PRE-FEASIBILITY REPORT

PRE-FEASIBILITY REPORT FOR M/S. Godavari Bio refineries Ltd., AT A/P - Sameerwadi, Tal - Mudhol, Dist - Bagalkot, Karnataka State. Pin No. 587 316 1

Prefeasibility Report 2

1. EXECUTIVE SUMMARY Godavari Biorefineries Ltd, is situated at Sameerwadi, Mudhol (Tq), Bagalkot (Dist). It has an existing distillery to produce Rectrified Spirit of 200 KLPD and downstream product such as ENA & Ethanol. Spent wash is treated based on Composting principles. It is proposed to treat spentwash both on Concentration and Incineration and Bio-composting principles. 1. Godavari Biorefineries Ltd., has as existing distillery of 200 KLPD for which the Environmental Clearance vide letter no. F. No. J-11011/191/2007-IA II (I) dated 28.03.2008 and amendment vide letter no. J-11011/191/2007-IA II (I) Dated 02.09.2008. The industry proposes to adopt a combination of Concentration and Incineration technology and bio composting till the available press mud is consumed on composting principles and shall adopt Concentration and Incineration technology for the entire spent wash generated from 200 KLPD distillery. The present proposal is for the amendment of environmental clearance conditions to permit to adopt Concentration and Incineration as well as bio composting for treatment of spentwash. 2. At present the industry is following Bio-composting technology based on anaerobic digestion followed by concentration and Bio-composting. It has 26 acres of concreted compost yard and two mixing machines for mixing of press mud and concentrated spentwash. There is sufficient availability of pressmud as the industry has attached sugar factory of 15000 TCD crushing capacity. The amount of press mud generated is around 80,000 MT/year which is adequate for composting for 250 days of distillery operation. 3. The industry proposes to adopt concentration. Incineration technology in order to operate the distillery for 330 days so that the project viability would further improve. 4. The Karnataka State Pollution Control Board vide letter no. KSPCB / RO (BGK) Lokadalat / Sugar / Pressmud / 2014-2015 / 2078 dated 18.08.2014 directed all the sugar industries of Karnataka state that the press mud generated from the sugar industries shall be treaded scientifically before it is disposed off as manure / soil conditioner, as per directives of the Lokadalat of Karnataka State. 5. In view of the directives of the Lokadalat of the Karnataka State, the industry proposes to adopt concentration, incineration technology for the spent wash generated from 150 KLPD distillery and the remaining spent wash generated from the 50 KLPD distillery shall be treated on bio composting principles for which the existing infrastructural facilities would be adequate. After the entire press mud is consumed by the industry the concentration incineration technology would be adapted for the entire quantity of spent wash from 200 KLPD distillery. 6. The project cost for the concentration incineration technology for 200 KLPD distillery is around 60 Crores. 3

7. The entire spent wash generated shall be burnt in an incinerator boiler and thus, zero liquid discharge shall be achieved. For air pollution emissions, ESP shall be installed with a stack height of 80 meters. The vapor condensates from the multiple effect evaporators and the washing of the equipment shall be treated in condensate polishing unit and the treated water shall be used as makeup water for cooling towers. 2. INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION A Brief Background on the Godavari Sugar Mills Ltd., Sameerwadi SOMAIYA GROUP is one of the old and well established Industrial Houses in India with diversified interests in: Sugar and its by Products Alcohol and Bulk Organic Chemicals Specialty Chemicals Renewable Energy Printing and Publishing A. SUGAR 1. The Godavari Sugar Mills Limited Sugar Plant Location: Sameerwadi, Dist. Bagalkot, State: Karnataka Capacity : 9,000 TCD Average Sugar production 1,60,000 M.T p.a. Co.generation Power plant Location: Sameerwadi, Tal Mudhol, Dist. Bagalkot, State: Karnataka Installed Capacity : 24 MW (1 st stage) 2. K.J. Somaiya Institute of Applied Agricultural Research (KIAAR). Location: Sameerwadi, Dist. Bagalkot, State: Karnataka Established with the objective of doing basic research in promoting early maturing & high yielding sugarcane varieties and propagating modern and scientific agricultural Practices. B. ORGANIC CHEMICALS 1. Somaiya Organo Chemicals. (A Unit of The Godavari Sugar Mills Ltd.) (a) Sakarwadi : Location: Sakarwadi, Tal Kopargaon, Dist. Ahmednagar, State: Maharashtra Distillery: Capacity: Industrial Alcohol 30,000 KL per annum Organic Chemical Plant Capacity: Acetic Acid : 22,000 MT per annum Ethyl Acetate : 30,000 MT per annum 4

Crotonaldehyde : 5,000 MT per annum Paraldehyde : 600 MT per annum Crotonic Acid : 150 MT per annum Crotonic Anhydride : 50 MT per annum (b) Sameerwadi : Location : Sameerwadi, Tal Mudhol, Dist. Bagalkot, State : Karnataka Distillery : Capacity : Ethyl Alcohol/Rectified Spirit : 20,000 KL per annum Ethanol (Absolute Alcohol) : 16,500 KL per annum Extra Neutral Alcohol (ENA) : 12,000 KL per annum Ethyl Lactate : 500 MT per annum Bhoomi Labh (An Organic Manur) : 15,000 MT per annum C. HERABLE & NEUTRACEUTICAL PRODUCTS 1. Genesis Labs Ltd. It has multipurpose plant for extraction of products such as LYCOPENE, GLUCOSAMINE, LUTEIN, CALCIUM SENNOSIDES. D. TWO SUGAR PLANTS IN MAHARASHTRA ON LEASE : The Company has taken on lease two 2500 TCD Co-operative Sugar Factories in Maharshtra Viz.: 1.M/s. Indira Gandhi Bharatiya Mahila Vikkas Sahakari Sakhar Karkhana Ltd., Tambale, Tal. Bhudargad, Dist. Kolhapur 416 003. Phone Kolhapur: (0231) 2668399/2662398 * Fax: 0231-2662398 Phone : Tambale : 02324) 237002-3 2. Pratapgad S.S.K. Ltd., Songaon Karnadoshi. Tal. Jaoli, Dist. Satara 415 514. Phone : (02378-235645/235646) * Fax : (02378) 235766 E. ACTIVATED BLEACHING EARTH (used in refining edible oil) Lakshmiwadi Mines & Minerals Pvt. Ltd. Factory : Survey No. 526, Village : Gundala, Tal. Mundra, Kutch (Gujarat) Phone : (02838) 226800/226534 Local Off.: Krishna Bhavan, Sector No.9/43, Shop No.4 Gandhidham, Kutch (Gujarat) Phone : (02836) 234659/226936 Fax : (02936) 230763 Registered Office : Yusuf Bldg., 2 nd Fllor, 43, M.G. Road, Fort, Mumbai 400 001. Phone : (022) 22048272/22858430 5

