technicalreport-alcoholtechnology.pdf

8/14/2019 technicalreport-alcoholtechnology.pdf

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ALCOHOL TECHNOLOGY

The department provides guidance to alcohol

industry for achieving maximum productivity,efficiency and yield from different feedstocks andalso to enhance the quality of finished products

viz. rectified spirit, extra neutral alcohol and

ethanol. The department is also engaged in researchin the areas of water conservation in distilleries for

achieving zero liquid discharge of effluent

generated. The consultancy and inspection ofongoing projects, proposed molasses and non-

molasses based distilleries and distillery effluent

treatment projects are the integral assignmentsof

the department. Government agencies at the centraland state level department seek technical inputs

and advice from the department. A publication onTechnical Performance of Distilleries affiliated toco-operative sugar mills of Maharashtra State is also

brought out annually.

A masters degree course in Wine Technology(brewing, distilling & wine making) affiliated to

University of Pune was started during the current

year. In addition, post graduate diploma course inIndustrial Fermentation and Alcohol Technology,

short-term training programmes and courses are

conducted in the Institute. The department also

provides guidance to the PhD, M Tech, M Pharm

and MSc students from different universities for theirproject work.

RESEARCH AND DEVELOPMENT

Studies on Improving Molasses Quality and Effect

of Sludge, Calcium, Total Organic Volatile Acids

(TOVA), Sulfur Dioxide Content and MicrobialCount on Fermentation Process

Improving Molasses Quality in Respect of

TOVA Content

In the year 2010-11, studies related to this aspect

were done at Shree Doodhganga Krishna SSKN.The TOVA of molasses was found to be above10,000 ppm, which affected the efficiency of

continuous fermentation process and continuity of

fermentation cycle. In association with thedepartment of sugar technology, the volatile acidity

levels at different stations in sugar manufacturing

process were measured. Steps were taken to reduce

the volatile acidity during sugar manufacturingprocess, which resulted in improving the quality

of molasses to a certain extent. The volatile acidity

of various intermediates and products of sugarcaneprocessing including primary juice, mixed juice,

clear juice, sulfured and unsulfured syrup, olivercombine filtrate, samples of A, B and C

massecuites, A-Heavy molasses, A-Light molasses,

B-Heavy molasses etc. was analyzed at this mill.

The precautions taken during this season helpedto reduce the TOVA content in final molasses from

10,000 ppm to 3,500 ppm.

Development of Method for Estimation of

Sulphur dioxide Content

It was observed that fresh molasses is difficult

to ferment due to higher concentration of dissolvedsulphur dioxide. Along with TOVA of molasses,its sulphur dioxide

content

can also inhibit the

alcoholic fermentation by Saccharomyces

cerevisiae.

To evaluate this aspect, a method was

developed for estimation of free sulphur dioxide

content of molasses solutions by employing

modified Ripper titrimetric method using potassiumper-iodate.

Estimation of sulphur dioxide content and

TOVA content of molasses samples were carriedout simultaneously and the results are given in table

27. It was observed that the free sulphur dioxide

content increases with increasing TOVA ofmolasses samples.


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This method was tested repeatedly with different

molasses samples. The method gave consistent andreproducible results. Further experiments will be

conducted to investigate the effect of individualvolatile acids (such as acetic, butyric, propionicacids etc.) as well as free sulfur dioxide on the

activity of yeast and fermentation process. Further

studies are also planned in association with thedepartment of sugar technology to control the sulfur

dioxide content of final molasses to the minimum

possible level.

Improving Molasses Quality in Respect of

Sludge Content

The sludge content of molasses has shown an

increasing trend in the last few years. Higher sludgecontent of molasses not only reduces the effectivevolume of fermenter but can be detrimental to yeast

activity and fermentation process.

In association with the department of sugar

technology, a study was undertaken at BhauraoChavan SSK Unit-II and III for the reduction in

sludge content of final molasses. The sludge

content in final molasses was found to be extremelyhigh at around 27%, which was seriously affecting

the operation of continuous fermentation process.The sludge content was measured at different

stations in sugar manufacturing process. Based on

the analysis, following measures were taken toreduce the sludge content in final molasses.

Stale cane percentage was reduced and fresh

cane was used for milling.

The quality of lime was found to be inferior

with calcium oxide content of 68-70%. This

was replaced with better quality lime.

The use of anti-scalant in the evaporatorswas stopped.

The phosphoric acid dose was increased to

bring phosphorus pentoxide (P2O

5) content

in mixed juice to 350 ppm.

These measures resulted in reducing the sludge

content of final molasses. The sludge content at

Unit-II was reduced to 17% and at Unit-III wasreduced to 21%.

Performance Evaluation of Bio-digesters andEvaporation/Membrane Filtration (RO) System for

Distillery Effluent

The Central Pollution Control Board (CPCB),New Delhi has sponsored this project for

Table 27 : TOVA and free sulphur dioxide content in analyzed molasses samples

Manganga SSK 3770 420Dnyaneshwar SSK 4113 690

Ajinkyatara SSK 4456 450



Kopargaon SSK 4713 490

Bhaurao Chavan SSK 5056 700

Bhaurao Chavan SSK 5142 660

Majalgaon SSK 5056 620

Siddheshwar SSK, Kumthe 5142 610

Vitthalrao Shinde SSK 5313 680

Sant Tukaram SSK 5741 670

Nira-Bhima SSK 5999 720Satpuda Tapi SSK 5999 680

Ashok SSK 6513 700

Gangakhed Sugars & Energy Ltd 7884 720

Doodhganga Krishna SSKN 6341 780

Parry Sugars Ltd 10541 940

Parry Sugars Ltd 4884 650

Malprabha SSK 5056 510

Name of mill TOVA by Conventional Free Sulphur dioxide

method (ppm) (ppm)


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undertaking performance evaluation of bio-digesters,

evaporation plants, reverse osmosis units andIncineration systems for disposal of distillery

effluent.

