A Presentation for All India Distillers Association EVAPORATION & DRYING SYSTEMS FOR ZERO EFFLUENT DISCHARGE (ZELD) Presented By R.P.Singh (Food & Biotech Engineers (I) Pvt. Ltd.)
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 RALLI OY (Ltd.) Jokiniementie 16A 00650 Helsinki, FINLAND Email: seppo@ralli.fi Joint Technical collaboration with M/s Crest Biotech Pvt. Ltd. A 30/B1, Mohan Co-operative Ind. Area Mathura Road, New Delhi-110044 India Email: crestbiotech@gmail.com
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
C.2. Five Effects falling film evaporating plant in combination with FF and FR calandria with gas removing system (for biomethanated spent wash) 19
C.3. Five Effects falling film evaporating plant in combination with FF and FR calandria with single stage finisher (for Raw spent wash) 20
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 Extra electrical load during CIP Extra steam consumption during CIP CIP Chemicals NaOH,flakes CIP Chemicals HNO3 1% Combination Evaporator with finisher (with 1 stand by calandria) 2,572 kw/ 8 days (321 Kw/day) 26,190 Kg/8 days (3,273 kg/day) 670 kg/8 days (83 kg/day) 335 kg/8 days (42 kg/day) Forced recirculation evaporator with finisher 3387 Kw/45 days (75 kw /day) 32,186 Kg/ 45 days (715 kg/day) 4400 Kg/45 days (97 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 Processing Cost / lit of spent wash Due to 20% capacity reduce for a period of time (2,619 kg/hr ) Rs. 0.53/ lit of spent wash Due to 5% capacity reduce for a period of time (654 kg/hr ) 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 Vapor from Analyzer Column Kg/hr 12,000-13,000 With the above heat available water evaporation can be achieved (Alcohol vapor @ 95 % + Water vapor @ 5% ) Temp. of vapor Deg C 98-102 Latent heat at 88 deg C (Cal 01 boiling temp.) Total water evaporation in 2 effects evaporator K Cal/kg 548 Kg/hr 10,293 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 Feed rate Kg/hr 45,000-40,000 Feed solids % 10-14 Stand Alone 3 or 4 effects forced recirculation evaporator to concentrate 55 % TS with heating media as dry saturated steam Feed rate Kg/hr 34,707-29,707 Concentrate Solids Concentrate rate Water Evaporation % 13-19 Kg/hr 34,707-29,707 Kg/hr 10,293 Feed solids % 13-19 Concentrate Solids Concentrate rate Water Evaporation % 55.0 Kg/hr 8,182-10,182 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 Water Evaporation/ m2 Area Kg/m2 7.5-10 Cal 01 Jacket Temp. Deg C 98-102 VS 01 temp. Deg C 88-90 Heat requirement / kg of Water Evaporation Kcal/ kg of WE 274 VS 02 temp. Deg C 75-78
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)
ONE TIME SOULTION : UF & ZELD 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
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 M/s Sona Sati Pvt.Ltd Bihar Three Effects Falling Film Integrated Evaporator With Single Stage Finisher For Corn Steep Feed Rate: 10,000 Kg/Hr 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)
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