Low Temperature evaporator with MVR in Distillery Operations

- A Game Changer

SPRAY ENGINEERING DEVICES LTD.

…Energy Efficient Engineering
“Dedicated for
Sustainable Environment
Development to Unlock
Perpetual Food and
Energy Resources”
 CORPORATE PROFILE

Year of Inception • 1992

Management • Vivek Verma (Managing Director)

• Thermal Energy Recycling Solutions for Sugar Refinery, Sugar,

Type of Industry
Distillery, Biofuel, Water and Jaggery Sectors
• Manufacturers/Design/Process/Engineering/Consultancy/R&D
Nature of Business
for Water, Sugar, Jaggery & Bio-Fuel Sector

R & D Recognition • Department of Scientific & Industrial Research (DSIR), GOI

Total Employees • 752 Nos.

Annual Sales • ₹ 215 Crore in FY 2021-22

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 THE SED JOURNEY ….

Vertical Spray Low Temperature

SCP®-Poland, Indonesia, Evaporator (LTE®)
Continuous FFE-Pakistan, Thailand Al-Khaleej Sugar
Nozzle Condensers & Condensate Flash Recovery System
Pan (SCP®) Sudan, Acquire-JMSIL Refinery, Dubai LTE® in Water (Dyeing,
Automation and Sugar Melter Paper, Textile, Pharma)

1992 1993-99 2000-01 2002-05 2006-08 2009 -13 2014-15 2015-16 2017 2018 2020-21

Spray Pond with Cooling & Turnkey Boiling House Sugar Plants
Direct Contact Tubular Falling Complete Turnkey Mornisa Jaggery LTE® in RO, Food,
Automation Condensing (Lowest Steam Consumption=26%OC) Oil, Spentwash,
Heater & Plant
System Film Evaporator Dhanalakshmi, Hemarus, GMR, NSL, Leachate
Molasses Gokul Mauli Sugar
Ugar, Venkateshkrup, DCM, Shiraguppi
Conditioners
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 BUSINESS AREAS

Business Verticals

Sugar Water Biofuel Jaggery Advisory Services

Technology & Products 100% Water Recovery Biomass to Ethanol/ Boiler-less MVR based Innovative Technological
for Lowest Steam with ZLD & ZLI, Zero Consultancy Services Jaggery plant with Solution and advices for
Demand in Sugar Plant Emission of CO, CO2 100% bagasse saving energy efficiency

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 BIOFUEL VERTICAL – BIOFUEL & GREEN CHEMICALS FROM WASTE

Consultancy Services
Biofuels(Sugars / Grains) / ENA / Ethanol / Malt /
Craft Spirits /Advance Biofuels

Project Management Services

Techno-
Economical
Project
Performance Feasibility
Optimization / BEDP / FEED Studies
Operation &
Improvement Documents for
Maintenance
of Existing Projects
Distillery
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 BIOFUEL SEGMENT – BIOFUEL & GREEN CHEMICALS FROM WASTE

Our Mission :
• To provide cost-effective biofuel
technology by improvement of existing
Process Blocks with Lanzatech .
• Optimisation of CAPEX & OPEX (less
than Rs 50/ Litre Ethanol)
• Development of value-added products
from by-products; Agro waste etc.
• Deployment of SEDL Patented LTE
Technology in production of Ethanol &
wastewater process treatment .

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 BIOFUEL VERTICAL – BIOFUEL & GREEN CHEMICALS FROM WASTE

Our Partners & Customers

M/s Himalayan Wines Pvt Ltd. M/s Hayati Beverages Pvt Ltd.

M/s Aadhar Green Industries LLP M/s Hempco Ventures

M/s Fylfot Geoworks Pvt Ltd. …………..

