September 22, 2011IIT, Delhi

MANAGEMENT OF DISTILLERY IN INDIA- AN OVERVIEW

By

Central Pollution Control Board (CPCB)

In this presentation ....

• Introduction

• Existing standards/ guidelines

• Summary of Compliance Status of Distilleries

• Case studies- Observations from a few distilleries

• Need for revisit

• Emerging Technologies

• Way Forward

Distillery Industry in India

• Number of sugar mills: 620

• Molasses based distilleries – 300

• Molasses based installed capacity : 4.29 bln

lit.

• Gain based distillery units: 100

• Grain based installed capacity : 1.8 bln lit.

• Molasses based distilleries produce spent

wash having very high pollution load

* Other than cooling tower

Average fresh water requirement in molasses based distilleries for different fermentation technologies.

Type of Fermentation Process (a)

Molasses Dilution fresh water (b)

Fresh Non process (RS Production)

Polluted Streams for recycle

Unpolluted Streams for recycle

(g)

Total Streams for recycle (h)

Total fresh water require--ment(b+c+d-h)

Cooling tower make up

(c)

Other non process *

(d)

For process   

(e)

For non process

 (f)

Batch 7.4 – 10.5 1.4 – 4.0 6.0 – 8.8 0.5 – 0.6 0.5 – 0.6 0.5 – 1.0 1.5 – 2.2 13.3–21.1

Cascade Continuous

7.7 – 9.2 3.0 – 4.0 5.5 – 6.5 0.5 – 1.5 0.5 – 0.6 0.5 – 1.0 1.5 – 3.0 14.7– 16.7

Biostill Continuous

4.0 – 5.0 3.0 – 4.0 5.0 – 6.0 2.0 – 4.0 0.5 – 0.6 0.5 – 1.0 3.0 – 5.6 9.0 – 9.4

Average waste water generation in molasses based distilleries for different fermentation technologies.

Type of FermentationProcess

Waste water generation

Spent wash Spent lees Other

Batch 11.1- 15.0 0.5 – 1.5 0.2 –0.4

Cascade Continuous

8.5 – 11.0 0.5 – 1.5 0.2 –0.4

Biostill Continuous

6.0 – 8.0 0.5 – 1.5 0.2 –0.4

General characteristics of raw spent washS.No. Parameter Batch process Cascade process Biostil process

1 Volume, L/L Alcohol 14-16 10-12 8-10

2 Colour Dark brown Dark brown Dark brown

3 PH 3.7-4.5 4.0-4.3 4.0-4.2

4 COD 80,000-1,10,000 1,10,000-1,30,000 1,40,000-1,60,000

5 BOD 45,000-50,000 55,000-65,000 60,000-70,000

6 SolidTotalTotal Volatile Inorganic dissolved

90,000-1,20,00060,000-70,00030,000-40,000

1,30,000-1,60,00060,000-75,00035,000-45,000

1,60,000-2,10,00080,000-90,00060,000-90,000

7 Chlorides 5,000-6,000 6,000-7,500 10,000-12,000

8 Sulphates 4,000-8,000 4,500-8,500 8,000-10,000

9 Total nitrogen 1,000-1,200 1,000-1,400 2,000-2,500

10 Potassium 8,000-12,000 10,000-14,000 20,000-22,000

11 Phosphorus 200-300 300-500 1,600-2,000

12 Sodium 400-600 1,400-1,500 1,200-1,500

13 Calcium 2,000-3,500 4,500-6,000 5,000-6,500

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

As notified under the Environment (Protection) Rule, 1986

Sr.No.

Parameter Range

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/ streamsDisposal on land or for irrigation.

30

100

4 Suspended solids, mg/L Max. 100

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 pre-sown irrigation– Biomethanation followed by treatment and Discharge

into deep sea.

