2Water Balance of 120 KLPD Molasses Distillery Distillery is among the major water consuming industries. However major part of this water can be recycled back and reused resulting in reducing the requirement of fresh water to about 50% and achieving practically zero liquid discharge from the industry.
3Water Consumption of a typical 120 KLPD Distillery Total water OutputsSection Unit - M3 / DayFermentationFor Dilution m3In cooling tower m3In fermentor washing - 25 m3In air blower -12 m3Total in Fermentation m3DistillationIn cooling water make up - 676 m3In vacuum pump - 144 m3Scrubber- 57 m3In fusel oil decanters – 19 m3 D.M. water for dilution – 190 m3 Total in Distillation – m3
4Water Consumption of a typical 120 KLPD Distillery E.T.PGas washing – 10 m3 Decanters cleaning - 15 m3R.O. plant rinsing - 30 m3Cooling water – 50 m3 Total IN ETP m3Co-generationFeed water – 432 m3Boiler blow down – 10 m3Turbine cooling water - 60 m3Total in ETP and Co- Gen. – 502 m3
5Water Consumption in 120 KLPD Distillery Bottling & OthersBottle washing – 168 m3 For blending -35 m3 Drinking & Toilets -10 m3 In D. M. water re-regeneration – 50 m3 In Water softener for re-regeneration -40 m3Total in Bottling & Others - 303 m3GRAND TOTAL IN ALL SECTIONS – 3227 m3
6Water Recycle Streams Water Recycle Streams In Process Section Unit M3 / DayFermentation –Spent lees in fermentation after Cooling m3RO Permeate in Fermentation after ultra filtration – 680 m3 DistillationVacuum Pump water into cooling tower -144 m3
7Water Recycle Streams In Process Co-generationSteam condensate in boiler – 384 m3Boiler blow down water in ash quenching-10 m3 TOTAL in Co-Generation m3Bottling & OthersWashing water of bottling back to raw water tank through fine filters - 158 m3Water Recycling to Other Than Process Gardening Filter backwash water in gardening- 10 m3D.M. & softener regeneration water for gardening after neutralization m3 Cooling Tower blow down for gardening -36 m3TOTAL- 136 m3GRAND TOTAL - 1669 M3
8Water Recycling Streams After recycling the given streams with either passing through Reverse Osmosis and ultra filtration ( In Case of Sp. Wash ) or normal fine filtration ( In case of Bottle Washing) etc , about 50% of the water requirement can be met with reprocessed / recycled water. The use of fresh water is required for following only.
9Fresh Water requirement Consumption delails of the fresh water SectionUnit M3 / DayFermentationFermentation cooling Tower Make Up - 200 m3Fermenter washing – 25 m3 Air blower cooling -12 m3 TOTAL in fermentation – 237 m3DistillationDistillation cooling water make up - 676 m3Vacuum pump - 144 m3Scrubber m3 Fusel oil decanter – 19 m3D.M. water for dilution - 190 m3TOTAL in DISTILLATION- 1086
10Fresh Water Requirement E.T.PGas washing – 10 m3 Decanter cleaning – 15 m3RO plant rinsing – 30 m3Cooling tower make up – 50 m3 TOTAL IN ETP – 105 m3Co-generationBoiler feed water – 48 m3Turbine cooling tower make up – 60 m3 TOTAL in CO-Generation -108 m3
11Fresh Water Requirement Bottling & OthersBlending – 35 m3Bottle washing- 10 m3Domestic -10 m3Filter backwash water in gardening -10 m3D.M. & softener regeneration water for gardening after neutralization - 90 m3 TOTAL in Bottling & Others- 155 m3GRAND TOTAL - 1691.0 M3 Total Intake of fresh water m3 / Day1648.0 Fresh water required m3/ KL m3
12Water Balance of 120 KLPD Distillery From the above it is observed that if managed properly the 50% water requirement out of about 27 m3/ KL of Spirit Production can be met with recycled water and fresh water is required only about 14 m3 / KL of Alcohol production including water required for bottling purposes.Recycled water can satisfy most of the water demands, as long as it is adequately treated to ensure appropriate water quality for use.