The detailed studies and performanceevaluation work at remaining two units were

completed in the year 2011-12. Data collected

during the visit were studied and investigated in

depth. Performance evaluation work of all tendistilleries as prescribed by the CPCB on different

technologies of effluent treatment was thus

completed. A presentation on this project was givento the officials and expert committee of the CPCB.

Final report of this project was also prepared and

submitted to CPCB.

Table 28 : Comparative performance evaluation of bio-methanation plants

Particulars Name of Distillery

A B* C D E* F H*

Type of digester Fixed D2, D3- Down flow Down flow D1-UASB CSTR UASB

(D1, D2 etc) film Packed followed by followed by D2-Fixed

media, up-flow up-flow film,

D4-UASB (Thermophilic) (Thermophilic) D3-CSTR

Designed and 600 D2-360 D1-600 D1-750 D2-390 1000 D2-236

actual capacity (360) (243) (550) (512) (130) (703) (175)

for SW treatment, D3-360 D2-600 D3-285 D3-226

m3/day (133) (550) (206) (208)

D4-400 D4-214

(424) (226)

Design HRT, 12.2 D2- 9.0 D1- 18.0 D1- 12.0 D2- 14.0 21.0 D2-8.0

Days (Actual (20.3) (13.7) (19.4) (18) (42.3) (30) (10.7)

HRT, Days) D3- 8.8 D2- 18.0 D3- 26.0 D3-10.6

(24) (19.4) (36) (11.5)

D4- 21.0 D4- 10.6

(20) (11.2)

Design COD 9.8 D2- 10.8 D1- 5.62 D1- 7.0 D2-9.95 7.16 D2-10.0

loading rate, (5.5) (7.1) (4.34) (7.1) (2.68) (4.94) (7.87)

kg/m3/day D3- 11.3 D2- 5.62 D3- 5.34 D3-10.0

(4.1) (4.34) (3.10) (7.3)

D4- 5.0 D4-10.0

(4.94) (7.55)

COD reduction, 64.81 D2- 61.11 63.70 55.0 D2- 54.21 64.25 D2- 66.0

% D3- 57.68 D3- 62.00 D3- 66.0

D4- 61.99 D4- 64.0

BOD reduction, 87.0 D2-89.41 90.0 72.21 Facilities 85.0 90.0

% D3- 85.88 were not

D4- 88.82 available

Gas generation, 0.49 D2- 0.50 D1- 0.59 0.47 D2- 0.50 0.55 0.60

m3/kg of COD D3- 0.50 D2- 0.59 D3- 0.50

reduction D4- 0.53

Gas generation 35.11 D2- 29.88 D1- 37.25 33.20 D2- 30.87 52.33 32.82

m3/m3of raw D3- 28.30 D2- 37.25 D3- 35.41

spent wash D4- 31.74

*D1 not operational


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The comparative performance evaluation,

conclusions and recommendations on different

technologies of effluent treatment studied underthis project are given in tables 28 to 32 respectively

i) A to J indicates the different distilleries in

the country where performance evaluationstudies were carried out.

ii) Figures in parenthesis ( ) are the actual

quantities.

Conclusions/Recommendations

It is possible to achieve COD reduction inthe range of 55-60 %, BOD reduction of 85-

90 % and gas generation of 0.50-0.60 m3/kg

COD consumed.

It is now well-established and results insubstantial reduction of COD and BOD and

brings the pH to near neutral. Bio-methanation is not suitable for seasonal

distilleries.

Ideally, distilleries with bio-methanation

should run throughout the year. Therefore,

bio-methanation followed by incineration

can be an ideal system. Digesters designed for COD loading rate of

5 Kg/M3/day has given best performance.

CSTR and UASB based digesters are moresuitable for molasses based distilleries.

Biogas based power generation or CNG

production can offer higher returns.

Gas zone region (particularly the mild steel

roof) of the digester is susceptible to heavy

corrosion and needs replacement every 8 to

10 years.

Further evelopments required in bio-methanation

Corrosion resistant roof for digesters made

of either SS 304 or polymeric membrane.

Biomethanation technology that can accept

high strength spent wash. Wet-corona discharge oxidation of bio-

methanated spent wash to break down therecalcitrant COD followed by secondary bio-

methanation.

Table 29 : Comparative performance evaluationof membrane filtration plants


B C E F H

Type of technology Disc & Disc & tube Disc & tube Disc & tube Membrane bioreactortube followed by with NF and RO

NF followed membrane system

by UF (Spirally wound type)

i) Number of stages 6 12 3 4 2

ii) Total number of 1,61,100 64,750 2,208 16,110 Nano- 45RO- 30membranes

Design and actual quantity 800 1400 RO1-Not in RO1- 500 840 (614)

of BMSW treatment, (697) (950) operation (436)M3/day (Actual feed, RO2-260 RO2- 500

M3/day) (190) (Not inRO3- Dismantled operation)

Design TSS, ppm 2000 4500 2000 3000 5000

Actual TSS, ppm 1480 2100 2200 - 500

Retention time before feed 10 days 0.5 days 9 days 25 days 9 days

Feed brix 6.1 6.3 6.0 5.5 2.1

Reject, M3/day 393 402.6 103 231 393

Reject Brix 10.0 11.3 11.0 10.5 5.1

Permeate, M3/day 304 547.4 87 205 221

Design and actual 55.0 55.0 55.0 55.0 60.0

permeate recovery ( %) (43.61) (57.6) (45.50) (47.0) (58.06)

Disposal of reject Bio-com Bio-com Feed to MEE Bio-com Feed to MEE

posting posting posting


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Conclusions/Recommendations About 70-80 RO plants are now installed in

the Indian distillery industry.

RO plants are more useful for bio-

methanated spent wash treatment than raw

spent wash treatment. Disc and tube configuration is well

established with 50% average recovery of

permeate from bio-methanated spent wash.Maximum recovery reported is about 60 %.

Suspended solids are most critical factor and

suspended solids are required to be

maintained below 2,000 ppm.

