2. Distillery Sector - gcpc-envis Sector.pdfprocesses: Praj type and Alfa Laval distillation named after systems. In Praj type, for one liter of alcohol produced, about 12 generated,

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CLEANER PRODUCTION

DISTILLERY SECTOR

Gujarat Cleaner Production Centre- ENVIS Centre

CLEANER PRODUCTION OPPURTUNITIES

IN

DISTILLERY SECTOR

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OPPURTUNITIES

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Introduction

Ethanol, an agriculture based product is known in several forms

and Denatured Spirit. It is a globally traded commodity and is used: to fire combustible engines,

as a potable drink and consumed in pharmaceutical and chemica

Ethanol is made by two routes: either by synthetic one from petroleum substances or by

fermentation from sugar-bearing or starchy substrates using yeast.

industry’ in India, covers a very large number

of micro organisms is the major feature.

a few fermentation industries are in function that too at the rate of only one or two plants in the

country. In India ethanol is produced by the fermentation of molasses

manufacture. India is the fourth largest ethanol producer after Brazil, the United States and

China, its average annual ethanol output amounting to 1,900 million liters

capacity of 3063 million liters per year. An estimated current production of alcoholic beverage

industry’s 480 million cases – consisting of country liquor (local spirits such as feni, toddy, and

arrack are collectively called country

distilled beverage, liquor, or spirit is a potable liquid containing ethanol produced by distillation

of fermented grain, fruit, or vegetables.

preferred raw material because of its easy and large scale availability.

industry categorized as Maltry, Brewery and Distillery based on either molasses or grain.

are about 350 distilleries based on Molasses and 100 based on

concentrated in Maharashtra, Uttar Pradesh, Andhra Pradesh, Karnataka,Tamil Nadu, Gujarat

and Madhya Pradesh. Alcohol is produced from molasses by two types of fermentation

processes: Praj type and Alfa Laval distillation named after

systems. In Praj type, for one liter of alcohol produced, about 12

generated, whereas, in the Alfa Laval continuous fermentation and distillation process only 7

liters of wastewater per liter of alcohol is produced. The process of distillation results in release

of large amounts of waste and wastewater, which have a considerable environmental impact by

polluting both water bodies and soil, by causing an adverse climatic effect as well as odo

nuisance. The effluent generated from the distillery is highly colored and contains high organic

as well as inorganic substances.

annually from distilleries alone in India. The 350


Ethanol, an agriculture based product is known in several forms - Ethyl Alcohol, Alcohol, Spirit


as a potable drink and consumed in pharmaceutical and chemical industries across the world.


bearing or starchy substrates using yeast. The term ‘fermentation

industry’ in India, covers a very large number of industries in which the reactions with the help

of micro organisms is the major feature. Many of these industries do not exist in India while only


In India ethanol is produced by the fermentation of molasses – a by-


China, its average annual ethanol output amounting to 1,900 million liters with a distillation


consisting of country liquor (local spirits such as feni, toddy, and

arrack are collectively called country liquor), whisky, brandy, rum, vodka, beer and wine.


of fermented grain, fruit, or vegetables. The Indian distillery units use sugarcane molasses as a

eferred raw material because of its easy and large scale availability. So the Indian fermentation

industry categorized as Maltry, Brewery and Distillery based on either molasses or grain.

are about 350 distilleries based on Molasses and 100 based on Grain in India, mostly


Alcohol is produced from molasses by two types of fermentation

processes: Praj type and Alfa Laval distillation named after the manufacturers of the production

, for one liter of alcohol produced, about 12– 15 liters of spent wash is

generated, whereas, in the Alfa Laval continuous fermentation and distillation process only 7

er of alcohol is produced. The process of distillation results in release


polluting both water bodies and soil, by causing an adverse climatic effect as well as odo


as well as inorganic substances. Currently, about 45.72 million m3 of spent wash is generated

illeries alone in India. The 350 distilleries in India produce 3.63 billion liters

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Ethyl Alcohol, Alcohol, Spirit


l industries across the world.


The term ‘fermentation

of industries in which the reactions with the help

Many of these industries do not exist in India while only


-product of sugar


with a distillation


consisting of country liquor (local spirits such as feni, toddy, and

liquor), whisky, brandy, rum, vodka, beer and wine. A


The Indian distillery units use sugarcane molasses as a

So the Indian fermentation

industry categorized as Maltry, Brewery and Distillery based on either molasses or grain. There

Grain in India, mostly


Alcohol is produced from molasses by two types of fermentation

the manufacturers of the production

15 liters of spent wash is

generated, whereas, in the Alfa Laval continuous fermentation and distillation process only 7–8

er of alcohol is produced. The process of distillation results in release


polluting both water bodies and soil, by causing an adverse climatic effect as well as odour


Currently, about 45.72 million m3 of spent wash is generated

s in India produce 3.63 billion liters

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of alcohol while generating 45 billion liters of wastewater annually. The wastewater from

distilleries, major portion of which is spent wash, is nearly 12

production. This massive quantity,

untreated can cause considerable stress on the water bodies. Ground water is the main water

source for these operations. The production and characteristics of spent wash are highly variable

and dependent on feed stocks and various aspects of the ethanol production process. The spent

wash is acidic (pH 3.94 - 4.30) dark brown liquid with high BOD (45000

COD (90000–210000 mg l-1), and emits obnoxious odor. Although it does not contain

substances, when discharged without any treatment, it brings about immediate discoloration and

depletion of dissolved oxygen in the receiving water streams, posing serious threat to the aquatic

flora and fauna The effluents of distillery require com

(UF), nano filtration (NF), reverse osmosis (RO) and membrane bioreactor (MBR)

prescribed standard for disposal into inland water. Distillery is, therefore, one of the highly water

polluting industry and is also listed as one among the 17 categories of highly polluting industries.

Category of Indian Fermentation Industry

a) Maltry

Malt is produced from grains, usually barley and less commonly wheat or other cereals.

major process steps are steeping, germination and kilning. Steeping is done to clean

initiate germination. The operation comprises adding water in adequate

certain additives if required. The water is changed two

24-60 hours is employed, as determined by the subjective

a variety of factors, from dormancy of the grain to

malting may be done in a variety of ways. In

the steeped grain is put in a couch,

10 days, depending on the nature of the grain and germination conditions. When it is judged that

an optimum amount of enzymatic breakdown of the original high molecular weight compounds

has taken place, the green malt is kilned to arrest germination and fix the desirable properties

like flavour, aroma and viability. The kilning process comprises of initial drying at 30

followed by curing at 70-105 °C.

� Throwing the skimmings from steep vessels on the floor, which are eventually



distilleries, major portion of which is spent wash, is nearly 12-15 times the total alcohol

production. This massive quantity, approximately 46 billion liters of effluent, if disposed


The production and characteristics of spent wash are highly variable

dent on feed stocks and various aspects of the ethanol production process. The spent

4.30) dark brown liquid with high BOD (45000–100000 mg l

1), and emits obnoxious odor. Although it does not contain



The effluents of distillery require comprehensive treatment like ultra filtration

(UF), nano filtration (NF), reverse osmosis (RO) and membrane bioreactor (MBR)


nd is also listed as one among the 17 categories of highly polluting industries.

of Indian Fermentation Industry

Malt is produced from grains, usually barley and less commonly wheat or other cereals.

steeping, germination and kilning. Steeping is done to clean

initiate germination. The operation comprises adding water in adequate quantity, along with

certain additives if required. The water is changed two-to-four times and a total steep c

60 hours is employed, as determined by the subjective judgement of the maltry depending on

a variety of factors, from dormancy of the grain to climatic conditions. The germination or

malting may be done in a variety of ways. In India, the common practice is floor malting. In this

the steeped grain is put in a couch, and when germination begins, it is spread on the floor for 7

nature of the grain and germination conditions. When it is judged that

matic breakdown of the original high molecular weight compounds

taken place, the green malt is kilned to arrest germination and fix the desirable properties

like flavour, aroma and viability. The kilning process comprises of initial drying at 30

105 °C. The plant practices that lead to pollution are:

Throwing the skimmings from steep vessels on the floor, which are eventually

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15 times the total alcohol

approximately 46 billion liters of effluent, if disposed


The production and characteristics of spent wash are highly variable

dent on feed stocks and various aspects of the ethanol production process. The spent

100000 mg l-1) and

1), and emits obnoxious odor. Although it does not contain toxic



like ultra filtration

(UF), nano filtration (NF), reverse osmosis (RO) and membrane bioreactor (MBR) to meet the


nd is also listed as one among the 17 categories of highly polluting industries.

Malt is produced from grains, usually barley and less commonly wheat or other cereals. The

steeping, germination and kilning. Steeping is done to clean the grain and

quantity, along with

and a total steep cycle of

judgement of the maltry depending on

climatic conditions. The germination or

practice is floor malting. In this

and when germination begins, it is spread on the floor for 7-

nature of the grain and germination conditions. When it is judged that

matic breakdown of the original high molecular weight compounds

taken place, the green malt is kilned to arrest germination and fix the desirable properties

like flavour, aroma and viability. The kilning process comprises of initial drying at 30-40°C

Throwing the skimmings from steep vessels on the floor, which are eventually drained during

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floor washing.

� Spillage of grains during manual transfer from one germin

rootlets

In general, the wastewater in open drains of maltries is rich in suspended solids and

characteristic foul odour due to deterioration.

b) Brewery

In the breweries, the malt is milled to very coarse

water in a process called ‘mashing’. There are three chief methods of

mashing, decoction mashing and double mashing. In India, the

mashing in which, unlike in the other systems, cooking of

extract from the mashing step, called ‘sweet wort’

the grain fed for mashing is removed. The

the enzymatic action, sterilize it and

characteristics flavour and bitterness to the beer, and sugar are also added in the brew ket

spent hops are separated in a ‘hop jack’ or on a strainer, and the ‘bitter wort’ is passed through

whirlpools, where it entraps some air and some of the resins are precipitated. The bitter

cooled to 10-15°C and fermented by yeast over a pe

being 10 days. The ‘green beer’ so obtained is lagered for 1

suspended matter settles down. It is then filtered, bottled and

is a clean industry. Most plants are imported and foreign plant

as the brew masters are usually trained abroad. In some

hops, when there are no spent hops to be disposed off.

c) Distillery

In India, the potable alcohols of different varieties are not made from different feedstock.

