dr. sanjay v. patil head and technical adviser …. sv.patiil.pdf · email:...

AIDA Technical Seminar www.vsisugar.com Bengaluru, 05-06-Oct-2017

DR. SANJAY V. PATIL

HEAD AND TECHNICAL ADVISER

DEPARTMENT OF ALCOHOL TECHNOLOGY

VASANTDADA SUGAR INSTITUTE, MANJARI, PUNE (INDIA)

Email: [email protected]

AIDA 2017 Vasantdada Sugar Institute, PuneAIDA Technical Seminar October 05-06, 2017 www.vsisugar.comAIDA Technical Seminar www.vsisugar.com Bengaluru, 05-06-Oct-2017

Types of assessments

Norms – SW Treatment/Disposal

Approved ZLD systems

Approach

Fermentation and Distillation

Effluent quantities and Characteristics

Biomethanation

Reverse osmosis

Multiple effect Evaporation

Biocomposting

Slop fired Incineration boiler

BMSW dryer

Condensate Polishing unit

On-line monitoring system and other requirements

Conclusions


Self Assessment

Third Party Assessment-VSI/NEERI/Distillers’ Association etc

Assessment by regulatory authority-SPCB/CPCB/MoEF


1. Red category and Zero Liquid Discharge (ZLD).

2. For Bio-composting as a final treatment:

MEE is essential

SW storage max. 30 days on raw SW basis.

Max. 270 days (With covered compost yard-

additional/throught-out the year can be allowed)

Yard has to be impervious as per CREP norms.

Bio-compost has to be bagged in polybags &

compost composition & manufacturers name to be

printed on it.

Compost quality has to be certified by Ministry of

Agriculture.


2. For Bio-composting as a final treatment (Continued):

For 5 to 12 % solids containing spent wash, the filler

material (PMC) to spent wash ratio prescribed is 1:

2.5 for 45 days cycle and 1:3.5 for 60 days cycle.

For concentrated spent wash (20 to 30 % solids), the

filler material (PMC) to spent wash ratio prescribed is

1: 1.6 for 60 days cycle.

Impervious compost yard area based on material

balance (plus ready compost storage area) should

be made available.

During rainy season, bio-composting process has to

be stopped.

Record of filler material used (PMC) and bio-

compost produced/sold should be maintained.


3. SW storage- Impervious as per CREP norms.

4. For Incineration route: Storage of 7 days on conc. SW

basis in impervious storage tank.

5. Secondary treatment: Process condensate, permeate,

spent lees, CT & boiler Blowdown, pump gland cooling

water etc. has to be treated (CPU) & recycled back.

6. Online monitoring :

Mass flowmeters before & after concentration of

SW.

Camera: 30 days SW storage tank & bio-compost

yard.

Stack Monitoring System (PM <150 mg/NM3 or 50

mg/NM3).

To be installed & connected to SPCB/CPCB server.


Biomethanation MEE Bio-composting

Biomethanation RO MEE Bio-composting

Biomethanation MEE DRYER

Biomethanation RO MEE

MEE Incineration

1

2

3

4

5

DRYER


1. Holistic Approach: Integrated management

employing Reduce-Recycle-Reuse principle

2. No End of Pipe Treatment.

3. No Discharge

4. Analytical & Necessary measurement facilities

(Water, Steam, Power, Effluents)

5. Fresh water consumption-section wise

6. Environment Management Cell:

(Unit Head + Distillery Manager + ET plant I/c

+ Concerned Officers/Chemists)


Distillery installed and Licensed capacity. Boiler

capacity. Source of electricity and water.

Distance from river/dam/canal/other water bodies.

Authentic data on alcohol production/molasses

consumed. Per day alcohol production data.

Authentic data on per day SW & SL production, total SW

& SL production.

No. of days of operation in a year.

Alcohol % (v/v) achieved in wash, Fermentations

efficiency, Distillation efficiency, Recovery etc.

Fermentation technology employed.

Distillation technology employed, reboilers used, spent

lees generation (Rectifier, PRC etc).

If sludge is generated, quantity of sludge MT/day & its

method of disposal.


