Processing Distillery MEE Condensate as an Energy Source with Water Recycle

Transcription

1 Processing Distillery MEE Condensate as an Energy Source with Water Recycle All India Distillers Association Annual Conference 2018 Arvind Lali 1, Hitesh Pawar 1, Sukhraj Soni 2 1 DBT-ICT Centre for Energy Biosciences, Institute of Chemical Technology, Mumbai 2 India Glycols Limited, Kashipur

2 Institute of Chemical Technology Mumbai (formerly UDCT)

3 DBT-ICT Centre for Energy Biosciences Matunga, Mumbai

4 DBT-ICT Centre of Energy Biosciences (Sanctioned Dec 2007; Functional May 2009) - India s first National Bioenergy Research Centre - Multidisciplinary State-of-the-Art facility with emphasis on developing cutting-edge science and translation to commercially viable technologies - Networked with Institutions & Industry in India and abroad >60 PhD scholars; >10 Senior Research Scientists in different disciplines of modern biological sciences and chemical engineering/technology

5 DBT-ICT Centre of Energy Biosciences (Sanctioned Dec 2007; Functional May 2009) Equipped to develop and translate projects Involving any combinations of: - Synthetic Biology - Protein Engineering & Technology - Chemical Catalysis - Fermentation Technology - Separation Technologies - Algal Technologies

6 India s First dedicated Bioenergy Research Centre State-of-the-Art Laboratory engaged in Basic and Translational Research in the areas of bioenergy and Biobased Products Capabilities : Designing Full scale Plants Molecules Biological & Chemical Catalysts Processes (Reactions + Separations) DBT-ICT Centre for Energy Biosciences 6

7 Waste-to-Value Opportunities 400 MMT/year Plastics & Bio-wastes 40 MMT/year 70,000 MLD Industrial Waste Distillery sludge & Spent wash 30 MMT/year Energy Distillery sludge & Spent wash 35 MMT/year Fuel/Energy and Materials

8 Waste & The Distillery Industry ~350 distilleries (30KLPD 400KLPD Capacity) Installed annual capacity ~ 350 crore L Distillery Spent Wash(DSW)/Vinasse: 10-15L/L ethanol COD: 80, ,000 ppm Solid Sludge waste: 30 kg/kl Ethanol WASTE Processing Technology: Predominantly Multiple Effect Evaporator (MEE) + Incinerator Systems; and Biogas+MEE+Biocomposting systems (Land + Press mud requirement) Products SLOPS produced: ~50% of Vinasse or DSW Energy Condensate water for re-use : ~1500 crore L Water lost to Evaporation : ~1500 crore L BioCompost for Sale!!

9 Waste & The Distillery Industry ~350 distilleries (30KLPD 400KLPD Capacity) Installed annual capacity ~ 350 crore L Distillery Spent Wash(DSW)/Vinasse: 10-15L/L ethanol COD: 80, ,000 ppm Processing Technology: Predominantly Multiple Effect Evaporator (MEE) + Incinerator Systems (SLOPS produced: ~50% of Vinasse or DSW) Not really usable Condensate water for re-use : ~1500 crore L without further treatment and cost!!! Water lost to Evaporation : ~1500 crore L Unnecessary Loss of water!!!

10 Sustainable Solutions required Short Term Find a way to re-use condensate water at no/low cost Medium Term Recover >90% water from Spent Wash or Vinasse at low/no cost Long Term Prevent formation of molasses Convert fermentation sludge to sustainable product

11 Sustainable Solutions The DBT-ICT ZeroD Technology (Version 1) Short Term Find a way to re-use condensate water at no/low cost Medium Term Recover >90% water from Spent Wash or Vinasse Long Term Prevent formation of molasses Convert sludge to sustainable product

12 Coloured Recalcitrant Polymeric Carbonaceous Matter (COD) In Spent Wash Coloured Biodegradable Polymeric Colourless Volatile Monomeric

13 ZeroD Evaporator Condensate Processing Technology Basic Concept: Capture of high MW Carbonaceous components and separate from VFAs and inorganic TDS Waste Water Carbonaceous matter VFAs Inorganic salts Capture Reactor Reagent RO + HP-RO Clean Water COD<150 TDS<100 Carbon Oil Fuel Reject MEE/Dryer

14 WORK PROGRESS AT DBT-ICT LABORATORIES Pilot scale validation system Operating scale 100 Lit/day Kg scale validation system Operating scale 10 Lit/day Lab scale system Operating scale 100 ml

15 Process Performance INPUT OUTPUT High COD Condensate COD ~ 8000 TDS ~ 3500 Recovered Water COD <200 TDS ~ 80

16 Process Material Balance 1500m 3 /day Condensate Processing Solvent Reagent 160kg/h Condensate 4000 COD 1600 TDS 65m3/h ph 2.5 R2 Reactor Block Flow Through COD 2500 TDS m3/h ph Stage RO Membrane Permeate 200 COD 80 TDS 60m3/h ph 7.5 Solvent Recycle Distillation Oil Solvent + Oil 95 kg/h Oil Solvent for recycle Dsitillation: 500LPH Reject COD TDS 5m3/h ph 7.5 MEE HP-RO Reject TDS TDS 1 m3/h ph 7.5 Permeate 200 COD 80 TDS 4 m3/h ph 7.5

