Central Pollution Control Board

Delhi
Environmental Issues and
Emerging Technologies in
Distillery Sector
Seminar cum - Workshop on Distillery Effluent Treatment and Water
Conservation
February 26 - 27, 2011 at New Delhi, India

J . S . Kamyotra
Member Secretary
Demand of alcohol in India :
For Potable: Apprx. 1000 million liters
For Industrial: Apprx. 1000 million liters
For Fuel: Apprx. 1040 million liters
Total alcohol demand: Apprx. 3000 million liters

Alcohol production in India : 1938 million liters (200910)
Maximum alcohol production in India: 2300 million liters (2006-07)
The cabinet committee of economics affairs approved the proposal
for implementation of Ethanol blended petrol program in India.
Ethanol blending : At present 5% and should reach 10 % by 2017.
Total Ethanol requirement is 1040 million liters during September
2010 to August 2011.

Distillery Industry (India):
Molasses based distilleries About 400 units.
Molasses based installed capacity: 4.00 billion
liters/annum
Grain based distilleries About 100 units.
Grain based installed capacity: 1.8 billion liters./annum
Maximum number of distilleries are attached to sugar
factory
Operation of the distilleries depends on cane molasses
availability
Fermentation Process (Batch or Continuous ):
1. Batch type fermentation process
2. Fed Batch type fermentation process
3. Cascade continuous fermentation process
4. Biostil continuous fermentation process
Distillation Process:
1. Atmospheric distillation system
2. Multi-pressure distillation system
Main product manufactured
1) Rectified spirit (Alcohol content 94.68 to 95.50 %, v/v)

2) Extra neutral alcohol (Alcohol content 95 to 96.0 %, v/v)

3) Fuel alcohol (Alcohol content 99.5 to 99.90 %, v/v)

Distilleries are under Red Category of industries.

Mandatory for every distillery to achieve Zero liquid
discharge as per CREP norms.

Spent Wash generated by molasses based distilleries have
High COD (80,000-1,20,000 mg/l), BOD (40,000- 60,000
mg/l), high Suspended Solid, inorganic solid, low pH, strong
odour & dark brown colour.

Spent Wash generation depends on:

Type of fermentation process (Batch or Continuous)
Type of distillation process (Atmospheric or Multi-pressure)
Distillation with reboiler or without reboiler
Distillation with or without integrated evaporation system
Stand alone evaporation system
Alcohol concentration in fermented wash depends on molasses
quality.
Selection of yeast culture
Spent wash recycle % (Depends on final alcohol quality)
1 pH 5.5- 9.0
2 Colour & Odour Absent
3 BOD3 (at 27oC, 3 days) mgs/L Max.
Disposal into land surface water/
rivers/ streams
Disposal on land or for irrigation

30

100
4 Suspended solids, mg/L Max. 100




Fermentation Industry : Effluent Discharge Standards
(Distilleries, Maltries & Breweries)


Protocols/ Guidelines related to Treatment
& Disposal options for distillery effluent
Protocols
Ferti-irrigation
One time application before sowing of crop (Pre-
sown irrigation)
Bio-composting of pre-treated spent wash



Protocols/ Guidelines related to Treatment &
Disposal options for distillery effluent
CREP Action Points:
Existing Molasses based Distilleries:
Zero Effluent Discharge (100% by Dec. 2005) through
Bio-composting,
Concentration and Incineration
Biomethanation followed by two stage secondary
treatment followed by ferti-irrigation
Biomethanation followed by treatment and Discharge
into deep sea.



Protocols/ Guidelines related to Treatment &
Disposal options for distillery effluent
CREP Action Points:

New Distilleries & Expansion of Existing Distilleries
(Molasses based)
Zero Effluent Discharge in surface water/ ground water




Protocols/ Guidelines related to Treatment
& Disposal options for distillery effluent
As on date (after June 2008)
New stand alone Distilleries:
Concentration incineration system
Co-processing in cement kilns/ furnaces of TPPs/
Steel Plants.
New attached Distilleries:
Bio-methanation followed by bio-composting
Concentration incineration system
Co-processing in cement kilns/ furnaces of TPPs/
Steel Plants


Protocols/ Guidelines related to Treatment
& Disposal options for distillery effluent

As on date (after June 2008)

Existing stand alone Distilleries (expansion):
Concentration incineration system
Co-processing in cement kilns/ furnaces of TPPs/
Steel Plants.



