1. Water Balance of 120 KLPD Molasses Distillery
PRESENTED BY
K.P.SINGH
(DIRECTOR)
RADICO KHAITAN LTD

2. Water Balance of 120 KLPD Molasses Distillery
Distillery is among the major water consuming industries. However major part of this water can be recycled back and reused resulting in reducing the requirement of fresh water to about 50% and achieving practically zero liquid discharge from the industry.

3. Water Consumption of a typical 120 KLPD Distillery
  Total water Outputs
Section Unit - M3 / Day
Fermentation
For Dilution m3
In cooling tower m3
In fermentor washing - 25  m3
In air blower -12 m3
Total in Fermentation m3
Distillation
In cooling water make up - 676  m3
In vacuum pump - 144 m3
Scrubber- 57 m3
In fusel oil decanters – 19 m3 
D.M. water for dilution – 190 m3 
Total in Distillation – m3

4. Water Consumption of a typical 120 KLPD Distillery
E.T.P
Gas washing – 10 m3
 Decanters cleaning - 15 m3
R.O. plant rinsing - 30 m3
Cooling water – 50 m3 
Total IN ETP m3
Co-generation
Feed water – 432 m3
Boiler blow down – 10 m3
Turbine cooling water - 60 m3
Total in ETP and Co- Gen. – 502 m3

5. Water Consumption in 120 KLPD Distillery
Bottling & Others
Bottle washing – 168 m3
 For blending -35 m3
 Drinking & Toilets -10 m3
 In D. M. water re-regeneration – 50 m3
 In Water softener for re-regeneration -40 m3
Total in Bottling & Others - 303  m3
GRAND TOTAL IN ALL SECTIONS – 3227 m3

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

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

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

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

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

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

12. Water Balance of 120 KLPD Distillery
From the above it is observed that if managed properly the 50% water requirement out of about 27 m3/ KL of Spirit Production can be met with recycled water and fresh water is required only about 14 m3 / KL of Alcohol production including water required for bottling purposes.
Recycled water can satisfy most of the water demands, as long as it is adequately treated to ensure appropriate water quality for use.