F. PRINTING & PUBLISHING 1. The Book Centre Ltd. It has a large, well equipped printing press in Mumbai to cater services of Graphic Communication under one roof. Being in the industry for last 30 years and with the team of professionals, it has expertise of executing any assignment of clients (Multicolour & B/W) of any size with secrecy and of course integrity of product. 2. Somaiya Publications Pvt. Ltd., Specialises in publication of nob-fictional and educational books of high standard. Also Publishes books on topics which have bearing on Economics, Philosophy, Management, Indian Culture and Heritage. G. EDUCATION & SOCIAL WELFARE 1. Somaiya Vidyavihar Founded in 1959, Somaiya Vidyavihar has come to encompass the entire educational spectrum from kindergarten to post graduate education, providing education to around 26,000 students every year, and has a faculty strength of over 1500 Teachers. It comprises of 34 institutes including Jr. & Sr. Colleges in Arts, Science & Commerce, a polytechnic, Engineering College, Sanskriti peetham, Buddhist Centre, Management Institute and a Kendriya Sanskrit Vidyapeeth, each having well equipped laboratories, libraties and hstel arrangements. 2. Somaiya Ayurvihar Somaiya Ayurvihar is committed to offering an integrated package of general and Specialized health care services. It comprises of a Medical College, a Nursing School, a 550 bed Hospital with a Blood Bank and an HIV Treatment Centre, a Research Centre complex and an Institute of Paramedical Studies a College of Physiotherapy. 3. Shri Girivanavasi Pragati Mandal In order to bring neglected brethren living in the forest and hilly regions to the mainstream of our national life, Shri Girivanavasi Pragati Mandal was formed in 1974. The Mandal held 7 (seven) annual Eye-cum-Medical Camps in different States from 1975 to 1981 and treated 1,85,417 people in these Camps held in the interior far away from the rail head or bus stops to reach out to people living in the remotest part. The Mandal has since established a 40 bed Eye- cum-general Hospital and a permanent Experimental Farm, a Dairy, an Agricultural Training Centre, and a free Boarding School at Nareshwadi, near Dahanu, in Thane District, Maharashtra, about 120 kms away from Mumbai for the welfare of the Tribals right in the midst of the Tribal Area. 6

2.1 Project Proponent Table No. 1 Sr. No. Name Designation 1 Suhas Uttam Godage General Manager 2.2 Brief description of nature of the project 2.2.1 Climate The normal temperatures in the region are between 18 0 C to 43 0 C in summer and 9 0 C to 27 0 C in winter. There is no occurrence of frost in area of operation of factory. Hence, climate of the region is well suited for sugarcane cultivation. 2.2.2 Topography The topography is slightly undulating. The entire land is medium to heavy Soil. There shall not be any permanent or temporary change in land use as the entire area is for industrial purpose. 2.3 Justification of the project for Concentration and incineration and Bio composting technology The existing distillery of 200 KLPD is based on Alfa Laval Technology. In this Technology two options are being explored. If BH or BIH (i.e. High Grade Molasses) Molasses are used, the fermentable Sugar Content would vary between 56 to 64% and as such the yield of R.S. per MT of Molasses shall be around 330 to 380 litres as shown in Table. I and the effluent quantity shall be around 1.3 to 2.7 litres per liter of R.S. production. The industry proposes to use (BH, BIH) Molasses whenever the sugar prices are very low as on to-day. When the Sugar prices are high, the industry proposes to use C grade Molasses which have Fermentable Sugar 42% to 48% at which time the effluent quantity would be brought down to 4.0 litres per litre of R.S. Production by using Multiple Effect Evaporators. The yield of Alcohol would be 250 litres Per MT of Molasses. The Spentwash generation at different FS concentrations are given in Table. II. Thus the Industry proposes to adopt a flexible operation of the Distillery depending on the Sugar prices in the market. In the event of using BH BIH Grade molasses, the quantity of effluent shall be around 400 Cum/day on an average and the COD Concentration shall be maximum 1,50,000 mg/l. to 2,20,000 mg/l. In the event of C Grade Molasses the quantity shall be around maximum 800 Cum/day and the COD concentration shall be maximum 3,20,000 mg/l after passing through Multiple Effect Evaporators. The characteristics of effluent at different Fermentable Sugar concentrations are given in Table. III. 7

The industry proposes to adopt this flexible operation as the Sugar production fluctuates depending on the climatic conditions, Natural forces and the Demand and supply situation in the Global Market. The variations of Sugar Production in the last twenty years are shown graphically. Under the National Ethanal programme there is a mandate to blend 5% ethanol in petrol in Nine States. This program was started on 1 st October 2003. This program took the back seat in 2004 due to the drought conditions and a disease affected sugarcane crop throughout the Country and especially in Southern States. Put to the good monsoons in 2004 onwards the country is set for a reasonably good crop this season. Also the Government of India has set a deadline for introduction of gasoline and diesel confirming to Euro 3 fuel standards in 11 cities of India. The Euro 3 standard specifies the presence of an oxidant in the fuel, which minimizes the emissions due to the combustion of these fuels. Ethanol being one of the most viable additives available, the oil companies have opted to use Ethanol for blending with petrol. There could be considerable savings in terms of foreign Exchange. The Ethanol program is expected to be restarted soon, and once this programme is taken to its next step where the blending would be 10% the demand would be more than doubled. In 2006-2007 Sugar season, the demand for ethanol at 5% blending in petrol is estimated as 682 million liters and if 10% blending becomes a reality, the requirement for ethanol would be 1300 million liters. The additional requirement of Rectified Spirit is estimated as 6100 lakh liters. In fact there was a shortfall of 1600 lakh liters of R.S. in the year 2005-2006. To exploit this opportunity the company proposes to expand the Distillery capacity to 200 KLPD. 8

