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    Low Grade Potash Recovery

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    SIVAKUMAR APPAVU
    The Ugar Sugar Works Ltd. installed a zero pollution plant in 2002 and another in 2007 to treat distillery effluent. The technology involves biomethanation, evaporation to reduce volume by 80%, and spray drying to produce a low-grade potash powder fertilizer. This recycles water, avoids groundwater pollution, produces a marketable byproduct, and requires minimal manpower and space. The government now provides a subsidy of Rs. 1467/MT for potash powder produced by distilleries.

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    Low Grade Potash Recovery

    Uploaded by

    SIVAKUMAR APPAVU
    11 views27 pages
    The Ugar Sugar Works Ltd. installed a zero pollution plant in 2002 and another in 2007 to treat distillery effluent. The technology involves biomethanation, evaporation to reduce volume by 80%, and spray drying to produce a low-grade potash powder fertilizer. This recycles water, avoids groundwater pollution, produces a marketable byproduct, and requires minimal manpower and space. The government now provides a subsidy of Rs. 1467/MT for potash powder produced by distilleries.

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    The Ugar Sugar Works Ltd. installed a zero pollution plant in 2002 and another in 2007 to treat distillery effluent. The technology involves biomethanation, evaporation to reduce volume by 80%, and spray drying to produce a low-grade potash powder fertilizer. This recycles water, avoids groundwater pollution, produces a marketable byproduct, and requires minimal manpower and space. The government now provides a subsidy of Rs. 1467/MT for potash powder produced by distilleries.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    11 views27 pages

    Low Grade Potash Recovery

    Uploaded by

    SIVAKUMAR APPAVU
    The Ugar Sugar Works Ltd. installed a zero pollution plant in 2002 and another in 2007 to treat distillery effluent. The technology involves biomethanation, evaporation to reduce volume by 80%, and spray drying to produce a low-grade potash powder fertilizer. This recycles water, avoids groundwater pollution, produces a marketable byproduct, and requires minimal manpower and space. The government now provides a subsidy of Rs. 1467/MT for potash powder produced by distilleries.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 27

    The Ugar Sugar Works Ltd.

    ,
    Ugar Khurd
    The Ugar Sugar Works Ltd.,

    Introduction.

    In India, there are about 400 distilleries under operation.

    Distillery is considered as one of the major revenue earning


    industry

    Distillery also come under highly polluting industry category .


    The Ugar Sugar Works Ltd.,

    Present Distillery Effluent Treatment Systems being operated in India.

    Raw Spentwash followed by evaporation followed by Incineration in high


    pressure boiler for production of steam & power
    Raw Spentwash followed by Biomethanation followed by Evaporation followed
    by mixing with bagasse, husk or any other biomass, drying in rotary dryer &
    burning in hot air generator & using the hot air for drying purpose in rotary
    dryer.
    Raw Spentwash followed by Biomethanation followed by Evaporation followed
    by mixing with bagasse, husk etc & burning in conventional boiler designed for
    using the effluent mixed fuel.
    The Ugar Sugar Works Ltd.,

    Raw Spentwash followed by Biomethanation followed by Evaporation


    followed by low grade potash recovery generation
    Raw Spentwash followed by Biomethanation followed by one time controlled
    land application
    Raw Spentwash followed by Biomethanation followed by Evaporation
    followed by composting
    Raw Spentwash followed by Evaporation followed by burning in cement
    plant kiln or thermal power plant furnace or steel plant furnace .
    Raw Spentwash followed by Biomethanation followed by Secondary
    treatment to bring down BOD level less than 2500 mg/l & disposal in sea.
    The Ugar Sugar Works Ltd.,

    USWL Case study -

    All above different technologies are being followed by distilleries based


    on their local conditions , resources available around the location, cost
    of the treatment & state pollution control board guidelines.

    The evaporation system is almost common in most of the options


    mentioned above. There are distilleries who are having more than one
    option in order to keep distillery operation for maximum days including
    rainy season
    The Ugar Sugar Works Ltd.,

    The USW limited installed the zero pollution plant ( Low


    Grade Potash Powder recovery plant.) in the year 2002 &
    another similar plant in 2007.

