In the framework of producing bio-ethanol, the implementation investigates the synergistic potential of compressed biogas and bio-potash.
In light of the increasing worldwide emphasis on sustainable and renewable energy sources, including these by-products into the ethanol production process offers a compelling opportunity to improve sustainability and efficiency.
The carbon footprint associated with the manufacture of bio-ethanol can be greatly decreased by using compressed biogas.
This reduces operating expenses, which increases the process’s economic viability while also aiding in climate change mitigation. Similar to this, bio-potash, a by-product rich in nutrients, can be used to make a beneficial fertilizer that will improve soil health and increase agricultural production.
Additionally, by integrating these byproducts, waste management issues are addressed and possible contaminants are converted into beneficial resources. The circular economy’s guiding principles—which minimize waste and constantly reuse and recycle resources—are best illustrated by this all-encompassing strategy.
Studies reveal that the utilization of compressed biogas and bio-potash in tandem can result in increased bio-ethanol yields and enhance energy self-sufficiency in rural regions. This is especially crucial for areas with a high agricultural dependence because it gives farmers another source of income and lessens their reliance on fossil fuels.
In addition to being a step toward a more sustainable future, the synergistic potential of compressed biogas and bio-potash in the manufacture of bio-ethanol is also evidence of human inventiveness in fully utilizing the range of renewable resources.
The potential for further optimization and application of these by-products will only increase with continued study and technical breakthroughs, opening the door to a more sustainable and greener future.
The Research and Development Division of Raj Process has created a technique that uses distillery effluent to create co-products like Bio-CBG and Bio-Potash. We have created and put into service 16 compressed biogas plants and 55 used wash units using spray drying technology till the year 2024.
With this method, concentrated Bio-Methanated Spent Wash from the Distillery is dried in a spray dryer, leaving the powder with less than 5–10% moisture and 45–50% solids. The aforementioned method makes it relatively easy to dispose of spent wash, which leads to the manufacture of BMSW powder, which is rich in phosphorus, nitrogen, and potassium and can improve soil productivity. In addition, the biogas produced during bio-methanation is compressed and further purified for use in applications.
Waste product and raw material for distilleries, molasses is produced after sugar is produced. The liquid effluent produced by distillery spent wash has a high organic content and strength. The COD (about 1,30,000 mg/l) and BOD (almost 60000 mg/l) of the wasted wash are extremely high. To achieve the required pollution control standards for the disposal of effluent, the spent wash needs to undergo thorough treatment. The usual features of Spent Wash are described in Table 1, which is provided below.
The spray dryer receives feed from the feed pump containing 50% of the concentrated bio-methanated spent wash from the multiple effect evaporator.
A high-speed atomizer located at the top of the chamber atomizes the liquid in the spray dryer. Burning coal or any other fuel produces flue gas, which is then further diluted with boiler flue gas. Hot air is fed into the chamber via a very effective air distributor.
Atomized feed is combined with flue gas in the chamber as the atomized spent wash comes into contact with hot air. Water evaporates instantly, and the chamber’s bottom is discharged with free-flowing, dry powder that contains less than 5% moisture.
Fine particles carried by the process air are further stopped in a highly effective cyclone.
In a cyclone, very small particles cannot be stopped. Using a wet scrubber, this small particle is cleaned. Particulate matter from the wet scrubber exhaust is less than 50 parts per million, which is within the Central Pollution Control Board’s allowable limit.
Because it is automated, the spray drying system uses relatively little labor. This system uses little fuel and moderate power. This system runs continuously for 365 days and doesn’t need to be cleaned. The expense of upkeep is minimal.
A viable approach to improving the sustainability and effectiveness of biofuel production is the use of compressed biogas and bio-potash into the ethanol production process. Through the utilization of these by-products’ natural qualities, the ethanol sector can attain noteworthy financial and ecological advantages.
To fully utilize the potential of CBG and bio-potash in the manufacture of ethanol, future research and development efforts should concentrate on overcoming the current obstacles and streamlining the integration processes. Since we’ll be using boiler flue gas as a source of energy to dry the spent wash spray in the chamber, the fuel consumption required to achieve zero liquid discharge is relatively low. When CBG is used on a commercial basis, imports of natural gas and petroleum will decline, and this will further reduce
