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EVAPORATION & DRYING SYSTEMS
FOR ZERO EFFLUENT DISCHARGE (ZELD)
Presented By
R.P.Singh
(Food & Biotech Engineers (I) Pvt. Ltd.)
A Presentation for
All India Distillers Association
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
M/s Crest Biotech Pvt. Ltd. A 30/B1, Mohan Co-operative Ind. AreaMathura Road, New Delhi-110044IndiaEmail: [email protected]
Joint Technical collaboration with
M/s RALLI OY (Ltd.)Jokiniementie 16A00650 Helsinki,FINLAND 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
19
C.2. Five Effects falling film evaporating plant in
combination with FF and FR calandria with gas
removing system (for biomethanated spent wash)
20
C.3. Five Effects falling film evaporating plant in
combination with FF and FR calandria with
single stage finisher (for Raw spent wash)
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…
Combination Evaporator
with finisher
(with 1 stand by
calandria)
Forced recirculation
evaporator with
finisher
Extra electrical load
during CIP
2,572 kw/ 8 days
(321 Kw/day)
3387 Kw/45 days
(75 kw /day)
Extra steam
consumption during
CIP
26,190 Kg/8 days
(3,273 kg/day)
32,186 Kg/ 45 days
(715 kg/day)
CIP Chemicals
NaOH ,flakes
670 kg/8 days
(83 kg/day)
4400 Kg/45 days
(97 kg/day)
CIP Chemicals
HNO3 1%
335 kg/8 days
(42 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 Due to 20% capacity
reduce for a period of
time (2,619 kg/hr )
Due to 5% capacity
reduce for a period of
time (654 kg/hr )
Processing
Cost / lit of
spent wash
Rs. 0.53/ lit of spent
wash
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
With the above heat available water
evaporation can be achieved
Latent heat at 88 deg
C (Cal 01 boiling
temp.)
K Cal/kg 548
Total water
evaporation in 2
effects evaporator
Kg/hr 10,293
Vapor from
Analyzer
Column
(Alcohol vapor
@ 95 %
+ Water vapor @
5% )
Kg/hr 12,000-
13,000
Temp. of vapor Deg C 98-102
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
Stand Alone 3 or 4 effects
forced recirculation evaporator
to concentrate 55 % TS with
heating media as dry saturated
steamFeed rate Kg/hr 45,000- 40,000
Feed solids % 10 - 14
Concentrate
Solids
% 13 - 19
Concentrate
rate
Kg/hr 34,707- 29,707
Water
Evaporation
Kg/hr 10,293
Feed rate Kg/hr 34,707- 29,707
Feed solids % 13- 19
Concentrate
Solids
% 55.0
Concentrate
rate
Kg/hr 8,182- 10,182
Water
Evaporation
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
Cal 01
Jacket Temp.
Deg C 98-102
VS 01 temp. Deg C 88-90
VS 02 temp. Deg C 75-78
Water
Evaporation/
m2 Area
Kg/m2 7.5- 10
Heat
requirement /
kg of Water
Evaporation
Kcal/
kg of
WE
274
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)
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
ONE TIME SOULTION : UF & ZELD
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
Three Effects Falling Film Integrated Evaporator With
Single Stage Finisher For Corn Steep
Feed Rate: 10,000 Kg/Hr
M/s Sona Sati Pvt.Ltd
Bihar
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)
Thanking You