raj process equipments & systems pvt ltd, pune wash spr… · 8. no. of 120 klpd distillery...

RAJ PROCESS EQUIPMENTS & SYSTEMS PVT LTD, PUNE

The Information and Technology represented herein is proprietary to RAJ PROCESS EQUIPMENT & SYSTMS PVT LTD. Pune India. The data is preliminary and requires further detailing and therefore should not be taken as contractual guarantee of designs, engineering or performance of any technology. The information represented herein shall be divulged only to those persons having a direct need to participate in the assessment exercise.

Confidential Information


By-Products: Molasses & Spent Wash

Molasses:

• Molasses is a Waste By-Product of Sugar Industries.

• Now Molasses plays major roll as a Raw material for Distilleries.

• Molasses based distilleries apparently largest revenue

contributor for Indian Government.

Spent Wash:

• Similarly, Distilleries generates large volume of high strength

liquid effluent called “Spent Wash”,

• Dark Brown colored effluent with Organic and Inorganic

contents.


Challenges for Spent Wash

• Spent Wash is Liquid Effluent and Treatment of Spent Wash is

Big Challenge for Distillery Plants.

• Spent Wash generation is about 8-15Liters / Liter of Alcohol

produced.

• It require comprehensive treatment to meet prescribed

standards for effluent disposal.

• Handling and storage issues.

• It is acidic effluent with high BOD and COD value.


Typical Characteristics of Spent Wash

Based On Various Manufacturing Process:

Sr. No

Parameter Batch Process Continuous

Process Fed-Batch Process

1 Volume L/L alcohol 14.0 - 15.0 10.0-12.0 7.0-9.0

2 Colour Dark Brown Dark Brown Dark Brown

3 pH 3.7-4.5 4.0-4.3 4.0-4.2

4 COD (mg/L) 80000-100000 110000-130000 140000-160000

5 BOD (mg/L) 45000-50000 55000-65000 60000-70000

6 Total Solids (mg/L) 90000-120000 130000-160000 160000-210000

7 Total Volatile Solids (mg/L) 60000-70000 60000-75000 80000-90000

8 Inorganic dissolved Solids (mg/L)

30000-40000 35000-45000 60000-90000

9 Chlorides (mg/L) 5000-6000 6000-7500 10000-12000

10 Sulphates (mg/L) 4000-8000 4500-8500 8000-10000

11 Total Nitrogen (mg/L) 1000-1200 1000-1400 2000-2500

12 Potassium (mg/L) 8000-12000 10000-14000 20000-22000


Positive Highlights:

• The excess calcium, phosphorous and sulphates are the result of

clarification and sulfatation processes used in the sugar production.

• Most of the constituents are carried from the Molasses and Other

organic elements come from sugar cane.

• Results in,

Rich in Potassium, Nitrogen, phosphorus.

• Efforts must be made to fruitfully utilization of spent wash for

agricultural applications.

• RAJ has invented & commissioned technology to use this rich source

of nutrients.

Positive Sides of Spent Wash:


CO2

Fermented Wash

ENA/RS/FA

Spent Wash

Fermentation

Distillation, FA & Evaporation

Ethanol Storage

Bio-Methanation

Yeast , Nutrients

Biogas to Boiler

BMSW

25% w/w Conc. BMSW

Spray Dryer Dry Organic Fertilizer

Biocompost

50% w/w Conc. BMSW

OR

Process Flow of Distillery:


Bio-Methanation Process

RAJ Spent Wash Treatment Scheme:

Fertilizer

Spent Wash

BMSW Evaporation

BMSW Spray Dryer

Dry BMSW Powder up to 5-10% Moisture

Bio-Gas


Bio-Methanation :

• Spent wash have high potential to

produce methane gas and It is

subjected to anaerobic digestion

for methane recovery.

• Raw spent wash is also

characterized by high BOD and

COD, intense brown colour and

high salt levels apart from being

rich in plant nutrients..

Highlights of Bio-methanation Process:


Bio-Methanation :

• Bio-methanation process reduce

the BOD by 85 – 90% and COD by

60 – 65% & Produce Methane Gas.

• Methane gas save 40 to 45 % fuel

requirement for Distillery

Complex.

