International Conference on Sunrise Technologies (13

th
-15
th
)Jan 2011 Conference Proceedings - Civil
S.S.V.P.Ss B.S.Deore College of Engineering & Polytechnic, Dhule (MS) India CE-3.8.1
STATE OF ART OF ANAEROBIC DIGESTION TECHNOLOGY FOR
TREATMENT OF DISTILLERY SPENT WASH

Lalit D. Chaudhari.
Department of Civil Engineering,
J. T. M. C. O. E., Faizpur. Jalgaon (M.S.), India.
Email:ldc.jtmcoe@gmail.com.
Dr. N. W. Ingole.
Principal, IBSS College of Engineering,
Amravati (M.S.), India.
Email:nwingole@yahoo.com

Abstract: In recent years there has been a growing interest in
anaerobic treatment of wastewaters. Compared to aerobic
growth, anaerobic fermentation produces much less biomass
from the same amount of COD removal. Alcohol distillery is
highly water intensive units generating large volumes of high
strength wastewater that poses serious environmental
problems. Anaerobic digestion is the most suitable option for
treatment of high strength organic effluent. The presence of
biodegradable components in the effluents coupled with the
advantages. Considerable progress has been achieved in the
development of high rate anaerobic reactors with several
configurations for treating concentrated industrial effluent.
Considerable amount of studies have carried out using
Hybrid up-flow anaerobic sludge blanket (HUASB) reactors.
Treatment of spent wash generated from the distilleries is
perceived as one of the serious pollution problem of the
countries producing alcohol from the fermentation and
subsequent distillation of sugar cane molasses. Distillery
effluent is a contaminated stream with COD values of up to
80000-1, 30,000 mg/l and low pH Values of between 3 to 4.
The HUASBR is widely used an effective step in removing
the COD with a great efficiency.
This paper reviews the suitability and the status of
development of anaerobic reactors for the digestion of
selected organic effluents and critically analyzes the process
parameter for reactors and main advantages of using
HUASBR for treatment of distillery wastewater.
Keywords: HUASB reactor, anaerobic digestion,
Distillery spent wash, Wastewater treatment parameters.

1. INTRODUCTION
One of the most important environmental
problems faced by the world is management of waste.
Industrial processes create a variety of wastewater
pollutants; which are difficult and costly to treat.
Wastewater characteristics and levels of pollutants vary
significantly from industry to industry. Now-a-days
emphasis is laid on waste minimization and revenue
generation through byproduct recovery.
Rapid industrialization has resulted in the
generation of a large quantity of effluent with high
organic content, which if treated suitably, can result in a
perpetual source of energy [2]. In recent years, anaerobic
wastewater treatment has become a technology of
growing importance, especially for highly polluted
wastewater from the sugar & distillery industries [5].
Distillery spent wash refers to the effluent generated from
alcohol distilleries. On an average 8-15 liters of effluent is
generated for every liter of alcohol produced [1, 4]. India
has around 319 distilleries; producing 3.25 billion liters of
alcohol and generating 40.4 billion liters of wastewater
annually [1]. The manufacturing process involves
fermentation of diluted sugarcane molasses with yeast.
The fermentation last about 80 hours and resulting
product contains 6-8% alcohol. The yeast cells are
separated by settling and cell free broth is steam distilled
and rectified to obtain 94-95% alcohol [4]. The residue of
fermented mash which comes out as liquid waste is
termed as spent wash [1].
The wastewater generated from distillation of
fermented mash is in the temperature range 70-80
0
c, deep
brown in color, acidic in nature (low pH), and has high
concentration of organic materials and solids. It is a very
complex, caramelized and cumbersome agro industrial
waste. However the pollution load of the distillery
effluent depends on the quantity of molasses, unit
operations for processing of molasses and process
recovery of alcohols [1].
TABLE 1.Typical characteristics of distillery spent wash
[4].