3.0 Location: The project site layout map is as below. Fig 1: Lay out plan 9

4.0 MANUFACTURING PROCESS (Distillery) MOLASSES BASED FERMENTATION TECHNOLOGY During the last decade, interesting developments have taken place in the field of technology of fermentation of alcohol, which promise high yield of alcohol, economy in space, economy in steam consumption and sizable reduction of quality of effluent. After the Second World War, considerable research and developments in the continuous process for industrial fermentation have taken place and the processes have been perfected to make them viable. Continuous processes for alcoholics fermentation are now commercialized. This has been possible for the outstanding research and development work carried in Russia, Sweden, Austria, U.S.A. etc. Many processes have been patented. There are variations in different processes of continuous fermentation. Some use only single fermenter whereas some use two fermenter or battery of fermentors. For example, US patent, 43,10,629 incorporates use of two fermentors. The first fermenter favors rapid cell growth and second fermenter favour high rate of fermentation. Yeast is recycled. The alcohol content in first fermenter is limited to not more than 4-6% v/v and alcohol content in second fermenter attained is 12% v/v Stillage containing soluble proteins and amino acids provide excellent source of nutrients for yeast propagation. The continuous fermentation process involve addition of fresh nutrients medium either continuously or intermittent withdrawal of portion of nutrient for recovery of fermentation products. In continuous process fermenter is in constant usage with little shut down and after initial inoculation of yeast culture, further inoculation is not necessary. Process for manufacture of alcohol: Molasses is the chief raw material used for production of alcohol. Molasses contains about 33% total sugars, of which 30 to 33% are cane sugar and the rest are reducing sugar. During the fermentation, yeast strains to the species Saccaromyces Cerevisieae, a living microorganism belonging to class fungi converts sugar present in the molasses such as sucrose of glucose in to alcohol. Chemically this transformation for sucrose to alcohol can be approximated by the equation: I) C 12 H 22 O 11 + H 2 O 2C 6 H 12 O 6 Cane Sugar Invertase Glucose + Fructose II) C 6 H 12 O 6 2C 2 H 5 OH + 2CO 2 180 Zymase 2 x 46 + 2 x 44 Glucose / Fructose Ethyl alcohol + Carbon di-oxide Thus, 180 gm. Of sugars on reaction gives 92 gms of alcohol. Therefore, 1 MT of sugar gives 511.1 kgs of alcohol. The specific gravity of alcohol is 0.7934, therefore, 511.1 kg of alcohol is equivalent to 511.1 / 0.7934 = 644.19 litres of alcohol. During fermentation other by-products like glycerin, succinic acids etc. also are formed from sugars. Therefore, actually 94.5% total fermentable sugars are available for alcohol conversion. Thus, one MT of sugar will give only 644 x 0.945 = 608.6 litres of alcohol, under ideal condition theoretically. 10

Normally only 80 to 82% efficiencies are realized in batch type plant. One MT of molasses containing 45% fermentable sugars gave an alcoholic yield of 230 litres per MT. For bringing out above biochemical reaction, we require proper and careful handling of yeast, optimum parameters like ph, temperature control and substrate concentration, which results into effective conversion of sugars to alcohol. For yeast propagation & multiplication separate equipment is required. Initially, yeast is developed in the laboratory form the single cell yeast culture. In the laboratory, yeast is propagated in a test tube on 10 ml. Then it is transferred to bigger flask of 500 ml. flask are transferred to 5 liter flask containing the sterilized molasses media solution. It is necessary to adjust the ph of the molasses solution in the range of 4.5 to 5.0. add necessary nutrients such as ammonium sulfate or urea, di-ammonium phosphate etc. Each stage of development of yeast from 10 ml to 500 ml and 500 ml to 5 litres requires 24 hours in the laboratory. On the plant side, there are again 3 stages of propagation namely 100 litres,500 litres and 5000 litres. All these equipments are designed so as to facilitate boiling molasses solution in order to sterilize it and also cooling to bring it to the proper temperature of 33 o C and letting in culture and taking out culture. Boiling, cooling, introducing culture etc. are done in aseptic manner, i. e. Keeping the fermentation medium free from any kind of infection. Further stages of yeast propagation are done in open tanks. i.e. pre-fermenter requires about 8 hours in order to build up necessary concentration of yeast in them. Finally prefermenter is emptied in an empty fermenter, which is previously cleaned and kept ready. Dilute molasses solution is allowed to flow in this fermenter so as to fill it to its working capacity say about one lakh litres. Now a day, readymade compressed yeast is used directly in the pre-fermenters. Good quality of yeast is available for use in distillery. The yeast is manufactured under strict controlled conditions. This yeast is useful to obtain a good yield of alcohol by fermentation of molasses. Te stages of yeast propagation as described above for producing yeast from laboratory scale to pre-fermenter stage may be totally eliminated. The fermentation of molasses in fermentors take about 24 to 30 hours for completely exhausting the sugars in molasses. The average efficiency of conversion of sugars from molasses to alcohol is 80 to 85% of theoretical value in batch type distilleries. All the sugars are not converted to alcohol during the process or fermentation because chemicals like glycerin, succinic acid etc are also produced by yeast during their metabolic process. Therefore, it is not possible to have 100% efficiency of conversion of sugars to alcohol. The average yield of alcohol from molasses is about 230 litres from 1 MT molasses in batch type distilleries. Recently attractive developments have taken place in the field of fermentation and distilleries whereby one can get high yield of 280 to 300 litres per MT of molasses. Different technologies are classified as: 1. High brix fermentation 2. Multistage continuous fermentation 3. Immobilized enzyme fermentation 4. Continuous fermentation without yeast separators. Joint venture of M/s. John Brown Engineers and Allied Breweries, U.K. has developed a process of continuous stirred fermentation. A continuous stirred fermenter is connected to a gravity 11

settler where yeast flocculates and settles out from broth. This process is tested on cane sugar molasses. High yield of 265 litres of alcohol per MT of molasses is obtained. In another process developed by Georgia Institute of Technilogy ethyl alcohol is continuously drawn off a fermenter and contacted with solvent in counter current liquid liquid extraction column. M/s. Dynes Holding Co. Atlanta licenses this technology of continuous fermentation followed by solvent extraction. It is claimed that this process is more energy efficient and alcohol is produced at lower cost than any other process. This process is also not available to the industry as it is in development stage. In Finland, M/s. Dy Alko have developed a continuous process, which involves molasses dilution to 10 o Bx and fermentation by yeast during fermentation process, a portion of this wash under fermentation is taken to subsidizer where the yeast is allowed to settle down and the same is recirculated for increasing the fermentation efficiency. The yield of alcohol is 270 280 litres/ MT of molasses. Technology for continuous fermentation process: The continuous fermentation proposed is the latest and proven technology as compared to the old batch fermentation technology. It has many advantages like continuity of operation to the batch fermentation technology. It has advantages like continuity of operation, higher efficiency and ease of operation. Continuous fermentation also results into consistent performance over a long period as compared with batch fermentation. Most modern ethanol production plants adopt this continuous fermentation technology. 1) K-SUPER continuous fermentation with immobilized yeast (KBK): K-Super proposed to adopt the efficient continuous fermentation in the distillery. The fermentation process employs a special yeast culture, which can withstand variations in the molasses equality, temperature and other shock loads. Fermentation plant consists of five to six numbers fermenter tanks connected in series with all the accessories like plate heat exchangers for cooling, air & CO2 sparger, broth mixers and air blowers etc. The yeast is immobilized using special media and it remains in the fermentation plant throughout and hence it gives tremendous advantages in maintaining the yeast population and in combating the bacterial infection. The technology is called continuous mixed bed fermentation (CMB) and which is the latest technology available in the industry at present. Molasses after weighing is diluted and also pre-treated to an appropriate sugar concentration while pumping through molasses broth mixer into the fermenter. The partial pre-treatment of molasses is required to reduce scaling of the equipment due to the sludge present in the molasses, which is separated out very easily in this pre-treatment. The fermenters are then inoculated with culture developed in the culture vessels. This culturing with suitable yeast is carried out only during the start up in the plant. The culture thus developed maintains itself in fermentors on a continuous basis. To help the fermentation sustain the assailable nitrogen are added in the medium in the form of Urea and DAP as required. Temperature in the fermenters is maintained to an optimum level as required for efficient reaction with the help of plate heat exchanger and recirculation pumping system. This recirculation also helps in proper mixing of fermented wash. The retention time for the reaction is about 24 to 32 hours. Air blower is provided to supply the necessary oxygen required for the yeast and also for agitation. After completion of reaction the fermented wash is delivered to wash setting clarifier. In Wash Settling Clarifier, settable solids settle down. The supernatant goes to Buffer Wash Tank (BWT) and sludge from bottom goes to sludge tank. 12

