Case studies on Sludge and water management...Sewage generation • According to CPCB report (2009...
Transcript of Case studies on Sludge and water management...Sewage generation • According to CPCB report (2009...
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Case studies on Sludge andwater management
Centre for Science and Environment
Sujit Kumar Singh
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Big question ????????
• Do we know that how much sewage wegenerate
• Do we know that HOW MUCH INDUSTRIALEFFLUENT WE GENERATE
• DO we have updated information (Yes/no)
Centre for Science and Environment
• Do we know that how much sewage wegenerate
• Do we know that HOW MUCH INDUSTRIALEFFLUENT WE GENERATE
• DO we have updated information (Yes/no)
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Sewage generation
• According to CPCB report (2009 – 10) approximately53898 MLD sewage is generated in India including allthe Metropolitan, Class1 and Class 2 cities and only19826.7 MLD of this is treated (around 37%) beforebeing discharged into the water bodies.
• According to CPCB, the total wastewater discharged byall major industrial sources is 83,048 million litres perday (mld) - 2003
Centre for Science and Environment
• According to CPCB report (2009 – 10) approximately53898 MLD sewage is generated in India including allthe Metropolitan, Class1 and Class 2 cities and only19826.7 MLD of this is treated (around 37%) beforebeing discharged into the water bodies.
• According to CPCB, the total wastewater discharged byall major industrial sources is 83,048 million litres perday (mld) - 2003
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Why we do Wastewater Treatment?
• To meet the regulatory standards
• Conventional treatment removes BOD and SS butunable to remove nutrients and complex compound.
• Decreasing assimilative capacity of water bodies
• Water scarcity also pushed industry to opt foradvanced wastewater (Recycle and Reuse)
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• To meet the regulatory standards
• Conventional treatment removes BOD and SS butunable to remove nutrients and complex compound.
• Decreasing assimilative capacity of water bodies
• Water scarcity also pushed industry to opt foradvanced wastewater (Recycle and Reuse)
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How we can achieve
• Understand - wastewater characteristic
• Estimate the Quantity of wastewater generation
• Check potential of segregation (process &utility)
• Selection of appropriate technology
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• Understand - wastewater characteristic
• Estimate the Quantity of wastewater generation
• Check potential of segregation (process &utility)
• Selection of appropriate technology
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Approach for wastewater Treatment
Wastewater Treatment
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Urban Industrial
Centralized DecentralizedCentralized
DecentralizedSTP Natural process
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Characteristic of Sewage
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Wastewater Treatment
Wastewater treatment mainly consists
– Preliminary treatment– Primary treatment– Secondary or biological treatment– Advanced treatment
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Wastewater treatment mainly consists
– Preliminary treatment– Primary treatment– Secondary or biological treatment– Advanced treatment
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Types of Solids
• Suspended solid or filterable solid– floating solid (> 1micron)
• Settleable solids – settled down after providing DT ( > 10micron – NO Coagulant, < 10 micron Coagulant is required)
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• Suspended solid or filterable solid– floating solid (> 1micron)
• Settleable solids – settled down after providing DT ( > 10micron – NO Coagulant, < 10 micron Coagulant is required)
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Types of Solids
• Colloidal solids – finesolids either in solutionor in suspension (< 1micron to 10-3 micron)
• Dissolved solid – indissolved state (lessthan 10-3 micron)
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• Colloidal solids – finesolids either in solutionor in suspension (< 1micron to 10-3 micron)
• Dissolved solid – indissolved state (lessthan 10-3 micron)
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Class exercise on DO
• Assume 2.5 ml of raw sewage diluted to 250ml
• Initial DO was 8 mg/lit
• Final DO was 5 mg/lit at three days at 20 C
• Estimate BOD in mg/lit in wastewater
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• Assume 2.5 ml of raw sewage diluted to 250ml
• Initial DO was 8 mg/lit
• Final DO was 5 mg/lit at three days at 20 C
• Estimate BOD in mg/lit in wastewater
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• Dilution ratio = 250/2.5 = 100
• Loss of dissolved oxygen = 8 – 5 = 3 mg/lit
• BOD = loss of oxygen x dilution factor
• = 3 x 100 = 300 mg/lit
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• Dilution ratio = 250/2.5 = 100
• Loss of dissolved oxygen = 8 – 5 = 3 mg/lit
• BOD = loss of oxygen x dilution factor
• = 3 x 100 = 300 mg/lit
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Class exercise
• Total sewage coming to STP = 95 MLD
• Average BOD of untreated waste water is300 mg/lit
• Estimate total population discharging ww(assume BOD of sewage 0.08 kg/day/person
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• Total sewage coming to STP = 95 MLD
• Average BOD of untreated waste water is300 mg/lit
• Estimate total population discharging ww(assume BOD of sewage 0.08 kg/day/person
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Solution
• Total organic load = 300 mg/lit x 95 MLD
• = (300 x 95 x 1000000)/ (1000 x1000)
• = 300 x 95 = 28500 kg/day
• Population equivalent = (Total BOD inkg/day)/ (Per capita BOD in kg/day/person)
Centre for Science and Environment
• Total organic load = 300 mg/lit x 95 MLD
• = (300 x 95 x 1000000)/ (1000 x1000)
• = 300 x 95 = 28500 kg/day
• Population equivalent = (Total BOD inkg/day)/ (Per capita BOD in kg/day/person)
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Waste Stabilisation PondsOrganic matter degradation by heterotrophic bacteria► Algae growth cause decomposition, leading to production of oxygen.► Replenish O2 in the pond and maintain aerobic condition► Microbes grow as suspended particles.
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Waste Stabilisation Ponds
• Robust and withstandhydraulic and organic shockload
• Effluent from maturationpond can be used foragriculture and aquaculture
• Very low O&M cost
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• Robust and withstandhydraulic and organic shockload
• Effluent from maturationpond can be used foragriculture and aquaculture
• Very low O&M cost
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Activated Sludge Process ( ASP )
• Primary wastewater mixed with bacteria-rich (activated) sludge and air or oxygen ispumped into the mixture
• Promotes bacterial growth and decomposition of organic matter• Last step is a settling tank where sludge settles out and then the treated wastewater
moves on for tertiary treatment.• Some settled sludge is used to inoculate incoming primary effluent.
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FeaturesHigh BOD removalMicrobial removal:Energy intensive
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Aeration tank
Final clarifier
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• Movie microbes
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Method of Aeration in ASP
• Diffused aerator
• Mechanical aerator
• Combination of both
• Average = 4000 to 8000 m3 of air is required permillion liter of sewage (depend of strength ofsewage)
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• Diffused aerator
• Mechanical aerator
• Combination of both
• Average = 4000 to 8000 m3 of air is required permillion liter of sewage (depend of strength ofsewage)
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Design criteria
• Volume of return activated sludge - dependof extend of BOD desired to be removed
= i.e. (Qr/ Q), where Qr – return sludge and Qvolume of sewage coming in AT
As thumb rule – quantity of return sludge is 35to 55 % of volume of sewage coming in AT
Centre for Science and Environment
• Volume of return activated sludge - dependof extend of BOD desired to be removed
= i.e. (Qr/ Q), where Qr – return sludge and Qvolume of sewage coming in AT
As thumb rule – quantity of return sludge is 35to 55 % of volume of sewage coming in AT
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Design criteria
• Important terms
(1) Aeration period or HRT
• DT (hr) = Volume of tank/ rate of flow ofsewage
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• Important terms
(1) Aeration period or HRT
• DT (hr) = Volume of tank/ rate of flow ofsewage
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(2) Volumetric BOD or organic loading – BODload applied per unit volume of aeration tank
• = Mass of BOD applied per day to AT/Volume of tank (m3)
• = (Q x inlet BOD)/ volume
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(2) Volumetric BOD or organic loading – BODload applied per unit volume of aeration tank
• = Mass of BOD applied per day to AT/Volume of tank (m3)
• = (Q x inlet BOD)/ volume
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(3) Food (F) to microorganism (M) ratio
• Food = Q x inlet BOD to AT
• Microorganism (M) = MLSS x volume of tank
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(3) Food (F) to microorganism (M) ratio
• Food = Q x inlet BOD to AT
• Microorganism (M) = MLSS x volume of tank
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OXYGEN REQUIREMENT AND TRANSFER
– Depends on BOD of wastewater– Amount of organisms wasted per day– Minimum oxygen level of 1 to 2 mg/l in Aeration
Tank– For F/M ratio of 0.3, air requirement is 30 to 55
m3/kg of BOD removed
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– Depends on BOD of wastewater– Amount of organisms wasted per day– Minimum oxygen level of 1 to 2 mg/l in Aeration
Tank– For F/M ratio of 0.3, air requirement is 30 to 55
m3/kg of BOD removed
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Sludge digestion
Sludge from primary and secondarysettling tanks (including waste activatedsludge must be treated in digesters.Sludge is thickened before passing intothe digesters
Sludge is treated anaerobically;Methane production takes place.