Sr.
No.
Parameter Range
1.
pH 3.80-4.40
2. Total Suspended Solids
(mg/lit.)
12,000-14,000
3.
Total Dissolved Solids (mg/lit.)
58,000-76,000
4
Total volatile solids (mg/lit.) 45000-65000
5
B.O.D.,20
0
C, 5 days (mg/lit.) 45,000-60,000
6 C.O.D. (mg/lit.) 80,000-
1,30,000
7
Raw-colour Dark- brown
8
Chlorides (mg/lit.) 5000-8000

Distillery spent wash has very high BOD, COD
and high BOD/COD ratio. The amount of organic
substances such as nitrogen, potassium, phosphates,
calcium, sulphates is also very high.. High COD total
nitrogen and total phosphate content of the influent may
result in eutrofication of the natural water body.
Disposal of the distillery spent wash on land is equally
hazardous to the vegetation it is reported to reduce soil
International Conference on Sunrise Technologies (13
th
-15
th
)Jan 2011 Conference Proceedings - Civil
S.S.V.P.Ss B.S.Deore College of Engineering & Polytechnic, Dhule (MS) India CE-3.8.2
alkanity and manages availability, thus inhabiting seed
germination. Application of distillery spent wash to soil
without proper monitoring, seriously affects the ground
water quality by altering its physiochemical properties
such as color, pH, electric conductivity due to leaching
down of organic and inorganic ions.
In spite of the fact of that there is the negative
environmental impact associated with industrialization,
the effect can be minimized and energy can be tapped by
means of anaerobic digestion of the waste water [2].
Biological treatment of the distillery spent wash is eighter
aerobic and anaerobic but in most cases the combination
of both is used. A typical COD/BOD ratio of 1.8to1.9
indicates the suitability of influent of biological treatment
[1].
In recent year considerable attention has been
paid toward the development of reactor for anaerobic
treatment of waste leading to conversion of organic
molecule into biogas. This reactor known as second
generation reactor or hi rate digester can handled waste at
a high organic loading rate of 24kg. COD / m
3
day and
high up flow velocity of 2 mm/h at a low hydraulic
retentions time [2].
Anaerobic digestion is the most suitable option
for the treatment of high strength organic effluents. The
presence of biodegradable components in the effluents
coupled with the advantages of anaerobic process over
other treatment methods makes it an attractive option.
1.1 Development of Anaerobic Reactors:
1. Septic Tank
2. Imhoff Tank
3. Single stage anaerobic reactors
4. Anaerobic Filter
5. Anaerobic Fluidized Bed Reactor
6. Upflow Anaerobic Sludge Blanket (UASBR).

2. HIGH RATE ANAEROBIC REACTORS
All modern high rate biomethanation processes
are based on the concept of retaining high viable biomass
by some mode of bacterial sludge immobilization. These
are achieved by one of the following methods.
Formation of highly settleable sludge aggregates
combined with gas separation and sludge settling, e.g.
upflow anaerobic sludge blanket reactor and anaerobic
baffled reactor.
Bacterial attachment to high density particulate
carrier materials e.g. fluidized bed reactors and anaerobic
expanded bed reactors.
Entrapment of sludge aggregates between
packing material supplied to the reactor, e.g. down flow
anaerobic filter and up flow anaerobic filter.
2.1. Fixed film reactor:
In stationary fixed film reactors (Fig. 1), the
reactor has a bio-film support structure (media) such as
activated carbon, PVC (polyvinyl chloride) supports, hard
rock particles or ceramic rings for biomass
immobilization. The wastewater is distributed from
above/below the media. Fixed film reactors offer the
advantages of simplicity of construction, elimination of
mechanical mixing, better stability at higher loading rates,
and capability to withstand large toxic shock loads and
organic shock loads. The reactors can recover very
quickly after a period of starvation. The main limitation of
this design is that the reactor volume is relatively high
compared to other high rate processes due to the volume
occupied by the media. Another constraint is clogging of
the reactor due to increase in bio-film thickness and/or
high suspended solids concentration in the wastewater [2].






TABLE (2)
Characteristics of reactor types [4].