Practically, all are made by blending suitable colours, flavours, additives,

made from the fermentation of molasses. Only a small amount of alcohol

preparation of whisky. The major quantity of rectified spirit is used for


Spillage of grains during manual transfer from one germination box to another;

In general, the wastewater in open drains of maltries is rich in suspended solids and

characteristic foul odour due to deterioration.

In the breweries, the malt is milled to very coarse flour called ‘grist’, which is then

water in a process called ‘mashing’. There are three chief methods of mashing,

mashing, decoction mashing and double mashing. In India, the common practice is decoction

mashing in which, unlike in the other systems, cooking of the malted cereal is not involved. The

extract from the mashing step, called ‘sweet wort’ is fed into ‘Iauter tun’ where about 25

moved. The sweet wort is then boiled in the ‘brew kettle’ to arrest

the enzymatic action, sterilize it and precipitate some protein matters. Hops, which impart the

bitterness to the beer, and sugar are also added in the brew ket

separated in a ‘hop jack’ or on a strainer, and the ‘bitter wort’ is passed through

whirlpools, where it entraps some air and some of the resins are precipitated. The bitter

15°C and fermented by yeast over a period of 6-14 days, the usual

being 10 days. The ‘green beer’ so obtained is lagered for 1-2 months, during which much of the

suspended matter settles down. It is then filtered, bottled and pasteurised. The brewery in general

try. Most plants are imported and foreign plant practices are generally followed,

as the brew masters are usually trained abroad. In some plants hop extract is used instead of

hops, when there are no spent hops to be disposed off.

the potable alcohols of different varieties are not made from different feedstock.

Practically, all are made by blending suitable colours, flavours, additives, etc., to rectified

made from the fermentation of molasses. Only a small amount of alcohol is made

preparation of whisky. The major quantity of rectified spirit is used for industrial purposes.

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ation box to another; Spillage of

In general, the wastewater in open drains of maltries is rich in suspended solids and creates a

flour called ‘grist’, which is then extracted in

mashing, viz. infusion

common practice is decoction

the malted cereal is not involved. The

is fed into ‘Iauter tun’ where about 25-30% of

sweet wort is then boiled in the ‘brew kettle’ to arrest

precipitate some protein matters. Hops, which impart the

bitterness to the beer, and sugar are also added in the brew kettle. The

separated in a ‘hop jack’ or on a strainer, and the ‘bitter wort’ is passed through

whirlpools, where it entraps some air and some of the resins are precipitated. The bitter wort is

14 days, the usual cycle in India

during which much of the

The brewery in general

practices are generally followed,

plants hop extract is used instead of

the potable alcohols of different varieties are not made from different feedstock.

., to rectified spirit

is made from malt for

industrial purposes.

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Classification of Distilleries based on Capacity

Production Scale

Small

Medium

Large

Manufacturing Process

(A) Process of Distilleries Based on Molasses

Alcohol

In India, alcohol is manufactured by two processes:

� Batch process

� Continuous process

a) Batch process

The molasses obtained from the sugar industry is first diluted to bring down the

concentration of sugar from 40

a yeast culture is developed from an inoculum. After 4

developed fully, the remaining molasses is mixed and allowed to ferment for 30

hours. The pH is maintained around 4

is exothermic, the contents of the fermentation tank are kept at 35

sprinkling cold water on the outer surface of the fermentation tank.

After fermentation is complete the yeast sludge is removed from the bottom and the

fermenter wash is pumped to the analyzer column for distillation using steam. The

mixture of alcohol vapours and steam is collected at the top of the column and

free spent wash is discharged from the bottom.

to rectification column where water and alcohol

rectified spirit is withdrawn. The condensed

forms another waste stream.

b) Continuous Process

In this process yeast is r

continuous supply of fermented beer for the distillation column. The advantage of the

process is that a highly active yeast cell initiates the fermentation rapidly and the alcohol


Classification of Distilleries based on Capacity

Production Scale Production Capacity kL/Annum

Up to 5,000

Above 5,000 and Up to 10,000


Process of Distilleries Based on Molasses

In India, alcohol is manufactured by two processes:


concentration of sugar from 40–45% to 10–15%. Using a portion of the diluted molasses

a yeast culture is developed from an inoculum. After 4 - 6 hours, when the cul

developed fully, the remaining molasses is mixed and allowed to ferment for 30

hours. The pH is maintained around 4-4.5 by addition of sulphuric acid. As the reaction

exothermic, the contents of the fermentation tank are kept at 35-37oC by constantly

sprinkling cold water on the outer surface of the fermentation tank.


s pumped to the analyzer column for distillation using steam. The

mixture of alcohol vapours and steam is collected at the top of the column and

spent wash is discharged from the bottom. The alcohol and the steam stream are fed

ation column where water and alcohol vapours condense at different levels and

rectified spirit is withdrawn. The condensed water from this stage is called spent lees and

forms another waste stream.

In this process yeast is recycled. Fermentation and distillation is coupled to get a



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Production Capacity kL/Annum

5,000 and Up to 10,000



15%. Using a portion of the diluted molasses

6 hours, when the culture has

developed fully, the remaining molasses is mixed and allowed to ferment for 30–40

4.5 by addition of sulphuric acid. As the reaction

37oC by constantly


s pumped to the analyzer column for distillation using steam. The

mixture of alcohol vapours and steam is collected at the top of the column and alcohol

The alcohol and the steam stream are fed

vapours condense at different levels and

water from this stage is called spent lees and

ecycled. Fermentation and distillation is coupled to get a



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yield is also much higher compared to the batch process.

Bio-still process is one of the continuous processes, which is a trade name in which

molasses is fed to the fermenter at a constant flow rate. The flow rate of molasses is

controlled to maintain the sugar

and 6-7% respectively.

The waste streams comprise spent wash which is the main source of wastewater, spent

lees and yeast sludge. Spent lees is usually mixed with the spent wash. The yeast sludge

is disposed separately after drying. In addition wastewater may be generated from the

bottling, fermentation tank cooling and washing and utility sections of the plant, which is

used as a diluent for the treated spent wash.

Figure 1 : Process Block Diagra


is also much higher compared to the batch process.

still process is one of the continuous processes, which is a trade name in which


controlled to maintain the sugar and alcohol concentrations in the wash at 0.2% or lower



disposed separately after drying. In addition wastewater may be generated from the


uent for the treated spent wash.

Process Block Diagram of Distillery (Molasses Based)

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still process is one of the continuous processes, which is a trade name in which


and alcohol concentrations in the wash at 0.2% or lower



disposed separately after drying. In addition wastewater may be generated from the


m of Distillery (Molasses Based)

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(B) Rectified spirit

Molasses-based distilleries are more common in India. The main process steps

in this operation are graphically shown in Figure

manufacturing process for rectified spirit is given

(1) Dilution - Preparation of molasses for fermentation

(2) Fermentation - Production of alcohol from fermentable sugars in molasses solution

(3) Distillation - Product recovery

(1) Dilution

Molasses available from Indian sugar mills has a solid content varying between 76 and

90% while the total sugar content varies between 45 and 55%.

The main dilution operation occurs in a diluter where the solid concentration is brought

down to 20-25° Brix. The bulk

while a small quantity is further diluted to 10

final yeast inoculum. Propagation of yeast for the final inoculation is done in successive

stages in volumes of 10, 100, 1000 and 10,000 litres where, in each stage, 10 parts of

diluted molasses is inoculated with 1 part of yeast culture.

(2) Fermentation

Fermentation in the fermentation tank continues for about 30 to 45 hours after the final

inoculum is added to it. The basic reaction in the fermentation process is exothermic.

Since the reaction is exothermic and proper growth of yeast requires a narrow temperature

range, water is sprayed on the outer walls of the fermentation tank to maintain the

temperature between 25°C and 32°C.

Fermented beer – the main product of this step is decanted and the remaining sludge

known as fermenter sludge is discharged from the bottom of the fermenters. The sludge

amounts to about 300 to 400 litres (l) per kilolitre (

one of the major contributors to the p


based distilleries are more common in India. The main process steps and water balance

operation are graphically shown in Figure 2. However, the detailed description of the

manufacturing process for rectified spirit is given below :

Preparation of molasses for fermentation

Production of alcohol from fermentable sugars in molasses solution

Product recovery

available from Indian sugar mills has a solid content varying between 76 and

90% while the total sugar content varies between 45 and 55%.


25° Brix. The bulk of this diluted molasses is fed to the fermentation tank

while a small quantity is further diluted to 10-15° Brix and used for preparation of the


of 10, 100, 1000 and 10,000 litres where, in each stage, 10 parts of

diluted molasses is inoculated with 1 part of yeast culture.


is added to it. The basic reaction in the fermentation process is exothermic.



perature between 25°C and 32°C.

the main product of this step is decanted and the remaining sludge


amounts to about 300 to 400 litres (l) per kilolitre (kL) of rectified spirit produced, and is

one of the major contributors to the pollution load from distilleries.