Permeate can be recycled after proper

treatment as make-up water in coolingtowers or for molasses dilution.

Operational cost is slightly less than MEE

plants for about 50% reduction in effluent

volume.

Major recurring cost in this option is the

membrane replacement cost.

Most of the membranes are imported.

Proper pre-treatment to bring down the

suspended solids would increase the life of

membranes.

This is a promising technology, whichwould bring further improvements in future.

Table 29 : Comparative performance evaluationof membrane filtration plants


B C E F H

Type of technology Disc & Disc & tube Disc & tube Disc & tube Membrane bioreactor

tube followed by with NF and RONF followed membrane system

by UF (Spirally wound type)

Disposal of permeate For For molasses For cooling For cooling For molassesprocess dilution tower make tower make dilution & floor

& non up water up water washingprocess

Polishing unit to treat Degasser Degasser Degasser Degasser Degasser followed

permeate followed followed by by ACFby ACF ACF

Table 30 : Comparative performance evaluation of multiple effect evaporation plants


A D E G H I J

Type of Falling film Falling film Falling film Falling film Falling film Falling film Forced

Technology & forced circulation

circulation

(Fluebex)

With or With TVR With TVR With TVR Without TVR With TVR Without TVR TVR was

Without TVR not in useType of BMSW BMSW RO reject Raw spent Nano reject Raw spent Raweffluent used wash /concentrated spent

as feed spent wash wash

Designed & 5.0 40.0 5.0 30.0 10.0 35.0 10.0 60. 02.0 40.0 IE-(14.024.0) 14.5 65.0

actual solids (6.540.0) (6.5 10.9) (20.1-53.5) (12.0 62.0) (5.552.5) (15.924.2) (17.061.0)concentration, SE-

% (24.0 55.0

(24.2-56.5)

No. of effects 5 5 5 5 5 3 + 4 5


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Table 30 : Comparative performance evaluation of multiple effect evaporation plants


A D E G H I J

Type of Falling film Falling film Falling film Falling film Falling film Falling film Forced

Technology & forced circulationcirculation

(Fluebex)

Design & 4.5 5.9 P1 2. 114 2.5 IE- Alcohol 9.0

actual Steam (4.5) (4.5) (P22.16) (6.16.3) (2.39) Vapour (9.0)requirement, SE 7.3 (5.4)

MT/hr

Design & 3.5 1.5 7.5 4.5 7.5 1.5 2.4

actual Steam (3.2) (1.2) (7.5) (4.5) (7.5) (1.2) (2.4)pressure,

kg/cm2

Design & 30.00 40.40 15.90 Each 67.70 15.00 IE- 26.00 45.37actual feed (17.00) (30.60) (P1-14.70) (15.00) (12.88) (21.70) SE (37.50)

M3/hr (P2-14.74) -20.00(14.40)

Design & 3.00 6.73 4.99 11.54 0.75 IE- 19.50 10.24

actualproduct (2.24) (18.60) (9.50) (Not in (1.60) (14.50) (12.77)output, M3/hr operation) SE - 8.00

(4.80)

Design & 25.00 33.66 10.90 56.16 13.00 IE -6.00 35.69actual Water (15.00) (12.00) (P1- 9.53) (12.10) (11.52) (7.10) (25.00)evaporation (P2 9.58) SE -11.50

rate, M3/hr (9.50)

Steam 5.50 5.70 NP 4.01 5.20 1.57 3.96economy, (3.30) (2.70) (P1 4.54) (1.97) (4.82) (1.76) (2.77)

Kg of water (P2 4.44)evaporated/

Kg of steam

used

Operation 20 20 20 24 20 24 24

hours/ day

Power 170 207 185 NP 74 IE- 226 501consumption, SE 339

Kw/hr

Treatment for Degasser No treatment Air sparger No treatment Degasser Reverse No

process followed is given provided in is given followed by osmosis treatmentcondensate by ACF RCC aeration ACF Plant is given

tank

Disposal of Ferti- Spent wash Cooling Molasses Cooling Molasses Irrigationcondensate irrigation dilution, tower dilution tower dilution,

water floor make up make up floor washing & washing &

pump sealing pump sealing

Disposal of Spray dryer Bio- Bio- Incineration Spray Incineration Incinerationconcentrate followed by composting composting dryer

product Incineration followed byIncineration

TVR- Thermal Vapor Re-compressor, IE- Integrated Evaporator, SE- Standalone Evaporator, ACF- Activated Carbon Filter,NP-Not provided.


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Well-established technology for

concentration up to 30% solids, which can

help in substantial reduction of spent wash

quantity. Susceptible to scaling above 2,000 ppm

suspended solids in feed. Concentrationabove 40% solids is yet not well established.

Proper de-gassing of bio-methanted spent

wash is required before concentration

through multiple effect evaporation plant. Substantial quantity of steam is required for

evaporation of spent wash and therefore,

there will be additional recurring cost.

Process condensate requires polishingtreatment before reuse in process and non-

process applications. Therefore, additional

treatment cost.

Integrated raw spent wash evaporation can

result in reduction of final spent wash

volume to between 3.5 to 6.5 lit./lit. ofalcohol produced without additional steam

requirement, depending on fermentation

technology employed.

Scaling is severe when the product isconcentrated above 50% solids and it is

extremely difficult to remove the scaling.

