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Distilleries and Alcohol Projects

Distilleries and Alcohol Projects
   
Distilleries and Alcohol Plants
Distilleries and Alcohol Plants
Distilleries and Alcohol Plants
Distilleries and Alcohol Plants


Distilleries and Alcohol Plants
VIJSUN provides a turnkey solutions for Distilleries and Alcohol Projects and Alcohol projects. VIJSUN has achieved an expertise in providing a turnkey solutions for Distillery Units as well as Grain based alcohol projects. VIJSUN offers these projects of various capacities ranging from 10KLPD to 75KLPD. VIJSUN with its Technical team have developed a small capacity ethanol project of capacity 5000LPD which is techno-economically very feasible.
DISTILLERY & ALCOHOL PLANTS
1 ) OVERVIEW 
 Concept to Commissioning of Complete Alcohol Plants & Distillery Molecular sieve ranging from 10 KLPD upto 100 KLPD alongwith Ethanol Plants. 
 Design and Manufacture of :
• Molasses Based & Multi-feed Distillery 
• Fermentation Section
• Multi-pressure Distillation Plant
• Evaporation plant
• Ethanol Plant
• Grain Based Alcohol plants
• Effluent Recycling & zero Liquid Discharge Solution
 
2 ) PRODUCTS
i ) Fermentation Section
It has many advantages like continuity of operation, higher efficiency and ease of operation. Continuous fermentation also results into consistent performance over a long period as compared with batch fermentation. Most modern ethanol production plants adopt this continuous fermentation technology. Considering all the above advantages, we have proposed to adopt the efficient fermentation in the distillery

The fermentation process employs a special yeast culture, which can withstand variations in temperature and other shock loads. Fermentation plant consists of four fermenter tanks connected with all the accessories like plate heat exchangers for cooling, sparges, broth mixers and air blowers etc.

The yeast is a remains in the fermentation plant throughout and hence it gives a tremendous advantages in maintaining the yeast population and in combating the bacterial infection.

Saccharified slurry from Saccharification section is pumped into Fermenter and is diluted to appropriate sugar concentration by adding water. It is, then inoculated with required quantity of suitable yeast. The assimilable nitrogen are added in the medium in the form of urea and dap. Temperature in the Fermenter is maintained with the help of plate heat exchanger.

The fermented mash is recirculated continuously through PHE. Recirculation also helps in proper mixing of fermented mash. The rate of fermentation reaction gradually increases and after 50 to 55 hours, fermentation completes. After completion of reaction the fermented mash is delivered to mash holding tank. The fermented mash collected in the Clarified Wash Tank is then pumped to Mash or Primary column for distillation.
 
 Starch Fermentation Process
• Good ease of operation and easy way daily cleaning / filling required.
• Consistency in plant operation and performance is very high.
• Less operating manpower required.
• The process can also be automated with less cost and great ease.
• Easy to control & trouble shoot, as it is a continuous process.
 Culture Yeast usage
• No fresh yeast dosage required. Yeast is present in its culture form and hence saving in cost of the yeast.
• Elimination of other yeast related problems like wild yeast and contamination along with the fresh yeast.
• Yeast culturing will also ensure optimum yeast concentration in the fermentors, even when there is some bacterial growth.
 Higher Alcohol Concentration in Wash
• Less effluent volume and low cost of treatment.
• Reduced steam consumption in Distillation.
• Higher alcohol concentration ensures low bacterial activity in fermentors.

ii ) Distillation Process
     Vacuum multi-pressure Distillation
• Multi-pressure operation results in to good overall energy savings over a longer period.
• Vacuum operation (low temperature) of Mash column ensures minimum scale formation of the trays / other column internals and hence very low cleaning frequency of Mash column is required.
• Lower temperature operation causes less pyrolysis in Mash column hence we ensure good quality alcohol.
• Much better stripping (separation) of low boiling impurities takes place under vacuum conditions.
 
Simple ENA distillation scheme
• The distillation scheme consists of optimum number of distillation columns and their configurations, allowing  lower capital cost.
• The scheme of distillation is very simple and allows easy operation.
• The simple distillation scheme allows for a cost effective level of automation using DCS system.
• The overall electricity requirement is also low, as compared to other complicated multipressure distillations.
 
Effective separation of Impurities and alcohol quality
• Better quality ENA, as both low boiling and higher boiling impurities are separated effectively in dedicated columns.
• Vacuum conditions also help in separation of many impurities.
• The alcohol produced is of Neutral taste and character, with a Potassium Permanganate Test Time of around 50 to 60 minutes as BP 1993 method.
• The number of trays and tray spacing in each column are designed, for handling different quality of fermented wash.
• The same distillation scheme can be easily made flexible to produce different quality products depending on the requirement.  
 
Higher Distillation efficiencies
• The distillation trays are of Bubble Cap construction, designed using vast experience, resulting in to good tray efficiencies at varying conditions.
• The turndown of the distillation plant is as high as 40 to 50%, which allows the operation at 40 to 50% capacity, without any significant change in the efficiency and steam consumption.
• Mash column losses are quite low due to less scaling at lower temperature operation.
• The alcohol vapors, after vacuum system are scrubbed to recover maximum alcohol.
 
3 ) Evaporation Section
Evaporation is the process of vaporization of solvent from solution in order to increase the concentration of the solute. Evaporation is extensively energy intensive unit operation. 
Evaporators
• Falling Film Evaporators
• Forced Circulation Evaporators
• Thin Film Evaporators
4 ) Water & Waste Water Treatment
Water from fresh water sources like rivers, canals, lakes, springs, tube well etc. is pre-treated in a water treatment plant of a suitable configuration.
• Pre-treatment involves
• Classification.
• Filtration
• Chlorination
• Ozonation
• Softening
• Demineralization
• Revers Osmosis etc.
Depending on the quality of water required in the process a suitable combination of above processes is selected.
Water is used in steam boiler, fermentation, cooling tower, make-up water, floor washing, Cip of equipment, etc.
Major water consumer in distillery is fermentation process wherein water is used for dilution. The Spentwash received from primary column (1st column) of distillation section is taken to wastewater treatment plant for suitable reuse & recycle. Part of the spentwash generated in the process is also recycled back to the fermentation.

The VEPL System combines the following unit process for maximizing recycle & minimizing low water consumption.
• Recycle to fermentation
• Decantation, solids removal and reuse.
• Evaporation for 1 : 2.5 Product : Waste water ratio.
• Effluent treatment plant
• Biomethanation
• Zero Liquid discharge. ( ZLD) etc
 

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