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AIDA Seminar. WATER AND WASTE WATER MANAGEMENT FOR DISTILLERY INDUSTRY. By Mr. Prasanna Deshpande. World Water Scenario. 70% of earth covered by water Out of which only 3 % available for drinking. Population demand and water supply Ratio is at alarming level

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AIDA Seminar

WATER AND WASTE WATER MANAGEMENT

FOR DISTILLERY INDUSTRY

By

Mr. Prasanna Deshpande

27th Feb, 2011


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World Water Scenario

  • 70% of earth covered by water

  • Out of which only 3 % available for drinking.

  • Population demand and water supply Ratio is at alarming level

  • Waste water out from industry pollutes Earth

  • Conscience appeals not only for Treatment of waste water but also for reuse and minimize the fresh water usage quantity


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Water Source Available

Trend shows a Steep Depletion in available water for usage.







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Water Consumption Areas in Distilleries

FLOUR SLURRY IN LIQUEFACTION

DILUTION IN FERMENTATION

DILUTION IN DISTILLATION (ENA)

VARIOUS CIP OPERATIONS

SEALING WATER FOR PUMPS / BLOWERS

Overall Water

STEAM GENERATION/ BOILER MAKEUP

COOLING TOWERS MAKEUP

FLOOR / EQUIPMENT WASHINGS

BLENDING & BOTTLING

OTHER DOMESTIC USE / CANTEEN, OFFICE


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Water Requirement

Water for running Process

  • Process Water

  • Fermentation dilution

  • Fermentation CIP

  • Evaporation

  • Sealing

  • CIP

  • Floor Washing


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Water Requirement

II Soft Water

For running Utilities

  • Cooling Tower make up

  • Vacuum Pump Sealing

  • Centrifugal pumps sealing

  • Process areas

  • Alcohol Scrubber

  • Alcohol Dilution


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Water Requirement

  • III Demineralised Water (DM Water)

  • Alcohol dilution in ED Column

  • Boiler DM Water make up

  • Blending of Alcohol


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Effluent Streams Generated

  • Premium effluent –

  • a. Spent wash/Vinasse in Molasses based distillery

  • b. Thin slops in grain based distillery.

  • Other Effluent Generated –

  • Distillery operations also generated various other streams

  • during its working as illustrated


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Other Effluent Streams Generated

  • Liquefaction

  • Pump Sealing

  • Floor Washings

  • Occasional PHE Cleaning

  • Fermentation

  • Fermentor CIP

  • Process Air Blower Sealing

  • Pump Sealing

  • Floor Washings


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Other Effluent Streams Generated

  • Evaporation

  • Concentrated Syrup and Wet cake

  • Evaporation Process Condensate

  • Vacuum pump Sealing

  • Equipment CIP

  • Pump Sealing

  • Flour washings

  • Distillation

  • Spent Lees

  • Vacuum Pump Sealing Water

  • Equipment CIP

  • Other Pump Sealing


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Other Effluent Streams Generated

  • Utility Reject

  • Boiler Blow down

  • Cooling tower Blow down

  • WTP Reject


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Categorized Effluent Streams

  • Effluent Streams generated in the distillery Operations can be categorized based on,

  • Compositional Analysis – Organic & Inorganic load

  • Physical Properties - Temperature, Color

  • Concentration of Hydroxyl Ion – pH Value

  • Chemical Oxygen Demand – COD

  • Biological Oxygen Demand – BOD

  • Volatile Acids - VA

  • Total Solids – TS

  • Total Suspended Solids – TSS


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Scientific Approach To Handle Effluent Streams

  • Effluent Streams generated in the distillery operations can be handled

  • Reduce Generation

  • Recycle as maximum as possible

  • Reuse

  • Treatment based on its characteristics

  • Proper Disposal , Utilization


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Reduce Generation – Molasses based

  • Spent Wash / Vinasse – Reduce generation

  • Higher Alcohol Concentration 9 – 11 % v/v in fermented wash (Depends on Molasses quality)

