STATUS OF EFFLUENT TREATMENT

IN
DISTILLERY INDUSTRY IN INDIA
Abhay Chaudhari,
Praj Industries Limited
26
th
Feb, 2011
Alcohol Industry-
Then and Now.
Historic Roundup....
Indian Alcohol Industry Year 1985
Fermentation Process Practices in 1985
Fermentation
Process
Fermentation
Efficiency
Alcohol
Concentration
Batch Type
conventional
8286 %
6-7 % v/v
Recycling of Spent
wash
No recycling
Molasses
Composition
Detailed analysis was not
utilized for
optimizing process
Waste Water
Generation
Not accounted
Fermentation Process Practices in 1985
Control Over
Contamination
Not monitored
Only molasses
Feedstock
Not practiced
Distillation Process
Distillation Efficiency
Product Preference
Automation
Atmospheric
Direct steam injection;
No reboiler
97-98 %
Rectified Spirit
Distillation Process Practices in 1985
30-40 % of
total alcohol for ENA
Plant Type
Focus on Energy
Conservation
Steam
Consumption
TA cut
Single Product
RS or ENA
NO
Distillation Process Practices in 1985
5.5 - 6 Kg / Ltr of
Alcohol for ENA
Spent Lees
PRC/RC Lees
FOC Lees
Spent Wash from
distillation
Fresh Water
Requirement
Utilities and Other
Waste Streams
14-15 Ltrs / Ltr
of alcohol
30-35 Ltrs / Ltr
of alcohol
Drained off
Distillation Process Practices in 1985
Drained off

Fermentation section
Fermentor cleaning water
Pump Sealing water
Floor Washings water
Process Air Blower Sealing water

Distillation Section
Molasses based Plant- Spent Wash
Grain based plant Thin slops
Spent Lees
Vacuum Pump Sealing Water
Other cleaning water

Liquefaction Section (For Grain Plants only)
Pump Sealing water
Floor Washing water
Other cleaning water
Waste Water Streams To Tackle With.
No solution
Spent Wash
Treatment Options
ZLD Solution
Lagooning
Katcha pit
Ferti irrigation
Not practiced
PRC/RC and FOC Lees
treatment
Utilities Reject and
Other streams
ETP Options Practices in 1985
Not practiced
Status of Indian Alcohol Industry

Year 2010
Fermentation Process Practices in 2010
Fermentation Process
Fermentation
Efficiency
Alcohol
Concentration
Recycling of Spent
wash
8890 %
8-10 % v/v
Recycled
(Quantity depends on
quality of molasses)
Flexi mode
Continuous / Fed Batch
(depending on molasses quality)
Molasses Composition
Waste Water
Generation
Accounted ;
Recycled and Reused
Fermentation Process Practices in 2010
Control Over
Contamination
Multi feed
Molasses, grain
Feedstock
Monitored regularly
Detailed analysis is
utilized for
process design
Available & Practiced;

Distillation Process
Distillation Efficiency
Product Preference
Automation
Multi pressure-
Heat integration-
Use of reboiler
98.5 %
Extra Neutral Alcohol ;
Absolute Alcohol
Distillation Process Practices in 2010
5-8 % of total alcohol
for ENA
Plant Type
Focus on Energy
Conservation
Steam Consumption
TA cut
Multi Product
RS / ENA / AA
YES
Distillation Process Practices in 2010
3.2 3.5 Kg / Ltr of
Alcohol for ENA
Spent Lees
PRC/RC Lees
FOC Lees
Spent Wash from
distillation
Fresh Water
Requirement
Utilities and Other
Waste Streams
Accounted;
treated and recycled
to process
7-10 Ltrs / Ltr
of alcohol
13-16 Ltrs / Ltr
of alcohol
Distillation Process Practices in 2010
treated and recycled
to process
Spent Wash Treatment
Options
Partly recycled
Biomethanation followed
by volume reduction and
followed by composting
Concentration & Incineration
Treated and recycled
PRC/RC and FOC Lees
treatment
ETP Options Practices in 2010
Thin Slop
Treatment Options
Partly recycled
Biomethanation followed by
secondary & tertiary
treatment followed by
land application
Concentration and drying
ZLD Solution
Utilities Reject and
Other streams
ETP Options Practices in 2010
treated
and recycled
Available
Evaporation Process
Condensate
treated
and recycled
So.


