Post on 19-Jan-2021
By K .P. SINGH
• Established in 1943.
• Among one of the oldest distilleries of the country.
• Renovation, Expansion and Modernization converted Radico into the Most Modern and Largest Potable Distillery of India.
• Replaced all the old plants by new most modern, DCS controlled Wash to ENA plants.
• Radico is an ISO 9000 (Since 2001 ) & 22000 (Since 2012).
• Obtained Koscher Quality Certificate for our Grain and Molasses during 2013 for ENA exports out of India.
• We are the First Having Biogas Plant Established in 1986-87.
• Radico is having SAP System for Integration of all the function of Organization as System Control.
• Up-Gradation & Modernization of Boilers
• Self reliance in power generation
• Modernization of distillation
• Modernization of fermentation
• Modernization of Bottling
• Up-gradation of ETP
• Backward integration ( Pet bottle plant & bottle Printing Plant)
• We had natural draft boilers till 1984. These
boilers were very inefficient.
• Since 1984 we started up-grading our boilers
and installed forced draft boiler with Turbo-
grate.
• 1988 we started feeding Bio-Gas in our boilers
which made us self sufficient in fuel and
increased consistency in steam pressure .
• We had natural draft boilers till 1984. These
boilers were very inefficient.
• Since 1984 we started up-grading our boilers
and installed forced draft boiler with Turbo-
grate.
• 1988 we started feeding Bio-Gas in our boilers
which made us self sufficient in fuel and
increased consistency in steam pressure .
• We modernized our batch fermentation By
installing PHE for Fermenter cooling in place
of surface cooling .
• Installed temperature indicators in each
fermenter for better temp. control of
fermenters.
• Installed series of Sludge settlers in order to
have clearer wash for distillation.
• We have installed improved batch
fermentation in our Molasses
Fermentation.
• Fermentation tanks are MS epoxy coated
and covered at the top for CO2 recovery.
• With High Brix Fermentation we are able to
maintain 9.5–10.0% Alcohol in Wash in a
Molasses having only 42-43% TRS.
• Fermentation Efficiency is maintained between 91.5-92.0% with efficient process controls during fermentation.
• Fresh yeast is used for every fermentation tank.
• Cell concentration in pre-fermenters is maintained at 4 X108 .
• With the recycling of Spent Lees and condensate water as dilution water, fresh water consumption in fermentation is reduced by about 80% and water born contamination is almost Zero.
YV.No Yeast Vessels Microbiology
Initial Sp.
Gr
Final
Sp. Gr Temp
Aeration
hrs
Yeast Cell
Concentration
Alc
% TBC WY MOLD
YV-1
1.044-
1.046
1.024-
1.026 35.0 10.0 hrs 1.50 - 1.60 x 108 < 1.0 NIL NIL NIL
YV-2
1.044-
1.046
1.024-
1.026 35.0 10.0 hrs 1.90-2.0 x108 < 1.0 NIL NIL NIL
YV-3
1.044-
1.046 1.024 35.0 10.0 hrs 2.20-2.40 x 108 < 1.0 5 / ML NIL NIL
PF.
No Prefermenter Microbiology
Initial
sp.gr
Final
sp.gr Temp.
