ZO/BPL/Distillery/2011-12/ Date: April 19, 2011

To

The Member Secretary

Central Pollution Control Board
Parivesh Bhawan
East Arjun Nagar
Delhi-110 032

Sub: Report on Assessment of grain based fermentation technology, waste treatment

options, disposal of treated effluents

Sir,

As per the Annual Action Plan 2010-11, a detailed study of Assessment of grain
based fermentation technology, waste treatment options, disposal of treated effluents
has been completed by this office. The report is enclosed for your kind perusal.

Yours faithfully

(S. Suresh)

Zonal Officer

Encl: As above.

Page 1 of 37
 A Report
On
Assessment of grain based fermentation
technology, waste treatment options, disposal of
treated effluents

2010-11

Central Pollution Control Board

Central Zonal Office
Bhopal

Page 2 of 37
 Report
On
Assessment of grain based fermentation
technology, waste treatment options, disposal of
treated effluents

Principal Coordinator : Sh. S. Suresh, Zonal Officer

Coordinator : Sh. P. Jagan, Scientist C

Sh. Sunil Kr Meena, Scientist B

Monitoring Team : Sh. Sunil Kr Meena, Scientist B

Dr Anoop Chaturvedi, JSA

Report Compilation : Sh. Sunil Kr Meena, Scientist B

Ms. Anamika Singh, SSA

Type Set By : Sh. Sunil Kr Meena, Scientist B

Page 3 of 37
 Contents

S. Details Page
No no.

1 Map Showing the Locations of Distilleries in Central Zone (State-wise) 5-7

2 Abstract 8-9

3 Introduction 10-13

4 Process details Grain based distillery units 14-22

5 Effluent treatment technologies 23-24

6 Conclusions 25-26

Annexures
I Process flow diagram for Grain based alcohol plant
7 27-28
II Effluent treatment Schematic diagram for Grain based alcohol plant

Case Studies 01: M/s United Spirits Limited, Udaipur (Rajasthan)

Case Studies 02:M/s Bhatia Wine Merchant s Pvt Ltd, Bilaspur,(Chattisgarh)
8 29-37
Case Studies 03: M/s Gwalior Distillers Ltd., Rairu, Gwalior (Madhya Pradesh)

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Map Showing the Locations of Distilleries in Rajasthan

Page 5 of 37
Map Showing the Locations of Distilleries in Madhya Pradesh

Page 6 of 37
Map Showing the Locations of Distilleries in Chattisgarh

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 Central Pollution Control Board
Zonal Office Bhopal

Assessment of grain based fermentation

technology, waste treatment options, disposal of
treated effluents

Abstract

Management of industrial waste is one of the most critical environmental problems faced by
the world. Its become costly as well as difficult to treat the variety of wastewater pollutants
generated through various industrial processes. Wastewater characteristics and levels of
pollutants vary significantly from industry to industry. Now-a-days emphasis is laid on waste
minimization and revenue generation through byproduct recovery.

Pollution prevention focuses on preventing the generation of wastes, while waste

minimization refers to reducing the volume or toxicity of hazardous wastes by water
recycling and reuse, and process modifications and the byproduct recovery as a fall out of
manufacturing process creates ample scope for revenue generation thereby offsetting the
costs substantially.

Critical environmental problems raised because of Red Category Molassas based distilleries
due to its very high Biological Oxygen Demand (BOD 40,000-65,000mg/l), Chemical
Oxygen Demand (COD 80,000-1,40,000 mg/l), inorganic impurities & dark brown color
presence in spent wash. Lots of conventional effluent treatment technologies recommended

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e.g. Anaerobic treatment of spent wash to generate biogas, aerobic surface composting to
manufacture bio-compost and reverse osmosis or multiple effect evaporation systems for
concentration of spent wash but the performance of treatment is very poor. Its become very
tough to achieve the Environment (P) Act, 1986 prescribed standards & to follow the
Corporate Responsibility for Environmental Pollution (CREP).

Many molassas based distillery units are switching to grain based distillery process because
of low COD 40,000-50,000mg/l load of Raw Spent Wash. Guidelines of effluent discharge &
CREP for grain based distillery units is yet to come. CPCB Zonal Office Bhopal has taken up
the performance study of grain based distillery units of Central Zone to assess the current
pollution status. It is suggested to have the new grain based guidelines as notification to have
the proper check on distilleries.

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Introduction

Alcohol has assumed very important place in the Countrys economy. It is a vital raw
material for a number of chemicals and become the source of large amount of revenue for
government as Excise Duty. In India about 350 distillery units of 4.0 billion litres & 100
distillery units of 1.8 billion litres are molasses & grain based respectively. Typical Indian
C heavy massecuites byproduct of Sugar industries is being used as raw material in
molasses based distilleries. Potatoes, Rice, Maize, Malt, Wheat, Barley, Sugarcane &
Sugarbeet are various raw materials used in grain based distilleries.

Molasses based distilleries in India are classified as Red Category because of the large
volume of high strength waste water (spent wash) generation (12-15 litres per litre of
alcohol). Spent wash has very high Biological Oxygen Demand (BOD 40,000-65,000mg/l),
Chemical Oxygen Demand (COD 80,000-1,40,000 mg/l) and high BOD/COD ratio. The high
amount of inorganic impurities as Chlorides, Sulphates, Phosphates, Potassium and Calcium
arise critical environmental pollution. Its recalcitrant nature is due the presence of
melanoidins, ceramal, polyphenols and variety of sugar decomposition products such as
anthocyanin, tannins and different xenobiotic compounds.

