Zero Spent Wash Discharge Technologies
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1 Zero Spent Wash Discharge Technologies 8 th October, 2015 Mahesh Kulkarni, Praj Industries Limited, Pune Praj Industries Ltd
2 In Focus Options for Zero Spent Wash Discharge Technology Raw Spent Wash Biomethanated Spent Wash Recycle, Reuse Technologies Value Maximization- Zero Spent Wash Discharge Technologies Praj Industries Ltd 2
3 Sustainability Drivers Volatility in Feedstock & Ethanol Prices Rising Energy & Water Cost Stringent Pollution control Norms Policy Uncertainty Praj Industries Ltd -6-
4 Sustainability Demands.. Reduce effluent generation at source itself Recover energy, recycle and reuse the water Integrate the effluent treatment systems with main process plant Praj Industries Ltd 7
5 Sugar Factory Streams-Value Maximization Cane 1 st mill Primary Juice Bagaase 2 nd / 3 rd /4 th /5 th mill Mixed Juice Secondary Juice Bagasse Power RVF Press Mud Composting/ power generation Muddy Juice Filtrate Juice Clarification Evaporation Syrup Crystallization Condensate Water Recovery? 1 st /2 nd / 3 rd /4 th Centrifuge Sugar B- Molasses C- Molasses Packaging Praj Industries Ltd -8-
6 Typical Sugar Juice Stream Composition Stream Primary Juice Secondary Juice Mixed Juice Filtrate Juice % w/w on Cane % Pol Brix FS Praj Industries Ltd -9-
7 Typical Properties of Concentrated Streams Parameter Syrup Molasses- B Molasses- C TDS (%w/w) FS (%w/w) TSS (%w/w) Specific Gravity Volatile Acidity (ppm) Praj Industries Ltd
8 Mash Column Rectifier Colum Aldehyde Column Sugary Feedstock Source of Effluent in Distillery Cooling Water Degassifyng Column Rectified Alcohol Impure Ethanol Mash OH Fusel oil OH Energy recovery From Molecular Sieve Reboiler Steam Steam Vapor Vinasse Spent Lees Process Condensate Vinasse Praj Industries Ltd 11
9 Distillery Effluent Streams Main effluent stream Spent wash / Vinasse for Molasses feedstock Other dilute streams Spent Lees Process Condensate CIP washing effluents Floor washing Cooling tower Blow down Praj Industries Ltd 12
10 Why Spent Wash or Vinasse is Challenge? Organic Residual Sugar : Organic Solids : Carbohydrates, polymers, starch, gums Nitrogenous: proteins Waxes Vitamins Inorganic Solids : Cations: Calcium Potassium Sodium Magnesium Silica Iron Manganese Organic acids: Acetic Butyric Propionic Valeric Colouring substances Anions: Sulfates Carbonates Phosphates Chlorides Nitrates Oxides Praj Industries Ltd 13
11 Distillery Spent Wash Characteristics.. Parameters Sugar Cane Molasses Spent Wash/Vinasse Sugar Cane/SS Juice Sugar Cane/SS Syrup Wastewater Generation, L/L of AA ph COD, mg/l BOD, mg/l BOD/COD ratio TS, % w/w TVS, % w/w TVS/TS, % w/w Praj Industries Ltd 14
12 Distillery Spent Wash Characteristics Vinasse Parameters Sugar Cane Molasses Sugar Cane/SS Juice Sugar Cane/SS Syrup Total Kjeldhal Nitrogen,mg/L Phosphorous, mg/l Potassium, mg/l Sulphates, mg/l Ratio of COD to Sulphates Praj Industries Ltd 15
13 Zero Process Discharge-Need of the Hour... High Steam Economy Maximum Usable Water Recovery Reliability Lower Down time Zero Spent Wash Discharge Technology Low Capex Praj Industries Ltd 16
14 Spent Wash Treatment Technologies Effluent Treatment Technologies Biological Concentration / Separation Polishing / Finishing Anaerobic Aerobic Composting Ferti-Irrigation Evaporation Dryer Incineration boiler Membrane Anaerobic followed by UF /RO Ozonisation Membrane Ultraviolet Combinations of treatment methods can be used in accordance with local norms and economics Praj Industries Ltd 17
15 ZSD- Raw Spent Wash Evaporation + Incineration Boiler Praj Industries Ltd
16 Zero Process Discharge Technologies-RSW Raw Spent Wash Treatment Technologies RSW Evaporation RSW Concentration by Membrane Polishing / Finishing Incineration Dryer Composting Dryer Anaerobic followed by UF /RO Ozonization Membrane Ultraviolet Combinations of treatment methods can be used in accordance with local norms and economics Praj Industries Ltd 19
17 ECOVAP -Raw Spent Wash Evaporation Technology FEED CW CONDENSER STEAM E-1 E-2 E-3 E-4 CP- 1 TP-1 CP- 2 TP-2 CP- 3 TP-3 CP- 4 TP-4 VACUUM PUMP FINISHER PRODUCT Praj Industries Ltd CP- 20 TP-5 5
18 Zero Process Discharge for Molasses Based Distillery - Vinasse Boiler Praj Industries Ltd 21