RAW

SPENT WASH

VALUES

Volume, M3/Day

Volume, L/L

pH

COD, mg/L

BOD, mg/L

TDS, mg/L

TSS, mg/L

Volatile acids,

mg/L

SPENT LEES VALUES

Total SL, M3/Day

Volume, L/L

SL Recycled,

M3/Day

SL for treatment

M3/Day

pH

COD, mg/L

BOD, mg/L

TDS, mg/L

TSS, mg/L


Setting cum cooling tank capacity = M3 (if any)

Setting cum cooling tank RT = days

Digester design basis= Hydraulic Retention Time = ----days(15-24 days)

= Organic Loading Rate = ------- kg/M3 /Day

= Volume = ----- M3

Type of Technology = CSTR/UASB/ Thermophilic/ Hybrid

Biomethanation Plant Performance (based on 1 month data)Parameters Minimum Performance parameters Actual Values

Feed rate, M3 /Day

0Brix, (Inlet/Outlet)

pH, (Inlet/Outlet)

COD, mg/L (Inlet/Outlet)

BOD, mg/L (Inlet/Outlet)

COD reduction % 60

BOD reduction % 85

Biogas generation, NM3 /Kg of COD

consumed0.5

Biogas generation, M3 /Day -


No. of days of operation of digesters (days/annum).

Restabilization method and period required.

How digester is maintained during ideal days?

Year of establishment of digester.

How temp of digester is maintained?

Total biogas generated (M3/annum) and baggase/coal

saved.

Whether digester has been revamped? If yes, how

many times & for what purpose?

Sludge generation from digester and how the sludge is

disposed off?

Log Book records supporting biogas plant performance.

Present Bottle-necks/problems


Particulars Raw spent wash (Feed)

Treated effluent (Outlet)

Quantity, M3/day

Colour

PH

Temperature, degree C

Conductivity, ms

BOD, ppm

COD, ppm

Total solids, %

Total dissolved solids, %

Total suspended solids, %


Setting tank capacity before RO = M3 (if any)

Year of installation/establishment & commissioning of

RO plant

Type of technology of membrane filtration.

Number of membranes per module & number of

modules.

Designed feed capacity of R.O. (M3/day).

Acceptable level of suspended solids, dissolved

solids & other membrane affecting components in

the feed.

No of days of operations.

Log Book supporting RO plant performance.

Further treatment/disposal of Permeate/Reject


Particulars Inlet (Feed)

Reject Permeate Rinsing

back

wash

Chem

Cleaning

Quantity, M3/day

Recovery, %

Colour

pH

Conductivity, ms

BOD, ppm

COD, ppm

Total solids, %

Total dissolved

solids, %

Total suspended

solids, %

Based on at least 1 month data


Setting tank capacity before MEE = M3 (if any)

Year of installation/establishment & commissioning of

MEE plant

Type of technology of MEE.

Number of Effects with their HTA and MOC. Number of

stand-by bodies and degasser provided.

Designed feed capacity and evaporation duty of MEE

(M3/day).

Acceptable level of suspended solids, dissolved solids

etc in the feed.

No of days of operations.

What is the frequency and duration of cleaning. Log Book supporting MEE plant performance.

Further treatment/disposal of Condensate/Concentrate


Particulars Unit Values

Feed rate @ Sp. Gr. (Approximate) Kg/hr

Solid content in feed/brix %/ degree

Water evaporation rate (Minimum) Kg/hr

Concentrate output Kg/hr

Solid content in concentrate/brix %/degree

Steam required for water evaporation Kg/hr

Cooling water circulation rate M3/hr

Power consumption for Evaporation KWH

Feed temperature 0C

Steam pressure / temperature Kg/cm2 /0C

Steam Economy, (Kg water /kg steam) Kg

Operation hour Hr / day- or week or month

Frequency of CIP Hr/ day or week or month

Quantity of CIP effluent M3/hr

Quantity of process condensate M3/hr


Particulars Conc. spent wash

Process Condensate

Quantity, M3/day

Colour

PH


BOD, ppm

COD, ppm

Total solids, %



Ammonical Nitrogen (as N), ppm NA 270



30 days holding tank capacity with dimensions and

construction details.

Biocompost yard details- Impervious biocompost yard

(PCC- 1:3:6 or RCC- 1:2:4 or brick on edge) with

construction details.