Table 31 : Comparative performance evaluation data/findings of spray dryers

Particulars A HFeed MEE concentrate MEE concentrate

Feed, M3/day 60 23.20

Drying hot air inlet temperature, 0C 400 400

Drying air outlet temperature, 0 C 125 120

Powder production, MT/day 20 3.49

Moisture % in powder 4 - 5 4 - 5

Calorific value of dry powder, Kcal/Kg 2600 2200

Table 32 : Comparative performance evaluation of incineration boilers


G I J H

Year or installation 2008-09 2009-10 2008-09 2009-10

Plant supplier Guangxi Luzhou Thermax Ltd., Pune Cheema Boilers Ltd., Industrial Boiler Thermal Power Chandigarh Ltd.,

Equipment Co., China Vapi

Capital investment 40.0-45.0 (Including 36.0 (Including 24.6(Including MEE 0.80 (Only boiler)

( `crore) civil and structure MEE plant, boiler plant, boiler works, MEE plant, slop and accessories) and accessories)

fired boiler and stack

control equipment)

Controlling system Semi-automatic DCS PLC Semi-automatic

used for plant

monitoring/operationDesign basis

Steam generation D: 25.0 D: 22.0 D:30.0 A: 2.0-2.5capacity, (TPH) A: 6.7 A: 19.0-20.0 A:22.0-23.0

Steam temperature, D: 400.0 +/- 20 D: 380.0 +/- 5 D: 425.0 +/-10 D:192.0+/- 5

(OC) A: 400.0 A: 380.0 A: 425.0 A: 170.0

Steam pressure, D: 32.0 D: 44.0 D: 45.0 D:10.5

Kg/cm2(g) A: 26.0-29.0 A: 43.0-44.0 A: 44.0 A:7.0-9.0

Boiler efficiency, (%) 70.0 60.0 60.0-62.0 80.8-82.0


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Technology is not matured and not yet well

established.

Various bottle-necks need to be overcome.

May not be economical for distilleries below

60 KLPD capacities.

Very high capital & operating cost.

Emission norms will have to be checked and

revised.

Due to high ash content in the spent wash

and supplementary fuel, fouling in flue gas

passage is severe and plant has to be

stopped for cleaning of ash deposition.

Due to frequent stoppages for cleaning

refractories of furnace are displaced, falls in

the furnace & disturbs fluidization.

Development of Standards and Guidelines forGrain Based Distillery Waste in India

The CPCB, Delhi has entrusted this project to

VSI. The proposed study will help CPCB to evolvenew standards and guidelines for disposal of solid,

liquid effluents and gaseous emissions from grain

based distilleries in the country.

Under the project, ten different distilleriesacross the country are to be studied for the systems

they have implemented for disposal of waste ofsolid, liquid and gaseous emissions. Out of the ten

proposed distilleries, detailed studies in three

distilleries have been completed. Collection of

design data, operating conditions/parameters andperformance evaluation of grain handling, milling,

saccharification and liquefaction, fermentation,

distillation, decantation, multi effect evaporation

Table 32 : Comparative performance evaluation of incineration boilers


G I J H

Furnace details

Type Fluidized bed Fluidized bed Two furnaces: Fire tube

Traveling grate withpulsating grate &

superheater furnace

Temperature,OC D: 950 D: 980 -1020 D: Not provided D :

A:938 -950 A: 960 -1000 A: 600 -800 A : 300Superheater: 502 -680

Fuel type Coal Coal Bagasse (or coal) i) Wooden chips

ii) Dried spentwash powder

Calorific value, 3,000 -3,500 3,800 2,000 i) 2,200

Kcal/Kg ii) 2,200Ash, % 30 25-30 20 (Bagasse) Less than 2%

Fuel consumption, D: 2,000 D: 2,250 D: 5,000 D: 1,850

Kg/hr. A:500 - 600 A:2,100 -3600 A:7,000 8,000 A: 2,200

Bagasse/Coal 1.5 3.0 NA

feeding pointheight, meter

Slop feedcharacteristics

Slop feed, Ton/hr. D: 11.2 D: 7.8 D: 10.5 150 -160 Kg/hr.

A: A: 6.5 - 6.7 A: 4.5 spent washpowder

Calorific value, 1,700 -1,800 1,705 1,865 NAKcal/Kg @ 60OBx @65OBx

Slop feed 60 -70 D:81-88 D:

temperature, OC A: 60-76 A: 60 - 65 NA


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(MEE) plants, DWGS, DDGS, biogas plants and

extended aeration system were completed.

Occurrence of stoppages, reasons for stoppagesand other problems faced by units were discussed

in detail with the distillery staff during visits.

Various bottle necks in the process operations of

different effluent treatment plants were identifiedand data was compiled. The configuration of the

distilleries studied has been given in table 33.

Research work of the remaining sevendistilleries will be completed in the following year.

Compilation and evaluation of data collected was

under progress.

Screening and Development of Thermotolerant

Yeast for Alcoholic Fermentation

Experiments were carried out using the selected

strain of yeast TSC-20073 on 100 litres pilot scaleto test its performance at higher temperature. The

fermentation experiments were carried out at

uncontrolled temperature i.e. cooling water for

controlling fermentation temperature was not used.

The molasses sample from Kumbhi Kasari SSK wasused for the experiments. Starting with 31.10C the

maximum temperature reached was 36.4C during

one of the experiments.

Table 33 : Configuration of grain based distilleries


A B C

Capacity 65 KLPD 30 KLPD 80 KLPD

Grain feed stocks used Maize/Sorghum Sorghum/Broken rice Sorghum/Broken rice

/Millet

Fermentation technology Batch Batch Batch

Distillation technology Multi-pressure Multi-pressure Multi-pressure

Main Product EQRS/ENA EQRS/ENA EQRS/ENA

Alcohol % in Wash 10.0 11.0 9.0 11.0 13.0 14.0

Whole stillage generated, 7.75 8.00 4.00

lit/lit of alcohol

Technology adopted for Decantation Decantation Decantationdisposal of whole stillage Evaporation DWGS Evaporation Bio-methanation

manufacture DWGS & DDGS Reverse Osmosismanufacture Bio-composting

Quantity of secondary 5.46 2.70 1.02

effluent generated, lit/lit ofalcohol

Effluent treatment system for Bio-methanation Bio-methanation Neutralization & recycledisposal of low strength Aerobic treatment Aerobic treatment for liquefaction.

waste (Secondary effluent) clarifier Ferti-irrigation Fermenter washingFerti-irrigation added into beer-well.

