By K .P. SINGH

RADICO KHAITAN lTD, Rampur

Radico Khaitan, One of the largest players in the

Indian Spirits industry, it was formerly known as

Rampur Distillery which was established in 1943.

Renovation, Expansion and Modernization

converted Radico into the Most Modern and Largest

Potable Distillery of India.

Radico has adopted reduce and

recycle process to manage effluent.

1. ON LINE EFFLUENT MONITORING SYSTEMS

a. Distilleries ( Molasses or Grain based) which are permitted to

discharge treated effluent outside the premises as per the consent to operate from SPCB’s shall install on line effluent

monitoring system for pH , BOD , COD, TSS, Flow Measurement at

the designated outlet point and data to be submitted to CPCB.

b. Distilleries ( Molasses or Grain Based) Which are adopting ZERO LIQUID DISCHARGE of Industrial Effluent as per the Consent to

Operate from SPCB’s shall install online flowmeters and PTZ

cameras as given below.

b.1,Raw Spent Wash / Whole Stillage generation , Concentrated Sp. Wash / Whole Stillage / Thick Syrup after MEE and data

connectivity to CPCB and SPCB server.

THE CPCB DIRECTIVES & GUIDELINES OF STATE POLLUTION BOARDS

THE CPCB DIRECTIVES & GUIDELINES OF STATE POLLUTION BOARDS

1. ON LINE EFFLUENT MONITORING SYSTEMS

a. Distilleries ( Molasses or Grain based) which are permitted to

discharge treated effluent outside the premises as per the consent to operate from SPCB’s shall install on line effluent

monitoring system for pH , BOD , COD, TSS, Flow Measurement at

the designated outlet point and data to be submitted to CPCB.

b. Distilleries ( Molasses or Grain Based) Which are adopting ZERO LIQUID DISCHARGE of Industrial Effluent as per the Consent to

Operate from SPCB’s shall install online flowmeters and PTZ

cameras as given below.

b.1,Raw Spent Wash / Whole Stillage generation , Concentrated Sp. Wash / Whole Stillage / Thick Syrup after MEE and data

connectivity to CPCB and SPCB server.

THE CPCB DIRECTIVES & GUIDELINES OF STATE POLLUTION BOARDS

1. ON LINE EFFLUENT MONITORING SYSTEMS

b.2, PTZ cameras with PAN , TILT Zoom , 5 X or above focal length

with Night Vision Capability should be installed al relevant locations like Bio-composting yard/ DWGS/DDGS production

area / Incineration area and Final storage lagoon / conc. Sp.

Wash storage tank as applicable. The camera feed shall be

provided without pre-requirement of any plug in software for

data display and shall be available on the Google Chrome Browser.

2. ON LINE EMISSION MONITORING SYSTEM

Distilleries ( Molasses or Grain based ) which are having dedicated boilers in the distillery premises as per the consent to operate

from SPCB’s shall provide on line Continuous Stack Monitoring

system for boiler stack / incineration boiler with real time data

logging and data transmission facility to SPCB and CPCB for the

particulate matter parameter.

THE CPCB DIRECTIVES & GUIDELINES OF STATE POLLUTION BOARDS – ZLD in Distillery

1. Distilleries to achieve ZLD by following either of the following two routes.

1.a.Reducing the volume to min. 40% with 30% solids and water conservation by

using appropriate technology such as RO and MEE. The condition of achieving 30% solid should not be applied unilaterally

because , As in in case of Radico despite of achieving reduction of volume to 25%

in place of 40% , the concentration of solids is less than 30% in the effluent being

used in Bio-composting

It is because of a different process which involves feeding of concentrated spent

wash of 24 % solids in digesters wherein the Solid Concentration is reduced again

by ~60% leaving only 8~9% at the outlet of Digesters from 24~25% after MEE ,which

is again concentrated through RO Plant and BMSW MEE to 26~27% but due to

settling of suspended solids and de-composition of organic matters in the storage lagoon at an average it remain 14~15% solids only for Bio-composting

1.b. Installing advance process technologies , multipressure distillation ,

integrated MEE and Incineration Boiler ( Slope Fired / Mixed with aux. fuel, etc.)

.

THE CPCB DIRECTIVES & GUIDELINES OF STATE POLLUTION BOARDS - ZLD in Distillery

2. Distilleries opting for Bio-composting to comply the following –

2.a. Obtaining valid registration / certification for production and quality of Bio-enriched organic manure under FCO.

2.b.The final storage capacity of conc. Sp. Wash after RO & MEE to be

strictly restricted to 30 days of concentrated sp. Wash ( 40% by volume of sp.

Wash .

2.c. The finished Bio-compost shall be packed in sealed poly bags with

the name of manufacturer industry.

However the Ministry of Agriculture and Farmer welfare is of the Opinion that the loose sale of Bio-fertilizers including Bio-enriched manure can be allowed

for Sale in loose condition for which Director (Agriculture – Govt of UP ) is

advised to permit loose sale of Bio-fertilizer

2.d. The Bio-composting activity shall be carried out under covered premises only in the rainy season.

THE CPCB DIRECTIVES & GUIDELINES OF STATE POLLUTION BOARDS - ZLD in Distillery

3. Distilleries opting for concentration & incineration shall restrict

the storage of Sp. Wash at any stage , to 7 days equivalent of production.

