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Turn key Techno Commercial Integrated Fermentation & ZED equipments specially Evaporator and Dryer
Presented By
R.P.Singh
(Food & Biotech Engineers (I) Pvt. Ltd.)
A Presentation for
All India Distillers Association
FOOD & BIOTECH ENGINEERS (I) PVT. LTD.
An ISO 9001: 2008, 18001: 2007, 14001: 2004 Co.
Works: Chaprola Road, Prithla, Tehsil-Palwal,
Distt: Palwal, Haryana-121102,
Phone No.: 01275-262157,58, 9312069945,Fax No:01275-262259,
Email: [email protected], website: www.foodbiotech.co.in
Joint Technical collaboration with
M/s Crest Biotech Pvt. Ltd. A 30/B1, Mohan Co-operative Ind. AreaMathura Road, New Delhi-110044IndiaEmail: [email protected]
Joint Technical collaboration with
M/s RALLI OY (Ltd.)Jokiniementie 16A00650 Helsinki,FINLAND Email: [email protected]
EVAPORATOR
An evaporator is a vessel working under
vacuum to evaporate water out of the feed
being given to it. .Application of evaporator can be
in fields of dairy, food, solvent extraction ad
effluent concentration
TYPES OF EVAPORATOR
Falling Film Evaporator
Forced Recirculation evaporator
Combination of Falling film and Forced recirculation evaporator
Scrapped surface evaporator
Natural Recirculation evaporator
A. Falling Film
Evaporator with long
tube
A.1. Falling Film Evaporator is Suitable for
Biomethanated Spent wash
RO reject water concentration
For products where low concentration is desired.
A.2. Falling Film Evaporator Working Principle
A: Product
B: Concentrate
C: Condensate
D: Vapor
E: Deaeration
F: Steam
1: Falling Film Calandria
2: Vapor Separator
A.3. Operational advantages and problems normally faced
in case of Falling Film Evaporator
Advantages
Suitable for concentration up to 26- 30 % TS.
Problems
Capacity reduction
Due to scale formation, evaporators need cleaning after
every 20 hrs or max. 8-10 days depending on wetting rate and
pretreatment of feed
Additional effluent generation due to chemical cleaning (CIP) & special treatment before discharging to main ETP plant
A.4. Remedial Measures
Use of Auto feed control and monitoring system
Use of Auto steam / Temp. control
Use of Cooling water temperature monitoring system
Use of Stand by calandria with extra valves manifolds
Monitoring of scale formation
Pretreatment is essentially required to avoid scale formation
Extended Wetting rate of value more than 2500 Kg/hr/m2 as
against 350 Kg/hr/m2.
A.5. Advantages of Stand By Calandria with extra valves
manifolds
o CIP of any effect / calandria is possible without shut
down of the plant.
o Plant can be run uninterrupted.
A.6. Problems in Biomethanated Spent wash
Problem:
o Excessive foaming thus contaminated condensate
Remedy :
A new design Gas removing system is incorporated consisting of
Rotary clarifier
Compressed air injection with filter cartridge for air micronization to removes suspended solids
Induced draft type gas removal unit cum fines (SS) removal cum sludge scrapper
DSI
Gas separator calandria
Anti foaming mechanism
A new mechanism in Vapor Separator design to suppress the foaming
tendency
12
A.7. Five Effects falling film evaporating plant with one
stand by calandria
13
A.8. Five Effects falling film evaporating plant with gas removing
system
B. Forced Recirculation
Evaporator
B.1. Forced Recirculation evaporator is suitable for
o High Concentration and for high viscous products
o Molasses based Raw spent wash
o Thin stillage concentration
o For products where high concentration is desired.
B.2. Forced Recirculation Evaporator Working Principle
A: Product
B: Concentrate
C: Condensate
D: Vapor
E: Deaeration
F: Steam
1: Forced Recirculation
Calandria
2: Vapor Separator
B.3. Operational advantages and problems normally
faced in case of Forced recirculation evaporator
Advantages
TS can be achieved up to 60% and above.
Scale formation is minimal.
Plant runs continuously for 45-60 days.
CIP is required after 45 days.
Processing cost per lit is lesser than Falling Film Evaporator.
Do not require extra space for holding the effluent for 4 hrs during CIP.
