Sugar | Bioenergy

SPENT WASH INCINERATION TECHNOLOGY

17 October 2016
Prepared by: T SAKTHIVEL
Confidential
Sugar | Bioenergy
Distillery effluent is called as Spent Wash / Slop / Vinasse / Stillage

Confidential
Spent wash Incinerator Sugar | Bioenergy 2
DSW Incineration is the attractive option to achive ZLD.

Confidential
Spent wash Incinerator Sugar | Bioenergy 3
Ch ll
Challenges iin th
these long
l years Chocking,
Ch ki Clogging,
Cl i Cli
Clinker
k &CCorrosion
i

Continual Improvement, now we assures

1. Complete firing of concentrated raw spent wash.

2. Continuous and consistent operation of incinerator for 60 days and more.

3. Meeting complete steam and power demand and making distillery self-reliant.

Hence, Incineration becomes reliable and viable solution to treat DSW today to
meet the zero spent wash discharge.

Confidential
Spent wash Incinerator Sugar | Bioenergy 4
 Sugar | Bioenergy

SALIENT FEATURES OF FC-KCP BRAND SPENT

WASH INCINERATOR

17 October 2016
Prepared by: T Sakthivel
Confidential
Sugar | Bioenergy
Spent wash Incinerator
Model representation of Spent wash Incinerator

Confidential
Spent wash Incinerator Sugar | Bioenergy 6
Salient Features of spent wash incinerator

Three pass boiler design with tall furnace

Very high residence time, >10.0 seconds.

Low flue gas temperature at convection zone, well below initial ash deformation
temperature, prevents fouling of alkalies. Ash fusion temperatures give an
g and melting
indication of the softening g behaviour of fuel ash.
No screen tubes at the furnace exit.
Specially designed slop gun. Possibility for cleaning during operation also.

Confidential
Spent wash Incinerator Sugar | Bioenergy 7
Salient Features of spent wash incinerator

FC-KCP make spent wash Incinerator is a multi-fuel fired boiler.

boiler

The spent wash incinerator is suitable for the following fuel combinations:
1. Conc. Spent wash + Bagasse,
2. Conc. Spent wash + Indian / Imported Coal
3. Concentrated Spent wash + Biomass + Bagasse
3. 100 % Bagasse
4. 100% Indian / Imported coal

Confidential
Spent wash Incinerator Sugar | Bioenergy 8
Salient Features of spent wash incinerator

Travelling Grate technology is

most suitable for such critical
application where bottom ash and
application,
potash rich fly ash is made
available separately, so that
potash rich fly ash is salable at
better commercial price.
Travelling grate continuously
f
conveys the ash from f
rear to front
driven by variable speed hydraulic
drive.

Confidential
Spent wash Incinerator Sugar | Bioenergy 9
Salient Features of spent wash incinerator

T stage
Two t super heater
h t with
ith attemperator
tt t ini horizontal
h i t l third
thi d pass off boiler
b il gives
i
consistent steam temperature.
Steam coil air preheater provided at the discharge of SA and FD fan to avoid
dew point corrosion. Finned type SCAPH is widely used to increase the air
temperature from ambient to requisite level using steam as heating medium.
Wall type soot blowers are provided in the water wall panels of 1st and 2nd pass
to remove the ash deposition from the tubes. Due to this continuous cleaning of
water wall panels which ensures the FOT always well below 540 Deg C.
Retractable soot blowers are provided in the super heater zones.
Rotary soot blowers are provided in Evaporators and Economizers.

Confidential
Spent wash Incinerator Sugar | Bioenergy 10
Salient Features of spent wash incinerator

Bag filter proves to be more suitable technology for this particular application.
Bag filters are used as dust collector as the ash particle sizes are 20 microns
(80% of the qty.)
qty )
The air to cloth ratio is limited to less than 0.5 m3/m2/min - 0.7 m3/m2/min.
The dust concentration shall be less than 50 mg / N cub.m.

