DISTILLERY EFFLUENT MANAGEMENT
Dated :26& 27th Feb,2011
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
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
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
“TO BE AN ENVIRONMENT FRIENDLY, STAKE
HOLDER CENTRIC, INNOVATIVE,
INTEGRATED SUGAR REFINING COMPANY
WITH LOW COST GLOBAL TECHNOLOGIES
PRODUCING RANGE OF VALUE ADDED
Team of Experienced ,qualified & devoted
In house expertise
Implementation of different management tools like
KRA, Business Plan, SWOT analysis, Quality Circle
Low employees turn over & In house training for
young technocrats for their 360 degree development
Caring of stake holders & implementation of different
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
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
e) Process sludge is decanted and settled in settlers and mixed with bio-
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 &
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
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)
Colour Dark Brown
Suspended Solids 4500-5000 mg/I
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
P (as phosphate ion) 30 mg/I
Characteristics Of Anaerobic Digested Spent Wash
Color Dark Brown
Suspended Solids 500
BOD (5 DAY AT 20°C) 6000-7000
Total Dissolved Solids 38000
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%
• 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.
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
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
water make STORAGE & DECANTATION
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
Windrows are turned at least three times at a very slow
creeping speed for homogenizing and moisture
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
Moisture is maintained at 50-65% by spraying and
Process of turning & spraying is continued for eight
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
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-
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
Process interrupted during mansoon (rainy season)
Odors due to decomposition of organic matters .
Needs big efforts for marketing & educating the
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
RO : Reverse Osrviosis
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