Aeration
hrs
Yeast Cell
Concentration Alc % TBC WY
PF-1
1.046-
1.048
1.022
-
1.024 35.0 10.0 hrs
3.30 – 3.40 x 108
1.00-1.20 1 - 2*102 1--2 x 102
ParticularsNorm without jet
cooker
Fermenter no-1
(Culture Yeast)
Fermenter no-2
(Culture Yeast)
Fermenter no-3
(Culture Yeast)
Fermenter no-2
(Culture Yeast)
Fermenter no-3
(Culture Yeast)
Fermenter no-4 (DRY
Yeast)
Fermenter no-5
(Culture Yeast)
Date 04.02.16 05.02.16 06.02.16 06.02.16 07.02.16 07.02.16 08.02.16
DS % in fermenter 30-33 33 33 33 33 33 33 33
Flour ( Ton) 115-118 118 118 118 117 117 117 118
Starch % 60--62 % 66.0 66.0 66.0 66.0 66.0 66.0 66.0
YCC in Bub /ml 3.20- 3.30 *108
3.45*108
3.35*108
3.35*108
3.35*108
3.35*108
3.40*108
3.35*108
Alcohol % 12.0 - 13.0 13.95 14.02 14.02 14.08 13.96 14.01 13.92
Residual Sugar 0.20-0.25 0.28 0.29 0.29 0.29 0.25 0.26 0.26
Residual Starch 0.80-0.90 0.78 0.85 0.85 0.85 0.88 0.78 0.76
Final Gravity 1.000--1.005 1.005 1.006 1.006 1.002 1.002 1.003 1.002
Fermentation Time 38--42 42.0 42.0 42.0 42.0 42.0 42.0 42.0
FE% 91.8 -92.0 % 92.19 92.23 92.29 92.23 92.26 92.19 92.26
Alcohol % after 10 hrs
• Cooling of Fermenting Wort through Heat
Exchangers for optimizing fermentation efficiency .
• Cleaning of Fermentation Tanks through Spray Balls
Water Jet to save Water.
• Use of cleaning agents for maintaining aseptic
conditions after washing of Fermentation Tanks
through CIP System.
• Adequate nutrient dosing for facilitating quick
fermentation.
We have installed covered fermentation tank in order to
recover CO2.
CO2 is recovered and sold in Liquid and Dry Ice form.
We are using our own CO2 for captive usage for RTD
Bottling.
• Till 2001 we had atmospheric Distillation plants of RS and RS to ENA.
• In 2001 we installed our First 55 KL multi-pressure Wash to ENA plant with PLC based control system. Plant capacity increased from 46000KL/ Annum to 60,000 KL/ annum.
• In 2006 we installed 80 KLPD Grain Spirit plant with further improved DCS control system.
• In 2012 we improved Molasses Distillation plant by installing new multi-pressure with integrated evaporation system ( replacing old RS and RS to ENA plants) in order to reduce effluent volume.
• Till 1987 we had lagoons for effluent
treatment .
• In 1987 we were amongst the first few
installing Thermo-philic Bio-digesters on AQUA
TECHNOS technology
• In 1991 we installed Extended Aeration
system.
• In 2005 we installed our First RO Plant.
Our focus has been mainly on following...
A> Effluent Volume Reduction and Controls:
Reduced Effluent Generation through Multi Effect Evaporators and RO Plant.
Improved efficiency of RO Plant by improved TSS reduction system through installations of series of Degasser, Settlers, Lamella Clarifier and Diffused Floating Aeration (DAF) Mechanism with the help of Special Polyelectrolyte.
B> Water Usage Reduction:
Recycling of Lees, Process Condensate and Permeate.
Treatment of Recycling Stream based on it’s Characteristics.
C> Energy Sustainability:
Self sufficient on Captive Power generation.
Periodic Energy Audits
Implementation of Encon Proposals
S.NO. GURANTEED PARAMETERS UNIT VALUES
1 Feed to Evaporator TPD 1690
2Alcohol to Spent wash Ratio
(Before Evaporation)Ratio 1 : 9
3 Initial Solid in Concentration %W/W 12
4 Final Solid in Concentration %W/W 22
5 Spent wash Volume Reduced to TPD 930
6Alcohol to Spent wash Ratio
(After Evaporation)Ratio 1 : 5
7
Total Process condensate
generated from Evaporation
Plant
TPD 760
8Thick Sludge separation at
Filter Press M3/day 90
9 Volume Redcution at RO % 58 ~60 %
10Final Spent wash Volume for
Bio-compost M3/day 390
11Alcohol to Spent wash Ratio
(After RO)Ratio 1 : 2
Note : Till Now we have achieved >60% ( 1: 4 Ratio ) reduction in overall effluent volume
and targeted to have 80% reduction after stabilization of currently installed systems.
