by k .p. singh 1 - aidaindia.org · x108 . with the ... power generation through highly efficient...

1 By K .P. SINGH

Production Capacity

Radico Khaitan Ltd. was established in the year 1943 & is one of the most efficiently-

run distilleries in India manufacturing high grade Extra Neutral Spirit (ENA) from ……

Molasses

Grain

Malt

Total production capacity of 1024.6 Million Liters p.a.

Raw material is Molasses, Grain and Malt.

The total land area 44,3920.0 sqm i.e. 40 Hectare in which 153407.0 sqm area is

building shed and roof top.

We at Radico continuously exploring and implementing the initiatives with regular

modification and Modernization for sustainable growth.

About Radico

We have modified conventional batch process toimproved high Brix batch fermentation in our MolassesDistillery.

Each fermentation tank is monitored for fermentationefficiency.

Fermentation tanks are MS epoxy coated and coveredat the top for CO2 recovery.

With High Brix Fermentation we are able to maintain9.5–10.0% Alcohol in Wash in a Molasses having only 42-43% TRS.

At our Aurangabad Distillery , we are achieveing 10.5 to11% Alcohol in Fermentation with TRS 48 to 50% TRS.

Effluent Volume Reduction by High BRIX Fermentation

Fermentation Efficiency is maintained between 91.5-92.0% with efficient process controls duringfermentation.

Fresh yeast is used for every fermentation tank.

Cell concentration in pre-fermenters is maintained at 4X108 .

With the recycling of Spent Lees and condensate wateras dilution water, fresh water consumption infermentation is reduced by about 80% and water borncontamination is almost Zero.

Effluent Volume Reduction through Improved Fermentation Efficiency

Cooling of Fermenting Wort through Heat Exchangers for optimizing fermentation efficiency .

Cleaning of Fermentation Tanks through Spray Balls Water Jet to save Water.

Use of cleaning agents for maintaining aseptic conditions after washing of Fermentation Tanks through CIP System.

Adequate nutrient dosing for facilitating quick fermentation.

Effluent Volume Reduction through Improved Fermentation Efficiency

Effluent Volume reduction Through RSW Evaporator (3 Stages ) & RO Plant at – RKL Rampur

Effluent Volume reduction Through BMSW Evaporator (7 Stages ) at – RNV Aurangabad

Installation of High Efficient Alfa Vap PHEs in place of conventional shell and Tube type Condensers at Pre Rectifier Inlet for Molasses Plant in 2013

Higher Thermal Efficiency & Energy conservation.

Less Heat Transfer area

Less Floor area for installation

Easy Maintenance ,

Easy to increase / decrease capacity just of adding / removing the PHE plates.

Installation of PHE Reboiler - Rampur

The same Technology is conceptualized now for the Grain Plant Rectifier Inlet also, in oder to have Steam Condensate Recovery……

Degritting system for Grain Distillery to have separation of Heavy particles…(System is basically two stage Cyclone system, which reduces the abrasion at Decanter level, resulting into..

Better Decanter Efficiency

Better Life of Decanter Scrolls

Low cost Decanter maintenance.

Degritting System for Grain Distillery - Rampur

The same Technology is adopted by Radico and expected to install in December’2016

Challenges ( High TSS in Digester Outlet )

Resulting into Low Efficiency of RO System (@35%) due to High TSS in Digester Outlet effluent.

New initiatives taken

Installation of Degasser and Series of Clarifiers.

Addition of Special Poly-electrolyte for better settling and Series of Lamella Clarifiers Followed by DAF System.

( Above Technology is adopted by Radico is 1st Time in India)

Effluent Management - Rampur(Challenges & Initiatives )

Radico has taken the decision for TSS reduction system during Jan’2015 alongwith the Technology provider. It’s installation and Performance Establishmenttook a quite long time to achieve 65% Recovery as of now. Further targeted toachieve 70% Recover by the Oct’16 end , necessary action already in place.

No Bio-Composting in Rainy season

Molasses Distilleries face problem in Bio-Composting in Rainy season.

Covered Bio-Composting

RKL-Rampur has covered composting area of about 12 acres to over come this problem and now composting is done uninterrupted in rainy season in covered area.

RNV-Aurangabad Bio-compost yard is also covered with the 12 Acres of Poly shed and now we able to run the Plant throughout the year.

