Value Maximisation solutions for

distilleries -Combiferm & Evaporative

Distillation
Technologies

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Fermentation

Yeast

Fermentation

Mode of Feedstock
Operation Composition

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Understanding Microbiology-Yeast Growth Kinetics

Budding Yeast produces alcohol 33 times faster than non-budding!

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Yeast Growth Kinetics
Yeast Specific Productivity ( liter

1.3 Volatile Acidity 0.13

Yeast production (kg yeast/kg

1.2 0.12
of alcohol/kg of yeast/hour)

1.1 0.11
1 0.1
0.9 0.09

alcohol)
0.8 0.08
0.7 PCV 0.07
0.6 0.06
0.5 0.05
0.4 0.04
0.3 0.03
0.2 0.02
0.1 0.01
4 5 6 7 8 9
Ethanol Concentration in Fermetned Mash (%V/V)

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Feedstock Composition- Stress Factors
Sugar Content
Ethanol
Yeast can tolerate up to
23% is possible
38% w/v
Lactic acid
> 0.8% w/v
kills
pH
3-4
Sulfite
>100 mg/L kills
(varies with strain)

Sodium ion
>500 mg/L kills
Temperature Acetic acid Dissolved
35°C max. > 2400www.praj.net
ppm Solids
© Praj Industries Ltd 5
inhibit > 20 % w/w
Fate of Sugar

Ethanol formation
88 – 91 %

Sugar Yeast growth

5–6%

Byproducts
formation
4–6%

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Mode of Operation
 Batch:
-Simultaneous Addition of Activated cell mass
and the feed
-Reaction completion
- Emptying
-Cleaning

 Synchronous (Fed Batch):

-Synchronized addition of activated cell mass
-Reaction Completion (partial addition of feed
and fermentation)
-Emptying
-Cleaning

 Continuous:
-Simultaneous addition of feed, activated cell
mass and reaction
-Emptying-NO
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Advantages of Synchronous & Continuous Fermentation

Parameters Synchronous Continuous

 Flexibility: Multiple feedstock
and their combination. Can be
terminated anytime depending
Advantages on feedstock composition
 Risk of Infection: Less as after
termination of batch,
fermenters are CIPed.
 Yield: Higher
 First fermenter acts as fresh yeast
supply to rest of the fermenter
 High active cellmass concentration
ensures fast reaction
 Minimal Yeast Usage
 Consistent mash quality
 Less CIP
 Less laborious
 Lower CAPEX
 Easily Automated

Is there fermentation technology giving

advantage of synchronous and continuous
Fermentation?

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CombiFerm
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Imperative-Identifying the Right Yeast!
-Collection of Yeast from different Flora and
Fauna

-Microbiological and biochemical assay for

different stress parameter

-Shortlisting of yeast and study of growth

Kinetics -Recycle Streams
-Volatile Acids
-FAN
-Bench and Pilot scale process optimization -Caramel
-Inorganic salts
and integration -Contamination

XP+ Yeast
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Fermentation Process Development

Feed Bottle
Feed Bottle

Chemostat Biostat-B
Biostat-A

Mash
Collection
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CombiFerm
Molasses
PRE
Process water  CombiFerm-
FERMENTOR-I/II
Nutrients/Yeast Combination of Fed batch and Continuous
fermentation process

Molasses  Biostat-A & B:

Biostat-I/II Process water -Hygienic equipment design
Nutrients
-Controlled feeding of feedstock & nutrient
Process stream -Homogenous mixing
Recycle
-Temperature control
Chemostat-I
-CIP facility for Hygienic condition for
optimum cell mass concentration

F. wash
 Chemostat :
Ethanol -Hygienic equipment design
DISTILLATION Homogenous mixing
-Temperature control
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CombiFerm….

Biostat Chemostat

 Separation of yeast growth phase (biostat) and ethanol generation phase

(Chemostat) in fermenter
 Ensuring hygienic operations in biostat by operating fermenter in fed batch
mode.
 Ethanol generation in continuous mode of operation (Chemostat) for consistent
© Praj Industries Ltd www.praj.net 12
mash feed to distillation.
CombiFerm-Sugar Fermentation Technology

Feature:
 Scientifically Designed Fermentation Technology
 Extra-productive, New Yeast strain XP+
 Advantage of Continuous and Synchronous fermentation
 Suitable for Sugarcane , Sweet Sorghum , Sugar beet based
feedstock and their combination

Advantage:
 Feedstock specific, higher ethanol concentration in fermented
mash-10-15% v/v
 Compliance to reduce, recycle and reuse of effluent streams
 Hygienic process design eliminates risk of contamination
 Higher fermentation efficiency
Benefits:
 Increase in profitability due to higher yield
 Excellent congener profile for beverage alcohol
 Modernization opportunity to expand batch fermentation
plant capacity by 15-20%
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CombiFerm- Modernization Opportunity
Case Study -Fed Batch

PRE Molasses
FERMENTOR-I/II Process water
Nutrients/Yeast 100 KLPD Distillery-
 Existing Fed Batch Fermentation:
Alcohol concentration in mash-8.5%v/v
Molasses Fermented mash Produced-1148 m3/day
Fermenter Process water No. of Fermenter-480 m3 (4 No.)
Nutrients
Beerwell- 480 m3 (1 No.)
Process stream
Recycle
 CombiFerm:
Beerwell
-Alcohol concentration in mash-8.5%v/v
-Fermented mash produced-1645 m3/day
-Plant capacity achieved-130 KLPD
F. wash