Biogas is used as fuel.
Centre for Science and Environment
Sludge from primary and secondarysettling tanks (including waste activatedsludge must be treated in digesters.Sludge is thickened before passing intothe digesters
Sludge is treated anaerobically;Methane production takes place.
Biogas is used as fuel.
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Membrane Bio-Reactors (MBR)
► Combination of membrane process like micro-filtration or ultra-filtration with suspended growth bio-reactor.
► Pore size of filter used: 0.003-0.01micrometer.► Provide better biodegradability and cell synthesis.
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Difference between ASP and MBR
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Membrane
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Type - microfiltration, ultrafiltrationCan operate at high MLSS concentration upto 15,000-25,000 mg/L
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Comparison of MBR Schematic Vs convention AS Process
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• Configurations include internal MBR and externalMBR.
• Produces high quality effluent with a relatively smallfootprint. Old plants can be retrofit, easily upgraded toMBR.
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• Configurations include internal MBR and externalMBR.
• Produces high quality effluent with a relatively smallfootprint. Old plants can be retrofit, easily upgraded toMBR.
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Advantages
• Can eliminate secondary clarifier and operate at higher MLSS concentration.
• Higher volumetric loading rates; thus shorter HRTs.
• Longer solids retention time resulting in less sludge.
• Operate at low DO with potential of simultaneous nitrification-denitrificationin longer SRT designs.
• Less space requirements: saves land costs; facilitates upgradation of oldplants.
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Advantages
• Can eliminate secondary clarifier and operate at higher MLSS concentration.
• Higher volumetric loading rates; thus shorter HRTs.
• Longer solids retention time resulting in less sludge.
• Operate at low DO with potential of simultaneous nitrification-denitrificationin longer SRT designs.
• Less space requirements: saves land costs; facilitates upgradation of oldplants.
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Disadvantages
• High capital costs.
• Limited data on membrane life.
• Potential high cost of periodic membrane replacement.
• Higher energy costs.
• Need to control membrane fouling.
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Disadvantages
• High capital costs.
• Limited data on membrane life.
• Potential high cost of periodic membrane replacement.
• Higher energy costs.
• Need to control membrane fouling.
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► BOD removal 95%. Can be increased up to96-99%.
► Effluent TSS is very low, Total P <0.1mg/l andextensive Total N removal.
Features of MBR
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► BOD removal 95%. Can be increased up to96-99%.
► Effluent TSS is very low, Total P <0.1mg/l andextensive Total N removal.
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Centre for Science and Environment
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MBR at ITC Maurya, New Delhi
► Installed Capacity: 800 KLD► Total capital investment: 2.5
crores► O&M cost : Rs 20/KL
Kitchen waste
Grease Traps(10)
Treated water
Equalization tanks with blowers
Centre for Science and Environment
Bar screens (3)
MBR
Softner
Treated water
100-125 KLDto coolingtowers
10-15KLD to fountainsmake up water
60-100 KLDfor horticulturepurposes
30-50 KLD to NDMC for Horticulture
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Moving Bed Biological Reactor (MBBR)
► Aeration is done in such a way to ensure thorough mixing andproper turnover of the media within the reactor.
► Efficient removal of carbonaceous and nitrogenous waste.
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Centre for Science and Environment
Reactors are filled with plastic carriers to provide surface
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Centre for Science and Environment
Screens are placed onthe downstream walls,to prevent media fromflowing out
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• Clarifier or DAF is placed at the downstream to separate thebiomass. No sludge recycle is required.
• During operation, carriers are kept in constant recirculation.– In aerobic: through introduction of air by coarse air bubble diffuser.– In anoxic, through submerged mixers.
• Carriers can occupy upto 50 to 70% of reactor volumes.
Centre for Science and Environment
• Clarifier or DAF is placed at the downstream to separate thebiomass. No sludge recycle is required.
• During operation, carriers are kept in constant recirculation.– In aerobic: through introduction of air by coarse air bubble diffuser.– In anoxic, through submerged mixers.
• Carriers can occupy upto 50 to 70% of reactor volumes.
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Advantage : MBBR
• Robust: Stable under load variation and provides consistenttreatment results.
• Compact: typically requires 1/3rd of the space for aconventional AS process.
• Cost: Low capital costs similar to AS.
• Flexible: Existing plants can be upgraded with an MBBR.
• Trouble free: Easy to operate, and no issues of media clogging
Centre for Science and Environment
• Robust: Stable under load variation and provides consistenttreatment results.
• Compact: typically requires 1/3rd of the space for aconventional AS process.
• Cost: Low capital costs similar to AS.
• Flexible: Existing plants can be upgraded with an MBBR.
• Trouble free: Easy to operate, and no issues of media clogging
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Sequencing Batch Reactor (SBR)
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Sequencing Batch Reactor (SBR)
• It is a single reactor which operates in a batchtreatment mode repeating a sequencecontinuously.
• It is a fill & draw activated sludge system
• Reaction & Settling takes place in the samereactor
Centre for Science and Environment
• It is a single reactor which operates in a batchtreatment mode repeating a sequencecontinuously.
• It is a fill & draw activated sludge system
• Reaction & Settling takes place in the samereactor
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• It comprises of four phases.i. Fillingii. Aeration & Reactioniii. Settlingiv. Decanting
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• It comprises of four phases.i. Fillingii. Aeration & Reactioniii. Settlingiv. Decanting
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Step 1 : Filling
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Step 2 : Aeration & Reaction
Aeration time depend on size & Wastewater quality; typically is 60-90min. Higher time upto 3 hr. required for nitrification.Phosphorus removal is aided by adding aluminum sulphate (alum).
Centre for Science and Environment
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Step 3: Settling
•Usually same time as that of aeration•Aerobic bacteria continues to multiply till DO is used up. Conditions are now suitable for anaerobic bacteria toflourish (especially near tank bottom).
