PROPOSED DISTILLERY WITH BOTTLING, BIO-GAS & BIOCOMPOST PLANT

INTRODUCTION
Being an agro based industry; Sugarcane and Sugar tend to fluctuate according to the climatic
factors such as draught, flood, pest and diseases. Growth in Sugar consumption globally
depends to a large extent and determined by the varying trends in the standards of living of the
people in the developed and developing countries. Considering the increasing population and
the necessity to increase the per capita consumption of Sugar, further increasing demand of
Power, Organic manure, Alcohol and Ethanol which are also produced from the by-products
of sugar plant add financial stability to the sugar industry.
In addition to the existing consumption of alcohol in different areas in Bangladesh, the avenue
of mixing ethanol with petrol/diesel is having high potential which will reduce the import value
and also additional revenue to the sugar industries. Since Brazil is already practicing at a very
large level for a very long time, it is catching up in many countries including India. Hence
Bangladesh can also plan for the same.
In developing countries, distillery industries have become a major source of pollution, as 88%
of its raw materials are converted into waste and discharged into the water bodies, causing
water pollution. The waste water from distilleries carry appreciable organic load. The spent
wash is colored, highly acidic with very offensive odor, which poses serious environmental
problems. To overcome its ill effects and to reduce the cost of the effluent treatment, the present
research has been undertaken to convert the distillery waste into compost by means of bio
composting.
At present, Carew and Company produces nine brand of foreign liquor products which are all
distilled alcoholic beverages with 42.76% alcohol contents or 75 proof.

A Modern Distillery Plant to produce exportable foreign liquor is to be established. At present,

the surplus molasses are being sold to local private buyers. Hence, The Government intended
to install two more Distillery plants in the country and produce exportable liquor. Therefore,
SSC was requested to make a proposal for installing one Distillery Plant partly utilizing the
power and steam generated in co-gen plant. The following factors in to consideration for
designing the suitable capacity of the Distillery Plant.

 The molasses availability from nearby factories.

 Demand for the export quality.
 Distance from other factories.
 Excess power and steam availability in Cogeneration plant.

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MANUFACTURING PROCESS DESCRIPTION
The process of converting molasses to RS / ENA can be divided into following sub sections:
1. Feed Preparation and weighing
2. Yeast Propagation and Continuous Fermentation
3. Multi-Pressure Distillation with integrated spent wash evaporator
4. Independent Evaporator

FEED PREPARATION AND WEIGHING

Molasses Stored in a storage tank is first weighed in a tank with load cells so that accurate
quantity can be fed to the fermentation section. The weighed molasses then transferred from
tank to the dilutor in fermentation section where it is diluted with water and fed to the fermenter.

YEAST PROPAGATION AND HIGH FERMENTATION

The yeast from Slant is transferred to Shaker Flasks and grown to the required volume. This
“genetically marked” yeast strain is the further propagated, under aseptic conditions, in yeast
culture vessel. These vessels are equipped with eductors which are designed to achieve
enhanced efficiencies through better sugar / yeast contact by shearing and mixing, efficient
oxygen transfer etc,.
The ready yeast “seed” is then transferred from culture vessel to fermenter. The molasses is
diluted by recycled weak beer (partially exhausted spent wash or vinasse) before fermentation.
This recycle conserves corresponding amount of Dilution Water. The glucose in the Feed
media gets converted to Distillery, in each of the 3 fermenters operating in Continuous Cascade
mode. A plate heat exchanger and a circulation pump is provided to each fermenter, which will
continuously re-circulate the Fermenting Wash through PHE for maintaining the Fermenters
at 30 deg. C the nutrients, biocide, acid and anti-foam agents are fed to the fermenters as per
process requirement. The CO2 liberated during fermentation is sent to CO2 Scrubber for
recovery of Distillery otherwise being lost in vent.
In cascade mode of operation the yeast is recycled by using centrifugal yeast separators and
then acidified in yeast acidification tank and then reactivated in activation vessel. The yeast
slurry is then again sent to 3rd culture vessel.
The Fermented Wash is then sent to the Clarification Tank equipped with Lamella Separator.
The settled sludge is sent to Sludge Washing Tank for recovery of alcohol and the washed
sludge is sent to a Decanter for further recovery of Wash and simultaneous reduction of
moisture in the sludge.