The CO 2 which is liberated in fermentation is scrubbed in water with the help of CO 2 scrubber. This CO 2 contains ethanol, which is recovered by colleting CO 2 scrubber water fed into sludge trough. The diluted sludge is pumped into sludge settling clarifier. The traces of ethanol present in diluted sludge from bottom is drained off. The fermented mash collected in the clarified wash tank is then pumped to Mash or Primary column for distillation. A closed loop cooling tower system with an induced draft-cooling tower with circulation pupms is also provided to ensure higher cooling efficiency and to minimize water wastage. 2) Cascade (HIFERM-GR) Continuous Process with yeast recycling (PRAJ) M/s. Praj Industries Ltd., Pune supply complete plants for the fermentation industry. The process is for continuous production of alcohol from sugar containing raw materials. The process developed by them for continuous fermentation is adopted for production of alcohol from raw molasses successfully in several countries like Yugoslavia, Austria, Ghana, Kenya, USA etc. A set of four /two fermentors is required for this process. This wort enters the first fermenter and is allowed to overflow to the second fermenter and the wash from 2 nd fermenter goes to 3 rd to 4 th fermenter. The wash coming from the 4 th fermenter, it contains 8 9.5% alcohol. Process water is also added to first one or two fermentrs. Water ring blowers sparged fermentation air into first and second fermenter, carbon dioxide generated into the first and second fermenter is collected and fed into third fermenter for proper mixing of the fermented wash, while part of the carbon dioxide generated into te last fermenter is scrubbed in water with the help of CO 2 scrubber. This CO 2 contains ethanol which is recovered by collecting CO 2 scrubber water fed into sludge trough. The wash coming out last fermenter goes to yeast separator (Yeast settling tank). In the yeast separator yeast cream is separated by gravity settling from the wash and returned back to the first fermenter by acidic treatment to avoid the contamination, nutrient dosing as well mixing of molasses by broth mixer with the help of O 2 scrubber. This CO 2 contains ethanol which is recovered by collecting CO 2 scrubber water fed into sludge trough. The wash coming out last fermenter goes to yeast separator (Yeast settling tank). In the yeast separator yeast cream is separated by gravity settiling from the wash and returned back to the first fermenter by acidic treatment to avoid the contamination, nutrient dosing as well mixing of moasses by broth mixer with yeast cream and sparging the air in yeast activation tank (YAT), therefore yeast activity will be increase and it is fed to the fermenter No. 1. The top fermented wash overflow collected in the wash settling tank (WST). In wash settling tank sludge is settled at the bottom while top supernatant wash over flow to the wash charger (wash holding tank), then it is pumped to Mash or Primary column for distillation system to recover the alcohol. The sludge drain from the bottom of WST is fed in to sludge trough where it is diluted with CO 2 scrubber water. The diluted sludge is pumped into Sludge settling tank (SST). The traces of ethanol present in diluted sludge are separated at the supernatant, which is collected into wash charger through overflow and washed sludge from bottom is drain off. Fermentation auxiliaries like nutrient preparation, sulfuric acid dilution and antifoam agent dosing are prepared on the ground floor. Nutrient solution and acid is fed to the first fermenter by metering or dosing pumps.in this maner by controlling parameters like molasses and water flows, ph, Nutrient 13

and temperature, alcohol concentration between 5.5 and 9.5 % v/v maintained in first and last fermenter respectively. Temperature of the individual fermentors is maintained in the desired range of 30 to 32 o C by recirculating the fermenting wash through the individual plate heat exchangers. A separate cooling tower and pump is used for recirculating the cooling water for fermentation. All the fermentors are covered and connected to a scrubber in order to recover alcohol from carbon dioxide. The yield of alcohol is 280 litres/mt of molasses containing 47% total fermentable sugars. Stillage would be appreciably less as alcohol concentration by 12 14 litres per liter of alcohol production depending on alcohol production in the wash. Average residence time is in fermentors is 24 30 hrs. with alcohol % in fermented wash in the range 8 9% (v/v) M/s Praj Ind. Ltd., Pune has introduced a system in the year 2001 02 in which a granulated flocculating type yeast strain is being used which has a property to settle by gravity force. This eliminates the use of yeast separators. The fermentation efficiency is claimed as 89 90 %. 3) Mojj Engg. Systems Ltd., Molasses after weighing is diluted and also pre-treated to an appropriate sugar concentration while pumping through molasses broth mixer into the fermenter. The partial pre-treatment of molasses is required to reduce scaling of the equipment due to the sludge present in the molasses, which is separated out very easily in this pre-treatment. The fermenters are then inoculated with culture developed in the culture vessels. This culturing with suitable yeast is carried out only during the start up of the plant. The culture thus developed maintains itself in fermentors on a continuous basis. Continuous yeast growth in yeast vessel YV 03 by adding pasteurized molasses and recycling partly, the yeast separated in yeast separator after acidification and activation treatment, which helps to avoid contamination and maintain consistency in operation. To help the fermentation sustain, the nitrogen is added in the medium in the form of Urea and DAP as required. Temperature in the fermentors is maintain to an optimum level as required for efficiency reaction with the help of plate of plate heat exchanger and recirculation pumping system. This recirculation time foe the reaction is about 22 to 24 hours. Air blower is provided to supply the necessary oxygen required for the yeast and also for agitation. This fermentation technology use genetically marked high osmo tolerant yeast strain. The system optimized the cooling system to maintain fermented broth temperature to 30 o C which results in improve yeast cell mass activity. The technology incorporated yeast recycle, which maintain high yeast concentration and reduced fermentation time result in lower fermenter volume, saving in capital and operating cost. After completion of reaction of the fermented wash is delivered to yeast separation centrifugal machine to separate the yeast cream. The technology incorporates yeast acidification and activation, which ensure the yeast, recycle in continuous propagation vessel & fermenter is bacteria free and ensures no contamination. In Wash Settling Clarifier, settable solids settle down. The supernatant goes to clarified wash tank (CWT) and sludge from bottom goes to sludge tank. 14

