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Pollution Control with Profit from
Dairy Waste
By Anaerobic Process using UASB
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UASB SYSTEM
- Upflow fluidised bed single stage reactor with granulation of anaerobic bacteria as media.
- Reactor consists of tank in RCC of 4 to 6 depth and suitably designed diameter.
- Effluent is evenly distributed at bottom and flows up through a bed of anaerobic sludge during which degradable matter is digested.
- Dissolved organic matter is removed by anaerobic bacteria.
- This is converted to biogas + new cells.
- Gas formed is collected at top portion by gas liquid solid separator.
- Liquid flows out and any sludge is trapped and flows down back to the blanket.
SALIENT FEATURES
- COD Reduction : 80 – 85%
- Biogas generated : 0.5 to 0.55 m3 kg COD reduced
- Detention time : 10-12 hrs
- Organic loading : 4-5 kg/m3
- Anaerobic process thus oxygen from external source not required and no limitation of a transfer of oxygen which is sparingly soluble.
- Higher loading rate, upto 15 kg/m3, thus area requirement drastically reduces.
- Practically no power requirement since no internal mixing /aeration required.
- Generation of methane rich biogas which can be used to generate power.
- Minimal sludge production due to higher sludge retention time.
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Cost-Benefit Analysis
INPUT
- COD : 2500 ppm
- FLOW : 1200 m3/day Dairy Waste
COST ANANLYSIS :
Annualised capital cost = C [ i(1+i)n]
(1+i)n – 1
= 54 [0.135 (1.135)15]
[ (1.135)15-1]
= 8.50 lakhs
( C = Capital Cost = Rs. 54 lakhs, i = rate of Interest = 13.5%, n = Life of reactor = 15 yrs.)
O & M Cost = Rs. 17.5 lakhs /annum
(Manpower + 50 HP+ spare part)
Annualised Cost = O& M + Annual Capital
= 17.5 + 8.50 lakhs/annum
= Rs. 26.00 lakhs/annum.
RECOVERY : Recovering is worked out based on 24 hrs. operation of dual fuel engine.
- Recovery in terms of biogas as = 1200 m3/d x 2 kg/ m3 x 0.54 m3 biogas/COD destroyed
generation of power x 0.8 COD destroyed/Kg x 365
= 3,78,432 m3 of biogas/year
= 3,78,432 x 1.4 KWH / year
= 5,29,804.8 KWH /year x Rs. 4.0 /KWH
= Rs. 21.2 lakhs.
- Recovery due to water recycling = 300 m3/ day x 25 Rs/ m3 x 365
= Rs. 27.37 lakhs
- Payback period = Capital cost / (Recovery in terms of electricity & water –
Annualised cost)
= 54 / (27.37 + 21.2 – 26.00)
= 2.5 years.
SOME OF OUR COMPLETED PROJECTS
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- Mahananda Dairy, Goregaon, Mumbai.
- Gokul Dairy, Kolhapur, Maharashtra.
- National Dairy Development Board, Bangalore.
- Pradeshik Co-Op. Dairy Federation Ltd., Lakhanow, U.P.
- Hassan Dairy, Karnataka.
- Hosakote Dairy, Karnataka.
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