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MULTI PRESSURE DISTILLATION
The fermentation mash containing Alcohol, non-fermentable solids and water is supplied to
Distillation to separate the alcohol and other impurities, as a continuous flow.
The Distillation system is designed for premium quality extra neutral alcohol. The system
details are as below.
The system consists of 8 main columns, namely CO2 Stripper, Stripper Column, Pre-rectifier
Column, Extraction Column, Rectification Column, Refining Column, Fusel Oil Column and
Heads Concentration Column.
Wash is fed to CO2 stripper column to remove CO2 gas present in wash. Alcohol is stripped
off water in stripper column. The top vapours from stripper column are fed to pre-rectifier
column as feed and as heat source too. Pre-rectifier remove most of the fuel oils. And the
distillate from pre-rectifier column is fed to extraction column after dilution where process
water is used as dilution water. In extraction column most of the high boiling impurities
separate from Ethanol in presence of water. The bottom Ethanol water mixture is pre-heated
by steam condensate and spent lees before being fed to rectifier column. In rectifier column
product rectified spirit is taken out from top tray and fed to refining column where mainly on
Ethanol impurities are separated. Pure ENA is obtained at bottom, which is cooled and stored.
The impure spirit from top of extraction column, rectifier column and refining column are fed
to heads column. The final impure spirit cut is taken out from heads column top and balance
alcohol is recycled to prerectifier column. The alcohol containing fusel oil from pre-rectifier
and rectifier column is fed to fusel oil column.
The top vapours from stripper column, Extraction column and Fusel Oil column are condensed
in evaporator for spent wash concentration. The rectifier column, fusel oil column and
prerectifier column get heat from steam at 3.5 bar (g).
Rectification column and pre-rectifier column works under positive pressure. The top vapours
from rectifier column are condensed in stripper column for giving heat to stripper re-boiler.
Most of the other columns work under vacuum. The Distillation process is operated through
PLC.

PROCESS DESCRIPTION ANHYDROUS ALCOHOL

Rectified Spirit at Azeotropic concentration is pumped by Feed Pump. This pump takes care
of the entire back pressure of the system. The pump is in Stainless Steel material of construction
for wetted parts complete with flameproof motor and mechanical seal.
The rectified spirit will first pass through feed economizer, which will pass through vaporizer
cum super heater which will convert the Rectified Spirit feed to superheated Alcohol vapour
stream ready to feed to the Molecular Sieve bottles. The degree of superheat is controlled via
a temperature control loop and the flow rate to the plant is controlled via flow control loop.
The superheated vapour will pass through a Sieve bottle, which is already regenerated, and

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pressurize to working pressure via. a bleed flow from an operating sieve bottle. After the drying
cycle the flow will be shifted to the next Sieve bottle which is ready after duly regenerated and
pressurize. This sequence minimizes the rate of rise and fall of pressure through the molecular
sieve. Thus minimizing the attrition of the sieve beeds. The sieve column after completion of
drying cycle is evacuated to remove the adsorb water through an evacuation system via a
condenser.
The condensed mixture of Alcohol and water is passed through a recovery column which
enriches the stream back to azeotropic composition using return heat of the Anhydrous alcohol
vapour. The Anhydrous Alcohol vapours duly condensed in the reboiler at the recovery column
and is further passed through feed economizer and final product cooler. A flow indicator
indicates the rate of Anhydrous Alcohol going to the Anhydrous Alcohol receivers.