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 OFFICES

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Copyright © Spray Engineering Devices Limited 10
 Global Presence

MITR Phol Group, Thailand

PT DUS Sugar Refinery, Indonesia

Al-Khaleej Sugar Co., Dubai

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 SUGAR SEGMENT GLOBALLY – SOME REFERENCES (150+ INSTALLATIONS)

AL-KHALEEJ SUGAR CO., DUBAI PFEIFER & LANGEN POLSKA, PT D.U.S. SUGAR REFINERY, WHITE NILE SUGAR COMPANY,
POLAND INDONESIA SUDAN

SUGAR ALLIED INDUSTRIES LTD., KIBOS SUGAR & ALLIED INDUSTRIES, GOLDEN SUGAR REFINERY,
UGANDA KENYA NIGERIA
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 SUGAR SEGMENT DOMESTIC – SOME REFERENCES (600+ INSTALLATIONS)
DEWAN SUGAR LTD., U.P. VISHWARAJ SUGAR INDUS., KARNATAKA A. B. SUGARS LTD., PUNJAB NSL SUGARS LTD., KARNATAKA

HEMARUS TECHNOLOGIES, DHANALAKSHMI SUGARS., JAY MAHESH SUGAR INDUSTRIES, VENKATESHKRUPA SUGAR MILLS LTD.,
KARNATAKA TAMIL NADU MAHARASHTRA MAHARASHTRA
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 Domestic Presence - Water

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 Domestic Presence – Jaggery Plant ( without Boiler )

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 Copyright @ Spray Engineering Devices Limited
Copyright © Spray Engineering Devices Limited
Low Temperature Evaporator
All-in-one Combination of Heat Exchanger + Vacuum +
Mechanical Vapour Compression in a small footprint
design delivers the higher evaporation capacity as
compared to other Conventional design Evaporators.

Horizontal Orientation Vertical Orientation

Current Evaporation Process Flow
LTE Evaporation Flow
Major Takeaways of LTE Technology – USP’s
Technology Development is an
Outcome of finding
Sustainable Solution to the
Problems……………..
Problem Statement :
Present Distillery Operation : Ethanol Production IMPACT

• Net Steam Consumption Molasses Based System : 3.6 Kg / liter of Ethanol OPEX
Stand Alone Evaporator: 1.00 -1.5 Kg / Liter of Ethanol ( 28-42% )

• Raw Water consumption: 6 KL/KL of ethanol Ground

Raw Water Consumption: 1.5 -2.5 KL/KL of Ethanol ( 25-42% ) Water
( Cooling Tower dedicated for MEE) Extraction

• Excessive Chocking issues with standalone MEE tubes

Spent wash + RO / CPU / Cooling tower rejects being treated in MEE. Operations
LTE Application in Distillery / Sugar Industry: Ethanol Production

A. Concentration of Molasses Based spent wash & Bio-methanated & Grain Based spent
wash.(Concentration from 6% / 13 % to 35 % / 60 % )
B. Cane juice-based Ethanol system:
• Raw cane juice to syrup from ( concentration from 12 bx. to 55-65 bx.),
• Concentration of Spent wash ( cane juice syrup based) from 4-5 bx. till 60bx.
C. Cooling Tower Blow down, DM water reject, CPU reject water recovery
systems..(Waste water with more than 1 % TDS concentrated to 25-28 %
Solids to have >90 % water recycled)
LTE Applications in Distillery/ Sugar Industry : Ethanol Production Case Study: A
Concentration of Molasses Based spent wash in a standalone MEE vs LTE system.
Ethanol Plant Capacity: 150 KLPD
Raw Spent wash: 1250 TPD ( 60-65 0C) TS : Inlet: 12 % //Outlet: 60 %
Standalone MEE MVR based LTE
Parameters
(conventional) System
Steam Requirement ( T / hr) 8.50 Steam Requirement:
Steam Cost(Rs / T feed) …….A 245 Nil

