Treatment of Distillery Spent wash. Babu Alappat Professor Department of Civil Engineering I.I.T Delhi.

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1 Treatment of Distillery Spent wash Babu Alappat Professor Department of Civil Engineering I.I.T Delhi

2 Generation of Spent wash Sugar Cane Sugar Mill Sugar Bagasse Alcohol Distillery Molasses Spent wash

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4 Molasses Distilleries Spent wash is the main waste stream It has a BOD 5 of about 30,000 to 60,000mg/lit COD of about 1,00,000 mg/lit ph acidic (4 5) Colour- dark brown About 15% solids content Ash contains Potash as K 2 O

5 Spent wash generation: about 8 to 15 litres per litre for alcohol produced 8 for new plants 15 for old plants

6 BOD Pollution load of all distilleries put together in India is more than 6 times the BOD load of the entire population of India

7 Attempts with Spent Wash For washing sugar cane For diluting molasses For irrigating sugar cane fields For manufacturing cattle feed For manufacturing yeast / dry ice / etc Nothing turned to be sustainable / feasible

8 Target Pollutants Organic matter ph Colour

9 WASTE TREATMENT ROUTES Biological for sure, THE BEST option More eco-friendly End products acceptable to the nature Low expenditures But slow, more uncertainiy, affected by weather / temp Chemical for lesser quantities Thermalusually costlier, probability of pollution, controversial but very fast, compact reactors, less area required, more fool proof, not affected by weather / temperature, less uncertainity

10 Biological treatment Removal of organic matter using microorganisms (mostly bacteria, fungi, actinomycetis, etc) Organics used for energy and growth Organics get converted to gases (that escaped the system) and cell mass (has to be removed)

11 Batch reactor growth of micro-organisams Live microorganisams (number / mass) acclimatization Log growth phase Endogenous decay compost Time in days (or hours)

12 Biological treatment Aerobic: in the presence of Oxygen Organics + O 2 CO 2 + H 2 O + Biomass More Biomass Anaerobic: in the absence of Oxygen Organic carbon 100 % No oxygen Different organisms in action Biogas (CH 4 + CO 2 +H 2 S) <90 % Biomass>10%

13 Biological reactors Batch or continuous: Composting batch process Activated sludge process (ASP) - continuous Suspended growth or attached growth Suspended growth: microorganisms are suspended in the waste water: ASP Attached growth: microorganisms are attached to some media like pebbles, plastic balls, etc: Tricking filters, Rotating Biological Contactor (RBC)

14 BIOLOGICAL WASTE WTAER TREATMENT Aerobic: ASP (Activated Sludge Process), TF (Trickling Filter), RBC (Rotating Biological Contactor) Anaerobic: Conventional Digester, Di-phasic digestion, UASB, FB, Hybrid reactor

15 Organics + O 2 CO 2 + H 2 O + Biomass More Biomass CO 2 Treated effluent Organic carbon, N, P O 2 Return Activated Sludge AEROBIC TREATMENT to sludge treatment Waste sludge

16 Anaerobic process Organic carbon 100 % No oxygen Different organisms in action Biogas (CH 4 + CO 2 +H 2 S) <90 % Biomass>10%

17 Comparing aerobic anaerobic techniques Aerobic Faster reaction kinetics Hence smaller reactors No bad odour But have to provide Oxygen No any recovery, more sludge to be handled

18 Anaerobic Fuel Gas recovery Less sludge to be handled No oxygn to be supplied But Slow reaction kinetics Large reactors Odour issues are there

19 The main treatment strategy BOD/COD = 50,000/90,000 = > 0.5 Hence biological treatment is effective Since it is high strength waste water, anaerobic treatment technique is better

20 Treatment strategy for sewage? BOD / COD = 250 / 400 = > 0.5 Hence biological treatment is effective It is low strength waste water and hence aerobic treatment techniques are better

21 Spent wash treatment Anaerobic digestion was the mostly tried option: anaerobic digester diphasic anaerobic digester UASB Fluidized bed anaerobic filter Hybrid Reactors

22 ph adjustments Anaerobic reactor Raw Spent Wash BOD =45, 000 mg/l sludge Effluent BOD about mg/l This effluent cannot be disposed off to a river or sewer line or ocean Disposal Standard = 30 mg/l for disposal into surface waters

