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DISCHARGE OF
MOLASSES EFFLUENT
(A Case History of Radico Khaitan Ltd)
By K .P. SINGH
DISTILLERIES
Radico
has Molasses Spirit ,
Grain
Spirit
&
Malt
Spirit
Production.
IMPROVEMENTS IN
FERMENTATION
Cooling of Wort through Heat Exchangers.
Cleaning of Fermenters through Spray
balls water jet.
Temp. indicators on each Fermenter.
Use of cleaning agents for maintaining
aseptic conditions after washing of
Fermenters through CIP system.
Adequate nutrient dosing for facilitating
quick fermentation.
Radico Khaitan
Limited
(Rampur Plant)
DESIGN BASIS
(DISTILLATION WITH INTEGRATED RAW SPENT WASH EVAPORATION)
S.
NO.
1.
DESCRIPTION
DISTILLATION PLANT
WITH INTEGRATED EVAPORATORS
7.
8.
PLANT OPERATION
2.
3.
4.
5.
6.
QUANTITY
180 KLPD
EFFLUENT MANAGEMENT
(REDUCE, RECYCLE & REUSE
EFFLUENT)
GURANTEED PARAMETERS
FEED TO THE EVAPORATOR
INITIAL SOLIDS CONCENTRATION
STEAM CONSUMPTION
FINAL SOLIDS CONCENTRATION
WATER EVAPORATION DUTY
TOTAL PROCESS CONDENSATE
GENERATED FROM EVAPORATION
PLANT
POWER CONSUMPTION
TPD
%W/W
MT/KL
%W/W
TPD
VALUE
S
1690
12
3.4
22
760
TPD
760
KWH
180
UNIT
HIGHLIGHTS OF INTEGRATED
RAW SPENT WASH
EVAPORATION
THERE ARE TWO OPTIONS OF EVAPORATION :
1. EVAPORATION OF SPENT WASH THROUGH INTEGRATED / STAND
ALONE EVAPORATORS.
2.
ADOPTED
INTEGRATED EVAPORATORS OF
Process Pumps
From All Sections
Make up
Tank
Make up
CWR
Vacuum Pump
/
Air Blower
Cooler
Tank
CWS
OVERHEAD COOLING
TOWER FOR ENERGY
SAVING
DESCRIPTION
Permeate
Anaerobic
Digesters
BOD REDN-88%
COD REDN67%
930 M3/d
COD63,000 Mg/L
Challenges
/
Initiatives
1. High TSS in
Digester
Outlet .
2. Low Efficiency of RO
System due to High
TSS in Digester
Outlet effluent.
3. Permeate recovery
only about 45%.
New
1. Installation of Degasser
and Series of Clarifiers
with Filter press.
2. Addition of Special Polyelectrolyte for better
settling and Series of
Lamella Clarifiers
Followed by DAF System.
3. Achieving Up to 60%
high grade permeate
recovery after adopting
above systems.
Molasses
Distilleries
face
problem in
BioComposting
in Rainy
season.
Covered Bio-Composting
TO
1.
Rectification, Pre-rectifier
column Lees Recycle
Fermentation
90% recovery
2.
Fermentation
90% recovery
3.
Steam Condensate
Recycle
Boiler
90% recovery
4.
Process Condensate
recycle
Fermentation
95% recovery
5.
Fermentation
98% recovery
6.
RO Permeate recycle
Cooling tower
and Gardening
45% recovery
Pre-rectifier &
Rectification column
Lees
Vacuum Pump water
Steam Condensate
Process Condensate
RO Permeate
Water
Consumption / BL
18.0
12.0
7.0
Compliance of CPCB
Directives
Volume Reduction through Integrated
Evaporators ( 40-45%) and through R
O Plants (60%). Over all volume
reduction more than 75%.
Covered Bio-composting under Poly
Shed for Composting in rainy season.
Usage of lesser polluted streams in
Fermentation, Cooling Tower make up
and Gardening.
Energy Conservation
Installation of VAM Integrated Chilled
Water System for air conditioning
requirement from Bio-Gas Engines.
Installation of Temperature Sensors at
Cooling Tower Tans to save the power
during winter season.
Timer installation on Street and Plant
Lights .
Replacement of copper chocks with
electronic chocks.
R O Plant Radico
R O Plant
Covered Bio-Composting
Bio Engine
THANK YOU