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Process Effluent Management Program

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        DISTILLERY EFFLUENT MANAGEMENT
                         &
                    CASE STUDY



                 Dated :26& 27th Feb,2011



                     Presented by:
               SIMBHAOLI SUGARS LIMITED
        AN ISO9001/ISO14001 & 22000 CERTIFIED COMPANY



About Simbhaoli Sugars
   Established in 1933.
   Operating 03 sugars & 03 distilleries in Uttar Pradesh.
   India's first 100% Sugar Refinery.
   Leading Quality manufacturer of sugar, specialty sugars, alcohols,
    liquor, CO2 , Power & Bio-manure
   An ISO 9001/ISO 14001 /ISO 22000 Certified Company.
   First Indian sugar complex having all such international
    certifications together
   Professionally managed company.
   Providing consultancy on global level for green field sugar
    complex –(Cane, sugar, distillery & Co-gen Projects, Operations,
    Maintenance , Agri –business, effluent management etc .
   Consultancy services are provide under flagship of Integrated
    case tech ( A sister company )
Our Production Capabilities
 Production Capacities
        23.43 LACS Qtls Of Sugar

        632.0 LACS Ltrs. OF RS/ENA

        540.0 LACS Ltrs. OF ETHANOL

        02 Million cases Liquor (IMFL & COUNTRY LIQUOR)
        18000 MT Carbon di Oxide

        60,000 MT Bio- mannure
           & EXPORTING 961 LACS KWHr TO UPPCL
OUR VISION

 “TO BE AN ENVIRONMENT FRIENDLY, STAKE
       HOLDER CENTRIC, INNOVATIVE,
         PROFESSIONALLY MANAGED,
  INTEGRATED SUGAR REFINING COMPANY
   WITH LOW COST GLOBAL TECHNOLOGIES
    PRODUCING RANGE OF VALUE ADDED
                PRODUCTS"
Our Strength
 Professional Management
 Team of Experienced ,qualified & devoted
  professionals
 In house expertise
 Implementation of different management tools like
  KRA, Business Plan, SWOT analysis, Quality Circle
  etc.
 Low employees turn over & In house training for
  young technocrats for their 360 degree development
 Caring of stake holders & implementation of different
  social activities
    Our Distilleries
     Capacities
      Simbhaoli                  90 KLPD
      Brijnathpur                60 KLPD
      Chilwaria                  60 KLPD

 All three units are equipped with most modern cutting edge
    technologies for Fermentation, Distillation,& Environment.

 ISO 9001, 14001 & 22000 certified .


 Producing best quality ENA, Liquors & export grade ENA


 Environment Friendly operation .
Steps to Environment Protection
 EFFLUENT MANAGEMENT PLAN
  a)   RSW followed by Bio- Methantion, Evaporation (concentration) and
       BIO COMPOSTING.
  b)   All distillation columns are equipped with Re-Boilers.
  c)   Use of 5-10 % RSW in fermenters for wort preparation.
  d)   RO reject from DM water plant is blended with Raw water in
       controlled way.
  e)   Process sludge is decanted and settled in settlers and mixed with bio-
       manure
  f)   Environmental Impacts are assessed, audited by the well qualified &
       experienced internal & external Auditors.
  g)   Ash from boilers is mixed with the bio-compost
  h)   Ground water analysis, mapping & monitoring is done by external &
       internal experts.
Environment……
 i) Energy & Effluent audit Programs
 j) Rain Harvesting
 k) Employees awareness program & training
 l) Ready to adopt improvements, modifications & new technologies
    for environment protection
 m) Full proof disposal methodology for engineering waste, scrap etc.
 n) Green belt development programs
 o) Promoting & educating the farmers for organic farming & uses of
    bio manure.
 p) Energy conservation programs
 q) Recycling of waste
 r) Periodic monitoring
 s) Medical check up programs for employees & surrounding people.
 ENVIRONMENT MANAGEMENT PLAN
ENVIRONMENTAL PROBLEMS AND CONTROL
 The Environmental problems arising out of the manufacturing process in
  the distillery plant is mostly caused due to the discharge of liquid effluent.
  The liquid effluent is mainly generated from the process system as spent
  wash and to a some extent as washings from the plant area. The spent wash
  requires special treatment before discharge. The pollution load of the
  washings is insignificant.
 In the manufacturing process spent wash releases from the bottom of
  distillation column. This is the res idual fraction of the fermentation broth
  that remains after the recovery of Alcohol. It is dark brown coloured liquid
  which contains unconverted Sugar, traces of alcohol and the yeast (left
  over's of fermented broth).
 The quantity of spent wash is depends on the amount of alcohol in the
  fermentation broth. The molasses contains large quantity of sugars other
  than easily fermentable glucose as well as some amount of polymerized
  organic compounds like caramel etc.
  Characteristics OF RSW (Raw Spent Wash)
Temperature                  50-60°C


