HomeApplications of Ozone & Ozone GeneratorsCONPOLAX AOP – Ozone for Treatment of Excess Sugar Condensates

CONPOLAX AOP – Ozone for Treatment of Excess Sugar Condensates

ORAIPL can design, manufacture and install CONPOLAX AOP, an advanced Ozone based system for the effective treatment and recovery of excess sugar condensates, and wastewater in the sugar mills and sugar industry.

CONPOLAX AOP - Ozone based System for Treatment and Recovery of Excess Sugar Condensate in Sugar Industry
The sugar industry, a vital component of the global economy, processes vast quantities of sugarcane and sugar beets to produce crystalline sugar. This process generates significant amounts of wastewater and condensates laden with various pollutants. If not treated properly, these pollutants can severely impact the environment. Ozone-based Advanced Oxidation Processes (AOP), particularly the CONPOLAX process, have emerged as effective methods for degrading pollutants in these streams, offering a robust and sustainable approach to wastewater treatment and enabling the condensate recovery and reuse of treated water.

Why sugar condensate water cannot be reused directly, without treatment

Direct reuse of sugar condensate water without treatment in the sugar industry is problematic due to several reasons:

  1. High Organic Content:
    • Sugar condensate water contains high levels of organic matter, including residual sugars and organic acids, which can lead to microbial growth and biofouling in equipment and pipelines, affecting process efficiency and product quality.
  2. Presence of Phenolic Compounds:
    • Phenolic compounds originating from the degradation of lignocellulosic materials are present in sugar condensate water. These compounds can impart undesirable flavors and odors to the final sugar product and can be toxic to aquatic life if discharged untreated.
  3. High Biochemical Oxygen Demand (BOD) and Chemical Oxygen Demand (COD):
    • The condensate water has high BOD and COD levels, indicating the presence of substantial amounts of biodegradable organic matter. High BOD and COD can deplete oxygen levels in receiving water bodies, leading to environmental issues such as eutrophication.
  4. Inorganic Contaminants:
    • The condensate may contain inorganic salts and metals that originate from the raw materials and processing chemicals. These contaminants can cause scaling and corrosion in equipment, leading to increased maintenance costs and reduced operational efficiency.
  5. Microbial Contamination:
    • Untreated sugar condensate water can harbor a variety of microorganisms, including bacteria, yeasts, and molds. These microorganisms can proliferate during storage and reuse, posing risks to both process hygiene and product safety.

Proper treatment of sugar condensate recovery water is necessary to address these issues, ensuring that the water meets quality standards for reuse and does not negatively impact the sugar production process or the environment.

Ozone-Based Processes in Sugar Condensate Recovery and Treatment

Ozone-based processes utilize ozone (O₃) as a potent oxidizing agent to degrade organic and inorganic pollutants. The effectiveness of ozone stems from its ability to decompose in water, forming highly reactive hydroxyl radicals (•OH) that can break down a wide range of pollutants. One of the advanced ozone-based AOPs is the CONPOLAX process.

CONPOLOX - Sugar Condensate Treatment with Ozone by ORAIPL
The CONPOLAX AOP Process

CONPOLAX stands for Continuous Ozone Process with Liquid-phase Oxidation and Advanced Extraction. It is a sophisticated ozone-based AOP designed specifically to handle the complex pollutant mixtures found in industrial wastewater, such as that from sugar mills. The CONPOLAX process involves several key stages:

  1. Pre-Treatment:
    • The wastewater undergoes preliminary filtration to remove large particles and debris, ensuring the efficient operation of subsequent stages.
  2. Ozonation:
    • Ozone is introduced into the wastewater stream using specialized diffusers that ensure optimal mixing and contact between ozone and the pollutants.
    • Ozone decomposes in water to form hydroxyl radicals, which initiate the oxidation of organic compounds.
  3. Oxidation:
    • The generated hydroxyl radicals attack the organic pollutants, breaking them down into smaller, less harmful molecules.
    • Intermediate products formed during this stage are further oxidized until they are completely mineralized into carbon dioxide, water, and inorganic salts.
  4. Advanced Extraction:
    • The oxidized wastewater undergoes a final treatment phase where remaining pollutants and by-products are extracted using advanced filtration and separation techniques.
  5. Post-Treatment:
    • The treated water is subjected to final polishing steps, such as activated carbon filtration or UV treatment, to ensure complete removal of any residual contaminants before discharge or reuse.