  • Indirect Heating in distillation systems through Reboiler


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Recycle – Molasses based

Recycle Spent wash as a process water (Care to be taken that product quality is not affected)


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Spent Wash / Vinasse

Biodigester

Bio -Composting

BIO GAS

10-20 % Recycle To Fermentation

(Depends on Molasses Quality)

Treatment of Spent wash – Molasses

Zero Liquid Discharge scheme-M1


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Treatment of Spent wash – Molasses

Zero Liquid Discharge scheme-M2

Spent Wash / Vinasse

Biodigester

Evaporation

Process condensate`

Reuse In

Process

Final

Treatment

Initial

Treatment

Conc. Product

To Composing


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Spent Wash / Vinasse

Evaporation

(Concentration @ 60%)

Incineration

Boiler

10-20 % Recycle To Fermentation

(Depends on Molasses Quality)

Treatment of Spent wash – Molasses

Zero Liquid Discharge scheme-M3


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Reduce Generation- Grain

  • Thin Slops reduce generation

  • Higher Alcohol Concentration 10 – 12 % v/v in fermented wash

  • Indirect Heating in Distillation systems through Reboiler


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Recycle - Grain

Recycle Thin Slops as a process water up to 35%


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Thin Slops

Biodigester

Secondary &

Tertiary

Partly Recycle

To Process

Land

Application

Treatment of Thin Slops - Grain

Zero Liquid Discharge scheme-G1


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Thin Slops

Syrup mixed

with Wet Cake

‘DWGS’

Evaporation

Partly Recycle

To Process

DDGS

Dryer

Treatment of Thin Slops – Grain

Zero Liquid Discharge scheme-G2


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PR , FOC COLUMN

Spent Lees

Evaporation Process

Condensate

1st Stage

Treatment

2nd Stage

Treatment

Recycle in

Process

Raw Water

Storage

3rd Stage

Treatment

Dilution in Distillation

To Vinasse

Evaporation

Reject to

Composting

Rectifier Lees

Fermentation

Treatment of Other Effluent Streams- Molasses


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Evaporation Process

Condensate

Cooling

Tower

Treatment

Partly Recycle to Process

Thin Slop

Evaporation

FOC Lees

PR Lees

Balance

Make up water

Distillation In Dilution

Rectifier Lees

Cooling Tower

Treatment of Other Effluent Streams- Grain


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Make up

Process Pump Sealing Water Reuse system

Process Pumps

From All Sections

Tank

Total Water Savings = 95 %


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Make up

Vacuum Pump / AIR Blower Sealing

Water Reuse System

CWR

Vacuum Pump /

Air Blower

Cooler

Tank

CWS

Total Water Savings = 95 %


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Molasses

Floor Washings

Treatment

Reuse In

Process

Reuse In

Process

Grain

Floor Washing


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Boiler Blow down

Boiler Ash

Quenching

Raw water tank

Cooling Tower

Blow down

Treatment

Field Application

Tree Plantation

WTP Rejects

Evaporation &

Dryer

Utility Reject


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Case Study - 1

100 KLPD Molasses Distillery Reduction in Fresh Water after Implementing Treatment Recycle technology


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Case Study - 1

(a) 100 KLPD Molasses Distillery

Total Water Savings = 42 %


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Case Study - 2

100 KLPD Grain Distillery Reduction in Fresh Water after Implementing, Treatment , Recycle technology


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Case Study - 2

100 KLPD Grain Distillery

Total Water savings = 60 %


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Conclusion

  • Trend emphasis on conservation of water in currently installed Alcohol Distilleries.

  • Need of time to maximize the reuse of water and to minimize the fresh water consumption.

  • To meet the above challenges Praj has developed technology for Treatment, Recycle and Reuse of the water from various effluent streams in Alcohol Distilleries.

    “SAVE WATER SAVE NATURE”



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