The unpleasant odour of the effluent is due to the presence of skatole, indole and other
sulphur compounds, which are not effectively decomposed during fermentation and
distillation. Melanoidins are formed by Millard amino carbonyl reaction and have antioxidant
properties, which make them toxic to many microorganisms. The high COD, total nitrogen
and phosphate content of spent wash can result in eutrophication of natural water bodies.

The highly colored compounds of the spent wash reduce sunlight penetration in water bodies,
which in turn decrease both photosynthesis activity and dissolved oxygen concentration
affecting aquatic life. Application of spent wash is also hazardous to the vegetation; reduce
soil alkalinity and manganese availability result in seed germination inhibition. Use of
biomethanated spent wash for irrigation without proper monitoring can
affect groundwater quality by altering its physiochemical properties such as colour, pH,
electrical conductivity etc. due to leaching down of organic and inorganic ions.

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To treat the generated effluent effectively many technologies has already been approved by
CPCB. Anaerobic treatment of spent wash to generate biogas, aerobic surface composting to
manufacture bio-compost and reverse osmosis or multiple effect evaporation systems for
concentration of spent wash.

The existing treatment technologies and their short-falls are as below:

1. Anaerobic Digester followed by controlled land application.

2. Anaerobic Digester followed by anaerobic filter, two stage aerobic treatment and
dilution with fresh water and applied on land as ferti-irrigation.
Controlled land application appears to be one of the viable alternatives if it is
practiced scientifically. The protocol developed by CPCB is based on the practices
followed in other parts of the world with a great success and also studies carried out
by Agricultural Universities in India.
However, the Regulating Agencies feel that Controlled Land Application is not
practicable as monitoring and controls are very difficult, even though the task was
entrusted to Agricultural Universities
Anaerobic Digestion followed by controlled land application/ferti-irrigation is not
encouraged by the CPCB/SPCB as these technologies are found to pollute land and
ground water sources also adoption of ferti-irrigation may not be a feasible
alternative as the secondary treatment is not able to yield the desired results. The
dilution water requirements are huge to meet irrigation standards.

3. Concentration and Incineration in Boiler

o The condensates from evaporators have high COD and require treatment
before discharged into environment or recycled as process water.
o Sludge from spent wash is to be removed before it is sent to evaporators for
concentration.
o The sludge requires treatment such as "composting" which is not permitted as
per the present protocol.
o The operation and maintenance problems of Boilers, especially the clogging
of Boiler tubes appear to be very frequent.
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 o Some suppliers recommend stand- by Boilers which makes the project very
expensive.
o Complaints regarding techno-economic viability of these plants are not
properly assessed.
o The Industry and also the suppliers of these plants are not willing to share the
success of the process.
o The sustainability of this technology needs to be established

4. Anaerobic Digestion followed by evaporation & composting

o The filler material press mud is not available in required quantity

o The ratio of press mud to spent wash of 1:2.5 appears to be impracticable.
o Needs revision depending on the moisture content of press mud.
o The disposal of compost as manure also appears to be difficult in some parts
of the Country.
o The land requirement is around 0.25 hectares per KL of spirit production
which is huge area.
o Due to the large requirement of press mud, the technology may not be suitable
for large capacity Distilleries.
o "Composting" process is not permitted for stand-alone Distilleries as per the
present guidelines.
o Technology is not allowed for raw spent wash due to the fear that leachate
concentrations may be high when raw spent wash is used.
o Whenever "composting" process is adopted, the Distillery should not operate
during rainy season.
o Thus 270 days of operation in a year is only permitted.

5. Recently, the CPCB initiated a project "Co-Incineration" wherein concentrated spent

wash is burnt as fuel in Cement/Steel industries along with other fuels/raw materials.
Even though, the initial trails appear to be encouraging, the effect of inorganic
constituents in spent wash on the finished product is to be assessed.
The applicability of the technology for Distilleries which are located far away is to be
assessed in terms of cost effectiveness.

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The huge quantities of high toxic spent wash and high COD load makes conventional
technologies insufficient to achieve the prescribed standards of inland discharge of
treated effluent. In most of the cases, the treated effluent also yields very high BOD,
COD, TSS, and TDS level with black colored and odor effluent to rivers & natural
water streams.

Compared to molasses-based spirit, grain-based spirit is costlier. But, with the rise in
price of molasses over the past few years, the cost of production from grain is almost
at par with that from molasses. Consequently almost all distilleries who were having
only molasses based fermentation have also installed grain based units so as to have
continuous operation of the plant. Although the grain based process may escalate the
cost of production of alcohol the waste water quality and quantity is reduced.

In the financial year 2010-11 an exercise was made to assess the grain based
fermentation technology, waste treatment options, disposal of treated effluents from
distilleries operating in central zone.

In central zone (Madhya Pradesh, Chattisgarh and Rajasthan), there are about 20
distilleries situated. Most of them have switched over to grains from molasses for
distillation. Out of them 03 purely grain based distilleries (M/s Gwalior Distilleries
Ltd, Gwalior (M.P.), M/s Bhatia Wines Merchant Pvt. Ltd, Bilaspur (C.G.) &
M/s Udaipur distillery Co, Udaipur (Raj.)) were inspected to assess their adopted
fermentation technology and to study the performance of effluent treatment plants.
This study will further guide in conducting studies in remaining distilleries.

