all india distillerys‟ association kodikar, vapco.pdf · · 2017-08-20fabrication works 1....

Confidential | Copyright © VAPCO Engineers Pvt. Ltd.

Building Energy Efficient Technology

VAPCO ENGINEERS PVT. LTD.

WELCOMES

ALL DELEGATES OF

ALL INDIA DISTILLERYS‟ ASSOCIATION

9th OCTOBER 2015


Content

VAPCO - INTRODUCTION

OFFERINGS & EXPERIENCE

DISTILLERY OVERVIEW

CHALLENGES & OPPORTUNITIES

VAPCO SOLUTIONS

BUSINESS MODEL

OUR REFERENCES


VAPCO in a snapshot

• Provide sustainable & greener solutions in the form of Engineering services & EPC solutions in the selected process industries.

• Suggest solutions for enhancement of operational efficiency.

• Offers Technologies & systems which are :

• more INCLUSIVE in nature.

• Provide RIGHT & SUSTAINABLE solutions & enhance growth of our CUSTOMERS

Genesis:

Explore, Develop & Design green ways of protecting our Surroundings, People and The Nature.

3


VAPCO in a snap shot

We aim to be recognized as CUSTOMER CENTRIC & FRIENDLY organization with goal of moderate growth, profitability and maintaining our sense of humour.

To be recognized as important & preferred EPC player in the Ethanol, Starches and allied industries and create VALUE for our customers & employees

VISION

VAPCO is committed to provide sustainable & environment friendly designs & EPC solutions in the field of Ethanol, Starch, Chemicals & Pharma Industries.

We view ourselves as partner with our customers, our employee, our community & environment.

4


Our Team

Promoted by Technocrats with extensive experience in the field of process industry in terms of design, engineering & operations of plants

Professional set up with focus on “ENGINEERING SOLUTIONS”

Management team with clear vision & thoughts in place

Executive team members with HANDS ON experience in selected domains

Proven Project & Construction Management & implementation team

5


Fabrication works

1. Mechanical design & fabrication

conforming to international

standards such as ASME, TEMA,

DIN, IS, IBR for equipment like

distillation columns, heat

exchangers, tanks & vessels.

2. Fabrication of pressure vessels as per

ASME for „U‟ stamping.

3. Manufacturing facility at Pune having

area of 10000 feet² with covered shed and

separate handling facilities for Stainless

steel and Carbon steel material.

6


VAPCO – Journey till Today…

2011

Establishment

2012 • First Contract for

45 KLPD

Distillation plant

2012

2014

2013

2015

2013 • First Distillation

plant commissioned

• 2 Overseas

contracts received

• Dryer orders for

Starch Industry

• 45 KLPD Grain

based distillery

order

2014 • Canada Re-distillation

plant commissioned

• First Integrated Evaporator

order

• First DDGS Dryer Order

• Commissioning of Starch,

Fiber & Gluten Dryers

2015 • Commissioning of 1st

Steam less Integrated

Evaporation

• DDGS Dryer

Commissioned

• Ethiopia Mini-Distillery

commissioned

• 170 KLPD Grain plant

under execution

• 90 KLPD up gradation &

capacity enhancement

7


Content



DISTILLERY OVERVIEW


VAPCO SOLUTIONS

BUSINESS MODEL

OUR REFERENCES


Our Industry focus

Major Sectors :

• Ethanol from various raw materials such as Molasses, Grains, Cassava, Cane Juice etc. for producing:

– Rectified Spirit

– Extra Neutral Alcohol

– Absolute Alcohol

• Starch & derivatives plant for producing various base & modified starches

• Standalone Evaporation & Drying systems for Ethanol, Starches, Chemical & Pharma Industries

• Zero Liquid discharge systems for various process industries

Offerings :

• Engineering Services:

– Basic

– Detailed

– Procurement

– Project Management

• Lump sum Turnkey packages :

– Complete plants

– Process units

– Battery limit plants

• Studies & Audits of existing plants for

– improving efficiencies & debottlenecking

9


Multi Disciplinary Engineering

Plant Engineering

Process

Mechanical

Civil/ Structural

Electrical

Instrumentation

Piping Engg.

Multi Disciplinary Customized engineering

Overall optimizati

on and RIGHT

SIZING of the

equipment

10


Present experiences…

Ethanol

Rich Experience in Molasses as

well as Grains as feed stock

From Technical audits to supply of Process

Packages to TURNKEY projects.

