Advancement in Distillation TechnologyA Green way to Sustainability

Prasanna Deshpande

Industry Challenges continued…

Stringent Pollution control Norms

Rising Energy &

Water Cost

Volatility in Feedstock & Product

Prices

Need of revenue

streams by value added Co-product

Sustainable Production

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Pillars of Sustainability

Sustainable Advanced Technologies

3

Feed-Stock

TechnologyTechnologyEnvironment

No control

Innovation and

Integration

Innovation and

IntegrationCompliance

Mandatory

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Advanced Distillation &

Evaporation Technologies

Energy and Water Saving

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3.2 Kg/lit of ENA

2.7 Kg/lit of ENA

2.15 Kg/lit of ENA

Extra Neutral Alcohol

Advanced Technology Ecofine-ED

offers 30 % Thermal Energy reduction

over conventional MPR Distillation

5© Praj Industries Ltd www.praj.net Yr.1999

Yr.2008

Yr.2016

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Advanced Distillation Technology M/s Kothari Sugars Tamilnadu 60 KLPD TS for Thermal Energy Reduction & Multiproduct facility

HARDWARE

Majority of existing EQUIPMETS used as it is with fewer new addition

STEAM CONSUMPTION

3.2 Kg/Liter

STEAM CONSUMPTION

2.3 Kg/Liter

PRODUCT

Extra Neutral Alcohol

PRODUCT BASKET AVAILABLE NOW

RS ,ENA, Fuel Ethanol, Pharma , Perfumery Grade

EXISTING CONFIGURATION

MPR Distillation - 2007

NEW CONFIGURATION

ECOFINE –Evaporative Distillation 2017

UTILITIES

Existing BOILER, TURBINE, COOLING TOQWES, DCS used as it is

OPEX REDUCTION

Reduced by 30% and Created Product flexibility

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2.3 Kg/lit

2.0 Kg/lit

1.7 Kg/lit

0.5 Kg/lit

Advanced Technologies : Ecofine-MVR – Distillation

Up to 80 % Thermal Energy reduction compared to conventional

9

STEAM for

Startup

STEAM for

Startup

SPENT LEES

SPENT WASH

ALCOHOL WATER

CONDENSATEALCOHOL WATER

CONDENSATE

DG

CONDENSATE

RECTIFIER

COLUMN

EXHAUST

COLUMN

MASH

COLUMN

FALLING FILM

EVAPORATOR

MVR

UNIT

ELECTRICITY

F. Wash

Fuel Ethanol

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EcoFine ED – Thia Roong Rang Co. Ltd, Thailand

Payback < 2 year

Demonstrated Energy Reduction by 30 % in TRR Thailand

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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 - 120 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

Value Maximization by Evaporative Distillation Technology.

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SAVINGS

Parameter Quantity Assumed

Profit Margin

Savings per

day

Savings for 250 days

operation

Increase in

Production

55000

LPD

5 Rs./ lit Rs. 275000 687 lakhs / year

Steam 98 TPD 1200 Rs/ MT Rs. 1,17,600 294 lakhs / year

Total

Savings

- - Rs 3,42400 981 lakhs / year

Existing plant : Steam required for 110 KLPD AA = 264 TPD (@ 2.4 Kg/Lit)

Modernization - Steam required for 110 KLPD AA = 166 TPD ( @1.6 Kg/Lit )

Saving on steam at 110 KLPD AA =(264-166) = 98 TPD

Simple Payback < One year

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ADVANCED EVAPORATION TECHNOLOGY

S P Singh / Prasanna Deshpande

� 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 - 16 -18 % w/w

� Product Solids:� For Incineration application – Avg. 55 - 60% w/w � For Bio Composting – Avg. 22 – 35 % 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

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Molasses Raw Spent Wash Evaporation-MEE –Current Features

2.8 Kg/lit

2.3 Kg/lit

0.3 Kg/lit

Advanced Technologies : Ecovap-MVR – Raw Spent wash Evaporation

Up to 90 % Thermal Energy reduction compared to conventional 17© Praj Industries Ltd www.praj.net

Effect-1Effect-2

Effect-3

SPENT WASH

CONC. SPENT WASH

Process

Cond.

Process

Cond.Process

Cond.

