EthaMem-G1

TURN-KEY DISTILLERY PLANT

ENHANCEMENT WITH HIGH EFFICIENCY AND LOW OPEX
ETHAMEM TECHONOLOGY
 Highlights of Presentation

 Introduction of Chemdist Group

 Chemdist Products, Services and capabilities
 Development of EthaMem-G1 Technology
 Process Units Introduction of EthaMem-G1 Technology
 Ethanol Quality Parameters
 Utility Norms and Quality
 Ethanol Processing Cost comparison
 Benefits of CD-Wet Unit
 R&D and Pilot unit facilities
 Snapshots of ongoing EthaMem-G1 Project
Chemdist Group

Chemdist is a group of companies leading in Process Technology, Process

Engineering, Process Equipment and Process Plant. We Specialized in Process
Application technology, Product and services in field of Distillation, Evaporation,
Mixing and Reaction, Environmental, Effluent Treatment and Membrane
Technologies.
 Catered our products and services to customers from various domain like Chemical,
Pharma, food, & Bio-tech, Ethanol distillery, Aromatic, Bio-Diesel, Petrochemical,
Upstream & Downstream of Oil & gas industries all over world
 More than 200 Projects completed
 More than 500 Happy Customers
 More than 25 Application developed
Chemdist: Products
In-house Manufacturing
 Distillation Column  Falling Film Evaporator  Pervaporation

 Mass Transfer Internals  Forced Circulation  Membrane Distillation

 Heat Exchangers Evaporator  Heat Pump

 ATFE  Ultra/ Nano Filtration
 Reboiler
 Pressure Vessel  WFE  Gas Separation

 Reactor  Strippers  CD-WET

 Scrubbers  CD-Oxy
 Agitator
 Static Mixers  Fermenters
Chemdist: Services
 Application Oriented & Conceptual
Studies
 Feasibility Study
 Project Management
 Project Engineering
 Process Safety Management
 Plant Commissioning assistance
 Pilot and Lab Studies
 Process Design with Simulations &
Hydraulics
 Capacity & Debottlenecking
Studies, Process Optimization
 Basic & Detail Engineering Services
 PFD’s & PID’s
 Design, Manufacturing & Supply of
Turn-Key System
Process Design and Mechanical
Design Engineering
 Software's Available to deliver efficient process solutions
 ASPEN
 PRO II
 HTRI
 ERP
 PV Lite
 CADEM
 PDMS
 TEKLA
 SAP
EthaMem-G1
 With a goal to make Future fuel consume less fuel in its production; CDMS’s
team worked extensively and with knowledge and expertise gained over time,
we redesigned traditional production process with our ingenious membrane,
CD-WET, Turbulators based technology.

 We have precisely identified the shortfall of each unit and systematically

enhanced conventional low performing process units with highly efficient
membrane technology

 Provided high efficient technology with marginally low operating cost compare
to Conventional technologies
 Process Flow Diagram

 Conventional Distillery

 EthaMem-G1
EthaMem-G1 Technology

 Process Units
 Feed water treatment : Use of Ultra-filtration membrane for raw water treatment to reduce Low TSS
<50PPM, organic components and Bacteria
 Fermentation Unit : Use of Oxygen enrichment unit to increases fermentation rate.
 Distillation Unit : Use of high efficiency contact material
Use of High efficiency Trays with inhouse design and Manufacturing facility
 Dehydration Unit : Compare to Molecular sieve dehydration unit Use of PV membrane to increase
ethanol concentration from 95% to 99.5% with low steam Consumption
 Spent-wash treatment : Compare to high OPEX MEE system use of Advanced MD system reduces Steam
Consumption by 70%
 Turbulators : Heat exchanger inserts enhances heat transfer efficiency by 20%
 Water treatment : Use of CD-WET to enhance quality of water and reduces scaling
issue and chemical consumption
Used in boiler Feed water and cooling tower circulation water
100 KLPD ETHANOL DISTILLERY
 Ethanol Quality
Physical Properties of Absolute Alcohol Specification of Rectified Spirit
Sr No Parameter Details Sr No Parameter Details
1 Ethanol content (Minimum), % v/v at 15.60C 99.5% 1 Ethanol content (Minimum), % v/v at 15.60C 96%
2 Boiling Point (0C) 78.4 2 Acidity as acetic acid, mg/100 ml (Max.) 2
3 Flash Point (0C) 21 3 Esters as ethyl acetate, mg/100 ml (max.) 10
4 Viscosity at 200C 1.22 4 Aldehydes as acetaldehyde, mg/100 ml. (Max.) 5
5 Vapor pressure at 200C (mmHg) 44.8 5 Residue on evaporation, mg/100 ml. (Max.) 2
6 Surface Tension at 200C (dynes/cm) 22.3 6 Methanol, mg/100 ml. (Max.) 5
7 Specific Heat at 200C 0.58 7 Butanol – 1 Nil
8 Refractive Index 1.36 8 Butanol – 2 Nil
9 Ignition Temperature in air 0C 371.43 9 Isobutanol - mg/100 ml. (Max.) 5
10 Heat of Vaporization (Cal/gm) 284.3 10 Isopentanol - mg/100 ml. (Max.) 1
11 Specific Gravity 0.7908 11 N-Propanol & Isopropanol, mg/100 ml. (Max.) 10
12 Copper as Cu, mg/100 ml. (Max.) 0.3
13 Lead as Pb, mg/100 ml. (Max.) 0.05
14 Furfural Nil
15 KMNO4 reaction, time, minutes (Min.) 30
Utility Norms
Process water specifications Cooling Tower water specifications

