Raj Process Equipment & System Private Limited has developed a large-scale biogas upgradation and bottling plant for Jakraya Sugars Limited in Watawate, Solapur, Maharashtra. The project has a cane crushing capacity of 4,900 TCD and a distillery capacity of 120 KLPD. The company faced the challenge of managing high COD and BOD waste generated at a capacity of 1250m3/day. This waste needed to be treated effectively and sustainably.
To address this challenge, Raj Group implemented a biogas upgradation system with zero liquid discharge. The system comprises three key components: a biogas generation section, a hybrid biogas cleaning process for H2S and CO2 removal, and a gas compressing and bottling system. The process begins with spent wash treatment in a bio-digester, producing 48,000 Nm3/day of biogas. This biogas is then upgraded to 97-98 per cent methane purity, resulting in the production of 20 TPD bio-CNG (Compressed biogas).
Furthermore, the process not only produces bio-CNG but also generates valuable by-products, including 100 TPD of high potash-rich fertiliser powder and elemental sulphur with 80-90 per cent purity. This innovative approach to waste management in the sugar industry offers significant environmental and economic benefits. It lowers methane emissions by capturing and utilising the gas as fuel. The production of renewable bio-CNG (20,000 kg/day) provides a sustainable energy source. The generation of high-quality organic fertiliser offers additional value to farmers.
Challenges faced by the Raj Process Equipment & System include:
1. Purifying highly contaminated raw biogas to 98 per cent pure CBG.
2. Conversion of spent wash (a toxic distillery effluent) into potash rich fertiliser.
3. Maintaining the purity of bio-CNG up to 98 per cent while minimising the methane slippage to less than 2 per cent.
4. Drying the spent wash powder through the waste heat recovery system that is boiler flue gases.
5. Granulating the spent wash powder to increase the life to store the granules while maintaining the quality as per government norms.
By converting waste into valuable products while addressing environmental concerns, this project serves as a case study for sustainable practices in agro-industrial operations.
The key details of the case study can be accessed here
