case studies on sludge and water management...sewage generation • according to cpcb report (2009...

Case studies on Sludge andwater management

Centre for Science and Environment

Sujit Kumar Singh

Big question ????????

• Do we know that how much sewage wegenerate

• Do we know that HOW MUCH INDUSTRIALEFFLUENT WE GENERATE

• DO we have updated information (Yes/no)


• Do we know that how much sewage wegenerate

• Do we know that HOW MUCH INDUSTRIALEFFLUENT WE GENERATE

• DO we have updated information (Yes/no)

Sewage generation

• According to CPCB report (2009 – 10) approximately53898 MLD sewage is generated in India including allthe Metropolitan, Class1 and Class 2 cities and only19826.7 MLD of this is treated (around 37%) beforebeing discharged into the water bodies.

• According to CPCB, the total wastewater discharged byall major industrial sources is 83,048 million litres perday (mld) - 2003


• According to CPCB report (2009 – 10) approximately53898 MLD sewage is generated in India including allthe Metropolitan, Class1 and Class 2 cities and only19826.7 MLD of this is treated (around 37%) beforebeing discharged into the water bodies.

• According to CPCB, the total wastewater discharged byall major industrial sources is 83,048 million litres perday (mld) - 2003

Why we do Wastewater Treatment?

• To meet the regulatory standards

• Conventional treatment removes BOD and SS butunable to remove nutrients and complex compound.

• Decreasing assimilative capacity of water bodies

• Water scarcity also pushed industry to opt foradvanced wastewater (Recycle and Reuse)


• To meet the regulatory standards

• Conventional treatment removes BOD and SS butunable to remove nutrients and complex compound.

• Decreasing assimilative capacity of water bodies

• Water scarcity also pushed industry to opt foradvanced wastewater (Recycle and Reuse)

How we can achieve

• Understand - wastewater characteristic

• Estimate the Quantity of wastewater generation

• Check potential of segregation (process &utility)

• Selection of appropriate technology


• Understand - wastewater characteristic

• Estimate the Quantity of wastewater generation

• Check potential of segregation (process &utility)

• Selection of appropriate technology

Approach for wastewater Treatment

Wastewater Treatment


Urban Industrial

Centralized DecentralizedCentralized

DecentralizedSTP Natural process

Characteristic of Sewage


Wastewater Treatment

Wastewater treatment mainly consists

– Preliminary treatment– Primary treatment– Secondary or biological treatment– Advanced treatment


Wastewater treatment mainly consists

– Preliminary treatment– Primary treatment– Secondary or biological treatment– Advanced treatment

Types of Solids

• Suspended solid or filterable solid– floating solid (> 1micron)

• Settleable solids – settled down after providing DT ( > 10micron – NO Coagulant, < 10 micron Coagulant is required)


• Suspended solid or filterable solid– floating solid (> 1micron)

• Settleable solids – settled down after providing DT ( > 10micron – NO Coagulant, < 10 micron Coagulant is required)

Types of Solids

• Colloidal solids – finesolids either in solutionor in suspension (< 1micron to 10-3 micron)

• Dissolved solid – indissolved state (lessthan 10-3 micron)


• Colloidal solids – finesolids either in solutionor in suspension (< 1micron to 10-3 micron)

• Dissolved solid – indissolved state (lessthan 10-3 micron)

Class exercise on DO

• Assume 2.5 ml of raw sewage diluted to 250ml

• Initial DO was 8 mg/lit

• Final DO was 5 mg/lit at three days at 20 C

• Estimate BOD in mg/lit in wastewater


• Assume 2.5 ml of raw sewage diluted to 250ml

• Initial DO was 8 mg/lit

• Final DO was 5 mg/lit at three days at 20 C

• Estimate BOD in mg/lit in wastewater

• Dilution ratio = 250/2.5 = 100

• Loss of dissolved oxygen = 8 – 5 = 3 mg/lit

• BOD = loss of oxygen x dilution factor

• = 3 x 100 = 300 mg/lit


• Dilution ratio = 250/2.5 = 100

• Loss of dissolved oxygen = 8 – 5 = 3 mg/lit

• BOD = loss of oxygen x dilution factor

• = 3 x 100 = 300 mg/lit

Class exercise

• Total sewage coming to STP = 95 MLD

• Average BOD of untreated waste water is300 mg/lit

• Estimate total population discharging ww(assume BOD of sewage 0.08 kg/day/person


• Total sewage coming to STP = 95 MLD

• Average BOD of untreated waste water is300 mg/lit

• Estimate total population discharging ww(assume BOD of sewage 0.08 kg/day/person

Solution

• Total organic load = 300 mg/lit x 95 MLD

• = (300 x 95 x 1000000)/ (1000 x1000)

• = 300 x 95 = 28500 kg/day

• Population equivalent = (Total BOD inkg/day)/ (Per capita BOD in kg/day/person)


• Total organic load = 300 mg/lit x 95 MLD

• = (300 x 95 x 1000000)/ (1000 x1000)

• = 300 x 95 = 28500 kg/day

• Population equivalent = (Total BOD inkg/day)/ (Per capita BOD in kg/day/person)

Waste Stabilisation PondsOrganic matter degradation by heterotrophic bacteria► Algae growth cause decomposition, leading to production of oxygen.► Replenish O2 in the pond and maintain aerobic condition► Microbes grow as suspended particles.


Waste Stabilisation Ponds

• Robust and withstandhydraulic and organic shockload

• Effluent from maturationpond can be used foragriculture and aquaculture

• Very low O&M cost


• Robust and withstandhydraulic and organic shockload

• Effluent from maturationpond can be used foragriculture and aquaculture

• Very low O&M cost

Activated Sludge Process ( ASP )

• Primary wastewater mixed with bacteria-rich (activated) sludge and air or oxygen ispumped into the mixture

• Promotes bacterial growth and decomposition of organic matter• Last step is a settling tank where sludge settles out and then the treated wastewater

moves on for tertiary treatment.• Some settled sludge is used to inoculate incoming primary effluent.


