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Process Modeling and Mass Balance Analysis using KBC WaterTracker Process Modeling and Mass Balance Analysis using KBC WaterTracker

Process Modeling and Mass Balance Analysis using KBC WaterTracker - PowerPoint Presentation

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Process Modeling and Mass Balance Analysis using KBC WaterTracker - PPT Presentation

Software for Wastewater Discharge Improvements and Water Conservation at a Colorado Sugar Refinery Presented by Ray Hamilton PE BCEE AMEC Environment amp Infrastructure Inc Denver CO ID: 759224

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Slide1

Process Modeling and Mass Balance Analysis using KBC WaterTracker® Software for Wastewater Discharge Improvements and Water Conservation at a Colorado Sugar Refinery

Presented by Ray Hamilton, PE, BCEEAMEC Environment & Infrastructure Inc., Denver, CO

April, 11

,

2014

PWO Industrial Wastewater

Seminar

Golden, CO

Slide2

Outline

History of Sugar Refineries in Colorado

Overview of Sugar Processing

Existing Wastewater Disposal System

New Regulatory Environment

Mass Balance Model Development

Existing System for Calibration

Proposed System

Summary and Questions

Slide3

Sugar Refineries in Colorado

Colorado “Sandwiched” Between Utah and Nebraska

1890s - Sugarbeets grown in Colorado shipped to Utah or Nebraska for processing

1899 – Colorado’s first sugar refinery opened in Grand Junction

Early Colorado Plains Sugar Refineries

1900 –

Rocky Ford and Sugar City in the Arkansas River valley of SE Colorado

Slide4

Sugar Refineries in Colorado (cont.)

Production Moves to the Front Range

1901 First Front Range sugar refinery opens in Loveland

1903 new sugar refineries in Windsor and Greeley

1904 Fort Collins and Eaton

1905 Sterling and Brush

1906 Fort Morgan

Boom and Bust leads to 23 Colorado sugar refineries

Slide5

The Sugarbeet

Sugarbeet has Three Parts

Central Root – stores sugar

Taproot – supplies moisture and minerals

Top – Photosynthesis provides energy

Sugar in Two Forms

Monosaccharide sugar, C

6

H

12

O

6

disaccharide

sugar C

12

H

22

O

11

Ideal Beet is 2 Pounds and >17% Sugar

Slide6

Composition of a Typical Sugarbeet

Slide7

The Sugar Refining Process

Beet Washing

Removes dirt and other field debris

Slicing

Produces “cossettes”

Diffusion

Hot water soaking produces “juice”

Still contains other beet products and impurities

Slide8

The Sugar Refining Process (cont.)

Liming and Pressing

High pH precipitates impurities

Filtration separates impurities

Recarbination and Filtration

Lowers pH

Removes dissolved lime

Precipitates calcium carbonate

Second filtration removes calcium carbonate

Slide9

The Sugar Refining Process (cont.)

Acidification and Filtration

Sulfuric acid to balance and bleach

Third filtration produces “standard liquor”

Sugar content of standard liquor

+

50%

Evaporation and Condensation

Series of evaporators to drive off water

Condensers cool and recycle water

Slide10

The Sugar Refining Process (cont.)

Crystallization

Super saturated solution put under vacuum to crystallize sugar

Separation

Centrifuge spins out sugar

Filtrate is “molasses”

Purified sugar dried and packaged

Slide11

Typical 1900 Era Sugar Refinery

Source: Silver Wedge: The Sugar Beet Industry In Fort Collins, SWCA Environmental Consultants, 2003

Slide12

Wastewater Discharges at Sugar Refinery

Major Sources of Wastewater

Mud from beet washing

Condenser water

Pressed calcium carbonate

Boiler blow-down to ash pond

Historic Discharge to Unlined Ponds

Evaporation and seepage

Integral part of water rights adjudication

Slide13

Typical Flow Patterns at Sugar Refinery

Campaign Driven – September to April

Slide14

Regulatory Concerns

Discharge to Groundwater

Groundwater standards apply

Total coliform standard – as if water supply

High Mn

++

levels in ash

Source well water above TDS standard

Potential nitrite/nitrate problems

Pond Seepage to South Platte River Alluvial Flow

Water Rights Issues Ignored

Slide15

Regulatory Concerns (cont.)

CDPHE Applied Surface Water Standards to Groundwater Discharge

South Platte River standards

EC/TDS/SAR limits controlled by downstream bean farmers

New ammonia limits

Measured as Weighted Average of In-Pond Values and Pond Influent Flows

Seepage does not equal influent

- biasing

mass based parameters (BOD5 and TSS)

No credit for effects of filtering through pond bottom

Slide16

Client Concerns

Water Rights

High Cost of Treatment

Low Hanging Fruit

PCC Press eliminated all liquid discharge to PCC pond

Mud Press significantly reduces flow to mud pond

How Much More Can be Saved with Water Recycling and Water Conservation?

Slide17

Mass Balance Approach

Simplest Mass BalanceUnfortunately It’s not that Simple

Slide18

Mass Balance Inputs – External to Process

Beets:

Sugar, TDS, TSS, N, H

2

O

Water Supply (wells and ditch):

TDS, N-NO

3

, H

2

O

Stormwater/Snow Runoff:

TDS, TSS

H

2

O

Coal:

TDS, TSS, N, S, Mn

Slide19

Mass Balance Inputs – Internal to Process

SO

2

and Sulfamic Acid:

S, TDS, N

Gypsum

TDS, S

Limestone, Soda Ash & Caustic

TDS, TSS, S

Slide20

Mass Balance Outputs

Evaporation

Mud, condenser, and

a

sh ponds

Granulator drier

Seepage

Mud,

condenser, and ash ponds

Discharge

Flue gas

Pressed mud

Slide21

Mass Balance Outputs (cont.)

Products

Processed Sugar

Molasses

Pressed PCC (animal feed byproduct)

Slide22

Mass Balance Software

Slide23

WaterTracker Top Level View

Slide24

WaterTracker Process Level View

Slide25

Recycle Alternatives Modeled

Separate Fly Ash from Bottom Ash

Closed Loop Condenser Circuit with Cooling Tower

Mud Press Enhancements

Internal Redirection of Process and Waste Streams

Slide26

Results of Water Recycling and Conservation

Slide27

Questions and Answers

Questions

Ray Hamilton – 303-975-2195 or

ray.hamilton@amec.com