FORM-2
THE PATENTS ACT, 1970
(39 of 1970)
AND
THE PATENTS RULES, 2003 COMPLETE SPECIFICATION
(See Section 10; Rule 13)
1. TITLE OF THE INVENTION:
"Sugar Condensate Recovery Process (Scrp) For Heat Extraction And Recycling Of Condesate To Cooling Tower & High Pressure Boiler"
2. APPLICANT:
(a) NAME: ION EXCHAGE (INDIA) LIMITED.
(b) NATIONALITY: AN INDIAN COMPANY INCORPORATE UNDER
THE COMPANIES ACT, 1956.
(c) ADDRESS: TIECICON HOUSE,
DR. E. MOSES ROAD, MAHALAXMI, MUMBAI-400 011, MAHARASHTRA, INDIA.
The following specification describes the nature of the invention and the manner in which it is to be performed:-

IREMBLE TO THE DESCRIPTION
Field of Invention
The present invention relates to a method to treat sugar condensate through biological and demineralization based process and to apparatus for carrying out the method. Embodiments of the invention relates to the method for the treatment and the operation of the biological and the demineralization process through which it is possible to recover the heat as well as water for use in boiler and cooling tower make up.
Background of the Invention & the Related Art
In the recent years, the water bodies have been contaminated due to the discharges of huge effluent from industries. Also the present water available in the country is not enough to fulfill the present demand. Therefore it becomes necessary in the present scenario to recover the energy and recycle effluent to the maximum extent possible.
The sugar industry generates huge quantity of effluent which is rich in organics and if discharged in the water bodies leads to depletion of dissolved oxygen thereby disturbing the ecological cycle prevailing there. Moreover a lot of heat is lost in the environment along with the effluent. The effluent is rich in organics and low in dissolved solids. Present practice is to treat this effluent along with other effluents and discharged. This effluent, if recycled will help in reducing the water consumption as well as preserving the water bodies.

Currently there is no method to treat the sugar condensate effluent by biological process and recycle it to boilers or cooling tower water including heat recovery. In contrast to prior process for sugar condensate recovery, it is proposed under current invention, a process for treatment and recycling of sugar condensate for boiler feed and cooling tower make up along with heat recovery. The process results in conversion of organics into useful well digested biomass which can be utilized as fertilizer in field.
4. DESCRIPTION OF THE INVENTION
SMMARY OF THE INVENTION
The invention described herein is a process of treating sugar condensate effluent rich in organics and nitrogen and recycling it for high pressure boiler and cooling tower make up. The process also involves recovery of heat thereby reduction in the fossil fuel consumption and reduction in green house gases. The multi step process involves reduction of condensate temperature with the help of heat exchanger, removal of TKN and organics by biological process, disinfection by oxidizing agents, and removal of suspended solids by media filter, polishing by activated carbon filter, demineralization by ion exchange resins or reverse osmosis membranes or electro-deionization units and raising temperature by heat exchanger. The novel process leads to more than 95% recovery. Based on the application, the treatment units can be reduced like if one wants to utilize the water for CT make up, the treatment will be limited to media filters.

DETAILED DESCRIPTION OF THE INVENTION
DESCRIPTION OF FIGURE:
Sugar condensate recovery unit schematic
1. Heat Exchanger.
2. Equalization Tank.
3. Biological reactor.
4. Media filter feed tank.
5. Media filter.
6. Activated carbon filter.
7. Demineralization unit.
8. Backwash pit.
In the invention under consideration, a new process for the treatment and recovery of sugar condensate rich in organics and other impurities is developed. The process has been thoroughly tested and has shown that it is capable of converting the sugar condensate to pure water suitable for feeding to boilers including heat recovery, cooling towers make-up water and any other suitable applications.
The sugar condensate in first stage, provided air stripping to remove dissolved gases and to stabilization of organics.
The second step is the reduction of temperature with the help of heat exchanger (1) such as utilizing the low temperature pure water or treated water outlet if it is for

boiler application. If the water is to be utilized for other applications, the cooling can be done by boiler feed water and the heat can be recovered. This will lead to decrease in fuel consumption required to raise the temperature of boiler feed water to such level.
The third step is removal of organics and total nitrogen in the biological reactor (3). This can be achieved by utilizing anaerobic/ anoxic/ aerobic biological process in single and /or two stages.
The fourth step involves, disinfecting the liquid with the help of oxidizing agents (4) in media filter feed tank.
The fifth step utilizes the media filtration (5) or self cleaning filters (e.g. Amiad) or polymer based filters ( microfiltration / ultrafiltration membranes) for removal of the suspended solids and the activated carbon filters (6) for the removal of trace organics escaping biological reactor.
The sixth step involves removal of dissolved minerals with the help of ion exchange resins / reverse osmosis membranes / electrodeionization units (7).
The final step involve raising the temperature of treated sugar condensate with the help of heat exchangers (1) by extracting heat from incoming hot sugar condensate effluent.
The backwash effluent generated during cleaning of media filter and activated carbon filter is collected in a backwash pit (8) and recycled back to equalization tank (2).