FeaturesHigh BOD removalMicrobial removal:Energy intensive


Aeration tank

Final clarifier

• Movie microbes


Method of Aeration in ASP

• Diffused aerator

• Mechanical aerator

• Combination of both

• Average = 4000 to 8000 m3 of air is required permillion liter of sewage (depend of strength ofsewage)


• Diffused aerator

• Mechanical aerator

• Combination of both

• Average = 4000 to 8000 m3 of air is required permillion liter of sewage (depend of strength ofsewage)

Design criteria

• Volume of return activated sludge - dependof extend of BOD desired to be removed

= i.e. (Qr/ Q), where Qr – return sludge and Qvolume of sewage coming in AT

As thumb rule – quantity of return sludge is 35to 55 % of volume of sewage coming in AT


• Volume of return activated sludge - dependof extend of BOD desired to be removed

= i.e. (Qr/ Q), where Qr – return sludge and Qvolume of sewage coming in AT

As thumb rule – quantity of return sludge is 35to 55 % of volume of sewage coming in AT

Design criteria

• Important terms

(1) Aeration period or HRT

• DT (hr) = Volume of tank/ rate of flow ofsewage


• Important terms

(1) Aeration period or HRT

• DT (hr) = Volume of tank/ rate of flow ofsewage

(2) Volumetric BOD or organic loading – BODload applied per unit volume of aeration tank

• = Mass of BOD applied per day to AT/Volume of tank (m3)

• = (Q x inlet BOD)/ volume


(2) Volumetric BOD or organic loading – BODload applied per unit volume of aeration tank

• = Mass of BOD applied per day to AT/Volume of tank (m3)

• = (Q x inlet BOD)/ volume

(3) Food (F) to microorganism (M) ratio

• Food = Q x inlet BOD to AT

• Microorganism (M) = MLSS x volume of tank


(3) Food (F) to microorganism (M) ratio

• Food = Q x inlet BOD to AT

• Microorganism (M) = MLSS x volume of tank

OXYGEN REQUIREMENT AND TRANSFER

– Depends on BOD of wastewater– Amount of organisms wasted per day– Minimum oxygen level of 1 to 2 mg/l in Aeration

Tank– For F/M ratio of 0.3, air requirement is 30 to 55

m3/kg of BOD removed


– Depends on BOD of wastewater– Amount of organisms wasted per day– Minimum oxygen level of 1 to 2 mg/l in Aeration

Tank– For F/M ratio of 0.3, air requirement is 30 to 55

m3/kg of BOD removed

Sludge digestion

Sludge from primary and secondarysettling tanks (including waste activatedsludge must be treated in digesters.Sludge is thickened before passing intothe digesters

Sludge is treated anaerobically;Methane production takes place.

Biogas is used as fuel.


Sludge from primary and secondarysettling tanks (including waste activatedsludge must be treated in digesters.Sludge is thickened before passing intothe digesters

Sludge is treated anaerobically;Methane production takes place.

Biogas is used as fuel.

Membrane Bio-Reactors (MBR)

► Combination of membrane process like micro-filtration or ultra-filtration with suspended growth bio-reactor.

► Pore size of filter used: 0.003-0.01micrometer.► Provide better biodegradability and cell synthesis.


Difference between ASP and MBR


Membrane


Type - microfiltration, ultrafiltrationCan operate at high MLSS concentration upto 15,000-25,000 mg/L

Comparison of MBR Schematic Vs convention AS Process


• Configurations include internal MBR and externalMBR.

• Produces high quality effluent with a relatively smallfootprint. Old plants can be retrofit, easily upgraded toMBR.


• Configurations include internal MBR and externalMBR.

• Produces high quality effluent with a relatively smallfootprint. Old plants can be retrofit, easily upgraded toMBR.

Advantages

• Can eliminate secondary clarifier and operate at higher MLSS concentration.

• Higher volumetric loading rates; thus shorter HRTs.

• Longer solids retention time resulting in less sludge.

• Operate at low DO with potential of simultaneous nitrification-denitrificationin longer SRT designs.

• Less space requirements: saves land costs; facilitates upgradation of oldplants.


Advantages

• Can eliminate secondary clarifier and operate at higher MLSS concentration.

• Higher volumetric loading rates; thus shorter HRTs.

• Longer solids retention time resulting in less sludge.

• Operate at low DO with potential of simultaneous nitrification-denitrificationin longer SRT designs.

• Less space requirements: saves land costs; facilitates upgradation of oldplants.

Disadvantages

• High capital costs.

• Limited data on membrane life.

• Potential high cost of periodic membrane replacement.

• Higher energy costs.

• Need to control membrane fouling.


Disadvantages

• High capital costs.

• Limited data on membrane life.

• Potential high cost of periodic membrane replacement.

• Higher energy costs.

• Need to control membrane fouling.

► BOD removal 95%. Can be increased up to96-99%.

► Effluent TSS is very low, Total P <0.1mg/l andextensive Total N removal.

Features of MBR


► BOD removal 95%. Can be increased up to96-99%.

► Effluent TSS is very low, Total P <0.1mg/l andextensive Total N removal.

MBR at ITC Maurya, New Delhi

► Installed Capacity: 800 KLD► Total capital investment: 2.5

crores► O&M cost : Rs 20/KL

Kitchen waste

Grease Traps(10)

Treated water

Equalization tanks with blowers


Bar screens (3)

MBR

Softner

Treated water

100-125 KLDto coolingtowers

10-15KLD to fountainsmake up water

60-100 KLDfor horticulturepurposes

30-50 KLD to NDMC for Horticulture

Moving Bed Biological Reactor (MBBR)

► Aeration is done in such a way to ensure thorough mixing andproper turnover of the media within the reactor.

► Efficient removal of carbonaceous and nitrogenous waste.



Reactors are filled with plastic carriers to provide surface


Screens are placed onthe downstream walls,to prevent media fromflowing out

• Clarifier or DAF is placed at the downstream to separate thebiomass. No sludge recycle is required.

• During operation, carriers are kept in constant recirculation.– In aerobic: through introduction of air by coarse air bubble diffuser.– In anoxic, through submerged mixers.

• Carriers can occupy upto 50 to 70% of reactor volumes.


• Clarifier or DAF is placed at the downstream to separate thebiomass. No sludge recycle is required.

• During operation, carriers are kept in constant recirculation.– In aerobic: through introduction of air by coarse air bubble diffuser.– In anoxic, through submerged mixers.

• Carriers can occupy upto 50 to 70% of reactor volumes.

Advantage : MBBR

• Robust: Stable under load variation and provides consistenttreatment results.

• Compact: typically requires 1/3rd of the space for aconventional AS process.

• Cost: Low capital costs similar to AS.

• Flexible: Existing plants can be upgraded with an MBBR.

• Trouble free: Easy to operate, and no issues of media clogging


• Robust: Stable under load variation and provides consistenttreatment results.

• Compact: typically requires 1/3rd of the space for aconventional AS process.

• Cost: Low capital costs similar to AS.

• Flexible: Existing plants can be upgraded with an MBBR.

• Trouble free: Easy to operate, and no issues of media clogging

Sequencing Batch Reactor (SBR)


Sequencing Batch Reactor (SBR)

• It is a single reactor which operates in a batchtreatment mode repeating a sequencecontinuously.

• It is a fill & draw activated sludge system

• Reaction & Settling takes place in the samereactor


• It is a single reactor which operates in a batchtreatment mode repeating a sequencecontinuously.

