Water Balance of 120 KLPD Molasses Distillery

1
Water Balance of 120 KLPD Molasses Distillery

• PRESENTED BY
• K.P.SINGH
• (DIRECTOR)
• RADICO KHAITAN LTD

2
Water Balance of 120 KLPD Molasses Distillery

• Distillery is among the major water consuming
  industries. However major part of this water can
  be recycled back and reused resulting in
  reducing the requirement of fresh water to about
  50 and achieving practically zero liquid
  discharge from the industry.

3
Water Consumption of a typical 120 KLPD
Distillery

•   Total water Outputs
• Section -
  Unit - M3 / Day
• Fermentation
• For Dilution - 994 m3
• In cooling tower - 200 m3
• In fermentor washing - 25  m3
• In air blower -12 m3
• Total in Fermentation- 1231 m3
• Distillation
• In cooling water make up - 676  m3
• In vacuum pump - 144 m3
• Scrubber- 57 m3
• In fusel oil decanters 19 m3 
• D.M. water for dilution 190 m3 
• Total in Distillation 1086 m3

4
Water Consumption of a typical 120 KLPD
Distillery

• E.T.P
• Gas washing 10 m3
•  Decanters cleaning - 15 m3
• R.O. plant rinsing - 30 m3
• Cooling water 50 m3 
• Total IN ETP - 105 m3
• Co-generation
• Feed water 432 m3
• Boiler blow down 10 m3
• Turbine cooling water - 60 m3
• Total in ETP and Co- Gen. 502 m3

5
Water Consumption in 120 KLPD Distillery

• Bottling Others
• Bottle washing 168 m3
•  For blending -35 m3
•  Drinking Toilets -10 m3
•  In D. M. water re-regeneration 50 m3
•  In Water softener for re-regeneration
  -40 m3
• Total in Bottling Others - 303  m3
• GRAND TOTAL IN ALL SECTIONS 3227 m3

6
Water Recycle Streams

•  Water Recycle Streams In Process Section
• Unit M3 /
  Day
• Fermentation
• Spent lees in fermentation after Cooling - 315
  m3
• RO Permeate in Fermentation after ultra
  filtration 680 m3 
• Distillation
• Vacuum Pump water into cooling tower -144   m3
           

7
Water Recycle Streams In Process

• Co-generation
• Steam condensate in boiler 384 m3
• Boiler blow down water in ash quenching-10 m3    
• TOTAL in Co-Generation -394 m3
• Bottling Others
• Washing water of bottling back to raw water tank
  through fine filters - 158  m3
• Water Recycling to Other Than Process Gardening
   
• Filter backwash water in gardening- 10 m3
• D.M. softener regeneration water for gardening
  after neutralization - 90 m3 
• Cooling Tower blow down for gardening -36 m3
• TOTAL-  136 m3
• GRAND TOTAL -  1669 M3

8
Water Recycling Streams

• After recycling the given streams with either
  passing through Reverse Osmosis and ultra
  filtration ( In Case of Sp. Wash ) or normal fine
  filtration ( In case of Bottle Washing) etc ,
  about 50 of the water requirement can be met
  with reprocessed / recycled water. The use of
  fresh water is required for following only.

9
Fresh Water requirement

•  Consumption delails of the fresh water Section
• Unit M3 / Day
• Fermentation
• Fermentation cooling Tower Make Up - 200 m3
• Fermenter washing 25 m3 
• Air blower cooling -12 m3     
• TOTAL in fermentation 237 m3
• Distillation
• Distillation cooling water make up - 676 m3
• Vacuum pump - 144 m3
• Scrubber - 57 m3 
• Fusel oil decanter 19 m3
• D.M. water for dilution - 190 m3
• TOTAL in DISTILLATION-  1086

10
Fresh Water Requirement

• E.T.P
• Gas washing 10 m3
•  Decanter cleaning 15 m3
• RO plant rinsing 30 m3
• Cooling tower make up 50 m3  
• TOTAL IN ETP 105 m3
• Co-generation
• Boiler feed water 48 m3
• Turbine cooling tower make up 60 m3     
• TOTAL in CO-Generation -108 m3

11
Fresh Water Requirement

• Bottling Others
• Blending 35 m3
• Bottle washing- 10 m3
• Domestic -10 m3
• Filter backwash water in gardening -10 m3
• D.M. softener regeneration water for gardening
  after neutralization - 90 m3 
• TOTAL in Bottling Others- 155 m3
• GRAND TOTAL -  1691.0  M3         
• Total Intake of fresh water m3 / Day1648.0   
•  Fresh water required m3/ KL - 14.0 m3

12
Water Balance of 120 KLPD Distillery

• From the above it is observed that if managed
  properly the 50 water requirement out of about
  27 m3/ KL of Spirit Production can be met with
  recycled water and fresh water is required only
  about 14 m3 / KL of Alcohol production including
  water required for bottling purposes.
• Recycled water can satisfy most of the water
  demands, as long as it is adequately treated to
  ensure appropriate water quality for use.