2.2. Up flow anaerobic sludge blanket reactor:
UASB technology is being used extensively for
effluents from different sources such as distilleries, food
processing units, tanneries and municipal wastewater. The
active biomass in the form of sludge granules is retained
in the reactor by direct settling for achieving high MCRT
thereby achieving highly cost-effective designs. A major
advantage is that the technology has comparatively less
investment requirements when compared to an anaerobic
filter or a fluidized bed system.
Among notable disadvantages, it has a long start-
up period along with the requirement for a sufficient
amount of granular seed sludge for faster startup.
Moreover, significant wash-out of sludge during the
initial phase of the process is likely and the reactor needs
skilled operation.


Feed storage
tank
Feed

International Conference on Sunrise Technologies (13
th
-15
th
)Jan 2011 Conference Proceedings - Civil
S.S.V.P.Ss B.S.Deore College of Engineering & Polytechnic, Dhule (MS) India CE-3.8.3
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A UASB reactor (fig. 2) essentially consists of
gas-solids separator (to retain the anaerobic sludge within
the reactor), an influent distribution system and effluent
draw off facilities. Effluent recycle (to fluidize the sludge
bed) is not necessary as sufficient contact between
wastewater and sludge is guaranteed even at low organic
loads with the influent distribution system. Also,
significantly higher loading rates can be accommodated in
granular sludge UASB reactors as compared to flocculent
sludge bed reactors. In the latter, the presence of poorly
degraded or no biodegradable suspended matter in the
wastewater results in an irreversible sharp drop in the
specific methanogenic activity because the dispersed
solids are trapped in the sludge. Moreover, any significant
granulation does not occur under these conditions. The
maximum loading potential of such a flocculent sludge
bed system is in the range of 1-4 kg COD/m3 day. Yet
another high rate digester, EGSB, is a modified form of
UASB in which a 5-10 m/h as compared to 3 m/ h for
soluble wastewater and 1-1.25 m/h for partially soluble
slightly higher superficial liquid velocity is applied
wastewater in an UASB). Because of the higher up flow
velocities, mainly granular sludge will be retained in an
EGSB system, whereas a significant part of granular
sludge bed will be in an expanded or possibly even in a
fluidized state in the higher regions of the bed. As a
result, the contact between the wastewater and sludge is
excellent. Moreover, the transport of substrate into the
sludge aggregates is much better as compared to
situations where the mixing intensity is much lower. The
maximum achievable loading rate in EGSB is slightly
higher than that of an UASB system, especially for a low
strength V&A containing wastewater and at lower
ambient temperatures.



Fig.2 UASB Reactor.

2.3. Anaerobic fluidized bed reactor:
In the anaerobic fluidized bed (Fig. 3), the media
for bacterial attachment and growth is kept in the
fluidized state by drag forces exerted by the up flowing
wastewater. The media used are small particle size sand,
activated carbon, etc. Under fluidized state, each media
provides a large surface area for biofilm formation and
growth. It enables the attainment of high reactor biomass
hold-up and promotes system efficiency and stability.
This provides an opportunity for higher organic loading
rates and greater resistance to inhibitors. Fluidized bed
technology is more effective than anaerobic filter
technology as it favors the transport of microbial cells
from the bulk to the surface and thus enhances the contact
between the microorganisms and the substrate.

International Conference on Sunrise Technologies (13
th
-15
th
)Jan 2011 Conference Proceedings - Civil
S.S.V.P.Ss B.S.Deore College of Engineering & Polytechnic, Dhule (MS) India CE-3.8.4

