20-06-2018

1

Waste Management & Recycling

from DISTILLERY EFFLUENT

COMPANY : E.I.D PARRY (INDIA) LTD.

LOCATION : SIVAGANGA - TAMILNADUParticipant - 1 KM.Muthukaruppan – Deputy General Manager

Participant - 2 S.Senthilvelan - Senior Manager Process

Participant - 3 S.Muralidharan – Manager Engineering

CII - Environmental Best Practices Award 2018

Let us be the change

RECAP OF CONVENTIONAL SYSTEM SUGAR & DISTILLERY

2

&

SUGAR PROCESS SUGAR MOLASSES FERMENTATION

DISTILLATIONEVAPORATORINCINERATION BOILERTURBINE

ASH To KASH RO PLANT

560 KLPD185 TPD of Con

Spent wash

412 KLPD of condensate

192 KLPD spent less

Fly Ash

20-06-2018

2

Present practice:

The distillery is a largest red category industry which has the Conventional

effluent treatment system.

Effluent is rich in Nutrients like N, P & K and other micro nutrients

Conventional method of treating this effluent is mixing with press mud to

produce bio compost which is sold as a fertilizer as well as sold to cement

industries to use as alternative fuel & grinding agent.

Need for change:

With the above technology, we were permitted to operate the plant only

for 270 days a year and we were proposing to operate 365 days a year

To achieve ZLD with new a concept & technology

To create wealth from waste

NEED FOR THE PRACTICE

3

Distillery can operate 365 days

Zero Liquid Discharge

Creating waste to wealth in terms of Potash rich fertilizer

Converting the spent wash in to renewal energy through Incineration

Entire concentrated Spent wash fired in the incineration boiler at 60 Bx

Converting the fly Ash (Solid waste) into Fertilizer – Value added product

Converting the emitted C02 gas in to valuable liquid product form

Recycle & Reuse of the generated process condensate from Evaporation

including the spent lees(Distillation) back into fermentation to conserve

the ground water.

UNIQUENESS OF OUR DISTILLERY

4

20-06-2018

3

DISTILLERY EFFLUENT – SPENT WASH

INCINERATION

Fly Ash

Evaporation- MEE system

RO PLANT

Fermentation

POTASH FERTILIZER

METHODS ADOPTED IN OUR DISTILLERY UNITS

5

Recycle/Complete ZLD

Condensate Con Spent wash

PROJECT TANGIBLE BENEFIT - 17 Crores per AnnumBoiler Steam generation : 480 TPDActual Coal requirement : 120 TPD (1MT coal generate 4MT of steam)Input of Concentrated Spent Wash : 195 TPD (1MT CSW generate 1.8MT Steam)Steam from the Con Spent wash : 352 TPDCoal Savings by Con Spent wash : 88 TPDCoal savings per annum (300 Days) : 26400 Mt

Project title No.1 CONVERTING THE SPENT WASH INTO RENEWABLE ENERGY

M/s THERMAX has partner in this journey

Project Commencement date : 02nd May 2008

Completion date : 31st Jan 2009

WAY FORWARD – PROJECT IMPLEMENTATION

6

20-06-2018

4

PROJECT TANGIBLE BENEFIT - 2.50 Crores per Annum

Fly Ash generation : 26 TPD.CSW as binding agent : 10 TPD (55% solids @ 58–60 bx) Expected production per day : 35 TPD (6- 6.5 % moisture)

Project title No.2 FLY ASH (SOLID WASTE) INTO FERTILIZER – VAP

In house innovation - Rich in water soluble potash 20 to 22 %

Project Commencement date : 15th Jan 2010

Completion date : 12th Jan 2013

7

Value Added Product-KASH

Fly Ash as Waste from Boiler

Sweet Potash Granules as Product of Fertilizer

20-06-2018

5

Kash

• Boiler ash rich in Potash is sold as fertlizer.• Ash is granulated to a size of 2 mm to 6 mm and sold.• Survey conducted in various state and good feed back is obtained from the farmers.

Field Trial and Findings

20-06-2018

6

PROJECT TANGIBLE BENEFIT - 0.75 Crore per Annum

C02 generation per day : 25 TPD.

Expected C02 per annum :7500 TPA

Project title No.3 CAPTURING THE EMITTED C02 - VAP

Safe Environment - Avoid Carbon Emission – Liquid C02

Project Commencement date : 18th Jan 2017

Completion date : 26th Aug 2017

11

PROJECT TANGIBLE BENEFIT

Ground water savingsOf

530 KLPD

Project title No.4 RECYCLE - REUSE PROCESS CONDENSATE

Resource Conservation

Project Commencement date : 02nd May 2008

Completion date : 31st Jan 2009.

12

20-06-2018

7

13

Tangible benefits: Revenue generation from waste – Rs 20 cr Recovering Resources from Industrial Waste – Potash fertilizer Water and Air pollution are completely eliminated. Water recovery and recycle thereby reducing the ground water drawl.

Intangible benefits :

Reduction in Green house gas emission Organizational goals are achieved Reduce foreign exchange due to import of Potash Employment opportunities Environment Best Practices

TANGIBLE & INTANGIBLE BENEFIT

14

PRODUCT QUALITY

Govt of India – Fertilizer division – Fertilizer control order has listed this product as “Fly ASH (KASH) derived from Molasses”

Sl.No ParametersFCO

Norms(%)KASH G

Results(%)

1 Moisture < 4.79 < 5.05

2 Water Soluble Potash >14.70 >18-19.5

3 Total Nitrogen >1.66 >0.65

4 Total Phosphorus >0.39 0.4

20-06-2018

8

Highly appreciated

by PCB officials for our

success of new technology.