Problems
Mechanical seal & pumps problem
High effluent drainage during break down or cleaning/maintenance
Recirculation power consumption is high
B.4. Remedial Measures
Use of Auto feed control and monitoring system
Use of vacuum monitoring system
Use of Cooling water temperature monitoring system
Use of VFD for all pumps
Use of conductivity transmitter
Use of continuous pump capacity and head monitoring system
Use of Stand by calandria with extra valves and manifolds
B.5. Five Effects Forced Recirculation Evaporator with Single
Stage Finisher
C. Multiple Effects
Evaporator in
combination with
Falling Film and Forced
Recirculation calandria
21
C.2. Five Effects falling film evaporating plant in
combination with FF and FR calandria with gas
removing system (for biomethanated spent wash)
22
C.3. Five Effects falling film evaporating plant in
combination with FF and FR calandria with
single stage finisher (for Raw spent wash)
C.4. Comparison Between Forced recirculation
evaporator with Finisher and combination
evaporating plant with finisher (+1 stand by
calandria)
Combination
Evaporator with
finisher
(with 1 stand by
calandria)
Forced recirculation
evaporator with
finisher
Feed rate 67,000 Kg/hr 67,000 Kg/hr
Feed solids 13% 13%
Concentrate
solids
60% 60%
Concentrate rate 14,516 Kg/hr 14,516 Kg/hr
Water evaporation 52,484 kg/hr 52,484 kg/hr
C.4. Comparison Continue…
Combination
Evaporator with
finisher
(with 1 stand by
calandria)
Forced recirculation
evaporator with
finisher
Steam
consumption
13,095 kg/hr 13,095 kg/hr
Average use
Electrical load
643 kw/hr (With
high wetting rate)
846 kw/hr
CIP requirement After 8 days After 45 days
Effluent
generation during
CIP
167,500 Lit /8
days (20,937
lit/day)
354,000 lit/45 days
(7866 lit/day)
C.4. Comparison Continue…
Combination Evaporator
with finisher
(with 1 stand by
calandria)
Forced recirculation
evaporator with
finisher
Extra electrical load
during CIP
2,572 kw/ 8 days
(321 Kw/day)
3387 Kw/45 days
(75 kw /day)
Extra steam
consumption during
CIP
26,190 Kg/8 days
(3,273 kg/day)
32,186 Kg/ 45 days
(715 kg/day)
CIP Chemicals
NaOH ,flakes
670 kg/8 days
(83 kg/day)
4400 Kg/45 days
(97 kg/day)
CIP Chemicals
HNO3 1%
335 kg/8 days
(42 kg/day)
2,200 Kg/ 45 days
(48 kg/day)
C.4. Comparison Continue…
Combination Evaporator
with finisher
(with 1 stand by
calandria)
Forced recirculation
evaporator with
finisher
Power loss Due to 20% capacity
reduce for a period of
time (128 kw/hr )
Due to 5% capacity
reduce for a period of
time (42 kw/hr )
Steam loss Due to 20% capacity
reduce for a period of
time (2,619 kg/hr )
Due to 5% capacity
reduce for a period of
time (654 kg/hr )
Processing
Cost / lit of
spent wash
Rs. 0.53/ lit of spent
wash
Rs. 0.51 / lit of spent
wash
D. Double effects
Scrapped Surface
Evaporator
D.1. P & I diagram
D.2. Salient Features of Scrapped Surface Evaporator
Useful for Concentration of very viscous material.
The concentration level can be achieved up to 65-80 % TS.
The scrapper attached with gear motor is a important part of this
evaporator.
Mainly used for the Effluent, Horlicks mix ,malt etc.
Optimizing thermal efficiency.
Saving Floor space.
High Concentrations of Solids.
Complies with strict international standard of hygiene.
E. Commercially and
technically viable
Fluidized Bed dryer
for drying distillery
effluent
E.1. P & I diagram
E.2. Drying MEE effluent concentrate;
Fluidized bed dryer
Use for
Fuel
Fertilizer/ dried biocompost
Animal feed
Less space requirement. For 75 KLPD
Distillery plant approx 4000 sq. yard
E.3. Salient Features
E.4. Processing cost for 4500 Kg powder output (8%
moisture)
Steam cost Electrical cost Processing
cost / Kg of
dry powder
(8%
moisture)
Evaporator 10000 Kg x
Rs.1.2
= Rs. 12000
500 kw x
Rs.7.5 =
Rs.3750
Rs. 3.50
Scrapped
surface
evaporator
+ Dryer
2500 Kg x
Rs.1.2
= Rs. 3000
250 kw x
Rs.7.5 =
Rs.1875
Rs. 1.08
Total Processing cost/ Kg of powder (8%
moisture)
Rs. 4.58
F. Our Valued
Customers
List of our Valuable Customer
M/s Doon Valley
Distillers(Liquors Unit)
Dehra Dun
Four effects falling film evaporating
plant with finisher (W.E. Cap: 7,650
kg/hr)
M/s Krebs Biochemicals &
Industries
Andhra Pradesh
Four effects falling film evaporating
plant (WE Cap: 6,378 kg/hr)
M/s Rana Sugars Ltd.