Fig. 3 Anaerobic fluidized bed reactor

These reactors have several advantages over
anaerobic filters such as elimination of bed clogging, a
low hydraulic head loss combined with better hydraulic
circulation and a greater surface area per unit of reactor
volume. Finally, the capital cost is lower due to reduced
reactor volumes. However, the recycling of effluent may
be necessary to achieve bed expansion as in the case of
expanded bed reactor. In the expanded bed design,
microorganisms are attached to an inert support medium
such as sand, gravel or plastics as in fluidized bed reactor.
However, the diameter of the particles is slightly bigger as
compared to that used in fluidized beds. The principle
used for the expansion is also similar to that for the
fluidized bed, i.e. by a high up flow velocity and
recycling.
2.4 The Anaerobic filter Processes (AF):
Biofiltration uses bacterial immobilization by
means of slime of films on an inert support material & the
entrapment of sludge flocs within the macro-porous
structure of the carrier material to retain as much of the
active sludge as possible.
Especially designed carrier materials are
available, usually made of polyethylene or polypropylene.
They are highly voided to reduce the risk of clogging &
have specific surface between 100&200 m
2
per m
3
carrier
materials.
Anaerobic filter are used whenever non-granular
or non settable sludge is expected & when available area
is limited. The high biomass concentration inside the
reactor allows volumetric loading rates of 5to10kg
COD/m
3
per day. A disadvantage of the Anaerobic Filter
is the relative high cost of the carrier material.
2.5 The Hybrid Reactor:-
Hybrid Type of reactor is a combination of an
Up flow Anaerobic Sludge Blanket reactor with an
anaerobic filter or an anaerobic contact process or a
combination of the three types.
The first hybrid Type of reactor is similar to an
UASB, except for the three-phase separator. The
separator is replacing by a later of floating carrier
material. This material serves a double function
(1) To separate & retain a large functions of sludge in the
reactor before the influent use the reactor, and
(2) To carries active sludge in the porous space of the
carrier material itself. This type of reactor is called the up
flow anaerobic contact filter reactor (UACF)
The second type of hybrid reactor has recently
been developed for waste water showing no granule
formation & requiring a longer hydraulic retention time. It
is called by up flow Anaerobic contact reactor
(UAC).This reactor allows some bio mass accumulation
in the lower part of the reactor the reactor is not totally
mix which is case for the anaerobic contact (AC) reactor
but is equipped with a sophisticated influent distribution
system similar to the one for the (UASB) reactor [5].

3. CONTROL OF ANAEROBIC DIGESTION
The anaerobic digestion process is affected
significantly by the operating conditions. As the process
involves the formation of volatile acids, it is important
that the rate of reaction be such that there is no
accumulation of acids, which would result in the failure of
the digester. This, in turn, is governed by the loading rate
and the influent strength. Temperature and pH are other
important variables as the methane producing bacteria are
sensitive to these as well.
3.1. Effect of temperature
Anaerobic digestion is strongly influenced by
temperature and can be grouped under one of the
following categories: psychrophilic (0-20C), mesophilic
(20- 42C) and thermophilic (42-75C). The details of the
bacterial processes in all the three temperature ranges are
well established though a large section of the reported
work deals with mesophilic operation. Changes in
temperature are well resisted by anaerobic bacteria, as
long as they do not exceed the upper limit as defined by
the temperature at which the decay rate begins to exceed
the growth rate. In the mesophilic range, the bacterial
activity and growth decreases by one half for each 10C
drop below 35C.Thus, for a given degree of digestion to
be attained, the lower the temperature, the longer is the
digestion time. The effect of temperature on the first stage
of the digestion process (hydrolysis and acidogenesis) is
not very significant. The second and third stages of
decomposition can only be performed by certain
specialized microorganisms (acidognic and methanogenic
bacteria) and thus, these are much more sensitive towards
temperature change [3]. However, an important
characteristic of anaerobic bacteria is that their decay rate
is very low at temperatures below 15C. Thus, it is
possible to preserve the anaerobic sludge for long periods
without losing much of its activity. This is especially
useful in the anaerobic treatment of wastewater from
seasonal industries such as sugar mills.
3.2. Effect of pH
Anaerobic reactions are highly pH dependent.
The optimal pH range for methane producing bacteria is
International Conference on Sunrise Technologies (13
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-15
th
)Jan 2011 Conference Proceedings - Civil
S.S.V.P.Ss B.S.Deore College of Engineering & Polytechnic, Dhule (MS) India CE-3.8.5
6.8-7.2 while for acid-forming bacteria, a more acid pH is
desirable. The pH of an anaerobic system is typically
maintained between methanogenic limits to prevent the
predominance of the acid-forming bacteria, which may
cause V&A accumulation. It is essential that the reactor
contents provide enough buffer capacity to neutralize any
eventual V&A accumulation, and thus prevent build-up of
localized acid zones in the digester. In general, sodium-
bicarbonate is used for supplementing the alkalinity since
it is the only chemical, which gently shifts the equilibrium
to the desired value without disturbing the physical and
chemical balance of the fragile microbial population.
3.3. Effect of nutrients
The presence of ions in the feed is a critical
parameter since it affects the granulation process and
stability of reactors like USAB. The bacteria in the
anaerobic digestion process requires micronutrients and
trace elements such as nitrogen, phosphorous, sulphur,
potassium, calcium, magnesium, iron, nickel, cobalt, zinc,
manganese and copper for optimum growth. Although
these elements are needed in extremely low
concentrations, the lack of these nutrients has an adverse
effect upon the microbial growth and performance.
Methane forming bacteria have relatively high internal
concentrations of iron, nickel and cobalt. These elements
may not be present in sufficient concentrations in
wastewater streams from the processing of one single
agro industrial product like corn or potatoes or the
wastewater derived from condensates. In such cases, the
wastewater has to be supplemented with the trace
elements prior to treatment. The required optimum
C: N: P ratio for enhanced yield of methane has
been reported to be 100:2.5:0.5. The minimum
concentration of macro and micronutrients can be
calculated based on the biodegradable COD concentration
of the wastewater, cell yield and nutrient concentration in
bacterial cells. The nutrient
Concentration in the influent should be adjusted
to a value equal to twice the minimal nutrient
concentration required in order to ensure that there is a
small excess in the nutrients needed.
3.4. Effect of organic loading rate
In anaerobic wastewater treatment, loading rate
plays an important role. In the case of nonattached
biomass reactors, where the hydraulic retention time is
long, overloading results in biomass washout. This, in
turn, leads to process failure. Fixed film, expanded and
fluidized bed reactors can withstand higher organic
loading rate. Even if there is a shock load resulting in
failure, the system is rapidly restored to normal. In
comparison to a CSTR system, fixed film and other
attached biomass reactors have better stability. Moreover,
high degree of COD reduction is achieved even at high
loading rates at a short hydraulic retention time.
Anaerobic fluidized bed appears to withstand maximum
loading rate compared to other high rate reactors.