Power Requirement (KWH/T of feed ) 12 25

Power Cost ( Rs/ T of feed)……B 90 188
Total Utility Cost( Rs/ T of feed)(A+B) 335 188
Steam Cost: Rs 1500/Ton Power reqd. : MEE (FC + Cooling No cooling Tower/ water
Power Cost: Rs 7.50/KWH Tower Water+ recirculation pumps. recirculation pump is req
i.e. 625 KWH)
LTE Applications in Distillery/ Sugar Industry : Ethanol Production

Case Study: A Concentration of Molasses Based spent wash

Ethanol Plant Capacity: 150 KLPD
Raw Spent wash: 1250 TPD ( 60-65 0C) TS : Inlet: 12 % //Outlet: 60 %
Standalone MEE MVR based LTE System
Parameters
(conventional)
Rs 147/ T of feed
Total Utility Cost Savings Rs 184 Lakhs / day
Rs 606 Lakhs / year
Cooling Water recirculation Rate in MEE. 1050 m3/ hr
Make up water Reqd. 265 m3/day No Cooling Water Reqd.
Raw Water required KL/KL of Ethanol 1.78 KL/KL of Ethanol
Manpower & Maintenance cost assumed same Cooling Tower makeup water reqd.: 1 year= 300 days working
1.05% avg.
LTE Applications in Distillery/ Sugar Industry : Ethanol Production

Molasses Based spent wash application

Conclusion:

Steam Saving : 1.36 Kg / Liter of Ethanol ( 8.5 T / hr)

Raw water Saving ( Ground : 1.77 KL / KL of Ethanol ( 265 m3/ day)

Water extraction)

OPEX Savings : Rs 618 lakh/annum.

LTE Applications in Distillery/ Sugar Industry : Ethanol Production

Case Study: B Cane juice syrup to Ethanol

• Raw cane juice to syrup ( concentration from 12 bx. to 55-65 bx.),

• Concentration of Spent wash ( cane juice syrup based) from 4-5 bx. till 60 bx.
DURING CANE CRUSHING SEASON

MVR Cane Juice Spent Wash Conc. Spent

Cane Juice BASED MVR BASED Wash To
Syrup DISTILLATION / (4 Bx)
EVAPORA FERMENTATION EVAPORATOR Incineration
Clear Juice TOR (LTE- ETHANOL SW 60 Bx
Boiler
65 Bx (LTE-2)
(12 - 13 Bx) Generation -
1) 4KL / KL of
Production Condensate
Spent Wash Recycling
To CPU /
Reuse
LTE Applications in Distillery/ Sugar Industry : Ethanol Production Case Study: B

Cane juice syrup to Ethanol

• Raw cane juice to syrup from ( concentration from 12 bx. to 55-65 bx.),
• Concentration of Spent wash ( cane juice syrup based) from 4-5 bx. till 60 bx.
DURING OFF SEASON

Molasses Conc. Spent

MVR BASED Wash To
Based
EVAPORATOR Incineration
Spent Wash 60 Bx
(LTE1 & LTE-2) Boiler
(12 - 14 Bx)

Condensate

To CPU / Reuse

System Design as per requirements for Diverting Cane juice for Ethanol Production
Kibos Sugar, Kenya
Application- Molasses Based Spent wash from Distillery Power Consumption: 16 kW-h/ Ton of feed
Plant Capacity – 300 m³/ day
Spent wash
TDS: 20-25%
COD: 2,50,000 ppm

Condensate
TDS: 250 ppm
COD: 3000 ppm

TDS: 65-70%
Shree Durga Khandsari Sugar Mills, Madhya Pradesh
Application: Concentration of clear juice to Syrup/ Power Consumption: 18-20 kW/Ton of feed
raw spent wash to SLOP Plant under optimization.
Plant Capacity : 600 m³/ day Spent wash
TS: 12 Brix

Condensate
pH: 3.35
TDS: 250 ppm

SLOP
TS: 50-60 Brix
LTE Applications in Distillery/ Sugar Industry : Ethanol Production Case Study: C
Cooling Tower Blow down, DM water reject, CPU reject water recovery systems.C.

