Distillery Sector1

Gujarat Cleaner Production Centre- ENVIS Centre
CLEANER PRODUCTION OPPURTUNITIES

IN
DISTILLERY SECTOR
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Introduction
Ethanol, an agriculture based product is known in several forms - Ethyl Alcohol, Alcohol, Spirit
and Denatured Spirit. It is a globally traded commodity and is used: to fire combustible engines,
as a potable drink and consumed in pharmaceutical and chemica
chemicall industries across the world.
Ethanol is made by two routes: either by synthetic one from petroleum substances or by
fermentation from sugar-bearing
bearing or starchy substrates using yeast. The term ‘fermentation
industry’ in India, covers a very large number of industries in which the reactions with the help
of micro organisms is the major feature. Many of these industries do not exist in India while only
a few fermentation industries are in function that too at the rate of only one or two plants in the
country. In India ethanol is produced by the fermentation of molasses – a by--product of sugar
manufacture. India is the fourth largest ethanol producer after Brazil, the United States and
China, its average annual ethanol output amounting to 1,900 million liters with a distillation
capacity of 3063 million liters per year. An estimated current production of alcoholic beverage
industry’s 480 million cases – consisting of country liquor (local spirits such as feni, toddy, and
arrack are collectively called country liquor), whisky, brandy, rum, vodka, beer and wine. A
distilled beverage, liquor, or spirit is a potable liquid containing ethanol produced by distillation
of fermented grain, fruit, or vegetables. The Indian distillery units use sugarcane molasses as a
preferred
eferred raw material because of its easy and large scale availability. So the Indian fermentation
industry categorized as Maltry, Brewery and Distillery based on either molasses or grain. There
are about 350 distilleries based on Molasses and 100 based on Grain in India, mostly
concentrated in Maharashtra, Uttar Pradesh, Andhra Pradesh, Karnataka,Tamil Nadu, Gujarat
and Madhya Pradesh. Alcohol is produced from molasses by two types of fermentation
processes: Praj type and Alfa Laval distillation named after the manufacturers of the production
systems. In Praj type,, for one liter of alcohol produced, about 12
12– 15 liters of spent wash is
generated, whereas, in the Alfa Laval continuous fermentation and distillation process only 7–8
7
liters of wastewater per liter
er of alcohol is produced. The process of distillation results in release
of large amounts of waste and wastewater, which have a considerable environmental impact by
polluting both water bodies and soil, by causing an adverse climatic effect as well as odour
odo
nuisance. The effluent generated from the distillery is highly colored and contains high organic
as well as inorganic substances. Currently, about 45.72 million m3 of spent wash is generated
annually from distilleries
illeries alone in India. The 350 distilleriess in India produce 3.63 billion liters
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of alcohol while generating 45 billion liters of wastewater annually. The wastewater from
distilleries, major portion of which is spent wash, is nearly 12
12-15
15 times the total alcohol
production. This massive quantity, approximately 46 billion liters of effluent, if disposed
untreated can cause considerable stress on the water bodies. Ground water is the main water
source for these operations. The production and characteristics of spent wash are highly variable
and dependent
dent on feed stocks and various aspects of the ethanol production process. The spent
wash is acidic (pH 3.94 - 4.30) dark brown liquid with high BOD (45000
(45000–100000
100000 mg l-1)
l and
COD (90000–210000 mg l-1),
1), and emits obnoxious odor. Although it does not contain toxic
substances, when discharged without any treatment, it brings about immediate discoloration and
depletion of dissolved oxygen in the receiving water streams, posing serious threat to the aquatic
flora and fauna The effluents of distillery require com
comprehensive treatment like ultra filtration
(UF), nano filtration (NF), reverse osmosis (RO) and membrane bioreactor (MBR) to meet the
prescribed standard for disposal into inland water. Distillery is, therefore, one of the highly water
polluting industry and
nd is also listed as one among the 17 categories of highly polluting industries.
Category of Indian Fermentation Industry

a) Maltry
Malt is produced from grains, usually barley and less commonly wheat or other cereals. The
major process steps are steeping, germination and kilning. Steeping is done to clean the grain and
initiate germination. The operation comprises adding water in adequate quantity, along with
certain additives if required. The water is changed two
two-to-four times and a total steep cycle
c of
24-60
60 hours is employed, as determined by the subjective judgement of the maltry depending on
a variety of factors, from dormancy of the grain to climatic conditions. The germination or
malting may be done in a variety of ways. In India, the common practice is floor malting. In this
the steeped grain is put in a couch, and when germination begins, it is spread on the floor for 7-
7
10 days, depending on the nature of the grain and germination conditions. When it is judged that
an optimum amount of enzymatic
matic breakdown of the original high molecular weight compounds
has taken place, the green malt is kilned to arrest germination and fix the desirable properties
like flavour, aroma and viability. The kilning process comprises of initial drying at 30-40°C
30
followed by curing at 70-105
105 °C. The plant practices that lead to pollution are:
� Throwing the skimmings from steep vessels on the floor, which are eventually drained during
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floor washing.
� Spillage of grains during manual transfer from one germin
germination
ation box to another; Spillage of
rootlets
In general, the wastewater in open drains of maltries is rich in suspended solids and creates a
characteristic foul odour due to deterioration.
b) Brewery
In the breweries, the malt is milled to very coarse flour called ‘grist’, which is then extracted in
water in a process called ‘mashing’. There are three chief methods of mashing, viz. infusion
mashing, decoction mashing and double mashing. In India, the common practice is decoction
mashing in which, unlike in the other systems, cooking of the malted cereal is not involved. The
extract from the mashing step, called ‘sweet wort’ is fed into ‘Iauter tun’ where about 25-30%
25 of
the grain fed for mashing is removed.
moved. The sweet wort is then boiled in the ‘brew kettle’ to arrest
the enzymatic action, sterilize it and precipitate some protein matters. Hops, which impart the
characteristics flavour and bitterness to the beer, and sugar are also added in the brew kettle.
ket The
spent hops are separated in a ‘hop jack’ or on a strainer, and the ‘bitter wort’ is passed through
whirlpools, where it entraps some air and some of the resins are precipitated. The bitter wort is
cooled to 10-15°C
15°C and fermented by yeast over a pe
period of 6-14
14 days, the usual cycle in India
being 10 days. The ‘green beer’ so obtained is lagered for 11-2 months, during which much of the
suspended matter settles down. It is then filtered, bottled and pasteurised. The brewery in general
is a clean industry.
try. Most plants are imported and foreign plant practices are generally followed,
as the brew masters are usually trained abroad. In some plants hop extract is used instead of
hops, when there are no spent hops to be disposed off.
c) Distillery
In India, the potable alcohols of different varieties are not made from different feedstock.
Practically, all are made by blending suitable colours, flavours, additives, etc.,
., to rectified spirit
made from the fermentation of molasses. Only a small amount of alcohol is made from malt for
preparation of whisky. The major quantity of rectified spirit is used for industrial purposes.
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Classification of Distilleries based on Capacity