Effluent Management at Rampur & Auragangabad(Challenges & Initiatives )

Process Flow of ….… ETP Plant (Rampur)

Distillation Plant with Integrated Evaporator… Rampur

In 2005 we installed our First RO Plant of 1000 m3 / day.

In 2007 we installed another RO plant of 1250 M3 / day .

In the year 2002 , we started Bio-Composting and at present

we have about 52 Acres of Bio-composting.

At present we have 12 Acres of covered Bio-Composting for

composting in rainy season.

In 2013, Volume reduction is achieved through re-boilers ,

integrated multi-effect evaporators ( MEE) before Bio-

Digesters

Up-gradation of Effluent Treatment Plant .. Rampur

In 2015-16, We have installed Sophisticated TSS reduction system comprising of Lamella

Clarifiers Series of Clariflocculators , filter press, Moving Bridge Clarifier

and Dissolved air Flotation (DAF) for further volume reduction through

R.O. plant

1.Reduced Effluent Generation through Multi Effect Evaporators and High

Pressure RO Plants of 1000 m3 and 1250 m3/ day followed by

permeate polishing unit.

2.Improved efficiency of RO Plant by increasing RO pressure from 60 Bar to 75

Bar and improved TSS reduction system.

3.Degasser to de-gassify the effluent for better settling of suspended solids.

4.Settlers (3 nos. ) for better sludge separation.

5.Lamella Clarifier for better sludge separation. (4 Nos)

6.Filter Press- for thickening of separated sludge.

7.Dissolved Air Floatation (DAF) Mechanism with the help of Special

Polyelectrolyte for settling of fine sludge particles .

Up gradation & Modernization of ETP Plant .. Rampur

S.NO. GURANTEED PARAMETERS UNIT VALUES

1 Feed to Evaporator TPD 1690

2Alcohol to Spent wash Ratio

(Before Evaporation)Ratio 1 : 9

3 Initial Solid in Concentration %W/W 12

4 Final Solid in Concentration %W/W 22

5 Spent wash Volume Reduced to TPD 930


(After Evaporation)Ratio 1 : 5

7Total Process condensate

generated from Evaporation

Plant

TPD 760

8Thick Sludge separation at

Filter Press M3/day 90

9 Volume Redcution at RO % 58 ~60 %

10Final Spent wash Volume for

Bio-compost M3/day 390


(After RO)Ratio 1 : 2

Note : Till Now we have achieved 60% reduction in overall effluent volume and targeted to

have 80% reduction after stabilization of currently installed systems.

Reduction of Spent wash Volume - Rampur


1 TSS Level at Digestor Outlet Mg/Liter 20000 ~ 22000

2 TSS Level at Lamella Outlet Mg/Liter 10000

3TSS Level at Clarifloculator

Outlet Mg/Liter 5500

4TSS Level at Settling Tank

Outlet and 2nd ClarifierMg/Liter 3200

5 TSS Level at DAF Outlet Mg/Liter 2000


1Thick Sludge separation at

Filter Press M3/day 90

2 Volume Redcution at RO % 58 ~60 %

3Final Spent wash Volume for

Bio-compost M3/day 390


(After RO)Ratio 1 : 2

Molasses Spent Wash Management Through TSS Reduction and RO Upgradation - Rampur

Bio-Digester for Biogas Recovery - Rampur

Sludge Settling system – Lamella & Filter Press

Sludge Settling system – Clarifucators

Sludge Settling system – Moving Bridge Clarifier

TSS Reduction Through – DAF Installation

RO-I

H.P.R.O.-I Plant

RO-II

H.P.R.O.-II Plant

After volume reduction through MEE & R.O.

remaining effluent is sent for Bio-Composting using

sugar mill press mud and manufacturing highly valuable

and micro-nutrient rich organic manure Bio-compost.

Sludge generated at Bio-Digesters and Fermentation

section is mixed with Bio-compost .

The Bio-compost manufactured in the Distillery is being

packed in sealed bags .

Achieving Zero Spent Wash Discharge Through Bi-composting

Installed Permeate polishing unit in RO plant forrecycling of Permeate in Process.

Recycling of lees , process condensate and Permeate infermentation for Molasses dilution.

Radico has been able to cut their fresh waterconsumption by about 60% through recycling ofsteam Condensate to Boilers , Using MEE condensatefor dilution of Molasses and recycling R O. permeateto cooling towers and for gardening .

Reduction in Water Consumption

Radico has adopted very innovative and effective wayof Bio-composting in Rainy season by covering Bio-composting yards .