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Process details Grain based distillery units

Raw material
Mostly Broken Rice, Kinki, Millet and Sorghum or mixed grains are being used as
raw material in these distillery units. Under table is about the starch percentage &
alcohol yield from various grains.

Raw material Fermentable Carbohydrate (Starch %) Alcohol yield (Lit. of

alcohol/MT)
Rice 62-67 380-418
Sorghum 62-65 380-410
Wheat 62-65 380-410
Potato 19-20 127-134
Malt 58-59 389-395

Maize 62-65 380-410

Composition of various grains:

Grain Starch Gluten & Dextrin, Fatty Cellulose Inorganic salts
other glucose, matter (Silica,
substances etc. Phosphates, etc.)
Wheat 65.99 18.03 7.63 2.16 3,50 2,69
Rye 65.65 13.50 12.00 2.15 4.10 2.60
Barley 65.43 13.96 10.00 2.76 4.75 3.10
Oats 60.59 14.39 9.25 5.50 7.06 3.25
Corn 67.55 12.50 4.00 8.80 5.90 1.25
Rice 89.15 7.05 1.00 0.80 1.10 0.90

Details given in tables state that potato as raw material gives very poor alcohol yield
because of the low starch contents. Rice, Sorghum, Wheat & Maize as raw material
gives alcohol yield of 30-40% and found very much suitable for fermentation process.

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Process (Raw material milling to distillation of alcohol) Annexure-I

Before the milling quality of the grain is being checked. After the quality check grain
is cleaned for removal of dust, lumps, sand, stone, iron etc. and finally store in Silos.

Milling: The cleaned grain is sent to milling machines for grinding grain flour (size
400-700) is conveyed to pre-masher for slurry preparation. In pre-masher, flour &
required water of ratio 1:2 are mixed by agitator. Uniform grain slurry is made and
transferred to another low shear tank (slurry tank) for proper mixing. In slurry tank
required pH of 6.0-6.2 is maintained by using lime if required and temperature as
550C to 600C. An enzyme called -amylase is added here in small (20-25%) dose
before the cooking process starts.

Cooking: The grain slurry is pumped to Jet Cooker (Hydro Heater) through open
impeller centrifugal pump. In jet cooker steam is applied at 8 to 10 kg/cm2 pressure to
cook the starch slurry to break down the chemical structure of starch in presence of
enzymes. The temperature of grain slurry at outlet of jet cooker is maintained between
115 to 1200C. After cooking the grain slurry is passed through the holding coil, which
has several U bends in series and sufficient capacity to provide desired retention
time at a given flow rate to convert starch into dextrin. In this step slurry pressure &
viscosity reduces. The slurry which is hot is transferred into the flash tank to reduce
the temperature of the slurry to 90- 950C before sending to saccharification tank.
Flash tank is attached to flash condensers where vapours are condensed and
condensate is sent to slurry tank.

Liquefaction: Grain slurry is transferred to liquefaction tank from flash tank where
remaining 75 to 80% of enzymes of -amylase is added which convert starch to
dextrin and 1-4 -glycosidase linkages are hydrolyzed into amylose and amylo pectin.
Enzymatic activity rapidly breakdown the starch to soluble dextrins and
oligosaccharides. To have good conversion of starch to dextrin retention time should
be about 2 hrs.

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Saccharification and Fermentation: Many distilleries have Partial Pre-
Saccharification tanks for saccharification process. Whereas conducting
saccharification and fermentation together is another process adopted. The liquefied
slurry pumped through Plate Heat Exchanger (PHE) to the fermenters. The outlet
temperature of grain slurry from PHE is 32 to 350C. In fermenters saccharification &
fermentation takes place simultaneously by adding glycol-amylase enzyme and yeast
culture. Fermentation of starch from grain is somewhat more complex than
fermentation of molasses sugars because starch must first be converted to sugar and
then to ethanol. Starch is converted enzymatically to glucose either by diastase
presents in sprouting grain or by fungal amylase.

The resulting dextrose is fermented to ethanol with the aid of yeast producing CO2 as
co-product. A second co-product of unfermented starch, fiber, protein and ash known
as distillers grain (a high protein cattle feed) is also produced. Glucoamylase
hydrolise dextrin into maltose. In this complete conversion of dextrin takes place and
to reduce the viscosity further spent wash after decanter is mixed to save water.
Maltose further breaks into glucose & fructose. Yeast i.e. Saccharomyces cerevisiae
which produce invertase and zymase enzyme convert glucose & fructose into alcohol.
Above both processes takes place in a fermenter. Glucose is converted into ethyl
alcohol and carbon dioxide evolved is let out. The total duration required is 60 to 65
hours.

The entire material is sent for distillation and yeast sludge in continuous process is
settled at bottom is mixed with water and used for fresh batch whereas in Batch
process the entire yeast sludge was let out. Due to more fermentation time side by-
products i.e. acids & higher alcohols are high as compared to molasses which affects
proper alcoholic fermentation.