17 Distillery Waste Oil Analysis Sr.No Entry Results 1 Color Dark yellow to Brown 2 Density gm/ml 3 Calorific Value MJ/Kg 4 ph 5-6 Carbon: 56%, 5 Hydrogen: 7%, Elemental composition Nitrogen: 0.2% (C,H,N,S and O) Sulfur:0.15% Oxygen: 36% 6 Ash content (by gravimetric analysis) % 7 Stability Stable at normal storage conditions 8 Chemical composition (by GC-MS) Volatile fatty acids hydrocarbons, esters, alcohols, carboxylic acids etc. 9 Flash Point C 10 Pour point C 11 Viscosity cp

18 Plant & Machinery ~ Rs. 4.5 cr

19 Advantages of the Process Can handle varying input condensate COD Carbon (other than VFAs) recovered as fuel The fuel earns revenue (after accounting for the process steam required) VFAs and salts concentrated on RO without fear of carbon fouling VFAs and Salts can be recovered by drying or in boiler ash (via MEE) 98% water recovered as clean re-usable water Disadvantage The process does not pay for itself!! Can we add more carbon to make more fuel-oil

20 ZeroD Condensate+Fermenter Wash Processing Technology Basic Concept: Capture of high MW Carbonaceous components and separate from VFAs and inorganic TDS Reagent Waste Water High Carbonaceous matter VFAs Inorganic salts 2 Step Capture Reactors RO + HP-RO Clean Water COD<150 TDS<100 Carbon Oil Fuel Reject MEE/Dryer

21 DISTILLERY CONDENSATE + FERMENTER WASHING PROCESSING TECHNOLOGY Aq. Solvent 50 m 3 Oil 1 + Oil 2 23 ton (< 3% moisture) Fermenter washing 250 m 3 COD 100,000 TDS 10% ph 4-5 R1 Reactor Block 225 m 3 COD 50,000 TDS 5% ph 3-4 Solvent + Oil + Water Solvent for recycle m 3 Distillation & Drying Aq. Solvent 14 m 3 Solvent + Oil + Water Solvent for recycle m 3 Condensate Clear Water 14 m 3 Condensate 1500 m 3 COD 4000 TDS 0.16% ph 2.5 Feed Mixing Tank Composite Feed 1725 m 3 COD 10,000 TDS 1% ph 3-4 R2 Reactor Block Flow Through 1710 m 3 COD 2500 TDS 0.94 % ph 7.5 RO Membrane Permeate 1368 m 3 COD 150 TDS 80 ppm ph 7.5 Clean Water 1574 m 3 COD < 150 PPM Chemical Agent 3.75 ton MEE 150 m3 TDS 10% HP-RO Reject 342 m 3 COD 11,900 TDS 4.6% ph 7.5

22 Capacity OPEX for Condensate + Fermenter Washing 1750 KLPD Variable Cost Quantity Expense Component Unit rate (Rs.) per day (Rs.) Solvent (kg) Power (kwh) Steam (ton) Chemicals (ton) Total variable cost per KL DSW Revenue Quantity Revenue Component Unit rate (Rs.) per day (Rs.) Bio-Oil (ton) Water, (m 3 ) Total per kl DSW Margin for servicing capital per KL Feed Plant & Machinery ~ Rs. 6.0 cr 71.52

23 Advantages of the Process Variant All Carbon (other than VFAs) recovered as fuel The fuel earns revenue (after accounting for the process steam required) VFAs and salts concentrated on RO without fear of carbon fouling VFAs and Salts can be recovered by drying or in boiler ash (via MEE) 90% water recovered as clean re-usable water Pays for itself within 3 years

24 Path Forward - Demonstration plant at India Glycols Ltd., Kashipur (by May 2018) - Design of 1500m3/day plant underway

25 Next Solutions required Short Term Find a way to re-use condensate water at no/low cost Medium Term Recover >90% water from Spent Wash or Vinasse The DBT-ICT ZeroD Technology Long Term (Version 2) Prevent formation of molasses Convert sludge to sustainable product

26 Sustainable Solutions required Short Term Find a way to re-use condensate water at no/low cost Medium Term Recover >90% water from Spent Wash or Vinasse DBT-ICT Long Term Sugar Refining Technology Prevent formation of molasses Convert sludge to sustainable product

27 Sustainable Solutions required Short Term Find a way to re-use condensate water at no/low cost Medium Term Recover >90% water from Spent Wash or Vinasse Long Term Prevent formation of molasses, DBT-ICT CTL-Technology Convert sludge to sustainable product

28 DBT-ICT Centre for Energy Biosciences Committed to - Converting waste into value - Novel self-sustaining technologies - Rescuing water from processing wastes - Making industry ZLD and ZSD - Working closely with Industry for RDD&D