19 Why Vinasse Boiler? 1. CPCB approved method for distillery spent wash in all new distilleries in India as ZPD requirement. 2. Rapid destruction of polluting organic material to small volume of sterile ash 3. Suitable for sites with constraint on land Praj Industries Ltd 22
20 Vinasse Boiler- Choice of Auxiliary Fuel 1. COAL (local/imported Indonesia/S. Africa) (low moisture) 2. RICE HUSK (silica ash is abrasive) 3. BAGASSE (low ash, but high moisture) Auxiliary fuel required for startups, shutdowns, and in normal operation to partially counter clinkering tendency due to low melting point of Potassium salts All auxiliary fuels stored under covered shed. Availability during full year to be checked. Praj Industries Ltd 23
21 Vinasse Boiler- Ash Characteristics COMPONENT COAL SPENT WASH Al2O CaO Fe2O K2O MgO MnO Na2O P2O SiO SO TiO ZnO Cl Note: E I D Parry Ltd., sample Praj Industries Ltd 24
22 RSW Condensate Polishing-ECOPHOTOx Praj Industries Ltd
23 ECOPHOTOx-Photochemical Oxidation Technology Complex Organic UV Activation Compounds Oxidant Intermediates UV Activation Oxidant CO 2 + H 2 O RSW Evap. Condensate + Spent Lees Filtration Unit (Sand Filtration) Filtration Unit ( Micron Filtration) Activated Carbon Filter Treated Water Praj Industries Ltd ECOPHOTOx Unit 26
24 Benefits of ECOPHOTOx. Praj Industries Ltd 27
25 Biomethanation based Integrated Zero Spent Wash Discharge Technology Praj Industries Ltd
26 Biomethanation Anaerobic reactor Degradation of organic matter by anaerobic bacteria in absence of O 2, yielding valuable biogas. Praj Industries Ltd 29
27 Biomethanation-Anaerobic Reaction Praj Industries Ltd 30
28 Zero Process Discharge Technologies-BMSW Biomethanated Spent Wash Treatment Technologies BMSW Evaporation BMSW Concentration using membranes Polishing / Finishing Evaporation Composting Dryer BMSW Concentration using RO Composting Ultrafiltration Stripping Combinations of treatment methods can be used in accordance with local norms and economics Praj Industries Ltd 31
29 Biomethanated Spent Wash Concentration-Membrane Sr. No Parameter Unit BMSW BMSW RO Reject 1 TS % w/w w/w 3-7 % 6-14% 2 ph Alkalinity mg/l NH 3 -N Mg/L Calcium mg/l Potassium mg/l Sulphate mg/l Chlorides mg/l Phosphates mg/l Ash w/w 1-2% 2-4% Note- Above mentioned ranges are avg. values actual may vary depending on plant performance. BMSW RO reject concentration will be ~ 2 times the BMSW feed Praj Industries Ltd 32
30 Typical Biomethanated Spent Wash Composition Sr. No Parameter Unit BMSW 1 TS % w/w w/w 3-7 % 2 ph Alkalinity mg/l NH 3 -N Mg/L Calcium mg/l Potassium mg/l Sulphate mg/l Chlorides mg/l Phosphates mg/l Ash w/w 1-2% Note- Above mentioned ranges are avg. values actual may vary depending on plant performance. Praj Industries Ltd 33
31 Challenges of BMSW Concentration Foaming Scaling and fouling Dissolved gases Viscosity at higher concentration Higher inorganic salts Praj Industries Ltd 34
32 BMSW Concentration The Complete Solution Pretreatment Concentration Condensate Treatment Objective 1. Remove Dissolved Gases 2. Reduce Scaling Objective 1. Concentration 2. Less Contaminated Condensate Objective 1. Remove Ammonia 2. Remove Hydrogen Sulfide Praj Industries Ltd 35
33 EcoVap BMSW- BMSW Evaporation Technology Praj Industries Ltd 36
34 BMSW Pretreatment - Steps Flashing Remove non-bound gases Stripping Remove thermally unstable bound gas forming compounds and reduce alkalinity. Acidification Increase the solubility of dissolved bicarbonate and stabilize the residual heat sensitive compounds. Praj Industries Ltd 37
35 BMSW Evaporation Multiple Effect Evaporator with or with out TVR. Flow scheme may be forward feed / Backward feed or mixed feed depending upon process requirement. Maximum number of effects up to 7 from stand alone and up to 3 for integrated BMSW evaporation (On Analyzer Vapors) Operational Philosophy will be 20 hr working and 4 hr CIP. Design Parameters* 1 st Effect Boiling Temperature: Deg. C 1 st Effect Jacket Temperature : Deg. C Last Effect Boiling Temperature : Deg. C Praj Industries Ltd 38
36 Ecofine CST -BMSW Condensate Treatment Technology Praj Industries Ltd 39
37 BMSW Condensate Recycle 80-90% water is recovered as BMSW evaporation process condensate. BMSW process condensate can be recycled back to process or utilities application like cooling tower makeup etc. It will reduce the distillery water consumption by 6 8 lit / lit of Ethanol. Praj Industries Ltd 40