The pre fermenters are filled with mash and loaded with contents of the yeast vessel.
The purpose of the aerated pre-fermentation is to allow time for the yeast cells to
multiply (01 gram of dry yeast for 01 litre of Rectified Spirit) and reduce the
chances of contamination. When the pre-fermentor contents are transferred to the
main fermenters, the concentration of yeast cells is high enough

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to substantially reduce the leg time associated with yeast growth in fermentation
process.

The overall transformation takes place into three steps:

Amylase / Gluco-amylase
n(C6H10O5) + n(H2O) n(C6H12O6)
n(162) n(18) n(180)
Invertase
C12H22O11 + H2O C6H12O6 + C6H12O6
342 18 180 180
Saccharomyces cerevisiae
C6H12O6 2C2H5OH + 2CO2
180 92 88

The speed of this transformation process can be influenced by two elements i.e.
temperature and available quantity & quality of water

Distillation
Its a physical process various compounds of a mixture get separated by virtue of their
differences in boiling points. Two types of distillation system are employed in
distilleries.

I. Atmospheric distillation system: To separate & concentrate the

fermented wash to 95% alcohol concentration (rectified spirit), separation of
components is carried out at close to atmospheric pressure. There are five
columns in this atmospheric distillation system:
1. Degassifying column: The distillation column consist number of bubble
cap plates where wash is boiled and alcoholic vapours are separated and
concentrated on each plate stage by stage.
The fermented wash first enters the beer heater, which is a condenser for
condensing alcoholic vapours by using wash as cooling medium. The
objective of the beer heater is to recover the heat from the hot vapours of
alcohol. Fermented wash from the beer heater goes to degassifying column
and degasifying column bottom goes to the top plate of the next column.

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2. Wash/Analyzer column: This column consists 18 plates. The steam is
admitted through the steam sparger situated at the bottom of the column.
As the steam rises up, the wash descending from the top to the bottom of
the column gets heated and by the time it reaches to bottom plate, it consist
practically no alcohol. The wash going out is called spent wash, which is
discharged to the drainpipe. The vapours coming from the wash column
now consists approximately 50% alcohol and 50% water with impurities
such as higher alcohols, aldehydes, acids, sulfur containing compounds
etc.

3. Aldehyde or Heads concentration column: Part of wash column vapours

led to heads concentration column where low boiling impurities are
separated from spirit which is produced at the rate of 10% of total
production depending on the extent of purity required & stored separately.

4. Rectification column & Exhaust column: Other portion of wash column

vapours, which is major quantity, is led to rectifying column, consists 44
plates, which helps the removal of bad smelling fusel oil, which is a
mixture of higher alcohol. As the vapours coming from wash column rise
to the top of rectifying column, the concentration of alcohol goes on
increasing & finally it reaches to the concentration of 95.5% alcohol.

The alcoholic vapours from rectifying column are condensed in the beer
heater against the wash and then in principle condensers and finally in vent
condenser using water as coolant. The condensates of all three condensers
go back to the top of the rectifying column & uncondensed gasses are let
out from the top & cooled in alcohol cooler & taken out as a product.

The fusel oil which is a mixture of higher alcohol is drawn from the 6th to
10th plate from bottom of rectifying column as a stream of vapours; it is
condensed, cooled & led into a decanter where it is mixed with water.
Fused oil being immiscible with water collects at the top and is decanted
through a funnel and sent to storage. The lower portion contains water and

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 alcohol and is sent back to wash column for recovery of alcohol. Fusel oil
is recovered at the rate of 0.2% of alcohol produced.

II Multiple-pressure vacuum distillation system: Vacuum distillation is

defined as that in which the operating pressure in the system is either less
than atmospheric pressure or more than atmospheric pressure. Vacuum is
nothing but sub-atmospheric pressure (negative gauge pressure).

Fermented wash to rectified spirit: Multi-pressure vacuum distillation

system for production of Rectified Spirit consists of distillation columns
namely-
1. Degasifying cum analyzer column- Operation under vaccum

2. Pre-rectification column- Operation under vaccum

3. Rectification cum exhaust column- Operated under pressure

4. Fusel oil concentration column- Operated under atmospheric

Fermented wash is preheated in pre-heater and fed at the top of the Analyzer
column, which is fitted with thermo-syphon reboiler. Top vapours of analyzer
column are spent to pre-rectifier column. Rest of the fermented wash flows
down and is taken out as spent wash from analyzer column bottom. Pre-
rectifier/stripper bottom liquid is preheated with thermo-syphon reboiler and
fed to rectifier cum exhaust column. Low boiling impurities are concentrated
in the pre-rectifier column.
A top reflux draw of condenser is taken out as impure alcohol from the top of
the pre-rectifier column. Rectifier exhaust is operated under pressure and
bottom liquid is preheated with thermo-syphon reboiler. Alcohol is enriched
towards the top and is drawn out as Rectified spirit. Fusel oil build up is
avoided in the Rectified column by withdrawing side streams of fusel oil is
sent to decanter for further separation. The fused oil wash water is recycled
back to the column. A top draw is taken out as impure alcohol from the top of
fused oil column.