Centre for Science and Environment
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Step 4: Decantin
Decanter
The outlet valve opens and the clean supernatant liquor exits the tank
Centre for Science and Environment
Decanter
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Delawas Jaipur - Waste to Energy STP
• STP commissioned in 2006, capacity of 62.5 MLD
• Based on aerobic biological process (ASP) withdiffused aerator
• Waste to Energy made STP self sufficient (75%energy demand)
Centre for Science and Environment
• STP commissioned in 2006, capacity of 62.5 MLD
• Based on aerobic biological process (ASP) withdiffused aerator
• Waste to Energy made STP self sufficient (75%energy demand)
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Salient Features of 62.50 MLD STP
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Advantage
• Prior commissioning of biogas plant =average monthly power consumption was208653 Kwh /month (grid)
• After power generation at plant site fromDecember, 2009 to April, 2012, the averagepower consumed from grid is only 55479Kwh/month (73% from biogas and rest fromgrid)
Centre for Science and Environment
• Prior commissioning of biogas plant =average monthly power consumption was208653 Kwh /month (grid)
• After power generation at plant site fromDecember, 2009 to April, 2012, the averagepower consumed from grid is only 55479Kwh/month (73% from biogas and rest fromgrid)
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Thumb Rule (conventional ASP)
• Average consumption of new plant 127-134 Kwh/MLD ofsewage treated
• Old plant 180-225 Kwh/MLD
• New plant 4.24-4.48 Kwh/Kg of BOD removed
• Thumb Rule approx 100 MLD capacity plant = potential toproduce 1 MW
• Note: Power consumption accounts for almost 75% of theexpenditure on O and M of any sewage treatment plant
Centre for Science and Environment
• Average consumption of new plant 127-134 Kwh/MLD ofsewage treated
• Old plant 180-225 Kwh/MLD
• New plant 4.24-4.48 Kwh/Kg of BOD removed
• Thumb Rule approx 100 MLD capacity plant = potential toproduce 1 MW
• Note: Power consumption accounts for almost 75% of theexpenditure on O and M of any sewage treatment plant
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Centre for Science and Environment
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Cost of ASP
• Land requirement (hectares/MLD installedcapacity) = 0.15 to 0.25
• O&M cost (million/year/ MLD installedcapacity) = Rs 0.3 to 0.5
• Capital cost (million /MLD capacity) = Rs 2 to 4
Centre for Science and Environment
• Land requirement (hectares/MLD installedcapacity) = 0.15 to 0.25
• O&M cost (million/year/ MLD installedcapacity) = Rs 0.3 to 0.5
• Capital cost (million /MLD capacity) = Rs 2 to 4
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Surat - Biogas to Energy generation
Centre for Science and Environment
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Gas Characteristic
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Economic
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Case study – Delhi STP
• 45 MGD sewage treatment plant (STP) at Kondliproducing = 10,000 kWh
• At Okhla STP, 12,000 KWH and at Rithala STP20,000 KWH
• Delhi produces 3800 MLD sewage = potential toproduce = 38 MWh
Centre for Science and Environment
• 45 MGD sewage treatment plant (STP) at Kondliproducing = 10,000 kWh
• At Okhla STP, 12,000 KWH and at Rithala STP20,000 KWH
• Delhi produces 3800 MLD sewage = potential toproduce = 38 MWh
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Coal-based Power Sector
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Water stress – power plant location
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Water Consumption
• Water: 70 % of the total withdrawal byindustries ~22 BCM
• Excess water consumption:Avg 4m3/MWh; Best ~2m3/MWh; Worst
~10m3/MWh
• A survey conducted by FICCI and ColumbiaUniversity Water Center reveal that ~ 87% ofcompanies believe that water availability willimpact their business over the next decade.
Centre for Science and Environment
• Water: 70 % of the total withdrawal byindustries ~22 BCM
• Excess water consumption:Avg 4m3/MWh; Best ~2m3/MWh; Worst
~10m3/MWh
• A survey conducted by FICCI and ColumbiaUniversity Water Center reveal that ~ 87% ofcompanies believe that water availability willimpact their business over the next decade.
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News from Maharashtra
• Due to severe water shortage - All six units of Parlithermal power plant shut down (Beed district ofMaharashtra) February (2013), resulting in a loss ofrevenue from stoppage of generation units
• During the recent drought in Maharashtra, powerplants came in for severe criticism with regard to theirwater consumption
• Nashik Municipal Corporation has committed to pro-vide treated sewage water (~190 MLD) instead offreshwater for the upcoming 2x660 MW power plant ofIndia Bulls. Requires additional investment for watertreatment for input to power plant
Centre for Science and Environment
• Due to severe water shortage - All six units of Parlithermal power plant shut down (Beed district ofMaharashtra) February (2013), resulting in a loss ofrevenue from stoppage of generation units
• During the recent drought in Maharashtra, powerplants came in for severe criticism with regard to theirwater consumption
• Nashik Municipal Corporation has committed to pro-vide treated sewage water (~190 MLD) instead offreshwater for the upcoming 2x660 MW power plant ofIndia Bulls. Requires additional investment for watertreatment for input to power plant
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Class exercise
• Estimate the water requirement, if thecapacity of plant is power plant (coal) – 1000MW
• Assume 4 to lit/Kwh, closed loop
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• Estimate the water requirement, if thecapacity of plant is power plant (coal) – 1000MW
• Assume 4 to lit/Kwh, closed loop
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Question
• Consider the scenario of a 1,000 MW powerplant shutdown its operations for one daydue to unavailability of water
• Question - Potential revenue loss (assumingRs 3/unit)
Centre for Science and Environment
• Consider the scenario of a 1,000 MW powerplant shutdown its operations for one daydue to unavailability of water
• Question - Potential revenue loss (assumingRs 3/unit)
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Pulp & Paper
Case study TNPL Paper mill
– Water consumption in 1995-96 = 200m3/paper
– In 2013 water consumption reduced to 58m3/tonne product (70% reduction)
– In May – June, specific waterconsumption dropped to as low as 34 m3
Centre for Science and Environment
Case study TNPL Paper mill
– Water consumption in 1995-96 = 200m3/paper
– In 2013 water consumption reduced to 58m3/tonne product (70% reduction)
– In May – June, specific waterconsumption dropped to as low as 34 m3
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Biogas generation from Wastewater
• Bagasse received from sugar mill having 3-4% residualsugars is stored in the open yard by wet bulk storagemethod for a period of 3 to 9 months. During storage, thebagasse is kept under wet condition by spraying waterover bagasse pile to preserve bagasse quality.
• TNPL is using nearly 9000 M3 fresh water/treated effluentin the bagasse handling and storage area. Papermachine wastewater, which contains relatively low TDS,was use
• Waste water generation = around 10,000 to 14,000 m3 ofwastewater from Bagasse storage yards and Bagassewashing
Centre for Science and Environment
• Bagasse received from sugar mill having 3-4% residualsugars is stored in the open yard by wet bulk storagemethod for a period of 3 to 9 months. During storage, thebagasse is kept under wet condition by spraying waterover bagasse pile to preserve bagasse quality.
• TNPL is using nearly 9000 M3 fresh water/treated effluentin the bagasse handling and storage area. Papermachine wastewater, which contains relatively low TDS,was use
• Waste water generation = around 10,000 to 14,000 m3 ofwastewater from Bagasse storage yards and Bagassewashing
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Flow diagram – water use for wetting bagasse
Freshwater
Paper machinewastewater
Clarifier
Centre for Science and Environment
ETP
Legend:
Before ProjectAfter Project
Fresh water saving :3000m3/day
Clarifier
Bagasse storage &washing
ETP
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Water characteristic and biogasgeneration
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BioBio--methanationmethanation PlantPlant
GasGasHolderHolder
MOLMOLTankTank
UASBUASBReactorReactor
AA
UASBUASBReactorReactor
BBLimeLime--KilnKiln
Centre for Science and Environment
Equal.Equal.TankTank
SludgeSludgePitPit
DecanterDecanterCentrifugeCentrifuge
BufferBufferTankTankClarifierClarifier
Neutral.Neutral.TankTank
MOLMOLTankTank
SludgeSludgeforfor
DisposalDisposal
To ActivatedTo Activatedsludge processsludge process
Bagasse.Bagasse.WashWash
EffluentEffluent
Nut.Nut.TankTank
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Project cost was Rs.4.00 crores.