Protocols/ Guidelines related to Treatment
& Disposal options for distillery effluent

As on date (after June 2008)

Distilleries (both stand alone and attached) not
complying with the required environmental standards
to switch over to emerging technologies from existing
technologies of Ferti-irrigation, One time land
application and composting in a time bound manner.


Protocols/ Guidelines related to Treatment
& Disposal options for distillery effluent
Emerging technologies:

Reboiler/ Evaporation/ Concentration
Incineration system
Co-processing in cement kilns/ furnaces of TPPs/
Steel Plants.



Treatment technologies for distillery spent wash
Biomethanation followed by multi-effect evaporation
followed by drying/ incineration/ co-processing.
Biomethanation followed by reverse osmosis followed by
drying/ incineration/ co-processing.
Biomethanation followed by reverse osmosis followed by
multiple effect evaporation followed by drying/
incineration/ co-processing.
Concentration through RO/ MEE followed by drying/
incineration/ co-processing.

Treatment technologies for distillery spent wash
Grain based Distillery:

Decantation (separation of wet cake) followed by
evaporation of thin slop (5% solids) followed by mixing of
wet cake with syrup (30% solids) followed by Dryer
(DDGS 90% solids).
Ferti-irrigation:
Storage of large quantity of partially treated effluent
(storage capacity < one fourth of average yearly
utilization of spent wash)
Partially treated effluent requires high dilution (upto 15
times) to meet irrigation norms
Requires large command area within a distance of 20 km

Ferti-irrigation:
Usually employ earthen distribution channels, not upto
standard of hosepipe/ impervious channels
Mostly, irrigational application of effluent not as per the
N-requirement of crop and type of soil,
Irrigation land to be given rest alternate year- not being
practiced

Ferti-irrigation:

Difficult to monitor ferti-irrigational practices
Dismal environmental compliance performance of
Distilleries with ferti-irrigation facilities
Public complaints/ reported cases of groundwater
contamination

Pre-sown irrigation (one time land application):
Only upto one-third of spent wash generated per year to
be utilised by pre-sown irrigation
Storage of large quantity of partially treated effluent
(storage capacity < one fourth of average yearly
utilisation of spent wash)
Partially treated effluent requires high dilution (upto 15
times) to meet irrigation norms

Pre-sown irrigation:

Requires large command area within a distance of 20 km
Difficult to monitor irrigational practices
Dismal environmental compliance performance of
Distilleries with one time land irrigation facilities
Public complaints/ reported cases of groundwater
contamination

Bio-composting:

Unavailability of adequate filler material like press mud
High moisture content (70%) of press mud rendering it
unfit as filler material for composting
Manual operations
Process parameters depends more on nature (sun drying/
natural aeration), less mechanical control system

Bio-composting:
Poor operation & maintenance not upto standards
High potential to leachate contanimation of groundwater
and surface water
Rate of spent wash utilisation through composting not
matching with its generation
Requires large storage facility for spent wash, potential
threat to groundwater contamination and discharge to
land/ surface water
Bio-composting:

Difficult to monitor protocol regarding utilisation of
press mud and compost
Dismal environmental compliance performance of
Distilleries with bio-composting facilities
Public complaints/ groundwater contamination

Biomethanation (Anaerobic digestion):

Primary treatment method.

75 to 80 % distilleries - biomethanation plants.

Well established technology for spent wash
treatment.


Reverse osmosis:

Membrane based separation technique
Feed is split in to Permeate (filtrate) and Reject
(retentate, concentrate).
Biomethanated Spent Wash: 50 -60% permeate
recovery.
Raw Spent Wash: 40 - 45 % permeate recovery.
Multiple-Effect Evaporation (MEE) :

To concentrate a non-volatile solute from a solvent,
usually water.

Concentration or crystallization of liquids.

Increase solid contents of the liquid product prior to
drying.