Fresh water consumption 21.66 24.83 15.14

without recycle, M3/KL

Fresh water consumption 12.16 11.97 6.93

with recycle, M3/KL

The effect of increasing temperature on yeast

cell growth, sugar consumption rate and ethanol

production rate were also checked (Fig. 19).

The sugar was almost completely consumed

under uncontrolled fermentation temperature. The

fermentation was completed in 30 hr with ethanol

volumetric yield of 9.53 % (v/v).

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The results indicate that the thermophilic yeast

strain developed gives the same performance asthat obtained with normal yeast strain requiring

proper temperature control. Further trails on plant

scale are proposed in the coming year.

Use of such thermophilic yeast will help the

distilleries to reduce the cost of production by saving

in the energy required for cooling fermenting broth.

EXTENSION AND ADVISORY SERVICES

Detailed Project Reports (DPRs) on newdistilleries, modernization of existing units and

ETPs completed during the year

The following DPRs were prepared by thedepartment. (Table 34)

Tender Documents

The department provided guidance to mills in

preparation of comprehensive tender documents

required for erection of various plants by memberdistilleries as listed in table 35.

Technical Meetings and Evaluation of Technical

Offers (SLMPC)

The staff of the department attended the pre-

bid, technical sub-committee and State level

machinery purchase committee (SLMPC) meetingsat MRSSK Sangh Ltd. for the following distilleries

as detailed in table 36. Technical offers received

for different technologies were critically evaluated

and comparative technical statements wereprepared.

Table 34 : Detailed Project Reports prepared

Name of Distillery Plant Configuration Assignment details

Dnyaneshwar SSK Rectified Spirit and Extra Neutral Expansion of 45 KLPD distillery to 75

Alcohol (MPR distillation). KLPD and up-gradation of effluenttreatment system

Majalgaon SSK Biogas based power generation 1.4 MW power generation from biogas

Rameshwar SSK Rectified Spirit, Extra Neutral Alcohol New 30 KLPD distillery

(MPR distillation) and Anhydrous

Alcohol (MSDH Technology)

Tridhara Sugars Anhydrous Alcohol (MPR New 30 KLPD distillery

distillation and MSDH Technology)

Makai SSK Anhydrous Alcohol (MPR distillation New 30 KLPD distillery

and MSDH Technology)

Mula SSK Anhydrous Alcohol (MSDH New 30 KLPD MSDH plant

Technology)

Lok. B. Patil SSK Biogas based power generation 1.22 MW power generation from biogas

Pad.Dr.VV Patil SSK Extra Neutral Alcohol New 20 KLPD - RS to ENA plant.

Datta Shetkari SSK Export Quality Rectified Spirit Modernization of existing 30 KLPD

distillery plant

Kumbhi Kasari SSK Rectified spirit and Extra Neutral Modernization of existing 30 KLPD

Alcohol (MPR distillation) distillation plant

NSL Sugars, Ghana Rectified spirit, Extra Neutral New 50 KLPD distillery plant

Alcohol and Anhydrous Alcohol

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Table 35 : Tender documents prepared

a Name of Distillery Plant Configuration Plant Capacity

Dnyaneshwar SSK RS and ENA (MPR distillation) Expansion of 45 KLPD to 75

KLPD and up-gradation of effluent

Vikas SSK RS / ENA / AA 30 KLPD

Vikas SSK Biogas plant 630 M3/day spent wash feed

Vikas SSK Biomethanated spent wash 630 M3/day biomethanated spent

evaporation plant wash feed

SMSM Patil SSK RS / ENA / AA 60 KLPD

Kumbhi Kasari SSK RS / ENA 30 KLPD

Datta Shetkari SSK Ltd Export Quality RS 30 KLPD

Datta Shetkari SSK Ltd Biogas plant 600M3/day spent wash feed

Datta Shetkari SSK Ltd Biomethanated spent wash 600M3/day biomethanated spent wash

evaporation plant feed

Sanjivani (Takli) SSK Ltd. Export quality RS 60 KLPD

Sahyadri SSK Compost yard as per CREP norms 45 KLPD

Table 36 : Technical Meetings (SLMPC) and evaluation of technical offers

a Name of Distillery Plant Configuration

Vikas SSK 30 KLPD distillery plant 630 M3/day spent wash

(Pre-bid, Technical subcommittee feed biogas plant 630 M3/day to 189 M3/day

and SLMPC meetings) (9% Total solids to 30% Total solids) spent wash

evaporation plant

SMSM Patil SSK (Pre-bid, Technical subcommittee 60 KLPD distillery plant with integrated spentwashand SLMPC meetings) evaporation plant

Kumbhi Kasari SSK (Pre-bid, Technical 30 KLPD distillery modernization

subcommittee and SLMPC meetings)

Datta Shetkari SSK (Pre-bid, Technical 30 KLPD distillery modernization

subcommittee and BoDs meetings)

Visits

The staff of department visited member and non-

member distilleries in Maharashtra and other states,

government offices, institutions etc. for differentassignments. The details of these 172 visits are

given in Annexure XIII

Recommendation of Proposals

VSIs technical recommendations are requiredfor installation of new as well as for modernization

and modification of distilleries and ETP plants.

Details of recommendations given to distilleries

are detailed in table 37.

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Inspection of Plant and Machinery /Consultancy

services

Distilleries request VSI to inspect the plant andmachinery during the plant erection period and

supervise the commissioning and performance trialrun. The department carried out the inspection/

consultancy services are mentioned in table 38.

Table 37 : Recommendations

Name of Distillery Recommendation

Dharani Sugars and Chemicals Ltd PRC, Rectifier cum exhaust and methanol column

specifications.P & I diagram for pipeline modification

of fermentation section

Dnyaneshwar SSK Installation of new molasses weighing system.

Manganga SSK Installation of pre-fermenters.

Sonhira SSK Installation of integrated evaporation plant.

Datta Shetkari SSK Installation of integrated evaporation plant.