38 BMSW Evaporation Key highlights No Cooling water requirement (with Adiabatic Evaporation) Simultaneous evaporative degassing system Less Foaming in evaporation system Less Scaling and fouling due preconditioned feed Clean water recovery for recycle and reuse Less operating cost Higher Plant availability Less Plant Downtime High reliability Praj Industries Ltd 41
39 Integrated BMSW ZLD Technology Reduction in in distillation steam consumption from 3.2 kg/lit to 2.8 kg/lit 100% Recycle of Process condensate for process and Utility application BMSW Volume reduction by 75-80% Praj Industries Ltd 42
40 Dryers- Current Availability in market Spray Dryer Rotary Dryer Agitated Thin Film Dryer Praj Industries Ltd 43
41 BMSW Dryer- Limitation of Spray and Rotary Dryer Spray Dryer High Capital and Overhead Cost Maintenance Issue High Energy loss along with hot air Fuel like FO or LDO is required which create pollution Integration / Energy Recovery is not possible Quality of product (Dried BMSW) Frequent chocking of the Spray Dryer Rotary Dryer (Comparison against ATFD) Higher investment Higher power consumption Higher steam consumption Energy recovery not possible Higher foot print Higher HTA required for same duty Higher heat loss Steam requirement is about 1.45 time of water evaporation Open process: dusty atmosphere Praj Industries Ltd 44
42 Advantage- PRAJ s BMSW Drying Technology Low investment (low fix cost) Low power requirement Lower steam requirement Energy recovery is possible through Vapor Integration Lower foot print Much lesser HTA required for given duty Lower heat loss Steam requirement is about 1.1 to 1.2 time of water evaporation Easy Start-up and Shut down Enclosed process: Cleaner surroundings Praj Industries Ltd 45
43 Value Maximization- Praj s Zero Process Discharge Technologies Praj Industries Ltd
44 PRAJ s BMSW Drying Technology-Soil Enricher Composition of BioManure Parameter Unit Value 1 Total Solids %w/w Ash % w/w Kjeldahl Nitrogen % w/w Phosphorus % w/w Phosphorus as P2O5 % w/w Potassium % w/w Potassium as K2O % w/w Magnesium % w/w Calcium % w/w Sulfur % w/w Sodium % w/w Zinc ppm Iron ppm Manganese ppm Copper ppm Calorific Value Kcal/kg Praj Industries Ltd 47
45 Value Added Co-products-EcoClean Technologies Praj Industries Ltd 48
46 Ecoclean Technologies-Biogas Quality Parameters Biogas quality for Boiler application Biogas quality for Power Biogas quality for BioCNG CH % 60-65% % CO % % 2-8% H 2 S % < 200ppm < 20ppm Moisture <1 % RH<80 <-40 o C DP Praj Industries Ltd 49
47 Process Water-Distillery Sustainability 80-90% water is recovered as RSW /BMSW evaporation process condensate. Water suitable for fermentation and Utility (Cooling Tower) It will reduce the distillery water consumption by 6 8 lit / lit of Ethanol. Praj Industries Ltd 50
48 Integrated distillery for value added products Ethanol Treatment Condensate Lees Molasses High Gravity Fermentation Advance Distillation & Dehydration Biomethanation Evaporation Steam Steam & Electricity Boiler / Turbine Biogas team Bio-Composting/ BMSW Dryer 20 % w/w Power/BioCNG Fertilizer Praj Industries Ltd 51
49 Performance Benchmarking Praj Industries Ltd
50 Performance Benchmarking Radico NV Distilleries Maharashtra Ltd, Aurangabad 1000 TPD BMSW Evaporation plant Concentration from 4 % w/w to 19.5 % w/w 7 effect falling film type mixed feed evaporation system. Feed flow scheme is Stripper Reactor Condensate Stripping and polishing unit for condensate recycle in fermentation and cooling tower. Praj Industries Ltd 53
51 Performance Benchmarking Nava Bharat Ventures Ltd, Samlkota Andrapradesh 170 TPD BMSW RO Reject Evaporation plant Concentration from 10 % w/w to 17.5 % w/w Feed Stripper for feed conditioning is provided. Standalone two effect falling film evaporation system. Provision of Integration with analyzer column. Praj Industries Ltd 54
52 Waste water treatment plant to Bio-refinery Waste is no more a waste Power Bio compost Steam BMV Power Bio CNG Distillery Waste water Recover Water It is valuable Co-product Praj Industries Ltd 56
53 Effluent is a problem, if not used at appropriate place with appropriate technology Effluent is useful resource, if used at appropriate place with appropriate technology Praj Industries Ltd o C
54 Thank You Visit us at Contact: Praj Industries Ltd
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