Production Scale Production Capacity kL/Annum
Small Up to 5,000
Medium Above 5,000 and Up to 10,000
Large Above 10,000 and Up to 20,000
Manufacturing Process
(A) Process of Distilleries Based on Molasses
Alcohol
In India, alcohol is manufactured by two processes:
� Batch process
� Continuous process
a) Batch process
The molasses obtained from the sugar industry is first diluted to bring down the
concentration of sugar from 40
40–45% to 10–15%.
15%. Using a portion of the diluted molasses
a yeast culture is developed from an inoculum. After 4 - 6 hours, when the culture
cul has
developed fully, the remaining molasses is mixed and allowed to ferment for 30–40
30
hours. The pH is maintained around 44-4.5
4.5 by addition of sulphuric acid. As the reaction
is exothermic, the contents of the fermentation tank are kept at 35
35-37oC
37oC by constantly
sprinkling cold water on the outer surface of the fermentation tank.
After fermentation is complete the yeast sludge is removed from the bottom and the
fermenter wash iss pumped to the analyzer column for distillation using steam. The
mixture of alcohol vapours and steam is collected at the top of the column and alcohol
free spent wash is discharged from the bottom. The alcohol and the steam stream are fed
to rectification
ation column where water and alcohol vapours condense at different levels and
rectified spirit is withdrawn. The condensed water from this stage is called spent lees and
forms another waste stream.
b) Continuous Process
In this process yeast is rrecycled.
ecycled. Fermentation and distillation is coupled to get a
continuous supply of fermented beer for the distillation column. The advantage of the
process is that a highly active yeast cell initiates the fermentation rapidly and the alcohol
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yield is also much higher compared to the batch process.

Bio-still
still process is one of the continuous processes, which is a trade name in which
molasses is fed to the fermenter at a constant flow rate. The flow rate of molasses is
controlled to maintain the sugar and alcohol concentrations in the wash at 0.2% or lower
and 6-7% respectively.
The waste streams comprise spent wash which is the main source of wastewater, spent
lees and yeast sludge. Spent lees is usually mixed with the spent wash. The yeast sludge
is disposed separately after drying. In addition wastewater may be generated from the
bottling, fermentation tank cooling and washing and utility sections of the plant, which is
used as a diluent
uent for the treated spent wash.
Figure 1 : Process Block Diagra

Diagramm of Distillery (Molasses Based)
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(B) Rectified spirit

Molasses-based
based distilleries are more common in India. The main process steps and water balance
in this operation are graphically shown in Figure 2. However, the detailed description of the
manufacturing process for rectified spirit is given below :
(1) Dilution - Preparation of molasses for fermentation
(2) Fermentation - Production of alcohol from fermentable sugars in molasses solution
(3) Distillation - Product recovery
(1) Dilution
Molasses available from Indian sugar mills has a solid content varying between 76 and
90% while the total sugar content varies between 45 and 55%.
The main dilution operation occurs in a diluter where the solid concentration is brought
down to 20-25°
25° Brix. The bulk of this diluted molasses is fed to the fermentation tank
while a small quantity is further diluted to 10
10-15°
15° Brix and used for preparation of the
final yeast inoculum. Propagation of yeast for the final inoculation is done in successive
stages in volumes of 10, 100, 1000 and 10,000 litres where, in each stage, 10 parts of
diluted molasses is inoculated with 1 part of yeast culture.
(2) Fermentation
Fermentation in the fermentation tank continues for about 30 to 45 hours after the final
inoculum is added to it. The basic reaction in the fermentation process is exothermic.
Since the reaction is exothermic and proper growth of yeast requires a narrow temperature
range, water is sprayed on the outer walls of the fermentation tank to maintain the
temperature
perature between 25°C and 32°C.
Fermented beer – the main product of this step is decanted and the remaining sludge
known as fermenter sludge is discharged from the bottom of the fermenters. The sludge
amounts to about 300 to 400 litres (l) per kilolitre ((kL)
kL) of rectified spirit produced, and is
one of the major contributors to the ppollution load from distilleries.
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(3) Distillation
The fermented beer from the fermenter vessel is preheated to about 90°C by heat exchange
with the spent wash flow from the analyzer column and is then fed into the degasifying
section of the analyzer column. Low boiling content of the fermented beer such as organic
acids, esters and aldehydes along with some alcohol vapours are condensed in the aldehyde
condensers. Purified wash
ash from the bottom of the degasifying section enters the top of the
analyzer column for steam stripping of alcohol which condenses at the top of the column as
40% alcohol. The down coming discharge from this column is spent wash. The 40% alcohol
stream from
om the top of the analyzer column is next fed to the bottom of the rectification
column where it is maintained at a temperature of about 95° to 100°C. Water and alcohol
vapour condense at different levels in this column and rectified spirit of an equilibrium
equilibri
boiling composition (95%) is withdrawn. Of this rectified spirit, a part is fed back into the
column. Spent lees, produced at this step are usually pumped back to the analyzer column.
The volume of spent lees is about 11-1.5 kL/kL of rectified spirit produced.
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Figure 2: Water Balance for a Distillery - Model Case
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(C) Ethanol
Ethanol is produced both as a petrochemical, through the hydration of ethylene, and biologically,
by fermenting sugars with yeast. Determining the most economical among the products depends
upon the prevailing prices of petroleum and of grain feedstock. This manual focuses on the
fermentation process of alcohols production.
Ethanol by Fermentation: Ethanol for use in alcoholic beverages, and the vast majority of
ethanol for use
se as fuel, is produced by fermentation. When certain species of yeast (e.g.,
Saccharomyces cerevisiae) metabolize sugar in the absence of oxygen, they produce ethanol and
CO2. The chemical equation below summarizes the conversion:
C6H12O6 2CH3CH2OH + 2CO2
Sequence For Production Of Ethanol Of Steps
Ethanol is the final end product of three processes namely shown in Figure 3
� Fermentation Process
� Distillation Process and
� Dehydration Process
Figure 3 : Block Flow Diagram of Ethanol Plant
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A. Fermentation process
Ethanol can be made by the fermentation of sugars (Shown in Figure 4).. Simple sugars such as
sugarcane juice or molasses are the raw material. Zymase, an enzyme from yeast, changes the
simple sugars into ethanol and CO2. The enzymatic reaction carried over by the yeast in
fermentation produces mainly ethanol, CO2 and heat. The fermentation reaction is actually very
complex. The impure culture of yeast produces varying amounts of other substances, including
glycerin, methanol and various organic acids.
Figure 4 : Preliminary Process Flow Sheet Depicting Fermentation of Molasses
B. Distillation process
Ethanol produced by fermentation ranges in concentration from a few percent up to about
14%;; the rest being water and other components (Shown In Figure 5).. The boiling point of
ethanol (78.4°C) is significantly lower than the boiling point of water (100°C). These materials
cannot be separated completely by distillation. Instead, an azeotropic mixture (i.e.
( a mixture of
96% ethanol and 4% water) is obtained. Azeotropic mixture of alcohol cannot be further
concentrated by distillation. Distillation is used to produce Rectified Spirit (RS).
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C. Dehydration of alcohol
Pure alcohol can't be obtained from distillation since it forms azeotrope with water at 96%
(v/v). Fuel ethanol or absolute alcohol is produced by dehydration of RS. Commercially
Figure 5 : Process Flow Sheet Depicting Distillation of Ethanol
available technologies for dehydration of RS are:

� Azeotropic Distillation
� Molecular Seive Technology
(i).. Azeotropic distillation method
To dehydrate ethanol from azeotropic concentration, a third substance called Entrainer (trichloro
ethylene, benzene, toluene, cyclo
cyclo-hexane etc.) is added to the mixture of ethanol and water
(Shown In Figure 6).. Entrainer breaks the azeotropic point of ethanol and water, i.e., it alters the
relative volatility of water making it more volatile. The ternary azeotropic mixture, formed at the
top of dehydration column, allows the removal of water and thus dehydrates alcohol. The
azeotropic mixture is heterogeneous and the ‘heavy’ phase, which is high in water content, is
extracted by decantation. The regeneration column allows water extraction from the ‘heavy’
phase and entrainer recycling
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ii. Molecular sieve technology

Molecular sieve technology works on the principle of Pressure Swing Adsorption (PSA).
Here water is removed by adsorption on surface of ‘molecular sieves’ under pressure and
then cyclically removed it under low pressure at different conditions. This process carries out
dehydration of mixed ethanol and water by adsorption of water into zeolite balls, which are
molecular sieves. The dehydration unit operates with two adsorbers accor
according to alternate steps
Figure 6 : Process Flow Sheet Depicting Azeotropic Distillation Process
of adsorption and desorption (Shown In Figure 7)

7).. Adsorption occurs in the vapour phase and
under pressure. Desorption regenerates water saturated molecular sieves. This step is performed
under vacuum. Part of the dehydrated alcohol is used for the molecular sieve desorption.
Alcoholic effluent from desorption is regenerated within the distillation column.
Figure 7 : Process Flow Sheet Depicting Molecular Seive Dehydration Process
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(D) Manufacturing process of spirits Based on Grain (whisky, vodka & gin)
(1) Different process units involved in Whisky manufacturing are summarized below Figure 8.
Figure 8: Process Flow Sheet Depicting Whisky Production
(i) Mashing
The mashing process consists of cooking (gelatinization) of the grain in water to
solubilize the starches from the kernels and converting (saccharification) of the starch to
‘grain sugar’ (primarily glucose and maltose). In general, cooking can be carried out at or
above atmospheric pressure in either a batch or continuous process. During mashing,
trace Volatile Organic Compound (VOC) emissions may result from constituents in the
grain. Small quantities of malted barley are sometimes added prio
priorr to grain cooking.
After partial cooling, conversion of the starch to sugar is accomplished by adding barley
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malt and/or enzymes (from other sources) to the cooked grain at approximately 63EC
(145EF). The mash then passes through a noncontact cooler to a fermenter. Between the
mashing and fermentation, the process generally is closed during cooling, with no
emissions. Distillers may vary mashing procedures, but generally conform to basic
principles, especially in the maintenance of sanitary conditions.
(ii) Fermentation
Fermentation, which usually lasts 3 to 5 days for whisky, involves the use of yeast to
convert the grain sugars into ethanol and CO2. The converted grain mash is cooled prior
to entering the fermenter or tank and inoculated with yeast. It iiss a common practice to
dilute the hot grain mash to its final solids concentration by adding backset stillage and/or
water. Backset is liquid stillage which is screened or centrifuged from the distillation
‘beer still bottoms.’ The use of backset provides water conservation, nutrient
supplements, pH adjustment of the fermentation, and some flavor components (e.g.,
( sour
mash).
The fermentation process varies slightly for the production of other distilled spirits. For
takes 1 to 2 days. In rum production,, black strap molasses is
instance, rum fermentation tak
the source of fermentable sugars and is stored in tanks prior to fermentation. The black
strap molasses also is not mashed ((i.e., cooked) prior to dilution with water to obtain the
proper concentration
tion of fermentable sugars. Congeners are flavor compounds which are
produced during fermentation, as well as during the aging process. These congeners
include trace aldehydes, esters, and higher alcohols ((i.e., fusel oils). Lactic acid bacteria
(lactobacillus)
llus) may simultaneously ferment within the mash and contribute to the overall
whisky flavor profile. On rare occasions lactobacillus may provide some pH control. On
other occasions, the addition of sulphuric acid, though rarely used, may result in trace
hydrogen
ydrogen sulphide emissions from the fermentation tank.
In whisky production,, significant increases in the amount of yeast consumed occur