Growth of Alcohol Industry is largely driven
by Innovative Technologies..!!
Alcohol Industry Adopting Innovative Solutions

Paradigm Shift
Technology
Feedstock preference
Energy Consumption
Effluent volume and handling
ETP solutions to meet Zero Liquid Discharge (ZLD) norms

Molasses still a preferred feedstock

Multi feedstock option - to overcome feedstock constraints

Adaptation of various ETP options for environmental concerns

Focus largely shifted on energy conservation, lowering water
foot print by reduce, recycle and reuse!!
Alcohol Industry - Molasses and Grain Plants
Today

focus for multi feed plant
Grain & molasses

Installed base major
locations :

Maharashtra
UP
Karnataka
Tamil Nadu
Punjab
368 units
192 units
Today

Grain plants contribute
25% to total operating
base in India

Grain Plants - Major
Locations:

Maharashtra
Andhra Pradesh
MP
Punjab
Alcohol Industry Installed Base
Figures in Million Ltrs
5.3 Billion Ltrs
1.9 Billion Ltrs
Today

Standalone Distilleries =
34% of total molasses
base

Standalone units Major
Locations:

Karnataka
Tamil Nadu
Maharashtra
UP
Molasses Distilleries - Attached & Standalone
295 Units
192 Units
Today

Grain plants contribute
29% to total alcohol
production in India

Grain Plants - Major
Locations:

Maharashtra
Andhra Pradesh
MP
Punjab
Alcohol Industry Production Growth
Figures in Million Ltrs
2.7 Billion Ltrs
1.0 Billion Ltrs
Today

Thin Slop generation =
7 Ltrs/ Ltr of alcohol

S/W generation=
8 Ltrs/ Ltr of alcohol

Adaptation of various ETP
solutions for s/w or thin
slop volume reduction

Alcohol Industry - Spent Wash Generation
Figures in Million Ltrs
15 Billion Ltrs
28.5 Billion Ltrs
1990- S/W quantity = 15 Ltrs/Ltrs of alcohol
Alcohol Industry Fresh Water Requirement
Figures in Million Ltrs
34 Billion Ltrs
62.5 Billion Ltrs
1990- fresh water req. = 34 Ltrs/Ltrs of alcohol
Today

Fresh Water requirement=
18 Ltrs/ Ltr of alcohol for
molasses plant

Fresh Water requirement=
13 Ltrs/ Ltr of alcohol for
grain based plant

Reduce, recycle and reuse
options for fresh water
requirement in distillery


Distillery effluents can be treated by a number of methods,
either singly or in combination

The selection of the effluent treatment route is dependent
upon:-
- Effluent characteristics (before treatment)
- Requirements of effluent characteristics (after treatment) for recycle
or disposal
- Other factors :
operating economics
initial/capital cost
land and power requirement
ease of operations etc.

ETP Options Selection Criteria by industry
So.


Innovative Technologies has been developed
keeping in mind Environment sustainability..!!
Key Challenges Faced by Alcohol Industry

Key Challenges for Indian Distillery Industry

(1) Raw Material -

Shortage of molasses and grain
High prices of feedstock (especially in off-season)
Deteriorating quality of feedstock starch or fermentable sugar

(2) Effluent Management

Effective handling of huge volume of spent wash
Operation during rainy season
Zero Liquid Discharge solutions need of more robust solution

Way Ahead...
Perfect existing waste water treatment technologies
Develop innovative technologies which will help to
operate ETP solutions in more economical way
Technology for reducing water footprint to greater extent
Contribute to environment by reducing GHG emissions
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Thank You..!!