Sr No Parameter UOM Details Sr No Parameter UOM Details

1 Hardness ppm < 500
1 Appearance App Clear colourless
2 pH pH 6.5 – 7.5
2 Chloride (Cl-) (Expressed as NaCl) ppm < 25
3 TDS ppm <800
3 pH pH 7-8
4 TSS ppm <30
4 Conductivity micro s < 40 5 MO Alkalinity as CaCO3 ppm <250
5 Coliform Bacteria Nos/ml Nil 6 Turbidity NTU <30
6 E. Coli Nos/ml Nil 7 Sodium ppm <50
8 Potassium ppm <25
7 H2S ppm Nil
9 Chloride ppm <75
8 Residual Free Chlorine ppm <1
9 Silica (SiO2) ppm <30
10 Turbidity NTU <1
Utilities Required
11 TDS ppm <250
1 Steam 148 0C 3.5 bar g
12 TSS ppm <1 2 Cooling Water 32 0C 4 bar g
13 Total Germs Nos/ml <60 CFU 3 Compressed Air 40 0C dew point 6 bar g
14 Total Hardness (as CaCO3) ppm <150 4 Electricity 50 Hz 415 V/ 4 wire /3 phase
Feedstock Cost and Ethanol Yield

Feedstock Cost/MT (INR) Ethanol/MT Feedstock Ex-mill Ethanol Price

(liter) (INR/Liter)
Sugarcane Juice/ Sugar/ 2,850 70 liter/ton of 62.65
Sugar syrup sugarcane
B Molasses 13,500 300 57.61
C Molasses 7,123 225 45.69
Damaged Food Grains 16,000 400 51.55
Rice available with FCI 20,000 450 56.87
Maize 15,000 380 54.55
GST is levied on ethanol :
In the range of Rs. 2.28/liter to Rs. 3.13 per liter of ethanol based on an ex-mill price in the range of Rs. 45.69/liter to Rs. 62.65/liter

Source: NITI Aayog: Roadmap for Ethanol Blending in India 2020-25

Ethanol Processing Cost

Conventional EthaMem-G1
Steam Requirement 5.04 3.12
(kg/Liter)
Cost (INR/Liter) 1.18 0.74
Electricity Requirement 0.75 0.61
(kW/Liter)
Cost (INR/Liter) 6.75 5.49
Cooling Tower Water Cost (INR/Liter) 0.62 0.03
Treatment

Basis:
Coal: 1600 INR/Ton
Steam: 6.8 kg/kg of coal
Electricity: 9 INR/kW
Benefits of CD-WET

 No chemical use 100% natural ore

 No power source to be required for the operation except water flow
 No operating cost.
 No maintenance to be required including the ceramic beads.
 Multiple effects including removal of scale and slime, lowering surface tension
and hardness, antioxidant effect and antimicrobial effect

For 4000TR Cooling Tower* With CD-WET Without CD-WET

Chemical Cost INR/Year 8,12,000 1,89,00,000 (1.89 Cr)

Blow-down Water cost INR/Year 0 14,40,000
*For 100 KLPD Ethanol Production
R& D Lab Facilities for Membrane
Systems
 At Chemdist, we believe in delivering the solutions per process
requirement to essentially reduce CAPEX and OPEX.
 We have lab facilities where initial trials are conducted for every
client requirement to evaluate the feasibility of process and product
fit for application
 We have high precision instruments for
 TDS/ Conductivity measurement
 Moisture content
 pH

Membrane Distillation – Lab Setup Pervaporation – Lab Setup

Pilot Facilities for Membrane
systems
 Pilot trials gives backup of process guarantees for commercial scale
 We also have 1KLD capacity Pilot facilities for
 Pervaporation
 Membrane Distillation
 Ultra-Filtration

Pervaporation & Membrane Distillation – Pilot Plant

Manufacturing Facilities
3D Model Snapshots of Ongoing
EthaMem-G1 Project (50 KLPD )
 Team

Mentor
Padma Bhushan Prof. J.B. Joshi IIT KANPUR
IIT GUWAHATI
President : Marathi Vidnyan Parishad
Professor Emeritus
J. C. Bose Fellow, ICT
DAE-Homi Bhabha Chair Professor

Dr. Sunil Dhole (PhD, Chem. Enng.) Tushar Wagh (Chem. Engg.)
Director and Co-founder Director and Co-founder
Chemdist Membrane Systems Pvt. Ltd. Chemdist Membrane System Pvt. Ltd.
Technorbital Advanced Materials Pvt. Ltd. Chemdist Process Solutions
Espin Nanotech Pvt. Ltd. Chemdist Mass Transfer
Indeema Fibres Pvt. Ltd.
Future of Ethanol

 Ethanol to Butanol
 CO2 to Methanol
 Ethanol Fuel cell
 Spent Wash to Levulinic Acid
 Our Renowned Products

SWASA: N95 Mask Water Purifier Oxygen Concentrator

 Phone Number Office & Factory Address Email
020-68143300 Plot No. 174, J-Block, info@chemdist.in
(+91)9545557224 PCNTDA, Bhosari MIDC,
(+91)9559213333 Pune-411026
Maharashtra, India