EXAMPLE
In order to ensure the efficacy of the proposed process piloting studies were conducted in M/s. Bannari Amman Sugar Limited, Sathymangalam, Erode (Tamil Nadu) and M/s Bhimashankar Sahakari Sakhar Kharkhana Ltd, Pargaon ,Pune (Maharashtra).
The sugar condensate was passed through the heat exchanger to bring down the temperature from 85 deg C to 35 deg C. The treated sugar condensate outlet whose temperature was ranging between 25°C to 27°C was utilized for extracting heat from hot condensate. The cooled condensate was stored in equalization tank for homogenization.
The homogenized effluent was then treated through different combination of biological reactors (anaerobic, aerobic, & anoxic) to bring down the organics and nitrogen content. The different type of reactors like fluidized media reactors; membrane bioreactors; sequencing batch reactors etc. were tried. It was observed that, the reduction and the quality of the treated effluent was almost similar for all types of reactors.
The effluent after organic and nitrogen removal was treated after disinfection to get rid of suspended solids and traces of organics.
The filter outlet was than treated through ion exchange units for the removal of dissolved minerals and produce demineralized water suitable for feeding to high pressure boilers. The quality of sugar condensate before and after treatments is shown in table 1.

Table 1: Characteristics of sugar condensate before and after treatment

SR. NO. PARAMETERS UNIT BEFORE TREATMENT AFTER TREATMENT
1 pH — 7.0-8.6 6.0-7.0
2 Conductivity µS/cm Up to 200 <0.5
3 Total dissolved solids mg/L 70- 120 Not detectable
4 Temperature °C 65-85 65-85
5 Chemical oxygen demand mg/L 400-1100 Not detectable
6 Total Nitrogen as N mg/L 60 Not detectable
7 Silica mg/L 4 < 0.015

5. We claim:
1. Sugar condensate recovery (SCR) process for treating and recycling organics rich sugar condensate to high pressure boiler including heat recovery & cooling tower make up water and household applications.
2. Sugar condensate recovery (SCR) process for treating and recycling organics rich sugar condensate to high pressure boiler including heat recovery & cooling tower make up water and household applications as claimed in claim 1, the major contaminants in sugar condensate being dissolved organics and the organics being removed by the biological degradation ,chlorination and filtration processing.
3. Sugar condensate recovery (SCR) process for treating and recycling organics rich sugar condensate to high pressure boiler including heat recovery & cooling tower make up water and household applications as claimed in claim 1 & 2, having under the next step of removal of dissolved minerals by demineralization processes like ion exchange resins, reverse osmosis membranes, electrodeionization etc.
4. Sugar condensate recovery (SCR) process for treating and recycling organics rich sugar condensate to high pressure boiler including heat recovery & cooling tower make up water and household applications as claimed in claim 1, 2 & 3, having under the second step treated sugar condensate outlet from ion exchange process again sent to heat recovery for exchange of heat from hot sugar condensate for boiler feed water..
5. Sugar condensate recovery (SCR) process for treating and recycling organics rich sugar condensate to high pressure boiler including heat

recovery & cooling tower make up water and household applications as claimed in claim 1, 2, 3 & 4, being the process able to remove the dissolved organics and dissolved solids to meet the high pressure boiler feed water and cooling tower make-up water including heat recovery so that the process scheme being used economically.
6. Sugar condensate recovery (SCR) process for treating and recycling organics rich sugar condensate to high pressure boiler including heat recovery & cooling tower make up water and household applications as claimed in claim 1, 2, 3, 4 & 5, having the combination of biological and ion exchange, reverse osmosis, electrodeionisation processes for the treatment of sugar condensate.
7. Sugar condensate recovery (SCR) process for treating and recycling organics rich sugar condensate to high pressure boiler including heat recovery & cooling tower make up water and household applications as claimed in claim 1, 2, 3, 4, 5 & 6, having after treatment of hot sugar condensate using above processes, can be used for Boiler make-up water, cooling tower or any other application without significant loss of heat.