable that remains as
residue upon venerating and subsequent drying at a defined temperature employed for
drying and ignition. In effluent, the total solids, total dissolved solids and total suspended
solids are composed mainly of carbonates bicarbonates, chlorides, sulphates, nitrates, Ca,
Mg, Na, K, Mn and organic matter silts and other particles polluting water increase the
concentration of total solids.

Total suspended solids

The T.S.S. affects the light intensity of water, suspended solids are the cause of
suspended particles inside the water body influencing turbidity and transparency. Effluents
from different industries have different amounts of solid particulate matter, either as
suspended solids or total dissolved solids.

Total dissolved solids

The total solid concentrations in waste effluent represent the colloidal form and
dissolved specters. It might be the fluctuation or the values of total solids and subsequent.
The value of dissolved solid is due to convent collision of the colliding particles. The rate of

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 collision of aggregated process is also influenced by pH of these effluents. In the rainy
season, less concentration of total dissolved solids is obtained due to the dilution of waste
effluent with rain water.

Chlorides

Chlorides are generally present in natural water. The presence of chloride in natural
water is attributed to dissolution of salt deposits’ discharge of effluents from chemical
industries oil well operations, sewage discharges initiation drainage, contamination from
refuse leachates, and sea water intrusion in coastal area.

Biochemical oxygen demand

Biochemical oxygen demand is defined as amount of oxygen required by

microorganism while stabilizing biological decomposable organic matter in waster aerobic
conditions. Biological oxygen demand is an important parameter that indicates the
magnitude of water pollution, by the oxidizable organic matter and the oxygen used to
oxidize inorganic materials, such as sulphides and ferrous ions. In natural source, the
oxidizable matter on oxidation enters biogeochemical cycle.

Chemical oxygen demand

The COD test determines the oxygen required for chemical oxidation of organic
matter with the help of strong chemical oxidant. The COD is a test, which is used to measure
pollution of domestic and industrial waste. The waste is measured in terms of quality of
oxygen required for the oxidation of organic matter to produce carbon dioxide and water.
The conjugation of BOD test with COD test is helpful in indication of toxic conditions and the
presence of biological resistance.

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Sulphate
Sulphate is polyatomic ions, which occurred in natural water as well as it has been
used in different industry. Effluent from certain industries also may be major sources of
sulphate to the receiving water. Sulphur itself has never been a limiting factor in aquatic
systems. The normal levels of sulphates are more than adequate to meet plant needs, odor
conditions are easily greater when water is overloaded with organic waste to the point that
oxygen is removed, so that SO4 as electron acceptor is often used for the breakdown of
organic matter and produces H2S and rotten egg smell.

Oil and grease

The concentration of dispersed oil and grease (OG) is an important parameter for
water quality and safety. Among other pollutants, oil and grease is one of the most
complicated pollutants to remove. Determination of oil and grease concentrations in effluent
does not determine the presence of specific substances, but groups of substances that can
be extracted from a sample using a effluent. Oil, grease, fats and waxes are dissolved in
suitable solvent and separated from the aqueous phase. The solvent layer is then evaporated
and the residue is weighed as oil and grease.

5.6 SUGAR INDUSTRY WASTE

The manufacture of sugar generates large quantities of biomass waste such as rice
husk, bamboo dust, bagasse, coconut coir, jute and sticks. This waste is ideal for use as fuel
to generate power. Press mud, which is discarded as a solid waste from sugar mills and
used as a manure or as a landfill, is found to be an useful substrate for biogas production.

Two types of solid wastes are produced during the manufacture of sugar. Bagasse
is produced in the mill house in a quantity of about 30% of the crushed cane. The bagasse
contains 50% moisture. Press mud or filter cake is produced in vacuum filters and press

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 filters. The mud is produced in a range of 3-8 % of the crushed cane, depending on the
nature of sugar manufacturing process.

Chromatographic methods are also used in sugar production processes to reduce

the non-sugars and to increase the quantity of crystallized sugar. The waste water from
sugar treatment plants is normally subjected to extended
aeration in ponds and is ultimately made to undergo intensive biological oxidation.