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and water balance

description of the

Production of alcohol from fermentable sugars in molasses solution

available from Indian sugar mills has a solid content varying between 76 and


of this diluted molasses is fed to the fermentation tank

15° Brix and used for preparation of the


of 10, 100, 1000 and 10,000 litres where, in each stage, 10 parts of


is added to it. The basic reaction in the fermentation process is exothermic.



the main product of this step is decanted and the remaining sludge


kL) of rectified spirit produced, and is

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(3) Distillation

The fermented beer from the fermenter vessel is preheated to about 90°C by heat

with the spent wash flow from the

section of the analyzer column. Low boiling content of the fermented beer

acids, esters and aldehydes along with some alcohol vapours are

condensers. Purified wash from the bottom of the degasifying

analyzer column for steam stripping of alcohol which

40% alcohol. The down coming discharge from

stream from the top of the analyzer column is next fed to the bottom of

column where it is maintained at a temperature of about 95° to 100°C.

vapour condense at different levels in this column and rectified spirit

boiling composition (95%) is withdrawn. Of this rectified spirit, a part

column. Spent lees, produced at this step are usually pumped back to

The volume of spent lees is about 1


The fermented beer from the fermenter vessel is preheated to about 90°C by heat

with the spent wash flow from the analyzer column and is then fed into the

section of the analyzer column. Low boiling content of the fermented beer

acids, esters and aldehydes along with some alcohol vapours are condensed in the aldehyde

ash from the bottom of the degasifying section enters the top of the

analyzer column for steam stripping of alcohol which condenses at the top of the column as

40% alcohol. The down coming discharge from this column is spent wash.

om the top of the analyzer column is next fed to the bottom of

column where it is maintained at a temperature of about 95° to 100°C. Water and alcohol

vapour condense at different levels in this column and rectified spirit of an equilibri

boiling composition (95%) is withdrawn. Of this rectified spirit, a part is fed back into the

column. Spent lees, produced at this step are usually pumped back to the analyzer column.

The volume of spent lees is about 1-1.5 kL/kL of rectified spirit produced.

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The fermented beer from the fermenter vessel is preheated to about 90°C by heat exchange

analyzer column and is then fed into the degasifying

section of the analyzer column. Low boiling content of the fermented beer such as organic

condensed in the aldehyde

section enters the top of the

condenses at the top of the column as

The 40% alcohol

om the top of the analyzer column is next fed to the bottom of the rectification

Water and alcohol

of an equilibrium

is fed back into the

the analyzer column.

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Figure 2: Water Balance for a Distillery


2: Water Balance for a Distillery - Model Case

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(C) Ethanol

Ethanol is produced both as a petrochemical, through the hydration of ethylene, and

by fermenting sugars with yeast. Determining the most economical among

upon the prevailing prices of petroleum and of grain feedstock.

fermentation process of alcohols production.

Ethanol by Fermentation: Ethanol for use in alcoholic beverages, and the vast majority

ethanol for use as fuel, is produced by fermentation. When certain species of yeast

Saccharomyces cerevisiae) metabolize sugar in the absence of oxygen, they

CO2. The chemical equation below summarizes the conversion:

C6H12O

Sequence For Production Of Ethanol Of Steps

Ethanol is the final end product of three processes namely

� Fermentation Process

� Distillation Process and

� Dehydration Process

Figure 3 : Block Flow Diagram of Ethanol Plant


Ethanol is produced both as a petrochemical, through the hydration of ethylene, and

by fermenting sugars with yeast. Determining the most economical among the products depends

upon the prevailing prices of petroleum and of grain feedstock. This manual focuses on the

fermentation process of alcohols production.

Ethanol for use in alcoholic beverages, and the vast majority

se as fuel, is produced by fermentation. When certain species of yeast

Saccharomyces cerevisiae) metabolize sugar in the absence of oxygen, they produce ethanol and

CO2. The chemical equation below summarizes the conversion:

O6 2CH3CH2OH + 2CO2

Sequence For Production Of Ethanol Of Steps

Ethanol is the final end product of three processes namely shown in Figure 3

Figure 3 : Block Flow Diagram of Ethanol Plant

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Ethanol is produced both as a petrochemical, through the hydration of ethylene, and biologically,

products depends

manual focuses on the

Ethanol for use in alcoholic beverages, and the vast majority of

se as fuel, is produced by fermentation. When certain species of yeast (e.g.,

produce ethanol and

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A. Fermentation process

Ethanol can be made by the fermentation of sugars

sugarcane juice or molasses are the raw material. Zymase, an enzyme from yeast, changes the

simple sugars into ethanol and CO

fermentation produces mainly ethanol, CO

complex. The impure culture of yeast produces varying amounts of other

glycerin, methanol and various organic acids.

Figure 4 : Preliminary Process Flow Sheet Depicting Fermentation of Molasses

B. Distillation process

Ethanol produced by fermentation ranges in concentration from a few percent up to about

14%; the rest being water and other components

ethanol (78.4°C) is significantly lower than the boiling point of water (100°C). These materials

cannot be separated completely by distillation. Instead, an azeotropic mixture (

96% ethanol and 4% water) is obtained. Azeotropic mixture of alcohol cannot

concentrated by distillation. Distillation is used to produce Rectified Spirit


Ethanol can be made by the fermentation of sugars (Shown in Figure 4). Simple sugars such as

juice or molasses are the raw material. Zymase, an enzyme from yeast, changes the

simple sugars into ethanol and CO2. The enzymatic reaction carried over by the yeast in

fermentation produces mainly ethanol, CO2 and heat. The fermentation reaction is

complex. The impure culture of yeast produces varying amounts of other substances, including

organic acids.

Preliminary Process Flow Sheet Depicting Fermentation of Molasses


; the rest being water and other components (Shown In Figure 5). The boiling point of

(78.4°C) is significantly lower than the boiling point of water (100°C). These materials

cannot be separated completely by distillation. Instead, an azeotropic mixture (

water) is obtained. Azeotropic mixture of alcohol cannot

concentrated by distillation. Distillation is used to produce Rectified Spirit (RS).

11 | P a g e

. Simple sugars such as

juice or molasses are the raw material. Zymase, an enzyme from yeast, changes the

reaction carried over by the yeast in

and heat. The fermentation reaction is actually very

substances, including

Preliminary Process Flow Sheet Depicting Fermentation of Molasses


. The boiling point of

(78.4°C) is significantly lower than the boiling point of water (100°C). These materials

cannot be separated completely by distillation. Instead, an azeotropic mixture (i.e. a mixture of

water) is obtained. Azeotropic mixture of alcohol cannot be further

(RS).

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C. Dehydration of alcohol

Pure alcohol can't be obtained from distillation since it forms azeotrope

(v/v). Fuel ethanol or absolute alcohol is produced by

Figure 5 : Process Flow Sheet Depicting Distillation of Ethanol

available technologies for dehydration of RS are:

� Azeotropic Distillation

� Molecular Seive Technology

(i). Azeotropic distillation method

To dehydrate ethanol from azeotropic concentration, a third substance called Entrainer

ethylene, benzene, toluene, cyclo

(Shown In Figure 6). Entrainer breaks the azeotropic point of ethanol and water,

relative volatility of water making it more volatile. The ternary azeotropic

top of dehydration column, allows the removal of water and

azeotropic mixture is heterogeneous and the ‘heavy’ phase,

extracted by decantation. The regeneration column

phase and entrainer recycling


Pure alcohol can't be obtained from distillation since it forms azeotrope with water at 96%

(v/v). Fuel ethanol or absolute alcohol is produced by dehydration of RS. Commercially

Process Flow Sheet Depicting Distillation of Ethanol

available technologies for dehydration of RS are:

. Azeotropic distillation method

To dehydrate ethanol from azeotropic concentration, a third substance called Entrainer

ethylene, benzene, toluene, cyclo-hexane etc.) is added to the mixture of ethanol and water

. Entrainer breaks the azeotropic point of ethanol and water,

relative volatility of water making it more volatile. The ternary azeotropic mixture, formed at the

top of dehydration column, allows the removal of water and thus dehydrates alcohol. The

azeotropic mixture is heterogeneous and the ‘heavy’ phase, which is high in water content, is

extracted by decantation. The regeneration column allows water extraction from the ‘heavy’

12 | P a g e

with water at 96%

dehydration of RS. Commercially

Process Flow Sheet Depicting Distillation of Ethanol

To dehydrate ethanol from azeotropic concentration, a third substance called Entrainer (trichloro

ethanol and water

. Entrainer breaks the azeotropic point of ethanol and water, i.e., it alters the

mixture, formed at the

dehydrates alcohol. The

which is high in water content, is

allows water extraction from the ‘heavy’

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ii. Molecular sieve technology

Molecular sieve technology works on the principle of Pressure Swing Adsorption (PSA).

Here water is removed by adsorption on surface of ‘molecular sieves’ under pressure and

then cyclically removed it under low pressure at different conditions. This process carries

dehydration of mixed ethanol and water by adsorption of water into zeolite balls,

molecular sieves. The dehydration unit operates with two adsorbers accor

Figure 6 : Process Flow Sheet Depicting Azeotropic Distillation Process

of adsorption and desorption (Shown In Figure 7)

under pressure. Desorption regenerates water saturated molecular

under vacuum. Part of the dehydrated alcohol is used for the molecular sieve

Alcoholic effluent from desorption is regenerated within the distillation

Figure 7 : Process Flow Sheet Depicting Molecular




cyclically removed it under low pressure at different conditions. This process carries

dehydration of mixed ethanol and water by adsorption of water into zeolite balls,

molecular sieves. The dehydration unit operates with two adsorbers according to alternate steps

Process Flow Sheet Depicting Azeotropic Distillation Process

(Shown In Figure 7). Adsorption occurs in the vapour phase

under pressure. Desorption regenerates water saturated molecular sieves. This step is

under vacuum. Part of the dehydrated alcohol is used for the molecular sieve

Alcoholic effluent from desorption is regenerated within the distillation column.