Separation of a liquid mixture into a liquid product
(concentrate or thick liquor) and a vapor byproduct.




Pollution control measures:

Distilleries to achieve zero effluent discharge through
emerging technologies in a time bound manner.

CPCB since June 2008 directed many distilleries to adopt
either concentration-incineration system or co-processing
for achieving ZLD.



.


Pollution control measures:

Study on co-processing of spent wash in cement kilns has
been successfully demonstrated.

Guidelines for co-processing of distillery effluents issued

Study initiated for formulation of standards for Grain based
distilleries

Revision of standards for distilleries initiated

.
Pollution control measures:
Recommending use of latest fermentation and
distillation systems so as to reduce consumption of
fresh water.

Restricting spent wash storage to 30 days equivalent
of treated spent wash

All old spent wash storage lagoons to be discarded.

All sludge drying beds to be discarded.


Co-Processing
Co-processing in cement industry refers to the
substitution of primary fuel and raw material by
waste, recovering energy and material from waste.

Waste materials used for co-processing are referred
to as alternative fuels and raw materials (AFR)

Why Choose Co-processing?
Avoid land disposal of spent wash
Avoid investment on developing boiler for
incineration of spent wash
Gain Environmentally responsible image
Be seen as a good steward of resources
Cement Kiln Suitability
High temperatures (1400
O
C) and residence time of 4 5
seconds in an oxygenrich atmosphere ensure the
destruction of organic compounds.
Any acid gases formed during combustion are neutralized
by the alkaline raw material and are incorporated into the
cement clinker.
Interaction of the flue gases and the raw material present
in the kiln ensures that the non combustible part of the
residue is held back in the process and is incorporated
into the clinker in a practically irreversible manner.
No waste is generated that requires subsequent
processing.
Benefits of Co-processing
Reduction in Green House gases emission
& related benefit of carbon trading
Conversion of waste into energy / as a
raw mix component
Conservation of fossil fuel resource
Reduction in energy / cement production
costs
Emissions from fossil fuel and
waste as fuel
Waste incineration & cement
manufacturing
Waste as fuel in cement
manufacturing

GHG


GHG


GHG

Emissions
Waste
Incinerator
Cement plant + Cement plant
Waste Fossil Fuels Waste Fossil Fuels Resources
S.
No.
Location Percentage of thermal
energy substituted by AFR
1. France 32%
2. Germany 35%
3. Norway 45%
4. Switzerland 47%
5. USA 25%
Share of AFR in the total fuel demand in the
Cement Industry in selected countries
Source: CEMBUREAU, SINTEF
Indian Experience of
Co Processing of Spent
Wash Concentrate
in Cement Kiln
Trial Run Conducted For Co-Processing of
Spent Wash Concentrate in Cement Kiln


M/s Ultratech Cement Ltd., Rajashree
Cement Works, Gulbarga Karnataka
Spent wash was concentrated in MEE
Spent wash concentrate of M/s Shree
Renuka Sugar Ltd., Belagaum, Karnataka.
Study conducted during june 25 july 8,
2010.
Proximate Analysis of Spent Wash


CONSTITUNT VALUE
Moisture Content 47.01%
Volatile Matter 35.69%
Ash Content 10.59%
Fixed Carbon 6.71%
Net Calorific Value 2000 Kcal/Kg
Ultimate Analysis of Spent Wash


CONSTITUNT VALUE
Carbon 19.92%
Hydrogen 2.59%
Nitrogen 1.35%
Sulphur 0.96%
Heavy Metals and Volatiles in Spent Wash


Item
28 June 2010
(Values in %)
2 July 2010
(Values in %)
4 July 2010
(Values in %)
SO3 0.24 0.35 0.27
Cl 3.13 1.89 2.61
Na2O 0.57 1.28 0.51
K2O 5.44 5.89 5.33
Moisture 40.52 36.61 31.40
As NIL NIL NIL
Ba 0.007 0.002 0.004
Cd 0.002 0.0006 0.002
Co 0.004 0.0006 Nil
Cr 0.003 0.0009 0.003
Heavy Metals and Volatiles in Spent
Wash(Contd)


