ALL INDIA DISTILLERYS’ ASSOCIATIONprocess industries. •Suggest solutions for enhancement of operational efficiency. •Offers Technologies & systems which are : •more ... per

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Building Energy Efficient Technology

VAPCO ENGINEERS PVT. LTD.

WELCOMES ALL DELEGATES OF

ALL INDIA DISTILLERYS’ ASSOCIATION

Feb 18th, 2016


Content

INTRODUCTION

FOCUS

DISTILLERY SCENARIO

CHALLENGES

SOLUTIONS

OPERATING MODEL


VAPCO in a snapshot

• Provide sustainable & greener solutions in the form of Engineering services & EPC solutions in the selected process industries.

• Suggest solutions for enhancement of operational efficiency.

• Offers Technologies & systems which are :

• more INCLUSIVE in nature.

• Provide RIGHT & SUSTAINABLE solutions & enhance growth of our CUSTOMERS

Genesis:

Explore, Develop & Design green ways of protecting our Surroundings, People and The Nature.


Team…..

Promoted by Technocrats

Focus on “RIGHT ENGINEERING BASED SUPPLIES & SOLUTIONS”

Management team with clear vision & thoughts in place

Team members with HANDS ON experience in selected domains


Fabrication works

Mechanical design & fabrication conforming to international standards

Fabrication of pressure vessels as per ASME for ‘U’ stamping.

Manufacturing facility at Pune having area of 8000 feet² with handling facilities for Stainless steel and Carbon steel material.


Our Evolvement from Inception…

2011 Establishment

2012 • First Contract for

45 KLPD Distillation plant

2014

2013

2015

2013 • 1st Distillation plant

commissioned • 2 Overseas contracts • Dryer orders for

Starch Industry • 45 KLPD Grain based

distillery order

2014 • Canada Re-distillation plant

commissioned • First Integrated Evaporator order • First DDGS Dryer Order • Commissioning of Starch, Fiber &

Gluten Dryers

2015 • 1st Steam less Integrated

Evaporation • 1st DDGS Dryer • 170 KLPD Grain plant

under execution • 90 KLPD up gradation &

capacity enhancement

2015

2016

2016 • Commissioning of 2nd

Steam less Integrated Evaporation

• Second DDGS Dryer shall be operating

• Integrated & Non Integrated BSW Evaporation plants shall be operational

Commissioning of

2012


Content

INTRODUCTION

FOCUS

DISTILLERY SCENARIO

CHALLENGES

SOLUTIONS

OPERATING MODEL


Industry focus

Sectors Served:

• Ethanol from various raw materials such as Molasses, Grains, Cane Juice etc. for producing:

– Rectified Spirit

– Extra Neutral Alcohol

– Absolute Alcohol

• Starch & derivatives plant for producing various base & modified starches

• Standalone Evaporation & Drying systems for Ethanol, Starches, Chemical & Pharma Industries

• Zero Liquid discharge systems for various process industries

Offerings :

• Engineering Services:

– Basic

– Detailed

– Procurement

– Project Management

• Lump sum Turnkey packages :

– Complete plants

– Process units

– Battery limit plants

• Studies & Audits of existing plants for

– improving efficiencies & debottlenecking

8


Content

INTRODUCTION

FOCUS

DISTILLERY SCENARIO

CHALLENGES

SOLUTIONS

OPERATING MODEL


Scenario in General : Present & Likely future

PRESENT FUTURE

• Single plant up to 300 KLPD • Reasonably low energy

consumption • Sustainably reduced water

consumption • Recovery of maximum by

products • Relatively low pollution &

Damage to environment • Proven Effluent treatment

packages for Grain & Molasses distilleries

• Further enhanced capacities • Refining & Purification of Co-

products & waste generated from plant

• Maximization of value through Value Added Products

• Integrated Schemes & Models with focus on ZERO LIQUID DISCHARGE with minimum energy consumption.


Energy & water Scenario : Present & Likely future

PRESENT FUTURE

• Overall steam consumption in grain plants 4.5 Kg/lit – 5.0 Kg/lit

• Unused waste energy • 9-10 Lit/Lit fresh water

consumption • Substantial Cooling water

requirement

• Steam consumption @ 4.0 kg/lit

• Waste / Recycle stream will have same temperature as input temperature

• Minimum cooling water requirement

• Lowest possible Fresh Water ; Consumption Limited to Atmospheric losses only


Content

INTRODUCTION

FOCUS

DISTILLERY SCENARIO

CHALLENGES

SOLUTIONS

OPERATING MODEL


General Concerns…….

• Lower Recoveries

• Higher steam consumption

• Inferior Product quality

• Higher Impure Spirit Cut

• Non utilization of 100 % syrup

• Evaporation of spent wash to the RIGHT SOLIDS

• Working of Spent wash incinerator

• Quality of DDGS

• How to approach ZERO LIQUID DISCHARGE?

• Process Streams

• Non Process streams

• Steam & Power Balance

TECHNICAL:

• Right Project Investments

• Ideal Operating Costs

• Commercial Viability of expansions

FINANCIAL:

• Skill sets of Team

• Operational philosophy

• Right mix between Manual Operations Vs Automation

OPERATIONAL


Challenges…..