Centre for Science and Environment
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Gas firing in Lime Kiln
Centre for Science and Environment
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Economic and pollution reduction benefit
Particulars Units 2013-14COD Treated MT / Yr 21577COD Reduced MT / Yr 18917Biogas generation M3 / Yr 9663897
Centre for Science and Environment
Biogas generation M3 / Yr 9663897Furnace oil saving KL / Yr 5798
Revenue fromFurnace Oil Saving
Rs. (in Million) 265.9
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Reducing water tread in Pulp & Paper
Centre for Science and Environment
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Specific water consumption
Centre for Science and Environment
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Specific water consumption in Indian steel plantsis compared to the global average of waterconsumption
Centre for Science and Environment
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Case study: Reuse of BangaloreSewage at Airport
• The STP plant at Yelahanka, treats 10 MLD ofsewage water, and gets Rs. 22, 00,000 everymonth by selling the tertiary treated water toindustries like Bharat Electronics Limitedand Bangalore International Airport
Centre for Science and Environment
• The STP plant at Yelahanka, treats 10 MLD ofsewage water, and gets Rs. 22, 00,000 everymonth by selling the tertiary treated water toindustries like Bharat Electronics Limitedand Bangalore International Airport
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Case study : Ganga Ram Hospital - Recycle andreuse of hospital water for flushing and gardening
CollectionTank
Aeration TankSecondary
Settling Tank
Sludge HoldingTank
MultiGradeFilter
ActivatedCarbonFilter
ChlorineContact Tank
Centre for Science and Environment
To Sludge DisposalPumps / Filter press
TreatedWater Tank
Ozonator
TreatedWater
Note: Planning to use treated water in cooling towers ofair-conditioning plants by installing softeners
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MBR at ITC Maurya, New Delhi
► Installed Capacity: 800 KLD► Total capital investment: 2.5
crores► O&M cost : Rs 20/KL
Kitchen waste
Grease Traps(10)
Treated water
Equalization tanks with blowers
Centre for Science and Environment
Bar screens (3)
MBR
Softner
Treated water
100-125 KLDto cooling
towers
10-15KLD to fountainsmake up water
60-100 KLDfor horticulture
purposes
30-50 KLD to NDMC for Horticulture
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Recycle and reuse of wastewater in vehicle washfacility of TATA Motors, New Delhi, India
Centre for Science and Environment
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Centre for Science and Environment
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Minimum criteria for wastewatertreatment
Centre for Science and Environment
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• The combined approximate cost ofconstruction of mud separator (grit chamber)and oil/ grease trap is around Rs. 7 per litre.
• For example, if vehicle wash operator wantsto treat 1 KL of wastewater per day, theconstruction cost will be around Rs. 7,000.
• See Flow diagram for Zero discharge
Centre for Science and Environment
• The combined approximate cost ofconstruction of mud separator (grit chamber)and oil/ grease trap is around Rs. 7 per litre.
• For example, if vehicle wash operator wantsto treat 1 KL of wastewater per day, theconstruction cost will be around Rs. 7,000.
• See Flow diagram for Zero discharge
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Effluent Treatment Plant and parameters –dyeing, printing cotton and blended textileproducts
Centre for Science and Environment
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Effluent Treatment Plant and parameters –Garment Washing Unit
Centre for Science and Environment
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Flow diagram to achieve zero discharge in atextile plant
Centre for Science and Environment
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Case Study 1: Zero discharge in Ranbaxy
Centre for Science and Environment
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Step 2: Technology selection based on effluentcharacteristic
Centre for Science and Environment
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Case Study 2: Zero discharge in Dr.Reddy’s Laboratories
Centre for Science and Environment
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Centre for Science and Environment
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SUGAR INDUSTRY DISTILLERY INDUSTRY
SUGAR & DISTILLERY
Centre for Science and Environment
Sujit Kumar Singh, Programme Manager, CSE
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Sugar – An Eco-Friendly IndustryWhat we take and What we Give back
SugarCane
Sugar MillSugarRefined Sugar
BagasseMolasses
Press Mud
Centre for Science and Environment
Molasses
Press Mud
Power Plant
Distillery
Rectified SpiritAbsolute AlcoholENA
Ash
Waste Water /Spent Wash
Organic ManurePlant& Biocompost
Organic ManurePlant& Biocompost
Bio-compostManure
Power
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Centre for Science and Environment
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Indian Sugar Industry at a glance
Sr. Particulars Crushing Season
2007-2008 2008-2009 2009-20102010-2011E
1 No. of Sugar Factories in Operation 516 488 500 520
2 Crushing Capacity (million TCD) 22.48 23.001 23.7 25
Centre for Science and Environment
2 Crushing Capacity (million TCD) 22.48 23.001 23.7 25
3 Sugarcane Crushed (million tons) 250 145.0 180.0 220.0
4 Sugar Produced (million tons) 26.357 14.538 18.63 23.1
5 Recovery % Cane 10.55 10.03 10.35 10.5
6 Yield of sugarcane (tons per hectare) 68.9 62.3 65 66
7 Molasses Production (million tons) 11.25 6.52 8.10 9.90
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Raw material
• Sugar mills consume large quantity of water; thewater consumption can be brought down to 100litres per tonne (L/T) of cane crushed by recyclingcooling and condensate
• Two type of water is used – Cold and hot condensewater (used as boiler feedback water, juice dilution,lime and sulphate preparation, dilution, molassesconditioning, etc.
• Recycling and reuse of hot condensate water canreduce the water consumption to as low as 100-200litres, as against 1,500-2,000 litres per tonne of canecrushed
Centre for Science and Environment
• Sugar mills consume large quantity of water; thewater consumption can be brought down to 100litres per tonne (L/T) of cane crushed by recyclingcooling and condensate
• Two type of water is used – Cold and hot condensewater (used as boiler feedback water, juice dilution,lime and sulphate preparation, dilution, molassesconditioning, etc.
• Recycling and reuse of hot condensate water canreduce the water consumption to as low as 100-200litres, as against 1,500-2,000 litres per tonne of canecrushed
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Centre for Science and Environment
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SUGAR INDUSTRY BY-PRODUCTS ; EFFLUENT STREAMS ;TREATMENT & UTILIZATION
1) BAGASSE :a) PRODUCED ABOUT 27-30% OF CANE CRUSHED ; CONTAINS 50%
MOISTURE ; 50% SOLIDS, MAINLY FIBRES
b) CALORIFIC VALUE OF 2000-2200 Kcal /Kg
c) COMPLETELY CONSUMED IN OWN STEAM & POWER GENERATION
d) REQUIRES LARGE STORAGE AREAS ; CAN BE PROCESSED INTOCUBICAL BLOCKS FOR LONGER & COMPACT STORAGE.
Centre for Science and Environment
1) BAGASSE :a) PRODUCED ABOUT 27-30% OF CANE CRUSHED ; CONTAINS 50%
MOISTURE ; 50% SOLIDS, MAINLY FIBRES
b) CALORIFIC VALUE OF 2000-2200 Kcal /Kg
c) COMPLETELY CONSUMED IN OWN STEAM & POWER GENERATION
d) REQUIRES LARGE STORAGE AREAS ; CAN BE PROCESSED INTOCUBICAL BLOCKS FOR LONGER & COMPACT STORAGE.
2) PRESS MUD :a) PRODUCED ABOUT 4-5% OF CANE CRUSHED ; CONTAINS 60%
MOISTURE ; 40% SOLIDS, MAINLY MUD & WAX.b) EARLIER USED TO BE SENT BACK TO SUGARCANE FIELDS AS
IS.c) PRESENT USEAGE IN BIO-COMPOSTING; VALUE ADDITION IN
TERMS OF N:P:K VALUE USING TREATED MOLASSES SPENTWASH IN DISTILLERIES. FORMS BIO-FERTILIZER & USEDMORE EFFECTIVELY BACK IN SUGARCANE FIELDS.