BOTTLING PROCESS
Required quantity of ENA will be pumped from ENA storage to the Blending tank meant for
individual liquor ie Brandy or Rum. Calculated amount of De-mineralised water is pumped to
the blending tank so that the contents attain a concentration of 100 degree proof or around 58%.
This mixture or blend is circulated through a Activated Carbon Filter to remove any odour till
it is mellow. Individual Essence combination by the specialist who is called Blender will be
added and thoroughly mixed. Then the contents are pumped to maturing vats and matured for
different period for different liquors .At the time of bottling required amount of DM water is
added to get a concentration of 75 degree proof or 42.8%v/v or as per requirement.
Once the liquor reaches the stage for Bottling which is fixed by the Blender it is circulated
through a sparkler filter .It is mixed with diatomaceous earth and filtered to get the required
clarity. And pumped to filling tanks..Calculated amount of caramel is added and thoroughly
mixed to get the required colour which differ for each liquor. Since product is organ sensitive
and taste and flavour is is important some of the operation sequences may slightly vary with
blenders choice.
Empty bottles from bottle yard are taken to a washing tank filled with water and washed
thoroughly to remove any dust or fibres .They are transported by conveyors to a mechanical
washer and get washed. They pass through an inspection panel and here any bottle which
contains dirt or not clean is removed. Clean bottles are filled with the liquor in a rotary type
vacuum filling machine and required quantity is filled in the bottles. e filled bottles are the
filled bottles pass through second inspection panel where any bottles having any foreign matter
are removed. Then the bottles are capped with pilfer proof seal caps automatically. Then the
bottles pass through third inspection panel to remove any bottle having broken glass piece is
removed. Remaining good bottles are labelled in automatic Labelling machine. Finally the
bottles are collected in a rotary table. The bottles are finally packed in corrugated cartons. The
packed cartons are transported to warehouse storage and stored. And ready for despatch.

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BIO METHANISATION & COMPOSTING TECHNOLOGY
Distillery generates spent wash, an obnoxious effluent, having foul odour, brown colour, acidic
pH, high organic load (BOD & COD) and high concentrations of dissolved solids. Sugar
industry generates Press mud, a low density, soft, amorphous waste material containing 1- 20%
N, 0.6-36% P and 0.3- 1.8% K. Composting is an interaction between Spent Wash – Press mud,
mixed population of micro organisms, moisture and oxygen.
Composting process accepts raw spent wash from batch / semi continuous / continuous system
and rejects of:-
1) Bio-methanisation Plants
2) Reverse Osmosis Plants
3) Evaporation Plants
4) Biogas followed by evaporation / Reverse Osmosis

Treatment of Distillery spent wash

Proposals for establishing distilleries attached with sugar units may be considered if they follow
one of the following options:
 Bio-methanisation followed by bio-composting; or
 Re-boiler/Evaporation/Concentration followed by incineration of concentrated spent
wash in boiler (for power generation)
Distilleries attached to sugar mills installed improved technologies for concentration of spent
wash by installing R.O/multiple effect evaporators etc for achieving 50% reduction in volume
of spent wash. The requirement of press mud as well as the land for making compost also gets
substantially reduced, strictly adhering to the protocol for making bio compost.
Concentration of spent wash in multiple effect evaporators and its subsequent incineration is
not found technically and economically feasible in majority of cases. Incineration of
concentrated spent wash in sugar mill boilers creates major problems due to scaling and
frequent shut down of boilers for maintenance etc. Hence it is proposed to consider only Bio-
Gas followed by Bio Composting for this project.
This method requires a large area for Bio-composting. To avoid seepages to the subsoil water
the entire area has to be concreted. Further, Bio-composting alone cannot be adopted during
Monsoon season.

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BIO-GAS AND BIO-COMPOST
RO PLANT
In many distilleries it is a practice to have RO plant to treat spent wash for following reasons.
1. To recycle water from spent wash.
2. To concentrate spent wash so that smaller area will be required for bio composting.
However we are not suggesting RO plant because initial and operating cost will increase
making production cost high. Apart from that additional operating staffs are required to operate
the RO plant.

BIO-GAS METHANISATION
Spent wash from analyser column which is at 1050C is passed through a plate heat exchanger
to pre heat the feed. Then it is cooled to room temperature in another heat exchanger. Since the
pH of spent wash will be around 4.5, it is treated with lime to increase the Ph to normal level
i.e around 6.5-7. It will be pumped to the Bio Gas reactor which is a cylindrical vertical tank
of 9000M3fitted with lateral entry agitators and vertical agitator, after starting the distillation
the digester is filled slowly to around half the level and inoculums will be added to the spent
wash and anaerobic digestion is started. The entire mass will agitated slowly and mixed for
uniform digestion. Bio-gas having around 50% Methane is taken from the top of the digester.
Gas will be scrubbed and collected in a gas holder. The gas system will be provided with safety
features like flare stack where excess gas is burnt. Gas from gas holding tank is sent to the
captive boiler where it is burnt and furnace oil is used as additional fuel.
De-methanated Spent wash from the digester is passed through degasser is sent to lamella
Clarifier. Lamella clarifier will be having set of parallel plates. When Spent wash with
suspended solids is passed through parallel plates suspended solids will be settled in the plates.
The spent wash is collected in a collection tank of 70M3 Capacity. The brix will be 4-5 B.O.D.
This will be sent for bio composting yard.
The Bio methanisation section is provided will be equipped with safety features like Flame
Arrester, Breather valves, Pressure gauges, etc.