Process Flow Sheet Depicting Molecular Seive Dehydration Process

13 | P a g e



cyclically removed it under low pressure at different conditions. This process carries out

dehydration of mixed ethanol and water by adsorption of water into zeolite balls, which are

to alternate steps

Process Flow Sheet Depicting Azeotropic Distillation Process

. Adsorption occurs in the vapour phase and

sieves. This step is performed

under vacuum. Part of the dehydrated alcohol is used for the molecular sieve desorption.

Seive Dehydration Process

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(D) Manufacturing process of spirits

(1) Different process units involved in

Figure 8: Process Flow Sheet Depicting Whisky Production

(i) Mashing

The mashing process consists of cooking (gelatinization) of the grain in water to

solubilize the starches from the kernels and converting (saccharification) of the starch to

‘grain sugar’ (primarily glucose and maltose). In general, cooking can

above atmospheric pressure in either a batch or continuous process. During

trace Volatile Organic Compound (VOC) emissions may result from constituents in the

grain. Small quantities of malted barley are sometimes added prio

After partial cooling, conversion of the starch to sugar is accomplished by adding barley


Manufacturing process of spirits Based on Grain (whisky, vodka & gin)

Different process units involved in Whisky manufacturing are summarized below

Figure 8: Process Flow Sheet Depicting Whisky Production



‘grain sugar’ (primarily glucose and maltose). In general, cooking can be carried out at or

above atmospheric pressure in either a batch or continuous process. During


grain. Small quantities of malted barley are sometimes added prior to grain cooking.


14 | P a g e

(whisky, vodka & gin)

manufacturing are summarized below Figure 8.



be carried out at or

above atmospheric pressure in either a batch or continuous process. During mashing,


r to grain cooking.


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malt and/or enzymes (from other sources) to the cooked grain at approximately 63EC

(145EF). The mash then passes through a noncontact cooler to a

mashing and fermentation, the process generally is closed during cooling, with no

emissions. Distillers may vary mashing procedures, but generally conform to basic

principles, especially in the maintenance of sanitary conditions.

(ii) Fermentation

Fermentation, which usually lasts 3 to 5 days for whisky, involves the use of yeast to

convert the grain sugars into ethanol and CO2. The converted grain mash is cooled prior

to entering the fermenter or tank and inoculated with yeast. It i

dilute the hot grain mash to its final solids concentration by adding backset stillage and/or

water. Backset is liquid stillage which is screened or centrifuged from the distillation

‘beer still bottoms.’ The use of backset

supplements, pH adjustment of the fermentation, and some flavor components (

mash).

The fermentation process varies slightly for the production of other distilled spirits. For

instance, rum fermentation tak

the source of fermentable sugars and is stored in tanks prior to fermentation. The black

strap molasses also is not mashed (

proper concentration of fermentable sugars. Congeners are flavor compounds which are

produced during fermentation, as well as during the aging process. These congeners

include trace aldehydes, esters, and higher alcohols (

(lactobacillus) may simultaneously ferment within the mash and contribute to the overall

whisky flavor profile. On rare occasions lactobacillus may provide some pH control. On

other occasions, the addition of sulphuric acid, though rarely used, may result in trace

hydrogen sulphide emissions from the fermentation tank.

In whisky production, significant increases in the amount of yeast consumed occur

during the first 30 hours of fermentation, when over 75% of the carbohydrate (sugar) is

converted to ethanol and CO2

and/or cooling means that facilitate temperature control. Fermentation vessels may be

constructed of wood or metal and may be open or closed top.



(145EF). The mash then passes through a noncontact cooler to a fermenter. Between the



principles, especially in the maintenance of sanitary conditions.



to entering the fermenter or tank and inoculated with yeast. It is a common practice to



‘beer still bottoms.’ The use of backset provides water conservation, nutrient

supplements, pH adjustment of the fermentation, and some flavor components (


instance, rum fermentation takes 1 to 2 days. In rum production, black strap molasses is


strap molasses also is not mashed (i.e., cooked) prior to dilution with water to obtain the

tion of fermentable sugars. Congeners are flavor compounds which are


include trace aldehydes, esters, and higher alcohols (i.e., fusel oils). Lactic acid bacteria

llus) may simultaneously ferment within the mash and contribute to the overall



ydrogen sulphide emissions from the fermentation tank.

, significant increases in the amount of yeast consumed occur

the first 30 hours of fermentation, when over 75% of the carbohydrate (sugar) is

converted to ethanol and CO2.Many fermentation vessels are equipped with agitation


constructed of wood or metal and may be open or closed top.

15 | P a g e


fermenter. Between the





s a common practice to



provides water conservation, nutrient

supplements, pH adjustment of the fermentation, and some flavor components (e.g., sour


, black strap molasses is


cooked) prior to dilution with water to obtain the

tion of fermentable sugars. Congeners are flavor compounds which are


fusel oils). Lactic acid bacteria

llus) may simultaneously ferment within the mash and contribute to the overall



, significant increases in the amount of yeast consumed occur

the first 30 hours of fermentation, when over 75% of the carbohydrate (sugar) is

Many fermentation vessels are equipped with agitation and


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(iii) Distillation

The distillation process

fermented grain Mash and is an add

production different from Beer and Wine. In addition to the alcohol and congeners, the

fermented mash contains

salts, lactic acid, fatty acids, and traces of glycerol and other trace congeners. Distillation

processes also include the continuous multicolumn extractive and rectifying systems, and

the batch rectifying pot still and condensing unit. Whisky stills are usually made of

copper, especially in the rectifying section, although stainless steel may be used in some

stills.

In a general whisky distillation process using a beer still, the whisky

consists of a cylindrical shell having three sections: stripping, entrainment removal, and

rectifying. The stripping section contains approximately 14 to 21 perforated plates,

spaced 56 to 61 centimetres (cm) (22 to 24 inches) apart. The

introduced at the top of the stripping section and descends from plate to plate until it

reaches the base where the stillage is discharged. Steam is introduced at the base of the

column, and the vapours from the bottom of the still pass u

the plates. Whisky stills are usually fitted with entrainment removal sections that consist

of a plate above the stripping plate to remove fermented grain particles entrained in the

vapour. Distillation columns operate under r

condensed and collected, although small amounts of non

emitted to the atmosphere.

Following distillation, the whisky, at high proof, is pumped to stainless steel tanks and

diluted with demineralized water to the desired alcohol concentration prior to filling into

oak barrels. The distillation of other spirits, such as rum, is similar.

(iv) Grain and liquid stillage

At most distilleries, after the removal of alcohol, still bottoms (know

are pumped from the distillation column to a dryer house. Whole stillage may be sold;

land applied (with appropriate permitting), sold as liquid feed, or processed and dried to


The distillation process separates and concentrates the alcohol products from the

fermented grain Mash and is an add-on unit for production of spirits and make the whisky


solid grain particles, yeast cells, water-soluble proteins, mineral



e batch rectifying pot still and condensing unit. Whisky stills are usually made of


In a general whisky distillation process using a beer still, the whisky separating column



spaced 56 to 61 centimetres (cm) (22 to 24 inches) apart. The fermented mash is



column, and the vapours from the bottom of the still pass up through the perforations in



vapour. Distillation columns operate under reflux (sealed) conditions and most vapors are

condensed and collected, although small amounts of non-condensable gases will be

emitted to the atmosphere.


demineralized water to the desired alcohol concentration prior to filling into

The distillation of other spirits, such as rum, is similar.

Grain and liquid stillage

At most distilleries, after the removal of alcohol, still bottoms (known as whole stillage)



16 | P a g e

separates and concentrates the alcohol products from the

on unit for production of spirits and make the whisky


soluble proteins, mineral



e batch rectifying pot still and condensing unit. Whisky stills are usually made of


separating column



fermented mash is



p through the perforations in



eflux (sealed) conditions and most vapors are

condensable gases will be


demineralized water to the desired alcohol concentration prior to filling into

n as whole stillage)



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produce distiller dried grains (DDG). The DDG consists of

vitamins, and fibers which are concentrated threefold by the removal of the grain starch

in the mashing and fermentation process. Distillers’ secondary products are divided into

four groups: DDG, distiller dried solubles (DDS), DD

condensed distiller solubles (CDS).

Solids in the whole stillage are separated using centrifuges or screens. The liquid portion

‘thin stillage’ may be used as a backset or may be concentrated by vacuum evaporation.

The resultant syrup may be recombined with the solid portion or dried separately. This

remaining mixture is then dried using one of a variety of types of dryers (usually

steamheated or flash dryers). The majority of DDG are used in animal feed, although

increasing quantities are being sold as food ingredients for human consumption due to its

nutrient and fiber content.

(v) Warehousing/aging

Newly distilled whisky is colorless with a strong, harsh and unpalatable odor. The new

whisky distillate undergoes many types

process that impart the distinctive color, taste and aroma of the whisky and gives it

character. These changes include extraction of the wood compounds, decomposition and

diffusion of the wood macromolecules i

distillate compounds with each other, and oxidation produced by diffusion to ambient

atmosphere.

During the aging, both the charred oak barrel in which beverage alcohol is stored and the

barrel environment are key

uniqueness. The aging process gives whisky its characteristic color and distinctive flavor

and aroma. Variations in the aging process are integral to producing the characteristic

taste of a particular brand of distilled spirits. Aging practices may differ from distillate to

distiller, and even for different products of the same distiller.

(vi) Blending/bottling

After whisky aging is complete, it is dumped or pumped from barrels into stainless steel

tanks and reduced in proof to the desired alcohol concentration by adding demineralized

water. The diluted whisky is processed and filtered. Following a filtration process the


produce distiller dried grains (DDG). The DDG consists of proteins, fats, minerals,


the mashing and fermentation process. Distillers’ secondary products are divided into

four groups: DDG, distiller dried solubles (DDS), DDG with solubles (DDG/S), and

condensed distiller solubles (CDS).



t syrup may be recombined with the solid portion or dried separately. This


or flash dryers). The majority of DDG are used in animal feed, although

quantities are being sold as food ingredients for human consumption due to its

nutrient and fiber content.


whisky distillate undergoes many types of physical and chemical changes in the aging



diffusion of the wood macromolecules into the alcohol, reactions of the wood and



barrel environment are key to producing distilled spirits of desired quality and



brand of distilled spirits. Aging practices may differ from distillate to

distiller, and even for different products of the same distiller.