The fermented wash collected in the clarified wash tank is then pumped to stripping column for distillation. The CO 2 which is liberated is scrubbed in water with the help of CO 2 Scrubber. This CO 2 contains ethanol which is recovered by collecting CO 2 Scrubber water into sludge decantation. The technology incorporated sludge decantation system, which consists of specially designed lamella separator as against conventional, designed to settle the sludge. The settled sludge after dilution from CO 2 scrubber water pass through the decanter. This ensures the clarified wash going to distillation is free from sludge, which results in clean distillation column, re-boiler tubes and integrated spent wash evaporator tubes, This also helps to maintain consistency in operation and avoid losses due to stoppages. Alternatively the technology also offer pre-clarification of molasses for high sludge / VFA content in molasses. A closed loop cooling tower system with an induced draft-cooling tower with circulation pumps is also provided to ensure higher cooling efficiency and to minimize water wastages. The system incorporated mechanical ejector in place of air sparger, which results in increase the dissolved oxygen level, facilitate better contact between yeast and fermentable sugar avoid hydraulically dead zones, increase yeast cell mass activity for high efficiency & better yield. The technology achieved 8 9% v/v alcohol percentage in fermentedwash. Biostill process: Process developed for Continuous Fermentation is Biostill process patented by Alfa Laval of Sweden. It has some special features. It is a very comprehensive and compact process aimed at only high yield of alcohol but also reduction of effluent substantially. In this process, concentrated substrate of 40 45 & of final molasses is fed to the fermenter at a constant flow rate. The process does not involve pretreatment of pasteurization of molasses. It envisages recycling of stillage to the extent of 70% of total volume in order to eliminate bacterial infection. The whole fermentation is carried continuously in two fermentors. Molasses wort is feeded at such a rate that the sugar percentage remains below 1.8 to 2 % w/w. Ethanol concentration is controlled at 6 to 7 % w/w. Special kind of yeast known as Saccharomyces pombe is used in the process. The yeast propagates by splitting and not by budding. It stands high osmotic pressure. The process requires yeast propagation vessels, nutrient tanks and pumps, yeast separators, hydrocycloses, carbon dioxide scrubber to recover alcohol and efficient plate heat exchangers for cooling recycled stillage and for cooling fermented wash. The distillation system differ from the conventional process as far as wash column is concerned. Other equipments are same as conventional plant. The wash column divided into two sections i) Vaporizer ii) Stripper. The wash is de-yeasted and also free from sludge by yeast separators of suitable design, as the wash is pumped from fermenter to wash feed tank. The wash is preheated by plate heat exchanger and outgoing stillage. It enters the top plate of vaporizing section of wash column. The wash is boiled by vapour pipe of the column. The concentration of alcohol in the vapour is approx. 50 % v/v. About 15

70% of weak wash is pumped from the bottom of vaporizer through the regeneration heat exchanger to return to the fermenter via a trim cooler in the form of heat exchange. A minor stream of 30% remaining weak wash flows to another section of distillation column called as stripping column. This column is heated by re-boiler instead of heating by steam sparger employed in conventional plant. The vapours going out consisting of steam and weak ethanol enters the bottom of vaporizer and provides heat necessary for boiling the wash. Te spent wash leaving the column is free from alcohol and is concerned to 25% solids. The duel purpose of this column heated by re-boiler for evaporation and distillation lead to the highest possible stillage concentration without increase in steam consumption. The recycling of spent wash for dilution of molasses is novel idea in this technique. This is useful to increase soluble salt concentration for optimum osmotic pressure, which is necessary to limit the growth of fermentation organism yeast without affecting the rate of fermentation and eliminate contamination. Choice of Technology: It would be seen that through the initial investment for modern process of continuous mode fermentation appears to be on much higher side, the advantages occurring are spectacular. Volume of effluent discharged is less than that of total effluent discharged in conventional distillation process. To adopt continuous process of fermentation is an appropriate step towards the updating technology of alcohol production for efficient performance. 2.2 MULTUPRESSURE VACUUM DISTILLATION After fermentation the next stage in the manufacture of alcohol is separate alcohol from fermented wash and to concentrate it to 95 % alcohol called as rectified spirit. For this purpose, method of distillation is employed. The distillation column system consist of number of bubble cap plates where wash is boiled and alcoholic vapours are separated according to their boiling point and concentrated on each plate stage by stage. Atmospheric Distillation; The fermented wash first enters the beer heater, which is a condensing alcoholic vapours by using wash as cooing medium. Fermented wash from the beer heater goes to degasifying column, degasifying column bottom goes to top plate of the wash column. This column consists of 18 plates. The steam is admitted through the steam sparger situated at the bottom of the column gets heated and by the time it reaches to bottom plate, it consist practically no alcohol. The wash going out is called spent wash, which is discharged to the drainpipe. The vapours coming from wash column now consists approximately 50% alcohol and 50% water with impurities such as higher alcohols, aldehydes, acids, sulfur dioxide etc. Part of these vapours are led to Pre-rectifier column where low boiling impurities are separated from spirit which is produced at the rate of total production depending on the extent of purity required & stored separately. Other portion of the vapours, which is major quantity, is led to rectifying column. This column consists of 44 plates, which helps the removal of bad smelling fusel oil, which is a mixture of higher alcohol. As the vapours coming from wash column rise to top of rectifying column, the concentration of alcohol goes on increasing & finally it reaches to the concentration of 95.5% alcohol. The alcoholic vapours from rectifying column are 16

condensed in the beer heater, principle condenser using water as a coolant and finally vent condenser. The condensates of all three condensers go back to the top of the rectifying column & uncondensed gasses are let out from the vent pipe. Actual product of rectifying spirit is drawn from the 3 rd plate from the top & cooled in alcohol cooler & taken out asa product. The fusel oil which is a mixture of higher alcohol is drawn from the 6 th to 10 th plate from bottom of rectifying column as a stream of vapours, it is condensed, cooled & led into a decanter where it is mixed with water. Fusel oil being immiscible with water collects at the top and decanted through a funnel and sent to storage. The lower portion contains water and alcohol and is sent back to wash column for recovery of alcohol. Fusel oil is recovered at the rate of 0.2% of alcohol produced. The alcohol both pure and impure is first led into separate receivers. The quantity of alcohol produced is assessed daily in the receivers and it is finally transferred to storage vats in the warehouse. The spirit to the tankers of the customer depending upon the type of requisition. Multi-pressure Vacuum Distillation: Multi-pressure distillation system for production of Rectified Spirit and ENA consists of distillation columns namely For Rectified Spirit mode 1. Degasifying um analyzer column 2. Rectification Column 3. Fusel Oil Concentration Column FOR ENA Mode 1. Degasifying cum analyzer column 2. Pre-rectifier Distillation column 3. Extractive Distillation column 4. Rectification column 5. Refining / simmering column 6. Fusel oil Concentration column 7. Head Concentration column Benefits of Pressure Vacuum Multi-pressure Distillation: Following are the advantages of pressure vacuum distillation. Since the analyser column operates under vacuum, the formation of by-products such as acetal may minimize there by improvement in quality of alcohol. Pre-rectification column ensure removal of sulfur compounds/mercaptans and also reduces load of lower boiing volatile compounds passing on to Rectifier cum exhaust column. 17

