1 DR. SANJAY V. PATIL HEAD AND TECHNICAL ADVISER DEPARTMENT OF ALCOHOL TECHNOLOGY VASANTDADA SUGAR INSTITUTE, MANJARI, PUNE (INDIA) AIDA Technical Seminar Bengaluru,
2 Types of assessments Norms SW Treatment/Disposal Approved ZLD systems Approach Fermentation and Distillation Effluent quantities and Characteristics Biomethanation Reverse osmosis Multiple effect Evaporation Biocomposting Slop fired Incineration boiler BMSW dryer Condensate Polishing unit On-line monitoring system and other requirements Conclusions
3 Self Assessment Third Party Assessment- VSI/NEERI/Distillers Association etc Assessment by regulatory authority- SPCB/CPCB/MoEF
4 1. Red category and Zero Liquid Discharge (ZLD). 2. For Bio-composting as a final treatment: MEE is essential SW storage max. 30 days on raw SW basis. Max. 270 days (With covered compost yardadditional/throught-out the year can be allowed) Yard has to be impervious as per CREP norms. Bio-compost has to be bagged in polybags & compost composition & manufacturers name to be printed on it. Compost quality has to be certified by Ministry of Agriculture.
5 2. For Bio-composting as a final treatment (Continued): For 5 to 12 % solids containing spent wash, the filler material (PMC) to spent wash ratio prescribed is 1: 2.5 for 45 days cycle and 1:3.5 for 60 days cycle. For concentrated spent wash (20 to 30 % solids), the filler material (PMC) to spent wash ratio prescribed is 1: 1.6 for 60 days cycle. Impervious compost yard area based on material balance (plus ready compost storage area) should be made available. During rainy season, bio-composting process has to be stopped. Record of filler material used (PMC) and biocompost produced/sold should be maintained.
6 3. SW storage- Impervious as per CREP norms. 4. For Incineration route: Storage of 7 days on conc. SW basis in impervious storage tank. 5. Secondary treatment: Process condensate, permeate, spent lees, CT & boiler Blowdown, pump gland cooling water etc. has to be treated (CPU) & recycled back. 6. Online monitoring : Mass flowmeters before & after concentration of SW. Camera: 30 days SW storage tank & bio-compost yard. Stack Monitoring System (PM <150 mg/nm 3 or 50 mg/nm 3 ). To be installed & connected to SPCB/CPCB server.
7 1 Biomethanation MEE Bio-composting 2 Biomethanation RO MEE Bio-composting 3 Biomethanation MEE DRYER 4 Biomethanation RO MEE DRYER 5 MEE Incineration
8 1. Holistic Approach: Integrated management employing Reduce-Recycle-Reuse principle 2. No End of Pipe Treatment. 3. No Discharge 4. Analytical & Necessary measurement facilities (Water, Steam, Power, Effluents) 5. Fresh water consumption-section wise 6. Environment Management Cell: (Unit Head + Distillery Manager + ET plant I/c + Concerned Officers/Chemists)
9 Distillery installed and Licensed capacity. Boiler capacity. Source of electricity and water. Distance from river/dam/canal/other water bodies. Authentic data on alcohol production/molasses consumed. Per day alcohol production data. Authentic data on per day SW & SL production, total SW & SL production. No. of days of operation in a year. Alcohol % (v/v) achieved in wash, Fermentations efficiency, Distillation efficiency, Recovery etc. Fermentation technology employed. Distillation technology employed, reboilers used, spent lees generation (Rectifier, PRC etc). If sludge is generated, quantity of sludge MT/day & its method of disposal.
10 RAW SPENT WASH Volume, M 3 /Day Volume, L/L ph VALUES SPENT LEES Total SL, M 3 /Day Volume, L/L SL Recycled, M 3 /Day VALUES COD, mg/l SL for treatment M 3 /Day BOD, mg/l ph TDS, mg/l COD, mg/l TSS, mg/l Volatile acids, mg/l BOD, mg/l TDS, mg/l TSS, mg/l
11 Setting cum cooling tank capacity = M 3 (if any) Setting cum cooling tank RT = days Digester design basis= Hydraulic Retention Time = ----days(15-24 days) = Organic Loading Rate = kg/m 3 /Day = Volume = M 3 Type of Technology = CSTR/UASB/ Thermophilic/ Hybrid Biomethanation Plant Performance (based on 1 month data) Parameters Minimum Performance parameters Actual Values Feed rate, M 3 / Day 0 Brix, (Inlet/Outlet) ph, (Inlet/Outlet) COD, mg/l (Inlet/Outlet) BOD, mg/l (Inlet/Outlet) COD reduction % 60 BOD reduction % 85 Biogas generation, NM 3 / Kg of COD consumed Biogas generation, M 3 / Day - 0.5
12 No. of days of operation of digesters (days/annum). Restabilization method and period required. How digester is maintained during ideal days? Year of establishment of digester. How temp of digester is maintained? Total biogas generated (M 3 /annum) and baggase/coal saved. Whether digester has been revamped? If yes, how many times & for what purpose? Sludge generation from digester and how the sludge is disposed off? Log Book records supporting biogas plant performance. Present Bottle-necks/problems
13 Particulars Quantity, M 3 /day Colour PH Temperature, degree C Conductivity, ms BOD, ppm COD, ppm Total solids, % Total dissolved solids, % Total suspended solids, % Raw spent wash (Feed) Treated effluent (Outlet)
14 Setting tank capacity before RO = M 3 (if any) Year of installation/establishment & commissioning of RO plant Type of technology of membrane filtration. Number of membranes per module & number of modules. Designed feed capacity of R.O. (M 3 /day). Acceptable level of suspended solids, dissolved solids & other membrane affecting components in the feed. No of days of operations. Log Book supporting RO plant performance. Further treatment/disposal of Permeate/Reject
15 Particulars Quantity, M 3 /day Recovery, % Colour ph Conductivity, ms BOD, ppm COD, ppm Total solids, % Total dissolved solids, % Total suspended solids, % Based on at least 1 month data Inlet (Feed) Reject Permeate Rinsing back wash Chem Cleaning