Kumbhi Kasari SSK Modernization of existing 30 KLPD atmospheric

distillation in to MPR distillation.

Sahyadri SSK Construction of impervious compost yard as per

CREP norms.

Datta Shetkari SSK 30 KLPD MPR distillation with Integrated evaporation

plant.

Dnyaneshwar SSK Installation of Molasses automatic weighing system.

Kopargaon SSK Thermal gasification project on BOOT basis.Molasses storage tank.

Ganesh SSK Repairs/replacement of distillery equipment.

Table 38 : Consultancy services

Name of Distillery Details of consultancy services

Bhima SSK, Patas 500 M3/day spent wash feed biogas plant.

Makai SSK 30 KLPD distillery to produce RS, ENA & AA.

350 M3/day spent wash feed biogas plant.Spent wash storage tanks and biocompost yard.

Vitthalrao Shinde SSK 30 KLPD distillery to produce RS, ENA & AA.

750 M3/day spent wash feed Biogas plant750 M3/day to 125 M3/day Spent wash evaporation plant

Pandurang SSK 45 KLPD distillery to produce RS, ENA & AA.

500 M3/day spent wash feed Biogas plant.

500 M3

/day to 167 M3

/day spent wash evaporation plantSpent wash storage tanks and biocompost yard.

Rena SSK 30 KLPD distillery to produce RS, ENA & AA.

350 M3/day spent wash feed biogas plant.

Spent wash evaporation plant.

Spent wash storage tanks and biocompost yard.

Kumbhi Kasari SSK 30 KLPD MPR distillation plant.

Dnyaneshwar SSK 45 KLPD MPR distillation plant.

Kopargaon SSK Thermal gasification plant.


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86

Checking and Approval of Drawings

Drawings such as Lay out, GA, Civil and

structural, P & I diagrams and invoices werechecked and approved for distilleries as detailed

in table 39.Design and Costing of Plant and Machinery

Design and costing of plant and machinery was

carried out for member and non-memberdistilleries as given in table 40.

Chem-cad Simulations

The department has prepared Chem-cad

simulation of 30 KLPD Multi-pressure distillation

plant having four columns for Datta SSK Ltd for

improving the quality of spirit. Simulation studywas also carried out for operation of old forced

circulation spent wash concentration reboilers towork under vacuum mode of operation. It was

observed that the same reboiler can be also

operated under vacuum for better performance.

Table 39 : Checking and approval of drawings

Name of Distillery Type of Project

Makai SSK 30 KLPD Distillery for RS and ENA.350 M3/day spent wash feed biogas plant.

Spent wash storage tanks and biocompost yard.

Vitthalrao Shinde SSK 30 KLPD Distillery for RS, ENA and AA.750 M3/day spent wash feed Biogas plant.750 M3/day to 125 M3/day Spent wash evaporation plant.

Dharani Sugars and Chemicals 110 KLPD distillery for RS, ENA and AA.

Kumbhi Kasari SSK 30 KLPD MPR distillation for RS and ENA.

Dnyaneshwar SSK 45 KLPD MPR distillation plant for EQRS.

Kopargaon SSK Thermal gasification Plant for disposal of spent wash.

Flowchart of RO, MEE, Dryer, CBT etc.

Datta Shetkari SSK 30 KLPD MPR distillation with integrated evaporation for RS.

Cheyyar Cooperative Sugar Mills 45 KLPD MPR distillation plant for RS.

Table 40 : Design and costing of plant and machinery

Name of Distillery Type of Equipment

Kumbhi Kasari SSK New 30 KLPD distillery foundations and structureTotal cost estimation of modernization for 30 KLPD distillery

Datta Shetkari SSK Total cost estimation for modernization of 30 KLPD distillery

600 M3/day spent wash feed biogas plant

Modernization 30 KLPD distillery with MPR distillation andintegrated evaporation plant

Manganga SSK Cost estimation of new fermenter and pre-fermenter

Datta Shetakari SSK Valuation of existing old batch fermentation and atmospheric

distillation plantDnyaneshwar SSK New 45 KLPD MPR distillation plant

Someshwar SSK Cost estimation for additional pipeline for new fermenter

Kisanveer Satara SSK Cost estimation for 6000 toones of molasses storage tank

Nira-Bhima SSK Cost estimation for new 210 M3fermenter

Ganesh SSK Verification of estimated cost of repairs/replacement/modification

of 30 KLPD distillery

Cheyyar Co-op. Sugar mills Cost estimation for 45 KLPD distillery and biocompost yard


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Yeast Culture Bank

The department has established a yeast culture

bank, wherein different cultures of yeast withvarious specific characters such as, osmo-

tolerance, thermo-tolerance, high alcohol toleranceetc. are preserved. These strains are either isolated

in the laboratory or collected from various sources.The department provides these strains in the form

of slants to distilleries across the country.

The feedback from these distilleries reveals thatthe performance of cultures supplied by VSI was

encouraging. Satisfied with the performance of the

yeast culture, Bannari Amman Sugars Ltd., NSLsugars Ltd., Kothari Sugars Ltd, Saswad Mali Sugars

Ltd, Shrigonda SSK, Ashok SSK have purchased

yeast slant in current year too. Yeast culture slants

were provided to the following distilleries. Bannari Amman Sugars Ltd.

Loknete B. Patil SSK

Vitthal SSK

KBK-Chem Pvt. Ltd.

EI D Parry Ltd.

RP Ghodganga SSK

Ajinkyatara SSK

India Brewery & Distillery Pvt. Ltd.

Rena SSK

Baramati Agro Industries Ltd.

Sanjivani (Takli) SSK GMR Industries Ltd.

Vijaynagar Sugar Pvt. Ltd.

Analytical Services

In all 340 samples of different products were

analyzed. The details of samples received and

tested during the year are as under.

Molasses samples - 174 nos.

RS & ENA samples - 60 nos.

Anhydrous alcohol - 10 nos.

IMFL samples - 64 nos.

