Treatment of Distillery Spent

wash

Babu Alappat
Professor
Department of Civil Engineering
I.I.T Delhi

[email protected]
 Generation of Spent wash

Sugar Cane Sugar Mill Sugar

Bagasse

Molasses
Distillery
Alcohol

Spent wash
 Molasses Distilleries

Spent wash is the main waste stream

It has a BOD5 of about 30,000 to 60,000mg/lit
COD of about 1,00,000 mg/lit
pH acidic (4 5)
Colour- dark brown
About 15% solids content
Ash contains Potash as K2O
 Spent wash generation: about 8 to 15 litres
per litre for alcohol produced

8 for new plants

15 for old plants
 BOD Pollution load of all distilleries put
together in India is more than 6 times the
BOD load of the entire population of India
 Attempts with Spent Wash
For washing sugar cane
For diluting molasses
For irrigating sugar cane fields
For manufacturing cattle feed
For manufacturing yeast / dry ice / etc

Nothing turned to be sustainable / feasible

 Target Pollutants
Organic matter

pH

Colour
 WASTE TREATMENT ROUTES
Biological for sure, THE BEST option
More eco-friendly
End products acceptable to the nature
Low expenditures
But slow, more uncertainiy, affected by weather / temp

Chemical for lesser quantities

Thermal-
usually costlier, probability of pollution, controversial but
very fast, compact reactors, less area required, more fool
proof, not affected by weather / temperature, less
uncertainity
 Biological treatment
Removal of organic matter using
microorganisms (mostly bacteria, fungi,
actinomycetis, etc)
Organics used for energy and growth
Organics get converted to gases (that
escaped the system) and cell mass (has to be
removed)
 Batch reactor growth of micro-organisams

Live micro- Endogenous decay

organisams
(number / mass)
Log growth phase

compost
acclimatization

Time in days (or hours)

 Biological treatment
Aerobic: in the presence of Oxygen
Organics + O2 CO2 + H2O +
Biomass More Biomass

Anaerobic: in the absence of Oxygen

Biogas (CH4 + CO2+H2S)
No oxygen
Different organisms in action <90 %
Organic carbon
100 % Biomass>10%
 Biological reactors
Batch or continuous:
Composting batch process
Activated sludge process (ASP) - continuous
Suspended growth or attached growth
Suspended growth: microorganisms are suspended
in the waste water: ASP
Attached growth: microorganisms are attached to
some media like pebbles, plastic balls, etc: Tricking
filters, Rotating Biological Contactor (RBC)
 BIOLOGICAL WASTE
WTAER TREATMENT
Aerobic:
ASP (Activated Sludge Process),
TF (Trickling Filter),
RBC (Rotating Biological Contactor)
Anaerobic:
Conventional Digester,
Di-phasic digestion,
UASB,
FB,
Hybrid reactor
 Organics + O2 CO2 + H2O +
Biomass More Biomass

Treated effluent
CO2

Organic carbon, N, P

O2 to sludge
treatment
Return Activated Waste
Sludge sludge
AEROBIC TREATMENT
 Anaerobic process

Biogas (CH4 + CO2+H2S)

No oxygen
Different organisms in action <90 %
Organic carbon
100 % Biomass>10%
 Comparing aerobic anaerobic
techniques
Aerobic
Faster reaction kinetics
Hence smaller reactors
No bad odour
But
have to provide Oxygen
No any recovery,
more sludge to be handled
 Anaerobic

Fuel Gas recovery

Less sludge to be handled
No oxygn to be supplied
But
Slow reaction kinetics
Large reactors
Odour issues are there
 The main treatment strategy
BOD/COD = 50,000/90,000 = > 0.5

Hence biological treatment is effective

Since it is high strength waste water,

anaerobic treatment technique is better
 Treatment strategy for sewage ?
BOD / COD = 250 / 400 = > 0.5

Hence biological treatment is effective

It is low strength waste water and hence

aerobic treatment techniques are better
 Spent wash treatment
Anaerobic digestion was the mostly tried
option:
anaerobic digester
diphasic anaerobic digester
UASB
Fluidized bed anaerobic filter
Hybrid Reactors
 pH adjustments Anaerobic reactor