Most sugar industries including Mill A and Mill B have spillages that goes thru their
creeks and rivers which cause damage to other livelihood like aqua farm, community, and
others.

5.7 REVERSE OSMOSIS (RO)

Considered as a water purification technology that uses a semipermeable

membrane to remove ions, molecules, and larger particles from drinking water. In reverse
osmosis, an applied pressure is used to overcome osmotic pressure, a colligative property,
that is driven by chemical potential differences of the solvent, a thermodynamic
parameter. Reverse osmosis can remove many types of dissolved and suspended species
from water, including bacteria, and is used in both industrial processes and the
production of potable water. The result is that the solute is retained on the pressurized
side of the membrane and the pure solvent is allowed to pass to the other side. To be
"selective", this membrane should not allow large molecules or ions through the pores,
but should allow smaller components of the solution to pass freely.

5.8 DEMINERALIZATION

Demineralization is the process of removing mineral salts from water by using the
ion exchange process. Raw water is passed via two small polystyrene bead filled (ion

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exchange resins) beds. While the cations get exchanged with hydrogen ions in first bed,
the anions are exchanged with hydroxyl ions, in the second one.

In the context of water purification, ion-exchange is a rapid and reversible process

in which impurity ions present in the water are replaced by ions released by an ion-
exchange resin. The impurity ions are taken up by the resin, which must be periodically
regenerated to restore it to the original ionic form.

The following ions are widely found in raw waters are shown in Table 2:

Table no. 2: Table of Ions (Cations and Anions)

Ions are widely found in raw waters

Cations Anions
Calcium (Ca2+) Chloride (Cl-)
Magnesium (Mg2+) Bicarbonate (HCO3-)
Sodium (Na+) Nitrate (NO3-)
Potassium (K+) Carbonate (CO32-)

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6 METHODOLOGY

To determine the physicochemical characteristics: The present wastewater in the

sugar industry should be analyzed beforehand, by testing the samples made available were
collected and analyzed for total coliform, fecal coliform, E. coli, total dissolved solids (TDS),
bio-chemical oxygen demand (BOD) and chemical oxygen demand (COD) values. The test
method used to obtain this data is by the multiple tube fermentation technique followed for
analysis, interpretation, collection for future reference.

To determine the usage and classification: The receiving body of water will be the
nearby bay, which wastewater coming from the factory, flows out to the creeks on the
outskirts of the factory premises and then flows out into the river and onto to sea, in which
marine life is present and abundant. The classification and usage of the water body can be
found on “Water Quality Guidelines and General Effluent Standards of 2016” (See Appendix
C) by the DENR.

To assess the present data with DENR standards: The wastewater is classified by
given parameters and usage. Given the available data on the wastewater, and for the water
quality guidelines for primary parameters. Assessment is made on the data obtained in
comparison to the guidelines of the water quality from the DENR. Therefore, we can
determine on how polluted the wastewater is and its effect on pollution to the surrounding
environment and community.

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 To determine the significant effluent parameters for water quality: As stated in the
administrative order from the DENR, discharge from any point source shall meet the
effluent standards to maintain the required water quality. The study involves the industry
category for sugar cane processing and milling and states that the significant parameters
are as followed: temperature, pH, BOD, TSS, and Nitrate.

To conduct on-site investigations and surveys of wastewater: Assessment is

made from on-site observations of the wastewater from the factory canal, going to the
creeks and other receiving bodies of water. Investigation is made through visual
inspection of photos and maps on what characteristics that can be seen in the canals and
creeks, the out flow of wastewater outside the factory premises, and what smell it has as
it flows out the creek. In addition, surveying local inhabitants of a nearby barangay on
their say or complains and impacts of what flowing wastewater affects the local
community.

To recommend a wastewater treatment plant: The recommendations made to

resolve or reduce the negative effects of the wastewater into the surrounding
environment is by using reverse osmosis (RO) and demineralization as an alternative
including its cost.