during the first 30 hours of fermentation, when over 75% of the carbohydrate (sugar) is
converted to ethanol and CO2
CO2.Many
Many fermentation vessels are equipped with agitation and
and/or cooling means that facilitate temperature control. Fermentation vessels may be
constructed of wood or metal and may be open or closed top.
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(iii) Distillation
The distillation process separates and concentrates the alcohol products from the
fermented grain Mash and is an add
add-on
on unit for production of spirits and make the whisky
production different from Beer and Wine. In addition to the alcohol and congeners, the
fermented mash contains solid grain particles, yeast cells, water-soluble
soluble proteins, mineral
salts, lactic acid, fatty acids, and traces of glycerol and other trace congeners. Distillation
processes also include the continuous multicolumn extractive and rectifying systems, and
thee batch rectifying pot still and condensing unit. Whisky stills are usually made of
copper, especially in the rectifying section, although stainless steel may be used in some
stills.
In a general whisky distillation process using a beer still, the whisky separating column
consists of a cylindrical shell having three sections: stripping, entrainment removal, and
rectifying. The stripping section contains approximately 14 to 21 perforated plates,
spaced 56 to 61 centimetres (cm) (22 to 24 inches) apart. The fermented mash is
introduced at the top of the stripping section and descends from plate to plate until it
reaches the base where the stillage is discharged. Steam is introduced at the base of the
column, and the vapours from the bottom of the still pass uup
p through the perforations in
the plates. Whisky stills are usually fitted with entrainment removal sections that consist
of a plate above the stripping plate to remove fermented grain particles entrained in the
vapour. Distillation columns operate under rreflux
eflux (sealed) conditions and most vapors are
condensed and collected, although small amounts of non
non-condensable
condensable gases will be
emitted to the atmosphere.
Following distillation, the whisky, at high proof, is pumped to stainless steel tanks and
diluted with demineralized water to the desired alcohol concentration prior to filling into
oak barrels. The distillation of other spirits, such as rum, is similar.
(iv) Grain and liquid stillage

At most distilleries, after the removal of alcohol, still bottoms (know
(known
n as whole stillage)
are pumped from the distillation column to a dryer house. Whole stillage may be sold;
land applied (with appropriate permitting), sold as liquid feed, or processed and dried to
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produce distiller dried grains (DDG). The DDG consists of proteins, fats, minerals,
vitamins, and fibers which are concentrated threefold by the removal of the grain starch
in the mashing and fermentation process. Distillers’ secondary products are divided into
four groups: DDG, distiller dried solubles (DDS), DD
DDG
G with solubles (DDG/S), and
condensed distiller solubles (CDS).
Solids in the whole stillage are separated using centrifuges or screens. The liquid portion
‘thin stillage’ may be used as a backset or may be concentrated by vacuum evaporation.
The resultantt syrup may be recombined with the solid portion or dried separately. This
remaining mixture is then dried using one of a variety of types of dryers (usually
steamheated or flash dryers). The majority of DDG are used in animal feed, although
increasing quantities are being sold as food ingredients for human consumption due to its
nutrient and fiber content.
(v) Warehousing/aging
Newly distilled whisky is colorless with a strong, harsh and unpalatable odor. The new
whisky distillate undergoes many types of physical and chemical changes in the aging
process that impart the distinctive color, taste and aroma of the whisky and gives it
character. These changes include extraction of the wood compounds, decomposition and
diffusion of the wood macromolecules iinto
nto the alcohol, reactions of the wood and
distillate compounds with each other, and oxidation produced by diffusion to ambient
atmosphere.
During the aging, both the charred oak barrel in which beverage alcohol is stored and the
barrel environment are key to producing distilled spirits of desired quality and
uniqueness. The aging process gives whisky its characteristic color and distinctive flavor
and aroma. Variations in the aging process are integral to producing the characteristic
taste of a particular brand of distilled spirits. Aging practices may differ from distillate to
distiller, and even for different products of the same distiller.
(vi) Blending/bottling
After whisky aging is complete, it is dumped or pumped from barrels into stainless steel
tanks and reduced in proof to the desired alcohol concentration by adding demineralized
water. The diluted whisky is processed and filtered. Following a filtration process the
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whisky is pumped to a tank, proof adjusted, and bottled.

Due to their value and marketability, used barrels are not generally stored but either
refilled with other whiskies or bung sealed and sold to manufacturers of Scotch Whisky,
Canadian Whisky, rum, brandy, Tequila, or wines.
New bottles are unloaded from cases and put on a convey
conveyor
or belt, where they are air
cleaned, filled, capped, and labeled. At the end of the conveyor belt, the final product is
put into cases, which are sealed, labeled, and shipped to distributors.
(2) Gin Manufacturing Process

Gin can be made from any neutral spirit alcohol - the base can be grain (normally barley
and maize) or molasses and has no flavor at all. As with the production of beer, the base
starch is mixed with water, heated, cooled, and allowed to ferment. The wash so
produced is then distilled to an alcohol content of 95% ABV. This is then diluted to
strength of about 45% ABV and left to steep with flavoring botanicals (famously juniper
but otherss may include citrus peel, various spices and angelica). The liquid is then heated
in a still and, as with whisky, only the middle portion is used. The foreshots and feints are
returned for distillation with the next batch. Finally the spirit is diluted to reach the
required minimum alcohol content (37.5% ABV) and then bottled. Cheaper gins can be
made by simply adding essential oils to the diluted neutral spirit alcohol. This ‘cold
compounded’ gin cannot be called distilled.
(3) Vodka manufacturing proces

process
The starting point for vodka is, as with gin, a neutral spirit. In the EU the spirit is usually
produced from grain (wheat, barley, maize, rye) or molasses. In the Eastern Europe it
may also be made from potatoes, or rice. As with gin, the wash is usually
usuall distilled twice
although many vodkas are triple distilled, some even more. The distillate is diluted to an
ABV of about 55% before it is filtered, usually through charcoal. Sometimes coagulants
are used to bind impurities so that they can be filtered outt more readily. Finally, more
water is added to give the vodka the minimum ABV (legal EU Standard) of at least
37.5%. At this stage some producers include additives while others may introduce
flavouring such as natural essences or fruits or herbs which aree steeped in the vodka for
several days. No maturation period is required.
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(4) Brandy manufacturing process