Effluent
Raw Spent BOD about 3000 4000 mg/L
Wash
BOD =45, 000 mg/L sludge

This effluent cannot be disposed off to a river or sewer line or ocean

Disposal Standard = 30 mg/L for disposal into surface waters

 pH adjustments Anaerobic reactor

Effluent
Raw Spent BOD about 3000 4000 mg/L
Wash sludge
BOD =45, 000 mg/L

ASP

Effluent
BOD < 30 mg/L Aeration tank
Colour persists sludge
 pH adjustments Anaerobic reactor

Raw Spent
Wash sludge
BOD =45, 000 mg/L

Adsorption tower ASP

Effluent Aeration tank

BOD < 30 mg/L sludge
 Anaerobic digestion

Macro-molcules

B. hydrolytiques
Hydrolyse
Monomres
B. acidognes
Acidognse
Acides organiques,
alcools, ...
B. actognes Actognse
Actate CO2+H2
B. homoactognes

A. mthanognes A. mthanognes
Mthanognse
actoclastes hydrognophiles

CO2+CH4 CH4
Conventional Anaerobic Digester

Biogas

Effluent Influent

Sludge
UASB (Upflow Anaerobic Sludge
Blanket) Reactor
Anaerobic Fluidized Bed Reactor (AFBR)
Biogas

Treated
water
Recycle line
Biofilm
Carrier

Wastewater
feed
 Anaerobic Digestion :
2 steps
Fresh sludges

55 C Heat 35 C
2-3d exchanger 8 - 12 d

Digested sludges

Hydrolysis Acetogenesis
+ +
Acidogenesis Methanogenesis
 Anaerobic digestion bring the BOD down to
about 2000 4000 mg/lit
But the discharge standards are normally
much lower (20 or 30 mg/lit)
Hence normally aerobic systems are used to
bring the BOD down to < 20 or 30 mg/lit
Unfortunately colour still persists !
Then go for an Adsorption Tower using
activated Carbon
Hence the process becomes costly
 Problems with Anaerobic
Systems
Requirement of polishing
Uncertainity involved with biological
systems
Influence of external parameters like
weather, temperature
Requirement of energy intensive secondary
treatment
 Colour problem still persists
Need for tertiary treatment like adosrption
CH4 generated in the first step is used in the
subsequent steps
Much slower than thermal systems
More space/volume required
 Why thermal methods ??
Biological methods:-
Are generally SLOW
Are affected by external parameters like temperature
Involves some uncertainty
Cannot solve the problem completely
Thermal methods:-
Are costly
But rapid
Are relatively compact
Involves less uncertainty
 Thermal Treatment of Spent
wash
There have been many other attempts to
deal with spent wash
Burning of concentrated spent wash dates
back to world war 1 period (not in India)
Production of activated carbon, Solid CO2,
potash, etc was one of them (reported by
Reich in 1945 from US)
Thermal properties of Spent wash
Sp gr 1.04 to 1.05
Total Solids: 10 to 22 %
Total VS: 6 to 8 %
Ash content: 2 to 3 %
HHV: 3200 to 3800 kCal/kg (dry solids)
Density of concentrated spent wash 1.350
g/cc
 PROCESS OF INCINERATION,

Combustion (controlled burning) of wastes in properly

designed and constructed furnace to sterile ash with
proper care for air pollution and water pollution.

It is proper to say INCINERATION SYSTEM rather than

simply incinerator

The prime objective of incineration is WASTE

DESTRUCTION, not power generation or ash recovery
Waste/
Coal Aux Fuel
FD Fan

Waste /Coal Waste /Coal

Preparation Feeding FURNACE Flue Gas

Gas out
Bottom Ash Heat
Recovery
S
T
A
C Acidic Gas Particle
Removal Heat
Removal
K ID Fan
For treatment & disposal
Incineration of Distillery Spentwash:
Indian Experience
First incineration was reported in early
nineteen sixties, but not popular
Became popular in late nineteen eighties.
Two popular designs were
Destrotherm from Thermax, Pune
Sprannihilator from Praj Consultech, Pune
Raw Spent wash Steam
10-13% Solids
content Evaporator
Concentrated
Spentwash of
Steam
About 60% Solids
content
Boiler
Excess steam
Flue Gas Water

Furnace
Air

Ash (high fertilizer value)