• It is a fill & draw activated sludge system

• Reaction & Settling takes place in the samereactor

• It comprises of four phases.i. Fillingii. Aeration & Reactioniii. Settlingiv. Decanting


• It comprises of four phases.i. Fillingii. Aeration & Reactioniii. Settlingiv. Decanting

Step 1 : Filling


Step 2 : Aeration & Reaction

Aeration time depend on size & Wastewater quality; typically is 60-90min. Higher time upto 3 hr. required for nitrification.Phosphorus removal is aided by adding aluminum sulphate (alum).


Step 3: Settling

•Usually same time as that of aeration•Aerobic bacteria continues to multiply till DO is used up. Conditions are now suitable for anaerobic bacteria toflourish (especially near tank bottom).


Step 4: Decantin

Decanter

The outlet valve opens and the clean supernatant liquor exits the tank


Decanter

Delawas Jaipur - Waste to Energy STP

• STP commissioned in 2006, capacity of 62.5 MLD

• Based on aerobic biological process (ASP) withdiffused aerator

• Waste to Energy made STP self sufficient (75%energy demand)


• STP commissioned in 2006, capacity of 62.5 MLD

• Based on aerobic biological process (ASP) withdiffused aerator

• Waste to Energy made STP self sufficient (75%energy demand)

Salient Features of 62.50 MLD STP


Advantage

• Prior commissioning of biogas plant =average monthly power consumption was208653 Kwh /month (grid)

• After power generation at plant site fromDecember, 2009 to April, 2012, the averagepower consumed from grid is only 55479Kwh/month (73% from biogas and rest fromgrid)


• Prior commissioning of biogas plant =average monthly power consumption was208653 Kwh /month (grid)

• After power generation at plant site fromDecember, 2009 to April, 2012, the averagepower consumed from grid is only 55479Kwh/month (73% from biogas and rest fromgrid)

Thumb Rule (conventional ASP)

• Average consumption of new plant 127-134 Kwh/MLD ofsewage treated

• Old plant 180-225 Kwh/MLD

• New plant 4.24-4.48 Kwh/Kg of BOD removed

• Thumb Rule approx 100 MLD capacity plant = potential toproduce 1 MW

• Note: Power consumption accounts for almost 75% of theexpenditure on O and M of any sewage treatment plant


• Average consumption of new plant 127-134 Kwh/MLD ofsewage treated

• Old plant 180-225 Kwh/MLD

• New plant 4.24-4.48 Kwh/Kg of BOD removed

• Thumb Rule approx 100 MLD capacity plant = potential toproduce 1 MW

• Note: Power consumption accounts for almost 75% of theexpenditure on O and M of any sewage treatment plant

Cost of ASP

• Land requirement (hectares/MLD installedcapacity) = 0.15 to 0.25

• O&M cost (million/year/ MLD installedcapacity) = Rs 0.3 to 0.5

• Capital cost (million /MLD capacity) = Rs 2 to 4


• Land requirement (hectares/MLD installedcapacity) = 0.15 to 0.25

• O&M cost (million/year/ MLD installedcapacity) = Rs 0.3 to 0.5

• Capital cost (million /MLD capacity) = Rs 2 to 4

Surat - Biogas to Energy generation


Gas Characteristic


Economic


Case study – Delhi STP

• 45 MGD sewage treatment plant (STP) at Kondliproducing = 10,000 kWh

• At Okhla STP, 12,000 KWH and at Rithala STP20,000 KWH

• Delhi produces 3800 MLD sewage = potential toproduce = 38 MWh


• 45 MGD sewage treatment plant (STP) at Kondliproducing = 10,000 kWh

• At Okhla STP, 12,000 KWH and at Rithala STP20,000 KWH

• Delhi produces 3800 MLD sewage = potential toproduce = 38 MWh

Coal-based Power Sector

Centre for Science and Environment Centre for Science and Environment

Water stress – power plant location


Water Consumption

• Water: 70 % of the total withdrawal byindustries ~22 BCM

• Excess water consumption:Avg 4m3/MWh; Best ~2m3/MWh; Worst

~10m3/MWh

• A survey conducted by FICCI and ColumbiaUniversity Water Center reveal that ~ 87% ofcompanies believe that water availability willimpact their business over the next decade.


• Water: 70 % of the total withdrawal byindustries ~22 BCM

• Excess water consumption:Avg 4m3/MWh; Best ~2m3/MWh; Worst

~10m3/MWh

• A survey conducted by FICCI and ColumbiaUniversity Water Center reveal that ~ 87% ofcompanies believe that water availability willimpact their business over the next decade.

News from Maharashtra

• Due to severe water shortage - All six units of Parlithermal power plant shut down (Beed district ofMaharashtra) February (2013), resulting in a loss ofrevenue from stoppage of generation units

• During the recent drought in Maharashtra, powerplants came in for severe criticism with regard to theirwater consumption

• Nashik Municipal Corporation has committed to pro-vide treated sewage water (~190 MLD) instead offreshwater for the upcoming 2x660 MW power plant ofIndia Bulls. Requires additional investment for watertreatment for input to power plant


• Due to severe water shortage - All six units of Parlithermal power plant shut down (Beed district ofMaharashtra) February (2013), resulting in a loss ofrevenue from stoppage of generation units

• During the recent drought in Maharashtra, powerplants came in for severe criticism with regard to theirwater consumption

• Nashik Municipal Corporation has committed to pro-vide treated sewage water (~190 MLD) instead offreshwater for the upcoming 2x660 MW power plant ofIndia Bulls. Requires additional investment for watertreatment for input to power plant

Class exercise

• Estimate the water requirement, if thecapacity of plant is power plant (coal) – 1000MW

• Assume 4 to lit/Kwh, closed loop


• Estimate the water requirement, if thecapacity of plant is power plant (coal) – 1000MW

• Assume 4 to lit/Kwh, closed loop

Question

• Consider the scenario of a 1,000 MW powerplant shutdown its operations for one daydue to unavailability of water

• Question - Potential revenue loss (assumingRs 3/unit)


• Consider the scenario of a 1,000 MW powerplant shutdown its operations for one daydue to unavailability of water

• Question - Potential revenue loss (assumingRs 3/unit)

Pulp & Paper

Case study TNPL Paper mill

– Water consumption in 1995-96 = 200m3/paper

– In 2013 water consumption reduced to 58m3/tonne product (70% reduction)

– In May – June, specific waterconsumption dropped to as low as 34 m3


Case study TNPL Paper mill

– Water consumption in 1995-96 = 200m3/paper

– In 2013 water consumption reduced to 58m3/tonne product (70% reduction)

– In May – June, specific waterconsumption dropped to as low as 34 m3

Biogas generation from Wastewater

• Bagasse received from sugar mill having 3-4% residualsugars is stored in the open yard by wet bulk storagemethod for a period of 3 to 9 months. During storage, thebagasse is kept under wet condition by spraying waterover bagasse pile to preserve bagasse quality.

