Does Effluent Treatment eat into your Distillerys Profit ? And you wish to get freedom from the cumbersome Effluent Treatment Process.
We at CBL make distilleries a zero discharge installation by burning Slop / Venasse as a fuel in boiler.
In this process we burn the concentrated distillery waste directly into the boiler. The effluent from distillery is taken to a concentrating unit and concentrated to 55 to 60% solids, either by RO or by evaporation system and then fired into a specially designed incineration boiler along with 35-40% support fuel like coal, rice husk, bagasse..
This consists of a specially designed boiler where the concentrated slop is sprayed from a height into the furnace in such a way that the slop gets dried and burns effectively in the large volumetric furnace. The boiler has special features to handle the high Potash present in slop.
This system is highly economical as the entire steam required for distillery & evaporator is generated at high pressure and passed through turbine before using for the process and evaporator, hence produces power as bi- product. The support fuel requirement is about 35-40% only as the major fuel is effluent.
Since bio mass is being used as fuel in this process, it is approved by UNFCCC under CDM project for carbon credit.
Great contribution in the field of Water pollution control as there is no effluent discharge at all.
Great contribution in the field of ground water retention. As the recovered water from the concentration unit can be reused in distillery after a minor treatment. Thus the water requirement of distillery is reduced drastically.
In our patented design we also use external super heater allowing us to design these kind of boilers up to 67 Kg/Cm² pressure at 490°C temperature for higher turbine power output.
Huge saving in investment on land for setting up distillery as construction of digester for effluent treatment and press mud conditioning is not required.
Using a high pressure boiler with suitable back pressure turbine generates much more power than plants requirement which can be exported as surplus.
In bio methanation system about 25% carbon energy is consumed by bacteria, which is saved in this system thus it becomes energy efficient.
The ash of this boiler contains high Potash. Thus it is used directly as fertilizer.
CLIENT NAME M/s Jagatjit Industries Limited (ARISTOCRAT) 150 KLPD Distillery Boiler Specification – 26 TPH, 32 Kg/cm² Fuel – Rice Husk + Slop Current working Load – 26 TPH, 32 Kg/cm² Rice Husk Consumption – 90 TPD or 3.75 TPH Slop Quantity – 7.5 m³/hr. or 9.5 TPH CASE STUDY – I
CASE STUDY – II CLIENT NAME M/s OUDH SUGAR MILLS LTD. Boiler Specification – 30 TPH, 45 Kg/cm² 430°C Fuel – Bagasse + Slop Current working Load – 27 TPH, 45 Kg/cm² 440°C Bagasse Consumption – 170 TPD or 7.10 TPH Slop Quantity – 7.5 m³/hr. or 9.52 TPH
CASE STUDY – III CLIENT NAME M/s U-Bio-Chem Limited (CHADHA GROUP )100 KLPD Distillery Boiler Specification – 25 TPH, 45 Kg/cm² 440°C Fuel – Rice Husk + Slop Current working Load – 23 - 24 TPH, 45 Kg/cm² 440°C Rice Husk Consumption – 80 TPD or 3.33 TPH Slop Quantity – 6.6 m³/hr. or 8 TPH
S.No.DESCRIPTIONUnits 25 TPH Net H.P. Incinerator Boiler 15 TPH Net L.P. Boiler 1.Steam generationKg / hr2300013500 2.Steam pressureKg / cm 2 4510.54 3.Steam temperature °C 440Saturated 4.Fuel (GCV) - Rice Husk - Slop (With 60% Solids Concentration) Kcal / Kg 3150 1859 3150 - PAY BACK PERIOD FOR 100 KLPD UNIT. Cont…
5.Fuel consumptionKg / hr 3333 (Husk)+8000 (Slop) 3800 6. Fuel Saving on Rice Husk Kg / hr467-- 7. Auxiliary power reqmt. KW410245 8.Addl. Aux. powerkW165-- 9.Power generationkW1500 - 10.Net power generation kW1335 -- Cont…
AADDITIONAL EXPENSES FOR POWER GENERATION 1)Cost of equipmentRs.Rs. 1600 LacsRs. 325 Lacs 2) Additional investment Rs.Rs. 1275 Lacs-- 3) Interest on addl. investment @ 12.50 % Rs.Rs.159 Lacs-- 4) Total add. expenses Rs.Rs. 1434 Lacs-- BSAVINGS ON FUEL CONSUMPTION 1) Fuel Saving in Incinerator boiler Kg / hr (3800-3333) 467 - 2)Rice Husk CostRs / hr3.5 3)Savings on FuelRs / hr1635 Cont…
CSAVING DUE TO POWER GENERATION 1) Units generated / hr kWH(1500 -165) =1335-- 2) Power cost from SEB DG Set Rs. / kWH Rs. 5.00 Rs. 12.00 -- 3.) Average Power Cost (Considering 20 Hrs Supply from SEB & 4 Hrs from DG Set) Rs. / kWHRs. 6.20-- 4)Saving / HrRs. / hrRs. 8277-- Cont…
5.) Annual saving from Power(Considering 24 hrs x 310 days a year) Rs. / yearRs. 616 lacs-- 6.) Annual saving from Fuel(Considering 24 hrs x 310 days a year) Rs. / yearRs. 122.0 lacs-- 7)Total Saving (Due to Fuel Saving & Power Generation) Rs. / yearRs. 738 lacs Cont…
8) Balance addl. investment at the end of first year (Addl. Investment – annual saving) 1434 – 738 = Rs. 696 lacs -- 9) Interest on balance investment @ 12.50 % Rs. 87 lacs-- 10)Total (C 8 + C 9)Rs. 783 Lacs-- Payback period2 YEAR AND 1 MONTHS --
Thus by installing incineration boiler technology you get rid of cumbersome press mud effluent disposal system. Save land requirement for putting up effluent treatment plant & press mud mixing. Also get solution to Power cut problems by generating in house GREEN POWER. Besides saving precious mother land & water resources. WITH PAY BACK PERIOD APPROXIMATELY TWO YEARS.
1. India Glycol Limited, Gorkhpur 40Tons 45 Kg– Working since 4 years 2. India Glycol Limited, Gorkhpur 2 nd unit 40 Tons 45 Kg–Under Comm. 3. Rana Sugars Limited, Punjab – Working since 4 years 4. Oudh Sugars Limited, (Birla Group) 30 Tons 45 Kg– Working since 3 years 5.U-Bio Chem Limited, Noida 25 Tons 45 Kg – Working since 3 years 6.Jagatjit Industries Ltd, Punjab 30 Tons 45 Kg– Working since 2 years. 7.India Glycol Limited, Kashipur 40 Tons 45 Kg – Under Commissioning. 8.Vijay Nagar Sugars, 30Tons 67Kg 490°C - Under Erection 9. S.V. Distilleries Ltd, Hyderabad, 30Tons 67Kg 490°C 10. Sona Sati Organics, 20 Tons 45 Kg 11. Shiraguppi Sugars works Ltd, Karnataka 35 Tons 67Kg 12. Shakumbari Sugar, Saharanpur 40 Tons 45 Kg 13. Shakumbari Sugar, Saharanpur 40 Tons 45 Kg