By K .P. SINGH - AIDA India. K P Singh.pdfTSS reduction plant (Degasser, Lamella Clarifier,...
Transcript of By K .P. SINGH - AIDA India. K P Singh.pdfTSS reduction plant (Degasser, Lamella Clarifier,...
By K .P. SINGH
RADICO KHAITAN lTD, Rampur
Radico Khaitan, One of the largest players in the
Indian Spirits industry, it was formerly known as
Rampur Distillery which was established in 1943.
Renovation, Expansion and Modernization
converted Radico into the Most Modern and Largest
Potable Distillery of India.
Radico has adopted reduce and
recycle process to manage effluent.
1. ON LINE EFFLUENT MONITORING SYSTEMS
a. Distilleries ( Molasses or Grain based) which are permitted to
discharge treated effluent outside the premises as per the consent to operate from SPCB’s shall install on line effluent
monitoring system for pH , BOD , COD, TSS, Flow Measurement at
the designated outlet point and data to be submitted to CPCB.
b. Distilleries ( Molasses or Grain Based) Which are adopting ZERO LIQUID DISCHARGE of Industrial Effluent as per the Consent to
Operate from SPCB’s shall install online flowmeters and PTZ
cameras as given below.
b.1,Raw Spent Wash / Whole Stillage generation , Concentrated Sp. Wash / Whole Stillage / Thick Syrup after MEE and data
connectivity to CPCB and SPCB server.
THE CPCB DIRECTIVES & GUIDELINES OF STATE POLLUTION BOARDS
THE CPCB DIRECTIVES & GUIDELINES OF STATE POLLUTION BOARDS
1. ON LINE EFFLUENT MONITORING SYSTEMS
a. Distilleries ( Molasses or Grain based) which are permitted to
discharge treated effluent outside the premises as per the consent to operate from SPCB’s shall install on line effluent
monitoring system for pH , BOD , COD, TSS, Flow Measurement at
the designated outlet point and data to be submitted to CPCB.
b. Distilleries ( Molasses or Grain Based) Which are adopting ZERO LIQUID DISCHARGE of Industrial Effluent as per the Consent to
Operate from SPCB’s shall install online flowmeters and PTZ
cameras as given below.
b.1,Raw Spent Wash / Whole Stillage generation , Concentrated Sp. Wash / Whole Stillage / Thick Syrup after MEE and data
connectivity to CPCB and SPCB server.
THE CPCB DIRECTIVES & GUIDELINES OF STATE POLLUTION BOARDS
1. ON LINE EFFLUENT MONITORING SYSTEMS
b.2, PTZ cameras with PAN , TILT Zoom , 5 X or above focal length
with Night Vision Capability should be installed al relevant locations like Bio-composting yard/ DWGS/DDGS production
area / Incineration area and Final storage lagoon / conc. Sp.
Wash storage tank as applicable. The camera feed shall be
provided without pre-requirement of any plug in software for
data display and shall be available on the Google Chrome Browser.
2. ON LINE EMISSION MONITORING SYSTEM
Distilleries ( Molasses or Grain based ) which are having dedicated boilers in the distillery premises as per the consent to operate
from SPCB’s shall provide on line Continuous Stack Monitoring
system for boiler stack / incineration boiler with real time data
logging and data transmission facility to SPCB and CPCB for the
particulate matter parameter.
THE CPCB DIRECTIVES & GUIDELINES OF STATE POLLUTION BOARDS – ZLD in Distillery
1. Distilleries to achieve ZLD by following either of the following two routes.
1.a.Reducing the volume to min. 40% with 30% solids and water conservation by
using appropriate technology such as RO and MEE. The condition of achieving 30% solid should not be applied unilaterally
because , As in in case of Radico despite of achieving reduction of volume to 25%
in place of 40% , the concentration of solids is less than 30% in the effluent being
used in Bio-composting
It is because of a different process which involves feeding of concentrated spent
wash of 24 % solids in digesters wherein the Solid Concentration is reduced again
by ~60% leaving only 8~9% at the outlet of Digesters from 24~25% after MEE ,which
is again concentrated through RO Plant and BMSW MEE to 26~27% but due to
settling of suspended solids and de-composition of organic matters in the storage lagoon at an average it remain 14~15% solids only for Bio-composting
1.b. Installing advance process technologies , multipressure distillation ,
integrated MEE and Incineration Boiler ( Slope Fired / Mixed with aux. fuel, etc.)
.
THE CPCB DIRECTIVES & GUIDELINES OF STATE POLLUTION BOARDS - ZLD in Distillery
2. Distilleries opting for Bio-composting to comply the following –
2.a. Obtaining valid registration / certification for production and quality of Bio-enriched organic manure under FCO.
2.b.The final storage capacity of conc. Sp. Wash after RO & MEE to be
strictly restricted to 30 days of concentrated sp. Wash ( 40% by volume of sp.
Wash .
2.c. The finished Bio-compost shall be packed in sealed poly bags with
the name of manufacturer industry.
However the Ministry of Agriculture and Farmer welfare is of the Opinion that the loose sale of Bio-fertilizers including Bio-enriched manure can be allowed
for Sale in loose condition for which Director (Agriculture – Govt of UP ) is
advised to permit loose sale of Bio-fertilizer
2.d. The Bio-composting activity shall be carried out under covered premises only in the rainy season.
THE CPCB DIRECTIVES & GUIDELINES OF STATE POLLUTION BOARDS - ZLD in Distillery
3. Distilleries opting for concentration & incineration shall restrict
the storage of Sp. Wash at any stage , to 7 days equivalent of production.