Conventional System :

Raw Spent Wash Condensate C.P.U.

Conventional Multiple
Fermentor Washings
Effect Evaporator
CPU/RO Rejects/ Concentrated Spent Wash (SLOP)
Cooling Tower Blowdowns for Boiler as fuel

Raw Spent wash / Fermentor washings + White effluent ( Low TDS ) being mixed &
fed to MEE for Solid concentration .
Salts in White effluent causes excessive chocking ( above 35 % concentration) in MEE.
LTE Applications in Distillery/ Sugar Industry : Ethanol Production Case Study: C
Cooling Tower Blow down, DM water reject, CPU reject water recovery systems.C.
LTE Based System :
MVR Based Low
Raw Spent Wash Condensate C.P.U.
Temperature
Fermentor Washings
Evaporator System Concentrated Spent Wash (SLOP)
for Boiler as fuel

Condensate
MVR Based Low
CPU/RO Rejects/ (TDS < 250 ppm) Water Recovery 95-97 %
Temperature
Cooling Tower Blowdowns Evaporator System Reject
(TDS: 1-2 %) (TDS: 30-35 %)
(can be mixed with SLOP
Separate LTE system for Raw Spent wash + Fermentor washings ( colored effluent) & White effluent.

Water recovery in case of White effluent LTE system is 95-97 % & water can be used in the process.
Reject with High TDS can be mixed with SLOP for boiler feed.
Load on CPU for Process Condensate decreases.
 Naini Papers Ltd., Kashipur
Application - Wastewater of RO reject of Paper Industry
Product Capacity – 500 KLD Power Consumption: <15 kW-h/m³

Wastewater recovery: 95%

TDS: 1.0 %
COD: 2,500 ppm
pH: 6

Condensate
TDS: < 50 ppm
COD: < 200 ppm
pH: 10

TDS: 30- 35 %
 Eco Tech Paper Industry
Application – Wastewater of RO reject of Paper Industry Power Consumption: 12-13 kW-h/m³
Product Capacity – 500 KLD
Wastewater recovery: 95%
TDS: 3.0 %
pH:6

Condensate
TDS: 247 ppm
pH:4

TDS: 72.0 %
LTE Applications in Distillery/ Sugar Industry : Ethanol Production
Green House Gas Emission Reduction
GH Gas emission ( Kg CO2/m3 of feed) Reduction (Kg Reduction
Project Details
Conventional MEE MVR based LTE CO2 / m3 of feed) (%)
Kibos Sugars, Kenya
39.22 12.80 26.42 67.36
Molasses RSW conc.; 300 KLD
Shri Durga Sugar Mill, MP.
38.83 16.00 22.83 58.80
Molasses RSW conc,; 600 KLD
Niani Papers, Uttarakhand
RO Reject water recovery: 56.46 12.00 44.46 78.75
500 KLD
ECOTECH Papers, Assam
RO Reject Water recovery: 56.46 10.40 46.06 81.58
500 KLD
Default Data Unit
GHG emission Factor (Thermal Energy)* 275 Kg CO2/ MT Considering eficiency of a boiler having
s tea m
generic efficiency
* Given data based on Default nos. Actual
GHG emission Factor (Electricity Power)* 0.8 Kg CO2/ Considering Grid Power emission factor may vary with the site conditions.
KWH
Low-Temperature evaporator with MVR in Distillery Operations:
Conclusion:

• For Spent wash concentration application for Ethanol production

Steam consumption ( 37.77 % ) OPEX

Ground Water Extraction ( 29.66 % ) Ground

Water
GH Gas Emissions ( 58-82 % ) Extraction

• Excessive Chocking issues Resolved

Operations
• Load on CPU for process ( Reduced )
Condensate & Treatment cost
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Environment Development Punjab - 160055

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