Confidential
Spent wash Incinerator Sugar | Bioenergy 11
 Sugar | Bioenergy

PERFORMANCE OF COAL SUPPORTED SPENT

WASH INCINERATOR
RAJSHREE SUGARS & CHEMICALS LTD, GINGEE

30 July 2016
Prepared by: K Prakash
Confidential
Sugar | Bioenergy
 BRIEF SPECIFICATION RSCL, GINGEE

DISTILLERY CAPACITY 80 KLPD

INCINERATOR CAPACITY 30 TPH

SUPPORTING FUEL COAL

OPERATING AT 26 TPH (from

(f 2014)

PRESSURE 45 ATA

TEMPERATURE 400 deg C

STG CAPACITY 3 MW

OPERATING AT 2 5 MW
2.5

CONTINUOUSLY OPERATED 64 DAYS

MAXIMUM SLOP BURNT / DAY 287 TONS

COMMISSIONED MAY 2012

Confidential
Spent wash Incinerator Sugar | Bioenergy 13
Coal Consumption graph:

Confidential
Spent wash Incinerator Sugar | Bioenergy 14
Ash Analysis:

Ash Analysis Report - 30 TPH - Slop fired Boiler (Chemical composition as per lab Report)
Bottom ash Eva & Eco
IInd pass (%) Bag filter (%) Total (%)
(%) (%)
Alumina 5.11 3.23 2.41 3.09 3.62
Iron 3 3.63 2.79 3.92 3.43
Calcium 14.91 11.28 11.17 7.52 10.85
Magnesium 9.54 14.3 14.26 3.8 8.67
Potassium 6.63 13.69 15.89 20.85 14.77
sodium 2.42 4.01 4.26 5.06 3.99
silica 54.29 34.18 34.8 27.29 37.55
Titanium 0.28 0.15 0.11 0.15 0.18
Phosphorous 0.48 1.51 1.45 0.87 0.94
Sulphur 3.14 13.82 12.66 22.65 13.97
Un burnt
0.2 10.21 7.82 7.36 5.71
Carbon
Oil - - - - -

Confidential
Spent wash Incinerator Sugar | Bioenergy 15
Zero effulent discharge
g at RSCL,, Gingee:
g
Ash discharge %

Ash % Ash%
Bottom
Bag filter ash (%)
Bottom ash (%) 30 (%) 30%
40%

IInd pass (%) 15

Eva & Eco (%) 15

II nd
Bag filter (%) 40 pass (%)
Eva & 15%
Eco (%)
Total (%) 100 15%

Confidential
Spent wash Incinerator Sugar | Bioenergy 16
 SPENT WASH INCINERATOR AT RSCL, GINGEE

Rajshree Sugars & Chemicals Ltd., Gingee, TN

Confidential
Spent wash Incinerator Sugar | Bioenergy 17
 SPENTWASH INCINERATOR PHOTOS AT RSCL:

Confidential
Spent wash Incinerator Sugar | Bioenergy 18
 OBSERVATIONS DURING SCHEDULED STOPPAGE AT RSCL:

Confidential
Spent wash Incinerator Sugar | Bioenergy 19
 Noteworthy observation in RSCL - Gingee

Every drop of Spent wash / vinasse

in incinerated. So that safety to
environment
i t is
i ensured.
d

Confidential
Spent wash Incinerator Sugar | Bioenergy 20
Vinasse Incinerator with bagasse as the supporting fuel

Next Big
g Question: Vinasse Incineration with bagasse
g

Mankapur Chini Mills, Mankapur, UP, India, is another significant leap

forward in Incineration Technology by Fives Cail KCP Ltd.

