EVAPORATION & DRYING SYSTEMS

FOR ZERO EFFLUENT DISCHARGE (ZELD)

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: info@foodbiotech.co.in, 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: crestbiotech@gmail.com

Joint Technical collaboration with

M/s RALLI OY (Ltd.)Jokiniementie 16A00650 Helsinki,FINLAND Email: seppo@ralli.fi

EVAPORATOR

An evaporator is an equipment employed under vacuum to evaporate water from inlet feed.

Application of evaporator can be for dairy, food, chemical and other industry.

For distillery industry, it is important for reducing volume of liquid effluents and recover water.

IMPORTANT ISSUES FOR WHICH CREST AND FBE ARE

WORKING INTENSIVELY FOR SUITABLE SYSTEM

CREST AND FBE have been working intensively on the following aspects and

have concluded that

Selection of correct combination of MEE for effective utilization

Characterization of various category of effluent

Clear condensate without product contamination having worked out.

Various end use effluent concentration has been worked out

An Effective De FOAMER has been developed to stop entrainment

CREST and FBE have worked out the various end uses of distillery effluent concentrate obtained by employing MEE . It is very important consideration

Based on these intensive and focus studies,

We can RECOMMEND, SUGGEST and SUCCESSFULLY INSTALL the type of MEE to be employed techno commercially successful for your distillery

TYPES OF EVAPORATOR

Falling Film Evaporator

Forced Recirculation Evaporator

Combination of Falling film and Forced Recirculation Evaporator

Scrapped Surface Evaporator

A. Falling Film

Evaporator

A.1. Falling Film Evaporator Is Employed In

Indian Distilleries For

Bio methanated Spent wash

RO reject water concentration

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. LIMITATIONS AND PROBLEMS ENCOUNTERED EMPLOYING

FALLING FILM EVAPORATOR ( SPECIALLY FOR BIO DIGESTER

OVER FLOW EFFLUENT )

Concentration up to 26- 30 % TS may possibly be achieved with great precautions and monitoring.

Fowl smell and odour resulting in air pollution and bed environment.

Limitation in achieving effective capacity

HIGH FOAMING, ENTRAINMENT, CARRY FORWARD IN CONDENSATES

SCALE FORMATION, Cleaning cycle after 8 – 10 DAYS after selecting

correct combination of MEE with efficient feed treatment.

Additional effluent generation due to chemical cleaning (CIP) & special treatment before discharging to main ETP plant

Using Bio digester overflow and employing falling film evaporator as an Integrated Evaporation System may be highly risky and undesirable

A.4. REMEDIAL MEASURES : BUT DIFFICULT ???

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.

Rotary Clarifier, Micronizer , Gas Seperater, Anti Foamming Mechanical Equipments and other feed treatment equipments are accurate standardization for achieving clear condensate and successful concentrate to 40% level.

A.5. PROBLEMS IN BIO METHANATED 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

B. Forced Recirculation

Evaporator

B.1. FORCED RECIRCULATION MEE – SUITABILITY

o HIGH TSS, DS AND VISCOUS LIQUIDS

o MOLASSES EFFLUENTS WITH HIGH SALT CONTENTS

o GRAIN LIQUID EFFLUENT

o HIGH CONCENTRATIONS MORE THAN 60 – 70 % DM

ARE REQUIRED IN FINAL MEE PRODUCTS

o CLEAR CONDENSATES ARE REQUIRED FOR

RECYCLING IN THE PROCESS.

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

High concentration ( 60 – 70% DM ) can be achieved.

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 – Solved by FBE

Integrated Continuous Settlers to get clean effluent inlet to MEE.

Mechanical Seal & Pumps working efficiencies.

Well Designed Calenderia, Vapor Separators, Entrainment Catchers,

Condensers, with most appropriate HTA , Vapor Area , Vacuum ,

Temperature Profile etc.

B.4. Problems – Solved by FBE

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

19

C.2. Five Effects falling film evaporating plant in

combination with FF and FR calandria with gas

removing system (for biomethanated spent wash)

20

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. Integrated Evaporator

E.1. Integrated Evaporator

Double effects FF evaporator with one stand by calandria and

Double stage FR finisher with one stand by calandria

E.2. Salient Features

Integrated Evaporator is 2/ 3 /4 effects Falling Film Evaporator which

utilizes waste heat from

Rectifier column

Vapor having Alcohol vapor 95% and Water vapor 5%

Vapor temp. 98-102 deg C

Or, Analyzer Column

Vapor having Alcohol vapor 52% and Water vapor 48%

Vapor temp. 72 deg C

Vapor from last effect’s Vapor separator is either fed to

Analyzer Column (incase of exhaust heat used from Rectifier column)

Or, Condenser (incase of exhaust heat used from Analyzer column)

E.3. Salient Features Cont.