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7 RESULTS AND DISCUSSION

7.1 WASTE WATER DISCHARGE

The water discharged into the creeks have tended to release a foul odor and an
awful discoloration of the water. This mostly happens during milling seasons in the sugar
industries, especially to those industries that tend to use up large volume of water. Before
proceeding into assessment as mandated by DENR regulations for industrial purpose, the
physicochemical characteristics of wastewater must be tested to know the level of
pollution it is giving off into the surrounding locality and nearby inhabitants, to gather
data, and to resolve the addressed problem. Figure 9 below shows that by visual
inspection alone, the water is contaminated at some level above the average due to its
discoloration and impurities found as it flows down into the stream shown in Figure 10.

The discoloration is mainly due to the molasses and other entrainments from
canals, sewerages, and mainly from molasses and massecuite pumps that has defective
packing glands.

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 Figure no. 9: Close-Up Photo of the wastewater flowing out

Figure no. 10: Photo of creek where the wastewater flows out

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 From the pictures illustrated are just one of the three creeks present on the sugar factory.
Moreover, the data obtained by method of multiple test tube fermentation technique shows a
relatively high level of total Coliform, fecal coliform and E. coli. The initial water quality available
parameters are mentioned in Table 3, Table 4 and Table 5 for each of the creeks (noted as river
in data source) respectively.

Table no. 3: Data Sheet of River Water 1

Table no. 4: Data Sheet of River Water 2

Table no. 5: Data Sheet of River Water 3

In addition, the effect of irrigation by sugar factory effluent and the well water
from adjoining area has been studied before in India. The effluent had high results, as
tabulated in Table 6, as shown below.

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 Table no. 6: Tabulated Data of Effluent

Parameter Unit Value/Range

Total Dissolved Solids (TDS) mg/L 422-608
Chemical Oxygen Demand (COD) mg/L 1152-17680
Biochemical Oxygen Demand (BOD) mg/L 380-650

As for the source of water of the sugar factory, which comes from the deep well,
has the results of which is seen in Table 7 below.

Table no. 7: Tabulated Data of deep well water

Parameter Unit Value

Total Dissolved Solids (TDS) mg/L 240
Chemical Oxygen Demand (COD) mg/L 3.8
Biochemical Oxygen Demand (BOD) mg/L 1.2

Other parameters have been found and measured, such as the nutrients, viz. N, P,
K, Zn, Cu, Fe, Mn in surface layer of soil in different seasons, this also includes heavy
metals (Cd, Co, Cr, Ni, Pb) were found to be within the permissible limits.

Unfortunately, it has only been stated that it is with the allowable limit without
the given values or range of concentration for each parameter mentioned. This sets as
one of the limitation of the assessment due to confidential reasons.

The receiving body of water will be the nearby bay, which wastewater coming
from the factory, flows out to the creeks on the outskirts of the factory premises and then
flows out into the sea (See Appendix A), in which marine life is present and abundant.

As per classification and usage of the water body can be found on “Water Quality
Guidelines and General Effluent Standards of 2016” (See Appendix C) by the DENR. The
intended beneficial use for the body of water classified is for boating, fishing. Therefore,
classified as Class SC.

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 The parameters shown below (Table 8) are for water quality followed by
classification, Class SC. This shows that allowable value or range for Fecal Coliform is 200
MPN/100mL.
Table no. 8: Table of Parameters for Water Class SC.

Setting this as the basis for the assessment, comparison can be made with the
available data gathered from the creeks in relation to this protocol given by the DENR. As
seen from Table 3, Table 4 and Table 5, the values for the Fecal Coliform are ,
, 680 MPN/ 100mL respectively. This shows a relatively high amount of Fecal
Coliform in each of the three creeks where the samples have been taken from, which is highly
above the water quality parameters for Class SC.

The study involves the industry category for sugar cane processing and milling, and
states that the significant parameters are as followed: temperature, pH, BOD, TSS, and Nitrate
(See Appendix C). However, for Class SC, BOD is disregarded as determined by its class,
temperature varies form 22-25 °C, pH ranges from 5-6.5 according to source from a personal
interview. Other remaining parameters such as BOD, TSS and Nitrate of wastewater situated
on the creeks were considered unavailable.

During on-site observation, on-site interviews. Photos have been taking of the
sedimentation lagoon and the experimental fish pond. The photos can be seen in Appendix
D of this paper.

