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
Slide2Outline
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
Slide3Sugar 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
Slide4Sugar 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
Slide5The 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
Slide6Composition of a Typical Sugarbeet
Slide7The 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
Slide8The 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
Slide9The 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
Slide10The 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
Slide11Typical 1900 Era Sugar Refinery
Source: Silver Wedge: The Sugar Beet Industry In Fort Collins, SWCA Environmental Consultants, 2003
Slide12Wastewater 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
Slide13Typical Flow Patterns at Sugar Refinery
Campaign Driven – September to April
Slide14Regulatory 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
Slide15Regulatory 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
Slide16Client 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?
Slide17Mass Balance Approach
Simplest Mass BalanceUnfortunately It’s not that Simple
Slide18Mass 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
Slide19Mass Balance Inputs – Internal to Process
SO
2
and Sulfamic Acid:
S, TDS, N
Gypsum
TDS, S
Limestone, Soda Ash & Caustic
TDS, TSS, S
Slide20Mass Balance Outputs
Evaporation
Mud, condenser, and
a
sh ponds
Granulator drier
Seepage
Mud,
condenser, and ash ponds
Discharge
Flue gas
Pressed mud
Slide21Mass Balance Outputs (cont.)
Products
Processed Sugar
Molasses
Pressed PCC (animal feed byproduct)
Slide22Mass Balance Software
Slide23WaterTracker Top Level View
Slide24WaterTracker Process Level View
Slide25Recycle 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
Slide26Results of Water Recycling and Conservation
Slide27Questions and Answers
Questions
Ray Hamilton – 303-975-2195 or
ray.hamilton@amec.com