Advancement in Distillation Technology A Green way to Sustainability. Prasanna Deshpande
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1 Advancement in Distillation Technology A Green way to Sustainability Prasanna Deshpande
2 Industry Challenges continued Volatility in Feedstock & Product Prices Rising Energy & Water Cost Stringent Pollution control Norms Need of revenue streams by value added Co-product Sustainable Production Praj Industries Ltd 2
3 Pillars of Sustainability No control Feed-Stock Compliance Mandatory Environment Technology Innovation and Integration Sustainable Advanced Technologies Praj Industries Ltd 3
4 Advanced Distillation & Evaporation Technologies Energy and Water Saving Praj Industries Ltd 4
5 Advanced Technology Ecofine-ED offers 30 % Thermal Energy reduction over conventional MPR Distillation 2.15 Kg/lit of ENA Yr Kg/lit of ENA 3.2 Kg/lit of ENA Yr.2008 Yr.1999 Praj Industries Ltd 5 Extra Neutral Alcohol
6 Advanced Distillation Technology M/s Kothari Sugars Tamilnadu 60 KLPD TS for Thermal Energy Reduction & Multiproduct facility EXISTING CONFIGURATION MPR Distillation STEAM CONSUMPTION 3.2 Kg/Liter PRODUCT Extra Neutral Alcohol NEW CONFIGURATION ECOFINE Evaporative Distillation 2017 STEAM CONSUMPTION 2.3 Kg/Liter PRODUCT BASKET AVAILABLE NOW RS,ENA, Fuel Ethanol, Pharma, Perfumery Grade UTILITIES Existing BOILER, TURBINE, COOLING TOQWES, DCS used as it is HARDWARE Majority of existing EQUIPMETS used as it is with fewer new addition Praj Industries Ltd Alcohol Master Class OPEX REDUCTION Reduced by 30% and Created Product flexibility 6
7 Praj Industries Ltd Alcohol Master Class
8 Praj Industries Ltd Alcohol Master Class
9 Advanced Technologies : Ecofine-MVR Distillation DG CONDENSATE F. Wash MVR UNIT ELECTRICITY 0.5 Kg/lit FALLING FILM EVAPORATOR MASH COLUMN RECTIFIER COLUMN 1.7 Kg/lit STEAM for Startup EXHAUST COLUMN 2.3 Kg/lit 2.0 Kg/lit ALCOHOL WATER CONDENSATE SPENT WASH STEAM for Startup Fuel Ethanol SPENT LEES ALCOHOL WATER CONDENSATE Up to 80 % Thermal Energy reduction compared to conventional Praj Industries Ltd 9
10 EcoFine ED Thia Roong Rang Co. Ltd, Thailand Demonstrated Energy Reduction by 30 % in TRR Thailand Payback < 2 year
11 Advance Ecofine ED Implemented at Balrampur Chini Mills Ltd. - (Babhanan- Unit) Existing Set up Capacity - 60 KLPD TS distillery with MPR Distillation Year of Installation 2004 by Praj ETP Option Biomethanation & Biogas Boiler Product 55 KLPD AA or 58 KLPD RS Modernized Set Up Capacity KLPD TS distillery with Ecofine ED Distillation Year of Installation 2017 by Praj ETP Option Incineration Boiler on Bagasse Product 110 KLPD AA or 116 KLPD RS Technology used Ecofine-ED and MEE for RSW Evaporation Distillation Steam for Fuel Ethanol: Reduced from 2.4 to 1.6 Kg/Liter Stand alone RSW Evaporator (MEE) newly added 4 FF + 2 FC with Stand by arrangement Concentrating Raw spent wash from 16% - 60% w/w Steam 2.4 kg/liter Power 300 KWH Lowest Praj Industries Ltd 11
12 Value Maximization by Evaporative Distillation Technology. Existing plant : Steam required for 110 KLPD AA = 264 TPD (@ 2.4 Kg/Lit) Modernization - Steam required for 110 KLPD AA = 166 TPD Kg/Lit ) Saving on steam at 110 KLPD AA =( ) = 98 TPD SAVINGS Parameter Quantity Assumed Profit Margin Savingsper day Savings for250 days operation Increase in Production LPD 5 Rs./ lit Rs lakhs/ year Steam 98 TPD 1200 Rs/ MT Rs. 1,17, lakhs/ year Total Savings - - Rs 3, lakhs/ year Simple Payback < One year Praj Industries Ltd 12
13 Praj Industries Ltd Alcohol Master Class
14 Praj Industries Ltd Alcohol Master Class
15 ADVANCED EVAPORATION TECHNOLOGY S P Singh / Prasanna Deshpande
16 Molasses Raw Spent Wash Evaporation-MEE Current Features Plants Operational for Molasses Raw spent wash Concentration India - 50 Nos. International 14 Nos. Technology offered MEE - Multiple Effect Evaporator Integrated / Stand alone / Combination Type of Evaporator - Falling film & forced circulation Feed solids % w/w Product Solids: For Incineration application Avg % w/w For Bio Composting Avg % w/w Features: Round the year Operation with Stand by arrangement Designed Flexibility to handle higher feed solids & Higher Product rate Evaporation Condensate 100% treated and recycled Built in facility for concentrating ETP reject in MEE to achieved ZLD Praj Industries Ltd 16
17 Advanced Technologies : Ecovap-MVR Raw Spent wash Evaporation MVR UNIT 0.3 Kg/lit ELECTRICITY Effect-1 Effect-2 Effect Kg/lit 2.8 Kg/lit Swaraj India Agro Ltd. 65 KLPD TS Molasses Based Distillery Project with Ecovap -MVR Technology Commissioning to start -May 2018 Process Cond. Process Cond. SPENT WASH Process Cond. CONC. SPENT WASH Standalone Evaporation Praj Industries Ltd 17 Up to 90 % Thermal Energy reduction compared to conventional