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SUGAR INDUSTRY BY-PRODUCTS ; EFFLUENT STREAMS ;TREATMENT & UTILIZATION
3) MOLASSES :
a) PRODUCED ABOUT 4.5-5% OF CANE CRUSHED ; CONTAINS 20%MOISTURE ; 80% SOLIDS, 38-45% FERMENTABLE SUGARS
b) OTHER SOLIDS INCLUDE UNFERMENTABLE SUGARS & CHEMICALSADDED IN SUGAR MILLS INCLUDING CaCO3, MgSO4, Sulphur, Etc.
c) MAY CONTAIN VOLATILE ACIDS DUE TO FORMATION OF WEAKACIDS DURING LONG STORAGES.
d) COMPLETELY CONSUMED IN DISTILLERIES FOR ALCOHOLPRODN.
e) REQUIRES CLOSED TANK STORAGE ; CONSTANT COOLINGARRANGEMENT ; VALUABLE BY-PRODUCT.
Centre for Science and Environment
3) MOLASSES :
a) PRODUCED ABOUT 4.5-5% OF CANE CRUSHED ; CONTAINS 20%MOISTURE ; 80% SOLIDS, 38-45% FERMENTABLE SUGARS
b) OTHER SOLIDS INCLUDE UNFERMENTABLE SUGARS & CHEMICALSADDED IN SUGAR MILLS INCLUDING CaCO3, MgSO4, Sulphur, Etc.
c) MAY CONTAIN VOLATILE ACIDS DUE TO FORMATION OF WEAKACIDS DURING LONG STORAGES.
d) COMPLETELY CONSUMED IN DISTILLERIES FOR ALCOHOLPRODN.
e) REQUIRES CLOSED TANK STORAGE ; CONSTANT COOLINGARRANGEMENT ; VALUABLE BY-PRODUCT.
4) BOILER ASH :
a) BOILER ASH, GENERALLY 2% OF BAGASSES USED, IS PASSEDTHROUGH WET SCRUBBER SYSTEM & SLAG IS REMOVED & STOREDIN SILOS. LATER IT IS SENT FOR LAND FILLING APPLICATIONS INPRE-IDENTIFIED LOW LINE AREAS. THIS SMALL QUANTITY IS ALSOUTILIZED ALONGWITH PRESSMUD IN BIO-COMPOSTING PROCESS.
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Characteristics of Combined waste Water
Parameter Range of ValueTemperature, (°C) 30-40
PH 4.6-6.0
Dissolved solids 1000-1200
Centre for Science and Environment
Dissolved solids 1000-1200
Suspended Solids 250-300
Oil and Grease 5-10
COD 2000-3000
BOD 1000-1500
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• Class exercise – pls suggest treatmentoption
Centre for Science and Environment
• Class exercise – pls suggest treatmentoption
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Centre for Science and Environment
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ALCOHOL PRODUCTION IN INDIA : 2600 MILLION LITERS
USE OF ALCOHOL :
A) INDUSTRIAL USE – ALCOHOL BASED CHEMICALS (25%) : 650 ML
B) FUEL ETHANOL – ABSOLUTE ALCOHOL (25%) : 650 ML
C) POTABLE ALCOHOL – EXTRA NEUTRAL ALCOHOL (50%) : 1300 ML
Centre for Science and Environment
ALCOHOL PRODUCTION IN INDIA : 2600 MILLION LITERS
USE OF ALCOHOL :
A) INDUSTRIAL USE – ALCOHOL BASED CHEMICALS (25%) : 650 ML
B) FUEL ETHANOL – ABSOLUTE ALCOHOL (25%) : 650 ML
C) POTABLE ALCOHOL – EXTRA NEUTRAL ALCOHOL (50%) : 1300 ML
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ALCOHOL PRODUCTION IN INDIA : 2600 MILLIONLITERS
RAW MATERIALS :
A) MOLASSES – FROM SUGAR MILLS (80%) :
B) GRAINS / STARCH – BROKEN/DAMAGED/SPOILT (19.8%) :
C) CANE /SWEET SORGHUM JUICE – FUEL ETHANOL (0.2%) :
Centre for Science and Environment
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I) MOLASSES BASED DISTILLERIES – BROAD CLASSIFICATION
A) SUGAR MILL ATTACHED DISTILLERIES – OWN MOLASSES & PRESSMUD
B) STANDALONE DISTILLERIES – PURCHASED MOLASSES & PRESS MUD
Centre for Science and Environment
A) SUGAR MILL ATTACHED DISTILLERIES – OWN MOLASSES & PRESSMUD
B) STANDALONE DISTILLERIES – PURCHASED MOLASSES & PRESS MUD
II) GRAIN BASED DISTILLERIES – CLASSIFICATION
A) STARCH BASED DISTILLERIES – HAVE OWN STARCH SURPLUS
B) GRAIN BASED DISTILLERIES – BROKEN GRAINS
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Case study : Rega distillery in Bihar
• Mill was surveyed by CSE in 2008• Survey finding
– Illegal discharge of Spent Wash in the river– Illegal dumping of Spent Wash on private land and along road
side within 5 km
Centre for Science and Environment
• Mill was surveyed by CSE in 2008• Survey finding
– Illegal discharge of Spent Wash in the river– Illegal dumping of Spent Wash on private land and along road
side within 5 km
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Centre for Science and Environment
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Centre for Science and Environment
Illegal discharge of spentwash on private land
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Centre for Science and Environment
Illegal discharge of spent wash on private land/govt land
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Centre for Science and Environment
Illegal discharge of spentwash in low lying area
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Dead frog – impact due to discharge of spent on land
Centre for Science and Environment
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Dead frog – impact due todischarge of spent on land
Centre for Science and Environment
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Industry discharge wastewater inriver during night
Centre for Science and Environment
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Centre for Science and Environment
Dead Snake – impact due toillegal discharge of spent
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Bird carcass due to illegal discharge of spent on land
Centre for Science and Environment
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Illegal discharge of spent wash in river during night: impacton water river characteristic
Centre for Science and Environment
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Industry discharge wastewater in river during night
Centre for Science and Environment
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Industry discharge wastewater in river during night
Centre for Science and Environment
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Illegal discharge of spent wash in river during night: impact onwater characteristic
Centre for Science and Environment
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People complain about cattle death and skin infection
Centre for Science and Environment
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• Molasses, a by-product of sugar industryused as raw material.
• The molasses contains about 40-50% sugar,which is diluted to bring sugar contents to10-15%.
Centre for Science and Environment
• Molasses, a by-product of sugar industryused as raw material.
• The molasses contains about 40-50% sugar,which is diluted to bring sugar contents to10-15%.