Wine samples - 28 nos.

Others (Ayurvedic formulations, etc.) - 4 nos.

The Gas Chromatography-Mass Spectrometry

(with EI, CI, SPME, DEAN SWITCH etc) was installedin the department. With the help of this instrument,

analysis of volatile compounds at ppm and ppb levels

from samples of various feed stocks, molasses, spirits,

liquors, wines, process intermediates, liquid and solideffluents will be possible.

Calibration Work

The department calibrated 47 hydrometers

(Sykes), 5 alcohol meters and 27 thermometers.

Gas Chromatographic (GC) analysis of total 335

spirit samples from different sources wereperformed during the year 2011-12. The details of

samples tested by GC analysis are as under.

ENA samples - 93 Rectified spirit samples -53 Impure spirit samples -14 Grape spirit - 6 Indian Made Foreign Liquor - 56 Anhydrous alcohol - 41 Ultraviolet test - 26 Potassium permanganate time test - 46

Microbial analysis of 19 samples which

includes 16 molasses samples, 2 water samplesand aurvedic formulation were carried out.

Analysis and Processing of Sweet Sorghum Stalks

from CF Biotech, Belgaum

CF Biotech is planning to set-up a distillery

based on sweet sorghum in the state of Karnataka.

Various sweet sorghum varieties were planted inand around Dharwad district of Karnataka. The

work of analysis and processing of six different

varieties (namely S1, S2, S3, S4, S5 and S6) of sweetsorghum was assigned to VSI .

These varieties were processed to extract juice

and manufacture of alcohol on bench scale in VSI

laboratories. Analysis of intermediates andproducts was carried out and a final report on

possible yields and efficiencies of operations was

submitted to CF Biotech.

Improving Performance of Distillery Units

The department staff helped distilleries in

improving performance and solving process

problems faced by distilleries. Some examples are

given in table 41.


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Table 41: Problems and remedial measures

Name of distillery Nature of problem Suggestions/Remedial measures and results

Ajinkyatara SSK Low yield of alcohol in 1) Microscopic examination of the fermented wash andtheir continuous analysis of molasses and fermented wash samples for its

fermentation process. TOVA content was carried out. 2) Care to be taken forreducing TOVA content of final molasses. 3) Antibiotic dosesto control the contamination were suggested.4) TOVA content of molasses was reduced from 8,000ppm to 4,000 ppm. 5) Alcohol concentration in thefermentation was increased from 5.5 to 7.5 % v/v.

Tulja Bhavani SSK Low yield of alcohol 1) Temperature of the fermentation process was in theand instability in range of 36-390C. 2) TOVA content of molasses wascontinuous 20,000 ppm. 3) Antibiotic doses were suggested tofermentation process. control the contamination. 4) Some operating parameters

of the fermentation process were modified. 5) Measures tobe taken for storage of molasses and to maintain hygieniccondition in the fermentation house were suggested.

Madhukar SSK Low yield of alcohol in 1) Due to high ambient temperature of 40-420C, it was notcontinuous possible to bring the fermentation temperature below 360C.fermentation process. 2) VSI thermotolerant yeast (TSC-20073) was used.

3) 8 % v/v alcohol in fermenter at 360C and improvment infermentation process was achieved

Renuka Sugars Methanol content in 1) Spirit samples were analyzed by gas chromatography.Pvt. Ltd. the ENA was on 2) Adjustment of reflux ratio of simmering column, vapour

higher side. load to simmering column re-boiler and impure cut wasdone. 3) Methanol content was reduced from 30 to 40 ppmto 12 ppm.

Kumbhi Kasari Foaming and low 1) Proper feeding to the fermenters and maintainingSSK production rate fermentation parameters properly, increased the alcohol

problem in continuous concentration and production rate to 8.5 - 9.0 % v/v andfermentation process. 30,000 to 35,000 lits. per day respectively. 2) Frequency

of pre-fermenter addition to fermenters was extended from3-4 days to 14 to 15 days.

Ashok SSK Disturbed fermentation 1) Yeast propagation was optimized by using VSI yeastprocess after weak beer culture. 2) Weak beer recycle was gradually increased fromrecycle of more than 10 % to 25 %. 3) Spentwash generation and fresh water10%. requirement for molasses dilution was substantially reduced.

Rajarambapu Patil Alcohol losses through 1) There was a difference in scanner temperature of 230CSSK spent lees from existing as compared to the caliberated thermometer. 2) Advice

20 KLPD ENA plant. was given to calibrate all temperature sensors, to supplysufficient flow of cooling water to the condensers and tooptimize the RS feed to the column. 3) After taking necessaryprecautions the performance of ENA plant improved.

Gangakhed Sugar Incidence of 1) Installation of external pipe in pipe molasses cooler toand Energy Ltd spontaneous keep the molasses temperature within permissible range

combustion of was suggested. 2) C - massccuite was not getting cooledmolasses in steel tank. to the desired extent due to blockage of passages in mono-

vertical crystallizer. 3) Molasses cooling system was put into operation and the molasses temperature came down by2 to 30C. 4) Immediate use of mixture of the burnt and goodquality molasses was advised before it became unfit forfermentation.


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Table 41: Problems and remedial measures

Name of distillery Nature of problem Suggestions/Remedial measures and results

Siddheshwar SSK, Low yield (5 to 6 %) 1) The use of chlorinated water for the molasses dilutionKumthe of alcohol in batch was suggested. 2) Use Strepto- penicillin from pre-fermenter

fermentation process. stage was suggested. 3) The alcohol % was increasedto 7.5- 8 % v/v.

Majalgaon SSK Fermentation process 1) Samples from pre-fermenter were found severelyproblems and low contaminated. 2) Recommended the use of selectedalcohol yield per ton antibiotics. 3) Yield of alcohol per ton of molasses wasof molasses. improved.