Domestic as well as

international experience

Stand alone package units for :

• Milling, Liquefaction & Fermentation

• Distillation

• Evaporation with drying systems

11


Present experiences…

Starch & Derivatives

Gaining Experience

through Maize as

major raw materials

From Technical audits to supply of Process

Packages to TURNKEY projects.

Domestic experience

Stand alone package

units for :

• Drying of Fiber, Germ, Gluten and starch

• Evaporation Systems

12


Present experience…

Dryers

Rich Experience in Maize & other

grains as feed stock

Products handled

Germ

Fiber

Starch

Gluten

Multiple choice of

Drying technologies

Types of Dryers

Rotary Steam Tube Bundle dryers

Flash dryers

13


Present experience…

DDGS Dryers

Supply of Rotary Steam Tube

Bundle Dryer at two Distilleries

Feed Stocks

Handled Syrup

Wet Cake

Operation at Steam Pressure

of 3.50 kg/cm2(g)

Features: Runs on conduction principle

Fixed shell & rotating tube bundle

- good material contact

- Better product

- Consumes less electricity

Properly sized and spaced baffles provides proper support to steam tubes

Provision for expansion of tube bundle prevents stress build-up and ensures longer life

14


Content



DISTILLERY OVERVIEW


VAPCO SOLUTIONS

BUSINESS MODEL

OUR REFERENCES


Overview : Distillery Plants

LEGACY CURRENT FUTURE

• Small capacities ,

10 – 20 KLPD

• High energy & Water

consumption

• No proper effluent

treatment

• Zero Recovery of By

products

• Poor quality of

Alcohol

• Polluting Industry

• High effluent

treatment cost

• Single plant up to 300

KLPD

• Reasonably low

energy consumption

• Sustainably reduced

water consumption

• Recovery of maximum

by products

• Relatively low

pollution & Damage to

environment

• Zero effluent

treatment cost for

Grain & almost

negligible for

Molasses

• Higher capacities

• Customer specific

production

• Refining & Purification

of all Co-products

• Integration with other

Industries – up stream

& Down stream

• Higher plant capacities

to fulfill future Fuel

Ethanol requirement

16


OVERVIEW : MOLASSES BASED PLANTS

PROCESS LEGACY CURRENT FUTURE

Fermentation • Continuous mode

• Low efficiencies

• Low alcohol

concentration ( 7-8%)

• No recycle of spent

wash

• Fed Batch / Batch

Operation,

• Higher efficiencies (90-

91%)

• Increased alcohol


• Spent wash recycle

• Raw material

pretreatment

• Higher Efficiencies

• Higher Alcohol

Concentration

• Higher spent wash recycle

Distillation • Atmospheric Distillation

• Higher Steam

Consumption

• Base Product Quality &

Higher TA Cut

• Multi-Pressure Distillation

• Optimized Steam

consumption

• Better Product Quality &

Low TA cut

• Further reduction of

energy by use of MVR

• Minimum TA Cut

De-Hydration • Azeotropic Distillation

• High Steam

Consumption

• Non Green Technology

• Mol. Sieve Technology

• Min. Steam consumption

• Membrane Technology

• No additional Steam

requirement

Effluent

Treatment • Zero Energy value

• Ferti-Irrigation

• Effluent: Energy and

Compost

• Reuse of process

condensate

GREEN INDUSTRY

17


OVERVIEW : GRAIN BASED PLANTS

PROCESS LEGACY CURRENT FUTURE

Liquefaction

• Multi Tank batch systems

• High pressure cooking

• Isolated Saccharification

• No recycles

• Low DS operation ( 26 – 28%)

• Two tank system

• Low pressure cooking

• Thin slop recycle

• High DS operation ( 30 -

34%)

• No cooking

• Extraction of

Proteins & Fibers

• Higher DS ( 36 – 40

%)

Fermentation

• Continuous mode,

• Low efficiencies

• Low alcohol concentration ( 9-

10%)

• Fed Batch Operation

• Higher efficiencies (90-

91%)

• Increased alcohol


• Efficiency up to 95%

• Higher Alcohol

Concentration

Distillation • Atmospheric Distillation

• More Steam Consumption

• Less purity & Higher TA Cut

• Multi-Pressure Distillation

• Optimized Steam

consumption

• Better Quality & Low TA

cut

• Further reduction of

energy by use of

MVR

• Low TA Cut

Effluent

Treatment • Zero Energy value

• Irrigation was the option

• Energy recovery

• Water recovery

• 100 % water recycle

• Use of other energy

GREEN INDUSTRY

18


Content



DISTILLERY OVERVIEW


VAPCO SOLUTIONS

BUSINESS MODEL

OUR REFERENCES


General Concerns & Problems

• Lower Recoveries

• Higher steam consumption

• Inferior product quality

• Higher Impure Spirit Cut

• Non utilization of syrup

• Evaporation of spent wash to the RIGHT SOLIDS

• Spent wash incinerator working

• Inadequate quality of DDGS

• How to approach ZERO DISCHARGE?