Confidential
Spent wash Incinerator Sugar | Bioenergy 21
 BRIEF SPECIFICATION MCML, MANKAPUR

DISTILLERY CAPACITY 120 KLPD

INCINERATOR CAPACITY 45 TPH

PRESSURE 45 ATA

TEMPERATURE 400 deg C

SUPPORTING FUEL BAGASSE

OPERATING AT 45 TPH

STG CAPACITY 6.6 MW

OPERATING AT 6.5 MW

CONTINUOUSLY OPERATED 52 DAYS

MAXIMUM SLOP BURNT / DAY 382.7 TONS

COMMISSIONED MAY 2016

Confidential
Spent wash Incinerator Sugar | Bioenergy 22
Vinasse Incinerator with bagasse as the supporting fuel

1 Commissioned on 25
1. 25.05.2016
05 2016 with bagasse
bagasse.

2. Concentrated spent wash was fed on 30.05.2016 at a rate of 4 TPH with

bagasse
g as support
pp fuel. The steam ggeneration was 20 to 23 TPH. At this load
the Incinerator was operated for one day.

3. Slop feeding on Incinerator was increased to 10 TPH on 31.05.2016 and

operated.
operated

4. The Incinerator was stopped for 2 days for first formal inspection.

5. The Incinerator was started again from 13.06.2016.

Confidential
Spent wash Incinerator Sugar | Bioenergy 23
Vinasse Incinerator with bagasse as the supporting fuel

6. Incinerator has reached its MCR capacity of 45 TPH steam generation with
concentrated spent wash firing of 15 to 15.92 TPH consistently. All parameters
are found in acceptable limits.

7. Incinerator was operated for more than 50 days continuously after first formal
7
inspection. All parameters are consistent and within acceptable limits.

8. Daily about 355 tons of concentrated spent wash is incinerated. So far, more
than 31065 tons of concentrated spent wash has been incinerated in this
incinerator.

9. This incinerator incinerated 382.7

9 382 7 tons of concentrated spent wash in a day,
day
which is the highest so far, averaging out to 15.92 TPH against guarantee of 15.2
tph.

10. It is observed that incinerating concentrated spent wash with the support of
bagasse, looks to be better, easier and more consistent than with support of coal.

Confidential
Spent wash Incinerator Sugar | Bioenergy 24
 ZERO EFFLUENT DISCHARGE IN
DISTILLERIES
THROUGH INCINERATION TECHNOLOGY

MANKAPUR CHINI MILLS, UTTAR PRADESH

Confidential
Spent wash Incinerator Sugar | Bioenergy 25
 ZERO EFFLUENT DISCHARGE IN
DISTILLERIES
THROUGH INCINERATION TECHNOLOGY

MANKAPUR CHINI MILLS, UTTAR PRADESH

Confidential
Spent wash Incinerator Sugar | Bioenergy 26
 PERFORMANCE GUARANTEES

I i
Incineration
ti off guaranteed
t d vinasse
i generated.
t d

Continuous operation of incinerator for 90 days.

Coal to vinasse
inasse ratio 25 : 75 on heat value
al e basis.
basis

Bagasse to vinasse ratio 30 : 70 on heat value basis.

Confidential
Spent wash Incinerator Sugar | Bioenergy 27
Performance Highlights

Operation friendly
friendl with
ith minim
minimum
m manpo
manpower.
er

Operable round the year irrespective of monsoon.

E
Easy cleaning
l i method.
th d

Thermal shock to the boiler avoided

R d
Reduced
d maintenance
i t cost.
t

Distillery Effluent is converted into potash rich manure.

S f t to
Safety t environment.
i t

Great relief of spent wash disposal problem.