The chances of scaling due to invert solubility of certain precipitating inorganic salts are minimized in vacuum distillation. Vacuum distillation requires low steam consumption with reboiler i.e. 2.2 Kg/lit. of Rectified Spirit around 3.2 Kg/lit. of ENA Manufacturing process for Anhydrous (Fuel) Alcohol: Anhydrous alcohol is an important product required by industry. As per IS Specification it is nearly 100% pure / water free alcohol. Alcohol as manufactured by Indian distilleries is rectified spirit, which is 94.68% alcohol. It is not possible to remove remaining water from rectified spirit by straight distillation as ethyl alcohol forms a constant boiling mixture with water at this concentration and known as azeotrope. Therefore, special process for removal of water is required for manufacture of anhydrous alcohol. In order to extract water from alcohol it is necessary to use some dehydrant or entrainer, which is capable of separating water from alcohol. Simple dehydrant is unslacked lime, Industrial alcohol is taken in a reactor and quick lime is added to that and the mixture is left over night for complete reaction. It is then distilled in fractionating column to get anhydrous alcohol. Water is retained by quick lime. This process is used for small scale production of anhydrous alcohol by bath process. The various processes used for dehydration of alcohol are as follows: I) Azeotropic Distillation II) Molecular Sieves III) Pervaporation / Vapour permeation system: III) Dehydration with Molecular Sieve Process: Molecular sieves are synthetic adsorbents and are developed for vapour phase ethanol dehydration is metal aluminosilcates with effective pore size opening 3 angstrom (3 x 10-8 cm). Molecular sieve of type 3A has chemical formula (K 2 O.Na 2 O).Al 2 O 3.2SiO 2.XH 2 O During potassium form of molecular sieve has pore size of 3 angstrom. The diameter of ethanol molecule is 4.4 angstrom The water vapour molecules are having strong dipoles and elastic. They are drawn into the pores and condensed at the wall of the pores. Ethanol vapour bigger in size passes through the bed without getting into the pores of the molecular sieves. Water strongly attracted to molecular sieve of 3- angstrom type that for each kilogram adsorbed, 990 Kcal of heat released. This effect is referred as the heat of adsorption. 18

When we remove that same kilagrom of water during regeneration, we must supply 990 Kcal of heat. This effect referred as the heat of desorption. 3A type molecular sieves is capable of adsorbing up to 22% of its weight in water. The salient features of the molecular sieve adsorption process: 1) Steam consumption of 0.5 to 0.6 Kg/lit of Rectified Spirit. 2) It is possible to use exhaust steam 1.5 Kg/cm 2 gm (90%) and medium pressure steam 3 3.5 Kg/cm 2 gm (10%). 3) Safety equipments such as relief valves, flame arresters etc. 4) Steel structure with prompt access to all equipments. 5) Explosion proof installation, easy and safe operation. The rectified spirit (94 96% v/v) from the rectifier feed tank is pumped to a feed preheater to evaporation (regeneration) column in evaporation column liquid phase converted in to vapour phase by application of steam through reboiler at the bottom of the column. The top vapour of the column fed to the superheater. The vapours are super heated by applying steam the vapour temp. app. 140 o C 150 o C. Superheated rectified spirit vapours from feed super heater is passed to one of the pair of molecular sieve beds for several minutes while passing through the molecular sieve bed water is absorbed and absolute alcohol vapour at 99.8 99.9 % v/v is removed, which is then condensed and cooled in sent to respective receivers and storage tank. During the adsorption cycle of app. 8 10 mins. The bed undergo a temp. rise due to heat adsorption (990 Kcal/kh water adsorbed). When the bed reaches the saturation factor, it is regenerated by vacuum application on the loaded bed and water plus ethanol mixture at 135 O proof boils and released the heat of adsorption and the bed temperature is reduced again. A moderate vacuum is applied by vacuum pump operating after condensation of the evaporation column by recycle pump to the regeneration preheater. The life of molecular sieve may be around five to seven years. However, the operating cost is considerably less than azeotropic distillation. Requirement of Input : Plant Capacity (KLPD) *Cooling Water(M 3 /hr) Cooling Water Make up (M 3 /day) **Steam (R.S. to BS. Alc.) (Kg/Lit.) ***Power (KwH/hr) Connected Operating 30 70 75 50-55 0.6 40 20 * Cooling water recirculation rate 50 M 3 /hr for Molecular Sieve Plant only @ 30 0 C maximum and 4 Kg/Cm 2 (g) pressure at cooling water header, ΔT=6 0 C ** Steam requirement will be at full capacity operation @ 5 Kg/Cm 2 (g) pressure in steam header. 19

*** Electricity will be 440 V, 3 ph, 50 Hz, AC Electric supply. The power requirement will be for molecular sieve plant only, which excludes utilities like boiler, cooling tower etc. Fig. 6 The Fermentation Process: 20

Continuous Fermentation: Fig. 7 Process Flow Diagram (typical) of Multi Pressure Distillation Plant : 21

MATERIAL BALANCE FOR PROPOSED150 KLPD CO2 out 4465.8 kg/hr (water nil) Steam to Rectifier reboiler 13125 Kg/hr. Molasses 22899.9 kg/hr wash feed to distillation Intigrated product alcohol fermentation 71632 kg/hr distillation 4938 kg/hr section (water : 262 kg/hr) Dilution water 29771 kg/hr section 14495.35 kg/hr Steam condensate to Boiler 13125 kg/hr Spent wash spent lease 31250 kg/hr (17% solid) 5673 kg/hr Intigrated (water 100%) evaporation system condensate process conden. polishing unit 12276.79 kg/hr 17949.79 kg/hr conc. sp wash to MEE 18973.21 kg/hr(28% solid). cooling tower make up & process Effluent Treatment: Introduction: The main effluent generated from molasses based distillery is spentwash. The flow and characteristics of effluent are as below: Sr.No. Parameter Units Percentage (%) 1. Flow cum/day 1200 2. ph - 4.0 to 4.5 3. Total solids mg/l 1,50,000 to 1,60,000 4. Total Volatile Solids mg/l 80,000 to 90,000 5. C.O.D mg/l 1,40,000 to 1,50,000 6. B.O.D mg/l 60,000 to 65,000 7. Chlorides mg/l 5,000 to 6,000 8. Sulphates mg/l 5,000 to 6,000 9. Total Nitrogen mg/l 1,000 to 1,200 10. Phosphorous mg/l 600 to 800 11. Potassium mg/l 1200 to 1400 22