Brandy is made from wine which is distilled by a process similar to that described above.
The spirit is distilled twice before being transferred to wooden barrels to mature. The
maturation period depends on the quality of the brandy sought – for example a minimum
of two years is required to qualify for the very superior (VS) label and four years for the
very superior old pale (VSOP) label.
(5) Beer production processes

Till fermentation, the process units in the case of beer production are same. The final
fermented grain alcohol mixture, called beer, is agitated to resuspend its solids and may
be transferred to the beer well (storage vessel) for hold
holding
ing until it is pumped to the beer
still. Distillers use mechanical or air agitation during transfer and storage to prevent
settling of solids. In the instance of air agitation, trace amounts of aldehydes may be
produced. The beer passes from the beer well through a pre-heater
heater where it is warmed by
the alcohol vapors leaving the still and then enters the still for distillation. The beer still
vapors condensed in the pre
pre-heater
heater generally are returned to the beer still as reflux.
During production, brewing al
alternately
ternately goes through three chemical and biochemical
reactions (mashing, boiling, fermentation and maturation) and three solid liquid
separations (wort separation, wort clarificati
clarification
on and rough beer clarification)
clarification
a) Malt
Malt is derived from a cereal grain, usually barley, after being germinated for a limited
period and then dried. Malting, even if it is not carried out on a brewery site, is an
integral part of the brewing industry. The barley undergoes malting process to convert it
to a form suitable for brewing. During the malting process, enzymes are generated, the
grain cell walls are broken down and some proteins are hydrolyzed. The malting process
of barley includes cleaning, sorting, steeping, germination, drying and polishing. The
barley is cleaned
ned of dust and foreign materials and then sorted according to size with the
smallest kernels (grade IV) being sold as animal feed.
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b) Milling and mashing

Malted barley is ground (either dry or wet) in a malt grinder so that the husk is left intact
while
le the rest becomes very coarse powder, rich in starch and enzymes. The enzymes
quickly degrade the starch to sugar on contact with water. The product, called sweet wort,
is a mixture of partially degraded starch, sugars, enzymes, proteins and water (BPCE,
1986). The wort is separated from the spent grains by straining through a porous filter in
the lauter tun where the grains are sprayed or sparged with water in order to extract the
maximum amount of useful material. Spent grains, spent hops and trub represent a
valuable source of protein for animal feed.
The spent grain yields typically 125
125-130
130 kg wet for every 100 kg of malt and its
composition is 28% protein, 8% fat and 41% nitrogen
nitrogen-free
free substances (BPCE, 1986).
c) Wort cooling and fermentation

In order to prepare for fermentation, the hopped wort is cooled to about 10oC. Further
precipitation of proteins and tannin (known as cool trub or fine break) occurs during the
cooling and aeration in preparation for fermentation which may continue from 2–16
2 days.
Yeast is added in the fermentation vessel to induce fermentation of sugar wort which is
converted to CO2, alcohol, heat and new yeast cells. When the fermentation process is
completed, the yeast is drawn off and used for a new batch of wort with the excess
exces being
disposed of as a by-product.
product. The surplus yeast can be resold as animal feed. On a dry
solids basis, the yeast contains 50
50-60% proteins, 15-35%
35% carbohydrates and 2-
2 12% fat
making it another valuable source of protein for animal feed (BPCE, 1986). Following
the primary fermentation, the produced beer (green beer) is transferred to storage or
maturation vessels for a certain period of time before filtration. Prior to filtration, the beer
may be centrifuged, cooled to -1oC to -1.5oC to precipitate any suspended solids. The
beer is then filtered in a Kieselguhr (diatomaceous earth) filter followed by a filter cloth.
d) Packaging and pasteurization

Bright beer is stored and then filled into bottles or cans. In the process of filling, a small
volume of beer
er (drip beer) is spilt. Bottling is usually preceded with bottle washing to
remove any residual beer mold, cigarette butts, labels and dust particles.
20 | P a g e
Major Environmental Issues in Molasses Based Distilleries In India
(1) Waste Water

The major sources of wastewater for molasses based distilleries are:
Process waste streams
• Spent wash from the analyzer column
• Fermented sludge
• Spent lees from the rectifier
Non-process
process waste streams
• Cooling water
• Waste wash water
• Water treatment plant wastewater
• Boiler blow down
• Bottling plant wash wastewater
• Other wastes
Quantity and Characteristics of Process Wastewater
SR. Source Flow in BOD SS Type of

No. KL/KL of Flow
RS
mg/lit Kg/KL mg/L Kg/KL
of RS of RS
1. Spent Wash from 10.0 50000 500 12000 120 Continuous
Analyzer Column
2. Fermenter sludge 0.05 125000 6.25 50000 2.5 Intermittent
3. Spent lees from the 1.0 500 0.5 16000 16 Continuous
rectifier (Recycled)
4. Cooling water 2.0 100- 0.4 500 1.0
200
5. Waste wash water 3500
6. Boiler blow down 15 Do
7. Water Treatment 2.1 Intermittent
Plant
21 | P a g e
8. Bottling Plant 2.8 100 0.28 200 0.56 Continuous

Wash Water
Characteristics of Spent Lees
S.No Parameter Range

1. pH 3.6 – 4.5
2. COD 5000 - 6000 mg/L
3. BOD 200 – 300 mg/L
4. Total Solids
Dissolved Solids 5000 – 6000 mg/L
Suspended Solids 500 – 1000 mg/L
5. Chlorides 50 – 100 mg/L
(Source:
Source: Draft report prepared on “Development of Methodology for Environmental
Auditing” by Dr. B. Subba Rao of EPRF, Sangli, for CPCB
CPCB)
Characteristics of Spent Wash from Various Types of Manufacturing Process
SR. Parameter Batch Continuous Bio-still