4. FACTORS GOVERNING REACTOR CHOICE
A technology is acceptable to an industry if it
requires less capital, less land area and is more reliable
when compared to the other well established options for
an anaerobic digestion system; this translates into the
process being able to run at high organic and hydraulic
loading rates with minimum operation and maintenance
requirements. To choose the most appropriate reactor type
for a particular application, it is essential to conduct a
systematic evaluation of different reactor configurations
with the wastewater stream. The organic and hydraulic
loading potential of a reactor depends on three factors
Viz: *Amount of active biomass that can be
retained by a reactor per unit volume.
Contact opportunity between the retained
biomass and the incoming wastewater.
Diffusion of substrate within the biomass.
With these considerations, granular sludge UASB reactor
stands out distinctively as the best choice with the only
limitations being the tendency of granules to float and
shearing of granules at high loading rates. These
constraints are also valid to a lesser degree for attached
biomass reactors (such as fixed film, fluidized bed and
rotary biological contactors). In addition, due to the space
occupied by the media, the attached biomass reactors
possess comparatively lower capacity for biomass
retention per unit volume of the reactor. The latter
depends on the film thickness, which would be the highest
in a fluidized bed reactor due to large surface area
available for biomass attachment. Also, there is better
contact between the biomass and the incoming
wastewater in both fluidized bed and EGSB systems.
However, due to the high upflow velocity, the substrate
diffusion in the biomass is limited in these configurations.
Based on these factors, it appears that the
maximum achievable loading rates with soluble
wastewater would decrease in the following sequence:
UASB > EGSB > fluidized bed reactor >
anaerobic filter. The capital cost of the reactors and the
land area requirements, therefore, follows the same order.
The digester operation and maintenance requirements are
minimum if the process is fairly stable towards
fluctuations in wastewater characteristics and changes in
environmental conditions. Susceptibility of the process
depends on the potential utilization of the reactor and thus
a system operating near maximum loading conditions is
more sensitive. Based on the comparisons of various
reactor types, the following order can be recommended
for reactor choice:
Parameters Rating
Operating skills: Fixed film < UASB < RBC <
Fluidized bed.
Energy consumption: UASB < fixed film <
EGSB < fluidized bed < RBC
International Conference on Sunrise Technologies (13
th
-15
th
)Jan 2011 Conference Proceedings - Civil
S.S.V.P.Ss B.S.Deore College of Engineering & Polytechnic, Dhule (MS) India CE-3.8.6
Capital cost, land requirement: RBC < fixed
film < UASB < EGSB < fluidized bed