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 Fermented wash to extra neutral alcohol (ENA): Multi-pressure vaccum
distillation system for production of Extra Neutral Alcohol consists of
distillation columns namely-
1. Degasifying-cum-analyzer column- Operation under vaccum

2. Pre-rectification-cum-Exhaust column- Operation under vaccum.

3. Extractive Distillation Column- Operation under pressure

4. Rectifier-cum- Exhaust column- Operated under pressure

5. Recovery/Fused Oil Column- Operated under pressure

6. Simmering Column- Operated under atmospheric or Vaccum

Pre-heated fermented wash is fed at the top of the Degassifier column.

Analyzer Column is provided with reboiler. Top vapours of analyzer column
containing all the alcohol in the wash are sent to Pre-rectifier column and are
taken out as spent wash from Analyzer column bottom. Low Boiling
impurities are concentrated in the Pre-rectifier column.

A draw of impure alcohol is taken out from the top of the Pre-rectifier column.
RS draw is taken from the top of Pre-rectifier column, which further is sent to
Extractive Distillation (Purifier) column. Dilution water in the ratio of 1:8 to
1:9 is fed to this column. The Extractive Column operates on the principle of
inversion of relative volatility.

Low boiling impurities are separated in the purifier column & bottom is sent
to Rectifier-cum-Exhaust column. The Rectifier/Exhaust Column concentrates
the alcohol to 96% v/v. The high- grade spirit is drawn from upper trays of the
rectification column. Fusel oil build up is avoided in the Rectifier-cum-
exhaust column by withdrawing side streams (Fusel oils).

Purifier condensates, Degasifier condensates & fusel oil draw from

Rectifier/Exhaust column are sent to Recovery column where these fusel oils
are concentrated and then sent to decanter where these streams are diluted with

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 water and fusel oil rich layer is separated. Washings are sent back to the
column to recover alcohol.

The high spirit draw from the Rectifier column is sent to the Simmering
column where methanol is separated in the form of a cut from the top and
ENA is taken out from the bottom. ENA draw from the simmering column is
taken to the receiver after cooling in ENA cooler. The steam consumption of
this set up would be of about 6.5% of total spirit production.

Benefits of pressure vaccum distillation: Following are the advantages of

pressure vaccum distillation
1. Since the analyzer column operates under vaccum, the formation of
by-products such as acetal may minimize there by improvement in
quality of alcohol.

2. Pre-rectification column ensure removal of sulfur

compounds/mercaptans and also reduces load of lower boiling volatile
compounds passing on to Rectifier-cum-exhaust column.

3. The chances of scaling due to invert solubility of certain precipitating

inorganic salts are minimized in vaccum distillation.

4. Vaccum distillation requires low steam consumption with reboiler i.e.

2.2 Kg/lit. of Rectified spirit and 3.2 Kg/lit. of Extra Neutral Alcohol.

Distillation System with reboilers: Some of the old atmospheric distillation based
as well as all new multi-pressure distillation based distilleries have installed
reboilers along with distillation column to concentrate spent wash & reduce
effluent generation. Use of reboilers results in indirect heating of distillation
columns and restricts the mixing of steam condensate with spent wash. Steam
condensate can be recycled as boiler feed water or can be used as process water.

Distillation with integrated evaporation system: Integrated evaporation or stand-

alone evaporation systems are now getting installed in few distilleries with an

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intension to concentrate the spent wash as per their requirement. It helps to reduce
the final quantity of spent wash generation.
Integrated evaporation system uses alcohol vapours as heating media for heating
the spent wash. Thus, good amount of steam saving can also be achieved in
integrated evaporation systems. Integrated evaporation is expected to concentrate
the spent wash to about 22-30% solids concentration depending on the type of
fermentation system used and final alcohol concentration in wash.

Page 22 of 37
Effluent treatment technologies Annexure II
The effluent aqueous stream with some dissolved solids and some suspended solids
(including fibre) called as raw stillage, is fed to a decanter for separation of
suspended solids from clear solution (called thin stillage). The thin stillage is to be
further processed to reduce it to soilds. Part of it practicing to be recycled to
fermentation to reduce water consumptions in fermentation process.

Balance thin stillage is being fed directly to multi effect evaporator (MEE) to
reduce the volume of the stream or being fed in Up-flow Anaerobic Sludge
Blanket (UASB) for bio-methanation. Bio-methanation is being followed by
extended aeration, clarifier effluent treatment technologies and finally stored in
lagoons used for ferti-irrigation as par the CREP.

In MEE the evaporated water is recycled back to fermentation process and

concentrate is mixed with the suspended solids separated in decanter. This mixer is
rich in nutrients solids and can be used as animal feed. It is called as distillers wet
grain stillage (DWGS). It has high moisture content and putrefied very easily. It
increases the shelf life it is being dried by stream. It is called DDGS (Distillers
dried grain stillage). Distillery can achieve the Zero Discharge Limit through
adopting MEE.

Reverse osmosis (RO), a membrane based separation technique that permits the
separation of certain species in a fluid by a combination of sieving & sorption
mechanisms. An RO is a high-pressure membrane process (15 kg/cm2 to 60
kg/cm2) for separating low molecular weight species from a feed stream. The pore
size 5-20 , typically will reject 99% of most ions & most organics over 150
molecular weight cut off.