16 Setting tank capacity before MEE = M 3 (if any) Year of installation/establishment & commissioning of MEE plant Type of technology of MEE. Number of Effects with their HTA and MOC. Number of stand-by bodies and degasser provided. Designed feed capacity and evaporation duty of MEE (M 3 /day). Acceptable level of suspended solids, dissolved solids etc in the feed. No of days of operations. What is the frequency and duration of cleaning. Log Book supporting MEE plant performance. Further treatment/disposal of Condensate/Concentrate
17 Particulars Unit Values Feed Sp. Gr. (Approximate) Kg/hr Solid content in feed/brix Water evaporation rate (Minimum) Concentrate output Solid content in concentrate/brix Steam required for water evaporation Cooling water circulation rate Power consumption for Evaporation Feed temperature Steam pressure / temperature Steam Economy, (Kg water /kg steam) %/ degree Kg/hr Kg/hr %/degree Kg/hr M 3 /hr KWH 0 C Kg/cm 2 / 0 C Kg Operation hour Frequency of CIP Quantity of CIP effluent Quantity of process condensate Hr / day- or week or month Hr/ day or week or month M 3 /hr M 3 /hr
18 Quantity, M 3 /day Colour PH Particulars Temperature, degree C BOD, ppm COD, ppm Total solids, % Total dissolved solids, % Total suspended solids, % Based on at least 1 month data Conc. spent wash Process Condensate Ammonical Nitrogen (as N), ppm NA 270
19 30 days holding tank capacity with dimensions and construction details. Biocompost yard details- Impervious biocompost yard (PCC- 1:3:6 or RCC- 1:2:4 or brick on edge) with construction details. Area of impervious biocompost yard (uncovered and covered) with biocompost storage area. Number & type of turning & mixing machine. Number of Bore well around compost yard. Number of Pizometers around the compost. Spentwash available for biocomposting (M 3 /Annum) and spentwash characteristics. Log Book supporting biocompost plant operations.
20 Biocompost filler material availability (Press mud/yeast sludge/boiler ash) (MT/day or MT/annum). Record of Press mud produced or purchased from out side. Average Press mud to spentwash mixing ratio. Windrows size (Length x width x height) Biocompost cycle (45 days or 60 days) and number of cycle per annum. Biocompost analysis report. Material balance for biocompost. Record of biocompost produced and sold with selling price of biocompost (Rs./MT). Biocompost sold in loose or bag packing.
21 Date of installation Design basis : Slop and subsidiary fuel ratio, calorific values and feed rates considered to finalise capacity and other details Boiler/Technology Supplier details and type of boiler Boiler capacity, pressure, temperature and other details Boiler performance details: Including slop and subsidiary fuel actual ratio achieved, no of working days, shut down dayscleaning period required, steam generation (MT/hr), steam pressure & temperature etc. Emission control system installed, its details, analysis report. Problems faced in operation and maintenance of Boiler. Quantity of ash generated method of disposal etc. (MT/day), its characteristics and Log Book records supporting incineration boiler performance.
22 Date of installation. Design basis : BMSW feed rates considered to finalise capacity and other details. Dryer/Technology Supplier details and type of dryer. Dryer capacity and other details. Dryer performance details: Including BMSW feed rate, steam/biogas used/hr, no of working days, shut down dayscleaning period required, powder produced (MT/hr) and other details. Emission control system installed and its details. Problems faced in operation and maintenance of dryer. Characteristics of powder produced and storage method. Quantity of condensate generated (M 3 /day), its characteristics and method of treatment/disposal etc. Log Book records supporting dryer performance.
23 Date of installation of CPU unit. Name of plant/technology supplier. Type of technology of CPU plant: Conventional /RO/ Striper / Photo-oxidation /In house technology etc). Design capacity of CPU unit (M 3 /day) and feed characteristics considered. Low strength effluents treated though CPU & their quantities (Process condensate, permeate, spent lees, etc). Recovery (%) and characteristics of treated water and its further utilization details. Is there any reject generated and how it is disposed? Total fresh water consumption after reuse of treated low strength effluents. Log Book records supporting CPU performance.
24 Particulars Mixed Influent Treated effluent Quantity, M 3 /day Colour PH Temperature, degree C BOD, ppm COD, ppm Total solids, % Total dissolved solids, % Total suspended solids, % Volatile acids Total Alkalinity Based on at least 1 month data
25 Number and location of mass flow meters installed (minimum two) with photographs. Number and location of cameras installed (minimum two) with photographs. Details of on-line emission (stack) boiler. monitoring system for Date on which the online monitoring system was commissioned/connected to the server. Name and contact details of the vendor who has supplied and commissioned the on-line monitoring system. Problems faced in maintaining the continuity of on-line monitoring system. Green belt surrounding biocompost yard (Photographs).
26 Identification of recipient drains/ rivulets and their u/s & d/s locations for monthly monitoring to ensure ZLD. Material and mass balance of your total distillery plant operations including ETPs showing ZLD. Also indicate how your distillery unit is achieving steam and power balance. Environment Management Cell- MoMs and necessary documents. EC, Consent to Operate, Directions received and related documents. Water conservation measures taken report (rain water harvesting etc). Prepare your own action plan for achieving ZLD.
27 Preparing self assessment report is first step towards compliance to ZLD norms. It indicates your concern to save the environment. It will definitely help you to identify bottle-necks and further improve your performance.
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