Dharani Sugars Low alcohol percentage 1) The technical staff were trained to operate the plant asand Chemicals in fermented wash and per standard norms and monitoring the fermentationLtd. alcohol losses in spent parameters. 2) Lectures for the technical staff of plant were

wash and spent lees. conducted.

Ganesh SSK Severe problem of 1) Dead sludge was replaced partly by fresh active sludge.digester disturbance. 2) Feeding of hot spent wash, addition of fresh cow-dung,

lime & nutrients etc. were suggested to maintain theparameters in the normal range, 3) The digester wasstabilized and operational parameters and biogasgeneration was restored.

Sanjivani (Takli) Souring of digesters, 1) Advised to water wash the digester, load fresh cow-dungSSK poor generation of & nutrients to the digesters. 2) The performance of digesters

biogas and increase in was brought under control and all digesters started runningcontent of hydrogen smoothly.sulphide

Malegaon SSK Digesters were unable 1) Suggested addition of fresh cow-dung, lime, nutrients.to accept the designed 2) The digesters were stabilized and biogas productionspent wash load. was also restored to normal. 3) The temperature of digesters

was maintained by maintaining the temperature of feed,.

Manjara Shetkari Digester of Manjara 1) The suction of feed pump was surrounded by sludgeSSK SSK was under resulting in carryover of sludge in to the digester leading to

stabilization but facing increase in TOVA. 2) Errors in estimation of TOVA werethe problem of increase corrected. 3) After changing the location of feed pumpin TOVA. suction & taking proper care during analysis, the TOVA

of the digester improved.

Compilation of Technical Performance Data of

Cooperative Distilleries

The department compiled information onperformance of distilleries in Maharashtra State,

which was published in a booklet entitled

Performance of Distilleries affiliated to CooperativeSugar Mills in Maharashtra for the financial Year

2009-10 and 2010-11. There are 68 operating

distilleries affiliated to cooperative sugar mills in

Maharashtra. The data on technical performance ofthese distilleries were compiled for the previous five

years and presented in table 42.

CPCB Sponsored Training Programme on

Compliance of Zero Discharge Norms inDistilleriesTechnical Challenges and solutions

The Department of Alcohol Technology

conducted a five days training programme on

Compliance of Zero Discharge Norms inDistilleries Technical Challenges and solutionsin collaboration with HRD programme of CPCB,Delhi at VSI, Pune. Around 20 officers from Centraland State Pollution Control Boards from variousparts of the country (i.e. Bihar, Chhattisgarh, Delhi,Haryana, Karnataka, Maharashtra, Orissa, UttarPradesh and West Bengal) participated in thistraining programme which covered all the subjects


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related to technologies of manufacture of alcoholand effluent treatment systems.

Workshop on Zero Liquid Discharge in Distilleries

with Emerging Technologies

A one day workshop was organized jointly withthe Central Pollution Control Board on Zero LiquidDischarge in Distilleries with Emerging Technologieson August 21, 2011 at VSI. The workshop aimed tobring members of the Distillery Industry from acrossthe state of Maharashtra to a common platform fordebating various aspects of environmentalmanagement with a techno economic perspective.The policy makers and technologists from all thedistilleries in the state actively participated in theworkshop which was inaugurated by Shri.Sharadchandra Pawar, Honble Minister, Agricultureand Food Processing Industry, Government of India.

He emphasized the need of adoption of emergingtechnologies for achieving ZLD from distilleries.

Consensus Resolution adopted during theWorkshop

(i) There is a need to switch over to cleaner andadvance technologies from the existing practicesof CREP guidelines, in a time bound manner, forachieving Zero Liquid Discharge in Distilleries.

(ii) As the co operative sector has significant role insocio economic welfare of rural population andfarmers, distilleries attached with smaller cooperative sugar mills may be considered for a whileto continue with unleachable bio compostingpractices with revised guidelines, considering thecapital intensive greener technologies.

(iii) The practices of ferti irrigation and one timeland application are not implementable, andpose potential threat to environmental pollutionand therefore shall be abandoned by thedistilleries at the earliest.

(iv) VSI shall draft proposal for fiscal and financialassistance from Central and State GovernmentDepartments seeking soft loans, tax holidays andgrants to make the adoption of greenertechnologies economically viable for distilleries.

(v) CPCB shall also extend their technical andlogistic support to VSI and distilleries inpreparation of action plan and proposals.

Technical Guidance to Government and Non-

Government Organizations

The member distilleries need administrative aswell as financial clearance from the State

Government when they intend to replace their oldmachinery by new one or venture into new projects.To arrive at a decision in this regard, theCommissioner of Sugar seeks technical guidancefrom VSI, which is provided by the department.Similar support was also provided to SLMPC,Purchase Committees of the mills, DistillersAssociation of Maharashtra, MPCB, GeographicalIndications Registry (Intellectual Property Office) etc.

MoU with National Research Centre for Grapes

MoU was signed by VSI and NRC for Grapes,

regarding collaboration in academic activities of

MSc (Brewing, Distilling & Wine making).

Table 42 : Technical performance of distilleries affiliated to co-operative sugar mills in Maharashtra

Parameter

Year

2006-07 2007-08 2008-09 2009-10 2010-11

Production Capacity (million lit./300days) 618.00 654.00 663.00 723.00 745.50considering all distilleries.

Production Capacity (million lit./300days) 489.48 618.00 604.50 604.50 640.50based on received information

Number of distilleries whose 49 53 51 51 53information was compiled

Average net working days 195.65 216.85 180.66 148.80 178.84

Molasses consumed (million tonnes) 1.363 1.754 1.468 1.125 1.344

Alcohol produced (million lit.) 347.54 446.07 364.24 309.33 363.68

Average Fermentation Efficiency (%) 89.17 89.44 89.44 89.78 89.70

Average Distillation Efficiency (%) 98.41 98.31 98.43 98.45 98.40

Recovery of Alcohol (lit./tonnes of molasses) 266.08 270.19 271.12 270.28 270.51

Capacity utilization (%) 63.31 76.69 66.85 47.34 52.25