Incineration of concentrated spent wash: Concentrated spent wash at 55 to 60%

solids or spent wash powder can be used to run a specially designed boiler with or
without subsidiary fuel. Steam generated can be used to run a steam turbine to
generate electricity and exhaust steam can be used for distillery and evaporation
plant operation. The overall system becomes self-sustaining after initial
stabilization period. This is a zero pollution system with generation of ash from

Page 23 of 37
 spent wash. It has been found that the concentration and incineration system of
spent wash disposal is not economical for distilleries below 60 KLPD capacity.
The co-processing of spent wash concentrate in cement kiln has been investigated
by CPCB and draft guidelines for the same has been prepared. Co-processing of
spent wash concentrate in cement kiln has following benefits:

(a) Wastes are destroyed at a higher temperature of around 1200-14000C and

longer residence time,
(b) Inorganic content gets fixed with the clinker apart from using the energy
content of the wastes leaving no residue behind
(c) The acidic gases, if any generated during co-processing gets neutralized, since
the raw material in cement kiln is alkaline in nature, and
(d) Such phenomenon also reduces resource requirement.

While in case of incineration, residuals require to be disposed suitably.

Page 24 of 37
Conclusions

The outcome of the limited studies conducted by this office could be used at national
level to prepare desired action plan in the studies proposed by M/s Vasantdada
Sugar Institute, Pune.

However, there is a strong need to look into following issues:

i. The existing system of treating the effluents till secondary clarifier is not able
to meet the standards.

ii. The dilution water is not adequate enough to dilute the treated effluent
generating from ETP for further usage like ferti-irrigation.

iii. The MEE technology adopted seems to be giving good results. However this
may be cross checked with cost effectiveness.

iv. The monitoring results at M/s United Spirits Ltd., Udaipur indicates that the
presence of the algal growth is helping to reduce the COD load. This may
further investigated.

v. The further augmentation of the treatment system with tertiary treatment could
further help in reduction of overall load.

vi. The mal-functioning of decantering system is adding to the total load on the
treatment system. Hence, there is a need to maintain the decanting system in
scientific manner to achieve the better results.

vii. The presence of thermophilic micro-organisms consortia in the bio-digester is

playing a vital role in the reduction of COD load. The in-depth study of
microbial consortia can throw more light on the issue.
viii. The possibility of studying micro-algal growth in effective COD reduction
requires to be investigated.

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ix. A detailed study of ground water quality assessment on use of treated effluent
for ferti-irrigation requires to be conducted.

x. The possibility of adding CO2 to grow algae in lagoons (used for storage of
treated effluent) in reduction of pollution load may also be explored.

Page 26 of 37
 Annexure-I

Process flow diagram for Grain based alcohol plant

Grain Grain Flour

Grain handling Pre-mashing
Cleaning Milling
& storage & Slurry Preparation

Recycle
Flour Slurry Steam

Initial Cooking Final

Liquefaction Pre-liquefied Cooked Slurry
Slurry Liquefaction

Low Pressure High Pressure Steam

Steam
CO2

Saccharified
Distillation Simultaneous Saccharification Slurry Partial
& Fermentation Saccharification

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 Annexure-II

Effluent treatment Schematic diagram for Grain based alcohol plant

Steam

Whole Process
Stillage Thin Slop Condensate
Distillation Decantation Evaporation

Wet
Cake
Syrup (30% Solid,
70% moisture)
Dehydration Distillers Wet
Grains
Stillage
(DWGS)
ENA/Potable
alcohol

ENA as Product Stream Dryer Vapours Water

Distillers dried grainDDGS Co-product

Ethanol Storage stillage (DDGS)
(Denaturing)
Ethanol
as Product

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Case Study 01: M/s United Spirits Limited, Udaisagar Road, Udaipur (Rajasthan)
inspected & monitored on 11thMarch, 2011 to access the performance of
treatment plant.

Date of Commissioning Grain based plant started in 2006

Capacity 15 KLD
Water consumption Purpose Consumption in KLD
(Source: Purchase water)
Process 143.7
Steam generation 9.0

Washing Nil
Cooling 54.5
Domestic 20.0

Waste water generation Type of waste water Quantity in KLD

Spent wash 111.5
Spent Leese 18.5
Fermenter washing --

Floor washing --

Bottle washing --

Condensate --
Cooling 1.6
Other 2.4
Total 134.0 KLD

Effluent treatment technologies Decanter

adopted UASB digester
First stage clarifier-cum-aeration
Second stage clarifier-cum-aeration
Tertiary clarifier-cum-aeration
Mode of disposal of treated Used for plantation & horticulture in factory premises
effluent area

Page 29 of 37
Observations

01. The industry is using Rice as a raw material, procured from Gujarat.

02. The industry has 7.77 Acre land which includes plant and green belt area. The treated
effluent is being used in industrial premises for plantation (HRTS) and horticulture.

03. High Speed Diesel (HSD) is being used as fuel in boiler; Coal is not used as a fuel.

04. Decanter was not working properly, only working at 15-20% of its total solid removal
capacity.

05. UASB of 1526 m3 volume, 150KLD hydraulic, 4.5 Kg COD/m3/d organic load is
being used to treat the effluent. Lime is being used for neutralizing the Raw Spent
Wash because the digestor volume is very less & retention time is more e.g. 6-7 days.
1000m3 is the biogas generation out of which 11.36%
biogas is being used in boiler as fuel.

06. After the UASB digester, three stage clarifier-cum-

aeration treatment technology is being used. Red algal
and green algal growth was observed in second stage &
third stage clarifier-cum-aeration respectively due to
sufficient amount of oxygen availability.