• TNPL is using nearly 9000 M3 fresh water/treated effluentin the bagasse handling and storage area. Papermachine wastewater, which contains relatively low TDS,was use

• Waste water generation = around 10,000 to 14,000 m3 ofwastewater from Bagasse storage yards and Bagassewashing


• Bagasse received from sugar mill having 3-4% residualsugars is stored in the open yard by wet bulk storagemethod for a period of 3 to 9 months. During storage, thebagasse is kept under wet condition by spraying waterover bagasse pile to preserve bagasse quality.

• TNPL is using nearly 9000 M3 fresh water/treated effluentin the bagasse handling and storage area. Papermachine wastewater, which contains relatively low TDS,was use

• Waste water generation = around 10,000 to 14,000 m3 ofwastewater from Bagasse storage yards and Bagassewashing

Flow diagram – water use for wetting bagasse

Freshwater

Paper machinewastewater

Clarifier


ETP

Legend:

Before ProjectAfter Project

Fresh water saving :3000m3/day

Clarifier

Bagasse storage &washing

ETP

Water characteristic and biogasgeneration


BioBio--methanationmethanation PlantPlant

GasGasHolderHolder

MOLMOLTankTank

UASBUASBReactorReactor

AA

UASBUASBReactorReactor

BBLimeLime--KilnKiln


Equal.Equal.TankTank

SludgeSludgePitPit

DecanterDecanterCentrifugeCentrifuge

BufferBufferTankTankClarifierClarifier

Neutral.Neutral.TankTank

MOLMOLTankTank

SludgeSludgeforfor

DisposalDisposal

To ActivatedTo Activatedsludge processsludge process

Bagasse.Bagasse.WashWash

EffluentEffluent

Nut.Nut.TankTank

Project cost was Rs.4.00 crores.


Gas firing in Lime Kiln


Economic and pollution reduction benefit

Particulars Units 2013-14COD Treated MT / Yr 21577COD Reduced MT / Yr 18917Biogas generation M3 / Yr 9663897


Biogas generation M3 / Yr 9663897Furnace oil saving KL / Yr 5798

Revenue fromFurnace Oil Saving

Rs. (in Million) 265.9

Reducing water tread in Pulp & Paper


Specific water consumption


Specific water consumption in Indian steel plantsis compared to the global average of waterconsumption


Case study: Reuse of BangaloreSewage at Airport

• The STP plant at Yelahanka, treats 10 MLD ofsewage water, and gets Rs. 22, 00,000 everymonth by selling the tertiary treated water toindustries like Bharat Electronics Limitedand Bangalore International Airport


• The STP plant at Yelahanka, treats 10 MLD ofsewage water, and gets Rs. 22, 00,000 everymonth by selling the tertiary treated water toindustries like Bharat Electronics Limitedand Bangalore International Airport

Case study : Ganga Ram Hospital - Recycle andreuse of hospital water for flushing and gardening

CollectionTank

Aeration TankSecondary

Settling Tank

Sludge HoldingTank

MultiGradeFilter

ActivatedCarbonFilter

ChlorineContact Tank


To Sludge DisposalPumps / Filter press

TreatedWater Tank

Ozonator

TreatedWater

Note: Planning to use treated water in cooling towers ofair-conditioning plants by installing softeners

MBR at ITC Maurya, New Delhi

► Installed Capacity: 800 KLD► Total capital investment: 2.5

crores► O&M cost : Rs 20/KL

Kitchen waste

Grease Traps(10)

Treated water

Equalization tanks with blowers


Bar screens (3)

MBR

Softner

Treated water

100-125 KLDto cooling

towers

10-15KLD to fountainsmake up water

60-100 KLDfor horticulture

purposes

30-50 KLD to NDMC for Horticulture

Recycle and reuse of wastewater in vehicle washfacility of TATA Motors, New Delhi, India


Minimum criteria for wastewatertreatment


• The combined approximate cost ofconstruction of mud separator (grit chamber)and oil/ grease trap is around Rs. 7 per litre.

• For example, if vehicle wash operator wantsto treat 1 KL of wastewater per day, theconstruction cost will be around Rs. 7,000.

• See Flow diagram for Zero discharge


• The combined approximate cost ofconstruction of mud separator (grit chamber)and oil/ grease trap is around Rs. 7 per litre.

• For example, if vehicle wash operator wantsto treat 1 KL of wastewater per day, theconstruction cost will be around Rs. 7,000.

• See Flow diagram for Zero discharge

Effluent Treatment Plant and parameters –dyeing, printing cotton and blended textileproducts


Effluent Treatment Plant and parameters –Garment Washing Unit


Flow diagram to achieve zero discharge in atextile plant


Case Study 1: Zero discharge in Ranbaxy


Step 2: Technology selection based on effluentcharacteristic


Case Study 2: Zero discharge in Dr.Reddy’s Laboratories


SUGAR INDUSTRY DISTILLERY INDUSTRY

SUGAR & DISTILLERY


Sujit Kumar Singh, Programme Manager, CSE

Sugar – An Eco-Friendly IndustryWhat we take and What we Give back

SugarCane

Sugar MillSugarRefined Sugar

BagasseMolasses

Press Mud


Molasses

Press Mud

Power Plant

Distillery

Rectified SpiritAbsolute AlcoholENA

Ash

Waste Water /Spent Wash

Organic ManurePlant& Biocompost

Organic ManurePlant& Biocompost

Bio-compostManure

Power

Indian Sugar Industry at a glance

Sr. Particulars Crushing Season

2007-2008 2008-2009 2009-20102010-2011E

1 No. of Sugar Factories in Operation 516 488 500 520

2 Crushing Capacity (million TCD) 22.48 23.001 23.7 25


2 Crushing Capacity (million TCD) 22.48 23.001 23.7 25

3 Sugarcane Crushed (million tons) 250 145.0 180.0 220.0

4 Sugar Produced (million tons) 26.357 14.538 18.63 23.1

5 Recovery % Cane 10.55 10.03 10.35 10.5

6 Yield of sugarcane (tons per hectare) 68.9 62.3 65 66

7 Molasses Production (million tons) 11.25 6.52 8.10 9.90

Raw material

• Sugar mills consume large quantity of water; thewater consumption can be brought down to 100litres per tonne (L/T) of cane crushed by recyclingcooling and condensate

• Two type of water is used – Cold and hot condensewater (used as boiler feedback water, juice dilution,lime and sulphate preparation, dilution, molassesconditioning, etc.

• Recycling and reuse of hot condensate water canreduce the water consumption to as low as 100-200litres, as against 1,500-2,000 litres per tonne of canecrushed


• Sugar mills consume large quantity of water; thewater consumption can be brought down to 100litres per tonne (L/T) of cane crushed by recyclingcooling and condensate

• Two type of water is used – Cold and hot condensewater (used as boiler feedback water, juice dilution,lime and sulphate preparation, dilution, molassesconditioning, etc.

