The Bio-Methanization plant was installed in the month of February ‘05, to handle 600 m3 of spentwash. The system is based on “Up Flow Anaerobic Sludge Blanket” (UASB) process by which sludge blanket is produced at different levels of bio-methanization plant eliminating the requirement of media.
The plant is designed to handle 600 m3/day of spentwash, however only 375 to 400 m3/day of spentwash is treated, because of the modern technology adopted in the distillery. The COD reduction is 65 to 70% and BOD reduction is 85 to 90%, there by producing 22000 to 24000 m3/day bio-gas, which replaces 80% of the distillery fuel requirement. Hence, substantial fuel saving is achieved which not only benefits financially, but also eliminates pollution load to the maximum extent.
The spentwash is utilized for bio composting along with pressmud and coal ash, which are the by-products of sugar factory. The company has established concrete lined bio compost yard to an extent of 10 acres as per the protocol evolved by KSPCB / CPCB guidelines. Two numbers of powerful aero tillers are utilized for the purpose of mixing the windrows to activate the aerobic composting process. The microbial culture developed in the laboratory is added during the formation of windrows. The pressmud with the application of spentwash is composted with the help of aerobic micro organisms. With cycle time of 40 to 50 days, the spentwash mixed pressmud becomes composted and forms organic manure. Composting is carried out as per KSPCB / CPCB protocols, with pressmud and spentwash at the ratio of 1:2.5. Our bio-compost yard has a capacity of producing 2000 MT of bio-compost per month. The quality of the compost is excellent and well accepted by the farmers.
|Nitrogen – 1.5 to 2%||Magnesium – 0.71%|
|Phosphorous – 1.5 to 2%||Sulphur – 0.22%|
|Potassium – 2 to 3.5%||Iron – 0.50%|