THERE ARE TWO OPTIONS OF EVAPORATION
1. EVAPORATION OF SPENT WASH THROUGH INTEGRATED / STAND ALONE
EVAPORATORS.
2. EVAPORATION OF BIO-METHANATED SPENT WASH THROUGH
INTEGRATED / STAND ALONE EVAPORATORS
RADICO HAS INSTALLED INTEGRATED EVAPORATORS OF SPENT WASH
NO EXTRA STEAM IS REQUIRED, EVAPORATION IS CARRIED OUT
USING ALCOHOL VAPOURS.
COMPACT PROCESS & SMOOTH OPERATIONS IN HANDLING &
CONCENTRATING SPENT WASH. STRUCTURAL COST IS REDUCED AS
THE STRUCTURE FOR EVAPORTION PLANT IS MERGED WITH THAT
OF THE DISTILLATION PLANT.
LESS MANPOWER IS REQUIRED, BOTH DISTILLATION & EVAPORATION
PLANTS CAN BE OPERATED BY A COMMON OPERATOR.
• Reduced Effluent Generation through Multi Effect Evaporators and RO Plant.
• Recycling of Lees, Process Condensate and Permeate.
• Treatment of Recycling stream based on it’s Characteristics.
• Challenges of TSS reduction :
Improved efficiency of RO plant by improved TSS reduction system through installations of series of Degasser, Settlers, Lamella Clarifier and Diffused Floating Aeration (DAF) Mechanism with the help of Special Polyelectrolyte.
• Radico has implemented all the above with a significant Capital Investment, now it’s the time for Technology providers to establish the design norms to achieve 60% Permeate from RO
• Project is under delayed stabilization phase with Technology Provider since last 4 month .
• Radico is one of the Pioneer
to accept and introduce the
new Technologies.
• For the First Time in India
we have installed the DAF
System on Distillery Effluent.
• TSS Reduction thru DAF is
around 38%.
Project is under establishment with Technology Provider
1. Installation of Degasser and
Series of Clarifiers with
Filter press.
2. An additional 90M3/Day of
Thick sludge will be
separated through this
Filter Press.
3. Above Separated sludge can
be directly sent for mixing in
Biocompost.
Project is under establishment with Technology Provider
1. High TSS in Digester
Outlet (20000 ~22000 )
2. Low Efficiency of RO System due to High TSS in Digester Outlet Effluent.
3. Permeate recovery only
about 45%.
1. Installation of Degasser and Series of Clarifiers with Filter press.
2. Addition of Special Poly-electrolyte for better settling and Series of Lamella Clarifiers Followed by DAF System.
3. Designed to achieve Up to 60% high grade permeate recovery after commissiong of above systems.
4. The equipment has been recently
commissioned and expected to achieve the design norms
Lamella
Degasser
Filter
Press
RO-II
RO-I
RO-II
NO Bio-Composting in
Rainy Season
• Molasses Distilleries
face problem in Bio-
Composting in Rainy
season.
Covered Bio-Composting
• Radico is having ~50 Acres of Total Bio-
composting Area.
• About 6 acre Area was utilized as Covered
Bio-composting since two years and
practicing uninterrupted composting in
rainy season in covered area.
• Further 8 Acres Covered Bio-composting
area added during current year.
• Now we have 14 acres of covered Bio-
composting..