• Recycling and reuse of hot condensate water canreduce the water consumption to as low as 100-200litres, as against 1,500-2,000 litres per tonne of canecrushed

SUGAR INDUSTRY BY-PRODUCTS ; EFFLUENT STREAMS ;TREATMENT & UTILIZATION

1) BAGASSE :a) PRODUCED ABOUT 27-30% OF CANE CRUSHED ; CONTAINS 50%

MOISTURE ; 50% SOLIDS, MAINLY FIBRES

b) CALORIFIC VALUE OF 2000-2200 Kcal /Kg

c) COMPLETELY CONSUMED IN OWN STEAM & POWER GENERATION

d) REQUIRES LARGE STORAGE AREAS ; CAN BE PROCESSED INTOCUBICAL BLOCKS FOR LONGER & COMPACT STORAGE.


1) BAGASSE :a) PRODUCED ABOUT 27-30% OF CANE CRUSHED ; CONTAINS 50%

MOISTURE ; 50% SOLIDS, MAINLY FIBRES

b) CALORIFIC VALUE OF 2000-2200 Kcal /Kg

c) COMPLETELY CONSUMED IN OWN STEAM & POWER GENERATION

d) REQUIRES LARGE STORAGE AREAS ; CAN BE PROCESSED INTOCUBICAL BLOCKS FOR LONGER & COMPACT STORAGE.

2) PRESS MUD :a) PRODUCED ABOUT 4-5% OF CANE CRUSHED ; CONTAINS 60%

MOISTURE ; 40% SOLIDS, MAINLY MUD & WAX.b) EARLIER USED TO BE SENT BACK TO SUGARCANE FIELDS AS

IS.c) PRESENT USEAGE IN BIO-COMPOSTING; VALUE ADDITION IN

TERMS OF N:P:K VALUE USING TREATED MOLASSES SPENTWASH IN DISTILLERIES. FORMS BIO-FERTILIZER & USEDMORE EFFECTIVELY BACK IN SUGARCANE FIELDS.

SUGAR INDUSTRY BY-PRODUCTS ; EFFLUENT STREAMS ;TREATMENT & UTILIZATION

3) MOLASSES :

a) PRODUCED ABOUT 4.5-5% OF CANE CRUSHED ; CONTAINS 20%MOISTURE ; 80% SOLIDS, 38-45% FERMENTABLE SUGARS

b) OTHER SOLIDS INCLUDE UNFERMENTABLE SUGARS & CHEMICALSADDED IN SUGAR MILLS INCLUDING CaCO3, MgSO4, Sulphur, Etc.

c) MAY CONTAIN VOLATILE ACIDS DUE TO FORMATION OF WEAKACIDS DURING LONG STORAGES.

d) COMPLETELY CONSUMED IN DISTILLERIES FOR ALCOHOLPRODN.

e) REQUIRES CLOSED TANK STORAGE ; CONSTANT COOLINGARRANGEMENT ; VALUABLE BY-PRODUCT.


3) MOLASSES :

a) PRODUCED ABOUT 4.5-5% OF CANE CRUSHED ; CONTAINS 20%MOISTURE ; 80% SOLIDS, 38-45% FERMENTABLE SUGARS

b) OTHER SOLIDS INCLUDE UNFERMENTABLE SUGARS & CHEMICALSADDED IN SUGAR MILLS INCLUDING CaCO3, MgSO4, Sulphur, Etc.

c) MAY CONTAIN VOLATILE ACIDS DUE TO FORMATION OF WEAKACIDS DURING LONG STORAGES.

d) COMPLETELY CONSUMED IN DISTILLERIES FOR ALCOHOLPRODN.

e) REQUIRES CLOSED TANK STORAGE ; CONSTANT COOLINGARRANGEMENT ; VALUABLE BY-PRODUCT.

4) BOILER ASH :

a) BOILER ASH, GENERALLY 2% OF BAGASSES USED, IS PASSEDTHROUGH WET SCRUBBER SYSTEM & SLAG IS REMOVED & STOREDIN SILOS. LATER IT IS SENT FOR LAND FILLING APPLICATIONS INPRE-IDENTIFIED LOW LINE AREAS. THIS SMALL QUANTITY IS ALSOUTILIZED ALONGWITH PRESSMUD IN BIO-COMPOSTING PROCESS.

Characteristics of Combined waste Water

Parameter Range of ValueTemperature, (°C) 30-40

PH 4.6-6.0

Dissolved solids 1000-1200


Dissolved solids 1000-1200

Suspended Solids 250-300

Oil and Grease 5-10

COD 2000-3000

BOD 1000-1500

• Class exercise – pls suggest treatmentoption


• Class exercise – pls suggest treatmentoption

ALCOHOL PRODUCTION IN INDIA : 2600 MILLION LITERS

USE OF ALCOHOL :

A) INDUSTRIAL USE – ALCOHOL BASED CHEMICALS (25%) : 650 ML

B) FUEL ETHANOL – ABSOLUTE ALCOHOL (25%) : 650 ML

C) POTABLE ALCOHOL – EXTRA NEUTRAL ALCOHOL (50%) : 1300 ML


ALCOHOL PRODUCTION IN INDIA : 2600 MILLION LITERS

USE OF ALCOHOL :

A) INDUSTRIAL USE – ALCOHOL BASED CHEMICALS (25%) : 650 ML

B) FUEL ETHANOL – ABSOLUTE ALCOHOL (25%) : 650 ML

C) POTABLE ALCOHOL – EXTRA NEUTRAL ALCOHOL (50%) : 1300 ML

ALCOHOL PRODUCTION IN INDIA : 2600 MILLIONLITERS

RAW MATERIALS :

A) MOLASSES – FROM SUGAR MILLS (80%) :

B) GRAINS / STARCH – BROKEN/DAMAGED/SPOILT (19.8%) :

C) CANE /SWEET SORGHUM JUICE – FUEL ETHANOL (0.2%) :


I) MOLASSES BASED DISTILLERIES – BROAD CLASSIFICATION

A) SUGAR MILL ATTACHED DISTILLERIES – OWN MOLASSES & PRESSMUD

B) STANDALONE DISTILLERIES – PURCHASED MOLASSES & PRESS MUD


A) SUGAR MILL ATTACHED DISTILLERIES – OWN MOLASSES & PRESSMUD

B) STANDALONE DISTILLERIES – PURCHASED MOLASSES & PRESS MUD

II) GRAIN BASED DISTILLERIES – CLASSIFICATION

A) STARCH BASED DISTILLERIES – HAVE OWN STARCH SURPLUS

B) GRAIN BASED DISTILLERIES – BROKEN GRAINS

Case study : Rega distillery in Bihar

• Mill was surveyed by CSE in 2008• Survey finding

– Illegal discharge of Spent Wash in the river– Illegal dumping of Spent Wash on private land and along road

side within 5 km


• Mill was surveyed by CSE in 2008• Survey finding

– Illegal discharge of Spent Wash in the river– Illegal dumping of Spent Wash on private land and along road

side within 5 km


Illegal discharge of spentwash on private land


Illegal discharge of spent wash on private land/govt land


Illegal discharge of spentwash in low lying area

Dead frog – impact due to discharge of spent on land


Dead frog – impact due todischarge of spent on land


Industry discharge wastewater inriver during night



Dead Snake – impact due toillegal discharge of spent

Bird carcass due to illegal discharge of spent on land


Illegal discharge of spent wash in river during night: impacton water river characteristic


Industry discharge wastewater in river during night


Illegal discharge of spent wash in river during night: impact onwater characteristic


People complain about cattle death and skin infection


• Molasses, a by-product of sugar industryused as raw material.