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7.2 WATER TREATMENT PLANT OPTIONS

Based on our research, Water Treatment Plant (WTP) on sugar industries is mainly
used to treat water that is fed to their Boiler as medium to produce steam. And for their
waste water, the common type of treatment for that is the use of sedimentation lagoon.

Sedimentation Lagoon

Figure no. 11: Flood Gate of a Sedimentation Lagoon

Figure no. 12: Sedimentation Lagoon of “Mill A”

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 This sedimentation lagoon that is owned by “Mill A”, uses a total of more than 45
hectares with a series of 9 ponds and releases its final water discharge to their
experimental fishpond in order for them to prove that the water released from their
lagoon is clean enough for the fishes to live.
As you can see in the Lagoon Sedimentation Pond Layout Plan (see appendix A),
the first pond (pond 1) is elevated enough to create movement by virtue of gravity, going
to their experimental fish pond. Sampling points are also indicated in the map shown
wherein inspection personnel can identify where those critical points can be located. It is
also important for them to separate large objects from the factory through a series of
screens and overflow to avoid clogging up their ponds especially during heavy rain.

Water Treatment Plant (2 Options)

Reverse Osmosis (RO) vs. Demineralization (DM)

Both demineralized water and reverse osmosis water have their own set of
standards to be passed for their quality. DM systems do not remove much of any organic
contaminants that do not have an electronic charge thus RO does a better job of this, yet
if feedwater is fairly clear of organic fouling then RO is a tad advantageous. DM water
should pass the hardness and pH test only whereas RO water has like description, pH,
conductivity, hardness, heavy metal, iron, nitrate, sulfate, residue on evaporation,
microbial limit test etc.

DM facilities exist to generate demineralized water. The higher the feed water total
dissolved solids (TDS), the higher is the chemical consumption, in application directly into
the stream desired for correction, for regeneration. Whereas, in Reverse Osmosis, there is
no need for any regeneration. Above 500 ppm inlet water TDS, the operating cost of a
Reverse Osmosis system is lower than that of a DM system, and the cost increases with
increasing TDS for a DM plant. Therefore we should use a Reverse Osmosis system if the
inlet TDS is > 500 ppm. If the outlet water quality required is lower than that achievable in

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a single pass Reverse Osmosis system, then it is more financially beneficial to have any of
the following schemes:

Generally, RO water and DM water can both be utilized in the same applications for
broad use -- drinking and soft water common applications and a number of other uses
where contaminants of ionic maturity is undesired, however, for applications such as
creating boiler feed water, especially water for higher pressure boilers, the need for the
ability of a DM unit to create “softer” water or higher purity water is necessary. However
it is very common to use the cheaper process of RO units to then feed a high purity dm
system for final "polishing" for reduction of the overall water manufacturing cost.

RO water generation is through the method of passing raw feed water though
membrane(s) that remove ionic and several non-ionic (organic and suspended) compounds
using high pressure to force water molecules through an osmotic membrane creating an
ion rich stream on the feed side of the membrane and a purer from ion stream on the
product side of the membrane. The RO process is generally produces water continuously
but does require the system to go down intermittently over say several hours every few
weeks /months to swap membranes to treat the membrane to achieve a longer membrane
life of say ~ 3 years before total replacement. This is dependent on diverse attributes such
as production volume, quality of the feedwater (as previously mentioned above) and
desired purity level. For an industrial grade Reverse Osmosis Plant with a capacity of 20
TPH of water, cost range is usually from 2.5 to 3 Million Pesos (based on a feasibility study).

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 Figure 13: Reverse Osmosis Treatment Plant from “Mill A” (Labels were omitted
due to confidentiality issues)

DM water is created by passing raw water though demineralization beds (most

often, there are two where one is designed to remove the positively charged ions, cations,
which then leads to a second bed designed to remove the negative charged ions, anions. It
will have less "slippage" of ions than RO units creating higher purity water. Individual beds
have a fixed amount of resin which interchanges H+ and OH- for the corresponding anion
and cation in the feed water locking (temporarily) the ions on the plastic resin in the bed.
Once all the "active sites" are filled with the ions from the feedwater the bed must undergo
a batch regeneration cycle where it is flushed with a strong acid or strong bases to remove
the ions and flush the waste stream to a sewer. The units are then flushed to clear excess
caustic and acid and placed back in service.