• Further treatment is still required

for safe disposal, Due to high

organic load and salts in BMSW.

Highlights of Bio-methanation Process:


BMSW Evaporation :

• Bio-methanation Process is followed by Multiple Effect Evaporation (MEE) plant.

• BMSW Wash contains 5 – 6 % w/w Solids.

• In Evaporation Plant BMSW is Concentrated to 50 – 55 % w/w solids.

• RAJ offers Heat Integration in Evaporation to reduce Steam Consumption.

Highlights of Evaporation Process:


Condensate Polishing Unit (Optional) :

• Steam Based Double Stripper Column to treatment of BMSW process Condensate

• Integrate to minimize Steam Consumption

• No add on cost for Chemical dosing as Acid or caustic as for conventional scheme

• COD & BOD to be reduce up to 200 to 400 ppm

• Treated water is recycle to use in Cooling tower makeup & Fermentor dilution etc.

Highlights of CPU Process:


BMSW Dryer :

• With expertise in drying process and vast experience in Dryer for Various applications.

• Raj Process has in house R&D Lab and it is equipped with Pilot Evaporator and Different types of Dryers.

• Raj Process has initiated technology & commissioned Spent Wash with Spray Drying technology.

• Concentrated BMSW with 50-55% solids dried in Spray Dryer resulting in 5-10% moisture in Powder.

Highlights of Spent Wash Dryer:


BMSW Powder :

• BMSW Powder is rich in Potassium, Nitrogen, phosphorus and it is good for soil.

• BMSW Powder is easily used as Fertilizer with rate of 4000 Rs/MT

(57 USD/MT) • BMSW Powder is Organic Fertilizer is

better option than Chemical Fertilizers. • BMSW Powder has calorific value of

approx. 1700-2200 kcal/hr and directly used as boiler fuel to reduce fuel consumption of Plant.

• BMSW Powder will generate higher revenue than Bio-composting or Incinration boiler.


4000 Rs/MT

57 USD/MT

BMSW Powder Granulation Plant:

• BMSW Powder can make granules with adding Binder

• Ash, Sludge can be added in some ratio

to enhance nutrient in powder and achieve total ZLD.

• After Granulation, It is easy to

Handling, Storage and Bagging & Reduces transportation cost.

• Raj has initiate to tie up with Fertilizer

company like Coromondal Fertilizer, GSFC, CMS Organic, Nirman Fertilizer


Analysis of BMSW Powder

Based On Various Analysis:

Sr. No Parameter BMSW Powder

1 Moisture 5 -10 %

2 Colour Dark Brown

3 Potassium (Dissolved Potash) 12 - 18 %

4 Total Nitrogen 1 – 1.5 %

5 Organic Carbon 36 – 39 %

6 Phosphorus 0.9 – 1 mg/ltr

7 Total Volatile Acid 55 – 58 mg/ltr

8 Chlorides 680 – 700 mg/ltr

9 Sulfates 520 – 540 mg/ltr

10 Sulfates in Ash 450 – 460 mg/ltr

11 Calcium 230 – 240 mg/ltr

12 Iron 455 – 465 mg/kg

13 Sodium 400 – 415 mg/ltr

14 Calorific Value 1800 – 2200 cal/g


Analysis of BMSW Powder


Market for Organic Fertilizer in India :

Sr. No. Parameter Value

1. Fertiliser Requirement in 1000 x MT/Year 26600

2. Fertiliser Produced in 1000 x MT/Year 17900

3. Bio-Fertiliser Manufactured in 1000 x MT/Year 48

4. Fertiliser Imported in 1000 x MT/Year 8500

5. Potash based Fertilizer Imported in 1000 x MT/Year 2925

5. Market for Potash based Bio-Fertilizer in 1000 x MT/Year 2877

6. Projection for 3 Year of Potash based Bio Fertilizer in 1000 x MT/Year (2021-22)

5225

7. No. of Seller Available in market of Bio-Fertilizer 200-250

8. No. of 120 KLPD Distillery Required for Powder (15% K) 710-720

9. No. of 120 KLPD Distillery Required for 3 Year projection 1300-1310


Sources : 1. Fertilizer Association of India 2. Dept of Fertilizer & Chemical Ministry 3. National Center of Organic Farming