BIO COMPOST
Bio Composting is a process by which de-methanated spent wash is reacted with press mud
from sugar mills. Press mud from sugar will have 70% moisture. Reaction with press mud is
exothermic and final moisture content will be 30%. To accomplish this, the entire bio
composting process will be under open atmosphere. Since it is an open to atmosphere process
it is considered to operate for 180days. Even though 310 M3 of spent wash is coming from Bio
gas reactor for bio composting around 500m3of spent wash will be utilised for bio composting.
After collecting 30 days spent wash in a tank bio composting can be started.

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For this purpose if storage is used then the tank has to be lined with 250 micron thick HDPE
sheets and stone sealing to pre vent seepage. Around 10 acres of compost yard is concreted
using HDPE sheets of 250 micron thick over which 1:2:4 Cement concrete of 150mm thick is
built. Curb wall around is built to avoid seepage of spent wash and a garland canal is to be
constructed to collect all seepage during composting operation. The seepages are collected in
a tank which is made as above. The spent will be pumped back to storage pond or used in
composting yard.
Press mud from sugar mill will have 70% moisture. Windrows of size 3.5Mtr wide and 1.5Mtre
height will be laid and allowed to dry for about 3-5days with periodical rotating using a tiller.
The moisture content is reduced to 30%.
Windrows are aero tilled and trimmed by breaking lumps and shredded to uniform consistency.
Then inoculums and spent wash are sprayed using spray mechanism with nozzles and aero
tilled. The reaction being exothermic the temperature rises to 60-700. The wind rows are tilled
regularly and sprayed for about 45-50 days depending upon the climate. This helps in
homogenising entire mass and maintaining uniform temperature and moisture, with effective
aeration and Oxygen supply. Bacteria separate Carbon and other complex materials from Press
mud and Spent wash.
Press mud to spent wash ratio will be initially 1:2.5 and at end stages it goes down to
1:1.2.Remaing days wind rows are tilled and rolled over to reduce moisture. From51st day
moisture reduces curing and aging and stabilisation gets underway .this again reduces moisture.
The entire cycle takes around 60 days.
Once the compost is ready it is trimmed to remove lumps. Sieved and collected in bags. The
biofertiliser is weighed and packed in gunny bags using filling machines and stored in the yard.
Around 2 acres are required for press mud storage and 10 acre for composting. Another 2 acres
of covered area is required for storing the product. Since above operations are carried out under
open air it is not during monsoon season.

SPENT LEES
Around 50KL of spent lees having traces of alcohol will be at around 100 0C. Previously it
was recycled to dilute R.S. in ENA distillation section. Since the quality of ENA was affected
this method was stopped. As we want very high quality ENA we cannot use in ENA section.
There are three types of utilising this.
1. Spent lees can be cooled and utilised for Dilution of Molasses for fermenters.
2. Spent lees can be added to spent wash for Bio Methanisation. But this increases load on
digester. Hence this is not advisable.
3. Spent lees cannot be added to Bio Compost since press mud and land area available is not
sufficient.

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4. Putting an RO plant for treating and recycling water is advisable as it increase Installation,
operational cost and addition of man power.
Hence in view of the above reasons it is advised to use spent lees for molasses dilution.

POWER PLANT
Bio-Gas obtained by anaerobic digestion will be collected and taken to the boiler with all safety
precautions and flame arresters. The biogas will be burnt in a package boiler from which is
about 6 Tons of steam will be produced. In addition to the available bio-gas, furnace oil will
be used to produce the required quantity of steam from the boiler. The boiler capacity shall be
about 10 tons capacity generating steam at 21 ata and 300 Deg.C. The steam will be sent to
Turbo-set where partial power for captive consumption will be produced. Balance power will
be taken from Cogeneration power plant. Exhaust steam from the Distillery plant Turbine will
be taken for Distillation process.

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