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Sugar Industry

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Effluents from sugar industry typically have biochemical oxygen demand (BOD) 1,700-6,600 milligrams per liter (mg/L) in untreated effluent from cane processing and 4,000-7,000 mg/L from beet processing, COD 2,300-8,000 mg/L from cane processing and up to 10,000 mg/L in beet processing, total suspended solids up to 5,000 mg/L, and high ammonium content. The wastewater may contain pathogens from contaminated materials, fly ash, unburnt bagasse, carbon particles, lime sludge and press mud, etc. A sugar mill often generates odor and dust, which need to be controlled. Most of the solid wastes can be processed into other products and by-products. Pretreatment of effluents consists of screening and normally followed by biological treatment. Other possible biological treatment systems include activated sludge and anaerobic systems which can achieve a reduction in the BOD level of over 95%. Anaerobic bacteria break down organic material in the absence of oxygen and produce biogas as a waste product. Waste sludge and sludge from filter press normally deposited to sludge yard. Biogas flare is used to burn residual gases. This effluent treatment is done by using anaerobic treatment followed by aerobic treatment, after filter press sludge is sent to disposal yard. The characteristics of discharge effluent vary, depending on the product manufactured, the materials used in the process, and the other process details. The typical characteristics of discharge effluent for chemical industries are listed in the table below:

Sr. No. Parameter Unit Concentration range
1 Color - Gray, thick black
2 Temperature ºC 30.5
3 pH - 8.30
4 Oil/Grease mg/lit 60
5 Total suspended solid mg/lit 792-2043
6 BOD mg/lit 667-1660
7 COD mg/lit 890-2260


Problems in ETP:

  • More chemical usage for neutralization
  • High concentration of readily decomposable organic matters
  • Foul smell due to decomposition of soluble and suspended organic matters present in the wastewaters
  • Presence of refractory compounds
  • High operating treatment cost
  • Low yield of biogas due to byproducts

HyCator® Reactor Systems for Sugar Industry

HyCa Technologies have a range of products which are environmentally safe and cost effective for effluent treatment of Sugar Industry. We generally suggest HyCator® reactor systems to effluent treatment plants in the following manners but it varies as per the client requirements and limitations.


The applications of HyCator® reactor at effluent treatment plant are listed below:

  1. HyCator® MBD will increase digestibility of the effluent in UASB digestor and aerator by breaking long-chain / polymeric/ refractory compounds and thus reduce the COD and increase the Biogas production. HyCator® MBD can also be installed in the inlet effluent streams (High load) / neutralization tank or recycle stream of effluent, if any.
  2. HyCator® OLM will ensures energy efficient, precise, microlevel, online mixing even at very high flows. It will help to reduce the chemicals in neutralization and subsequent processes.
  3. HyCator® DOB will increase the dissolved oxygen content in aerator tanks in compared to conventional surface aerator or diffused aerator and also increase the activity of microbes by de-flocking it. Thus results in reduction in sludge generation, hence lesser load on clarifiers and less solid disposal issues.

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