• Process Streams

• Non Process streams

• Steam & Power Balance

TECHNICAL:

• Higher Project Investments

• Higher Operating Costs

• Viability of expansions:

• Green

• Brown

FINANCIAL:

• Skill sets of Team

• Operational philosophy

• Manual vs Automation

OPERATIONAL

20


Specific Challenges & Opportunities

Grain Based Plants

• Further reduction in energy consumption in all unit operations

• Evaporation of thin slops without steam

• No recycle of Thin slops in the Liquefaction

• Maintaining higher solids in thick slops

• Use of 100% Syrup in Drying process

Molasses Based Plants

Effluent treatment:

• BSW Evaporation or RSW or RO Reject Evaporation

• Reduction in steam & overall energy

• Recycle of waste streams

Investment:

• Which route : EPC/EPCM/ Turn Key Contract ?

• In house Project Management or out sourced ?

21


Two different types of

Feed

Wet cake + Thick Slurry

Variation in feed specifications

• Inlet solids

• Different grains as feed to Distillery

• Stable unit operations (Decantation & Evaporation)

Large amount of mass

Higher Steam Consumption

Capability to handle Syrup

Higher product

temperature

Higher Back Mixing

Maintaining Nutritional

value of DDGS

Maintaining DDGS Color & Fragrance

Challenges : DDGS Drying


Content



DISTILLERY OVERVIEW


VAPCO SOLUTIONS

BUSINESS MODEL

OUR REFERENCES


Solutions from VAPCO……

MOLASSES MODULE:

• Forced circulation Reboilers for reduction in the spent wash quantity at the generation stage.

• Lower steam consumption models in distillation

• Integrated Evaporation Models with minimum add on energy for concentration of :

• RSW

• BSW

• RO Reject

• Maximum Evaporation through use of Alcohol vapours of distillation

24


Solutions from VAPCO……

GRAIN MODULE:

• Low energy cooking process

• Lower cooling water recirculation rates

• Elimination of Agitators in fermentation

• No Thin Slop recycle

• Maximum Evaporation through use of Alcohol vapours of distillation- Steam less Evaporation

• Maximization of syrup quantity being produced

• Systems to utilize 1:1 wet cake and syrup for Drying

• Lower energy requirement in the Drying systems

25


Differentiators…….

26

General Trend VAPCO

Distillation Plant with

Integrated Evaporation

3.2-3.4 Kg / Lit of Total

Spirit

2.7 Kg / Lit of Total

Spirit for Grain

3.2 - 3.3 Kg / Lit of Total

Spirit for BSW up to

30% w/w solids ( 7 Lit /

Lit of Alcohol)

Integrated Evaporation

3.0 – 3.25 Lit / Lit of

Alcohol

4.0 – 5.0 Lit / Lit of

Alcohol

Thin Slop Recycle 15 – 35 % Zero Recycle

DDGS Dryer Rotary Dryer Multiple Options –

Rotary Dryer

Flash Dryer

Fluidised Bed Dryer

Dryer Energy

Consumption

1.3 – 1.5 Kg/Lit of Water

Evaporation

1 – 1.3 Kg/ Lit of Water

Evaporation


Technical collaboration to offer Innovative &

sustainable drying solutions in India


Water treatment Airports Automotive

industry

Tunnels Buildings Research

• 28,000 employees and over 5.1 billion euro revenue

Security Telephony/data (Petro)chemicals Energy Marine Infra/Traffic

• Technical services provider in electrical engineering, ICT and

mechanical engineering

28


Fluid Bed Drying Systems

Belt Drying Systems

Flash Drying Systems

Air Dehumidifying Systems

De-dusting / flue gas treatment Systems

Continuous Pasteurisation / Sterilisation Systems

Delivery program Imtech Ventilex

IMTECH VENTILEX

Specialist in Drying Technology

29


Applications @ Fluid Bed Dryer

DRYING

COOLING

HEATING

CALCINING

ROASTING

STERILISING

PASTEURISING

30


More than 900 fluid bed dryers worldwide for a large scale of products

31


Accurate temperature control for high quality DDGS Excellent flowability Lower energy consumption Fire extinguisher and explosion safe Long life-time, reliable, low maintenance Plug Flow: uniform and gentle drying

