1. CHALENGES IN ZERO DISCHARGE OF MOLASSES EFFLUENT ( A Case History of Radico Khaitan Ltd) By K.P. SINGH

2.  The distillery of Radico Khaitan Ltd at Rampur was established in 1943.  At present the daily production capacity of distillery is 300 KLPD.  Radico has Molasses Spirit, Grain Spirit & Malt Spirit Production. DISTILLERIES

3. Initiatives taken by Radico to achieve Zero Effluent Discharge

4. VOLUME REDUCTION BY HIGH BRIX FERMENTATION We have batch fermentation in our Molasses Fermentation. Fermenters are MS epoxy coated and covered at the top for CO2 recovery. Molasses Quality in the State of U.P. does not suit to Continuous Fermentation. With High Brix Fermentation we are able to maintain 9.5 – 10% Alcohol in wash in a molasses having only 42- 43 % TRS.

5. REDUCTION IN VOLUME THROUGH IMPROVED FERMENTATION EFFICIENCY Fermentation efficiency is maintained between 91.5 - 92 % with better microbiology in yeast propagation and fermentation. Fresh yeast is used for every Fermenter. Cell concentration in pre-fermenters is maintained at 4 X10 8. With the recycling of lees and condensate water as dilution water, fresh water consumption in fermentation is reduced by about 80% and water born contamination is almost Zero.

6. IMPROVEMENTS IN FERMENTATION Cooling of Wort through Heat Exchangers. Cleaning of Fermenters through Spray balls water jet. Temp. indicators on each Fermenter. Use of cleaning agents for maintaining aseptic conditions after washing of Fermenters through CIP system. Adequate nutrient dosing for facilitating quick fermentation.

7. Radico Khaitan Limited (Rampur Plant)

8. DESIGN BASIS (DISTILLATION WITH INTEGRATED RAW SPENT WASH EVAPORATION)

9. DISTILLATION PLANT WITH INTEGRATED EVAPORATORS

10. REDUCED GENERATION THROUGH MEE and RO. RECYCLING LEES, PROCESS CONDENSATE AND PERMEATE. TREATMENT OF RECYCLING STREAMS BASED ON IT’S CHARACTERISTICS. IMPROVED EFFICIENCY OF RO PLANT BY IMPROVED TSS REDUCTION SYSTEM THROUGH SERIES OF SETTLERS, LAMELLA CLARIFIER AND DIFFUSED AERATION FLOATING MECHANISM WITH THE HELP OF SPECIAL POLYELECTROLYTES. UPGRADATION TO ACHIEVE UP TO 60% PERMEATE FROM RO. PROJECT UNDER IMPLEMENTATION (PARTLY DELAYED IN ORDER TO FIND A TECHNO-COMMERCIALLY FEASIBLE SOLUTION BY ROCHEM) EFFLUENT MANAGEMENT (REDUCE, RECYCLE & REUSE EFFLUENT)

11. REDUCTION OF SPENT WASH – INTEGRATED RAW SPENT WASH EVAPORATION - RKL,RAMPUR (U.P.)

12. S.NO.GURANTEED PARAMETERSUNITVALUES 1. FEED TO THE EVAPORATORTPD1690 2. INITIAL SOLIDS CONCENTRATION%W/W12 3. STEAM CONSUMPTIONMT/KL3.4 4. FINAL SOLIDS CONCENTRATION%W/W22 5.WATER EVAPORATION DUTYTPD760 6. TOTAL PROCESS CONDENSATE GENERATED FROM EVAPORATION PLANT TPD760 7.POWER CONSUMPTIONKWH180

13. HIGHLIGHTS OF INTEGRATED RAW SPENT WASH EVAPORATION THERE ARE TWO OPTIONS OF EVAPORATION : 1.EVAPORATION OF SPENT WASH THROUGH INTEGRATED / STAND ALONE EVAPORATORS. 2. EVAPORATION OF BIO - METHANATED SPENT WASH THROUGH INTEGRATED / STAND-ALONE EVAPORATORS. RADICO HAS ADOPTED INTEGRATED EVAPORATORS OF SPENT WASH NO EXTRA STEAM IS REQUIRED, EVAPORATION IS CARRIED USING ALCOHOL VAPOURS. COMPACT PROCESS & SMOOTH OPERATIONS IN HANDLING & CONCENTRATING SPENT WASH. STRUCTURAL COST IS REDUCED AS THE STRUCTURE FOR EVAPORTION PLANT IS MERGED WITH THAT OF THE DISTILLATION PLANT. LESS MANPOWER IS REQUIRED, BOTH DISTILLATION & EVAPORATION PLANTS CAN BE OPERATED BY A COMMON OPERATOR.

14. PROCESS PUMP SEALING WATER REUSE SYSTEM Total Water Savings = 95 % Process Pumps From All Sections Tank Make up

15. VACUUM PUMP / AIR BLOWER SEALING WATER REUSE SYSTEM Vacuum Pump / Air Blower Tank CWR CWS Cooler Make up Total Water Savings = 95 %

16. HIGHLIGHTS OF ADOPTING WATER RECYCLE, REUSE & TREATMENT SYSTEMS WATER RECOVERY AND ITS CONFIRM USAGE. REDUCTION IN LAND REQUIREMENT FOR BIO- COMPOSTING OPERATIONS AND PRESS MUD REQUIREMENT AS A RESULT OF EFFLUENT REDUCTION. REDUCTION IN WATER CONSUMPTION DUE TO HIGHER RECYCLE OF TREATED PROCESS CONDENSATE.