17 | P a g e

proteins, fats, minerals,


the mashing and fermentation process. Distillers’ secondary products are divided into

G with solubles (DDG/S), and



t syrup may be recombined with the solid portion or dried separately. This


or flash dryers). The majority of DDG are used in animal feed, although

quantities are being sold as food ingredients for human consumption due to its


of physical and chemical changes in the aging



nto the alcohol, reactions of the wood and



to producing distilled spirits of desired quality and



brand of distilled spirits. Aging practices may differ from distillate to




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whisky is pumped to a tank, proof adjusted, and bottled.

Due to their value and

refilled with other whiskies or bung sealed and sold to manufacturers of Scotch Whisky,

Canadian Whisky, rum, brandy, Tequila, or wines.

New bottles are unloaded from cases and put on a convey

cleaned, filled, capped, and labeled. At the end of the conveyor belt, the final product is

put into cases, which are sealed, labeled, and shipped to distributors.

(2) Gin Manufacturing Process

Gin can be made from any neutral

and maize) or molasses and has no flavor at all. As with the production of beer, the base

starch is mixed with water, heated, cooled, and allowed to ferment. The wash so

produced is then distilled to an alcohol content of 95% ABV. This is then diluted to

strength of about 45% ABV and left to steep with flavoring botanicals (famously juniper

but others may include citrus peel, various spices and angelica). The liquid is then heated

in a still and, as with whisky, only the middle portion is used. The

returned for distillation with the next batch. Finally the spirit is

required minimum alcohol content (37.5% ABV) and then bottled.

made by simply adding essential oils to the diluted neutral spirit

compounded’ gin cannot be called distilled.

(3) Vodka manufacturing proces

The starting point for vodka is, as with gin, a neutral spirit. In the EU the spirit is usually

produced from grain (wheat, barley, maize, rye) or molasses. In the Eastern Europe it

may also be made from potatoes, or rice.

although many vodkas are triple distilled,

ABV of about 55% before it is filtered,

are used to bind impurities so that they

water is added to give the vodka the

37.5%. At this stage some producers

flavouring such as natural essences or fruits

several days. No maturation period is


whisky is pumped to a tank, proof adjusted, and bottled.

Due to their value and marketability, used barrels are not generally stored but either


Canadian Whisky, rum, brandy, Tequila, or wines.

New bottles are unloaded from cases and put on a conveyor belt, where they are air


put into cases, which are sealed, labeled, and shipped to distributors.

Gin Manufacturing Process

Gin can be made from any neutral spirit alcohol - the base can be grain (normally barley


is mixed with water, heated, cooled, and allowed to ferment. The wash so



s may include citrus peel, various spices and angelica). The liquid is then heated

in a still and, as with whisky, only the middle portion is used. The foreshots and feints are

returned for distillation with the next batch. Finally the spirit is diluted to

required minimum alcohol content (37.5% ABV) and then bottled. Cheaper gins can be

made by simply adding essential oils to the diluted neutral spirit alcohol. This ‘cold

compounded’ gin cannot be called distilled.

Vodka manufacturing process



may also be made from potatoes, or rice. As with gin, the wash is usuall

although many vodkas are triple distilled, some even more. The distillate is diluted to an

ABV of about 55% before it is filtered, usually through charcoal. Sometimes coagulants

are used to bind impurities so that they can be filtered out more readily. Finally, more

water is added to give the vodka the minimum ABV (legal EU Standard) of at least

37.5%. At this stage some producers include additives while others may introduce

flavouring such as natural essences or fruits or herbs which are steeped in the vodka for

several days. No maturation period is required.

18 | P a g e

marketability, used barrels are not generally stored but either


or belt, where they are air


the base can be grain (normally barley


is mixed with water, heated, cooled, and allowed to ferment. The wash so



s may include citrus peel, various spices and angelica). The liquid is then heated

foreshots and feints are

diluted to reach the

Cheaper gins can be

alcohol. This ‘cold



As with gin, the wash is usually distilled twice

some even more. The distillate is diluted to an

usually through charcoal. Sometimes coagulants

t more readily. Finally, more

minimum ABV (legal EU Standard) of at least

include additives while others may introduce

e steeped in the vodka for

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(4) Brandy manufacturing process

Brandy is made from wine which is distilled by a process similar to that described above.

The spirit is distilled twice before being transferred to

maturation period depends on the quality of the brandy sought

of two years is required to qualify for the very superior (VS) label and four years for the

very superior old pale (VSOP) label.

(5) Beer production processes

Till fermentation, the process units in the case of beer production are same. The final

fermented grain alcohol mixture, called beer, is agitated to resuspend its solids and may

be transferred to the beer well (storage vessel) for hold

still. Distillers use mechanical or air agitation during transfer and storage to prevent

settling of solids. In the instance of air agitation, trace amounts of aldehydes may be

produced. The beer passes from the beer well

the alcohol vapors leaving the still and then enters the still for distillation. The beer still

vapors condensed in the pre

During production, brewing al

reactions (mashing, boiling, fermentation and maturation) and three solid liquid

separations (wort separation, wort clarificati

a) Malt

Malt is derived from a cereal

period and then dried. Malting, even if it is not carried out on a brewery site, is an

integral part of the brewing industry. The barley undergoes malting process to convert it

to a form suitable for brewing. During the malting process, enzymes are generated, the

grain cell walls are broken down and some proteins are hydrolyzed. The malting process

of barley includes cleaning, sorting, steeping, germination, drying and polishing. The

barley is cleaned of dust and foreign materials and then sorted according to size with the

smallest kernels (grade IV) being sold as animal feed.


Brandy manufacturing process


The spirit is distilled twice before being transferred to wooden barrels to mature. The

maturation period depends on the quality of the brandy sought – for example a minimum


very superior old pale (VSOP) label.

production processes



be transferred to the beer well (storage vessel) for holding until it is pumped to the beer



produced. The beer passes from the beer well through a pre-heater where it is warmed by


vapors condensed in the pre-heater generally are returned to the beer still as reflux.

During production, brewing alternately goes through three chemical and biochemical


separations (wort separation, wort clarification and rough beer clarification

Malt is derived from a cereal grain, usually barley, after being germinated for a limited



for brewing. During the malting process, enzymes are generated, the



ned of dust and foreign materials and then sorted according to size with the

smallest kernels (grade IV) being sold as animal feed.

19 | P a g e


wooden barrels to mature. The

for example a minimum




ing until it is pumped to the beer



heater where it is warmed by


heater generally are returned to the beer still as reflux.

ternately goes through three chemical and biochemical


on and rough beer clarification)

grain, usually barley, after being germinated for a limited



for brewing. During the malting process, enzymes are generated, the



ned of dust and foreign materials and then sorted according to size with the

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b) Milling and mashing

Malted barley is ground (either dry or wet) in a malt grinder so that the husk is left intact

while the rest becomes very coarse powder, rich in starch and enzymes. The enzymes

quickly degrade the starch to sugar on contact with water. The product, called sweet

is a mixture of partially degraded starch, sugars, enzymes, proteins and water

1986). The wort is separated from the spent grains by straining through a porous

the lauter tun where the grains are sprayed or sparged with water in order to

maximum amount of useful material. Spent grains, spent hops and trub

valuable source of protein for animal feed.

The spent grain yields typically 125

composition is 28% protein, 8% fat and 41% nitrogen

c) Wort cooling and fermentation

In order to prepare for fermentation, the hopped wort is cooled to about 10oC. Further

precipitation of proteins and tannin (known as cool trub or fine break) occurs during the

cooling and aeration in preparation for fermentation which may continue from 2

Yeast is added in the fermentation vessel to induce fermentation of sugar wort which is

converted to CO2, alcohol, heat and new yeast cells. When the fermentation process is

completed, the yeast is drawn off and used for a new batch of wort with the exces

disposed of as a by-product. The surplus yeast can be resold as animal feed. On a dry

solids basis, the yeast contains 50

making it another valuable source of protein for animal feed (BPCE, 1986).

the primary fermentation, the produced beer (green beer) is transferred to

maturation vessels for a certain period of time before filtration. Prior to

may be centrifuged, cooled to

beer is then filtered in a Kieselguhr (diatomaceous earth) filter

d) Packaging and pasteurization

Bright beer is stored and then filled into bottles or cans. In the process of filling, a small

volume of beer (drip beer) is spilt. Bottling is usually preceded with bottle washing to

remove any residual beer mold, cigarette butts, labels and dust particles.



le the rest becomes very coarse powder, rich in starch and enzymes. The enzymes

quickly degrade the starch to sugar on contact with water. The product, called sweet

is a mixture of partially degraded starch, sugars, enzymes, proteins and water

1986). The wort is separated from the spent grains by straining through a porous

where the grains are sprayed or sparged with water in order to

maximum amount of useful material. Spent grains, spent hops and trub

valuable source of protein for animal feed.