23 ph adjustments Anaerobic reactor Raw Spent Wash BOD =45, 000 mg/l sludge Effluent BOD about mg/l ASP Effluent BOD < 30 mg/l Colour persists sludge Aeration tank

24 ph adjustments Anaerobic reactor Raw Spent Wash BOD =45, 000 mg/l sludge Adsorption tower ASP Effluent BOD < 30 mg/l sludge Aeration tank

25 Anaerobic digestion Macro-molécules Acétate Monomères B. hydrolytiques B. acidogènes Acides organiques, alcools,... B. acétogènes B. homoacétogènes CO 2 +H 2 Hydrolyse Acidogénèse Acétogénèse CO 2 +CH 4 A. méthanogènes acétoclastes A. méthanogènes hydrogénophiles CH 4 Méthanogénèse

26 Conventional Anaerobic Digester Biogas Effluent Influent Sludge

27 UASB (Upflow Anaerobic Sludge Blanket) Reactor

28 Anaerobic Fluidized Bed Reactor (AFBR) Biogas Treated water Recycle line Biofilm Carrier Wastewater feed

29 Fresh sludges Anaerobic Digestion : 2 steps 55 C 2-3 d Heat exchanger 35 C 8-12 d Digested sludges Hydrolysis + Acidogenesis Acetogenesis + Methanogenesis

30 Anaerobic digestion bring the BOD down to about mg/lit But the discharge standards are normally much lower (20 or 30 mg/lit) Hence normally aerobic systems are used to bring the BOD down to < 20 or 30 mg/lit Unfortunately colour still persists! Then go for an Adsorption Tower using activated Carbon Hence the process becomes costly

31 Problems with Anaerobic Systems Requirement of polishing Uncertainity involved with biological systems Influence of external parameters like weather, temperature Requirement of energy intensive secondary treatment

32 Colour problem still persists Need for tertiary treatment like adosrption CH 4 generated in the first step is used in the subsequent steps Much slower than thermal systems More space/volume required

33 Why thermal methods?? Biological methods:- Are generally SLOW Are affected by external parameters like temperature Involves some uncertainty Cannot solve the problem completely Thermal methods:- Are costly But rapid Are relatively compact Involves less uncertainty

34 Thermal Treatment of Spent wash There have been many other attempts to deal with spent wash Burning of concentrated spent wash dates back to world war 1 period (not in India) Production of activated carbon, Solid CO2, potash, etc was one of them (reported by Reich in 1945 from US)

35 Thermal properties of Spent wash Sp gr 1.04 to 1.05 Total Solids: 10 to 22 % Total VS: 6 to 8 % Ash content: 2 to 3 % HHV: 3200 to 3800 kcal/kg (dry solids) Density of concentrated spent wash g/cc

36 PROCESS OF INCINERATION, Combustion (controlled burning) of wastes in properly designed and constructed furnace to sterile ash with proper care for air pollution and water pollution. It is proper to say INCINERATION SYSTEM rather than simply incinerator The prime objective of incineration is WASTE DESTRUCTION, not power generation or ash recovery

37 Waste/ Coal FD Fan Aux Fuel Waste /Coal Preparation Waste /Coal Feeding FURNACE Flue Gas S T A C K Gas out ID Fan Acidic Gas Removal Bottom Ash Particle Removal For treatment & disposal Heat Recovery Heat

38 Incineration of Distillery Spentwash: Indian Experience First incineration was reported in early nineteen sixties, but not popular Became popular in late nineteen eighties. Two popular designs were Destrotherm from Thermax, Pune Sprannihilator from Praj Consultech, Pune

39 Raw Spent wash 10-13% Solids content Steam Evaporator Steam Boiler Concentrated Spentwash of About 60% Solids content Flue Gas Water Excess steam Furnace Air Ash (high fertilizer value)

40 1 st incineration plant for spentwash Set up at Dyer Meakin Breweries Ltd., Lucknow in 1960 Capacity: 90 gal spent wash / hour Uses forced circulation evaporator for concentrating spentwash to 60% solids content Ash from spentwash incinerator: contains high Potash as K 2 O (37% of the ash)

41 Destrotherm from Thermax Govt. Distillery at Chitali, Maharshtra in 1984 Expected performance for a 45KLD distillery Spent wash generation: 3000lit/hr Ash collection: 700 kg/hr Power generation: 700kW (Process electricity consumption 500 kw) Steam generation: kg/hr (40bars, 400oC) and steam consumption 5500kg.hr (at 5 bars)

