The Ugar Sugar Works Ltd., Ugar Khurd Dist: Belgaum Karnataka State

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1 Ugar Khurd Dist: Belgaum Karnataka State

2 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. Hence strict measure are necessary to achive Zero Pollution / Zero Discharge

3 M/s. SSP limited Faridabad has supplied the zero pollution plant ( Low Grade Potash Powder recovery plant.) Govt. of India has supported this plant through Technology Development Board, New Delhi. Plant was installed & commissioned another similar plant in in the year 2002 &

4 Project Details Biomethanation Plant The Evaporator Plant The Spray Drying Plant This system has similler process like milk powder plant.

5 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).

6 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 2500 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 evaporation. required. The spent wash volume is reduced to 80% by No additional infrastructure required to handle voluminous product (biocompost.)

7 CSTR Digester UASB Reactor

8 Zero Pollution Plant Capacity 1060 m3/day for 75 KLPD Old Evaporator plant 360 m3/day New Evaporator Plant

9 Zero Pollution Plant Capacity 1060 m3/day for 75 KLPD New Dryer plant Old Dryer plant

10 Hot Air Generator The Ugar Sugar Works Ltd.,

11 Flow Chart Distillery Effluent Treatment The Ugar Sugar Works Ltd., Biomethanation Effluent Steam Evaporators (5 Effect) Water evaporation Spray Dryer Biogas Fired Hot Air Generator Powder Low grade Potash Powder

12 Analysis of Distillery Effluent The Ugar Sugar Works Ltd.,

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14 Observations made during field application of Low Grade Potash Fertilizer Low Grade Potash was found better replacement in place of K - fertilizer as it contains other micro nutrients Crop response to Low Grade Potash application was better than Chemical fertilizer.

15 Guaranteed specifications of Low Grade Potash suitable for direct application for incorporated in FCO:- Water soluble potash as K2O = Total Phosphate as P2O5 = 0.39 Total Nitrogen as N = 1.6 Micronutrients like Iron, =1043 ppm Maganese = 62 PPM Moisture % Max by weight minimum Particle Size = 5% Max = less than 100 micron (100% Below 60 Tyler Mesh)

16 From above table, it shows that with the financial support from the government distillery industries will be able to recycle 30% of potash out of total import and also to achiving Zero pollution /Zero discharge

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18 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 PMT ex-plant.

19 THE LIST OF DISTILLERY UNITS PRESENTLY PRODUCING LGP Sr No LGP production Capacity in The Company Name of the equipment MT/annum, Application Ugar Sugar Works Ltd, Ugar Five Effect Falling Film Evaporator 1 (Karnataka) with Spray Dryer 6000 Five Effect Falling Film Evaporator Ashoka Distilleries & (34219 kg/h WE) with Spray Dryer 2 Chemicals (P) Ltd (1900 kg/h WE) 8000 Five Effect Falling Film Evaporator Kanoria Chemicals & with TVR and Spray Dryer for 3 Industries Ltd, Ankleshwar Effluent Concentrate 6000 IFB Agro Industries Ltd, West 5 Effect Falling Film Evaporator with 4 Bengal TVR and Spray Dryer 7000 SCM Sugar Limited (Distillery 5 Effect Falling Film Evaporator with 5 Division), Bangalore TVR with Spray Dryer 6000 Nizam Deccam Sugars Ltd, Five Effect Falling Film Evaporator 6 Hyderabad with TVR with Spray Dryer 7000 Haryana Distillery Limited, Five effect Falling Film Evaporator 7 Yamunanagar with TVR system + Spray Dryer Biomethanated Spent wash Biomethanated Spent wash Biomethanated Spent Wash Biomethanated Spent Wash Biomethanated. Spent wash Biomethanated Spent wash Biomethanated Spent Wash

20 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.

21 Bio - K The Ugar Sugar Works Ltd.,

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