Transcription

1

2 Excel Engineers & Consultants, Pune INDIA Welcomes You To AIDA 2 Days Technical Seminar 26 th & 27 th March

3 Sheer Excellence!

4 Pioneering Technology E-max and E-max 2 Steam Lowest Steam Molasses Distillery Lowest Steam Grain Distillery Quality High Grade ENA (with low TA) acceptable to all bottling brands Pharma & Fuel Ethanol at 99.9% v/v Value DDGS Dryer operation at 100% Syrup and No Protein Degradation Utilization of Dryer vapour to operate Evaporation ZLD Practically Zero Effluent Discharge Distilleries Most scientifically designed CPU for Molasses / Grain Distilleries Design Highly Efficient Steam & Power Balancing Holistic approach in Conceptualization and Design

5 Excel -Office & Laboratory

6 Excel Manufacturing Facility

7 Improving Profitability of Distilleries With Various ZLD Options Using Energy Efficient Innovative E-max 2 Technology By Sanjay Desai & Sandeep Chichbankar Excel Engineers & Consultants, Pune INDIA

8

9

10

11

12

13

14

15 Present Scenario Conventional Technology for Process & ZLD Huge Project Investments / Interest Burden High Energy Requirement High Cost of ETP Operation Uncertainty caused by external factors

16 Low Capex + Low Opex. + ZLD = More Profit Enormous Advancement in Distillery Technology Improvement in Performance Benchmarks Innovative Technologies for Energy Integration Various proven ZLD systems available Necessity of Right Technology Partner & Selection of ZLD option

17 Ethanol Cost of Production Effluent Treatment Cost =? 1% 4% 5% Raw Material - 73% 17% Utilities (Steam, Power, Water) - 17% Manpower & Maintenance - 5% Chemicals, Yeast etc. - 1% Interest on Capex - 4% 73%

18 E3 Approach

19 Molasses Distillery Molasses Storage Fermentation Distillation Dehydration Evaporation Bio-methanation Storage Bio-Composting Evaporation Turbine Slop Boiler WTP, ETP, CT

20 Possibilities of Heat Integration & Effluent Reduction

21 Fermentation Steam Required (kg/lit) of Total Alcohol Spent Wash Generation (KL/KL) Alcohol % (v/v) in Fermented Mash Alcohol % (v/v) in Fermented Mash Alcohol % in Fermented Mash

22 Possibilities in Distillation Spent lees from various process columns can be used for pre-heating various column feed Flash steam from steam condensate pot can be used to drive columns with moderate energy requirement (DFOC / DAC) Fermented mash can be pre-heated using distillation column vapour through beer-heater. Also reduces load on CT Fermented mash can be pre-heated using hot spent wash using PHE Maximum column to be kept under vacuum to reduce steam consumption and scaling; hence increased plant uptime

23 Possibilities in Distillation Atmospheric Hydro column vapour can be used to drive atmospheric De-methanol column Pre-rectifier column can be kept under pressure and vapour can be used to drive both Hydro and De-methanol column Distillation vapour can be used for heating evaporation calendrias wherever possible. Also reduced CT load All feed streams such as RC feed, Hydro feed etc. to be preheated using waste streams Minimum use of DM water for dilution

24 Possibilities in Evaporation Increasing number of effects reduces steam consumption Improvement in design, CIP, use of stand by effects and process control to minimize downtime, thereby reducing energy loss in startstop process Integrating evaporation plant on various waste vapour from Distillation Automated CIP reduction in water requirement

25 RS Distillation + Evaporation

26 ENA Distillation + Evaporation

27 Comparison of Steam Consumption kg per litre of Ethanol Produced Prevailing Industry Practice Excel s E-max Technology E-max 2 Technology Molasses Distillery - RS Distillation + Dehydration + Vinasse Evaporation upto 60% w/w Molasses Distillery - ENA Distillation + Vinnase Evaporation upto 60% w/w Solids A step further - E-Max 2

28

29 Comparison of Fresh Water Requirement Per Litre of Spirit Prevailing Industry Practice Excel s E-max Technology E-max 2 Technology Fresh Water Requirement 11 KL / KL 8.5 KL / KL 7 KL / KL A step further - E-Max 2

30 Practical ZLD Reduce ReUse Recycle Scientific Design ZLD Systems

31 Case A Biomethanation Route

32 Case B Slop Fired Boiler Route

33 Capex Comparison -100 KL Ethanol Plant Case A Case B Plant Section Investment in INR Lacs Plant Section Investment in INR Lacs Molasses Storage & Transfer 500 Molasses Storage & Transfer 500 Fermentation, Primary Distillation, Dehydration 1000 Fermentation, Primary Distillation, Dehydration 1000 Biomethanation 800 Evaporation 5% to 30% 1100 CPU 250 BioComposting + Land 1600 Boiler & Turbine 1000 Civil, Structure, Electrical etc Evaporation 15% to 60% 1100 CPU 250 Boiler & Turbine 3500 Civil, Structure, Electrical etc Total 7400 Total 7350

34 Opex Comparison -100 KL Ethanol Plant Capacity KL Capacity KL Recovery 225Litre/MT Recovery 225Litre/MT Process Steam 2.2Kg/litre Process Steam 2.2Kg/litre Evaporation Steam 1.8Kg/litre Evaporation Steam 1.8Kg/litre Total Steam 4Kg/litre Total Steam 4Kg/litre CASE 1 CASE 2 Costs Costs Particulars Consumption Unit Rate Cost in INR Particulars Consum ption Unit Rate Cost in INR Molasses MT Molasses MT Steam Kg Steam 0Kg Power KWH Power KWH Chemical, yeast Chemical, yeast etc. Lot etc. Lot Press mud 83.00MT 0.00 Manpower Lot Manpower Lot Revenue Revenue Steam from Biogas kg Steam from Slop kg Compost 83.00MT