ELECTRICITY

Standalone Evaporation

MVR

UNIT

Swaraj India Agro Ltd. 65 KLPD TS

Molasses Based Distillery Project

with Ecovap - MVR Technology

Commissioning to start - May 2018

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Air Cooled Heat Exchanger

Ecocool – AR Technology

Distillation Evaporation

MVR

Distillation EvaporationEnergy

In

Energy Out

Energy

In

Smart Distillation , Evaporation – MVR integrated

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Condenser

Water Out

Energy Saving Water Saving

Energy In

Energy Out

Conventional cooling system

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Condenser

Water Out

Energy In

Energy Out

Air cooled condenser will help in saving up to 80 % of cooling tower make-up water.

Up to 60 % Reduction In Overall Water Consumption

Conventional cooling system Air cooled Heat exchanger ( Condenser )

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Trim Cooler

Cooling

Tower

Distillation

Column

Feed

Air Cooled Condenser

Ecocool – AR Air cooled Heat exchanger Schematic

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Swaraj India Agro Ltd. 65 KLPD TS

Molasses Based Distillery Project

with Ecocool – AR Technology

Commissioning to start - May 2018

Raw Spent wash Evaporation

Process Condensate treatment

ZLD Technologies

23© Praj Industries Ltd www.praj.net

Recover & Reuse

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

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Typical RSW Evaporation condensate parameters

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Parameter Values

pH 3.0 -3.5

BOD, mg/l 2500 – 4500

COD, mg/l 4000 – 7000

VFA, mg/l 3000 - 4500

TDS, mg/l 600-800

Alcohol traces ppm 400-800

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Treatment processes and selection criteria

�Available treatment options

1. Pre treatment of Biological followed by membranes

2. Only Membrane based system

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Biological + Membrane based system

Equalization Neutralization Buffer tank A H R

Aerobic

system

Polishing

filtration

Reverse

Osmosis

system

Caustic

dosing

Nutrients

dosing

Permeate to Cooling

tower

Rejects to

evaporation

Pre treatment

RO System

28© Praj Industries Ltd www.praj.net

RO configuration – Molasses

Primary Reverse

Osmosis system

Permeate to Cooling

tower / Fermentation

Rejects to

evaporation

Permeate RO

system

Reject RO system

Neutralization and

two stage

filtration

VA : 3500 – 4000 mg/l

TDS : 5000 – 6000 mg/l

VA < 500

TDS < 500

TDS : 20,000 – 30,000 mg/l

29© Praj Industries Ltd www.praj.net

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

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

30© Praj Industries Ltd www.praj.net

Partial reference list - RO system for Molasses

based Evaporation condensate treatment

Client Capacity

M3/day

Year of

Commissioning

EID Parry – Shivganga Unit 600 2008

Sunil Hitech Pvt Ltd. 600 2010

Daund Sugar Pvt. Ltd. 720 2014

Ambalika Sugar Pvt. Ltd.– 650 2015

Dalmiya Bharat Sugar Ind. Ltd

350 2016

Gem Sugars Ltd. 480 2017

Mawana Sugars Ltd. 750 Under testing

Dhanlakhami, Kranti, Shradha, Manas, SOM Distilleries plants

are under Execution

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Sustainable Bio-refinery

Technology Modernization

Water & Energy Reduction

Smart Effluent Recycle & Reuse

Product & Co Product Product & Co Product Maximization

Thank You !

United States

Mexico

Guatemala EI

Salvador Nicaragua

Jamaica

Dominican Republic

Trinidad & Tobago

Venezuela Guyan

a

BrazilBolivia

Argentina

Peru

Colombia

BarbadosCosta RicaPanama

Algeria

Egypt

Sierra Leone

Nigeria Kenya

Ethiopia

Tanzania

Malawi

MozambiqueZimbabwe

Swaziland

South Africa

United Kingdom

Russia

Poland

Hungary

Czech Republic

Bulgaria

Belgium

RomaniaSwitzerland

GermanySpain

Saudi

United Arab Emirates

Turkey

IndiaArabia

Australia

Papua New Guinea

Indonesia

Philippines

CambodiaSri Lanka

Thailand

Vietnam

Nepal

PakistanBhutan

JapanItaly

Canada

Praj a global leader in ethanol with over 750 references in

more than 75 countries across 5 continents.32© Praj Industries Ltd www.praj.net