18 Air Cooled Heat Exchanger Ecocool AR Technology Praj Industries Ltd Alcohol Master Class
19 Smart Distillation, Evaporation MVR integrated Energy In Distillation Evaporation Energy Out Energy In Distillation Evaporation MVR Praj Industries Ltd 19
20 Conventional cooling system Water Out Energy Out Energy In Condenser Energy Saving Water Saving Praj Industries Ltd 20
21 Conventional Air cooled Heat cooling exchanger system ( Condenser ) Water Out Energy Out Energy In Condenser Air cooled condenser will help in saving up to 80 % of cooling tower make-up water. Up to 60 % Reduction In Overall Water Consumption Praj Industries Ltd 21
22 Ecocool AR Air cooled Heat exchanger Schematic Distillation Column Trim Cooler Cooling Tower Feed Air Cooled Condenser Swaraj India Agro Ltd. 65 KLPD TS Molasses Based Distillery Project with Ecocool AR Technology Commissioning to start -May 2018 Praj Industries Ltd 22
23 Recover & Reuse Raw Spent wash Evaporation Process Condensate treatment ZLD Technologies Praj Industries Ltd 23
24 Why treatment is required for RSW Evaporation condensate Contain predominantly lower molecular weight volatile fatty acids (VFA) High COD, BOD Levels & Low PH < 3.0 Characteristic varies with variation in Molasses quality Slow down Fermentation process and yield loss if recycle w/o treatment With higher VA can not recycle in Cooling tower make up water, since it imposes higher organic load, and fouls the components in the cooling circuit Praj Industries Ltd 24
25 Typical RSW Evaporation condensate parameters Parameter Values ph BOD, mg/l COD, mg/l VFA, mg/l TDS, mg/l Alcohol traces ppm Praj Industries Ltd 25
26 Treatment processes and selection criteria Available treatment options 1. Pre treatment of Biological followed by membranes 2. Only Membrane based system Praj Industries Ltd 26
27 Biological + Membrane based system Caustic dosing Nutrients dosing Equalization Neutralization Buffer tank A H R Permeate to Cooling tower Reverse Osmosis system Polishing filtration Aerobic system RO System Rejects to evaporation Pre treatment Praj Industries Ltd 27
28 RO configuration Molasses VA : mg/l TDS : mg/l Permeate RO system Permeate to Cooling tower / Fermentation Neutralization and two stage filtration Primary Reverse Osmosis system VA < 500 TDS < 500 Reject RO system Rejects to evaporation TDS : 20,000 30,000 mg/l Praj Industries Ltd 28
29 Qualitative comparison No Parameter Biological + RO Only RO 1 Flexibility of operation Moderate High 2 Dependability Moderate High 3 Sensitivity High Low 4 Flexibility Moderate High 5 Area requirement Very high Low 6 Civil cost Very high Low 7 Overall CAPEX High Low 8 OPEX High Moderate 9 Output suitability Fermentation / CT make up Praj Industries Ltd Fermentation / CT make up 10 Stabilization period Long (3 4 months) Short (1 week) 11 Manpower requirement Moderate to large Low 12 Reject generation (RO) Yes, 15 18% Yes, 15 18% 13 Sludge generation Yes, from biology No 29
30 Partial reference list - RO system for Molasses based Evaporation condensate treatment Client Capacity M3/day Praj Industries Ltd Year of Commissioning EID Parry Shivganga Unit Sunil Hitech Pvt Ltd Daund Sugar Pvt. Ltd Ambalika Sugar Pvt. Ltd Dalmiya Bharat Sugar Ind. Ltd Gem Sugars Ltd Mawana Sugars Ltd. 750 Under testing Dhanlakhami, Kranti, Shradha, Manas, SOM Distilleries plants are under Execution 30
31 Sustainable Bio-refinery Product & Co Product Maximization Technology Modernization Water & Energy Reduction Smart Effluent Recycle & Reuse Praj Industries Ltd 31
32 Thank You! Russia Canada United States Mexic o Trinidad & Tobago Guatemal Jamaic Dominican Republic a EI a Barbados Costa Salvador Rica Panam Nicaragu Venezuel a a a Guyan Colombi a a Peru Bolivia Brazil United Kingdom Hungary Switzerland Czech Spain Romania Germany Republic Poland Belgium Italy Bulgaria Turkey Nepal Algeria Saudi Arabia Pakistan Egypt India Bhutan United Arab Emirates Sierra Leone Nigeria Zimbabwe Ethiopia Kenya Tanzania Malawi Mozambique Swaziland Sri Lanka Cambodia Thailand Vietnam Indonesia Philippines Japan Papua New Guinea Argentina South Africa Australia Praj a global leader in ethanol with over 750 references in more than 75 countries across 5 continents. Praj Industries Ltd 32
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Japan s Leading Exhibition for Robotics Technologies Jan. 17[Wed]-19[Fri], 2018 Tokyo Big Sight, Japan Web: http://www.robodex.jp/en/ POST SHOW REPORT 2018 FACTS & FIGURES 17,186 Visitors 200 Exhibitors
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