Bio Process
No Process Process
1. Volume, L/L 14 – 15 10 – 12 7–9
alcohol
2. Color Dark brown Dark brown Dark brown
3. pH 3.7 – 4.5 4.0 – 4.3 4.0 – 4.2
4. COD 80000-100000 110000 – 140000 – 160000 mg/L
130000
5. BOD 45000 – 50000 55000 – 65000 60000 – 70000 mg/L
6. Solids
Total 90000 – 120000 130000 - 160000 160000 – 210000 mg/L
Total volatile 60000 – 70000 60000 – 75000 80000 – 90000 mg/L
Inorganic 30000 – 40000 35000 – 45000 60000 – 90000 mg/L
dissolved
7. Chlorides 5000- 6000 6000 – 7500 10000 – 12000 mg/L
8. Sulphates 4000 – 8000 4500 – 8500 8000 – 10000 mg/L
9. Total Nitrogen 1000 – 1200 1000 – 1400 2000 – 2500 mg/L
10. Potassium 8000 – 12000 10000 – 14000 20000 – 22000 mg/L
11. Phosphorous 200 – 300 300 – 500 1600 – 2000 mg/L
12. Sodium 400 – 600 1400 – 1500 1200 – 1500 mg/L
13. Calcium 2000 – 3500 4500 – 6000 5000 – 6500 mg/L
(Source:
Source: Draft report prepared on “Development of Methodology for Environmental
uditing” by Dr. B. Subba Rao of EPRF, Sangli, for CPCB
CPCB)
22 | P a g e
Standards for Wastewater Discharges from Distilleries As per CPCB

SR. Parameter Industrial Sector
No Fermentation (Distilleries,
Matrices & Breweries)
1. pH 5.5 - 9.0
2. Suspended Solids, mg/l 100
3. BOD, mg/l(27
mg/l(27ºC for 3 30 (disposal into inland
days) water)
100 (disposal on land)
4. Colour, hazen unit All efforts should be made
to remove colour,
odour as far as practicable.
(2) Air Emissions from Distillery Industry

Air emissions may be categorized as fugitive and point source emissions.
Fugitive emissions
These are emissions that are not released through a vent or stack. Examples of fugitive emissions
include evaporation of wastewater, dust from stockpiles, volatilization of vapour from vats, open
vessels, or spills and material handling. Emissions emanating from ridgeline roof-vents,
roof louvers,
and open doors of a building as well as equipment leaks, and leaks from valves and flanges are
also examples of fugitive emissions. Emission factors are the usual method for determining
losses through fugitive emissions.
Possible Emissions from Beer and Wine Industries
Emission Source Possible Emissions
Fermentation � Ethanol (largest emission by volume)
� Acetaldehyde
� Methanol
� Hydrogen Sulfide
� Total Volatile Organic Compounds (Total
VOCs)
� Ethyl Acetate
� Fugitive Sources � Ethanol
� Screening of red wine � Sulfur dioxide
� Pressing
23 | P a g e
� Ageing in Oakcooperage
� Bottling process
� Preservation agents
Fuel Combustion � Carbon monoxide (CO)
� Sulfur dioxide (SO2)
� Total VOCs
� Particulate Matter (PM10)
� Oxides of Nitrogen (NOx)
(Source: Adapted from USEPA, AP
AP-42, Section 9.12.2.1995)
Point source emissions
These emissions are exhausted into a vent (excluding roof vent) or stack and emitted through a
single point source into the atmosphere. The main emissions to air from the manufacture of beer
and wine may include VOCs, greenhouse gases, odour, noise and dust. As per the U.S.
Environmental Protection Agency (USEPA) and the California Air Resources Board, breweries
and distilleries are only minor sources of emissions of VOCs to the atmosphere.
GHG emissions
However, several greenhouse gases may also be produced in the beer, wine and spirit making
process including:
� CO2 (a by-product
product of fermentation);
� Nitrous oxide (N2O) (a by-product
product of the internal combustion engine); and,
� Sulphur dioxide (SO2) (if used during kilning)
Present Status Of Treatment And Disposal

Spent wash treatment is proposed by three different routes currently viz; (a) Concentration
followed by incineration, (b) Anaerobic digestion with biogas recovery followed by aerobic
polishing and (c) Direct wet oxidation of stillage by air at high temperature with generation of
steam followed by aerobic polishing. All of these processes are capital intensive. The
incineration process involves an investment of the order of 400% of the distillery cost, whereas
the other two processes along with the secondary treatment require an investment of 200-300%
200
of the distillery cost. The unfavourable economics make it difficult to implement these treatment
processes on the plant scale.
e. Because anaerobic digestion and wet oxidation are less expensive,
these alternatives are more attractive. However, there is a need for development of a suitable
24 | P a g e
process with lower investments and higher energy recovery. Many distilleries in India are
allowing their effluent for application on land as direct irrigation water, spent wash cake and
spent wash-press
press mud compost. The advances manifesting the possibilities of energy
conservation are also discernible in the case of distilleries. The methane ga
gass generated in the
digesters is used as a fuel to compensate the energy needs of the industry. A general estimate
suggests that the cost of an anaerobic biological digester is recovered within 2-3
2 years of
installation because of substantial saving of coal and other fuels.
Cost Recovery/Cleaner Production Methods From The Distillery Effluents

The wastewaters generated during the distillery and brewery operations contain high organic
loads. It has a BOD from 30,000 to 60,000 mg/1. So due to this high organic contents, the
production of biogas, composting,
wastewaters can be subjected to treatment for the produc
aquaculture and potash recovery.
(a) Biogas.
For the production of biogas from distillery effluent, anaerobic biomethanation of the
effluent is adopted,
ed, generally. High rate anaerobic technologies are utilized for
biogas generation. Fluidised Bed Reactors and Up flow Anaerobic Sludge Blanket
(UASB) Reactors are mostly utilized for the production of biogas from thet effluents.
Some of the Cleaner P Production processes of Biogas being commercial1y established
in India at present are:
are:-
• BIOTHANE PROCESS
This process uses the UASB reactor for the production of biogas. This is a stable
and automatic process with low operational costs.
• BIOBED PROCESS
It is similar to Bio thane process. It uses UFB reactors. It needs less installation
area and its construction cost is lower compared to any other system.
• BIOPAQ PROCESS
In this process anaerobic bacteria are used to treat the distillery effluents for the
th
production of biogas. UASB proc
process
ess is utilized here. The separated sludge in this
process makes excellent manure. The generated biogas is used to produce steam
for the distillation of alcohol and thus it replaces 50
50-60%
60% of the total required
energy in the process of distillation. For a plant having 40
40-45,000
45,000 kg COD/day
25 | P a g e
75-80%
80% of COD can be reduced and nearly Rs. 25.50 lakhs can be saved annually
for a distillery having 300 working days in a year. The generated biogas from
UASB reactor of BioPaq pro
process
cess can be collected and be used as a fuel in gas/dual
engine. Through suitable coupling the engine can be coupled with the A/C generator
for generation of electricity from biogas. For a 45 klpd distillery 11 KV of power is
generated which is then utilize
utilized in the distillery thus cutting
ting down the power
consumption.
• SULZER' S PROCESS
PROCESS:: The technology of this type of biogas plant is provided
by Sulzer Brothers Limited, Switzerland. It is specifically made for Indian conditions.
A biogas plant at the distiller
distilleryy of Padmashri Dr. Vitthalrao Vikhe Patil S.S.K. Ltd.,
Pravaranagar, Ahmednagar District, Maharashtra is based on Sulzer's technology.
The capacity of this distillery is 6,000 lpd which generates 900 m3 of spent wash per
day. The biogas production is in th
the range of 16,550 to 21,870 m3 per day. The
savings in the cost of fuel is in the range of Rs. 312 lakhs to Rs. 652 lakhs per year.
Economics of the Biogas Plant of Sulzer’s Design