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43 Destrotherm Spent wash of 60% solids content is sprayed into the furnace Raw spent wash is concentrated to 60% in external forced draft evaporators using process steam The flue gas generated goes for the production of steam Ash is rich in potash

44 Destrotherm did not pick up the expected popularity may be due to The complexity involved in the evaporation system Large area / volume occupied by the evaporators Clinker formation on the boiler tubes High cost involved

45 Sprannihilator from Praj Counseltech Aimed at solving some of the problems with Destrotherm Evaporation section made simple and easy to handle Plants becomes more compact First plant at Kohlapur (M/S. Gadhinglaj Taluka Sahakari Sakhar Karkhana Ltd.)

46 Raw Spent wash 10-13% Solids content Evaporator Flue gas with evaporated water Concentrated Spentwash of About 60% Solids content Flue Gas Furnace Air Ash (high fertilizer value)

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48 Sprannihilator About 60% solids content spent wash is sprayed into the furnace Raw spent wash is concentrated to 60% using the flue gas heat in a venturievaporator Ash is rich in potash

49 One at M/S. Polychem Ltd., Nira 45KLD distillery Another at Liquors India Pvt. Ltd., Hyderabad 20 KLD distiller

50 Incineration Plants for Distillery Spent wash All together, about 40 incineration plants working

51 Problems with Incineration of spent wash Solids content of spent wash is to be brought to about 60% before firing into the furnace. This brings the economics down as it is energy intensive. Also, damaging to the material of construction. Spent wash is sticky It swells (up to about 5 times the original volume) while heating

52 Raw Spent wash 10-13% Solids content PROBLEMATIC Evaporator Concentrated Spentwash of About 60% Solids content Flue Gas Furnace Air Ash (high fertilizer value)

53 Recirculating Fluidized Beds (RCFB) Gas exit Freeboard The spouted bed with a central riser tube Riser tube Also called Internally Circulating Fluidized Bed Gas flow Solids flow Downcomer Distributor plate Downcomer fluidizing air Air jet

54 RCFB for the Incineration of Spent wash The idea is to separate evaporation from combustion to the extent possible Combustion takes place in the central riser tube Drying and Evaporation takes place in the downcomer Mixing of the dry solids and combustion air takes place in the zone below the central riser tube

55 RCFB Incineration Hot sand particles from the combustion zone move to the downcomer Spent wash is sprayed onto these hot sand particles Evaporation takes place on the hot sand particles in the downcomer Dry solids on the sand particles get in contact with combustion air and catches fire Combustion of dry solids on the sand surface in the central riser tube heating up sand grains

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57 Concentrating spent wash About 100 RO (Reverse Osmosis) plants working in distilleries About 100 MEE (Multiple Effect Evaporation) system working in distilleries

58 Raw Spent wash 10-13% Solids content Reverse Osmosis Concentrated Spentwash of 55-60% Solids Content to Boilers / Incinerators Cement Kilns / Drying MEE (Multiple Effect Evaporator)

59 Fermentation & Distillation Industries > 400 Molasses based Distilleries ~ 300 Distilleries attached with Sugar Mills ~ 125 Distilleries with RO Concentration system 100 Distilleries with MEE concentration system 100

60 Co-Processing Co-processing in cement industry refers to the substitution of primary fuel and raw material by waste, recovering energy and material from waste. Waste materials used for co-processing are referred to as alternative fuels and raw materials (AFR).

61 Cement Kiln Suitability High temperatures (1400 O C)andresidencetimeof4 5 seconds in an oxygen rich atmosphere ensure the destruction of organic compounds. Any acid gases formed during combustion are neutralized by the alkaline raw material and are incorporated into the cement clinker. Interaction of the flue gases and the raw material present in the kiln ensures that the non combustible part of the residue is held back in the process and is incorporated into the clinker in a practically irreversible manner. No waste is generated that requires subsequent processing.

62 Benefits of Co-processing Reduction in Green House gases emission & related benefit of carbon trading Conversion of waste into energy / as a raw mix component Conservation of fossil fuel resource Reduction in energy / cement production costs

63 Different treatment technology routes for ZERO LIQUID DISCHARGE (ZLD) Biomethanation followed by multi-effect evaporation followed by drying/ incineration/ co-processing. Biomethanation followed by reverse osmosis followed by drying/ incineration/ co-processing. Concentration through RO/ MEE followed by drying/ incineration/ co-processing.