07. To access the performance of treatment technologies adopted by distillery waste water
samples were collected and analyzed at Zonal office, Bhopal laboratory.

Analysis report of samples collected on 11th March, 2011

Location pH TS TSS COD BOD
UASB I/L 3.89 41492 15100 61200 20808
UASB O/L 7.63 8012 6030 10520 3580
First (clarifier-cum-aeration) O/L 7.42 4986 2640 2742 877
Second (clarifier-cum-aeration) O/L 7.37 3188 788 908 217
Final outlet 7.42 2094 50 110 18
Permitted under EP Act 5.5 9.0 --- 100 --- 100

Note: All units are mg/l accept pH.

Page 30 of 37
08. The analysis report of samples collected to study the performance of treatment facility
suggest that at inlet of UASB, COD load is 61,200mg/l and after the digestion it
decreases to 10,520mg/l, 82.81% of COD removal is taking place only at bio-
methanation level. The COD load after UASB O/L is
being treated at three stage Clarifier-cum-aeration,
where in presence of red & green algal growth the %
removal of COD is 73.93%, 66.88% & 87.88%
respectively. The overall % removal of COD is
99.82%. Suggest that treatment technologies are
working effectively.

09. The TSS before decanter was 18,450 mg/l & after decanter was 15,100 mg/l. It
suggests that decanters suspended particles (Solids) removal is only 18.15% that is
very poor.

10. Overall the decanter followed by UASB digester & three stage Clarifier-cum-
aeration treatment technology can allow distillery to achieve the prescribed effluent
discharge limit as per E(P)Act,1986. Decanters efficiency should to be improved
through timely maintenance to get good amount of wet cattle feed as by-product.

Page 31 of 37
Case Study 02: M/s Bhatia Wine Merchant s Pvt Ltd, Bilaspur (Chattisgarh), inspected
& monitored on 24th February, 2011 to access the performance of
treatment plant.

Date of Commissioning In the year 2006-07

Capacity Plant -1 Molasses & Grain (30KLD)
Plant-2 Grain based 30KLD
Water consumption Purpose Consumption in KLD
(Source: Borewell) Process Plant 1- Molasses based -300
Grain based- 150
Plant 2 Grain Based - 150
Steam generation 296
Washing 40
Cooling 392
Domestic 204
Waste water generation Type of Quantity in KLD Treatment/mode
waste water of disposal
Spent wash Plant 1- Molasses Plant 1- Primary
based -360 ETP, double stage
Grain based- 150 Secondary ETP &
Plant 2 Grain Ferti-irrigation
Based - 150 Plant 2- MEE
Spent Leese 96 Recycle for spirit
dilution
Fermenter 10 Goes to ETP
washing
Floor 5
washing Lagoon no. 03 (for
Bottle 25 dilution storage)
washing
Condensate 144 Boiler feed tank
Cooling 10 Lagoon no. 03 (for
dilution storage)
Other 204 Lagoon no. 03 (for
dilution storage)

Effluent treatment Complete mixed reactor

technologies adopted UASB digester
Activated Sludge process

Page 32 of 37
Observations

01. The industry is having two plants; one is running on molasses as well as grain (Rice)
and another is purely on grain (Rice) as a raw material.

02. The industry has 25 Acre land which includes plant and green belt area.The treated
effluent is being used in ferti-irrigation through proper networking.

03. The effluent generated in plant 01 from molassas as

well as grain is being first sent to equilization tank
(complete mixed tank) of 50m3.Equilization tank is
followed by UASB(supplied by M/s Praj Industries
Ltd, Pune) of 3626 m3 volume, 240KLD hydraulic,
18 Kg COD/m3/d organic load is being used to treat
the effluent. 140-160m3/hr is the biogas generation
out of which 60% biogas (methane) is being used in
boiler as fuel that gives saving of 20-25% rice husk.

After the UASB digester, the effluent is being treated in extended (Two-stage)
aeration treatment technology. Primary aeration followed by primary clarifier.
Secondary aeration is followed by secondary clarifier. Finally the treated effluent is
stored in lagoons to use the effluent in ferti-irrigation.
04. The effluent of plant 02 (grain based) is being decanted and
then send to Multi effect evaporator to concentrate the
effluent. The decanted solid is being used as cattle feed along
with the MEE concentrate. This MEE technology can achieve
zero discharge of effluent through concentrating the spent
wash.
Generation of biogas is not possible in MEE technology as
we concentrate the wash through steam. Also MEE
technology is not suitable for molasses based distillery due to
sticky nature of molasses.

05. To access the performance of treatment technologies adopted by distillery waste water
samples were collected and analyzed at Zonal office, Bhopal laboratory.

