Value Maximisation solutions for distilleries -Combiferm & … pillai, Praj.pdf · Combination of Fed batch and Continuous fermentation process Biostat-A & B:-Hygienic equipment design-Controlled

Value Maximisation solutions for

distilleries -Combiferm & Evaporative

Distillation

Technologies

© Praj Industries Ltd www.praj.net

Fermentation


Fermentation

Yeast

Feedstock Composition

Mode of Operation

2

Understanding Microbiology-Yeast Growth Kinetics


Budding Yeast produces alcohol 33 times faster than non-budding!3


Yeast Growth Kinetics

1.3 Volatile Acidity 0.13

1.2 0.12

1.1 0.11

1 0.1

0.9 0.09

0.8 0.08

0.7 PCV 0.07

0.6 0.06

0.5 0.05

0.4 0.04

0.3 0.03

0.2 0.02

0.1 0.01

4 5 6 7 8 9

Yeast

pro

duction (

kg y

east/

kg

alc

ohol)

Yeast

Specific

Pro

ductivity (

liter

of

alc

ohol/kg o

f yeast/

hour)

Ethanol Concentration in Fermetned Mash (%V/V)

4


Feedstock Composition- Stress FactorsSugar Content

Yeast can tolerate up to

38% w/v

Sulfite

>100 mg/L kills

(varies with strain)

pH

3 - 4

Sodium ion

>500 mg/L kills

Temperature

35°C max.

Acetic acid

> 2400 ppm

inhibit

Lactic acid

> 0.8% w/v

kills

Ethanol

23% is possible

Dissolved

Solids

> 20 % w/w5


Fate of Sugar

Sugar

Ethanol formation88 – 91 %

Yeast growth5 – 6 %

Byproducts

formation4 – 6 %

6

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

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?

CombiFerm8

-Recycle Streams

-Volatile Acids

-FAN

-Caramel

-Inorganic salts

-Contamination

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

XP+ Yeast9

Fermentation Process Development


Feed BottleFeed Bottle

Mash

Collection

Biostat-AChemostat Biostat-B

10

PRE FERMENTOR-I/II

MolassesProcess waterNutrients

MolassesProcess waterNutrients/Yeast

DISTILLATION

F. wash

Process stream Recycle

Ethanol

CombiFerm


Biostat-I/II

Chemostat-I

CombiFerm-

Combination of Fed batch and Continuous

fermentation process

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

Chemostat :

-Hygienic equipment design

Homogenous mixing

-Temperature control

11

CombiFerm….


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.

Biostat Chemostat

12

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 efficiencyBenefits: 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

PRE FERMENTOR-I/II

MolassesProcess waterNutrients

MolassesProcess waterNutrients/Yeast

DISTILLATION

F. wash

Process stream Recycle

Ethanol

CombiFerm- Modernization Opportunity

Case Study -Fed Batch


Fermenter

Beerwell

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 -2-2.5 year

14

Advanced Technology-Success Stories

CombiFerm Fermentation Technology

Shreenath Mhaskoba SSK (45 KLPD)

© Praj Industries Ltd www.praj.net 16

Way Forward -CombiFerm Starch & 2 G Sugars


Feed Bottle

Mash

Collection

Biostat-BChemostatBiostat-A

17

www.praj.net

Evaporative Distillation


19

Ecofine – TVS

M

A

S

H

R

E

C

LeesThick

Slops

E

X

H

Flash

Tank M

A

S

H

R

E

C

E

X

Ecofine – PV

Thick

SlopsLees

Distillation TechnologyRS / AA Production


20

Analyser Rectifier

RSFermented

Wash

Evaporative Distillation Rectifier RSFermented

Wash

Normal Distillation


ConceptEvaporative Distillation


21

Alcohol Concentration

% v/v

Single Mash Column

Kg/lit of TS


(single Split)

Kg/lit of TS

8 1.8 1.25

10 1.6 1.05

12 1.35 0.9

15 1.25 0.8

Energy ComparisonVarious Technologies


22

• Thermal Energy Lesser than Normal DistillationEnergy

• Cost is similar to Normal Distillation ColumnCost

• Integration with Evaporation is PossibleIntegration

AdvantagesEvaporative Distillation


23


RS

AAENA

For Both Sugary and Starchy Feedstock

ApplicationEvaporative Distillation


24

REC

1.0 kg/lit

Evap

AA Scheme

1.5 kg/lit

0.45 kg/lit

MSDH

0.2 kg/lit


Steam Consumption : 1.5 - 1.7 Kg/lit of AA

SchematicsEvaporative Distillation – RS/AA Production


25

Scheme suitable for retrofitting in Existing Plant

Existing Distillation Plant Capacities can be increased by 40 -50 %

Lower Energy Consumption even compared to Evaporation

integrated scheme

Lower Water Footprint

AdvantagesEvaporative Distillation – AA Production


www.praj.net

Plant Modernization Case Study -

Evaporative Distillation Technology


Applicability of Modernization to Existing Plant


EXISTING

MPR DISTILLATION

ATM DISTILLATION


Energy Efficient

High Capacity

DISTILLATION

FACILITY

MODIFIED TO

EXISTING

COLUMNS

HEAT EXCHANGES

PUMPS, TANKS &

EQUIPMENTS

UTILISATION

NEW

MAJORITY OF

EXISTING

EQUIPMETS USED

Current Scenario


Parameter

Plant Capacity

Steam Consumption

60KLPD MPR

60000 LPD of AA

2.3 Kg/ Lit of Fuel Ethanol

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

Value Addition in Modernization


Parameter

Plant Capacity

Steam Consumption

60KLPD MPR

60000 LPD of AA

2.3 kg/lit

100 KLPD Evaporative Distillation

100000 LPD of AA

1.7 kg/lit

Value Addition in Modernization


SAVINGS

Parameter Quantity AssumedProfit Margin

Savings per day Savings for 250 days operation

Production 40000 LPD 10 Rs./ lit Rs. 400000 1000 lakhs / year

Steam 60 TPD 1200 Rs./ MT Rs. 72000 180 lakhs / year

Total Savings - - Rs 472000 1180 lakhs / year

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 = (230-170) = 60TPD

Simple Payback < 9 – 11 months

32

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.

PatentEvaporative Distillation


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 60 -100 Under Engg

Sustainability through Advanced Technologies


Thank you

Documents

Value Maximisation solutions for distilleries -Combiferm & … pillai, Praj.pdf · Combination of Fed batch and Continuous fermentation process Biostat-A & B:-Hygienic equipment design-Controlled