35 Operation Days Case A Case B 270 Days & More if Covered Composting 330 Days

36 Grain Distillery Liquefaction Fermentation Distillation Storage Grain PreCleaning, Storage & Milling Decantation Evaporation DDGS DRYER Turbine Boiler WTP, ETP, CT

37 Possibilities of Heat Integration & Effluent Reduction

38 Liquefaction FT SMT RT LT

39 Possibilities in Liquefaction DM Water pre-heating using hot liquefied slurry. Also reducing cooling tower load Fermented mash pre-heating using hot liquefied slurry. Also reducing cooling tower load Use of flash vapour condensate as hot water for slurry preparation High DS operation Recycle of Slop

40 Fermentation Steam Required (kg/lit) of Total Alcohol Spent Wash Generation (KL/KL) Alcohol % (v/v) in Fermented Mash Alcohol % (v/v) in Fermented Mash Alcohol % in Fermented Mash

41 Possibilities in Distillation Spent lees from various process columns can be used for pre-heating various column feed Flash steam from steam condensate pot can be used to drive columns with moderate energy requirement (DFOC / DAC) Fermented mash can be pre-heated using distillation column vapour through beer-heater. Also reduces load on CT Fermented mash can be pre-heated using hot spent wash using PHE Maximum column to be kept under vacuum to reduce steam consumption and scaling; hence increased plant uptime

42 Possibilities in Distillation Atmospheric Hydro column vapour can be used to drive atmospheric De-methanol column Pre-rectifier column can be kept under pressure and vapour can be used to drive both Hydro and De-methanol column Distillation vapour can be used for heating evaporation calendrias wherever possible. Also reduced CT load All feed streams such as RC feed, Hydro feed etc. to be preheated using waste streams Thin Slop in Flash Tank

43 Possibilities in Evaporation Increasing number of effects reduces steam consumption Improvement in design, CIP, use of stand by effects and process control to minimize downtime, thereby reducing energy loss in startstop process Integrating evaporation plant on various waste vapour from Distillation Integrating evaporation plant on waste vapour from DDGS Dryer

44 Sturdy Design 100% Syrup Integrated Evaporation E-max Dryer & DDGS Plants

45 Dryer Vapour Integration to Drive Evaporation

46 Comparison of Steam Consumption kg per litre of Ethanol Produced Prevailing Industry Practice Excel s E-max Technology E-max 2 Technology Grain Distillery - Cooking Fermentation ENA Distillation Thin Slop Evaporation DDGS Dryer A step further - E-Max 2

47 Streams for CPU Spent Lees Process Condensate Pump sealing water Air blower / Vacuum pump water Floor washings WTP / RO Rejects Cooling Tower Blow Down Boiler Blow Down

48 CPU Philosophy Sr. no 1 DATA INTERPRETATION REPORT Flow m3/day Hardne ss TDS COD BOD ph Temp Streams TSS Evaporation Process Condensate Spent lees from Distillation CIP Water Sealing water from Plant Floor Washing Cooling Tower Blowdown Reject water from WTP Boiler Blowdown Composite Sampling Analysis

49 CPU Philosophy Parameters Reductions Across Each Stage Flow m3/day TSS Hardn ess TDS COD BOD ph Temp Equilization Tank % Reductions Purpose For Equalize all the influent and consistent flow to system Acetogenesis / Buffer Tank % Reductions Influent ph adjustment by R/C, Optimise chemical consumption Anaerobic Media Reactor Anarobic COD & BOD removal % Reductions MBBR Aerobic COD & BOD removal % Reductions Tube Settler + Sand Filter + Activated Carbon Filter % Reductions Ultra filtration % Reductions Suspended solids Removal and odour removal Total Germs, Ecoli and Total caliform bacteria removal Suspended solids Removal and enhance the RO membrane Life RO TDS Removal Final OUTPUT

50 Food for Thought Air Cooled Condensers

51 Esteemed Clientele

52 The Spirit of Excellence

53 100% Customer Satisfaction

54 Presence in UP TIkaula ula SVP Nazib abad SVP Radico Op Dalmia DSCL DSC L KM KM Azam garh UP Co - Op

55 NSL Krishnaveni- 60 KL Distillery

56 EID Parry - 75 KL Wash to ENA Distillation

57 Tikaula - BMSW / RSW Evaporation

58 CDBL- 300 KL Grain + Molasses Distillery

59 IFB Agro Limited

60 Madhucon Sugar & Power Ltd.

61 Globus, WB- 110 KL Grain Distillery

62 Rana Sugars - ZLD Distillery

63

64 UP Nazibabad - ZLD Distillery

65 DSCL 160 KLPD ZLD Distillery

66 DSCL 160 KLPD ZLD Distillery

67 DSCL 160 KLPD ZLD Distillery

68 DSCL 160 KLPD ZLD Distillery

69 UP Nazibabad - ZLD Distillery

70 UP Azamgarh - ZLD Distillery

71 San Carlos, Philippines - Ethanol Plant

72

73 Conservation of energy and achieving ZLD in distillery is of utmost importance Various Innovative Techniques are available Adoption of new techniques would bring feasibility Excel s E-max design technologies are redefining the performance benchmarks Various upcoming projects and existing distilleries adopting E-max Technology for Energy Economy and ZLD

74 Excel Engineering & Consultants , Pride Kumar Senate, Phase-I, Senapati Bapat Road, Near ICC, Shivajinagar, Pune (India) Tel: Cell: Web:

75