These calculations are made for a distillery producing 30,000 litres of alcohol per
day. The effluent characteristics are for conventional batch type fermentation process.
Effluent Characteristics
Before Treatment After Treatment
Flow m3/day 450 450
pH 4.0 to 4.5 7.0 to 7.8
BOD mg/l 45,000 to 50,000 6,000 to 8,000
COD mg/l 80,000 to 1000,000 25,000 to 35,000
Performance
Reduction of BOD % 80 to 85 %
Reduction of COD % 65 to 70 %
26 | P a g e
Biogas Production Nm3/day 12,300
Specific Biogas Production Nm3/kg of COD degraded 0.4 to 0.5
% of methane in biogas 60 to 65 %
Economics
Calorific value of biogas 6000 Kcal/ Nm3

Calorific Value of Coal 4000 Kcal/Kg
Coal equivalent of Biogas pper day 18.45 tonnes
Cost of Coal at Rs 1800 per tonne Rs 33,210 per day
Annual fuel savings Rs 99.63 lacs
Capital cost of plant Rs 230 lacs
Interest at 15 % on 75 % of the capital cost** Rs 26,73,750
Maintenance costs Rs 2,00,000
Staff Salary Rs 1,50,000
Power
wer 40 KW at Rs 2/ 2/- per unit Rs 5,76,000
Total Annual Cost Rs 36,00,000
Net Savings per year Rs 99.36 – 36
= Rs 63.63 lacs
Total Pay back period = 230 / 63.63
= 3 to 4 years.
(b) Composting
In this process, press mud generated from sugar mill is utilised to produce compost by
mixing distillery effluent. Both anaerobic and aerobic composting systems are practiced.
In some plants composting with treated effluent treated through bio
bio-methanation
methanation plant is
also practiced. This system can achieve zero effluent if the press mud quantity matches
with the effluent generated.
• Economics Of Bioearth Composting
Capacity of the Distillery 50 KLPD

Number of working days in a year
In the Distillery 300
In the Composting Plant 275
27 | P a g e
Generated spentwash 350 KLPD (Biostil Plant)

Solid content in spentwash 17 %
Spentwash to Press mud Ratio 2.5 KL : 1 MT
Man Power Required 50
Culture Requirement 31.5 MT/annum
Press mud requirement 43,000 MT/ annum
Cost of Culture Rs 1.75 lakhs per MT
Cost of Press mud Rs 12 per MT
Man Power cost Rs 50 per day
Capital Cost Rs 175 lakhs (excluding land)
Land Requirement 25 acres
Bio Earth Producti
Production 38,000 MT per year
Annual Maintenance Costs 1.5 % of equipment costs
% Costs of Funds 20 % per annum
• Operation Costs
Cost of Culture 55.13 lakhs

Average Cost of Funds 17.5 lakhs
Cost of Diesel 11.32 lakhs
Cost of Press mud 5.16 lakhs
Cost of Transportation of Press mud 0.00
Annual Man Power Cost 6.88 lakhs
Depreciation (@ 10 %) 15.00 lakhs
Maintenance 2.25 lakhs
Annual Operational
ational Cost of Compost Plant 113.24 lakhs
Cost off One Metric Tonne of Bioearth = Annual Operational cost of plant
Compost Produced in MT
= 11324000
38000
= Rs 298.00 per MT
28 | P a g e
• Net Cost/Benefit For Different Selling Prices Of Compost
SP of Bio earth Net Cost / Benefit

in Rs In Rs
0 -11324000.00
100.00 -7524000.00
200.00 -3724000.00
298.00 0.00
350.00 1976000.00
400.00 3876000.00
500.00 7676000.00
Net annual cost/benefit of Compost = Sales value of 38000 MT of

compost less annual operating
costs
• COMPUTATION OF PAY BACK PERIOD

1. SP of Bioearth - Rs 250.00
Initial cash outflow - Rs 17500000.00
Net annual cash inflow - Rs 1738000.00
Pay Back Period - 10.06 Years
(17500000/1738000.00)
(17500000.00/5226000.00)
(17500000.00/10926000.00)
(17500000.00/10926000.00
29 | P a g e
(C) Potash Recovery

It is done by incinerating the distillery spent wash. In this process, the raw distillery
spent wash is first neutralized with lime and filtered. This is further concentrated to about
60% solids in multiple-effect
effect forcer circulation evaporators. Now this thick liquor from
the evaporator is burnt in an incinerator and is converted into ash. The dry solids
so of the
spent wash in the form of coke in the incinerator has an average calorific value of 2
Kcal/kg, which is sufficient for supporting self
self-combustion
combustion of the thick liquor in the
incinerator. The resulting ash is found to contain about 37% of potash as potassium oxide
on an average. This ash is further leached with water to dissolve the potassium salts.
Then it is neutralized with sulphuric acid and is evaporated. The potassium salts are
crystallized in a crystal1izer. The crystallized mixed potassium salt contains 73.5% of
potassium sulphate (K2SO4) 16.5% potassium chloride (KCl) and 5% of sodium salts. It
discharging about 300 m3 of spent wash per day could
is estimated that a distillery dis
recover 3 tonnes of Potassium as Potassium oxide or about 5.3
5.344 tonnes of Potassium
sulphate and 1.2 tonnes of Potassium chloride per day. This potassium is used as a
fertilizer.
(d) Distillery Wastewater Utilisation In Agriculture