• 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

CPCB Resolution (June 2008)

• New stand alone Distilleries: Concentration – incineration system

• New attached Distilleries: Bio-methanation followed by bio-composting Concentration– incineration system {Reboiler/

Evaporation/ Concentration followed by incineration of concentrated spent wash in boiler (for power generation)}

• Existing stand alone Distilleries (expansion): Concentration – incineration system

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

CPCB Resolution (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.

Co-Processing of Distillery Spent wash concentrate in Cement Industry

(CPCB, 2010)

Co-processing of molasses based distillery spent wash concentrate in Cement Kilns, furnaces of Thermal Power Plants/ Steel Plants, Incinerators

Existing Guidelines related to Disposal Options for Distillery Effluent

• CREP Programme (2002-2003)

– Ferti-irrigation– One time application (Pre-sown irrigation)– Bio-composting of pre-treated spent wash– Concentration and drying/ Incineration

• Emerging Technologies (2008)

– Evaporation/ Concentration– Incineration system

• Co-processing (2010-2011) – Co-processing in cement kilns/ furnaces of TPPs/

Steel Plants.

Ferti-Irrigation Practice

• Biomethanation followed by 2-stage biological treatment to achieve BOD<800 mg/l

• Storage of treated effluent in lagoons with capacity < one fourth of average yearly utilization of spent wash and impervious liner system (duly lined with 250 micron HDPE sheet and pitched by stone/bricks with cement mortar to prevent leachate).

• Dilution of treated effluent prior to irrigation to meet critical water quality parameters, Such as N- requirement of crop, soil type.

• One or more SW irrigations.

• Further irrigations to be done using fresh water

• Application of SW each alternate year

• Command area- radial distance of 20 km

• Distribution network of impervious conduits

• In no case the effluent shall be allowed to flow in earthen channels

Pre-Sown Irrigation Practice

• Use of biomethanated SW of BOD < 7000 mg/L.

• Irrigation application on N-requirement of crop, soil type as advised by agricultural institutions. N- requirement of the crop to be applied in a single dose.

• Maximum of one third of the SW generated per year shall be utilised for pre-sown irrigation.

• Application to be done at least 30 days in advance of sowing and on set of rains.

• Storage lagoon capacity < one fourth of average yearly utilization of spent wash

Bio-Composting Practice

• Open windrows to be 3m long x 2m wide x 1.5m high, with a total volume < 9.0 cu.m.

• Press-mud as filler material is continuously mixed with pre-treated Spent wash

• On 30th day, windrow to be broken down and sieved to remove the oversize contrary material.

• Screened compost to be stored for about 15 days in heaps about 2m wide x 1.5m high x 20m long to ensure stabilization before sale.

• Press-mud has an initial C/N ratio of around 20-24, almost stabilized solid material.  

• Distilleries operate for 270 days.

• Storage of pre-treated effluent < 30 days

• As per the specifications, with 850 MT press-mud/ acre, (a) for 45 days cycle, SW disposal to be 2125 cum (i.e.70 KLD)

Performance Assessment of Distilleries practicing Ferti-

irrigation, One time application (Pre-sown irrigation), and Bio-

composting

Compliance Status of Distilleries under ESS Programme

Monitoring carried out in more than 100 distilleries, randomly selected, by teams of scientist & engineers, during the last five years shows significant violation in more than 60% of units.

Case Studies- Observations from a few

Distilleries

• 40 to 50% effluent disposal through Bio-composting route.

• Bio-methanation – RO/MEE – Bio-composting. • Storage of pre-treated/ raw spent wash in

lined/ unlined lagoons with capacity > 30 days.

• Inadequate ETP and Non-operational treatment units.  

– Poor Operation & Maintenance of Anaerobic Digesters

– Non operation of RO/ MEE Plants

Composting process not up to standard: No composting in operation. No press mud availability. No storage sheds for press mud/ final compost. Open storage of large quantity of unfinished/

finished compost. Large unlined/ lined areas under compost yard. No provision for mechanical spray system. Pit composting technique without any pre-treatment

with unlined/ broken pits. Unlined bio-composting yard. No spent wash distribution net work in compost

yard. No leachate collection system provided to stop the

surface run off from compost yard to nearby water body/land.