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• In India, alcohol is manufactured by twoprocesses
– Batch process
– Continuous process
Centre for Science and Environment
• In India, alcohol is manufactured by twoprocesses
– Batch process
– Continuous process
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Water requirement
• Water consumption - 25 to 28 lit/lit of alcohol
• New – 22 lit/lit of alcohol, after adoptingrecycle and reuse water consumption gonedown to 15 lit/lit of alcohol
• Starch/grain (old) 26 – 30 lit/lit of alcohol,after adopting recycle and reuse waterconsumption gone down to 13 to 15 lit/lit ofalcohol
Centre for Science and Environment
• Water consumption - 25 to 28 lit/lit of alcohol
• New – 22 lit/lit of alcohol, after adoptingrecycle and reuse water consumption gonedown to 15 lit/lit of alcohol
• Starch/grain (old) 26 – 30 lit/lit of alcohol,after adopting recycle and reuse waterconsumption gone down to 13 to 15 lit/lit ofalcohol
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Wastewater sources
Sources of wastewater for molasses based distilleries
Process waste streams
• Spent wash from the analyser column• Fermenter sludge• Spent lees from the rectifier
Non-process waste streams
• Cooling water• Waste wash water• Water treatment plant wastewater• Boiler blow down• Bottling plant wash wastewater• Other wastes
Centre for Science and Environment
Sources of wastewater for molasses based distilleries
Process waste streams
• Spent wash from the analyser column• Fermenter sludge• Spent lees from the rectifier
Non-process waste streams
• Cooling water• Waste wash water• Water treatment plant wastewater• Boiler blow down• Bottling plant wash wastewater• Other wastes
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Characteristics of Spent Wash from Various Types ofmanufacturing process
Centre for Science and Environment
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Process Stream Discharge from DistilleriesBased on Molasses
Centre for Science and Environment
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Spent wash
Centre for Science and Environment
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Ferti-irrigation• Biomethanation – aerobic treatment -- effluent should
not exceed 500 mg/L -- diluted with freshwater prior toirrigation (100 mg/lit)
• Disadvantage:– Requires large land area and fresh water for dilution, pose risk of ground
water pollution– Requires proper monitoring and supervision– Past experience were not satisfactory
• For example, a plant of capacity 30 kld alcoholproduction will requires 270 ha of minimum land forirrigation. Many state pollution control boards areprohibiting this method
Centre for Science and Environment
• Biomethanation – aerobic treatment -- effluent shouldnot exceed 500 mg/L -- diluted with freshwater prior toirrigation (100 mg/lit)
• Disadvantage:– Requires large land area and fresh water for dilution, pose risk of ground
water pollution– Requires proper monitoring and supervision– Past experience were not satisfactory
• For example, a plant of capacity 30 kld alcoholproduction will requires 270 ha of minimum land forirrigation. Many state pollution control boards areprohibiting this method
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Treatment, Recycle & ReuseTreatment, Recycle & ReuseA. Spent wash – Cane Molasses
Bio -CompostingSpent Wash
10-20 % Recycle To Fermentation(Depends on Molasses Quality)
Biodigester
Option – I : Biomethanation & BioCompostingRoute
Centre for Science and Environment
10-20 % Recycle To Fermentation(Depends on Molasses Quality)
Bio -CompostingSpent Wash
10-20 % Recycle To Fermentation(Depends on Molasses Quality)
Bio-digester RO/Evapn
Hence, Zero Discharge of Effluent in Surface Waters is achieved
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Centre for Science and Environment
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Bio-digester
Centre for Science and Environment
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Centre for Science and EnvironmentRO PLANT – YASHRAJ – Alcohols (MAH)
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• 1 kg of press mud – absorb 2.5 to 3 lit ofspent wash
• 60% distillery in India adopted this method
Centre for Science and Environment
• 1 kg of press mud – absorb 2.5 to 3 lit ofspent wash
• 60% distillery in India adopted this method
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Centre for Science and Environment
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Centre for Science and Environment
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Bio-composting
Centre for Science and Environment
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Bio-composting
Centre for Science and Environment
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Bio-compost Bagging
Centre for Science and Environment
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CALCULATION OF COMPOSTINGCALCULATION OF COMPOSTING
• CRITERIA:• Press mud/spent wash ratio= 1:3• Thumb rule – on 1 Acre land = 850 T press mud can be laid
down• Maximum = 5 cycle /year (No Composting rainy season)• 1 cycle = 60 days• EXAMPLE
40 KL/day Distillery• Spent generation – 40 x 12 = 480 KL/day• For 1 cycle , spent wash required – 60 x 40 x 12 KL• Press mud required – (60 x 40 x 12 ) /3 T = 9600T
• CRITERIA:• Press mud/spent wash ratio= 1:3• Thumb rule – on 1 Acre land = 850 T press mud can be laid
down• Maximum = 5 cycle /year (No Composting rainy season)• 1 cycle = 60 days• EXAMPLE
40 KL/day Distillery• Spent generation – 40 x 12 = 480 KL/day• For 1 cycle , spent wash required – 60 x 40 x 12 KL• Press mud required – (60 x 40 x 12 ) /3 T = 9600T
Centre for Science and Environment
• CRITERIA:• Press mud/spent wash ratio= 1:3• Thumb rule – on 1 Acre land = 850 T press mud can be laid
down• Maximum = 5 cycle /year (No Composting rainy season)• 1 cycle = 60 days• EXAMPLE
40 KL/day Distillery• Spent generation – 40 x 12 = 480 KL/day• For 1 cycle , spent wash required – 60 x 40 x 12 KL• Press mud required – (60 x 40 x 12 ) /3 T = 9600T
• CRITERIA:• Press mud/spent wash ratio= 1:3• Thumb rule – on 1 Acre land = 850 T press mud can be laid
down• Maximum = 5 cycle /year (No Composting rainy season)• 1 cycle = 60 days• EXAMPLE
40 KL/day Distillery• Spent generation – 40 x 12 = 480 KL/day• For 1 cycle , spent wash required – 60 x 40 x 12 KL• Press mud required – (60 x 40 x 12 ) /3 T = 9600T
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• To lay down 9600T press mud on land ,area required =9600/850 =11.29 Acre land
• 30% more land required for finished product as well aspress mud storage = 3.5 acre
• Total Land = 11.5 +3.5 = 15 Acre
• If R.O is used = 7.5 Acre land is required
• To lay down 9600T press mud on land ,area required =9600/850 =11.29 Acre land
• 30% more land required for finished product as well aspress mud storage = 3.5 acre
• Total Land = 11.5 +3.5 = 15 Acre
• If R.O is used = 7.5 Acre land is required
Centre for Science and Environment
• To lay down 9600T press mud on land ,area required =9600/850 =11.29 Acre land
• 30% more land required for finished product as well aspress mud storage = 3.5 acre
• Total Land = 11.5 +3.5 = 15 Acre
• If R.O is used = 7.5 Acre land is required
• To lay down 9600T press mud on land ,area required =9600/850 =11.29 Acre land
• 30% more land required for finished product as well aspress mud storage = 3.5 acre
• Total Land = 11.5 +3.5 = 15 Acre
• If R.O is used = 7.5 Acre land is required
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Q1. There is 30KL /day Alcohol production indistillery attached to a sugar factory of capacity2500 T/day, The factory has 10 acre land. Whatshall be choice of distillery to treat the spentwash?
Q2. There 50 KL/day alcohol production in adistillery, there is a sugar factory of capacity5000T/day. The factory has 15 Acre extra land.What shall be the choice of a distillery to treat thespent wash?
Q1. There is 30KL /day Alcohol production indistillery attached to a sugar factory of capacity2500 T/day, The factory has 10 acre land. Whatshall be choice of distillery to treat the spentwash?
Q2. There 50 KL/day alcohol production in adistillery, there is a sugar factory of capacity5000T/day. The factory has 15 Acre extra land.What shall be the choice of a distillery to treat thespent wash?
Centre for Science and Environment
Q1. There is 30KL /day Alcohol production indistillery attached to a sugar factory of capacity2500 T/day, The factory has 10 acre land. Whatshall be choice of distillery to treat the spentwash?
Q2. There 50 KL/day alcohol production in adistillery, there is a sugar factory of capacity5000T/day. The factory has 15 Acre extra land.What shall be the choice of a distillery to treat thespent wash?
Q1. There is 30KL /day Alcohol production indistillery attached to a sugar factory of capacity2500 T/day, The factory has 10 acre land. Whatshall be choice of distillery to treat the spentwash?