17. OVERHEAD COOLING TOWER FOR ENERGY SAVING

18. ACHIEVEMENTS OF ADOPTING RSW EVAP TECHNOLOGY AT RKL,RAMPUR SR.NO.DESCRIPTION 1SAVINGS ON ACCOUNT OF O/P COST FOR BIOCOMPOSTING WITH REDUCED QTY 2SAVINGS OF PROCESS WATER ON ACCOUNT OF UNTREATED PROCESS CONDENSATE RECYCLE TO FERMENTATION 3SAVINGS OF PROCESS WATER ON ACCOUNT OF RECYCLE & REUSE OF PUMP SEALING WATER,AIR BLOWER WATER. 4USE OF RO PERMEATE IN FERMENTATION AND COOLING TOWER.

19. MOLASSES SPENT WASH MANAGEMENT ZERO SPENT WASH DISCHARGE Sp. Wash from Distillation,1690 M3 / day with 12% Solids Multi effect Evaporators 40-45% Reduction in volume Anaerobic Digesters BOD REDN-88% COD REDN- 67% Series of Settlers,DAF & Filter Press for TSS Reduction Conc, SP. Wash 930 M3/d, BOD- 90,000, COD- 1,90,000 Mg/L 22% solids R.O. Plan t 60% REDN 880 M3/d 930 M3/d COD-63,000 Mg/L Recycled to Process (fermentation & cooling Tower Permeate 528 M3/d BIO COMPOSTING 50 M3/d Sludge Reject 352 M3/d Condensate 760 M3/d

20. Challenges / New Initiatives 1.High TSS in Digester Outlet. 2.Low Efficiency of RO System due to High TSS in Digester Outlet effluent. 3.Permeate recovery only about 45%. 1. Installation of Degasser and Series of Clarifiers with Filter press. 2. Addition of Special Poly- electrolyte for better settling and Series of Lamella Clarifiers Followed by DAF System. 3. Achieving Up to 60% high grade permeate recovery after adopting above systems.

21. Challenges / New Initiatives NO Bio-Composting in Rainy Season Molasses Distilleries face problem in Bio- Composting in Rainy season. Covered Bio-Composting Radico has covered composting area of about 6 acres since two years and practicing uninterrupted composting in rainy season in covered area. We have increased the covered area by another 8 acres this year. Now we have 14 acres of covered Bio- composting.

22. Reduction in Water Consumption through Recycling (Molasses Spirit Plant ) Stream Recycle TO 1.Rectification, Pre-rectifier column Lees Recycle Fermentation90% recovery 2.Vacuum Pump water recycleFermentation90% recovery 3.Steam Condensate RecycleBoiler90% recovery 4.Process Condensate recycleFermentation95% recovery 5.CO2 Scrubber Water recycleFermentation98% recovery 6.RO Permeate recycleCooling tower and Gardening 45% recovery Water Consumption / BL of Alcohol Before adopting Recycling Systems 12 Liter / BL Targeted Water Consumption / BL of Alcohol 6 - 7 Liter / BLAbout 45% Reduction

23. Reduction in Water Consumption through Recycling (Molasses Spirit Plant) S.noStream recycled Year -2013-14Year -2014-15Year -2015-16 under Implementation 1Pre-rectifier & Rectification column Lees Recycled to fermentation house 2Vacuum Pump waterRecycled to fermentation house 3Steam CondensateRecycled to boiler section 4CO2 Scrubber Water Recycled to fermentation house 5Process CondensateRecycle to cooling tower 6RO PermeateRecycle to cooling tower Water Consumption / BL of Alcohol 18.012.07.0

24. Compliance of CPCB Directives Volume Reduction through Integrated Evaporators ( 40-45%) and through R O Plants (60%). Over all volume reduction more than 75%. Covered Bio-composting under Poly Shed for Composting in rainy season. Usage of lesser polluted streams in Fermentation, Cooling Tower make up and Gardening.

25. Inclusion of Distillery in Orange Category In view of the compliance of Zero Spent Wash discharge, Distilleries should be placed in orange category in place of Red category. Discharge of Bottle Washing Water, DM Water back washing, boiler blow down etc. streams should be allowed to be discharged after proper treatment in order to minimize cost of achieving Zero Discharge for lesser polluted streams.

26. Measures Taken for Energy Conservation Replaced all the old un-efficient motors and pumps with the new highly efficient pump and motors. Adopted Dyano Drive Systems for Flexibility in loads. Overhead Cooling tower basins to provide positive suction head for pumps. Power Generation through highly efficient Bio- Gas Engines of MWM GERMANY.

27. Energy Conservation Installation of VAM Integrated Chilled Water System for air conditioning requirement from Bio-Gas Engines. Installation of Temperature Sensors at Cooling Tower Tans to save the power during winter season. Timer installation on Street and Plant Lights. Replacement of copper chocks with electronic chocks.

28. Plant Control Room

29. Bio – Gas Engine

30. Distillation With Integrated Evaporators

31. Bio Gas Digester

32. R O Plant Radico R O Plant

33. Covered Bio-Composting

34. Challenges in Molasses Effluent Treatment

35. Bio Engine

36. Zero Discharge – TSS Reduction – Complete Process Flow