RADICO KHAITAN IMPLEMENTED ALL THE DIRECTIVES & GUIDELINES OF POLLUTION BOARDS

1. Radico Khaitan installed Online Mass Flow Measurement with online data

transfer facility to CPCB & SPCB servers for following applications: These flow

meters are operative since Sept. 2017 as per Guide lines dated 11th May

2017.

a. Molasses based distillation plant’s Weak Spent Wash as a feed to

Evaporator.

b. Molasses based distillation plant’s Strong (Concentrate) Spent Wash as output of Evaporator.

c. Molasses based BMSW evaporator Feed and Conc. BMSW flowmeter (

W.E.F. May 2018).

d. Grain based distillation plant’s Weak Spent Wash as a feed to Evaporator.

e. Grain based distillation plant’s Strong (Concentrate) Spent Wash as output

of Evaporator.

UPGRADATION OF EFFLUENT TREATMENT PLANTS

EFFLUENT VOLUME REDUCTION

SN Gauranteed Parameters UOM Values

1 Feed to Evaporator M3 1800

2 Alcohol to Spent Wash Ratio Ratio 1 : 9

3 Initial Solids in Concentration % 12

4 Final Solids in Concentration % 18

5 Sp Wash Volume Reduce After Evaporator M3 1170

6 Alcohol sp Wash Ratio (After Evaporation) Ratio 1 : 6

7 Total Process Condensate Genearted M3 630

8 Effluent of Other Stream M3 90

9 Volume Reduction at RO % 54

10 Volume Feed to BMSW Evaporator M3 580

11 Volume Reduction at BMSW Evaporator % 30

12 Final Sp Wash Volume of Biocompot M3 406

13 Alochol to sp wash Ratio After BMSW Evaporator Ratio 1 : 2

Bio-digester for Biogas Recovery

RO-I

RO-II

COMPLIANCE OF Achieving Zero Discharge

BMSW EVAPORATOR

Process Flow Sheet - Molasses Fer. Wash 1650 TPD

DM / soft water 408 TPD

Molasses DistillationSteam 475 TPD, Steam condensate 475

TPD goes to Boiler

Spent Lees 516 TPD

spent wash 1585 to 1595 TPD

Reboiler and Integrated MEE process condensate 420 TPD goes to

cooling tower & fermentation

Conc. Spent wash 1030 to 1040 TPD

Biodigesters(Biogas sent to bolier)

Bio Digesters Over Flow 1025 to 1035 TPD

TSS reduction plant (Degasser, Lamella

Clarifier, Clariflocculators, Belt Press, Settling

Tank, Final clarifier and DAF)

Thick Sludge to Biocompost

R O Plant (feed 960 to 1050 TPD)Permeate 460 to 490 TPD for CT Make

up water

RO Reject as - Feed to BMSW evaporator 540

to 560 TPD

Process Condensate 170 to 180

M3/day goes to cooling tower

Press Mud

Biocompost

Cocentrated qty 370 - 380

TPD goes to biocompost

>>>> Goes Fermentation for Dilution of Molasses

>>>>>>>>Feed to MEE

CHALLENGES FOR DISTILLERY – CONDENSATE TREATMENT

CHALLENGES FOR DISTILLERY – CONDENSATE TREATMENT

CHALLENGES FOR DISTILLERY – CONDENSATE TREATMENT

CPU – Executive summary

Project

Revised

Installation

Date

Status as on 24.01.2019

B

C

R

Installation of

Condensate

Polishing Unit

(2000M3/Day )

1No ICX Reactor

Biogas Holder

Secondary Clarifier

MGF / ACF and UV

System

01.04.2019

1> Civil Foundation work completed for ICX Reactor and Reactor

Fabrication and Erection work completed .... scaffolding for Epoxy

work is under progreee.

2> Constrcution wok in progress for Equilisation Tank , Filter water

tank , Biogas Holder and Seconadry Clarifer is under progress

3> Civil work completion is targeted by 25h Feb'2019 and

Mechanical Installation is Targetted by 25.03.2019

CPU – Process Flow Diagram ….. 1/2

CPU ….. Process Flow Diagram …. 2/2

ICX REACTOR

FOR CPU

SLUDGE SETTLING TANK

CPU GAS HOLDER

REDUCTION IN WATER CONSERVATION

Reduction in water consumption through recycling

S.No Stream recycled Year -2014-15 Year -2015-16 Year -2017-18

1 Pre-rectifier & Rectification

column Lees

Recycled to

fermentation

house

2 Vacuum Pump water Recycled to

fermentation

house

3 Steam Condensate Recycled to boiler

section

Recycled to boiler

section

4 CO2 Scrubber Water Recycled to

fermentation

house

5 Process Condensate Recycle to cooling

tower

6 RO Permeate Recycle to cooling

tower

Water Consumption / BL

of Alcohol 18 12 8

Covered Bio-composting

Bio-composting

Radico Khaitan installed Online Mass Flow Measurement in distillation

plants with online data transfer facility to CPCB & SPCB Servers

VIEW OF Covered Bio-composting in online CAMERA

Biocompost - Bagging Photographs

ONLINE MONITORING OF BIOCOMPOST FACILITIES WITH PTZ CAMERA AND ONLINE CONNECTIVITY FACILITY WITH CPCB & SPCB SERVERS

COVERED BIO-COMPOSTING

COVERED BIO-COMPOSTING

BIO- COMPOSTING