These poly sheds are very useful in the rainy seasonand protect the press mud from rain water in order tocontinue the process of Sp. Wash consumption in thepress mud in the rainy season as well.

By adopting covered Bio-composting , Radico is ableto achieve ZSD in the rainy season and therebyfacilitate operation of distillery throughout the yearincluding rainy season.

Covered Bio-Composting

Radico Khaitan Ltd has achieved remarkablelandmarks in the field of water management ,achieving Zero Spent wash discharge through variousmeans , Ground water Extraction Management andreduction in fresh water consumption per litre ofalcohol production .

a Success Story of Distillery… Water Management

Covered Bio-composting

Bio-composting - bagging

Radico has conceived the optimum utilization energy resources available in thecomplex by setting up Biogas Fired boiler. Biogas is a bio product in the distilleryand by utilized importance of energy conversation of firing the same in boiler.

Also we have one rice husk fired Rice husk + Biogas Boiler for making steam andthen making power out of it by feeding into turbine.

Radico has set up a good profit center in the form of Cogeneration Plant and twoBio Gas Gensets. At present Cogeneration Plant and Bio Gas Gensets caters100% Captive Consumption of Steam and Power to Radico.

Radico is conducting periodic Energy Audits and implementing the EnergyEfficient Programmes.

Radico is continuously participating in the National Energy Award nominationsof Bureau of Energy Efficiency (BEE) arranged thru Ministry of Power.

Energy – An Overview at Radico

With the implementation of various energy conversation measures as anongoing practice, there is steady decline of specific energy consumption.Last three years specific energy consumption figures are shown below:

Note : During Q2 of FY 2013-14 Integrated Evaporators were installed at both sections of Alcohol Plant.

Energy …An Overview at Radico

SN DESCRIPTION UNIT 2013-14 2014-15 2015-16

A: Steam Saving

1 Specific Steam Consumption in

Wash to ENA (Molasses) KG/BL 3.43 3.41 3.38

1 Specific Steam Consumption in

Wash to ENA (Grain) KG/BL 3.74 3.58 3.54

B: Power Saving

1 Specific power Consumption in

Wash to ENA (Molasses) Kwh/KBL 114 135 132

2 Specific power Consumption in

Wash to ENA (Grain)Kwh/KBL 301 300 294

Replaced all the old un-efficient motors and pumps with the new highly efficient pump and motors.

Adopted Dyno Drive Systems for Flexibility in loads.

Overhead Cooling Tower Basins to provide positive suction head for pumps.

Power Generation through highly efficient Bio-Gas Engines of MWM, GERMANY.

Installation of VAM Integrated Chilled Water System for Air Conditioning requirement from Bio-Gas Engines.

Installation of Temperature Sensors at Cooling Tower Fans to save the power during Winter Season.

Timer installation on Street and Plant Lights

Replacement of Copper Chocks with Electronic Chocks.

Measures Taken for … Electrical Energy Conservation

UPPCB vide letter No F74665 dated 02.03.2016 has directed for the First time, for

getting the NOC from Central Ground Water Authority, (Also refer Gazette

notification dated 16th Nov. 2015 making it mandatory for all existing industrial

units also to obtain NOC from CGWA )

Guide lines / Criteria for Evaluation of requests for Ground Water Abstraction

Criteria for Industries

Category Mandatory Recycle / Reuse

Withdrawal permitted (% of Proposed recharge)

1.Safe Major & Medium Industries to recycle and reuse at least 40% of water

NOC is required for Ground water withdrawal subject to adoption of artificial recharge to Ground water.

2.Semicritical Major & Medium Industries to recycle & reuse at least 50% of the waster water

Withdrawal may be permitted subject to ground water recharge measures**. The withdrawal should not exceed 200% of the recharge quantity.

3. Critical Major & Medium industries should fully recycle & reuse the waste water

Withdrawal may be permitted subject to undertaking of ground water recharge** measures. The withdrawal should not exceed 100% of the recharge quantity.

4.Over Exploited

All Industries to fully recycle and reuse the waste water.

Withdrawal may be permitted subject to undertaking of ground water recharge** measures. The withdrawal should not exceed 50% of the recharged quantity.

** The recharge should be implemented within the premises and / or same Water Block shed/ assessment unit. Detail project shall be included along with the application for NOC.