The spent grain yields typically 125-130 kg wet for every 100 kg of malt and its

composition is 28% protein, 8% fat and 41% nitrogen-free substances (BPCE, 1986).

c) Wort cooling and fermentation

to prepare for fermentation, the hopped wort is cooled to about 10oC. Further


cooling and aeration in preparation for fermentation which may continue from 2



completed, the yeast is drawn off and used for a new batch of wort with the exces

product. The surplus yeast can be resold as animal feed. On a dry

solids basis, the yeast contains 50-60% proteins, 15-35% carbohydrates and 2

making it another valuable source of protein for animal feed (BPCE, 1986).

the primary fermentation, the produced beer (green beer) is transferred to

maturation vessels for a certain period of time before filtration. Prior to filtration, the beer

may be centrifuged, cooled to -1oC to -1.5oC to precipitate any suspended solids. The

beer is then filtered in a Kieselguhr (diatomaceous earth) filter followed by a filter cloth.

d) Packaging and pasteurization


er (drip beer) is spilt. Bottling is usually preceded with bottle washing to

remove any residual beer mold, cigarette butts, labels and dust particles.

20 | P a g e


le the rest becomes very coarse powder, rich in starch and enzymes. The enzymes

quickly degrade the starch to sugar on contact with water. The product, called sweet wort,

is a mixture of partially degraded starch, sugars, enzymes, proteins and water (BPCE,

1986). The wort is separated from the spent grains by straining through a porous filter in

where the grains are sprayed or sparged with water in order to extract the

maximum amount of useful material. Spent grains, spent hops and trub represent a

130 kg wet for every 100 kg of malt and its

free substances (BPCE, 1986).

to prepare for fermentation, the hopped wort is cooled to about 10oC. Further


cooling and aeration in preparation for fermentation which may continue from 2–16 days.



completed, the yeast is drawn off and used for a new batch of wort with the excess being

product. The surplus yeast can be resold as animal feed. On a dry

35% carbohydrates and 2- 12% fat

making it another valuable source of protein for animal feed (BPCE, 1986). Following

the primary fermentation, the produced beer (green beer) is transferred to storage or

filtration, the beer

suspended solids. The

followed by a filter cloth.


er (drip beer) is spilt. Bottling is usually preceded with bottle washing to

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Major Environmental Issues

(1) Waste Water

The major sources of wastewater for molasses based distilleries are:

Process waste streams

• Spent wash from the analyzer

• Fermented sludge

• Spent lees from the rectifier

Non-process waste streams

• Cooling water

• Waste wash water

• Water treatment plant wastewater

• Boiler blow down

• Bottling plant wash wastewater

• Other wastes

Quantity and Characteristics of Process Wastewater

SR.

No.

Source

1. Spent Wash from

Analyzer Column

2. Fermenter sludge

3. Spent lees from the

rectifier

4. Cooling water

5. Waste wash water

6. Boiler blow down

7. Water Treatment

Plant


Major Environmental Issues in Molasses Based Distilleries In India

wastewater for molasses based distilleries are:

analyzer column

Spent lees from the rectifier

process waste streams

Water treatment plant wastewater

Bottling plant wash wastewater

Quantity and Characteristics of Process Wastewater

Flow in

KL/KL of

RS

BOD SS

mg/lit Kg/KL

of RS

mg/L Kg/KL

of RS

10.0 50000 500 12000 120

0.05 125000 6.25 50000 2.5

Spent lees from the 1.0 500 0.5 16000 16

2.0 100-

200

0.4 500 1.0

3500

15

2.1

21 | P a g e

In India

Type of

Flow

Kg/KL

of RS

Continuous

Intermittent

Continuous

(Recycled)

Do

Intermittent

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8. Bottling Plant

Wash Water

Characteristics of Spent Lees

S.No Parameter

1. pH 2. COD 3. BOD 4. Total Solids Dissolved Solids Suspended Solids 5. Chlorides

(Source: Draft report prepared on “Development of Methodology for Environmental

Auditing” by Dr. B. Subba Rao of EPRF, Sangli, for CPCB

Characteristics of Spent Wash from Various Types of Manufacturing

SR.

No

Parameter

1. Volume, L/L

alcohol

2. Color

3. pH

4. COD

5. BOD

6. Solids

Total

Total volatile

Inorganic

dissolved

7. Chlorides

8. Sulphates

9. Total Nitrogen

10. Potassium

11. Phosphorous

12. Sodium

13. Calcium

(Source: Draft report prepared on “Development of Methodology for Environmental

uditing” by Dr. B. Subba Rao of EPRF, Sangli, for CPCB


2.8 100 0.28 200 0.56

Characteristics of Spent Lees

Range 3.6 – 4.5 5000 - 6000 mg/L 200 – 300 mg/L 5000 – 6000 mg/L 500 – 1000 mg/L 50 – 100 mg/L

Source: Draft report prepared on “Development of Methodology for Environmental

Dr. B. Subba Rao of EPRF, Sangli, for CPCB)

Spent Wash from Various Types of Manufacturing

Batch

Process

Continuous

Process

Bio

14 – 15 10 – 12 7 – 9

Dark brown Dark brown Dark brown

3.7 – 4.5 4.0 – 4.3 4.0 – 4.2

80000-100000 110000 –

130000

140000

45000 – 50000 55000 – 65000 60000 –

90000 – 120000 130000 - 160000 160000

60000 – 70000 60000 – 75000 80000 –

30000 – 40000 35000 – 45000 60000 –

5000- 6000 6000 – 7500 10000 –

4000 – 8000 4500 – 8500 8000 –

1000 – 1200 1000 – 1400 2000 –

8000 – 12000 10000 – 14000 20000 –

200 – 300 300 – 500 1600 –

400 – 600 1400 – 1500 1200 –

2000 – 3500 4500 – 6000 5000 –


Dr. B. Subba Rao of EPRF, Sangli, for CPCB)

22 | P a g e

Continuous


Spent Wash from Various Types of Manufacturing Process

Bio-still Process

Dark brown

4.2

140000 – 160000 mg/L

– 70000 mg/L

160000 – 210000 mg/L

– 90000 mg/L

– 90000 mg/L

– 12000 mg/L

10000 mg/L

2500 mg/L

– 22000 mg/L

2000 mg/L

1500 mg/L

6500 mg/L


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Standards for Wastewater Discharges from Distilleries

SR.

No

Parameter

1. pH

2. Suspended Solids, mg/l

3. BOD, mg/l(27

days)

4. Colour, hazen unit

(2) Air Emissions from Distillery Industry

Air emissions may be categorized as fugitive and point source emissions.

Fugitive emissions

These are emissions that are not released through a vent or stack. Examples of fugitive

include evaporation of wastewater, dust from stockpiles, volatilization of

vessels, or spills and material handling. Emissions emanating

and open doors of a building as well as equipment

also examples of fugitive emissions.

losses through fugitive emissions.

Possible Emissions from Beer and Wine Industries

Emission Source

Fermentation

� Fugitive Sources

� Screening of red wine

� Pressing


Standards for Wastewater Discharges from Distilleries As per CPCB

Parameter Industrial Sector

Fermentation (Distilleries,

Matrices & Breweries)

5.5 - 9.0

Suspended Solids, mg/l 100

BOD, mg/l(27ºC for 3

days)

30 (disposal into inland

water)

100 (disposal on land)

Colour, hazen unit All efforts should be made

to remove colour,

odour as far as practicable.

Emissions from Distillery Industry

Air emissions may be categorized as fugitive and point source emissions.

These are emissions that are not released through a vent or stack. Examples of fugitive

include evaporation of wastewater, dust from stockpiles, volatilization of vapour from vats, open

vessels, or spills and material handling. Emissions emanating from ridgeline roof

and open doors of a building as well as equipment leaks, and leaks from valves and flanges are

also examples of fugitive emissions. Emission factors are the usual method for determining

losses through fugitive emissions.

Possible Emissions from Beer and Wine Industries

Possible Emissions

� Ethanol (largest emission by volume)

� Acetaldehyde

� Methanol

� Hydrogen Sulfide

� Total Volatile Organic Compounds (Total

VOCs)

� Ethyl Acetate

� Ethanol

� Sulfur dioxide

23 | P a g e

As per CPCB

These are emissions that are not released through a vent or stack. Examples of fugitive emissions

vapour from vats, open

from ridgeline roof-vents, louvers,

leaks, and leaks from valves and flanges are

Emission factors are the usual method for determining

Ethanol (largest emission by volume)

Total Volatile Organic Compounds (Total

Gujarat Cleaner

� Ageing in Oakcooperage

� Bottling process

� Preservation agents

Fuel Combustion

(Source: Adapted from USEPA, AP

Point source emissions

These emissions are exhausted into a vent (excluding roof vent) or stack and emitted

single point source into the atmosphere.

and wine may include VOCs,

Environmental Protection Agency (USEPA) and the California Air

and distilleries are only minor sources of emissions of VOCs

GHG emissions

However, several greenhouse gases may also be produced in the beer, wine and spirit

process including:

� CO2 (a by-product of fermentation);

� Nitrous oxide (N2O) (a by-product of the internal combustion engine); and,

� Sulphur dioxide (SO2) (if used during kilning)

Present Status Of Treatment And Disposal

Spent wash treatment is proposed by three different routes currently viz; (a) Concentration

followed by incineration, (b) Anaerobic digestion with biogas recovery followed

polishing and (c) Direct wet oxidation of stillage by air at high temperature with generation of

steam followed by aerobic polishing. All of these processes are capital intensive. The

incineration process involves an investment of the order of

the other two processes along with the secondary treatment require an investment of 200

of the distillery cost. The unfavourable economics make it difficult to implement these treatment

processes on the plant scale. Because anaerobic digestion and wet oxidation are less expensive,

these alternatives are more attractive. However, there is a need for development of a suitable


� Carbon monoxide (CO)

� Sulfur dioxide (SO2)

� Total VOCs

� Particulate Matter (PM10)

� Oxides of Nitrogen (NOx)

AP-42, Section 9.12.2.1995)

These emissions are exhausted into a vent (excluding roof vent) or stack and emitted

single point source into the atmosphere. The main emissions to air from the manufacture of beer

greenhouse gases, odour, noise and dust. As per the U.S.