• The molasses contains about 40-50% sugar,which is diluted to bring sugar contents to10-15%.


• Molasses, a by-product of sugar industryused as raw material.

• The molasses contains about 40-50% sugar,which is diluted to bring sugar contents to10-15%.

• In India, alcohol is manufactured by twoprocesses

– Batch process

– Continuous process


• In India, alcohol is manufactured by twoprocesses

– Batch process

– Continuous process

Water requirement

• Water consumption - 25 to 28 lit/lit of alcohol

• New – 22 lit/lit of alcohol, after adoptingrecycle and reuse water consumption gonedown to 15 lit/lit of alcohol

• Starch/grain (old) 26 – 30 lit/lit of alcohol,after adopting recycle and reuse waterconsumption gone down to 13 to 15 lit/lit ofalcohol


• Water consumption - 25 to 28 lit/lit of alcohol

• New – 22 lit/lit of alcohol, after adoptingrecycle and reuse water consumption gonedown to 15 lit/lit of alcohol

• Starch/grain (old) 26 – 30 lit/lit of alcohol,after adopting recycle and reuse waterconsumption gone down to 13 to 15 lit/lit ofalcohol

Wastewater sources

Sources of wastewater for molasses based distilleries

Process waste streams

• Spent wash from the analyser column• Fermenter sludge• Spent lees from the rectifier

Non-process waste streams

• Cooling water• Waste wash water• Water treatment plant wastewater• Boiler blow down• Bottling plant wash wastewater• Other wastes


Sources of wastewater for molasses based distilleries

Process waste streams

• Spent wash from the analyser column• Fermenter sludge• Spent lees from the rectifier

Non-process waste streams

• Cooling water• Waste wash water• Water treatment plant wastewater• Boiler blow down• Bottling plant wash wastewater• Other wastes

Characteristics of Spent Wash from Various Types ofmanufacturing process


Process Stream Discharge from DistilleriesBased on Molasses


Spent wash


Ferti-irrigation• Biomethanation – aerobic treatment -- effluent should

not exceed 500 mg/L -- diluted with freshwater prior toirrigation (100 mg/lit)

• Disadvantage:– Requires large land area and fresh water for dilution, pose risk of ground

water pollution– Requires proper monitoring and supervision– Past experience were not satisfactory

• For example, a plant of capacity 30 kld alcoholproduction will requires 270 ha of minimum land forirrigation. Many state pollution control boards areprohibiting this method


• Biomethanation – aerobic treatment -- effluent shouldnot exceed 500 mg/L -- diluted with freshwater prior toirrigation (100 mg/lit)

• Disadvantage:– Requires large land area and fresh water for dilution, pose risk of ground

water pollution– Requires proper monitoring and supervision– Past experience were not satisfactory

• For example, a plant of capacity 30 kld alcoholproduction will requires 270 ha of minimum land forirrigation. Many state pollution control boards areprohibiting this method

Treatment, Recycle & ReuseTreatment, Recycle & ReuseA. Spent wash – Cane Molasses

Bio -CompostingSpent Wash

10-20 % Recycle To Fermentation(Depends on Molasses Quality)

Biodigester

Option – I : Biomethanation & BioCompostingRoute



Bio -CompostingSpent Wash


Bio-digester RO/Evapn

Hence, Zero Discharge of Effluent in Surface Waters is achieved

Bio-digester


Centre for Science and EnvironmentRO PLANT – YASHRAJ – Alcohols (MAH)

• 1 kg of press mud – absorb 2.5 to 3 lit ofspent wash

• 60% distillery in India adopted this method


• 1 kg of press mud – absorb 2.5 to 3 lit ofspent wash

• 60% distillery in India adopted this method

Bio-composting


Bio-compost Bagging


CALCULATION OF COMPOSTINGCALCULATION OF COMPOSTING

• CRITERIA:• Press mud/spent wash ratio= 1:3• Thumb rule – on 1 Acre land = 850 T press mud can be laid

down• Maximum = 5 cycle /year (No Composting rainy season)• 1 cycle = 60 days• EXAMPLE

40 KL/day Distillery• Spent generation – 40 x 12 = 480 KL/day• For 1 cycle , spent wash required – 60 x 40 x 12 KL• Press mud required – (60 x 40 x 12 ) /3 T = 9600T











• To lay down 9600T press mud on land ,area required =9600/850 =11.29 Acre land

• 30% more land required for finished product as well aspress mud storage = 3.5 acre

• Total Land = 11.5 +3.5 = 15 Acre

• If R.O is used = 7.5 Acre land is required



• Total Land = 11.5 +3.5 = 15 Acre





• Total Land = 11.5 +3.5 = 15 Acre




• Total Land = 11.5 +3.5 = 15 Acre


Q1. There is 30KL /day Alcohol production indistillery attached to a sugar factory of capacity2500 T/day, The factory has 10 acre land. Whatshall be choice of distillery to treat the spentwash?

Q2. There 50 KL/day alcohol production in adistillery, there is a sugar factory of capacity5000T/day. The factory has 15 Acre extra land.What shall be the choice of a distillery to treat thespent wash?








• Solution:• Problem1: Spent wash = 30 x 12 = 360 KL/day• 60 days is one cycle for composting ,spent wash= 60 x 360 Kl• 1 acre land = 850 T press mud per cycle• Press mud required = (60 x 360)/3T = 7200T• 10 acre of land = 850 x 10 T premud can be laid down in cycle =

8500T• To lay down 7200 T press mud = 7200/850 = 8.5 Acre.• 30% more land is required = 2.5• Total land = 8.5 + 2.5 = 11 acre• Land available 10 Acre• Therefore RO shall be installed before composting.


• Solution:• Problem1: Spent wash = 30 x 12 = 360 KL/day• 60 days is one cycle for composting ,spent wash= 60 x 360 Kl• 1 acre land = 850 T press mud per cycle• Press mud required = (60 x 360)/3T = 7200T• 10 acre of land = 850 x 10 T premud can be laid down in cycle =

8500T• To lay down 7200 T press mud = 7200/850 = 8.5 Acre.• 30% more land is required = 2.5• Total land = 8.5 + 2.5 = 11 acre• Land available 10 Acre• Therefore RO shall be installed before composting.