Stream Recycle TO
1. Rectification, Pre-rectifier column
Lees Recycle
Fermentation Recycled
2. Vacuum Pump water recycle Fermentation 95% recovery
3. Steam Condensate Recycle Boiler 98% recovery
4. Process Condensate recycle Fermentation 95% recovery
5. CO2 Scrubber Water recycle Fermentation 98% recovery
6. RO Permeate recycle Cooling tower ,
Fermenters and
Gardening
100% recovery
Water Consumption / BL of
Alcohol Before adopting
recycling Systems
12 Liter / BL
Targeted Water Consumption
/BL of Alcohol
7 Liter / BL On achieving 100%
guaranteed norms
supplied by Technology
Provider
S.No Stream Recycled Year -2013-14 Year -2014-15 Year -2015-16
under
Implementation
1 Pre-rectifier & Rectification
Column Lees
Recycled to
Fermentation
House
2 Vacuum Pump water Recycled to
Fermentation
House
3 Steam Condensate Recycled to Boiler
Section
Recycled to Boiler
Section
4 CO2 Scrubber Water Recycled to
Fermentation
House
5 Process Condensate Recycled to
Cooling Tower
6 RO Permeate Recycled to
Cooling Tower
Water Consumption /
BL of Alcohol 18.0 12.0 7.0
Total Water Savings = 95 %
Process Pumps
From All Sections
Tank
Make up
Vacuum Pump /
Air Blower
Tank
CWR
CWS
Cooler
Make up
Total Water Savings = 95 %
• Radico has conceived the optimum utilization energy resources available in the complex by setting up TBW boiler. Biogas is a bio product in the distillery and by utilized importance of energy conversation of firing the same in boiler.
• Also we have one rice husk fired CBL Boiler for making steam and then making power out of it by feeding into turbine.
• Radico has set up a good profit center in the form of Cogeneration Plant and two Bio Gas Gensets. At present Cogeneration Plant and Bio Gas Gensets caters 100% Captive Consumption of Steam and Power to Radico.
• Radico is conducting periodic Energy Audits and implementing the Energy Efficient Programmes.
• Radico is continuously participating in the National Energy Award nominations of Bureau of Enginery Efficiency (BEE) arranged thru Ministry of Power.
• With the implementation of various energy conversation measures as an ongoing practice, there is steady decline of specific energy consumption. Last three years specific energy consumption figures are shown below:
Note : During Q2 of FY 2012-13 Integrated Evaporators were installed at both
sections of Alcohol Plant.
SN DESCRIPTION UNIT 2013-14 2014-15 2015-16
(Targetted )
A: Steam Saving
1 Specific Steam Consumption
in Wash to ENA (Molasses)KG/BL 3.43 3.41 3.38
1 Specific Steam Consumption
in Wash to ENA (Grain) KG/BL 3.74 3.58 3.54
B: Power Saving
1 Specific power Consumption in
Wash to ENA (Molasses) Kwh/KBL 114 135 132
2 Specific power Consumption in
Wash to ENA (Grain)Kwh/KBL 301 300 294
• Replaced all the old un-efficient motors and pumps with the new
highly efficient pump and motors.
• Adopted Dyno Drive Systems for Flexibility in loads.
• Overhead Cooling Tower Basins to provide positive suction head
for pumps.
• Power Generation through highly efficient Bio-Gas Engines of
MWM, GERMANY.
• Installation of VAM Integrated Chilled Water System for Air
Conditioning requirement from Bio-Gas Engines.
• Installation of Temperature Sensors at Cooling Tower Fans to save
the power during Winter Season.
• Timer installation on Street and Plant Lights
• Replacement of Copper Chocks with Electronic Chocks.
Savings achieved through above Heat Integration
is equivalent to 1800 Kg/Hr of Dearator Steam.
Biogas Engines ( Two Nos.)
Rated Capacity - 1200 Kwh
Maximum Capacity– 1080 Kwh
(@ 90% Efficiency)
Captive consumption – 114 Kwh
Net Generation – 966 Kwh
• We have replaced all the manual and low
speed bottling lines with most modern high
speed washing and bottling machines.
• We have our own PET bottle production unit
in order to ensure food grade quality of PET
bottles.
• We have our own Frosting and Bottle printing
facilities .
• By adopting continuous modernization and
UP-gradation we have been able to convert
our very old distillery into a largest potable &
Most Modern distillery of the country.
PRINTING MACHINE
• We are pleased to inform that CONTESSA RUM has
won GOLD MEDAL at the New York World Wine & Spirits
Competition held in Sept 2014.
• Other Winners from our Brand Portfolio include:
• Magic Moments Premium Grain Vodka – Silver Medal
• M2 Remix Chocolate Vodka – Silver Medal
• M2 Remix Orange Vodka – Silver Medal
• M2 Remix Green Apple Vodka – Bronze Medal