5. HUASB REACTOR & ITS PERFORMANCE:
The hybrid up flow anaerobic sludge blanket
(HUASB) reactor has received widespread acceptance
and has been successfully used to treat a variety of
industrial as well as domestic wastewaters. In the HUASB
process, the whole waste is passed through the anaerobic
reactor in an up flow mode, with a hydraulic retention
time (HRT) of only about 8-10 hours at average flow. No
prior sedimentation is required.COD removal efficiencies
depends largely on wastewater type; however the removal
efficiency with respect to biodegradable COD is generally
in excess of 85 or even 90%.
The biodegradable COD is sometimes reflected
in the parameter biological oxygen demand (BOD). The
four top applications of high rate anaerobic reactor
systems are for:
1. Breweries & beverage industry.
2. Distilleries and fermentation industries.
3. Food industries.
4. Pulp & paper industries.
Furthermore in warm climate the HUASB
concept is also suitable for the domestic wastewater.

Advantages of Anaerobic Reactors:
Low energy cost
Less bio-mass generation
Less solid waste to dispose
Stable digested sludge is produced
Less space required
Off-gas air pollution eliminated

Limitations of HUASBR:
Post Aerobic Treatment is required (one day
polishing pond for sewage).
To meet coli form level in the treated effluent
maturation pond or chemical treatment is required.
CONCLUSION
A brief summary of results of laboratory and
pilot scale studies extracted from expensive literature
survey are presented. The HUASBR technology is well
suited for the pre-treatment of high strength distillery
effluents. It must be noted that this is only when the
process has been successfully started up and it is in stable
operation. It order to achieve a successive start up it is
recommended that the reactor be started up at a low
loading rate between 4-8 Kg.COD/m
3
.day and the COD
removal efficiency must be monitored carefully. Attention
must also be paid to the temperature and high loading rate
should not be applied until the temperature in the reactor
has reached the recommended 34 to 36
0
c.This especially
important in effluent steams that have low flow rate with
correspondingly high COD concentration such as
distillery waste. Once the plant has been successfully
started up, fluctuations in volumetric loading rate do not
significantly affect the performance of the reactor.

ACKNOWLEDGMENT
The literature reviewed in this paper is the part of
ongoing thesis work name Study on performance of
Tapered conical shaped hybrid Upflow anaerobic sludge
blanket Reactor (HUASBR) for treatment of distillery
spent wash at SGB University, Amravati under the
guidance of Dr. N. W. Ingole. The author thanks the
Principal, J. T. M. C. O. E. Faizpur, Dist- Jalgaon for
extending all facilities for conducting the research work.

REFERENCES
[1] Sarayu Mohana, Bahvik K. Acharya , Datta
Madamwar, Distillery spent wash: Treatment
technologies and potential application,
Journal of Hazardous Materials 163 (2009) 12-25.
[2] K.V. Rajeshwari, M. Blakrishan, A. Kansal, Kunsum
Lata, V.V.N. Kishore. State-of-the-art of anaerobic
digestion technology for industrial wastewater
treatment, Renewable and Sustainable energy
Reviews 4 (2009) 135-156.
[3] Medhat, M. A. Saleh and Usma F. Mahmood.
Anaerobic waste water technology for industrial
waste water treatment, Eight International Water
Technology Conference IWTC8 2004, Alexzandria
Egypt.
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