Item
28 June 2010
(Values in %)
2 July 2010
(Values in %)
4 July 2010
(Values in %)
Cu 0.004 0.001 0.003
Mn 0.007 0.0004 0.007
Ni NIL NIL 0.004
Pb NIL NIL 0.004
Se NIL NIL NIL
Sr 0.004 0.001 0.004
Te 0.007 0.002 NIL
Tl 0.036 NIL NIL
Zn 0.005 0.001 0.003
V 0.001 NIL NIL
ITEMS, % BEFORE
TRIAL
DURING TRIAL AFTER
TRIAL
REMARKS
26-6-10 29-6-10 2-7-10 4-7-10 7-7-10
LOI 0.54 0.58 0.76 0.74 0.80
NO
CHANGE
SiO
2
21.75 21.72 21.54 21.09 21.70
Fe
2
O
3
4.69 4.41 4.57 4.60 4.40
Al
2
O
3
5.17 5.23 5.66 5.52 5.31
CaO 64.75 65.01 64.71 65.10 65.16
MgO 1.51 1.53 1.20 1.06 1.06
SO
3
0.61 0.62 0.76 0.67 0.44
Na
2
O 0.27 0.29 0.29 0.33 0.26
K
2
O 0.26 0.28 0.28 0.30 0.24
Cl 0.007 0.006 0.006 0.008 0.008
IMPACT OF SPENT WASH ON CHEMICAL
ANALYSIS OF CLINKER
ITEMS, % BEFORE
TRIAL
DURING TRIAL AFTER
TRIAL
REMARKS
26-6-10 29-6-10 2-7-10 4-7-10 7-7-10
As NIL NIL NIL NIL NIL
NO
CHANGE
Cd NIL NIL NIL NIL NIL
Co NIL NIL NIL NIL NIL
Cr 0.008 0.009 0.008 0.007 0.007
Mn 0.042 0.039 0.035 0.034 0.034
Ni 0.004 0.005 0.004 0.002 0.003
Pb 0.016 0.006 0.010 NIL NIL
Se NIL NIL NIL NIL NIL
Tl NIL NIL NIL NIL NIL
Zn 0.007 0.004 0.006 NIL NIL
V 0.014 0.011 0.012 0.018 0.014
IMPACT OF SPENT WASH ON HEAVY METALS IN
CLINKER
Observations During Plant Trial


Total of about 105KL spent wash concentrate
consumed
Moisture content in spent wash varied from
32% to 42% during trial
Spent wash feeding started with 200LPH and
gradually raised upto 1000LPH in 3000TPD
Kiln
Co-processing of spent wash does not seem
to influence clinker quality or change kiln
behaviour subject to it is fed @ 3.0-3.5% of
heat/coal substitution.
Guideline For Co-Processing of Spent wash
Concentrate in Cement Kiln


Guidelines available on CPCB website
Cement industry and distillery may apply to
SPCB to get the permission for co-
processing of spent wash concentrate upto
3.5% of heat/coal substitution
For higher percentages trail run may be
conducted after taking permission from
SPCB
Emission Standards
For Particulate matter: As per consent order issued
by concerned SPCB.

For CO. TOC, NOx, HCl, SO2, HF, Total dioxins and
furans, Cd+Tl+ their compounds, Hg and its
Compounds, Sb+ AS+ Pb+Co+Cr+Cu+Mn+Ni+V+their
compounds:
Emission values during co-processing should
not exceed the base line emissions i.e. during
pre co-processing levels

Monitoring Requirements
For Particulate matter : Continuous measurement
For other Pollutants : As & when asked by the CPCB


Air Pollution Control Requirements

For Particulate matter : ESP / Bag House
For other Pollutants : Cement industries has to ensure
that emission during co-processing
is not exceeding the base line
emissions i.e. during co-processing

Way Forward

Distilleries may place the data on website related to
characterization and quantification of spent wash
generated.
Cement Industries should come forward for co-
processing of spent wash concentrate in cement kiln.
Cement industries may reduce green house gas
emission by co-processing of waste in cement kiln
and take benefit of carbon trading.
Awareness programmes should be organised.

..aiming to conserve natural resources