32


Content



DISTILLERY OVERVIEW


VAPCO SOLUTIONS

BUSINESS MODEL

OUR REFERENCES


VAPCO – BUSINESS MODEL

Critical Sections Non Critical / Bought out Sections

- Basic & Detailed Engineering

- Equipment Fabrication

- Erection Services

- Commissioning Services

(Liquefaction, Distillation, Evaporation, Dryers)

- Basic Engineering

- Detailed Engineering

- Supervision of Erection

- Commissioning Services

( Milling, Silos, Fermentation, Storage, Utilities)

34


VAPCO – BUSINESS MODEL

ADVANTAGES

- Process configuration with solution approach rather than

HARDWARE

- Value engineering

- Optimized Project Investment

- Optimized financial cost ( Interest Cost)

- Technically sound interface between Vendor and Client

- Increase in profitability & sustainability

35


Road Map Ahead……

36


Value Proposition

• Plants based on International Standards

• Flexible approach

• Environment Friendly and sustainable Plants with:

– Better product quality

– Optimized Product Yields

– Lower utilities & Operating Costs

– Compact Size

Results in Sustainability & attractive paybacks 37


Content



DISTILLERY OVERVIEW


VAPCO SOLUTIONS

BUSINESS MODEL

OUR REFERENCES


References


References

Sr.

No.

CLIENT PLANT SCOPE STATUS

1 Pioneer Industries

Ltd, Pathankot,

Punjab, INDIA.

De-bottlenecking and revamping

of Grain based Wash to ENA

Multi-pressure Distillation Plant to

increase production capacity from

50,000 LPD to 70,000 LPD.

Engineering, Supplies,

Erection & Commissioning

supervision

Completed

2

Vindhyachal

Distilleries Pvt. Ltd.,

Bhopal, Madhya

Pradesh, INDIA

25,000 LPD Grain based

Fermentation Plant (milling,

liquefaction & fermentation

facilities).

Basic & Detail Engineering Completed

3

Gwalior Distilleries

Ltd.,

Gwalior, Madhya

Pradesh, INDIA


Fermentation Plant (expansion of

flour handling, liquefaction &

fermentation facilities).


4

Piccadily Agro

Industries Ltd.,

Karnal, Haryana,

INDIA




facilities).


5 Piccadily Sugar &

Allied Industries Ltd.,

Patran, Punjab, INDIA




facilities).


ETHANOL SYSTEMS :


Sr.

No.

CLIENT PLANT SCOPE STATUS

6 Bhutan Centennial

Distillery, Gelephu,

BHUTAN

30,000 LPD Grain based Neutral

Alcohol Distillery (Turnkey Project

including civil works)

Turnkey Completed

7

Tantia Agro Industries

Ltd.,

Kolkata, West Bengal,

INDIA

Feasibility study and Detailed Project

Report for installing a 60,000 LPD

Neutral Alcohol Plant with maize

starch plant using starch-B liquid

stream as feedstock.

Study & Report Completed

8 Army Welfare Project,

Gelephu, BHUTAN

Supply of Blending Tanks with

Agitators.


Erection &

Commissioning

supervision

Completed

9 Pioneer Industries Ltd.,

Pathankot, Punjab, INDIA

Supply of Fusel Oil Column with

condensers, cooler, reboiler, feed

tank, pumps, instrumentation and

accessories.

Engineering,

Supplies,Erection &

Commissioning

supervision

Completed

10 Pioneer Industries Ltd.,



Alcohol Plant


Erection &

Commissioning

supervision

Completed

References


Sr. No. CLIENT PLANT SCOPE STATUS

11

North West Bio-energy

Ltd.,

CANADA

70,000 LPD RS TO ENA Distillation

Plant (MPR)


