Does Effluent Treatment eat into your Distillery’s 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.
12% - Solid 88% - Water
60 - 65 % Solid 35 - 40% Water
ADVANTAGESOF
INCINERATION
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
plant’s 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.
CASE STUDY
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 TPHCASE 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
.
DESCRIPTION Units 25 TPH Net H.P.
Incinerator
Boiler
15 TPH Net L.P.
Boiler
1. Steam generation Kg / hr 23000 13500
2. Steam pressure Kg / cm2 45 10.54
3. Steam
temperature
°C 440 Saturated
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
consumption
Kg / hr 3333 (Husk)
+8000 (Slop)
3800
6. Fuel Saving on
Rice Husk
Kg / hr 467 --
7. Auxiliary power
reqmt.
KW 410 245
8. Addl. Aux. power kW 165 --
9. Power
generation
kW 1500-
10. Net power
generation
kW 1335--
Cont…
A ADDITIONAL EXPENSES FOR POWER GENERATION
1) Cost of equipment Rs. Rs. 1600 Lacs Rs. 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 --
B SAVINGS ON FUEL CONSUMPTION
1) Fuel Saving in
Incinerator boiler
Kg / hr (3800-3333)
467
-
2) Rice Husk Cost Rs / hr 3.5
3) Savings on Fuel Rs / hr 1635Cont…
C SAVING DUE TO POWER GENERATION
1) Units
generated / hr
kWH (1500 -165)
=1335
--
2) Power cost from SEB
DG Set
Rs. / kWHRs. 5.00
Rs. 12.00--
3.) Average Power
Cost
(Considering 20
Hrs Supply
from SEB & 4
Hrs from DG
Set)
Rs. / kWH Rs. 6.20 --
4) Saving / Hr Rs. / hr Rs. 8277 -- Cont…
5.) Annual saving
from
Power(Considering
24 hrs x 310 days
a year)
Rs. / year Rs. 616 lacs --
6.) Annual saving
from
Fuel(Considering
24 hrs x 310 days
a year)
Rs. / year Rs. 122.0 lacs --
7) Total Saving (Due
to Fuel Saving &
Power Generation)
Rs. / year Rs. 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 period 2 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 2nd 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
Glimpses of Slop fired Boilers
CONCENTRATION UNIT
INDIA GLYCOL PLANT AT
GORAKHPUR
40 TPH 45 KG/CM2 SLOP FIRED BOILER
INDIA GLYCOL PLANT AT GORAKHPUR
30 TPH SLOP FIRED
BOILER AT
OUDH SUGAR,
HARGAON (U.P).
30 TPH
45 Kg/cm2
Slop Fired Boiler
at Oudh Sugar
CBL MANUFACTURING CBL MANUFACTURING FACILITIESFACILITIES
CBL MANUFACTURING CBL MANUFACTURING FACILITIESFACILITIES
The Tribune , The Tribune , ChandigarhChandigarh(Saturday, June 09, (Saturday, June 09, 20072007))
The Economic Times , The Economic Times , Monday, August 06, 2007Monday, August 06, 2007
>>TECHNOLOGY AT IT’S BEST<<
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