Q2. There 50 KL/day alcohol production in adistillery, there is a sugar factory of capacity5000T/day. The factory has 15 Acre extra land.What shall be the choice of a distillery to treat thespent wash?
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• Solution:• Problem1: Spent wash = 30 x 12 = 360 KL/day• 60 days is one cycle for composting ,spent wash= 60 x 360 Kl• 1 acre land = 850 T press mud per cycle• Press mud required = (60 x 360)/3T = 7200T• 10 acre of land = 850 x 10 T premud can be laid down in cycle =
8500T• To lay down 7200 T press mud = 7200/850 = 8.5 Acre.• 30% more land is required = 2.5• Total land = 8.5 + 2.5 = 11 acre• Land available 10 Acre• Therefore RO shall be installed before composting.
Centre for Science and Environment
• Solution:• Problem1: Spent wash = 30 x 12 = 360 KL/day• 60 days is one cycle for composting ,spent wash= 60 x 360 Kl• 1 acre land = 850 T press mud per cycle• Press mud required = (60 x 360)/3T = 7200T• 10 acre of land = 850 x 10 T premud can be laid down in cycle =
8500T• To lay down 7200 T press mud = 7200/850 = 8.5 Acre.• 30% more land is required = 2.5• Total land = 8.5 + 2.5 = 11 acre• Land available 10 Acre• Therefore RO shall be installed before composting.
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• Problem 2: Spent wash = 50 x 12 = 600 KL/day• Spent Wash required for composting = 60 x 50 x12 = 36000KL• Press mud required = 36000/3 = 12000 T• 15 Acre land 850 x 15 = 12,750 T• To lay down 12,750 T press = 12,750/850 = 14.11• 30% More land = 4.23• Total land 4.23 +14.11 = 18.34• However , press mud availability is less• Press mud available for a cycle 5000x.04x60= 12000T• Excess amount of spent wash shall be incinerated or fresh mud
shall be collected.
Centre for Science and Environment
• Problem 2: Spent wash = 50 x 12 = 600 KL/day• Spent Wash required for composting = 60 x 50 x12 = 36000KL• Press mud required = 36000/3 = 12000 T• 15 Acre land 850 x 15 = 12,750 T• To lay down 12,750 T press = 12,750/850 = 14.11• 30% More land = 4.23• Total land 4.23 +14.11 = 18.34• However , press mud availability is less• Press mud available for a cycle 5000x.04x60= 12000T• Excess amount of spent wash shall be incinerated or fresh mud
shall be collected.
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Concentration followed by incineration(best practice)
Method 1• Power generation - SW is concentrated up to 50-60 per
cent and fired in boiler, with or without subsidiary fuel
• Exhaust steam from power plant is used in distilleryand concentration of SW though MEE (e.g of completeZLD)
Method 2• Possible to concentrate SW up to 40-50% and mix it
with rice husk, bagasse etc. and dryed in a rotary dryerto about 75-80 % solids and use it for power generation
Centre for Science and Environment
Method 1• Power generation - SW is concentrated up to 50-60 per
cent and fired in boiler, with or without subsidiary fuel
• Exhaust steam from power plant is used in distilleryand concentration of SW though MEE (e.g of completeZLD)
Method 2• Possible to concentrate SW up to 40-50% and mix it
with rice husk, bagasse etc. and dryed in a rotary dryerto about 75-80 % solids and use it for power generation
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Concentration & Burning of Spent-wash
SPENTWASH 12 M3/ KL
REBOILERS
Centre for Science and Environment
REBOILERS
SPENTWASH10-11 M3/ KL
EVAPORATOR
CONDENSATECONCENTRATE
BURNING PROCESS
CONCENTRATE 2 -3M3/ KL
CONDENSATE 7 - 8M3/ KL
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Treatment, Recycle & ReuseTreatment, Recycle & ReuseA. Spent wash - MolassesOption – II : Concentration & IncinerationRoute
IncinerationBoiler
Evaporation(Concentration)
10-20 % Recycle To Fermentation(Depends on Molasses Quality)
Spent Wash
Centre for Science and Environment
10-20 % Recycle To Fermentation(Depends on Molasses Quality)
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Concentration followed byincineration
Advantages
• Spent wash is used as fuel, every kg of concentrated spentwash replaces nearly 0.33 kg of Indian coal
• Less land requirement
• Zero liquid discharge
• Independent from monsoon, statutory requirements, etc.
• Energy conservation - no separate boiler for steam generation,exhaust steam for power plant can be use in process andoperating evaporator.
Centre for Science and Environment
Advantages
• Spent wash is used as fuel, every kg of concentrated spentwash replaces nearly 0.33 kg of Indian coal
• Less land requirement
• Zero liquid discharge
• Independent from monsoon, statutory requirements, etc.
• Energy conservation - no separate boiler for steam generation,exhaust steam for power plant can be use in process andoperating evaporator.
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Concentration followed byincineration
• Standalone factory – no other option
• Ash generated from the boiler has high potashcontent, which can be used in fields for improvingsoil conditions
• Promotes water conservation
• No requirement of storage lagoons and hence lesserchances of pollution
Centre for Science and Environment
• Standalone factory – no other option
• Ash generated from the boiler has high potashcontent, which can be used in fields for improvingsoil conditions
• Promotes water conservation
• No requirement of storage lagoons and hence lesserchances of pollution
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Concentration followed byincineration
• According to Mr. M. Prakash (V.P., EID Parry)
• Economically viable to generate power from SpentWash if plant capacity >45 KLPD of alcoholproduction
– Capital cost is Rs. 2 crore per KL of alcohol– O&M cost is Rs. 1.50 /liter alcohol.– Payback period is 4.5 to 5 years
Centre for Science and Environment
• According to Mr. M. Prakash (V.P., EID Parry)
• Economically viable to generate power from SpentWash if plant capacity >45 KLPD of alcoholproduction
– Capital cost is Rs. 2 crore per KL of alcohol– O&M cost is Rs. 1.50 /liter alcohol.– Payback period is 4.5 to 5 years
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Case study - Sivaganga distillery
Capacity 60 KLPD, Molassesbased
Cost of the Project Rs. 90 Crores
Cost for incineration Rs. 38 crores
Water requirement Total 853 m3/day, of total 380 m3/day is fresh waterand 473 m3/day condensate and recycle water fromevaporator
Centre for Science and Environment
Water requirement Total 853 m3/day, of total 380 m3/day is fresh waterand 473 m3/day condensate and recycle water fromevaporator
Capacity of power plant 1.6 MWhCoal to spent wash ratio On weight basis (norms 30 : 70, but actual they are
using 20:80)Ash from power plant Ash is rich in nutrient contains total potash >19% and
water soluble potash >15% is transformed intogranules and sold in the market
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Centre for Science and Environment
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Centre for Science and Environment
View of MEE
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Centre for Science and Environment
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Cost economicss.no. Bio-methanization followed by
Bio-composting Concentration followed by incineration
1 Steam – No cost as requirement met fromBiogas
Steam – Requires coal of 60 tons per day@ Rs. 3.0 lacs per day (Rs 5 per ltr ofalcohol)
2 Power – Rs. 2.0 per ltr of Alcohol Rs.0.5 per ltr of alcohol
3 R & M – Rs. 0.25 per ltr of alcohol R & M – Rs 1.0 per ltr of alcohol
Centre for Science and Environment
3 R & M – Rs. 0.25 per ltr of alcohol R & M – Rs 1.0 per ltr of alcohol
4 Income through Biocompost Rs 0.2 / ltr Income through potash ash Rs 1.5 / ltr
4 Investment – Rs 25 crores Investment – Rs 38 crores
When compared to conventional distillery with bio methanation followed by bio-composting, the cost of production is higher by about Rs. 3 to 4 per ltr of alcoholwith incineration system
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What was the ISSUE after Spent WashIncineration?
