Value Maximisation solutions for distilleries -Combiferm & Evaporative Distillation Technologies. Praj Industries Ltd

Transcription

1 Value Maximisation solutions for distilleries -Combiferm & Evaporative Distillation Technologies

2 Fermentation Yeast Fermentation Mode of Operation Feedstock Composition 2

3 Understanding Microbiology-Yeast Growth Kinetics Budding Yeast produces alcohol 33 times faster than non-budding! 3

4 Yeast Specific Productivity ( liter of alcohol/kg of yeast/hour) Yeast production (kg yeast/kg alcohol) Yeast Growth Kinetics 1.3 Volatile Acidity PCV Ethanol Concentration in Fermetned Mash (%V/V) 4

5 Feedstock Composition- Stress Factors Lactic acid > 0.8% w/v kills ph 3-4 Sulfite >100 mg/l kills (varies with strain) Sugar Content Yeast can tolerate up to 38% w/v Ethanol 23% is possible Sodium ion >500 mg/l kills Temperature 35 C max. Acetic acid > 2400 ppm inhibit Dissolved Solids > 20 % w/w 5

6 Fate of Sugar Ethanol formation % Sugar Yeast growth 5 6 % Byproducts formation 4 6 % 6

7 Mode of Operation Batch: -Simultaneous Addition of Activated cell mass and the feed -Reaction completion - Emptying -Cleaning Synchronous (Fed Batch): -Synchronized addition of activated cell mass -Reaction Completion (partial addition of feed and fermentation) -Emptying -Cleaning Continuous: -Simultaneous addition of feed, activated cell mass and reaction -Emptying-NO -Cleaning-NO 7

8 Advantages of Synchronous & Continuous Fermentation Parameters Synchronous Continuous Advantages Flexibility: Multiple feedstock and their combination. Can be terminated anytime depending on feedstock composition Risk of Infection: Less as after termination of batch, fermenters are CIPed. Yield: Higher First fermenter acts as fresh yeast supply to rest of the fermenter High active cellmass concentration ensures fast reaction Minimal Yeast Usage Consistent mash quality Less CIP Less laborious Lower CAPEX Easily Automated Is there fermentation technology giving advantage of synchronous and continuous Fermentation? CombiFerm 8

9 Imperative-Identifying the Right Yeast! -Collection of Yeast from different Flora and Fauna -Microbiological and biochemical assay for different stress parameter -Shortlisting of yeast and study of growth Kinetics -Bench and Pilot scale process optimization and integration -Recycle Streams -Volatile Acids -FAN -Caramel -Inorganic salts -Contamination XP + Yeast 9

10 Fermentation Process Development Feed Bottle Feed Bottle Biostat-A Chemostat Biostat-B Mash Collection 10

11 CombiFerm PRE FERMENTOR-I/II Molasses Process water Nutrients/Yeast CombiFerm- Combination of Fed batch and Continuous fermentation process Process stream Recycle Biostat-I/II Chemostat-I Molasses Process water Nutrients Biostat-A & B: -Hygienic equipment design -Controlled feeding of feedstock & nutrient -Homogenous mixing -Temperature control -CIP facility for Hygienic condition for optimum cell mass concentration F. wash DISTILLATION Ethanol Chemostat : -Hygienic equipment design Homogenous mixing -Temperature control 11

12 CombiFerm. Biostat Chemostat Separation of yeast growth phase (biostat) and ethanol generation phase (Chemostat) in fermenter Ensuring hygienic operations in biostat by operating fermenter in fed batch mode. Ethanol generation in continuous mode of operation (Chemostat) for consistent mash feed to distillation. 12

13 CombiFerm-Sugar Fermentation Technology Feature: Scientifically Designed Fermentation Technology Extra-productive, New Yeast strain XP + Advantage of Continuous and Synchronous fermentation Suitable for Sugarcane, Sweet Sorghum, Sugar beet based feedstock and their combination Advantage: Feedstock specific, higher ethanol concentration in fermented mash-10-15% v/v Compliance to reduce, recycle and reuse of effluent streams Hygienic process design eliminates risk of contamination Higher fermentation efficiency Benefits: Increase in profitability due to higher yield Excellent congener profile for beverage alcohol Modernization opportunity to expand batch fermentation plant capacity by 15-20% 13