Being very rich in organic matters, tthe utilisation of distillery
lery effluents in agricultural
fields creates organic fertilization in the soil which raises the pH of the soil, increases
availability of certain nutrients and capability to retain water and also improves the
physical structure of soil. Mostly the distillery wastewaters are used for pre-sowing
pre
irrigation. The post-harvest
harvest fields are filled with distill
distillery
ery effluents. After 15-20
15 days,
when the surface is almost dried, the fields are tilled and the crops are sown and subse-
subse
quent irrigation is given w
with
ith fresh water. However, the effluent is diluted 2-3
2 times
before application on crops. Apparently, the irrigation with distillery wastewater seems to be
an attractive agricultural practice which not only augments crop yield but also provides a
plausible solution for the land disposal of the effluents. One cubic metre of methanated
effluent contains nearly 5 kg of potassium, 300 grams of nitrogen and 20 grams of
phosphorus. If one centimetre of post methanation effluent is applied on one hectare of
30 | P a g e
agricultural
tural land annually, it will yield nearly 600 kg of potassium, 360 kg of calcium, 100 kg
of sulphates, 28 kg of nitrogen and 2 kg of phosphates. The distillery effluent contains 0.6 to
21.5 percent potash as K O , 0.1 to 1.0 percent phosphorus as PO and 0.01 to 1.5 percent
Nitrogen as N2. The irrigational and manorial potential of distillery wastewaters
ters is given below:
i) Total Volume available in Million m3 /annum : 6.87
ii) Nutrients Contribution Potential (tonnes/annum) : N - 69380
PO - 11335
KO - 27480
Economic Aspects
When the distillery effluents are used for irrigation in fallow lands, the microbes present
in it transform the lands into fertile ones, giving high yields of paddy and sugarcane.
Farmers could save nitrogenous fertilisers worth Rs 1335 crores per annum if at least 200
distilleries of out country recycled their wastes to the agricultural fields. However, it is
predicted that the utilisation of distillery effluent for irrigation of land would make a v a i l -
able nitrogen, phosphorous and potash valued at about Rs 500 crores each year. The added
advantage of this application would be that these fertilisers would be available to so il in
organic form. As the secondary and tertiary systems for the treatment of distillery effluent are
highly energy intensive and according to the estimates of the Union Ministry of Energy a total
connected
nected load of 200 M.W. would be required to energising these systems if 246
2 distilleries
endeavour to reduce the BOD level of effluent to the extent possible. The generation of the
desired energy would need an installed load of 350 M.W. which would require capital
investment of the order of about Rs 1400 crores. So it will be an
n attractive practice to utilise the
31 | P a g e
distillery effluents for ferti

ferti-irrigation of land after primary treatment,
ment, as land is available in
abundance around the distiller
distilleries which are located in the sugarcane belts.
32 | P a g e

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Gujarat Cleaner Production Centre- ENVIS Centre

CLEANER PRODUCTION OPPURTUNITIES

Category of Indian Fermentation Industry

Classification of Distilleries based on Capacity

yield is also much higher compared to the batch process.

Figure 1 : Process Block Diagra

(B) Rectified spirit

Figure 2: Water Balance for a Distillery - Model Case

Figure 3 : Block Flow Diagram of Ethanol Plant

Figure 4 : Preliminary Process Flow Sheet Depicting Fermentation of Molasses

Figure 5 : Process Flow Sheet Depicting Distillation of Ethanol

available technologies for dehydration of RS are:

ii. Molecular sieve technology

Figure 6 : Process Flow Sheet Depicting Azeotropic Distillation Process

of adsorption and desorption (Shown In Figure 7)

Figure 7 : Process Flow Sheet Depicting Molecular Seive Dehydration Process

Figure 8: Process Flow Sheet Depicting Whisky Production

In whisky production,, significant increases in the amount of yeast consumed occur

(iv) Grain and liquid stillage

whisky is pumped to a tank, proof adjusted, and bottled.

(2) Gin Manufacturing Process

(3) Vodka manufacturing proces

(4) Brandy manufacturing process

(5) Beer production processes

b) Milling and mashing

c) Wort cooling and fermentation

d) Packaging and pasteurization

Major Environmental Issues in Molasses Based Distilleries In India

(1) Waste Water

Quantity and Characteristics of Process Wastewater

SR. Source Flow in BOD SS Type of

8. Bottling Plant 2.8 100 0.28 200 0.56 Continuous

S.No Parameter Range

Characteristics of Spent Wash from Various Types of Manufacturing Process

SR. Parameter Batch Continuous Bio-still

Standards for Wastewater Discharges from Distilleries As per CPCB

(2) Air Emissions from Distillery Industry

Present Status Of Treatment And Disposal

Cost Recovery/Cleaner Production Methods From The Distillery Effluents

Economics of the Biogas Plant of Sulzer’s Design

Flow m3/day 450 450

pH 4.0 to 4.5 7.0 to 7.8

BOD mg/l 45,000 to 50,000 6,000 to 8,000

COD mg/l 80,000 to 1000,000 25,000 to 35,000

Biogas Production Nm3/day 12,300

Specific Biogas Production Nm3/kg of COD degraded 0.4 to 0.5

Calorific value of biogas 6000 Kcal/ Nm3

Capacity of the Distillery 50 KLPD

Generated spentwash 350 KLPD (Biostil Plant)

Cost of Culture 55.13 lakhs

Cost of Diesel 11.32 lakhs

Cost of Press mud 5.16 lakhs

Cost of Transportation of Press mud 0.00

Annual Man Power Cost 6.88 lakhs

Depreciation (@ 10 %) 15.00 lakhs

Maintenance 2.25 lakhs

• Net Cost/Benefit For Different Selling Prices Of Compost

SP of Bio earth Net Cost / Benefit

Net annual cost/benefit of Compost = Sales value of 38000 MT of

• COMPUTATION OF PAY BACK PERIOD

(C) Potash Recovery

(d) Distillery Wastewater Utilisation In Agriculture

i) Total Volume available in Million m3 /annum : 6.87

ii) Nutrients Contribution Potential (tonnes/annum) : N - 69380