Colour                      Dark Brown

Suspended Solids            4500-5000 mg/I

PH                          4-4.5

BOD at 20°C                 50000 mg/I
COD                         120000 mg/I

Total Dissolved Solids      90000-110000 mg/I

Total volatile Solids       45000-50000 mg/I

TKN                         800mg/I

P (as phosphate ion)        30 mg/I
Characteristics Of Anaerobic Digested Spent Wash
( PMSW)
Color                     Dark Brown

Suspended Solids          500

pH                        6.5-7.5

BOD (5 DAY AT 20°C)       6000-7000

Total Dissolved Solids    38000

TKN                       400

COD                       30,000-     35000
ALL PARAMETER EXCEPT PH
expressed as mg/I.
EMP Adopted for Zero Discharge
• Uses of Re-boilers
• Use of 5-10% RSW in fermenters
• Alcohol concentration in fermenter is maintained 8-9%
  v/v
• Recycling of water, lees in process
• RSW generation as low as 8 KL/KL of alcohol Production.
 Spent wash generated is cooled & treated in Bio Reactor .
  Bio gas is produced in the process that resulted in the
  reduction of COD by 65-70% and BOD by 90%
 Bio-methanated spent wash is settled and degasified to
  remove the dissolved gases.
EMP adopted…
 Degassed effluent is concentrated in MEE & RO plant
  (from 5 brix to 20 brix) volume reduced by 70-75%
 Concentrated effluent is sprayed on press mud to get
  bio-manure
 Effluent to Press cake ratio 1: 3
 Process sludge & boiler ash is blended with bio-compost
  to increase nutrition values of manure.
 Bio-manure is graded, packed in poly bags and
  marketed as “SOM” Brand name .
 Team of agri scientists monitor the quality of SOM
 Ground water mapping & rain water harvesting
 Green belt development.
Flow Diagram for Effluent Management

               SPENT WASH        FERMENTER


 Re-cycle
    In       BIO-METHANATION
 Cooling
water make      STORAGE &      DECANTATION
    up,      DEGASSIFICATION
Fermenter,
gardening,                       SLUDGE
   ash       CONCENTRATION
quenching
                  BIO
               COMPOSTING
Bio Compost Process
- PROCESS & EXPERIENCES
 Filler material(Press mud/boiler ash& cane yard waste)
  has generally very high affinity for water.
 Filler materials windrows of 3m x 1.5 m tall are laid on
  plot.
 Windrows are turned at least three times at a very slow
  creeping speed for homogenizing and moisture
  reduction.
 Windrows are then inoculated with microbial culture
  and well mixed.
 Temperature of windrows shoots up to 70 deg cel.
 An active windrows is daily turned and simultaneously
  sprayed with concentrated effluent
                         --2
 Moisture is maintained at 50-65% by spraying and
  turning.
 Process of turning & spraying is continued for eight
  weeks.
 Mature windrows are dried and graded .
 Shifted to packaging yard for screening and packing.
 Packed “SOM” is marketed to different agencies.
 SOM is approved by Indian & international agencies
Merits of Bio-Composting
 Proven Technology.
 Required effluent concentration up to 15-20 deg brix
  which is easily achievable.
 Energy efficient & effective process for zero discharge.
 Conversion of effluent in to good quality of organic
  manure having rich nutrients .
 Effluent consumption to filler materials is achieved in
  the ratio of 3:1 on regular basis.
 Since the process takes place on poly lined pucca yards
  therefore no chances of leaching.
 Bio manure does not give effluent colour and is eco-
  friendly.
De- merits of Bio -Composting
 Requires huge land
 Press mud is available with sugar mills only so not
  viable for stand alone distilleries.
 Needs huge labourers and material handling
  equipments.
 Process interrupted during mansoon (rainy season)
 Odors due to decomposition of organic matters .
 Needs big efforts for marketing & educating the
  farmers.
Mass balance for Bio composting
 Distillery capacity            :   90 KLPD
 Effluent Generated             :   900 KLPD
 Effluent after Evaporation     :   225 KL
  (BY MEE & RO)
 Filler Material Required       :   75 MT/DAY
 Filler Material Required       :   20,250 MT/YEAR
 Bio –manure production         :   7200 MT/YEAR
 Data are for Simbhaoli Plant
 MEE                            :   Multiple Effect
                                     Evaporators.
 RO                             :   Reverse Osrviosis
Energy Balance
 Distillery Capacity         :90 KLPD
 Effluent Generation         : 720 KLPD
 Biogas Generation           : 45,000 NM3/Day
 Steam generation on biogas : 272 TPD
 Steam Required with MEE     : 400 TPD
 Steam on supplementary fuel : 128 TPD
 Supplementary fuel required : 65 TPD
 Power Generation            : 1000 KW/hr
 Power Requirement           : 850-1000 kw/hr
THANK YOU

				
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