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: [email protected], website: www.foodbiotech.co.in
Joint Technical collaboration with Joint Technical collaboration with
M/s RALLI OY (Ltd.) M/s Crest Biotech Pvt. Ltd.
Jokiniementie 16A A 30/B1, Mohan Co-operative Ind. Area
00650 Helsinki, Mathura Road, New Delhi-110044
FINLAND India
Email:
[email protected] Email:
[email protected] 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 Forced recirculation
Evaporator with evaporator with
finisher finisher
(with 1 stand by
calandria)
Feed rate 67,000 Kg/hr 67,000 Kg/hr
Feed solids 13% 13%
Concentrate 60% 60%
solids
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 Forced recirculation
Evaporator with evaporator with
finisher finisher
(with 1 stand by
calandria)
Steam 13,095 kg/hr 13,095 kg/hr
consumption
Average use 643 kw/hr (With 846 kw/hr
Electrical load high wetting rate)
CIP requirement After 8 days After 45 days
Effluent 167,500 Lit /8 354,000 lit/45 days
generation during days (20,937 (7866 lit/day)
CIP lit/day)
C.4. Comparison Continue…
Combination Evaporator Forced recirculation
with finisher evaporator with
(with 1 stand by finisher
calandria)
Extra electrical load 2,572 kw/ 8 days 3387 Kw/45 days
during CIP (321 Kw/day) (75 kw /day)
Extra steam 26,190 Kg/8 days 32,186 Kg/ 45 days
consumption during (3,273 kg/day) (715 kg/day)
CIP
CIP Chemicals 670 kg/8 days 4400 Kg/45 days
NaOH ,flakes (83 kg/day) (97 kg/day)
CIP Chemicals 335 kg/8 days 2,200 Kg/ 45 days
HNO3 1% (42 kg/day) (48 kg/day)
C.4. Comparison Continue…
Combination Evaporator Forced recirculation
with finisher evaporator with
(with 1 stand by finisher
calandria)
Power loss Due to 20% capacity Due to 5% capacity
reduce for a period of reduce for a period of
time (128 kw/hr ) time (42 kw/hr )
Steam loss Due to 20% capacity Due to 5% capacity
reduce for a period of reduce for a period of
time (2,619 kg/hr ) time (654 kg/hr )
Processing Rs. 0.53/ lit of spent Rs. 0.51 / lit of spent
Cost / lit of wash wash
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
Vapor from Kg/hr 12,000- evaporation can be achieved
Analyzer 13,000
Column
(Alcohol vapor Latent heat at 88 deg K Cal/kg 548
@ 95 % C (Cal 01 boiling
+ Water vapor @ temp.)
5% )
Total water Kg/hr 10,293
Temp. of vapor Deg C 98-102 evaporation in 2
effects evaporator
Latent heat of Kcal/kg 217
vapor
Heat available Kcal/ 28,20,350
hr
E.5. Typical Example of Mass balance for 100 KL distillery plant
Integrated Double effects falling Stand Alone 3 or 4 effects
film evaporator with heating forced recirculation evaporator
media Vapor from Rectifier to concentrate 55 % TS with
column heating media as dry saturated
steam
Feed rate Kg/hr 45,000- 40,000
Feed solids % 10 - 14
Feed rate Kg/hr 34,707- 29,707
Concentrate % 13 - 19
Feed solids % 13- 19
Solids
Concentrate Kg/hr 34,707- 29,707
rate Concentrate % 55.0
Solids
Water Kg/hr 10,293
Evaporation Concentrate Kg/hr 8,182- 10,182
rate
Water Kg/hr 26,525- 19,525
Evaporation
E.6. U Value/ Temp. Profile/ Area for Integrated Evaporator
(Double effects)
U Value Kcal/hr/
m2 Water Kg/m2 7.5- 10
deg C Evaporation/
850-1,050
m2 Area
Cal 01 Deg C 98-102
Jacket Temp.
Heat Kcal/ 274
requirement / kg of
VS 01 temp. Deg C 88-90 kg of Water WE
Evaporation
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 Double effects evaporator, (Water evap: 500
Development Organization, Kg/hr)
Austria.
M/s Oudh Sugar Mills Ltd. Five effects evaporating plant followed with
(Distillery Division) Single Stage Finisher (W.E: 35,690 kg/hr)
Hargaon, Sitapur, (U.P.)
M/s UFLEX Ltd. Five effects evaporating plant followed with
Sector-4, Noida Single Stage Finisher (W.E: 40,000 kg/hr)
List of our Valuable Customer
M/s Gujrat Ambuja Exports Lt. ThreeEffects Forced Recirculation
Gujrat 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. Three Effects Falling Film Integrated Evaporator With
Gujrat Single Stage Finisher For Corn Steep Liquor
Feed Rate: 20,000 Kg/Hr
M/s Gujrat Ambuja Exports Lt. Three Effects Falling Film Integrated Evaporator With
Gujrat Single Stage Finisher For Corn Steep
Feed Rate: 10,000 Kg/Hr
M/s Sona Sati Pvt.Ltd Five Effects Forced Recirculation Evaporating
Bihar Plant With Single Stage Finisher, W.E
Capacity: 21,000 kg/hr
List of our Valuable Customer
M/s Bajaj Hindustan Ltd. Double Effect falling film evaporating plant, WE
Palia U.P Cap: 150,000 kg/hr
M/s Bajaj Hindustan Ltd. Double Effect falling film evaporating plant, WE
Gola U.P Cap:150,000 kg/hr
M/s Bajaj Hindustan Ltd. Five effects evaporating plant in combination
Radaulli 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 Three Effects Evaporating Plant In
Pvt.Ltd. Chandigarh Combination With
Falling Film And Forced Recirculation
Calandria (W.E: 2,700 Kg/Hr)
M/s Parabolic Drug Three effects evaporating plant in
Chandigarh 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 Five Effects Forced Recirculation Evaporating
Tamilnadu Plant With Single Stage Finisher, W.E
Capacity: 47,620 kg/hr
M/s Kothari Fermentation & Five effects evaporating plant followed with
Biochem Ltd. Single Stage Finisher (W.E: 14,000 kg/hr)
Sikandrabad, Bulandshahr
M/S Simbhaoli Sugar Mills Ltd., Five Effects Forced Recirculation Evaporating
New Delhi Plant With Single Stage Finisher, W.E
Capacity: 25,300 kg/hr
List of our Valuable Customer
M/s Sentini Bioproducts Pvt. Ltd. Five Effects Forced Recirculation Evaporating
Hyderabad Plant With Single Stage Finisher, W.E Capacity:
27,734 kg/hr
M/s Gulshan Polyols Ltd Five effects falling film evaporator with Single
Delhi stage forced recirculation finisher for RO reject
water, W.E:5,893 lit/hr
M/s Seksaria Biswan sugar Four Effects Evaporating Plant In Combination
factory With Falling Film And Forced Recirculation
Ltd. P.O.:Biswan Calandria (W.E: 16,000 Kg/Hr)
List of our Valuable Customer
M/s Mankapur Chini Mills ( A unit Five Effects Forced Recirculation Evaporating
of BCML) Mankapur 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