Centre for Science and Environment
FlyableFlyable PollutionPollution Threat to Health & EnvironmentThreat to Health & Environment Difficult to DisposeDifficult to Dispose Additional Expenses on DisposalAdditional Expenses on Disposal
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Fly Ash as WasteFly Ash as Waste
Centre for Science and Environment
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KASH specification
• The FCO specification for this fertilizer is as follows:– Moisture % by weight, Max - 4.79– Total Nitrogen % by weight, Mini - 1.66– Water soluble phosphate (as P2O5) % by weight, Mini - 0.39– Water soluble potash (as K2O) % by weight, Mini - 14.70
• Our Kash product specs– Moisture % by weight, Max - 4.0– Total Nitrogen % by weight, Max - 2.0– Water soluble phosphate (as P2O5) % by weight, Max - 0.5– Water soluble potash (as K2O) % by weight, Min - 15.0
Centre for Science and Environment
• The FCO specification for this fertilizer is as follows:– Moisture % by weight, Max - 4.79– Total Nitrogen % by weight, Mini - 1.66– Water soluble phosphate (as P2O5) % by weight, Mini - 0.39– Water soluble potash (as K2O) % by weight, Mini - 14.70
• Our Kash product specs– Moisture % by weight, Max - 4.0– Total Nitrogen % by weight, Max - 2.0– Water soluble phosphate (as P2O5) % by weight, Max - 0.5– Water soluble potash (as K2O) % by weight, Min - 15.0
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Ash converted as Fertilizer
Product Specification:Product Specification:
••Brown to black ColourBrown to black Colour••Round GranuleRound Granule••22--6 mm Size6 mm Size••MoistureMoisture –– 44--5%5%••Dispersible in WaterDispersible in Water••Total PotashTotal Potash -- >19%>19%••W.S. PotashW.S. Potash -- >15%>15%
As per FCO norms
Centre for Science and Environment
Product Specification:Product Specification:
••Brown to black ColourBrown to black Colour••Round GranuleRound Granule••22--6 mm Size6 mm Size••MoistureMoisture –– 44--5%5%••Dispersible in WaterDispersible in Water••Total PotashTotal Potash -- >19%>19%••W.S. PotashW.S. Potash -- >15%>15%
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Concentration & biofertilizers
• Not economical to generate power, if plant capacity< 45 KLPD
• In such cases, viable option to achieve ZLD– bio-methanation followed by concentration spent wash (RO/MEE
up to 35 to 40%.) - further concentrated to 95% with the help ofspray dryer’s - use as fertilizers
– Cost of the fertilizer is approx. Rs.1500 per metric ton– Example Ugar sugar works, Karnataka– Fertilizer is also included under FCO (Fertilizer Control Order)
act by Ministry of Agricultural & Co-operation
Centre for Science and Environment
• Not economical to generate power, if plant capacity< 45 KLPD
• In such cases, viable option to achieve ZLD– bio-methanation followed by concentration spent wash (RO/MEE
up to 35 to 40%.) - further concentrated to 95% with the help ofspray dryer’s - use as fertilizers
– Cost of the fertilizer is approx. Rs.1500 per metric ton– Example Ugar sugar works, Karnataka– Fertilizer is also included under FCO (Fertilizer Control Order)
act by Ministry of Agricultural & Co-operation
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Treatment, Recycle & ReuseTreatment, Recycle & ReuseA. Thin Slops - Grain as feedstock
Option – II : EVAPORATION & CATTLEFEED
Syrup mixedwith Wet Cake
‘DWGS’
Thin Slops Evaporation
35-40 % RecycleTo Liquefaction
Centre for Science and Environment
35-40 % RecycleTo Liquefaction
TECHNOLOGY & ADVANTAGES :1. 35-40% THIN SLOPS RECYCLE POSSIBLE TO LIQUEFACTION
1. COMPACT PLANT, HUGE ENERGY SAVINGS WITH INTEGRATEDEVAPORATION WITH DISTILLATION PLANT
3. WET CAKE (FIBRES) SEPARATED EARLIER IN DECATATION ISENRICHED WITH DISSOLVED PROTEINS (SYRUP) FROMEVAPORATION. HENCE VALUE ADDED CATTLE FEED
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Case StudyCase Study
A. 100 KLPD Distillery complexCane - Molasses as Feedstock
Water Quality Requirement WithoutTreatment & Recycle
(M3/day)
Requirement WithTreatment & Recycle
(M3/day)Process Water 1054 253
Centre for Science and Environment
Process Water 1054 253
Soft Water 1306 991
DM Water 290 290
Total 2650 1534
ConsumptionKL / KL
26.50 15.34
Total Water Savings = 42 %
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Case StudyCase StudyB. 100 KLPD Distillery complex
Grain as Feedstock
Water Quality Requirement WithoutTreatment & Recycle
(M3/day)
Requirement WithTreatment & Recycle
(M3/day)Process Water 982 250
Centre for Science and Environment
Process Water 982 250
Soft Water 1300 720
DM Water 290 290
Total 2572 1260
ConsumptionKL/ KL
25.72 12.6
Total Water savings = 51 %
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Comparative Analysis ofTechnologies
Centre for Science and Environment
Comparative Analysis ofTechnologies
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ProcessTechnology
Landrequirement(hectares/MLDinstalledcapacity)
O&M cost(million/year/MLDinstalledcapacity)
Energyrequirement(KWh/MLtreated)
Capital cost(million/MLDcapacity)
Effluent Quality Distinct Advantage
ASP 0.15 to 0.25 Rs 0.3 to 0.5 180 to 225 Rs 2 to 4 BOD: 10-20mg/L.Suspended solids
(SS):20-50 mg/L.The effluent
obtained iscolourless.
Land requirement is veryless and performance is notaffected by normalvariation in wastewatercharacteristic.
Trickling Filter(TF)
0.25 to 0.65 Slightlylower thanASP
180 Relativelylower thanASP
Comparable toASP
Rugged system with simpleand silent operation
Centre for Science and Environment
WasteStabilizationPonds (WSP)
0.8 to 2.3 Rs 0.06 to 0.1 Energy requiredfor the operationof screen andgrit chamber,negligible ascompared toASP
Rs 1.5 to 4.5 BOD: 30-50mg/L.SS: 75-125 mg/L.
The colour ofwater is greenish.
Very easy operation andmaintenance
UpflowAnaerobicSludge Blanket(UASB)
0.2 to 0.3 Rs 0.08 to0.17
10 to 15 Rs 2.5 to 3.5 BOD: 30-40 mg/L
SS:75-100 mg/L
Can absorb hydraulic andorganic shock loading.Sludge handling is minimal
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RotatingBiologicalContractor(RBC)
N.A N.A Very low ascompared toASP
N.A Comparable to ASP Ease of installationand commissioning.Simple to operateand maintain
SequencingBatchReactor(SBR)
0.1 to 0.15 Higher than ASP 150 to 200 Higher thanASP
BOD<5 mg/L
TSS<10 mg/L
The process is timecontrolled andflexible.
FluidizedAerobic Bed(FAB)
0.06 0.5 -0.75 99-170 3-5 BOD<10 mg/LSS <20 mg/L
No sludge recyclingand monitoring ofMLSS required.
Centre for Science and Environment
SubmergedAerobicFixed Film(SAFF)reactor.
0.05 1.14 390 7 BOD<10 mg/LSS <20mg/L
More compact thanthe conventionalSTP’s
MembraneBioreactor(MBR)
0.035 Rs 0.6 to 0.75 180 to 220 3 to 5. BOD<5 mg/LSS<10 mg/LColourless water isobtained.
Highest effluentquality for reuse andvery high life cyclecost.