The Ugar Sugar Works Ltd.

,
Ugar Khurd

AIDA Seminar – Jaipur

Recovery of Low Grade Potash a case study at USWL
 The Ugar Sugar Works Ltd.,

Introduction.

In India, there are about 300 distilleries under operation.

Distillery is considered as one of the major revenue earning

industry

Distillery also come under highly polluting industry category .

 The Ugar Sugar Works Ltd.,

Present Distillery Effluent Treatment Systems being operated in India.

Raw Spentwash followed by evaporation followed by Incineration in high

pressure boiler for production of steam & power
Raw Spentwash followed by Biomethanation followed by Evaporation followed
by mixing with bagasse , husk or any other biomass ,drying in rotary dryer &
burning in hot air generator & using the hot air for drying purpose in rotary
dryer.
Raw Spentwash followed by Biomethanation followed by Evaporation followed
by mixing with bagasse , husk etc & burning in conventional boiler designed
for using the effluent mixed fuel.
 The Ugar Sugar Works Ltd.,

Raw Spentwash followed by Biomethanation followed by Evaporation

followed by low grade potash recovery generation
Raw Spentwash followed by Biomethanation followed by one time controlled
land application
Raw Spentwash followed by Biomethanation followed by Evaporation
followed by composting
Raw Spentwash followed by Evaporation followed by burning in cement
plant kiln or thermal power plant furnace or steel plant furnace .
Raw Spentwash followed by Biomethanation followed by Secondary
treatment to bring down BOD level less than 2500 mg/l & disposal in sea.
 The Ugar Sugar Works Ltd.,

USWL Case study -

All above different technologies are being followed by distilleries based

on their local conditions , resources available around the location, cost
of the treatment & state pollution control board guidelines.

The evaporation system is almost common in most of the options

mentioned above. There are distilleries who are having more than one
option in order to keep distillery operation for maximum days. Our
suggestion is to add one more spray dryer to make the low grade
potash powder. The details are mentioned in next slides.
 The Ugar Sugar Works Ltd.,

The USW limited installed the zero pollution plant ( Low

Grade Potash Powder recovery plant.) in the year 2002 &
another simillar plant in 2008.

Govt. of India has supported this plant through

Technology Development Board, New Delhi.
 The Ugar Sugar Works Ltd.,

Project Details

Biomethanation Plant

The Evaporator Plant

The Spray Drying 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 25,000 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
New Evaporator Plant Old Evaporator plant – 360 m3/day
 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.,
The GA of Sugar unit Process is as under
Bagasse

Potash Sugarcane Sugar

Molasses

Pressmud

(Potash) Alcohol
Spent Wash (Industrial &
Potable)
 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.,

Details of Estimation considered total molasses production in

India for the year
 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. 1400 PMT ex-plant.

 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.,

Thank You

Presented By :- Dr. S.M.Pattanshetty

(Chief Manager Environment)