Confidential
Spent wash Incinerator Sugar | Bioenergy 28
 Sugar | Bioenergy

LIST OF SPENT WASH INCINERATOR REFERENCES

Confidential
Spent wash Incinerator Sugar | Bioenergy 29
Reference list:

Capacity Temperature Pressure

Sl. No. Customer Name Status
(TPH) ((C)
C) (ata)
M/s, Rajshree Sugars & Chemicals Commissioned
1 30 400 45
Ltd., Tamil Nadu 2012
M/s,, Jamkhandi Sugars
g Limited,,
2 22 400 45 U d Execution
Under E ti
Karnataka
M/s, Dhanalakshmi Srinivasan
Under
3 Sugars Pvt. Limited (DSSPL) , Tamil 23 390 45
Commissioning
Nadu
M/s, United Spirits Limited (USL), Under
4 20 400 45
Uttar Pradesh Commissioning
M/s, Gem Sugars Limited (GSL),
5 24 400 45 U d Execution
Under E ti
Karnataka
M/s, Mankapur Chini Mills Limited
Commissioned
6 (MCML) Balrampur group, Uttar 45 400 45
2016
Pradesh
M/s, Balrampur Chini Mills Limited
7 45 400 45 Under Execution
(Babhnan Unit), Uttar Pradesh

Confidential
Spent wash Incinerator Sugar | Bioenergy 30
 Capacity
C it Temperature
T t Pressure
P
Sl. No. Customer Name Status
(TPH) (C) (ata)
M/s. K.M Sugar Mills Limited,
8 16 390 45 Under execution
Uttar Pradesh
M/s. Swaraj India Agro Limited,
9 33 410 45 Under Execution
Maharashtra
M/s. Dhampur sugar Mills (Dhampur
10 75 400 45 U d Execution
Under E ti
Unit), Uttar Pradesh

M/s. Dhampur sugar Mills, (Asmoli

11 35 400 45 Under Execution
), Uttar Pradesh
Unit),

Confidential
Spent wash Incinerator Sugar | Bioenergy 31
 Sugar | Bioenergy

SPENT WASH INCINERATOR

Photographs of Fives Cail-KCP brand Vinasse
Incinerator

Confidential
Spent wash Incinerator Sugar | Bioenergy 32
 SPENTWASH INCINERATOR AT RSCL, GINGEE, INDIA - 30 TPH

Rajshree Sugars & Chemicals Ltd., Gingee, TN

Confidential
Spent wash Incinerator Sugar | Bioenergy 33
 SPENTWASH INCINERATOR AT DSSL, PERAMBALUR, INDIA - 23 TPH

Confidential
Spent wash Incinerator Sugar | Bioenergy 34
 SPENTWASH INCINERATOR AT DSSL, PERAMBALUR, INDIA - 23 TPH

Confidential
Spent wash Incinerator Sugar | Bioenergy 35
 SPENTWASH INCINERATOR AT JAMKHANDI, BIJAPUR, INDIA - 22 TPH

Confidential
Spent wash Incinerator Sugar | Bioenergy 36
 SPENTWASH INCINERATOR AT UNITED SPIRITS, ROZA, INDIA - 20 TPH

Confidential
Spent wash Incinerator Sugar | Bioenergy 37
 SPENTWASH INCINERATOR AT UNITED SPIRITS, ROZA, INDIA - 20 TPH

Confidential
Spent wash Incinerator Sugar | Bioenergy 38
 SPENTWASH INCINERATOR AT MANKAPUR, INDIA - 23 TPH

Confidential
Spent wash Incinerator Sugar | Bioenergy 39
 FC-KCP BRAND SPENT WASH INCINERATOR AT
RSCL, GINGEE, INDIA 30 TPH

Rajshree Sugars & Chemicals Ltd.,

Ltd Gingee,
Gingee TN

Confidential
Spent wash Incinerator Sugar | Bioenergy 40
 THANK YOU
FOR YOUR
KIND
ATTENTION

Confidential
Spent wash Incinerator Sugar | Bioenergy 41
 K.Prakash
Head Marketing
Energy

sales.energy@fivescail-kcp.com
T +91 44 6612 8867
M +91 97 90 90 07 45

Fives Cail-KCP Limted

No.2, Ramakrishna Buildings,
Dr. PV Cherian Crescent Road
Egmore, Chennai 600 008. INDIA

Confidential
Spent wash Incinerator Sugar | Bioenergy 42