• 50 to 60% effluent disposal through one time land application/ ferti-irrigation.

• Bio-methanation -- primary clarifier – two-stage extended aeration system – secondary clarifier -- sludge drying beds followed by storage of partially treated effluent in lined/ unlined lagoons for ferti-irrigation/ one time land application.

• Treated spent wash having high BOD requiring high dilution ration (45 times) resulting in large quantity of fresh water requirement for irrigation.

• Arrangements with Agriculture Universities for utilization of treated Spent wash with land availability of 1000 to 3000 hectare.

Completely filled Lined Lagoons with storage capacity > 3 months.

Completely/ partially filled Unlined lagoons spread over 3 to 20 hectares land.

Disposal of spent wash with BOD > 20000 mg/l, COD-80000 mg/l through land application.

Spent wash disposal along with storm water into nearby river bodies through bypass pipeline or drains.

Public complaint of ground water contamination and regular discharge of coloured effluent through closed pipe.

Ground water pollution in nearby areas.

Ground water samples indicate contamination

with Colour, TDS and high conductivity.

Demand & Need for revisiting

Guidelines namely, Ferti-irrigation, Pre-sown irrigation and Bio-composting are not able to management SW @ equivalent to its generation rate, resulting in accumulation & discharge of SW.

Permission for storage of pre-treated SW, resulted in non-operation of treatment units like digesters, RO, MEE.

Promote non-conservation of water.

Demand & Need for revisiting

Ferti-irrigation/ Pre-sown irrigation:

High dilution ratio, less no of irrigation requires large command area, which is not available to distilleries.

Faulty liner system.

Practically not possible to monitoring and effective control.

SW irrigation to be employed for about 6 months in a year only.

Demand & Need for revisiting

Bio-Composting:

• Faulty liner system for compost yard/ storage lagoon.

• Unavailability of large press-mud.

• Unable to handle SW in 1:2.5 to 1:3.5 ratio.

• Existing practices not in accordance with the principle of composting.

• Practically not possible to monitoring and effective control.

Emerging Technologies

Established technologies:

1. Anaerobic digestion – Biogas2. Aerobic surface bio-composting - Bio-compost3. Reverse osmosis - Permeate/Reject 4. Multiple effect evaporation (Concentration) –

Concentrate/Process condensate

Emerging technologies:

5. Incineration- Spray/ Rotary Dryer, SFB6. Co-processing 7. Gasification

Emerging Technologies About 100 distilleries have installed RO plants About 100 distilleries have installed MEEs About 30 to 40 incineration plants have been

installed. 55 to 60 % solids concentrate or spentwash

powder is fired in a specially designed boiler with or without subsidiary fuel.

Steam generated runs a TG set to generate electricity.

Exhaust steam is used in distillery and evaporation plant operations

Potash rich ash as a by-product.

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).

Cement Kiln Suitability

High temperatures (1400 O C) and residence time of 4 – 5 seconds in an oxygen–rich 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

Department Related Parliamentary Standing Committee on Commerce

95th Report on Performance of Cement Industry

The Committee feels that the co-processing of wastes in cement plants that have successfully been put to trial run need to be commercially implemented. Necessary guidelines be formed for this purpose. The cement plants should start co-processing of waste.