 1st incineration plant for spentwash
Set up at Dyer Meakin Breweries Ltd.,
Lucknow in 1960
Capacity: 90 gal spent wash / hour
Uses forced circulation evaporator for
concentrating spentwash to 60% solids
content
Ash from spentwash incinerator: contains
high Potash as K2O (37% of the ash)
 Destrotherm from Thermax
Govt. Distillery at Chitali, Maharshtra in 1984
Expected performance for a 45KLD distillery
Spent wash generation: 3000lit/hr
Ash collection: 700 kg/hr
Power generation: 700kW (Process electricity
consumption 500 kW)
Steam generation: 11515 kg/hr (40bars, 400oC) and
steam consumption 5500kg.hr (at 5 bars)
 Destrotherm
Spent wash of 60% solids content is sprayed
into the furnace
Raw spent wash is concentrated to 60% in
external forced draft evaporators using
process steam
The flue gas generated goes for the
production of steam
Ash is rich in potash
 Destrotherm did not pick up the expected
popularity may be due to
The complexity involved in the evaporation system
Large area / volume occupied by the evaporators
Clinker formation on the boiler tubes
High cost involved
 Sprannihilator from Praj
Counseltech
Aimed at solving some of the problems with
Destrotherm
Evaporation section made simple and easy
to handle
Plants becomes more compact
First plant at Kohlapur (M/S. Gadhinglaj
Taluka Sahakari Sakhar Karkhana Ltd.)
Raw Spent wash Flue gas with evaporated water
10-13% Solids
content Evaporator
Concentrated
Spentwash of
About 60% Solids
content

Flue Gas

Furnace
Air

Ash (high fertilizer value)

 Sprannihilator
About 60% solids content spent wash is
sprayed into the furnace

Raw spent wash is concentrated to 60%

using the flue gas heat in a venturi-
evaporator
Ash is rich in potash
 One at M/S. Polychem Ltd., Nira
45KLD distillery

Another at Liquors India Pvt. Ltd.,

Hyderabad
20 KLD distiller
Incineration Plants for Distillery
Spent wash

All together, about 40 incineration

plants working
Problems with Incineration of spent
wash
Solids content of spent wash is to be
brought to about 60% before firing into the
furnace.
This brings the economics down as it is
energy intensive. Also, damaging to the
material of construction.
Spent wash is sticky
It swells (up to about 5 times the original volume)
while heating
Raw Spent wash
PROBLEMATIC
10-13% Solids
content Evaporator
Concentrated
Spentwash of
About 60% Solids
content

Flue Gas

Furnace
Air

Ash (high fertilizer value)

 Recirculating Fluidized Beds
(RCFB)
Gas exit

Freeboard

The spouted bed

with a central riser Riser tube

tube
Downcomer

Also called
Internally Distributor plate
Circulating Downcomer
fluidizing air
Fluidized Bed Gas flow Air jet
Solids flow
 RCFB for the Incineration of
Spent wash
The idea is to separate evaporation from
combustion to the extent possible
Combustion takes place in the central riser
tube
Drying and Evaporation takes place in the
downcomer
Mixing of the dry solids and combustion air
takes place in the zone below the central riser
tube
 RCFB Incineration
Hot sand particles from the combustion zone
move to the downcomer
Spent wash is sprayed onto these hot sand
particles
Evaporation takes place on the hot sand
particles in the downcomer
Dry solids on the sand particles get in contact
with combustion air and catches fire
Combustion of dry solids on the sand surface
in the central riser tube heating up sand grains
 Concentrating spent wash
About 100 RO (Reverse Osmosis) plants
working in distilleries

About 100 MEE (Multiple Effect

Evaporation) system working in distilleries
 Reverse Osmosis
Concentrated
Spentwash of
Raw Spent wash
55-60% Solids
10-13% Solids
Content to
content
Boilers / Incinerators
Cement Kilns / Drying
MEE (Multiple Effect
Evaporator)
Fermentation & Distillation Industries > 400

Molasses based Distilleries ~ 300

Distilleries attached with Sugar Mills ~ 125

Distilleries with RO Concentration 100

system

Distilleries with MEE concentration 100

system
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 oxygenrich 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 noncombustible 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
 Different treatment technology routes for
ZERO LIQUID DISCHARGE (ZLD)

Biomethanation followed by multi-effect evaporation

followed by drying/ incineration/ co-processing.

Biomethanation followed by reverse osmosis followed by

drying/ incineration/ co-processing.

Concentration through RO/ MEE followed by drying/

incineration/ co-processing.