Chandigarh
Five effects forced recirculation
evaporating plant (Cap: 32 kl/hr)
List of our Valuable Customer
M/s Dashmesh Medicare
Pvt.Ltd. Chandigarh
Three Effects Evaporating Plant In
Combination With
Falling Film And Forced Recirculation
Calandria (W.E: 2,700 Kg/Hr)
M/s Chandigarh Distiller &
Bottlers Ltd. Chandigarh
Three effects falling film evaporating
plant with Single stage Finisher, WE
Cap: 22,300 kg/hr
M/s Parabolic Drug
Chandigarh
Three effects evaporating plant in
combination with falling film and
forced recirculation type calandrias
(W.E capacity: 3,600 kg/hr)
List of our Valuable Customer
M/s Dalmia Sugars Ltd. Sitapur Five effects evaporating plant in combination of
falling film and forced recirculation type
calandrias (W.E Capacity : 21,000 kg/hr)
Surface condenser
M/s Oudh Sugar Mills Ltd.
(Distillery Division)
Hargaon, Sitapur, (U.P.)
Five effects evaporating plant followed with
Single Stage Finisher (W.E: 35,690 kg/hr)
M/s Kothari Fermentation &
Biochem Ltd.
Sikandrabad, Bulandshahr
Five effects evaporating plant followed with
Single Stage Finisher (W.E: 14,000 kg/hr)
List of our Valuable Customer
M/s UFLEX Ltd.
Sector-4, Noida
Five effects evaporating plant followed with
Single Stage Finisher (W.E: 40,000 kg/hr)
M/s Seksaria Biswan sugar factory
Ltd. P.O.:Biswan
Four Effects Evaporating Plant In Combination
With Falling Film And Forced Recirculation
Calandria (W.E: 16,000 Kg/Hr)
M/s Tilaknagar Industries Limited
Mumbai
Five Effects Forced Recirculation Evaporating
Plant With Stage Finisher (W.E:21,277 kg/hr)
List of our Valuable Customer
M/s Bajaj Hindustan Ltd.
Palia U.P
Double Effect falling film evaporating plant, WE
Cap: 150,000 kg/hr
M/s Bajaj Hindustan Ltd.
Gola U.P
Double Effect falling film evaporating plant, WE
Cap:150,000 kg/hr
M/s Bajaj Hindustan Ltd.
Radaulli
Five effects evaporating plant in combination
with 3-Effects falling film and 2 effects forced
recirculation type calandrias with one standby
calandria & gas Removing System
(W.E capacity: 60,637 kg/hr)
List of our Valuable Customer
M/s Dharni Sugars & Chemicals Ltd
Tamilnadu
Five Effects Forced Recirculation Evaporating
Plant With Single Stage Finisher, W.E
Capacity: 47,620 kg/hr
M/S Simbhaoli Sugar Mills Ltd.,
New Delhi
Five Effects Forced Recirculation Evaporating
Plant With Single Stage Finisher, W.E
Capacity: 25,300 kg/hr
M/s S.V.Distillers Pvt.Ltd.
Karnataka
Five Effects Forced Recirculation Evaporating
Plant With Single Stage Finisher (W.E:34,580
kg/hr)
M/s Sona Sati Pvt.Ltd
Bihar
Five Effects Forced Recirculation Evaporating
Plant With Single Stage Finisher, W.E
Capacity: 21,000 kg/hr
List of our Valuable Customer
M/s Sentini Bioproducts Pvt. Ltd.
Hyderabad
Five Effects Forced Recirculation Evaporating
Plant With Single Stage Finisher, W.E Capacity:
27,734 kg/hr
M/s Gulshan Polyols Ltd
Delhi
Five effects falling film evaporator with Single
stage forced recirculation finisher for RO reject
water, W.E:5,893 lit/hr
M/s Dhampur sugar Mills Ltd.
New delhi
Single effects Forced Recirculation Evaporating
Plant
M/s Gujrat Ambuja Exports Lt.
Gujrat
Three Effects Forced Recirculation evaporator
for Effluent ,Feed Rate:5,000 kg/hr
Five Effects Forced Recirculation evaporator for
Effluent ,Feed Rate:11,000 kg/hr
List of our Valuable Customer
M/s Gujrat Ambuja Exports Lt.
Gujrat
Three Effects Falling Film Integrated Evaporator With
Single Stage Finisher For Corn Steep Liquor
Feed Rate: 20,000 Kg/Hr
M/s Gujrat Ambuja Exports Lt.
Gujrat
Three Effects Falling Film Integrated Evaporator With
Single Stage Finisher For Corn Steep
Feed Rate: 10,000 Kg/Hr
M/s Mankapur Chini Mills ( A unit
of BCML) Mankapur
Five Effects Forced Recirculation Evaporating
Plant With Double Stage Finisher (W.E:52,386
kg/hr)
Thanking You
