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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
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
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
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%
E3 Approach
Molasses Distillery Molasses Storage Fermentation Distillation Dehydration Evaporation Bio-methanation Storage Bio-Composting Evaporation Turbine Slop Boiler WTP, ETP, CT
Possibilities of Heat Integration & Effluent Reduction
Fermentation 1.8 12. Steam Required (kg/lit) of Total Alcohol 11. 10. 9. 8. 7. 6. Spent Wash Generation (KL/KL) 1. 5 6 8 9 11 12 14 15 Alcohol % (v/v) in Fermented Mash 5. 5 6 8 9 11 12 14 15 Alcohol % (v/v) in Fermented Mash Alcohol % in Fermented Mash
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
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
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
RS Distillation + Evaporation
ENA Distillation + Evaporation
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 4.0 3.0 2.7 Molasses Distillery - ENA Distillation + Vinnase Evaporation upto 60% w/w Solids 4.5 4.0 3.3 A step further - E-Max 2
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
Practical ZLD Reduce ReUse Recycle Scientific Design ZLD Systems
Case A Biomethanation Route
Case B Slop Fired Boiler Route
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. 1100 Evaporation 15% to 60% 1100 CPU 250 Boiler & Turbine 3500 Civil, Structure, Electrical etc. 1100 Total 7400 Total 7350
Opex Comparison -100 KL Ethanol Plant Capacity 100000KL Capacity 100000KL 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 444.44MT 3000.0 0 1333333.33 Molasses 444.44MT 3000.00 1333333.3 3 400000.0 Steam 400000.00Kg 1.30 520000.00 Steam 0Kg 1.30520000.00 Power 52800.00KWH 6.00 316800.00 Power 52800.00KWH 6.00316800.00 Chemical, yeast Chemical, yeast etc. Lot 100000.00 etc. Lot 100000.00 Press mud 83.00MT 0.00 Manpower Lot 100000.00 Manpower Lot 200000.00 24.70 23.70 Revenue Revenue Steam from Biogas 196625.00kg 1.30 2.56 Steam from Slop 425000.0 0kg 1.30 5.53 Compost 83.00MT 0.00 22.15 18.18
Operation Days Case A Case B 270 Days & More if Covered Composting 330 Days
Grain Distillery Liquefaction Fermentation Distillation Storage Grain PreCleaning, Storage & Milling Decantation Evaporation DDGS DRYER Turbine Boiler WTP, ETP, CT
Possibilities of Heat Integration & Effluent Reduction
Liquefaction FT SMT RT LT
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
Fermentation 1.8 12. Steam Required (kg/lit) of Total Alcohol 11. 10. 9. 8. 7. 6. Spent Wash Generation (KL/KL) 1. 5 6 8 9 11 12 14 15 Alcohol % (v/v) in Fermented Mash 5. 5 6 8 9 11 12 14 15 Alcohol % (v/v) in Fermented Mash Alcohol % in Fermented Mash
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
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
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
Sturdy Design 100% Syrup Integrated Evaporation E-max Dryer & DDGS Plants
Dryer Vapour Integration to Drive Evaporation
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 5.5 4.4 3.9 A step further - E-Max 2
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
CPU Philosophy Sr. no 1 DATA INTERPRETATION REPORT Flow m3/day Hardne ss TDS COD BOD ph Temp Streams TSS Evaporation Process Condensate 370 50 150 150 3500 2500 3.5 60 2 Spent lees from Distillation 90 175 150 500 3500 2500 3.5 60 3 CIP Water 10 500 1000 12000 4000 4 40 4 Sealing water from Plant 15 100 200 200 60 6 35 5 Floor Washing 15 500 1000 12000 3000 6 35 6 Cooling Tower Blowdown 60 100 4000 200 60 6 35 7 Reject water from WTP 40 100 4000 200 60 6 8 Boiler Blowdown 10 1 150 10 5 10 100 Composite Sampling Analysis 610 95 868 3169 2035 4.15 52
CPU Philosophy Parameters Reductions Across Each Stage Flow m3/day TSS Hardn ess TDS COD BOD ph Temp Equilization Tank 610 100 0 900 3200 2050 4 55 % Reductions 0 0 0 0 0 0 0 0 Purpose For Equalize all the influent and consistent flow to system Acetogenesis / Buffer Tank 610 100 0 2700 3200 2050 4 38 % Reductions 0 0 0 0 0 0 0 0 Influent ph adjustment by R/C, Optimise chemical consumption Anaerobic Media Reactor 610 100 0 2700 3200 2050 4 38 Anarobic COD & BOD removal % Reductions 0.02 0 0 0.1 0.85 0.9 MBBR 597 100 2430 480 205 7.5 38 Aerobic COD & BOD removal % Reductions 0.03 0 0 0.1 0.8 0.85 Tube Settler + Sand Filter + Activated Carbon Filter 579 100 2187 96 30.75 7.2 36 % Reductions 0.05 0.9 0 0 0.7 0.8 Ultra filtration 550 10 2187 28 6 7.2 35 % Reductions 0.25 0.99 0 0.9 0.2 0.2 Suspended solids Removal and odour removal Total Germs, Ecoli and Total caliform bacteria removal Suspended solids Removal and enhance the RO membrane Life RO 413 0.1 218 23 4 7 35 TDS Removal Final OUTPUT 413 0.1 0 218 23 4 7 35
Food for Thought Air Cooled Condensers
Esteemed Clientele
The Spirit of Excellence
100% Customer Satisfaction
Presence in UP TIkaula ula SVP Nazib abad SVP Radico Op Dalmia DSCL DSC L KM KM Azam garh UP Co - Op
NSL Krishnaveni- 60 KL Distillery
EID Parry - 75 KL Wash to ENA Distillation
Tikaula - BMSW / RSW Evaporation
CDBL- 300 KL Grain + Molasses Distillery
IFB Agro Limited
Madhucon Sugar & Power Ltd.
Globus, WB- 110 KL Grain Distillery
Rana Sugars - ZLD Distillery
UP Nazibabad - ZLD Distillery
DSCL 160 KLPD ZLD Distillery
DSCL 160 KLPD ZLD Distillery
DSCL 160 KLPD ZLD Distillery
DSCL 160 KLPD ZLD Distillery
UP Nazibabad - ZLD Distillery
UP Azamgarh - ZLD Distillery
San Carlos, Philippines - Ethanol Plant
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
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