14 CombiFerm- Modernization Opportunity Case Study -Fed Batch Process stream Recycle PRE FERMENTOR-I/II Fermenter Beerwell F. wash DISTILLATION Molasses Process water Nutrients/Yeast Molasses Process water Nutrients Ethanol 100 KLPD Distillery- Existing Fed Batch Fermentation: Alcohol concentration in mash-8.5%v/v Fermented mash Produced-1148 m3/day No. of Fermenter-480 m3 (4 No.) Beerwell- 480 m3 (1 No.) CombiFerm: -Alcohol concentration in mash-8.5%v/v -Fermented mash produced-1645 m3/day -Plant capacity achieved-130 KLPD -Increase in plant capacity- 30% Payback year 14

15 Advanced Technology-Success Stories

16 CombiFerm Fermentation Technology Shreenath Mhaskoba SSK (45 KLPD) 16

17 Way Forward -CombiFerm Starch & 2 G Sugars Biostat-A Chemostat Biostat-B Feed Bottle Mash Collection 17

18 Evaporative Distillation

19 Distillation Technology RS / AA Production M A S H R E C E X H R E C E X Flash Tank M A S H Thick Slops Lees Lees Thick Slops Ecofine TVS Ecofine PV 19

20 Concept Evaporative Distillation Normal Distillation Fermented Wash Analyser Rectifier RS Evaporative Distillation Fermented Wash Evaporative Distillation Rectifier RS 20

21 Energy Comparison Various Technologies Alcohol Concentration % v/v Single Mash Column Kg/lit of TS Evaporative Distillation (single Split) Kg/lit of TS

22 Advantages Evaporative Distillation Energy Thermal Energy Lesser than Normal Distillation Cost Cost is similar to Normal Distillation Column Integration Integration with Evaporation is Possible 22

23 Application Evaporative Distillation RS Evaporative Distillation ENA AA For Both Sugary and Starchy Feedstock 23

24 Schematics Evaporative Distillation RS/AA Production AA Scheme 1.5 kg/lit REC 1.0 kg/lit Evaporative Distillation Evap 0.45 kg/lit 0.2 kg/lit MSDH Steam Consumption : Kg/lit of AA 24

25 Advantages Evaporative Distillation AA Production Scheme suitable for retrofitting in Existing Plant Existing Distillation Plant Capacities can be increased by % Lower Energy Consumption even compared to Evaporation integrated scheme Lower Water Footprint 25

26 Plant Modernization Case Study - Evaporative Distillation Technology

27 Applicability of Modernization to Existing Plant EXISTING MPR DISTILLATION ATM DISTILLATION MODIFIED TO Evaporative Distillation Energy Efficient High Capacity DISTILLATION FACILITY COLUMNS EXISTING HEAT EXCHANGES PUMPS, TANKS & EQUIPMENTS UTILISATION NEW MAJORITY OF EXISTING EQUIPMETS USED 27

28 Current Scenario Parameter 60KLPD MPR Plant Capacity LPD of AA Steam Consumption 2.3 Kg/ Lit of Fuel Ethanol 28

29 Change in Existing Plant Performance due to Modernization. Evaporative Distillation retrofitted in existing set up Existing plant capacity increased without major changes 30 % Reduction in overall Steam Consumption Proportionately reduction in water required for cooling tower. Reduction in Water Footprint Reduction in Effluent quantity Multi product facility like RS & Absolute Alcohol upgradable to Pharma Grade ENA, Perfumery Grade ENA Market demands can best handled for Profitability. Capacity Enhancement in existing utilities 29

30 Value Addition in Modernization Parameter 60KLPD MPR 100 KLPD Evaporative Distillation Plant Capacity LPD of AA LPD of AA Steam Consumption 2.3 kg/lit 1.7 kg/lit 30

31 Value Addition in Modernization Current Operation : Steam required for 100 KLPD AA = 230 TPD (@2.3 Kg/Lit) Modernization - Steam required for 100 KLPD AA( Plant expanded from 60 to 100 KLPD) = 170TPD(@1.7Kg/Lit) Saving on steam at 100 KLPD TS = ( ) = 60TPD SAVINGS Parameter Quantity Assumed Profit Margin Savings per day Savings for 250 days operation Production LPD 10 Rs./ lit Rs lakhs / year Steam 60 TPD 1200 Rs./ MT Rs lakhs / year Total Savings - - Rs lakhs / year Simple Payback < 9 11 months 31

32 Patent Evaporative Distillation Production of ethanol by evaporative distillation Date of filing : 8 August 2013 Patent No. : 2620/MUM/2013 Major Claims: Size of said mash column is reduced by 50% first evaporator is energized using Mash Vapors. 32

33 Evaporative Distillation Reference List Sr No Client Name Capacity In KLPD Remark 1 Dalmia Bharat Sugars Ltd 65 Under Execution 2 Madhucon 45 Under Execution 3 Balrampur Sugars Ltd Under Engg 33

34 Thank you Sustainability through Advanced Technologies