RADICO KHAITAN IMPLEMENTED ALL THE DIRECTIVES & GUIDELINES OF POLLUTION BOARDS
1. Radico Khaitan installed Online Mass Flow Measurement with online data
transfer facility to CPCB & SPCB servers for following applications: These flow
meters are operative since Sept. 2017 as per Guide lines dated 11th May
2017.
a. Molasses based distillation plant’s Weak Spent Wash as a feed to
Evaporator.
b. Molasses based distillation plant’s Strong (Concentrate) Spent Wash as output of Evaporator.
c. Molasses based BMSW evaporator Feed and Conc. BMSW flowmeter (
W.E.F. May 2018).
d. Grain based distillation plant’s Weak Spent Wash as a feed to Evaporator.
e. Grain based distillation plant’s Strong (Concentrate) Spent Wash as output
of Evaporator.
UPGRADATION OF EFFLUENT TREATMENT PLANTS
EFFLUENT VOLUME REDUCTION
SN Gauranteed Parameters UOM Values
1 Feed to Evaporator M3 1800
2 Alcohol to Spent Wash Ratio Ratio 1 : 9
3 Initial Solids in Concentration % 12
4 Final Solids in Concentration % 18
5 Sp Wash Volume Reduce After Evaporator M3 1170
6 Alcohol sp Wash Ratio (After Evaporation) Ratio 1 : 6
7 Total Process Condensate Genearted M3 630
8 Effluent of Other Stream M3 90
9 Volume Reduction at RO % 54
10 Volume Feed to BMSW Evaporator M3 580
11 Volume Reduction at BMSW Evaporator % 30
12 Final Sp Wash Volume of Biocompot M3 406
13 Alochol to sp wash Ratio After BMSW Evaporator Ratio 1 : 2
Bio-digester for Biogas Recovery
RO-I
RO-II
COMPLIANCE OF Achieving Zero Discharge
BMSW EVAPORATOR
Process Flow Sheet - Molasses Fer. Wash 1650 TPD
DM / soft water 408 TPD
Molasses DistillationSteam 475 TPD, Steam condensate 475
TPD goes to Boiler
Spent Lees 516 TPD
spent wash 1585 to 1595 TPD
Reboiler and Integrated MEE process condensate 420 TPD goes to
cooling tower & fermentation
Conc. Spent wash 1030 to 1040 TPD
Biodigesters(Biogas sent to bolier)
Bio Digesters Over Flow 1025 to 1035 TPD
TSS reduction plant (Degasser, Lamella
Clarifier, Clariflocculators, Belt Press, Settling
Tank, Final clarifier and DAF)
Thick Sludge to Biocompost
R O Plant (feed 960 to 1050 TPD)Permeate 460 to 490 TPD for CT Make
up water
RO Reject as - Feed to BMSW evaporator 540
to 560 TPD
Process Condensate 170 to 180
M3/day goes to cooling tower
Press Mud
Biocompost
Cocentrated qty 370 - 380
TPD goes to biocompost
>>>> Goes Fermentation for Dilution of Molasses
>>>>>>>>Feed to MEE
CHALLENGES FOR DISTILLERY – CONDENSATE TREATMENT
CHALLENGES FOR DISTILLERY – CONDENSATE TREATMENT
CHALLENGES FOR DISTILLERY – CONDENSATE TREATMENT
CPU – Executive summary
Project
Revised
Installation
Date
Status as on 24.01.2019
B
C
R
Installation of
Condensate
Polishing Unit
(2000M3/Day )
1No ICX Reactor
Biogas Holder
Secondary Clarifier
MGF / ACF and UV
System
01.04.2019
1> Civil Foundation work completed for ICX Reactor and Reactor
Fabrication and Erection work completed .... scaffolding for Epoxy
work is under progreee.
2> Constrcution wok in progress for Equilisation Tank , Filter water
tank , Biogas Holder and Seconadry Clarifer is under progress
3> Civil work completion is targeted by 25h Feb'2019 and
Mechanical Installation is Targetted by 25.03.2019
CPU – Process Flow Diagram ….. 1/2
CPU ….. Process Flow Diagram …. 2/2
ICX REACTOR
FOR CPU
SLUDGE SETTLING TANK
CPU GAS HOLDER
REDUCTION IN WATER CONSERVATION
Reduction in water consumption through recycling
S.No Stream recycled Year -2014-15 Year -2015-16 Year -2017-18
1 Pre-rectifier & Rectification
column Lees
Recycled to
fermentation
house
2 Vacuum Pump water Recycled to
fermentation
house
3 Steam Condensate Recycled to boiler
section
Recycled to boiler
section
4 CO2 Scrubber Water Recycled to
fermentation
house
5 Process Condensate Recycle to cooling
tower
6 RO Permeate Recycle to cooling
tower
Water Consumption / BL
of Alcohol 18 12 8
Covered Bio-composting
Bio-composting
Radico Khaitan installed Online Mass Flow Measurement in distillation
plants with online data transfer facility to CPCB & SPCB Servers
VIEW OF Covered Bio-composting in online CAMERA
Biocompost - Bagging Photographs
ONLINE MONITORING OF BIOCOMPOST FACILITIES WITH PTZ CAMERA AND ONLINE CONNECTIVITY FACILITY WITH CPCB & SPCB SERVERS
COVERED BIO-COMPOSTING
COVERED BIO-COMPOSTING
BIO- COMPOSTING