Energy Efficiency Bulletin

Case Study Bulletins from CII-Sohrabji Godrej Green Business Centre

Bulletin No. 13

Biomethanation (UASB) Treatment of Bagasse Wash Water: An Environment Friendly Process for Generating Energy from Waste

October 2007

Company details TNPL was set up in 1984 to manufacture newsprint/fine paper using bagasse as primary raw material. TNPL is the largest integrated Paper mill in India, in a single location with a production capacity of 230,000 tpa. By utilising bagasse on a large scale, the mill conserves around 30,000 acres of forest land from commercial exploitation for pulping. TNPL is an ISO14001 and ISO9001; 2000 certified company. Project details Bagasse is the primary raw material in paper making at TNPL. Substantial amount of waste water is generated from bagasse storage yards and bagasse preparation process. The waste water generated from this process is having high BOD (Biological Oxygen Demand) content.

Controlled Anaerobic Digestion (UASB - up flow anaerobic sludge bed) This high BOD waste water is taken through a mechanical bar screen to a primary clarifier to settle suspended solids. It is then treated in a UASB (Upflow Anaerobic Sludge Bed) reactor followed by the process of settling in a secondary clarifier. The process flow diagram of the system is given below:

The bio-gas generated from the plant is utilised in the Lime Kiln to partially replace the expensive Furnace Oil. Financing of the project The plant was installed at a total cost of Rs 40 million with 50% subsidy from Ministry of Non-conventional Energy Sources (MNES), Govt of India as a demonstration projects under GEF sponsored high rate biomethanation process for waste to energy Projects. The plant invested remaining 50% of the project cost from its internal fund. Issues faced during implementation The pressure variation between furnace oil and biogas line disturbed the biogas firing in the kiln.This problem was solved by the addition of pressure control valve in biogas line and by regulating biogas flow the lime kiln.

Effluent Treatment System Anaerobic digestion: In conventional anaerobic digestion, the biodegradable pollutants in the waste water are converted to biogas containing methane, carbon dioxide and biomass (little) in the absence of oxygen by Anaerobic microorganisms. The net energy generated during anaerobic digestion process is in the form of methane (CH4) bearing biogas and CO2. These gases are emitted in to atmosphere without any useful work.

The biogas generated from the UASB is having high moisture content. This has resulted in condensing of water in the pipe line. This problem was rectified by the addition of moisture trap at lime kiln. The problem of sludge wash-out from reactors was observed due to variation in flow and Chemical Oxygen Demand (COD). Additional Storage/Equalization tank was constructed to regulate the flow and COD. Comments from the plant team Environment impact reduction should also be a key aspect of plant operation. Wherever possible, the industry should identify and implement environment impact reduction projects in a cost effective manner. Results of the project Installation of biomethanation plant has resulted in both environmental and energy saving benefits. Environmental benefits Description
Reduction of Pollution Load Waste water treated COD Reduction Reduction in GHG Emission Methane avoidance Fuel Saving Total

Cost benefit analysis

l Investment Rs 40 million (50 % subsidy) l Net investment Rs 20 million l Annual savings Rs 24 million l Payback 10 Months

About CII & CII-Godrej GBC CII is a non-government, not-for-profit, industry led and industry managed organisation, playing a proactive role in India's development process. Founded over 112 years ago, it is India's premier business association, with a direct membership of over 6500 organisations from the private as well as public sectors, including SMEs and MNCs, and an indirect membership of over 90,000 companies from around 350 national and regional sectoral associations. Cll-Godrej GBC is a Centre of Excellence in Energy Efficiency, Green Buildings, Renewable Energy, Water, Environment & Recycling and Climate Change activities in India. About 3 Country Energy Efficiency The Project "Developing Financial Intermediation Mechanisms for Energy Efficiency Projects in Brazil, China and India" aimed to substantially increase investments in energy efficiency by the domestic financial sectors in Brazil, China and India. The project was a partnership between the World Bank, the United Nations Environment Programme (UNEP) through the UNEP Risoe Centre on Energy, Climate and Sustainable Development (URC), and institutions in Brazil, China and India. Additional information is available at www.3countryee.org This Energy Efficiency Bulletin comprises of a series of case studies on successful energy efficiency projects implemented by Indian industry. The bulletin is supported under the "3 Country EE" initiative and by USAID.

Unit
M /Year M3/Year MT CO2e/Y MT CO2e/Y MT CO2e/Y
3

Value
3, 052, 431 9092 47500 9500 57000

Economical benefits Description

Average Biogas Generation Avg. F. Oil saving in lime-kiln F. Oil Cost Saving against F. Oil Plant Operation Cost Net Saving Annual Saving

Value
15,000 M /Day 9,000 Lit/Day Rs. 11.50/Lit Rs.103,500 / Day Rs. 35,000 / Day Rs. 68,000 / Day Rs. 24 Million
3

Benefits of the project

l Reduction in waste water l Methane avoidance l Fuel saving

For further details contact

Dr S Chinnaraj Research and Development Division Tamilnadu Newsprint and Papers Ltd Kagithapuram, Karur , Tamil Nadu - 639 136 Tel : 04324 277001 to 10 Fax: 04324 - 277025 Email: biotech@tnpl.co.in

Mr K S Venkatagiri / Mr K Sivaram
Survey No 64, Kothaguda, Near Hitech City Hyderabad - 500 032 Tel: 040-23112971 73, Fax: 040-23112837 Email : k.s.venkatagiri@ciionline.org / k.sivaram@ciionline.org www.greenbusinesscentre.com