Potash Fertilizer Import in India :

Sr. No. Parameter Value

1. Potash (100%) based Fertilizer Imported in 1000 x MT/Year

2877

2. Potash Fertiliser Cost (244.5 USD/MT) Rs /MT 17115

3. Potash Fertiliser transportation up to FOB & Duty Cost (60 USD/MT) Rs /MT

4200

4. Potash Fertiliser Local transportation Cost (0 to 500 km = 108 to 500 Rs/MT) Avg. Taken Rs /MT

304

5. Subsidy on Potash (100%) Fertilizer Imported , Rs /MT 12400

5. Total Expenses on Potash Import, Rs /MT 34019

6. Total Expenses on Potash Import Yearly (Saving ), Rs Crore

~10000


Agreement Copy :

BMSW Powder Agreement with M/s Nirman Fertilizers Pvt. Ltd.


BMSW Powder Tax Invoice Copy :

BMSW Powder Purchase Rate 4000 Rs/MT (57 USD/MT)


Advantages of RAJ ZLD :

Sr. No.

Traditional Incineration Method Advanced RAJ-ZLD Technology

1. Operating Cost : High Operating Cost : 25-30% Lower

2. Capital Investment : High Capital Investment : 25-30% Lower

3. Cleaning Cycle : Frequent (Approx.45 Days)

Cleaning Cycle : Regular boiler Frequent cleaning is not required .

4. Maintenance Cost : High Maintenance Cost : 10-12 times lower than incineration boiler

5. High Capacity Boiler is required to burn 55% w/w Spent wash, Since excess steam is generated.

Boiler Capacity suitable for distillery complex, Since no any additional Steam generation.

6 Due to Excess steam , Steam and Power is not balanced as per Process requirement.

Steam and Power is Balanced as per Process requirement.

7. Not Suitable for Juice & Syrup to Ethanol case

Suitable option for Juice & Syrup to Ethanol Case


Case study for Raj-ZLD against Incineration Boiler :


Case Study for 120 KLPD_India

Case Study for 120 KLPD_Export

Case study for 120 KLPD for Option I & II.pdf










Case study for 120 KLPD for Option I & II_Abroad.pdf










Green Effect (CO2 Emission) Raj-ZLD against Incineration Boiler :


120KLPD Molasses Base Distillery For North_CO2 emission

120KLPD Molasses Base Distillery For North_CO2 emission.pdf















EC Clearance Reference 1 (Tamilnadu)


EC Clearance Reference 2 (AP)


EC Clearance Reference 3 (Karnataka)


EC Clearance Reference 4 (Maharashtra)


EC Clearance Reference 5 (Telangana)


VIDEO:

Video of Khandoba Plant Spent Wash Dryer

Video 1

Video 2

Video 4 (RAJ ZLD Animation)


Video 3 (Powder Dilution in Water)

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Photo Gallery:

Distillery Plant (Khandoba Distillery Ltd., 110 KLPD):


Photo Gallery:

Bio-Digester (Khandoba Distilleries Ltd., 110 KLPD):


Photo Gallery:

BMSW Evaporation & CPU (Khandoba Distilleries Ltd., 110 KLPD):


Photo Gallery:

Spray Dryer (Khandoba Distillery Ltd., 110 KLPD):


Photo Gallery:

RS Distillation & BMSW Evaporation (Jakraya Sugar Ltd., 45 KLPD):


Photo Gallery:

Spray Dryer (Jakraya Sugar Ltd., 45 KLPD): Erection Done


Photo Gallery:

BMSW Spray Dryer (Kanoria Sugar. 15 KLPD)


Photo Gallery:

Supplied Evaporator in ZLD Scheme in Other Industry


Photo Gallery:

Supplied Dryer in ZLD Scheme in Various Industry


Photo Gallery:

Distillery Plant (Athani Sugar Ltd., 90 KLPD):


Photo Gallery:

Distillery Plants


Thank You


raj process equipments & systems pvt ltd, pune wash spr… · 8. no. of 120 klpd distillery...

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