• Problem 2: Spent wash = 50 x 12 = 600 KL/day• Spent Wash required for composting = 60 x 50 x12 = 36000KL• Press mud required = 36000/3 = 12000 T• 15 Acre land 850 x 15 = 12,750 T• To lay down 12,750 T press = 12,750/850 = 14.11• 30% More land = 4.23• Total land 4.23 +14.11 = 18.34• However , press mud availability is less• Press mud available for a cycle 5000x.04x60= 12000T• Excess amount of spent wash shall be incinerated or fresh mud

shall be collected.


• Problem 2: Spent wash = 50 x 12 = 600 KL/day• Spent Wash required for composting = 60 x 50 x12 = 36000KL• Press mud required = 36000/3 = 12000 T• 15 Acre land 850 x 15 = 12,750 T• To lay down 12,750 T press = 12,750/850 = 14.11• 30% More land = 4.23• Total land 4.23 +14.11 = 18.34• However , press mud availability is less• Press mud available for a cycle 5000x.04x60= 12000T• Excess amount of spent wash shall be incinerated or fresh mud

shall be collected.

Concentration followed by incineration(best practice)

Method 1• Power generation - SW is concentrated up to 50-60 per

cent and fired in boiler, with or without subsidiary fuel

• Exhaust steam from power plant is used in distilleryand concentration of SW though MEE (e.g of completeZLD)

Method 2• Possible to concentrate SW up to 40-50% and mix it

with rice husk, bagasse etc. and dryed in a rotary dryerto about 75-80 % solids and use it for power generation


Method 1• Power generation - SW is concentrated up to 50-60 per

cent and fired in boiler, with or without subsidiary fuel

• Exhaust steam from power plant is used in distilleryand concentration of SW though MEE (e.g of completeZLD)

Method 2• Possible to concentrate SW up to 40-50% and mix it

with rice husk, bagasse etc. and dryed in a rotary dryerto about 75-80 % solids and use it for power generation

Concentration & Burning of Spent-wash

SPENTWASH 12 M3/ KL

REBOILERS


REBOILERS

SPENTWASH10-11 M3/ KL

EVAPORATOR

CONDENSATECONCENTRATE

BURNING PROCESS

CONCENTRATE 2 -3M3/ KL

CONDENSATE 7 - 8M3/ KL

Treatment, Recycle & ReuseTreatment, Recycle & ReuseA. Spent wash - MolassesOption – II : Concentration & IncinerationRoute

IncinerationBoiler

Evaporation(Concentration)


Spent Wash



Concentration followed byincineration

Advantages

• Spent wash is used as fuel, every kg of concentrated spentwash replaces nearly 0.33 kg of Indian coal

• Less land requirement

• Zero liquid discharge

• Independent from monsoon, statutory requirements, etc.

• Energy conservation - no separate boiler for steam generation,exhaust steam for power plant can be use in process andoperating evaporator.


Advantages

• Spent wash is used as fuel, every kg of concentrated spentwash replaces nearly 0.33 kg of Indian coal

• Less land requirement

• Zero liquid discharge

• Independent from monsoon, statutory requirements, etc.

• Energy conservation - no separate boiler for steam generation,exhaust steam for power plant can be use in process andoperating evaporator.


• Standalone factory – no other option

• Ash generated from the boiler has high potashcontent, which can be used in fields for improvingsoil conditions

• Promotes water conservation

• No requirement of storage lagoons and hence lesserchances of pollution


• Standalone factory – no other option

• Ash generated from the boiler has high potashcontent, which can be used in fields for improvingsoil conditions

• Promotes water conservation

• No requirement of storage lagoons and hence lesserchances of pollution


• According to Mr. M. Prakash (V.P., EID Parry)

• Economically viable to generate power from SpentWash if plant capacity >45 KLPD of alcoholproduction

– Capital cost is Rs. 2 crore per KL of alcohol– O&M cost is Rs. 1.50 /liter alcohol.– Payback period is 4.5 to 5 years


• According to Mr. M. Prakash (V.P., EID Parry)

• Economically viable to generate power from SpentWash if plant capacity >45 KLPD of alcoholproduction

– Capital cost is Rs. 2 crore per KL of alcohol– O&M cost is Rs. 1.50 /liter alcohol.– Payback period is 4.5 to 5 years

Case study - Sivaganga distillery

Capacity 60 KLPD, Molassesbased

Cost of the Project Rs. 90 Crores

Cost for incineration Rs. 38 crores

Water requirement Total 853 m3/day, of total 380 m3/day is fresh waterand 473 m3/day condensate and recycle water fromevaporator


Water requirement Total 853 m3/day, of total 380 m3/day is fresh waterand 473 m3/day condensate and recycle water fromevaporator

Capacity of power plant 1.6 MWhCoal to spent wash ratio On weight basis (norms 30 : 70, but actual they are

using 20:80)Ash from power plant Ash is rich in nutrient contains total potash >19% and

water soluble potash >15% is transformed intogranules and sold in the market


View of MEE

Cost economicss.no. Bio-methanization followed by

Bio-composting Concentration followed by incineration

1 Steam – No cost as requirement met fromBiogas

Steam – Requires coal of 60 tons per day@ Rs. 3.0 lacs per day (Rs 5 per ltr ofalcohol)

2 Power – Rs. 2.0 per ltr of Alcohol Rs.0.5 per ltr of alcohol

3 R & M – Rs. 0.25 per ltr of alcohol R & M – Rs 1.0 per ltr of alcohol


3 R & M – Rs. 0.25 per ltr of alcohol R & M – Rs 1.0 per ltr of alcohol

4 Income through Biocompost Rs 0.2 / ltr Income through potash ash Rs 1.5 / ltr

4 Investment – Rs 25 crores Investment – Rs 38 crores

When compared to conventional distillery with bio methanation followed by bio-composting, the cost of production is higher by about Rs. 3 to 4 per ltr of alcoholwith incineration system

What was the ISSUE after Spent WashIncineration?