Page 33 of 37
 Analysis report of samples collected on 24th February, 2011
Location pH TS TSS COD BOD
UASB I/L 3.63 34,764 13,700 55,255 22,600
UASB O/L 7.82 7,772 3,880 9,095 3,150
Primary aeration tank O/L 7.86 5,436 2,880 8,820 2,800
Clarifier - A O/L 7.57 4,770 2,480 5,027 1,792
Extended (Secondary) Aeration O/L 7.62 4,016 1,520 1,389 493
Treated effluent used for ferti-irrigation 7.49 1,586 106 941 240
MEE concentrate 6.76 282 02 240 88
Permitted under EP Act 5.5 9.0 100
--- --- 100
Note: All units are mg/l accept pH.
06. The analysis report of samples collected to study the performance of treatment facility
suggest that at inlet of UASB, COD load is
55,255mg/l and after the digestion it decreases to
9,095mg/l, 83.53% of COD removal is taking place
only at bio-methanation level. The COD load after
UASB O/L is being treated at two stage extended
aeration, where % removal of COD is 3.02%, 43.00%
& 72.36% respectively. The overall % removal of
COD is 98.29%. Suggest that treatment technologies
are working effectively but the treatment efficiency of
clarifier and aeration system is very poor because improper sludge removal practices.
Primary clarifier was not working at the time of inspection.

07. The outlet of MEE concentrate of plant 02 is 240mg/l COD & 88mg/l BOD suggest
that this concentration technology can achieve the prescribed limits of effluent
discharge. But the loss of biogas generation & used only for grain based raw material
make this not economical and profitable technology for distillers.

08. Overall the MEE outlet can allow distillery to achieve the prescribed effluent
discharge limit as per E(P)Act,1986 at the cost of no biogas generation. If the
sludge removal practice followed seriously and regularly then grain based distillery
can achieve all effluent discharge limits.

Page 34 of 37
Case Study 03: M/s Gwalior Distillers Ltd., Rairu, Gwalior (Madhya Pradesh), inspected &
monitored on 27th January, 2011 to access the performance of treatment
plant.

Date of Commissioning 1986

Capacity Grain based 180 KLD, On the day of inspection production was
100KLD. Earlier was running on molasses.
Water consumption Purpose Consumption in KLD
(Source: Borewell & R.O.)
Process 486
Steam generation 480

Washing 10
Cooling 32
Domestic 14

Waste water generation Type of Quantity in Treatment/mode of

waste water KLD disposal
Spent wash 632 Biomethanation followed by
secondary treatment
Spent Leese 276 Recycle for spirit dilution
Fermenter 30
washing
Floor washing 5

Bottle 10
washing To ETP

Condensate 4.8
Cooling 12
Other 9.3

Effluent treatment Decanter

technologies adopted UASB digester
Extended aeration system

Page 35 of 37
Observations

01. The industry is using Bajra (Millate), Jawar & Rice as a raw material.

02. The industry has 185 Acre land which includes factory premise and green belt area.
The treated effluent is being used in plantation (HRTS) & ferti-irrigation through
proper networking.

03. In plant there are two type of digester system; Bulk Volume
Fermentor (BVF-Mesophilic digestor) & UASB
(Thermophilic digestor). The effluent generated is being
first sent to decanter unit to separate out the solids as cattle
feed. Decanter is followed by BVF(supplied by
UEM,Delhi) of 1000m3 volume & UASB (supplied by M/s Aqua Technos Asia Co.
Ltd, Thailand) of 1500m3 volume, 2500KLD hydraulic, 135 Kg COD/m3/d organic
load is being used to treat the effluent. 15,000m3/day is the biogas generation that is
being used as fuel in boiler.

After the UASB digester, the effluent is being treated in

extended (Three-stage) aeration treatment technology.
Primary aeration followed by primary clarifier & primary
clarifier is followed by Secondary clarifier-cum-aeration
system. Finally the treated effluent is stored in lagoons to
use the effluent in ferti-irrigation.
Earlier Turbo Mist Evaporator technology was used to
concentrate the treated effluent, but as the technology is
not CPCB approved. Use of said technology has been
stopped.
04. To access the performance of treatment technologies adopted by distillery waste water
samples were collected and analyzed at Zonal office, Bhopal laboratory.

Page 36 of 37
 Analysis report of samples collected on 27th January, 2011
Location pH TS TSS COD BOD

UASB I/L or decanter O/L 3.59 23,080 9,350 46,291 14,625

UASB O/L 7.92 11,876 4,130 11,404 3,166
Primary aeration tank O/L 7.65 8,360 2,040 8,525 2,088
Primary Clarifier O/L 7.21 8,184 2,850 6,358 1,276
Secondary Clarifier-cum- Aeration O/L 8.12 5,392 590 1,521 419
Treated effluent used for ferti-irrigation 7.59 3,556 355 879 214
Permitted under EP Act 5.5 9.0 100 100
--- ---
Note: All units are mg/l accept pH.

05. The analysis report of samples collected to study the performance of treatment facility
suggest that at inlet of UASB, TSS load is 9,350 mg/l e.g. is
very less, it suggest that decanter is working with good
efficiency, COD load is 46,291mg/l and after the digestion it
decreases to 11,404mg/l, 75.36% of COD removal is taking
place only at bio-methanation level. The COD load after
UASB O/L is being treated at three stage extended aeration,
where % removal of COD is 25.04%, 25.41% &
76.07% respectively. The overall % removal of COD
is 96.71%. Suggest that treatment technologies are
working effectively but the treatment efficiency of
clarifier and aeration system is very poor because
improper sludge removal practices.

06. Overall the distillery is not meeting the prescribed

limits of ferti-irrigation because of poor sludge
removal practice that was observed during visit. If the
sludge removal practice followed seriously and
regularly then grain based distillery can achieve all
effluent discharge limit as per E(P)Act,1986.

Page 37 of 37