Area of impervious biocompost yard (uncovered and

covered) with biocompost storage area.

Number & type of turning & mixing machine.

Number of Bore well around compost yard.

Number of Pizometers around the compost.

Spentwash available for biocomposting (M3/Annum)

and spentwash characteristics.

Log Book supporting biocompost plant operations.


Biocompost filler material availability (Press mud/Yeast

sludge/Boiler ash) (MT/day or MT/annum).

Record of Press mud produced or purchased from out

side.

Average Press mud to spentwash mixing ratio.

Windrows size (Length x width x height)

Biocompost cycle (45 days or 60 days) and number of

cycle per annum.

Biocompost analysis report.

Material balance for biocompost.

Record of biocompost produced and sold with selling

price of biocompost (Rs./MT).

Biocompost sold in loose or bag packing.


Date of installation

Design basis : Slop and subsidiary fuel ratio, calorific values

and feed rates considered to finalise capacity and other

details

Boiler/Technology Supplier details and type of boiler

Boiler capacity, pressure, temperature and other details

Boiler performance details: Including slop and subsidiary fuel

actual ratio achieved, no of working days, shut down days-

cleaning period required, steam generation (MT/hr), steam

pressure & temperature etc.

Emission control system installed, its details, analysis report.

Problems faced in operation and maintenance of Boiler.

Quantity of ash generated (MT/day), its characteristics and

method of disposal etc.

Log Book records supporting incineration boiler performance.


Date of installation.

Design basis : BMSW feed rates considered to finalise

capacity and other details.

Dryer/Technology Supplier details and type of dryer.

Dryer capacity and other details.

Dryer performance details: Including BMSW feed rate,

steam/biogas used/hr, no of working days, shut down days-

cleaning period required, powder produced (MT/hr) and

other details.

Emission control system installed and its details.

Problems faced in operation and maintenance of dryer.

Characteristics of powder produced and storage method.

Quantity of condensate generated (M3/day), its

characteristics and method of treatment/disposal etc.

Log Book records supporting dryer performance.


Date of installation of CPU unit.

Name of plant/technology supplier.

Type of technology of CPU plant: Conventional /RO/

Striper / Photo-oxidation /In house technology etc).

Design capacity of CPU unit (M3/day) and feed

characteristics considered.

Low strength effluents treated though CPU & their

quantities (Process condensate, permeate, spent lees,

etc).

Recovery (%) and characteristics of treated water and

its further utilization details.

Is there any reject generated and how it is disposed?

Total fresh water consumption after reuse of treated low

strength effluents. Log Book records supporting CPU performance.


Particulars Mixed Influent Treated effluent

Quantity, M3/day

Colour

PH


BOD, ppm

COD, ppm

Total solids, %



Volatile acids

Total Alkalinity



Number and location of mass flow meters installed (minimum

two) with photographs.

Number and location of cameras installed (minimum two)

with photographs.

Details of on-line emission (stack) monitoring system for

boiler.

Date on which the online monitoring system was

commissioned/connected to the server.

Name and contact details of the vendor who has supplied

and commissioned the on-line monitoring system.

Problems faced in maintaining the continuity of on-line

monitoring system.

Green belt surrounding biocompost yard (Photographs).


Identification of recipient drains/ rivulets and their u/s &

d/s locations for monthly monitoring to ensure ZLD.

Material and mass balance of your total distillery plant

operations including ETPs showing ZLD.

Also indicate how your distillery unit is achieving steam

and power balance.

Environment Management Cell- MoMs and necessary

documents.

EC, Consent to Operate, Directions received and

related documents.

Water conservation measures taken report (rain water

harvesting etc).

Prepare your own action plan for achieving ZLD.


Preparing self assessment report is first step towards

compliance to ZLD norms.

It indicates your concern to save the environment.

It will definitely help you to identify bottle-necks and

further improve your performance.

AIDA 2017 Vasantdada Sugar Institute, PuneAIDA Technical Seminar October 05-06, 2017 www.vsisugar.comAIDA Technical Seminar www.vsisugar.com Bengaluru, 05-06-Oct-2017www.vsisugar.com

dr. sanjay v. patil head and technical adviser …. sv.patiil.pdf · email:...

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