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8 TIMELINE OF THE STUDY
Figure no. 11: Gantt Chart of the study

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9 CONCLUSION

The physicochemical value of the sugar industry effluent is very high which cross the
standard limit. If it is not treated, it affects the ecology system. Physico-chemical and biological
methods are generally used to treat the sugar industries’ effluent. The treated effluent of sugar
industries is well balanced in chemicals if it is diluted with other fresh water and can be used for
irrigation purpose. Effluents which are released from sugar industry after treatment may be
utilized for industrial processing again.

10 RECOMMENDATIONS

After a thorough analysis of data, the following recommendations are hereby made:
1. This research study suggests that every Sugar Factory should take their Waste Water
Management seriously by adopting to the advance technology and also improve
consistent maintenance. This may be a Food Factory but water analysis shows number
of heavy metal and VOC’s which is a violation to DENR when improperly discharged.
Based on our research, “Mill A” had a poor management of their waste water since most
of their discharge water had a poor separation or screening section of large object
(garbage). Another is the foul smell from their creek especially near the community,
wherein several people living nearby the creek consistently complains the foul smell
particularly during night time where the temperature drops.
2. As for the Water Treatment Plant, the study suggests that sugar factory should go with
Industrial Reverse Osmosis (RO) since Demineralization (DM) Process uses toxic
chemicals as additives and cleaning purposes unlike RO uses less additives and cost
cheaper than DM. Another thing with DM is that, as per DENR, factories with DM Plants

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 will be monitored closely due to the effluents that is being discharge by the plant. RO
also produces water that is potable and can be supplied to the workers.
3. Since all Sugar Factory are driven with Bagasse-Fired Boilers, Ash Settling Pond is also
important to avoid discharging water to their creeks with particles such as ash.
4. Also, observed in our research is the number of leaking pumps that are all washed to
their canals that contains molasses, massecuites, and lubricants which is a violation of
DENR Standards. Those should be maintained well and proper waste management
should be strictly imposed.

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11 REFERENCE

 Brown Sugar, Practical Action Technical Brief

 Honey Processing, Practical Action Technical Brief

 Candy Production, Practical Action Food Chain No 22

 Small and Medium Scale Sugar Processing Technology, Andrew Russell, Practical Action

Bangladesh, 1998

 Sugar Processing: The Development of a Third-world Technology, Raphael Kaplinsky,

Practical Action Publishing, 1984

 Cane Sugar Raphael Kaplinsky, Practical Action Publishing 1989

 Sugar Cane: The Tropical Agriculturalist R. Fauconnier, CTA/MacMillan, 1993

 https://link.springer.com/article/10.1007/s13201-015-0264-4

 https://www.ncbi.nlm.nih.gov/pmc/articles/PMC4441162/

 http://www.sra.gov.ph/policy/?tab=laws

 http://prwreri.uprm.edu/publications/A-033-PR.pdf

 http://www.icontrolpollution.com/articles/sugar-industry-wastewater-treatment-using-

adsorption-109-112.pdf

 http://www.envicaresystems.com/demineralization-water-treatment-plants-pune.html
 http://2.imimg.com/data2/VH/SU/MY-/attachment.pdf
 https://ph.answers.yahoo.com/question/index?qid=20110108033042AAUn48U
 http://www.pharmaguideline.com/2013/08/difference-between-purified-water-and-de-
mineralized-water.html

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 Schematic Diagram of Sedimentation Lagoon and Experimental Fishpond (Mill A)
12 APPENDICES

12.1 APPENDIX A (SEDIMENTATION LAGOON OF MILL A)

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12.2 APPENDIX B (SUGAR FACTORY FLOW CHART)

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12.3 APPENDIX C (DENR STANDARD TABLE)

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12.4 APPENDIX D (MILL B SEDIMENTATION LAGOON)

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