Treatment Details: The Spentwash shall have a temperature of 70 to 80 C., which shall be passed through a Plate heat exchanger to reduce the temperature to 30 C. It is then passed The Decanted effluent is taken to a storage tank of 7 days capacity (8,400 cum). The sludge from Centrifuge/Decanter is composted. Spentwash from storage tank which has 15 to 16% solids shall be concentrated to 60% solids in Multiple Effect Evaporators (MEE). The condensates from the MEE and spentlees from the distillation process shall be treated in condensate polishing unit (CPU) and the treated water is recycled as makeup water in Cooling Towers. The concentrated solids of Spentwash shall be burnt along with addition of coal in Incinerator boiler the ratio of Spentwash solids to coal is maintain between 4:1 to 4:1.5 depending on the type of the technology chosen. The flue gases emanating from the Incinerator boiler shall be dispersed through a stack having a height of 65 to 70meters after passing through ESP. The Ash from the Boiler shall have the following characteristics which can be used as a fertilizer after blending. 5.0 PROCESS DETAILS 1) Assessment of New & Untested technology for the risk of Technological Failure 1) Composting Process: Traditionally Composting Process is adopted for treatment of Spent wash as one of the proven technology as zero discharge system. At present the SOC has been practicing Composting technology preceded by Bio-Methanisation for its 60 KLPD Distillery Unit. The Details of this process is attached. The present system adopts the solid concentration of 5 to 6% for Composting operations. The Pressmud to Spentwash ratio is as 1: 3.5 and the cycle of operation is 60 days. In the expansion of the Distillery project, the solids concentration is estimated as 18% solids. The pressmud to spentwash ratio is taken as 1:1.5 and the cycle of operation shall be maintained as 60 days. The Laboratory investigations are also been conducted to confirm these assumptions, even though the Alfa Laval (India) Ltd. the suppliers of technology have assured that it is possible to achieve the assumptions made in the composting operations. The Quality of Compost shall have to be also assessed even though the suppliers of this technology have again assured that there will be no change in compost characteristics. The risk involved in this technology could be mainly of two types a. Whether Press mud to Spent wash ratio of 1:1.5 would be sufficient and also the days for each cycle required would be 60 days or more. b. With regard to compost quality whether C/N ratio below 17 can be achieved for effluents having solids concentration of 18% The industry has already provided the required compost area of 26 acres and made it seepage proof /impervious by concreting the entire area. This is over and above the stipulated conditions by the Central Pollution Control Board for Surface composting. The Industry has 23

also provided garland canal to collect the leachate and also a sump well to pump back the leachate for recirculation in the compost area/storage pond. These are as per the guidelines of CPCB. The industry has provided 30 days storage capacity for spent wash as per the guidelines of CPCB by laying HDPE sheet and stone soling. The required machinery such as Compost Mixing Machine (Aerotiller), Excavator cum Loaders and Sieving machines and Bagging Facilities are being provided as per the Guidelines. Thus the industry has implemented all the stipulated conditions of CPCB guidelines for surface composting and therefore it can be conclusively said that there will no risk involved in the implementation and operation of Compost technology. 2) Concentration and Incineration: The expert appraisal committee has recommended to adopt Concentration and Incineration technology for treatment of spent wash within two years from the date of starting of the Production of Rectified Spirit. The project proponent has studied the technologies that are in operation both in India and Abroad and have to make the following observations. Indigenous Technology: a) The Evaporators and Boilers are required to be cleaned frequently and the exact number of cleanings required is yet to be established. b) Even though the Concentration and Incinerations plants are working in one or two places for the last six months in India, the techno economic viability is not known and the working of the units is yet not evaluated by any expert committee. c) It is learnt that in the Industries where the Concentration and Incineration technology is adopted the modifications are still being made and the nature of modifications and the present performance is not clearly known. d) The suppliers are not prepared to give any guarantee for the material used in the construction and longevity of the system. Chinese Technology: Spentwash is concentrated to 65% solids through Multiple Effect Evaporators. The Concentrated Effluent is burnt in a specially designed Boiler. If Spentwash alone is burnt the steam requirement can be met to an extent of 30 to 35% of the process requirement after fulfilling the steam required for concentration. The power requirement for the process as well as for the concentration and burning shall have to be met from external source. The capital cost of the project is around 45 Crores for 200 KLD distillery. The main constraints are as below: a) If the project is to be made feasible the pressure of the boiler should be above 40 kg/sqcm. At present the boilers are designed for a maximum pressure 25 kgs/sqcm. However the Chinese firm claims that have the capability of designing the boiler to the required pressure. This appears to be the major risk factor in this technology. 24

b) Even though the advocators of the technology assures the payback period as 2 to 2.5 years there are no plants erected yet in India to verify the claim. CONCENTRATED SPENTWASH FIRED BOILERS FOR ZERO LIQUID DISCHARGE & COGENERATION APPLICATION IN DISTILLERIE Boiler and Heater Group, A division of Thermax Ltd. Thermax Limited CONCENTRATED SPENTWASH FIRED BOILER Distilleries across the world are increasingly coming under pressure from government and society regarding the discharge of the polluting effluents i.e. spent wash from the core process. Since the ph of the concentrated spentwash from the process effluent is less than 4 to 5 it is highly dangerous to drain this effluent to environment. Considering the potential threat to the soil damage Zero effluent discharge (ZED) norm for distilleries is already in place in number of countries including India. Existing disposal methods practiced by Distilleries like Bio-methanisation and Biocomposting are unable to meet the ZED norms as; Bio- Methanisation Does not eliminate water Regulation is difficult Bio-composting Availability of press mud Operational problem during rainy season Area required is large Land pollution leads to leaching 25

Considering the practical problems in meeting the ZED with the conventional methods, Distilleries are increasingly looking for an alternative solution of concentrating the spentwash and then firing it in a specially designed Boiler. This fundamental shift in practice in the distillery sector has been facilitated by Thermax s successful efforts to develop a commercial-scale boiler technology for firing concentrated Spentwash. The benefits of this technology include; (1) Ability to dispose effluent discharge of distilleries in a safe and environmentally sound way (by meeting ZED norm) (2) Steam generation for meeting the process steam and produce electricity requirements of the distillery through STG. 26

Boiler Features; The technology offered by Thermax is an AFBC, bottom support, over bed fuel feeding with single drum and three pass (gas) construction. Heat transfer sections like Super heater, evaporator and economizer are located in third pass. Feed water from deaerator is pumped to economizer through drum coil pre heater Drum coil pre heaters are provided to heat the water to the desired limit prior to enter the economizer, to protect the economizer from dew point corrosion. To control the final steam temperature, spray type attemperator is provided in between the primary and secondary super heater sections. Combustor is constructed with special refractory material, enclosed by steel casing and structure. Combustor is divided in to multiple compartments depends on the boiler generation capacity. Each compartment is provided with bed thermocouples for measuring bed temperature and bed level measuring probes. Coal firing system consists of coal bunker with variable speed screw feeders to feed the coal. Coal is distributed inside the combustor by pneumatic spreading system. Concentrated (58 to 60%) and pre heated Spentwash from the day storage tank is conveyed to boiler through variable speed pump. Spentwash is sprayed over the fluidizing bed at first pass through 2 nos. off spray guns (per compartment), which is located at upper furnace. 27