Environmental Protection Agency (USEPA) and the California Air Resources Board, breweries

and distilleries are only minor sources of emissions of VOCs to the atmosphere.

However, several greenhouse gases may also be produced in the beer, wine and spirit

product of fermentation);

product of the internal combustion engine); and,

dioxide (SO2) (if used during kilning)

Present Status Of Treatment And Disposal


followed by incineration, (b) Anaerobic digestion with biogas recovery followed



incineration process involves an investment of the order of 400% of the distillery cost, whereas

the other two processes along with the secondary treatment require an investment of 200


e. Because anaerobic digestion and wet oxidation are less expensive,


24 | P a g e

These emissions are exhausted into a vent (excluding roof vent) or stack and emitted through a

The main emissions to air from the manufacture of beer

As per the U.S.

Resources Board, breweries

However, several greenhouse gases may also be produced in the beer, wine and spirit making


followed by incineration, (b) Anaerobic digestion with biogas recovery followed by aerobic



400% of the distillery cost, whereas

the other two processes along with the secondary treatment require an investment of 200-300%


e. Because anaerobic digestion and wet oxidation are less expensive,


Gujarat Cleaner

process with lower investments and higher energy recovery.

allowing their effluent for application on land as direct irrigation water, spent wash cake and

spent wash-press mud compost.

conservation are also discernible in the case of distilleries. The methane ga

digesters is used as a fuel to compensate the energy needs of the industry. A general estimate

suggests that the cost of an anaerobic biological digester is recovered within 2

installation because of substantial saving of coal

Cost Recovery/Cleaner Production Methods

The wastewaters generated during the distillery and brewery operations contain high organic

loads. It has a BOD from 30,000 to 60,000 mg/1. So due to this high

wastewaters can be subjected to treatment for the produc

aquaculture and potash recovery.

(a) Biogas.

For the production of biogas from distillery effluent, anaerobic biomethanation of the

effluent is adopted, generally. High rate anaerobic technologies are utilized for

biogas generation. Fluidised Bed Reactors and Up flow Anaerobic Sludge Blanket

(UASB) Reactors are mostly utilized for the production of biogas from t

Some of the Cleaner P

in India at present are:

• BIOTHANE PROCESS

This process uses the UASB reactor for the production of biogas. This is a stable

and automatic process with low operational costs.

• BIOBED PROCESS

It is similar to Bio thane process. It uses UFB reactors. It needs less installation

area and its construction cost is lower compared to any other system.

• BIOPAQ PROCESS

In this process anaerobic bacteria are used to treat the distillery effluents for th

production of biogas. UASB proc

process makes excellent manure. The generated biogas is used to produce steam

for the distillation of alcohol and thus it replaces 50

energy in the process of distillation. For a plant having 40


process with lower investments and higher energy recovery. Many distilleries in India are


press mud compost. The advances manifesting the possibilities of energy

conservation are also discernible in the case of distilleries. The methane gas generated in the

fuel to compensate the energy needs of the industry. A general estimate

suggests that the cost of an anaerobic biological digester is recovered within 2

installation because of substantial saving of coal and other fuels.

Production Methods From The Distillery Effluents


loads. It has a BOD from 30,000 to 60,000 mg/1. So due to this high organic contents, the

wastewaters can be subjected to treatment for the production of biogas, composting,

aquaculture and potash recovery.


ed, generally. High rate anaerobic technologies are utilized for


(UASB) Reactors are mostly utilized for the production of biogas from t

Some of the Cleaner Production processes of Biogas being commercial1y established

in India at present are:-

BIOTHANE PROCESS


and automatic process with low operational costs.

BIOBED PROCESS



BIOPAQ PROCESS

In this process anaerobic bacteria are used to treat the distillery effluents for th

production of biogas. UASB process is utilized here. The separated sludge in this


for the distillation of alcohol and thus it replaces 50-60% of the total required

in the process of distillation. For a plant having 40-45,000 kg COD/day

25 | P a g e

Many distilleries in India are


The advances manifesting the possibilities of energy

s generated in the

fuel to compensate the energy needs of the industry. A general estimate

suggests that the cost of an anaerobic biological digester is recovered within 2-3 years of

From The Distillery Effluents


organic contents, the

biogas, composting,


ed, generally. High rate anaerobic technologies are utilized for


(UASB) Reactors are mostly utilized for the production of biogas from the effluents.

being commercial1y established




In this process anaerobic bacteria are used to treat the distillery effluents for the

ess is utilized here. The separated sludge in this


60% of the total required

45,000 kg COD/day

Gujarat Cleaner

75-80% of COD can be reduced and nearly Rs. 25.50 lakhs can be saved annually

for a distillery having 300 working days in a year. The generated biogas from

UASB reactor of BioPaq pro

engine. Through suitable coupling the engine can be coupled with the A/C generator

for generation of electricity from biogas. For a 45 klpd distillery 11 KV of power is

generated which is then utilize

consumption.

• SULZER' S PROCESS

by Sulzer Brothers Limited, Switzerland. It is specifically made for Indian conditions.

A biogas plant at the distiller

Pravaranagar, Ahmednagar District, Maharashtra is based on Sulzer's technology.

The capacity of this distillery is 6,000 lpd which generates 900 m3 of spent wash per

day. The biogas production is in th

savings in the cost of fuel is in the range of Rs. 312 lakhs to Rs. 652 lakhs per year.

Economics of the Biogas Plant of

These calculations are made for a distillery producing 30,000 litres

day. The effluent characteristics are for conventional batch type fermentation process.

Effluent Characteristics

Flow m3/day

pH

BOD mg/l

COD mg/l

Performance

Reduction of BOD %

Reduction of COD %


80% of COD can be reduced and nearly Rs. 25.50 lakhs can be saved annually


UASB reactor of BioPaq process can be collected and be used as a fuel in gas/dual



generated which is then utilized in the distillery thus cutting down the power

SULZER' S PROCESS: The technology of this type of biogas plant is provided


A biogas plant at the distillery of Padmashri Dr. Vitthalrao Vikhe Patil S.S.K. Ltd.,



day. The biogas production is in the range of 16,550 to 21,870 m3 per day. The


of the Biogas Plant of Sulzer’s Design

These calculations are made for a distillery producing 30,000 litres


Effluent Characteristics

Before Treatment After Treatment

450

4.0 to 4.5

45,000 to 50,000

80,000 to 1000,000 25,000 to 35,000

Performance

Reduction of BOD % 80 to 85 %

Reduction of COD % 65 to 70 %

26 | P a g e

80% of COD can be reduced and nearly Rs. 25.50 lakhs can be saved annually


cess can be collected and be used as a fuel in gas/dual



ting down the power

: The technology of this type of biogas plant is provided


y of Padmashri Dr. Vitthalrao Vikhe Patil S.S.K. Ltd.,



21,870 m3 per day. The


These calculations are made for a distillery producing 30,000 litres of alcohol per


After Treatment

450

7.0 to 7.8

6,000 to 8,000

25,000 to 35,000

80 to 85 %

65 to 70 %

Gujarat Cleaner

Biogas Production Nm

Specific Biogas Production Nm

% of methane in biogas

Economics

Calorific value of biogas

Calorific Value of Coal

Coal equivalent of Biogas p

Cost of Coal at Rs

Annual fuel savings

Capital cost of plant

Interest at 15 % on 75 % of the capital cost**

Maintenance costs

Staff Salary

Power 40 KW at Rs 2/

Total Annual Cost

Net Savings per year

Total Pay back period

(b) Composting

In this process, press mud generated from sugar mill is utilised to produce compost by

mixing distillery effluent. Both anaerobic and aerobic composting systems are practiced.

In some plants composting with treated effluent treated through bio

also practiced. This system can achieve zero effluent if the press mud quantity matches

with the effluent generated.

• Economics Of Bioearth Composting

Capacity of the Distillery

Number of working days in a year

In the Distillery

In the Composting Plant


Biogas Production Nm3/day 12,300

Biogas Production Nm3/kg of COD degraded 0.4 to 0.5

% of methane in biogas 60 to 65 %

Calorific value of biogas 6000 Kcal/ Nm

Calorific Value of Coal 4000 Kcal/Kg

Coal equivalent of Biogas per day 18.45 tonnes

Cost of Coal at Rs 1800 per tonne Rs 33,210 per day

fuel savings Rs 99.63 lacs

Capital cost of plant Rs 230 lacs

Interest at 15 % on 75 % of the capital cost** Rs 26,73,750

Maintenance costs Rs 2,00,000

Rs 1,50,000

wer 40 KW at Rs 2/- per unit Rs 5,76,000

Total Annual Cost Rs 36,00,000

Net Savings per year Rs 99.36

= Rs 63.63 lacs

Total Pay back period = 230 / 63.63

= 3 to 4 years.



In some plants composting with treated effluent treated through bio-methanation


with the effluent generated.