Erection &

Commissioning

supervision

Commissioned

12

Vindhyachal Distilleries

Pvt. Ltd.,

Bhopal, Madhya

Pradesh, INDIA

40,000 LPD Wash to ENA Distillation

Plant with Integrated Evaporation


Erection &

Commissioning

supervision

Completed

13 SCI India Ltd.,

Bhagalpur, India


Alcohol Plant: Engineering + Turnkey

supply of wash to ENA distillation and

Evaporation


Erection &

Commissioning

supervision

Completed

14 Gaia Association, Addis

Ababa,Ethiopia

Molasses based 1 KL RS plant on

Turnkey basis with Utilities system


Erection &

Commissioning

supervision

Under

Commissioning

16 Pioneer Industries,


Modification of Wash to ENA MPR

plant of 75,000 LPD Grain based

Distillation plant


Erection &

Commissioning

supervision

Under Erection

17 Bihar Distilleries &

Bottlers private limited,

Bihar, INDIA

Modification of Wash to ENA MPR

plant of 170,000 LPD Grain based

Distillation plant


Erection &

Commissioning

supervision

Under

Manufacturing

References





Bihar, INDIA

Integrated Evaporation Plant for Wash

to ENA MPR plant of 170,000 LPD

Grain based Distillation plant


Erection &

Commissioning

supervision

Under

Manufacturing



Bihar, INDIA

Liquefaction system for 170,000 LPD

Grain based Distillation plant


Erection &

Commissioning

supervision

Under

Manufacturing

20 Haryana Liquors Private

Limited, Karnal ,

Haryana, NDIA

Modification of existing Wash to ENA

MPR and Integrated Evaporation plant

along with capacity enhancement


Erection &

Commissioning

supervision

Under

Engineering

21 Confidential BSW Evaporation


Erection &

Commissioning

supervision

Under signing

References


References for Dryer


DRYING SYSTEMS


1 Millennium Starch India

Pvt. Ltd.,

Maharashtra, INDIA

Fiber Drying System for 160 TPD

Maize Starch Plant.


Erection &

Commissioning

supervision

Completed

2 Paramesu Biotech Pvt.

Ltd.,

Andhra Pradesh, INDIA

Native Starch Drying System for 160

TPD Maize Starch Plant.


Erection &

Commissioning

supervision

Completed

3 Paramesu Biotech Ltd.,


Gluten Drying System for 160 TPD

Maize Starch Plant.


Erection &

Commissioning

supervision

Completed

4 Paramesu Biotech Ltd.,


Starch (Modified) Drying System for

160 TPD Maize Starch Plant.


Erection &

Commissioning

supervision

Completed

5 Kasyap Sweetners Ltd.,

Madhya Pradesh, INDIA

Germ Drying System for 200 TPD

Maize Starch Plant.


Erection &

Commissioning

supervision

Completed

References





Fiber Drying System for 200 TPD

Maize Starch Plant.


Erection &

Commissioning

supervision

Completed



Gluten Drying System for 200 TPD

Maize Starch Plant.


Erection &

Commissioning

supervision

Completed

8 SCI India Ltd.,

Bihar, INDIA

DDGS Drying System for 45,000 LPD

Grain based Distillery Plant


Erection &

Commissioning

supervision

Under

execution

9 Millennium Starch India

Pvt. Ltd.,

Maharashtra, INDIA

Starch (Modified) Drying System for

160 TPD Maize Starch Plant.


Erection &

Commissioning

supervision

Under

execution

10

Vindhyachal Distilleries

Pvt. Ltd.,

Bhopal, Madhya

Pradesh, INDIA

DDGS Drying System for 40,000 LPD

Grain based Distillery Plant


Erection &

Commissioning

supervision

Under

Commissioning

References


MISCELLANEOUS SYSTEMS


1

Swastik Tungsten Pvt.

Ltd.

Mumbai, INDIA

1,500 Ammonium Para-Tungstate

Plant


Erection &

Commissioning

supervision

Completed

2 Galaxy Surfactants

Limited, Mumbai, INDIA Paddle Dryer System


Erection &

Commissioning

supervision

Under

Execution



Bihar, INDIA

Supply of Cyclone systems for Rotary

Dryers


Erection &

Commissioning

supervision

Under

Manufacturing

4 Chandigarh Distillers &


Punjab, INDIA

Supply of Cyclone systems for Rotary

Dryers


Erection &

Commissioning

supervision

Under

Manufacturing

References


References https://www.youtube.com/watch?

v=dAqJUSMjcXw https://www.youtube.com/watch?

v=hb_YzppOrp4

References

https://www.youtube.com/watch?v=dAqJUSMjcXw



https://www.youtube.com/watch?v=hb_YzppOrp4




The contents of this document are the sole and exclusive property of VAPCO Engineers Private Limited.. They may not be disclosed to any third party, copied or

reproduced in any form or used for any purpose, other than that for which they were provided, without the permission of VAPCO Engineers Private Limited.

Copyright © 2015

VAPCO Engineers Private Limited

THANK YOU

all india distillerys‟ association kodikar, vapco.pdf · · 2017-08-20fabrication works 1....

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