Suitable to Preconcentrate the spent wash upto 15-20% TS (depending

upon the waste heat available) before feeding to bio-digester.

Further concentration upto 35% to 55 % TS can be done in Stand

alone evaporator

E.4. Typical Example of Integrated Evaporator for Distillery

Plant of 100 KL

With the above heat available water

evaporation can be achieved

Latent heat at 88 deg

C (Cal 01 boiling

temp.)

K Cal/kg 548

Total water

evaporation in 2

effects evaporator

Kg/hr 10,293

Vapor from

Analyzer

Column

(Alcohol vapor

@ 95 %

+ Water vapor @

5% )

Kg/hr 12,000-

13,000

Temp. of vapor Deg C 98-102

Latent heat of

vapor

Kcal/kg 217

Heat available Kcal/

hr

28,20,350

E.5. Typical Example of Mass balance for 100 KL distillery plant

Integrated Double effects falling

film evaporator with heating

media Vapor from Rectifier

column

Stand Alone 3 or 4 effects

forced recirculation evaporator

to concentrate 55 % TS with

heating media as dry saturated

steamFeed rate Kg/hr 45,000- 40,000

Feed solids % 10 - 14

Concentrate

Solids

% 13 - 19

Concentrate

rate

Kg/hr 34,707- 29,707

Water

Evaporation

Kg/hr 10,293

Feed rate Kg/hr 34,707- 29,707

Feed solids % 13- 19

Concentrate

Solids

% 55.0

Concentrate

rate

Kg/hr 8,182- 10,182

Water

Evaporation

Kg/hr 26,525- 19,525

E.6. U Value/ Temp. Profile/ Area for Integrated Evaporator

(Double effects)

U Value Kcal/hr/

m2

deg C 850-1,050

Cal 01

Jacket Temp.

Deg C 98-102

VS 01 temp. Deg C 88-90

VS 02 temp. Deg C 75-78

Water

Evaporation/

m2 Area

Kg/m2 7.5- 10

Heat

requirement /

kg of Water

Evaporation

Kcal/

kg of

WE

274

F. FBE Unique Drying

System

F.1. DRYERS

SUITABLE AND WELL DESIGNED DRYERS ARE ESSENTIALLY NEEDED FOR HANDLING MOLASSES AND GRAIN EFFLUENT CONCENTRATES OBTAIN BY EMPLOYING MEE

DRYERS ARE AN ULTIMATE SOLUTION TO ACHIEVE ZELD

F.2. FBE Unique drying system (For

molasses based effluent)

F.3. FBE Unique drying system (For grain

based effluent)

CREST’S UNIQUE FERMENTATION TO GET CLEAN, CLEAR LOW VOLUME & HIGH DM SPENT WASH

FBE WELL DESIGNED MEE & DRYERS FOR CONCENTRATING SPENT WASH AND DRYING TO GET FREE FLOWING POWDERS / SOLIDS.

CREST’S HAS DEVELOPED TECHNOLOGY AND KNOW HOW FOR MANUFACTURING HIGH VALUE POWDERS / SOLIDS FROM CONCENTRATED MEE SPENT WASH

ONE TIME SOLUTION FOR ZELD IS PROVIDED ON TURN KEY BASIS AS AN INTEGRATED PACKAGE FOR DISTILLERY INDUSTRY IN INDIA AND WORLD WIDE BY CREST AND FBE

ONE TIME SOULTION : UF & ZELD

G. Our Valued

Customers

List of our Valuable Customer

United Nations Industrial

Development Organization,

Austria.

Double effects evaporator, (Water evap: 500

Kg/hr)

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 UFLEX Ltd.

Sector-4, Noida

Five effects evaporating plant followed with

Single Stage Finisher (W.E: 40,000 kg/hr)

List of our Valuable Customer

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

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 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 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 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 Parabolic Drug

Chandigarh

Three effects evaporating plant in

combination with falling film and

forced recirculation type calandrias

(W.E capacity: 3,600 kg/hr)

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)

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 Kothari Fermentation &

Biochem Ltd.

Sikandrabad, Bulandshahr

Five effects evaporating plant followed with

Single Stage Finisher (W.E: 14,000 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

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 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)

List of our Valuable Customer

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)

M/s Superior Industries Ltd Four Effects falling film Evaporating plant Along

With sludge and Gas Removing System for

processing biomethanated spent wash (W.E:

9271 kg/hr)

Thanking You