Grain Based Plants

• Further reduction in energy consumption

• Evaporation of entire quantity of thin slops without steam

• No recycle of Thin slops in the Liquefaction

• Maintaining higher solids in thick slops

• Use of 100% Syrup in Drying process

• Use of Dryer vapours for energy optimization

Molasses Based Plants

Effluent treatment:

• BSW / RSW / RO Reject Evaporation

• Reduction in steam & energy

• Recycle of waste streams

Investment:

• Which route : EPC/EPCM/ Turn Key Contract ?

• In house Project Management or out sourced ?


Two different types of Feed

Wet cake + Thick Slurry

Variation in feed specifications

• Inlet solids

• Different grains as feed to Distillery

• Stable unit operations (Decantation & Evaporation)

Large amount of mass

Higher Steam Consumption

Capability to handle Syrup

Higher product temperature

Higher Back Mixing

Maintaining Nutritional value of DDGS

Maintaining DDGS Color & Fragrance

Challenges in Drying @ DDGS


DDGS Drying : Case Study

Higher starch Grains : Rice Lower Starch Grain : Corn, Bajara

• Plant Capacity : 100 KLPD Total Spirit

• Starch content : 68 %

• Alcohol concentration in FW : 14%

• Thick slop Generation : ~ 496 m3/Day

• Wet Cake Generation : ~ 100 Ton/Day

• Thin Slop Generation : ~ 396 m3/Day

• Solids in thin Slop : ~ 3.5 %

• Solids in Syrup : 35 % max.

• Qty. of DWGS : ~ 139.6 Ton / Day

• Plant Capacity : 100 KLPD Total Spirit

• Starch content : 60 %

• Alcohol concentration in FW : 13 %

• Thick slop Generation : ~ 549 m3/Day

• Wet Cake Generation : ~ 149 Ton/Day

• Thin Slop Generation : ~ 400 m3/Day

• Solids in thin Slop : ~ 6.5 %

• Solids in Syrup : 35 % max.

• Qty. of DWGS : ~ 223 Ton/Day

62% Increase in DDGS Dryer Capacity ???


What does it mean…

Dryer for which material?

• Usage pattern of RM on yearly basis

• Influencing Grain

• Uniform mix of usage

• Heavy use of one type of Grain on yearly basis

• Selection Criteria:

• Technical Requirement

• Investment Vs Returns

• keep option of DWGS !!!


Content

INTRODUCTION

FOCUS

DISTILLERY SCENARIO

CHALLENGES

SOLUTIONS

OPERATING MODEL


Summarized Solutions ……

GRAIN MODULE:

• Low energy cooking process

• Minimal Cooling water recirculation rates

• Fermenters without Agitators

• Evaporation systems to handle entire Thin slops generated

• Maximum Evaporation through use of Alcohol vapours of distillation- Steam less Evaporation

• Systems to utilize 1:1 wet cake and syrup for Drying

• Lower energy requirement in the Drying systems


Summarized Solutions ……

MOLASSES MODULE:

• Forced circulation Reboilers for reduction in the spent wash quantity at the generation stage.

• Lower steam consumption models in distillation

• Integrated Evaporation Models with minimum add on energy for concentration of :

• RSW

• BSW

• RO Reject

• Maximum Evaporation through use of Alcohol vapours of distillation


Differentiators…….

Parameter General Trend VAPCO

Liquefaction system 0.60 Kg/lit with Cooling water requirement

0.30 Kg/lit with minimal Cooling water req.

Distillation Plant –Wash to ENA with Integrated Evaporation-Thin Slops

3.0 Kg / Lit of Total Spirit with add on steam in FC

2.50 -2.70 Kg / Lit of TS for Grain with NIL steam for Thin Slop Evaporation

Distillation Plant –Wash to ENA with Integrated Evaporation-BSW

No running reference Expected 3.2- 3.3 Kg / Lit of Total Spirit for BSW up to 30% w/w solids ( Plant under execution)

Net water Evaporation through Alcohol Vapours

3.0 – 3.25 Lit of water / Lit of Alcohol

Max 5.0 Lit of water / Lit of Alcohol

Thin Slop Recycle 15 – 35 % Zero Recycle

DDGS Dryer Rotary Dryer Multiple Options


Content

INTRODUCTION

FOCUS

DISTILLERY SCENARIO

CHALLENGES

SOLUTIONS

OPERATING MODEL


OPERATING MODEL…..

Critical Sections Non Critical / Bought out Sections

- Basic & Detailed Engineering

- Propriety Items

- Erection Services

- Commissioning Services

(Liquefaction, Distillation, Evaporation, Dryers)

- Basic Engineering

- Detailed Engineering

- Supervision of Erection & Commissioning Services

( Milling, Silos, Fermentation, Storage, Utilities)


BENEFITS….

Profitability & sustainability

Sustainable Financial cost

Optimized Project Investment

Process configuration with solution based approach rather than HARDWARE CENTRIC

Value engineering


Value based Schemes READY for Implementation …


Value Proposition

• Plants based on International Standards

• Flexible approach

• Environment Friendly and sustainable Plants with:

– Better product quality

– Optimized Product Yields

– Lower utilities & Operating Costs

– Compact Size

Results in Sustainability & attractive paybacks


Content

INTRODUCTION

FOCUS

DISTILLERY SCENARIO

CHALLENGES

SOLUTIONS

OPERATING MODEL


THANK YOU

Documents

ALL INDIA DISTILLERYS’ ASSOCIATIONprocess industries. •Suggest solutions for enhancement of operational efficiency. •Offers Technologies & systems which are : •more ... per