FlyableFlyable PollutionPollution Threat to Health & EnvironmentThreat to Health & Environment Difficult to DisposeDifficult to Dispose Additional Expenses on DisposalAdditional Expenses on Disposal

Fly Ash as WasteFly Ash as Waste


KASH specification

• The FCO specification for this fertilizer is as follows:– Moisture % by weight, Max - 4.79– Total Nitrogen % by weight, Mini - 1.66– Water soluble phosphate (as P2O5) % by weight, Mini - 0.39– Water soluble potash (as K2O) % by weight, Mini - 14.70

• Our Kash product specs– Moisture % by weight, Max - 4.0– Total Nitrogen % by weight, Max - 2.0– Water soluble phosphate (as P2O5) % by weight, Max - 0.5– Water soluble potash (as K2O) % by weight, Min - 15.0


• The FCO specification for this fertilizer is as follows:– Moisture % by weight, Max - 4.79– Total Nitrogen % by weight, Mini - 1.66– Water soluble phosphate (as P2O5) % by weight, Mini - 0.39– Water soluble potash (as K2O) % by weight, Mini - 14.70

• Our Kash product specs– Moisture % by weight, Max - 4.0– Total Nitrogen % by weight, Max - 2.0– Water soluble phosphate (as P2O5) % by weight, Max - 0.5– Water soluble potash (as K2O) % by weight, Min - 15.0

Ash converted as Fertilizer

Product Specification:Product Specification:

••Brown to black ColourBrown to black Colour••Round GranuleRound Granule••22--6 mm Size6 mm Size••MoistureMoisture –– 44--5%5%••Dispersible in WaterDispersible in Water••Total PotashTotal Potash -- >19%>19%••W.S. PotashW.S. Potash -- >15%>15%

As per FCO norms


Product Specification:Product Specification:

••Brown to black ColourBrown to black Colour••Round GranuleRound Granule••22--6 mm Size6 mm Size••MoistureMoisture –– 44--5%5%••Dispersible in WaterDispersible in Water••Total PotashTotal Potash -- >19%>19%••W.S. PotashW.S. Potash -- >15%>15%

Concentration & biofertilizers

• Not economical to generate power, if plant capacity< 45 KLPD

• In such cases, viable option to achieve ZLD– bio-methanation followed by concentration spent wash (RO/MEE

up to 35 to 40%.) - further concentrated to 95% with the help ofspray dryer’s - use as fertilizers

– Cost of the fertilizer is approx. Rs.1500 per metric ton– Example Ugar sugar works, Karnataka– Fertilizer is also included under FCO (Fertilizer Control Order)

act by Ministry of Agricultural & Co-operation


• Not economical to generate power, if plant capacity< 45 KLPD

• In such cases, viable option to achieve ZLD– bio-methanation followed by concentration spent wash (RO/MEE

up to 35 to 40%.) - further concentrated to 95% with the help ofspray dryer’s - use as fertilizers

– Cost of the fertilizer is approx. Rs.1500 per metric ton– Example Ugar sugar works, Karnataka– Fertilizer is also included under FCO (Fertilizer Control Order)

act by Ministry of Agricultural & Co-operation

Treatment, Recycle & ReuseTreatment, Recycle & ReuseA. Thin Slops - Grain as feedstock

Option – II : EVAPORATION & CATTLEFEED

Syrup mixedwith Wet Cake

‘DWGS’

Thin Slops Evaporation

35-40 % RecycleTo Liquefaction


35-40 % RecycleTo Liquefaction

TECHNOLOGY & ADVANTAGES :1. 35-40% THIN SLOPS RECYCLE POSSIBLE TO LIQUEFACTION

1. COMPACT PLANT, HUGE ENERGY SAVINGS WITH INTEGRATEDEVAPORATION WITH DISTILLATION PLANT

3. WET CAKE (FIBRES) SEPARATED EARLIER IN DECATATION ISENRICHED WITH DISSOLVED PROTEINS (SYRUP) FROMEVAPORATION. HENCE VALUE ADDED CATTLE FEED

Case StudyCase Study

A. 100 KLPD Distillery complexCane - Molasses as Feedstock

Water Quality Requirement WithoutTreatment & Recycle

(M3/day)

Requirement WithTreatment & Recycle

(M3/day)Process Water 1054 253


Process Water 1054 253

Soft Water 1306 991

DM Water 290 290

Total 2650 1534

ConsumptionKL / KL

26.50 15.34

Total Water Savings = 42 %

Case StudyCase StudyB. 100 KLPD Distillery complex

Grain as Feedstock

Water Quality Requirement WithoutTreatment & Recycle

(M3/day)

Requirement WithTreatment & Recycle

(M3/day)Process Water 982 250


Process Water 982 250

Soft Water 1300 720

DM Water 290 290

Total 2572 1260

ConsumptionKL/ KL

25.72 12.6

Total Water savings = 51 %

Comparative Analysis ofTechnologies


Comparative Analysis ofTechnologies

ProcessTechnology

Landrequirement(hectares/MLDinstalledcapacity)

O&M cost(million/year/MLDinstalledcapacity)

Energyrequirement(KWh/MLtreated)

Capital cost(million/MLDcapacity)

Effluent Quality Distinct Advantage

ASP 0.15 to 0.25 Rs 0.3 to 0.5 180 to 225 Rs 2 to 4 BOD: 10-20mg/L.Suspended solids

(SS):20-50 mg/L.The effluent

obtained iscolourless.

Land requirement is veryless and performance is notaffected by normalvariation in wastewatercharacteristic.

Trickling Filter(TF)

0.25 to 0.65 Slightlylower thanASP

180 Relativelylower thanASP

Comparable toASP

Rugged system with simpleand silent operation


WasteStabilizationPonds (WSP)

0.8 to 2.3 Rs 0.06 to 0.1 Energy requiredfor the operationof screen andgrit chamber,negligible ascompared toASP

Rs 1.5 to 4.5 BOD: 30-50mg/L.SS: 75-125 mg/L.

The colour ofwater is greenish.

Very easy operation andmaintenance

UpflowAnaerobicSludge Blanket(UASB)

0.2 to 0.3 Rs 0.08 to0.17

10 to 15 Rs 2.5 to 3.5 BOD: 30-40 mg/L

SS:75-100 mg/L

Can absorb hydraulic andorganic shock loading.Sludge handling is minimal

RotatingBiologicalContractor(RBC)

N.A N.A Very low ascompared toASP

N.A Comparable to ASP Ease of installationand commissioning.Simple to operateand maintain

SequencingBatchReactor(SBR)

0.1 to 0.15 Higher than ASP 150 to 200 Higher thanASP

BOD<5 mg/L

TSS<10 mg/L

The process is timecontrolled andflexible.

FluidizedAerobic Bed(FAB)

0.06 0.5 -0.75 99-170 3-5 BOD<10 mg/LSS <20 mg/L

No sludge recyclingand monitoring ofMLSS required.


SubmergedAerobicFixed Film(SAFF)reactor.

0.05 1.14 390 7 BOD<10 mg/LSS <20mg/L

More compact thanthe conventionalSTP’s

MembraneBioreactor(MBR)

0.035 Rs 0.6 to 0.75 180 to 220 3 to 5. BOD<5 mg/LSS<10 mg/LColourless water isobtained.

Highest effluentquality for reuse andvery high life cyclecost.

case studies on sludge and water management...sewage generation • according to cpcb report (2009...

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