LOCATION OF CEMENT, IRON & STEEL, DISTILLERY AND THERMAL POWER PLANTS

Thermal Power

Iron & Steel

Cement

Distellery

Legend

WEST

ASSAM

ARUNACHALPRADESH

NAGALAND

MANIPUR

MIZORAM

TRIPURA

MEGHALAYA

SIKKIM

JHARKHAND

BENGAL

ORISSA

CHATTISGARH

UTTAR PRADESH

MADHYA PRADESH

HARYANA

GUJARAT

RAJASTHAN

JAMMU

AND

KASHMIR

PUNJAB

UTTARAKHAND

HIMACHALPRADESH

ANDHRA

MAHARASHTRA

PRADESH

KARNATAKA

TAMILNADU

KERALA

BIHAR

DELHI

Ahmednagar Hingoli

Satara

Washim

Ankleshwar

AurangabadJalna

Bharuch

Bhavnagar

Jalgaon

Nandurbar

Kolhapur

Thane

BeedLatur

Nagpur

Nanded

Nashik

Khapoli

OsmanabadPune

SolapurSangli

SuratVapi

Navsari

Raisen

Rajgarh

Bilaspur

Chattarpur

Gwalior

Dhar

Ratlam

Alwar

Jodhpur

Udaipur

Sikar

Angul

Ganjam

24 Parganas

Kolkata

FerozepurDehradun

VaranasiMokhama

GorakhpurFaizabad

Balrampur

Kanpur

Lucknow

SitapurLakhimpur KheriBareilly

KashipurBulandshaharGajraula

MoradabadBijnore

Muzaffarnagar

SolanY.Nagar Meerut

Dharuhera Faridabad

GhaziabadHisarSonipat

PanipatAmbalaPatiala

BilaspurHoshiarpurAmritsar

Guurdaspur

SrikakulamVishakhapatnam

Koraput

E. Godavari

W. GodavariKrishna

Prakasam

NelloreChitoor

Bellary

Raichur

Rangareddy

Medak

Nizamabad

CanaconaBelgaum

Dharwad

Bidar

DavangereChitradurga

TumukurBangalore

MandyaKolarVellore

DharmapuriKanchepuram

VillupuramPodicherryCuddaloreThanjavur

Sivaganga

TrichyCoimbatore

Theni

ChitturChalakudy

Alappuzha

Kanjikkodu

Tirunelveli

Mysore

salemErode

Saharanpur

Sitamarhi

Banka

UttarparaKhayerpur

Khargone

Tiruvallur

Thoothukudi

Sonebhadra

Ramagundem

Vijaywada

Rayalseema

SimhadriKothagudem

Kakatiya

BarauniKahalgaonMuzaffarpur

KorbaSipat

Raigarh

KoriyaKutch Gandhinagar

Bokaro

North-chennai

Bongaihaon

Akola

BhatindaRupnagar

Kota

Ganganagar

BaranBarner

Singrauli

DadriRampur

Jhansi

Aligarh Shahjahanpur

Murshidabad

BankuraNorth 24 Parganas

Puruliya

Birbhum

HooghlyBardhaman

Medinipur

Ratnagiri

Jhajhar

MEGHALAYA

ORISSA

LOCATION OF CEMENT, IRON & STEEL, DISTILLERY ANDTHERMAL POWER PLANTS

Thermal Power

Iron & Steel

Cement

Distillery

Legend

Bongaigaon

WEST

ASSAM

ARUNACHALPRADESH

NAGALAND

MANIPUR

MIZORAMTRIPURA

SIKKIM

JHARKHAND

BENGAL

BIHAR

CHATTISGARH

UTTAR PRADESH

MADHYA PRADESH

HARYANA

GUJARAT

RAJASTHAN

JAMMU

AND

KASHMIR

PUNJAB

UTTARAKHAND

HIMACHALPRADESH

GOA

ANDHRA

MAHARASHTRA

PRADESH

KARNATAKA

TAMILNADU

KERALA

DELHI

State wise Distribution of Distilleries, Cement Plants, TPPs and Iron & Steel Industries

Sl. No.

State No. of Distilleries

Molasses based Distilleries

No. of Cement Plants

No. of TPPs

No of I&S Ind.

Total Attached with Sugar Mills

1 Andhra Pradesh

34 26 10 20 8 1

2 Assam 1 1 1 1 1 -

3 Bihar 13 13 3 1 3 -

4 Chhattisgarh 3 6 6 2

5 Daman & Diu 4 6 - - - -

6 Delhi - - 2 -

7 Goa 4 1 - - -

8 Gujarat 18 10 5 9 9 1

9 Haryana 12 7 1 - 3 -

State wise Distribution of Distilleries, Cement Plants, TPPs and Iron & Steel Industries

Sl. No.

