the ugar sugar works ltd., ugar khurdaidaindia.org/presentations2019/jaipur/ugar sugar dr pattan...

The Ugar Sugar Works Ltd.,Ugar Khurd

AIDA Seminar – Jaipur Recovery of Low Grade Potash a case study at USWL

The Ugar Sugar Works Ltd.,

Introduction.

In India, there are about 300 distilleries under operation.

Distillery is considered as one of the major revenue earning industry

Distillery also come under highly polluting industry category .


Present Distillery Effluent Treatment Systems being operated in India.

Raw Spentwash followed by evaporation followed by Incineration in highpressure boiler for production of steam & power

Raw Spentwash followed by Biomethanation followed by Evaporation followedby 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 rotarydryer.

Raw Spentwash followed by Biomethanation followed by Evaporation followedby mixing with bagasse , husk etc & burning in conventional boiler designedfor using the effluent mixed fuel.

Raw Spentwash followed by Biomethanation followed by Evaporationfollowed by low grade potash recovery generation

Raw Spentwash followed by Biomethanation followed by one time controlledland application

Raw Spentwash followed by Biomethanation followed by Evaporationfollowed by composting

Raw Spentwash followed by Evaporation followed by burning in cementplant kiln or thermal power plant furnace or steel plant furnace .

Raw Spentwash followed by Biomethanation followed by Secondarytreatment to bring down BOD level less than 2500 mg/l & disposal in sea.


USWL Case study -

All above different technologies are being followed by distilleries basedon their local conditions , resources available around the location, costof the treatment & state pollution control board guidelines.

The evaporation system is almost common in most of the optionsmentioned above. There are distilleries who are having more than oneoption in order to keep distillery operation for maximum days. Oursuggestion is to add one more spray dryer to make the low gradepotash powder. The details are mentioned in next slides.


The USW limited installed the zero pollution plant ( LowGrade Potash Powder recovery plant.) in the year 2002 &another simillar plant in 2008.

Govt. of India has supported this plant throughTechnology Development Board, New Delhi.



Project Details

Biomethanation Plant

The Evaporator Plant

The Spray Drying Plant


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 additional manpower required through out the year (2 operators

/ shift).


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.)


UASB Reactor

CSTR Digester


Zero Pollution Plant Capacity – 1060 m3/day for 75 KLPD

New Evaporator Plant Old Evaporator plant – 360 m3/day


Zero Pollution Plant Capacity – 1060 m3/day for 75 KLPD

Old Dryer plantNew Dryer plant


Hot Air Generator

Flow Chart

Biomethanation Effluent

Evaporators(5 Effect)

Spray Dryer

Powder

Water evaporation Steam

Biogas Fired Hot Air

Generator

Distillery Effluent Treatment

Low grade Potash Powder


Potash Sugarcane Sugar

Bagasse

Molasses

Pressmud

Alcohol(Industrial & Potable)

(Potash)Spent Wash

The GA of Sugar unit Process is as underThe Ugar Sugar Works Ltd.,

Analysis of Distillery EffluentThe 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 itcontains other micro nutrients

Crop response to Low Grade Potash application was better than Chemicalfertilizer.


Guaranteed specifications of Low Grade Potash suitable for direct application for incorporated in FCO:-

Water soluble potash as K2O = 14.70Total Phosphate as P2O5 = 0.39Total Nitrogen as N = 1.6Micronutrients like Iron, =1043 ppmMaganese = 62 PPMMoisture % Max by weight minimum = 5% MaxParticle Size = less than 100 micron

(100% Below 60 Tyler Mesh)

Details of Estimation considered total molasses production in India for the year



Progress on Subsidy Matter :-

USWL through AIDA has presented the project details to Ministry of Agriculture & brought this product under FCO 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 as under

Based on the present NBS policy the subsidy to the manufacturers of LGP may be granted at Rs.4500/- PMT. & shall be paid to the manufacturers as per quantity sold by them.

The MRP for LGP be fixed at Rs. 1400 PMT ex-plant.


Conclusion

It is mandatory to put up zero pollution/ zero liquid discharge plant.

Potash recovery will give more returns than composting or incineration

Require lesser investment & space

This will also save our foreign exchange by recycling of Potash through the process explained as above.

Distilleries can add a spray dryer to start generating LGP fertilizer after existing evaporation plant.


Thank You

Presented By :- Dr. S.M.Pattanshetty (Chief Manager Environment)

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