    Govt. of India has also supported through Technology


    Development Board, New Delhi.
    The Ugar Sugar Works Ltd.,

    Project Details

    Biomethanation Plant

    The Evaporator Plant

    The Spray Drying Plant


    The Ugar Sugar Works Ltd.,

    Brief Description on impact of technology on the plant /


    environment

    Technology conserves almost complete water as it can be recycled.


    Storage requirement of spent wash is minimized.
    The spent wash volume is reduced to 80% by evaporation.
    Ground water pollution problem is completely avoided.
    The by-product is an easily marketable commodity.
    Minimum manpower required through out the year .
    The Ugar Sugar Works Ltd.,

    Brief Description on impact of technology on the plant /


    environment

    Continuous trouble free plant operation.


    Semi automatic plant operation
    No scaling and froth formation during the operation.
    Maximum space required 25,000 sq. mtr.
    * 1000 sq. mtr. For evaporator & spray dryer.
    * 1500 sq. mtr. For boiler & cooling tower.
    Totally integrated self sustaining zero pollution system.
    Power is saved in existing distillery as secondary& tertiary effluent
    treatment is not required. The spent wash volume is reduced to 80% by
    evaporation.
    No additional infrastructure required to handle voluminous product (bio-
    compost.)
    The Ugar Sugar Works Ltd.,

    CSTR Digester

    UASB Reactor
    The Ugar Sugar Works Ltd.,

    Zero Pollution Plant


    Capacity – 1060 m3/day for 75 KLPD
    New Evaporator Plant Old Evaporator plant – 360 m3/day
    The Ugar Sugar Works Ltd.,

    Zero Pollution Plant


    Capacity – 1060 m3/day for 75 KLPD
    New Dryer plant Old Dryer plant
    The Ugar Sugar Works Ltd.,
    Flow Chart
    Distillery Effluent Treatment

    Biomethanation Effluent

    Steam Evaporators Water evaporation


    (5 Effect)

    Spray Dryer

    Steam & biogas


    based Powder
    Hot Air
    Generator

    Low grade Potash


    Powder
    The Ugar Sugar Works Ltd.,
    The GA of Sugar unit Process is as under
    Bagasse

    Potash Sugarcane Sugar


    C / B heavy Molasses
    /Cane syrup
    Pressmud

    Spent Wash Alcohol


    (Industrial &
    Potable)
    The Ugar Sugar Works Ltd.,
    Analysis of Distillery Effluent
    The Ugar Sugar Works Ltd.,
    The Ugar Sugar Works Ltd.,

    Observations made during field application of Low Grade


    Potash Fertilizer

    Low Grade Potash was found better replacement in place of K - fertilizer as it


    contains other micro nutrients

    Crop response to Low Grade Potash application was better than Chemical
    fertilizer.
    The Ugar Sugar Works Ltd.,

    Guaranteed specifications of Low Grade Potash suitable for direct


    application for incorporated in FCO:-

    Water soluble potash as K2O = 14.70


    Total Phosphate as P2O5 = 0.39
    Total Nitrogen as N = 1.6
    Micronutrients like
    Iron, =1043 ppm
    Maganese = 62 PPM
    Moisture % Max by weight minimum = 5% Max
    Particle Size = less than 100 micron
    (100% Below 60 Tyler Mesh)
    The Ugar Sugar Works Ltd.,

    Progress on Subsidy Matter :-


    USWL & AIDA has presented the project details to Ministry of Agriculture &
    brought this product under FCO in 2009 to get the subsidy.

    Further USWL has submitted request letter to Ministry Of fertilizer & Chemicals,
    GOI, New Delhi.

    AIDA has also submitted request letter to get the benefit to all the distilleries .

    After 14 years of follow up ,GOI granted Rs.1467/MT directly to Potash


    powder mfg distilleries.
    The Ugar Sugar Works Ltd.,
    The Ugar Sugar Works Ltd.,
    The Ugar Sugar Works Ltd.,
    The Ugar Sugar Works Ltd.,
    FCO letter
    The Ugar Sugar Works Ltd.,
    The Ugar Sugar Works Ltd.,
    The Ugar Sugar Works Ltd.,
    The Ugar Sugar Works Ltd.,

    Thank You

    Presented By :- Dr. S.M.Pattanshetty


    (Chief Manager Environment)

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