Advantages of CONPOLAX AOP

  1. High Efficiency:
    • The CONPOLAX process achieves high levels of pollutant degradation, often leading to complete mineralization of organic compounds.
  2. Broad Applicability:
    • It is effective against a wide range of organic pollutants, including those typically found in sugar mill condensate streams.
  3. Minimal Sludge Production:
    • Unlike conventional biological treatment methods, CONPOLAX generates minimal sludge, reducing the need for sludge handling and disposal.
  4. Scalability:
    • The process can be adapted for both small-scale and large-scale operations, making it suitable for sugar mills of varying capacities.
  5. Enhanced Process Control:
    • The continuous nature of the CONPOLAX process allows for precise control over treatment parameters, ensuring consistent and reliable performance.
  6. Environmental Benefits:
    • By effectively degrading pollutants, the CONPOLAX process reduces the environmental impact of sugar mill wastewater, contributing to a cleaner and more sustainable industry.

Sample Photo - CONPOLAX AOP For Sugar Industry
Benefits of CONPOLAX for Sugar Condensates Recovery and Treatment

  1. Water Reclamation:
    • The CONPOLAX process produces high-quality treated water that can be reused within the sugar mill for various purposes, such as cooling, irrigation, and process water, reducing the demand for fresh water.
  2. Resource Conservation:
    • Reusing treated condensates helps conserve natural water resources, an essential consideration in regions facing water scarcity.
  3. Cost Savings:
    • By reusing water, sugar mills can significantly reduce their water procurement and wastewater discharge costs, leading to overall cost savings.
  4. Compliance with Regulations:
    • Treated water that meets regulatory standards can be safely discharged or reused, helping mills comply with environmental regulations and avoid potential fines.
  5. Sustainability:
    • Implementing water reuse practices contributes to the sustainability goals of the sugar industry by minimizing waste and promoting the efficient use of resources.

Reduction in Pollutants in Sugar Condensates after CONPOLAX AOP Ozone Treatment
Mechanism of Pollutant Degradation in CONPOLAX

The CONPOLAX process relies on the generation of hydroxyl radicals, which are highly reactive and capable of breaking down complex organic molecules. The primary steps include:

  1. Ozone Decomposition:
    • Ozone introduced into the wastewater decomposes in water to form hydroxyl radicals.
    • O₃ + H₂O → 2 •OH + O₂
  2. Radical Attack:
    • The hydroxyl radicals attack the pollutant molecules, initiating oxidative reactions that break down the organic compounds.
    • Pollutant + •OH → Intermediate Products → CO₂ + H₂O + Inorganic Salts
  3. Complete Mineralization:
    • Through a series of oxidation reactions, the intermediate products are further broken down until complete mineralization is achieved, resulting in environmentally benign end products.

ORAIPL’s CONPOLAX AOP – A Superior Condensate Recovery and Treatment  Solution for Sugar Mills

The CONPOLAX process represents a significant advancement in the recovery and treatment of pollutant-laden condensate streams in sugar mills. Its ability to effectively degrade a wide range of organic pollutants with minimal sludge production and enhanced process control makes it an attractive option for the sugar industry. Additionally, the benefits of reusing treated condensates further enhance the sustainability and economic viability of sugar mills. As technology advances and process optimization continues, the CONPOLAX process has the potential to become a standard practice in industrial wastewater treatment, promoting a cleaner and more sustainable future for the sugar industry and beyond.

ORAIPL can design, manufacture and install CONPOLAX AOP systems for any size sugar mill. We also manufacture Ozone based systems for Whitening of Sugar Liqueurs. Get in touch with us today for a FREE Quote.