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

Introduction.

In , 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 The Ugar Sugar Works Ltd.,

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 in the year 2002 & another similar plant in 2008. The Ugar Sugar Works Ltd.,

Project Details

Biomethanation Plant

The Evaporator Plant

The Spray Drying Plant

This system has similler process like milk powder plant. The Ugar Sugar Works Ltd.,

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). The Ugar Sugar Works Ltd.,

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 required. The spent wash volume is reduced to 80% by evaporation. No additional infrastructure required to handle voluminous product (bio- compost.) The Ugar Sugar Works Ltd.,

CSTR Digester

UASB Reactor The Ugar Sugar Works Ltd.,

Zero Pollution Plant Capacity – 1060 m3/day for 75 KLPD Old Evaporator plant – 360 m3/day New Evaporator Plant The Ugar Sugar Works Ltd.,

Zero Pollution Plant Capacity – 1060 m3/day for 75 KLPD

New Dryer plant Old Dryer plant The Ugar Sugar Works Ltd.,

Hot Air Generator The Ugar Sugar Works Ltd., Flow Chart Distillery Effluent Treatment

Biomethanation Effluent

Steam Evaporators Water evaporation (5 Effect)

Spray Dryer

Biogas Fired Hot Air Powder Generator

Low grade Potash Powder The Ugar Sugar Works Ltd., Analysis of Distillery Effluent The Ugar Sugar Works Ltd., The Ugar Sugar Works Ltd.,

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. The Ugar Sugar Works Ltd.,

Guaranteed specifications of Low Grade Potash suitable for direct application for incorporated in FCO:-

Water soluble potash as K2O = 14.70 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 = 5% Max Particle Size = less than 100 micron (100% Below 60 Tyler Mesh) The Ugar Sugar Works Ltd.,

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 The Ugar Sugar Works Ltd., The Ugar Sugar Works Ltd.,

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. 2000 PMT ex-plant. The Ugar Sugar Works Ltd.,

THE LIST OF DISTILLERY UNITS PRESENTLY PRODUCING LGP

LGP production Sr Capacity in No The Company Name of the equipment MT/annum, Application

Ugar Sugar Works Ltd, Ugar Five Effect Falling Film Evaporator Biomethanated 1 (Karnataka) with Spray Dryer 6000 Spent wash

Five Effect Falling Film Evaporator Ashoka Distilleries & (34219 kg/h WE) with Spray Dryer Biomethanated 2 Chemicals (P) Ltd (1900 kg/h WE) 8000 Spent wash

Five Effect Falling Film Evaporator Kanoria Chemicals & with TVR and Spray Dryer for Biomethanated 3 Industries Ltd, Ankleshwar Effluent Concentrate 6000 Spent Wash

IFB Agro Industries Ltd, West 5 Effect Falling Film Evaporator with Biomethanated 4 Bengal TVR and Spray Dryer 7000 Spent Wash

SCM Sugar Limited (Distillery 5 Effect Falling Film Evaporator with Biomethanated. 5 Division), TVR with Spray Dryer 6000 Spent wash

Nizam Deccam Sugars Ltd, Five Effect Falling Film Evaporator Biomethanated 6 Hyderabad with TVR with Spray Dryer 7000 Spent wash

Haryana Distillery Limited, Five effect Falling Film Evaporator Biomethanated 7 Yamunanagar with TVR system + Spray Dryer 30000 Spent Wash The Ugar Sugar Works Ltd.,

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. The Ugar Sugar Works Ltd., Bio - K The Ugar Sugar Works Ltd., The Ugar Sugar Works Ltd., The Ugar Sugar Works Ltd., The Ugar Sugar Works Ltd., The Ugar Sugar Works Ltd., The Ugar Sugar Works Ltd., The Ugar Sugar Works Ltd., The Ugar Sugar Works Ltd.,

The Ugar Sugar Works Ltd.,

The Ugar Sugar Works Ltd.,

Thank You

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