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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