Professional Documents
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MVR in Distillery
MVR in Distillery
- A Game Changer
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
Copyright © Spray Engineering Devices Limited 4
BUSINESS AREAS
Business Verticals
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
Consultancy Services
Biofuels(Sugars / Grains) / ENA / Ethanol / Malt /
Craft Spirits /Advance Biofuels
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 .
M/s Himalayan Wines Pvt Ltd. M/s Hayati Beverages Pvt Ltd.
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
Copyright © Spray Engineering Devices Limited 12
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
Copyright © Spray Engineering Devices Limited 13
Domestic Presence - Water
• 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% )
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
Conclusion:
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 / 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
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:
E- MAIL ADDRESS
sukhraj.soni@sprayengineering.com,
distillery@sprayengineering.com