Water Intensive Industries

1. Packaged Drinking Water

2. Mineral Water Plant

3. Tannery

4. Distillery

5. Brewery

6. Soft Drink

7. Paper & Pulp

8. Fertilizer

9. Textile Dyeing

10. Textile Printing

11. Textile Spinning

12.Sugar

13.Dairy Product

14. Water Park & Amusement center

Guide lines / Criteria for Evaluation of requests for Ground Water Abstraction

We at Radico has immediately taken the action and applied to Regional CGWA –

Lucknow wide letter dated 10.05.2016 & 02.07.2016 , our Application was reviewed

and recommended by Regional Director - Lucknow office on 02.08.2016 for

necessary approval from Central Board Authority – Delhi.

Final NOC from the CGWA board Delhi Received on 03.10.206

Action Taken By Radico on CGWA NOC

TOTAL WATER REQUIREMENT

6078 m3/Day

INDUSTRIAL

5628 m3/Day DOMESTIC

10 m3/Day

GREEN BELT AND OTHER

USE

440 m3/Day

CONDENSATE / LEESE/

BLOWSOWNS

3100 m3/Day

WATER FOR RECYCLING

2978 m3/Day

FRESH WATER REQUIREMENT

3100 m3/Day

WATER FOR RECYCLING

2978 m3/Day

Net fresh Water Requirement : 3100.0 M3/ Day

Total Water Requirement : 6078.0 M3/ Day

Water for recycling :2978.0 M3/ Day

Approx 100 % recycling is being achieved after treatment of waste water

and it is a zero waste water discharge unit .

4% LOSS

Water Balance

S.No Stream Recycled Year -2014 Year -2015 Year -2016

1 Pre-rectifier & Rectification Column Lees

Recycled to Fermentation House

2 Vacuum Pump water Recycled to Fermentation House

3 Steam Condensate Recycled to Boiler Section

Recycled to Boiler Section

4 CO2 Scrubber Water Recycled to Fermentation House

5 Process Condensate Recycled to Cooling Tower

6 RO Permeate Recycled to Cooling Tower

Water Consumption /BL of Alcohol

18.0 12.0 8.0

Reduction in Water Consumption through Recycling

Printing Plant – Roof water collection and Water Recharging system

Rain Water Harvesting – Within Premises

RKTC– Roof water collection and Water Recharging system



Fermentation area Roof water collection and Water

Recharging system


ETP area Roof water collection and Water

Recharging system

Number of structure = ---------------------------------------- = ------------ =19.6 or Say 20

Each structure Recharge capacity 288

Twenty structures are suggested for rain water harvesting.

Sl.No.

Land Use TypeArea(m²)

Coefficient of runoff

Intensity of Rainfall

(m)

Quantity of Rainwater

(m³)

1 Roof area (Building) 153407.00 0.800 0.035 4295.39

2Paved Area (Road &

Others)23300.00 0.65 0.035 530.0

3 Green Area 156862.00 0.15 0.035` 823.52

Total 443920 5648.91

Total water available 5648.9

Water available for recharge: 5648.91 m³/hour

Tube well recharge capacity = 50% of average discharge i.e. 1000 lpm

Or 60 m³/hour

One recharge trench capacity = 14.0 x 4.0x 3.0 = 168 m³

One recharge trench+ 2 bore well can recharge = 168+120 = 288 m³/hour

Total water available = 5648.91 m³/hour

Hourly Computation of Runoff (35MM/Hr)

Recharge Pit with Bore-well

Ground Water Level Monitoring Thru

Piezometers

Water Level Monitoring

- Radico had made 35 Nos bore wells at Rampur Village’s pond with an objective to

Tap the Natural water resource available which ultimately raises the water level in

Rampur District….

- Further 50 Nos recharging bore well installation is in pipeline in the ponds of

nearby villages …..

CSR INITIATIVES ON WATER RECHARGING

Water Conservation through Water Recharging

After Rain

Artificial Recharge …. At Village Ponds

Artificial Recharge …. At Various Rampur Village Ponds

CSR – Other Activities

Radico Khaitan understands its responsibility towardssociety. Various activities are being arranged for societyfrom last more than 15 years under CSR.

1. Skill Development & Job Opportunities

2. Infrastructure & Educational Support

3. Academic Excellence Recognition

4. Health Care & Medical Facilities

5. Safe, Clean & Green Environment

6. Sports & Fitness Events

Skill Development & Job Opportunities

CSR Activities

Thank You

by k .p. singh 1 - aidaindia.org · x108 . with the ... power generation through highly efficient...

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