Economics Of Bioearth Composting

Capacity of the Distillery 50 KLPD

Number of working days in a year

300

In the Composting Plant 275

27 | P a g e

12,300

0.4 to 0.5

60 to 65 %

6000 Kcal/ Nm3

4000 Kcal/Kg

18.45 tonnes

Rs 33,210 per day

Rs 99.63 lacs

Rs 230 lacs

Rs 26,73,750

Rs 2,00,000

Rs 1,50,000

Rs 5,76,000

Rs 36,00,000

Rs 99.36 – 36

= Rs 63.63 lacs

= 230 / 63.63

= 3 to 4 years.



methanation plant is


Gujarat Cleaner

Generated spentwash

Solid content in spentwash

Spentwash to Press mud Ratio

Man Power Required

Culture Requirement

Press mud requirement

Cost of Culture

Cost of Press mud

Man Power cost

Capital Cost

Land Requirement

Bio Earth Producti

Annual Maintenance Costs

% Costs of Funds

• Operation Costs

Cost of Culture

Average Cost of Funds

Cost of Diesel

Cost of Press mud

Cost of Transportation of Press mud

Annual Man Power Cost

Depreciation (@ 10 %)

Maintenance

Annual Operational Cost of Compost Plant

Cost of One Metric Tonne of Bioearth


Generated spentwash 350 KLPD (Biostil Plant)

Solid content in spentwash 17 %

Spentwash to Press mud Ratio 2.5 KL : 1 MT

Man Power Required 50

Culture Requirement 31.5 MT/annum

Press mud requirement 43,000 MT/ annum

Rs 1.75 lakhs per MT

Cost of Press mud Rs 12 per MT

Rs 50 per day

Rs 175 lakhs (excluding land)

Land Requirement 25 acres

Bio Earth Production 38,000 MT per year

Annual Maintenance Costs 1.5 % of equipment costs

% Costs of Funds 20 % per annum

Operation Costs

55.13 lakhs

Average Cost of Funds 17.5 lakhs

11.32 lakhs

mud 5.16 lakhs

Cost of Transportation of Press mud 0.00

Annual Man Power Cost 6.88 lakhs

Depreciation (@ 10 %) 15.00 lakhs

2.25 lakhs

ational Cost of Compost Plant 113.24 lakhs

f One Metric Tonne of Bioearth = Annual Operational cost of plant

Compost Produced in MT

= 11324000

38000

= Rs 298.00 per MT

28 | P a g e

350 KLPD (Biostil Plant)

2.5 KL : 1 MT

31.5 MT/annum

43,000 MT/ annum

Rs 1.75 lakhs per MT

Rs 12 per MT

Rs 50 per day

Rs 175 lakhs (excluding land)

38,000 MT per year

1.5 % of equipment costs

20 % per annum

Operational cost of plant

Compost Produced in MT

Rs 298.00 per MT

Gujarat Cleaner

• Net Cost/Benefit For Different Selling Prices Of Compost

SP of Bio earth

in Rs

0

100.00

200.00

298.00

350.00

400.00

500.00

Net annual cost/benefit of Compost

• COMPUTATION OF PAY BACK PERIOD

1. SP of Bioearth

Initial cash outflow

Net annual cash inflow

Pay Back Period

2. SP of Bioearth



Pay Back Period

3. SP of Bioearth



Pay Back Period


Net Cost/Benefit For Different Selling Prices Of Compost

earth Net Cost / Benefit

In Rs

-11324000.00

-7524000.00

-3724000.00

0.00

1976000.00

3876000.00

7676000.00

annual cost/benefit of Compost = Sales value of 38000 MT of

compost less annual operating

costs

COMPUTATION OF PAY BACK PERIOD - Rs 250.00

Initial cash outflow - Rs 17500000.00

Net annual cash inflow - Rs 1738000.00

- 10.06 Years

(17500000/1738000.00)

- Rs 350.00



- 3.34 Years

(17500000.00/5226000.00)

- Rs 500.00



- 1.6 Years

(17500000.00/10926000.00

29 | P a g e

Sales value of 38000 MT of

compost less annual operating

(17500000/1738000.00)

(17500000.00/5226000.00)

(17500000.00/10926000.00)

Gujarat Cleaner

(C) Potash Recovery

It is done by incinerating the distillery spent wash. In this process, the raw distillery

spent wash is first neutralized with lime and filtered. This is further concentrated to about

60% solids in multiple-effect forcer circulation evaporators. Now this thick liquor from

the evaporator is burnt in an incinerator and is converted into ash. The dry so

spent wash in the form of coke in the incinerator has an average calorific value of 2

Kcal/kg, which is sufficient for supporting self

incinerator. The resulting ash is found to contain about 37% of potash

on an average. This ash is further leached with water to dissolve the potassium salts.

Then it is neutralized with sulphuric acid and is evaporated. The potassium salts are

crystallized in a crystal1izer. The crystallized mixed potassium

potassium sulphate (K2SO

is estimated that a distillery dis

recover 3 tonnes of Potassium as Potassium oxide or about 5.3

sulphate and 1.2 tonnes of Potassium chloride per day. This potassium is used as a

fertilizer.

(d) Distillery Wastewater Utilisation In Agriculture

Being very rich in organic matters, t

fields creates organic fertilization in the soil which raises the pH of the soil, increases

availability of certain nutrients and capability to retain

physical structure of soil.

irrigation. The post-harvest fields are filled with distill

when the surface is almost dried, the fields are tilled and the crops are sown and subse

quent irrigation is given w

before application on crops.

an attractive agricultural practice which not only augments crop yield but also provides a

plausible solution for the land

effluent contains nearly 5 kg of potassium, 300 grams of nitrogen and 20 grams of

phosphorus. If one centimetre of post methanation



wash is first neutralized with lime and filtered. This is further concentrated to about

effect forcer circulation evaporators. Now this thick liquor from

the evaporator is burnt in an incinerator and is converted into ash. The dry so


Kcal/kg, which is sufficient for supporting self-combustion of the thick liquor in the

incinerator. The resulting ash is found to contain about 37% of potash as potassium oxide



crystallized in a crystal1izer. The crystallized mixed potassium salt contains 73.5% of

SO4) 16.5% potassium chloride (KCl) and 5% of sodium salts. It

is estimated that a distillery discharging about 300 m3 of spent wash per day could

recover 3 tonnes of Potassium as Potassium oxide or about 5.34 tonnes of Potassium


Distillery Wastewater Utilisation In Agriculture

organic matters, the utilisation of distillery effluents in agricultural


of certain nutrients and capability to retain water and also improves the

physical structure of soil. Mostly the distillery wastewaters are used for pre

harvest fields are filled with distillery effluents. After 15

when the surface is almost dried, the fields are tilled and the crops are sown and subse

quent irrigation is given with fresh water. However, the effluent is diluted 2

before application on crops. Apparently, the irrigation with distillery wastewater seems to be


solution for the land disposal of the effluents. One cubic metre of methanated


If one centimetre of post methanation effluent is applied

30 | P a g e


wash is first neutralized with lime and filtered. This is further concentrated to about

effect forcer circulation evaporators. Now this thick liquor from

the evaporator is burnt in an incinerator and is converted into ash. The dry solids of the


combustion of the thick liquor in the

as potassium oxide



salt contains 73.5% of

) 16.5% potassium chloride (KCl) and 5% of sodium salts. It

of spent wash per day could

4 tonnes of Potassium


lery effluents in agricultural


water and also improves the

distillery wastewaters are used for pre-sowing

ery effluents. After 15-20 days,

when the surface is almost dried, the fields are tilled and the crops are sown and subse-

ith fresh water. However, the effluent is diluted 2-3 times

Apparently, the irrigation with distillery wastewater seems to be


One cubic metre of methanated


on one hectare of

Gujarat Cleaner

agricultural land annually, it

of sulphates, 28 kg of nitrogen and 2 kg of phosphates.

21.5 percent potash as KO,

Nitrogen as N2. The irrigational and manorial potential of

i) Total Volume available

ii) Nutrients Contribution Potential

Economic Aspects

When the distillery effluents are used for

in it transform the lands

Farmers could save nitrogenous

distilleries of out country

predicted that the utilisation

able nitrogen, phosphorous and potash

advantage of this application

organic form. As the secondary and tertiary systems for the treatment of

highly energy intensive and according

connected load of 200 M.W. would be required to energising these

endeavour to reduce the BOD level

desired energy would need an installed load of 350 M.W. which

investment of the order of about Rs


tural land annually, it will yield nearly 600 kg of potassium, 360 kg of calcium, 100 kg

28 kg of nitrogen and 2 kg of phosphates. The distillery effluent contains 0.6 to

KO, 0.1 to 1.0 percent phosphorus as PO and 0.01

The irrigational and manorial potential of distillery wastewaters is given below:

Total Volume available in Million m3 /annum :

Nutrients Contribution Potential (tonnes/annum) : N

PO

KO

effluents are used for irrigation in fallow lands, the microbes present

lands into fertile ones, giving high yields of paddy and sugarcane.

Farmers could save nitrogenous fertilisers worth Rs 1335 crores per annum if at least 200

country recycled their wastes to the agricultural fields.

utilisation of distillery effluent for irrigation of land would

able nitrogen, phosphorous and potash valued at about Rs 500 crores each year. The added

application would be that these fertilisers would be available

As the secondary and tertiary systems for the treatment of distillery effluent are

highly energy intensive and according to the estimates of the Union Ministry of Energy a total

nected load of 200 M.W. would be required to energising these systems if 2

endeavour to reduce the BOD level of effluent to the extent possible. The generation of the

desired energy would need an installed load of 350 M.W. which would require capital

investment of the order of about Rs 1400 crores. So it will be an attractive practice to utilise the

31 | P a g e

600 kg of potassium, 360 kg of calcium, 100 kg

effluent contains 0.6 to

and 0.01 to 1.5 percent

ters is given below:

6.87

N - 69380

- 11335

- 27480

lands, the microbes present

into fertile ones, giving high yields of paddy and sugarcane.

crores per annum if at least 200

fields. However, it is

would make a v a i l -

crores each year. The added

available to soil in

distillery effluent are

to the estimates of the Union Ministry of Energy a total

systems if 246 distilleries

of effluent to the extent possible. The generation of the

would require capital

n attractive practice to utilise the

Gujarat Cleaner

distillery effluents for ferti

abundance around the distiller


effluents for ferti-irrigation of land after primary treatment, as land is available in

abundance around the distilleries which are located in the sugarcane belts.

32 | P a g e

ment, as land is available in

Documents

2. Distillery Sector - gcpc-envis Sector.pdfprocesses: Praj type and Alfa Laval distillation named after systems. In Praj type, for one liter of alcohol produced, about 12 generated,