State No. of Distilleries

Molasses based Distilleries

No. of Cement Plants

No. of TPPs

No of I&S Ind.

Total Attached with Sugar Mills

10 Himachal Pradesh

4

8

6 - -

11 Jammu & Kashmir

6 2 - -

12 Jharkhand - 1 5 2

13 Karnataka 43 33 6 9 4 1

14 Kerala 9 8 2 1 - -

Sl. No.

State No. of distilleries

Molasses based Distilleries

No. of Cement Plants

No. of TPPs

No of I&S Ind.

Total Attached with Sugar Mills

15 Madhya Pradesh

20 20 1 10 4 -

16 Maharashtra

91 75 52 4 12 -

17 Meghalaya - 3 - -

18 Nagaland 1 1 - - -

19 Orissa 8 8 3 2 3 3

20 Punjab 11 8 3 - 3 -

21 Pondicherry

3 3 - - -

22 Rajasthan 16 10 2 16 6 -

23 Sikkim 1 1 - - - -

Sl. No.

State No. of Distilleries/ Breweries

Molasses based Distilleries

No. of Cement Plants

No. of TPPs

No of I&S Ind.

Total Attached with Sugar Mills

24 Tamilnadu 26 21 11 16 7 -

25 Tripura 1 - - -

26 Uttaranchal

3 3 1 - - -

27 Uttar Pradesh

61 56 24 1 11 -

28 West Bengal

11 7 - - 14 2

Total 404 326 125 108 102 12

Distilleries vis-à-vis Emerging Technologies

Fermentation & Distillation Industries

400

Molasses based Distilleries 300

Distilleries attached with Sugar Mills 125

Distilleries with Concentration-incineration system

30

Distilleries with MEE system 100

Distilleries directed for adoption of Emerging Technologies

60

Different treatment technology routes for distillery effluent/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.

Why Emerging Technologies ?

• To attain actual ZLD.• To operate throughout the year• Promotes water conservation (80-90% water

recycled/ reused).• No requirement of storage lagoons and

hence the least chances of pollution.• Co-processing- a more cost effective/ trouble

fee operational option.• Successfully demonstrated in about 30

distilleries.

Way Forward

· Distilleries are important for growth and development.

· Shifting towards zero liquid discharge paradigm is feasible and must be implemented to save rivers and help maintain “Nirmal and Aviral Dhara”.

· Improvements in technology and following best practices can lead to substantial reduction in water consumption and lower the cost of attaining zero discharge paradigm.

· Emerging Technologies, namely RO, MEE, Slop fired boilers, Spray/ Rotary Dryers, Co-processing are capable of attainment of ZLD.

· Experience of about 4 to 5 years of operation of emerging technologies are available with distilleries.

· More than 10% of distilleries have adopted emerging technologies

· Distilleries are important for growth and development.

· Shifting towards zero liquid discharge paradigm is feasible and must be implemented to save rivers and help maintain “Nirmal and Aviral Dhara”.

· Improvements in technology and following best practices can lead to substantial reduction in water consumption and lower the cost of attaining zero discharge paradigm.

· Emerging Technologies, namely RO, MEE, Slop fired boilers, Spray/ Rotary Dryers, Co-processing are capable of attainment of ZLD.

· Experience of about 4 to 5 years of operation of emerging technologies are available with distilleries.

· More than 10% of distilleries have adopted emerging technologies

Way Forward· Fiscal and financial schemes may be formulated by Government

Departments and Financial Institutions to support industry.· Expert Committee constituted by CPCB to revisit the effluent &

emission standards vis-à-vis emerging technologies implementability & cost economics

· Fiscal and financial schemes may be formulated by Government Departments and Financial Institutions to support industry.

· Expert Committee constituted by CPCB to revisit the effluent & emission standards vis-à-vis emerging technologies implementability & cost economics

Thank You !!