DISTILLERY OPERATIONS & ENVIRONMENTAL MANAGEMENT

CASE STUDY OF BAJAJ HINDUSTHAN LIMITED

CONTENTS OF PRESENTATION
Raw materials Distillery process description Source of Pollution Brief on Flubex Integrated Distillation Advantage of FLUBEX Technology Biogas Plant & brief description Biocomposting for ZERO DISCHARGE Conclusion

RAW MATERIAL AND UTILITIES

Molasses : Enzymol Antifoam H2SO4 MgSO4 Steam Power Main raw material

DISTILLERY PROCESS
MOLASSES STORAGE FERMENTATION

DISTILLATION
BIOGAS BIOCOMPOSTING

POLLUTION & ITS SOURCES

Water Pollution Spent wash Cooling tower blowdown Boiler blowdown Floor washing

Solid Waste Ash from boiler

Air Pollution Boiler

MOLASSES STORAGE
DISTILLERY HAS ONE MOLASSES UNLOADING TANK. DISTILLERY HAS TWO MOLASSES STORAGE TANK ( EACH TANK CAPACITY IS 1 LAC QUINTAL ). IT HAS MOLASSES TRNSFER PUMPS FOR TRANSFER OF MOLASSES FROM UNLOADING PIT TO STORAGE TANK & STORAGE TANK TO PLANT.

PROCESS DETAILSFERMENTATION
CO2 GAS (108 MT) MOLASSES 700 MT /DAY RAW WATER 1750 M3/DAY ENZYME,MgSO4, SUL ACID, ANTIFOAM FERMENTED WASH (2200 M3)

FERMENTATION

SLUDGE + WATER ( 100 M3)

PROCESS DETAILSDISTILLATION
FERMENTED WASH (2200 M3)
RS
STEAM 240 TON

F L U B E X 2

F L U B E X 1

DISTILLATION ( RS PRODN)

MSDH PLANT

AA 155 KL

STEAM 40 TON

STEAM 100 TON

CONDENSATE

WAREHOUSE

SPENT WASH (1640 M3)

S.W TO BIOGAS (1200 M3)

RECTIFIED SPIRIT (165 KL)

DISTILLATION PLANT

FLUBEX PROCESS DESCRIPTION

Flubex is a shell and tube type heat exchanger with solid wire bits.Remove any scales formed by gentle scouring action which ensures sustained heat transfer.

The spent wash is fed from an inlet nozzle into the lower section by a specially designed distribution plate.It cosists of vertical tubes running from top to bottom.

ADVANTAGES OF FLUBEX EVAPORATOR

1. 2. It ensures continuous evaporation of spent wash. Reduced cleaning frequency of Evaporator resulting reduction in CIP chemicals, which otherwise become a source of Pollution themselves in conventional evaporators. Operates on Vacuum application and is integrated with Distillation for steam Economy. Down time of equipment for maintenance is quite minimum.

3. 4.

BIOGAS PLANT Spent wash coming from distillation plant is send to Biogas plant for biogas generation. Biogas has 60 % methane . Biogas is transferred to boiler for using as fuel . 400 KW / Hr biogas genset is also operated to generate power to meet out off season power requirement when turbine is not in operation and thus diesel is saved by renewable source of energy.

PROCESS DETAIL-BIOGAS
FLARE BOILER BIOGAS BLOWER
BUFFER TANK

CLARIFIER

S.W. 1200 M3

BIOGAS DIGESTER ( 2 No )

LAMELLA

BIOCOMPOST

Sludge recycle EFFLUENT RECYCLE

BIOGAS PLANT

ANAEROBIC TREATMENT PROCESS ( Biogas )

The digested effluent from digester flows to Lamella Clarifier from where settled solid is recycled back to digester to maintain the sludge index

ANAEROBIC TREATMENT PROCESS

Performance of Biogas plant is as follows:

BOD Removal : 85 5% COD Removal : 70 5%

BIOGAS UTILIZATION Biogas Utilization: Biogas generated from the biogas plant is utilized gainfully as fuel in the boiler and consequent steam is routed through turbine to generate the power, The exhaust steam of turbine is utilized in Distillery process. The composition of Bio Gas is as under: CH4- 60-62 % CO2- 38-39 % H2S- 1-1.5 %

BIOGAS ENGINE
400 kw Biogas Genset has been installed and commissioned to generate power from biogas. Biogas engine is procured from Green Power International (Pvt.) Limited, Noida and H2S removal system(scrubber)from Innovative environmental Technology Pvt. Ltd, Pune. Thus non renewable resources will be saved in coming years.

BIO-COMPOSTING
The treated spent wash from lamella is stored into lagoon subsequently consumed in press mud to achieve zero discharge and a good quality organic manure is also produced as by product. Bio-compost manufactured in distilleries is a very good source of major as well as micro nutrients and organic matter which improves soil texture thereby increasing the yield significantly

PROCESS OF BIO-COMPOSTING
Composting is the biological decomposition of ligno cellulosic organic material into simple compound/humus like end-product called ''compost'' , the product is of value in agriculture both as an organic fertilizer and as a soil improver. The process is aerobic which uses various microorganisms such as bacteria, actinomyces and fungi to break down the higher organic compound (cellulose and lignin etc) into simpler substances.

BIO-COMPOSTING
Spent wash is sprayed on each windrow at specific intervals along with turning. Due to turning of mixture of press mud and spent wash by aero tiller, oxygen is supplied to bacteria and composting gets accelerated. It also dissipates the excess heat generated. This helps in homogenizing entire mass, maintaining uniform temp & moisture with effective aeration & oxygen supply

BIO-COMPOSTING
Dissociation of carbon & other complex compound in press mud and spent wash is carried out by bacteria. During composting process temperature goes up to 65-70 degree C. Since Biocomposting is a thermophillic process therefore a considerable amount of heat is generated which causes the evaporation of water present in Spent Wash.

ZERO DISCHARGE SCHEME

The biocomposting is adopted to achieve the zero discharge. Raw material and land requirement for Bio composting process of 160KLPD as per CPCB norms.

Capacity of Distillery : 160 KLPD Total Spent wash generation : 5x160=800 KL (@5KL/KL of production) Max nos. of working days : 270 Days Spent wash generation per year:800x270
=216000KL

TURNING OF BIO-COMPOST

PACKING OF BIO-COMPOST

CONCLUSION
The bio-composting of distillery effluents with sufficient quantities of Press Mud mixed has been found to be most suitable option for achieving the zero discharge as well as a lower cost good fertilizer supplement.

Salient features of biocomposting are This process ensures zero discharge as required under CPCB norms. This process is found to be energy efficient. Bio-Compost has proved as an effective soil conditioner and supplements C, N, P and K.

CONCLUSION
As the distillery is attached with own sugar mill and having sufficient press-mud to achieve the zero liquid discharge through bio-composting & also effectively fulfilling all the Corporate Responsibility for Environmental Protection (CREP) conditions.

There is clean and safe environment in and around of factory