Combustion air, to wind box is supplied from a variable speed FD Fan through Steam Coil Air Pre Heater with isolation/control dampers at wind box inlets. For complete combustion, secondary air is provided in two elevations at upper furnace. Spent wash Spray Gun is located below the secondary air nozzles. SA Fan is provided to supply the secondary air and coal spreader air at required pressure and flow. For on-line cleaning of ash deposits on the pressure parts, mechanical rapping system is provided for all the heat absorbing sections in third pass i.e. SH 1/2, Evaporators and Economisers with separate drives. Since the spent wash ash is sticky in nature, mechanical rapping system is preferred and provided in our design To drain the bed ash from combustor, 4 nos. of bed drain ports are provided in each compartment with isolation gate. Fly ash from second pass and third pass is evacuated to ash handling system through RAV from individual hoppers. Challenges in spentwash firing: Fluctuation of solids content in spent wash, cause combustion in stability and leads to bed slumping as combustion not self sustainable below 55% solid content Ash Analysis: Acidic nature- hence the handling need special material. Highly viscous at solid concentration (>50%) High alkali content in ash leading to fouling of heat transfer surfaces. Alkalis in the ash are ranging up to 50% depending on cane growing area. Source of alkalis mainly through fertilizer. Presence of chlorides leading to high temperature corrosion on the super heater section Sr. No. Parameter Percentage (%) 1. Silica (SiO 2 ) 20 22 % 2. Iron Oxide (FeO 3 ) 1.5 2.0 % 3. Calcium Oxide (CaO) 8.0 8.5 % 4. Magnesium Oxide (MgO) 7.0 6.5 % 5. Sulphates (SO 4 ) 8.0 8.5 % 6. Phosphates as P 2 O 5 1.5 1.8 % 7. Potassium as K 2 O 43 44 % 8. Sodium Oxides (NaO 2 ) 2.5 3.0 % 9. Aluminium Oxide (Al 2 O 3 ) 0.06 0.08 % 10. Titanium Oxide 0.01 0.0168 % 11. Chloride (Cl - ) 5.5 6.5 % 28

1) The Central Pollution Control Board has identified the following alternatives for Spentwash Treatment. a) Bio-Methanisation followed by Ferti-irrigation/Controlled land Application/Composting b) Raw Spentwash Composting after reducing the volume of Spentwash with the help of Reboiler/Evaporators/Reverse Osmosis c) Concentration and Incineration In the present case the option a) is not advisable as the quantity of effluent to be treated shall be around 2400 cum/day (i.e for Bio-Methanisation the spentwash quantity generated is taken as 12 liters/liter RS production). To handle such huge quantity of effluent for Ferti-irrigation/Controlled land Application/Composting requires large area and also filler material. Therefore this option has been ruled out. The option b) has been found to be feasible for two reasons: 1) The effluent quantity shall be brought down to 400 cum/day during the sugarcane crushing season by using heavy grade molasses and to 800 cum/day in the remaining period by using Multiple effect Evaporators for concentration of effluents. 2) All the existing facilities of Composting can be used for this purpose and no additional infrastructure facilities are required as per the enclosed report on the adequacy of the effluent treatment plant facilities and the existing effluent treatment plant facilities 6.0 EXISTING EFFLUENT TREATMENT PLANT FACILITIES Spentwash Storage Pond: A 30 days capacity storage pond of 24,000 cum is provided. The pond is lined with HDPE sheet of 250 micron thick and stone soling was carried out to prevent seepage/percolation. Compost Yard : 26 acres of compost yard is concreted using HDPE sheet of 250 micron thick over which RCC of 1:2:4 mixture of 150 mm is used. Curb wall is provided to prevent the seepage of Spentwash from the compost yard. A garland canal is constructed to collect seepages during the composting operations. The seepages are collected in a tank which is made seepage proof as per the specifications mentioned for Spentwash storage pond. The efluent from the sump well is pumped back either on to the compost yard/ spentwash storage pond. 29

Fig : Concreted Compost yard and Aerotiller. Effluent Spraying System A) Under Ground Piping System: The entire composting yard is provided with under ground piping spraying chambers, valves, and Nylon breaded hose with nozzles. The effluent is pumped from the spraying lagoon having 2000 m3 capacity through pump 90 m3 per hour capacity into the spraying system and Effluent is sprayed manually over windrows through Nylon hoses with nozzles. Around 20 hoses are operating per day for effluent spraying. Windrow: 3.5 x 1.5 M Spraying Chamber. Line Diagram of Windrow & Spraying System 30

B) 2 ES Automatic Dispenser Spraying System Mounted on Mahindra LCV. Used for Mechanical Spraying of Effluent. Make : Sartime Horological Pvt Ltd. Capacity : 20 M 3 per Hour. Fig : 2ES Despensor Spraying machine. It could spray around 20 m3 /Hr of distillery effluent. Spraying can be continuous for any length of time. 2 windrows can be sprayed uniformly and simultaneously. No Dependence of Man power Work continuously in Hot summer. Shifting of hose pipes avoided. Consistent and uniform spraying. Composting Machinery A) Aerotiller: For mixing and accelerating composting reaction. 1 - No. Make - Alfa Laval Engine - 320 kv Turing capacity - 2500 MT/HR Drum Speed - 700 RPM 31

A specially designed machine for large scale aerobic composting. Performs the duties of agitating, shredding, aerating and temperature control in the composting mass. Effectively reduces BOD by supplying fresh air. High-powered engine (320 HP) with high carding drum speed (600 rpm). Fig : Aerotilling on windrow. B) L/T FRONT END LOADER CUM EXCAVATOR: 3 NO. For trimming and reshaping windrows after Aerotilling. For loading and handling of press mud. For Loading of compost. Fig : Trimming of Windrow with L&T Loader 32

C ) TRACTORS 6 Nos. For handling press mud & compost. D) GRASS HOPPER /SIEVER : 3 Nos.: For sieving compost. Capacity 15 MT/HR Sieve size is 4 Mesh. Tray 1 M width and 10 M length Fig : Sieving of the Bhumilabh. MICROBIAL CULTURE: MIXED POPULATION OF FUNGI, BACTERIA & ACTINOMYCETES ) Starter culture specially designed for spent wash-press mud degradation Help to increase press mud to effluent consumption ratio. Non-pathogenic, non-hazardous. Can degrade press mud wax. Also contains beneficial soil microorganisms. Can be used with concentrated effluent. 33

Fig : Inoculation of windrow with microbial culture. Godown, Packing and Weighing Facilities 1 200 kg capacity scale for weighing 50 kg bags. 2 Weigh bridge 30MT capacity for weighing Trucks & Tractors. 3 Stitching machine 2 No. for Stitching HDPE bags. 4 Conveyer 1 NO. for loading of Bags. 5 Sealing machine for sealing of 2 kg plastic pouch. 6 Godown for storing of Packed Material & packing. Size 15 x 12 m. 34