First Distillery to Obtain

MOEF clearance for operating

Plant for 365 Days in a Year.

ECONOMICAL BENEFIT - KASH

15

Introduction of new technology for converting Ash in to Granule form for Ease field Application

KASH Granule Production cost SheetS.No Description Cost Rs/Ton

Variable cost1 Packing & Stitching Cost (50 Kg Bags) 300.002 Loading Cost 60.003 Stitiching cost 4.004 Diesel for Tractors 25.00

Total-Variable Cost per MT 389.00Fixed cost

1 Tractor Rent-2 Nos 75.002 JCB rental charges 35.003 Depreciation of equipments 14.004 R&M-SS Line & Others(Electrical Maintanence) 75.005 Supervisor salary 25.006 Admin & Miscell. Exp- Safety ,stationery etc 5.50

Total -Fixed Cost per MT 229.50

Total cost of Production Rs per Ton 618.50Selling price Rs Per Ton 3000Net Relaisation [Profit] Rs per Ton 2,381.50Expected production per Annum-Tons 10500Revenue Generation Per Annum in Lac 250.06

REPLICATION POTENTIAL WITHIN THE SECTOR

We have already replicated this in other unit which is located in

Rajashree Sugars, BannariAmman Sugars, TN.

16

Best Distillery Award in the case of ZLD system has bagged during 2015-16 in SISSTA

We have already replicated this in our other unit which is located in Haliyal, Karanataka.

PCB instructed to implement the technology as its proven one for ZLD system.

20-06-2018

9

CHALLENGES FACED & OVERCOME METHODOLOGY

17

S.No CHALLENGES OVERCOME METHODOLOGY1 Boiler Run Days:

- Boiler was operated only 20-25 days due to chocking of ash in the coils

Primary super heater coil pitch was increased from 90mm to 103 mm Secondary super heater coil pitch was increased from 100mm to 117mm.

2 Boiler coil chocking:- Incinerated ash started to deposit in the coils leads to

blocking of flue gas path

Introduced soot blower system in the flue gas path to eliminate the ash deposition in the coils

3 Struggling in Bag filter(emission level):- Actual flow gas flow 65000 Cum is higher than

estimated flow45000, the installed 2 modules was notsufficient to handle the volume

- Supplied oven Bags was not tolerating the nature of flyash, resulted in escaping of the particulate matter

Additional 2 modules has been placed par alley to handle the quantity of the flue gas.

Imported PTFE bags are replaced and meet the norms of PCB

4 Erosion of Boiler Air Nozzle:- Top of the Air nozzle(SS 446) are eroded due to the

nature of spent wash incinerated resulted in improperfiring

Hard facing done in the top of the air nozzle to withstand the erosion

5 Installation of standby Evaporation system:- On improving the boiler run days, problem faced in the

MEE system, where it is run for 20 days only

Standby evaporator bodies only placed with common utility system to continue

6 Plate failures in Pre Heating system:- Pitting's are developed in the supplied plates of the

PHE and holes are created due to recycling ofcondensate contains chlorides resulted in product loss

Plates has been replaced with titanium coated SS 304 materials

National Bench mark/ standardsBench Mark / Standards - Environmental Parameter

Water:• No effluent is let out, the generated effluent is

concentrated in MEE / incinerated in boiler.• The generated condensate in the evaporation is

being used for molasses dilution.• Monitoring of BOD/COD is not applicable ,hence

total ZLD is achieved in the case of liquid front.

Emission:• The incinerated flue gas passed through properly

installed APC ( Bag filters).• Online Monitoring system is installed and same has

been connected to SPSB/CBCP portal.• The norms are well within,

Pollutants Unit Norms Actual

SPM Micro G/M3 100 35-45

SO2 Micro G/M4 80 20-25

NO2 Micro G/M4 80 30-35

Energy:• On power, VFD are installed achieved best

consumption of 0.57 Kw/lit against the design of 0.6 Kw/lit. ( Savings - 5.55 Lakh units – Rs 1.10 Cr )

• On Fuel, coal reduction is achieved by operation fine tuning and emission is controlled.

Carbon:• The generated CO2 is captured and converted in to

liquid form/ carbon emission avoided on environmental front.

Toxicity:• The hazardous waste- Turbine oil is disposed

through authorized TNPCB vendor by obtained license from TNPCB

20-06-2018

10

Best Practices- Design Vs Actual

S.no Description Units Design Actual

1. Coal Consumption Air fuel ratio adjusted. Coil pitch increased

Tons/Day 75 42

2 Boiler run days Modification done in the coil pitch

Day 25 65

3 Power consumption Introduction of VFD in heavy duty pumps. Logic control system introduced for auto mode

operation

Kw per lIt 0.6 0.57

4 Impure spirit production: Fine tuning of the operation/based on the

analysis report part of the impure spirit is recycled.

Fetches additional main product and obtained margin of Rs 134900 per day.

No customer complaints

% 6.5 0.95

Future Focus…

Our Future Focus

Predictive & Preventive Maintenance

Value added products

Developing product with Yeast Sludge rich in protein

Improving Efficiency

CapacityEnhancement

74 KLPD

20-06-2018

11

Our Journey Continues For Excellence…

As a