Ethanol
-Increasein plant capacity- 30%
DISTILLATION Payback -2-2.5 year
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Advanced Technology-Success Stories
CombiFerm Fermentation Technology
Shreenath Mhaskoba SSK (45 KLPD)

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Way Forward -CombiFerm Starch & 2 G Sugars

Biostat-A Chemostat Biostat-B

Feed Bottle

Mash
Collection

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 Evaporative Distillation

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Distillation Technology
RS / AA Production

R Flash
E R Tank M
M C E
A A
C S
S
H H
E E
X X
H

Thick Lees Thick

Slops Slops
Lees

Ecofine – TVS Ecofine – PV

© Praj Industries Ltd www.praj.net 19

Concept
Evaporative Distillation

Normal Distillation

Fermented Analyser Rectifier

Wash RS

Evaporative Distillation

Evaporative
Distillation Rectifier RS
Fermented
Wash
© Praj Industries Ltd www.praj.net 20
Energy Comparison
Various Technologies

Alcohol Concentration Single Mash Column Evaporative Distillation

% v/v Kg/lit of TS (single Split)
Kg/lit of TS

8 1.8 1.25
10 1.6 1.05
12 1.35 0.9
15 1.25 0.8

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Advantages
Evaporative Distillation

• Thermal Energy Lesser

Energy than Normal Distillation

• Cost is similar to Normal

Cost Distillation Column

• Integration with
Integration Evaporation is Possible

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Application
Evaporative Distillation

RS

Evaporative
Distillation

ENA AA

For Both Sugary and Starchy Feedstock

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Schematics
Evaporative Distillation – RS/AA Production

AA Scheme
1.0 kg/lit

1.5 kg/lit
REC Evaporative Distillation Evap

0.45 kg/lit 0.2 kg/lit

MSDH

Steam Consumption : 1.5 - 1.7 Kg/lit of AA

© Praj Industries Ltd www.praj.net 24

Advantages
Evaporative Distillation – AA Production

 Scheme suitable for retrofitting in Existing Plant

 Existing Distillation Plant Capacities can be increased by 40 -50 %

 Lower Energy Consumption even compared to Evaporation

integrated scheme

 Lower Water Footprint

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 Plant Modernization Case Study -

Evaporative Distillation Technology

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 Applicability of Modernization to Existing Plant

EXISTING Evaporative Distillation

MPR DISTILLATION Energy Efficient
ATM DISTILLATION MODIFIED TO High Capacity
DISTILLATION
FACILITY

EXISTING NEW
COLUMNS MAJORITY OF
UTILISATION EXISTING
HEAT EXCHANGES
EQUIPMETS USED
PUMPS, TANKS &
EQUIPMENTS

© Praj Industries Ltd www.praj.net 27

 Current Scenario

Parameter 60KLPD MPR

Plant Capacity 60000 LPD of AA

Steam Consumption 2.3 Kg/ Lit of Fuel Ethanol

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 Change in Existing Plant Performance due
to Modernization.

• Evaporative Distillation retrofitted in existing set–up

• Existing plant capacity increased without major changes
• 30 % Reduction in overall Steam Consumption
• Proportionately reduction in water required for cooling tower.
• Reduction in Water Footprint
• Reduction in Effluent quantity
• Multi product facility like RS & Absolute Alcohol – upgradable to
Pharma Grade ENA, Perfumery Grade ENA
• Market demands can best handled for Profitability.
• Capacity Enhancement in existing utilities

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 Value Addition in Modernization

100 KLPD
Parameter 60KLPD MPR Evaporative
Distillation

Plant Capacity 60000 LPD of AA 100000 LPD of AA

Steam Consumption 2.3 kg/lit 1.7 kg/lit

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 Value Addition in Modernization

Current Operation : Steam required for 100 KLPD AA = 230 TPD (@2.3 Kg/Lit)
Modernization - Steam required for 100 KLPD AA( Plant expanded from 60 to 100
KLPD) = 170TPD(@1.7Kg/Lit)
Saving on steam at 100 KLPD TS = (230-170) = 60TPD
SAVINGS
Parameter Quantity Assumed Savings per day Savings for 250
Profit Margin days operation
Production 40000 LPD 10 Rs./ lit Rs. 400000 1000 lakhs /
year
Steam 60 TPD 1200 Rs./ MT Rs. 72000 180 lakhs / year

Total Savings - - Rs 472000 1180 lakhs /

year

Simple Payback < 9 – 11 months

© Praj Industries Ltd www.praj.net 31

Patent
Evaporative Distillation

Production of ethanol by evaporative distillation

Date of filing : 8 August 2013

Patent No. : 2620/MUM/2013

Major Claims:

 Size of said mash column is reduced by 50%

 first evaporator is energized using Mash Vapors.

© Praj Industries Ltd www.praj.net 32

Evaporative Distillation – Reference List

Sr No Client Name Capacity In Remark

KLPD

1 Dalmia Bharat Sugars Ltd 65 Under Execution

2 Madhucon 45 Under Execution

3 Balrampur Sugars Ltd 60 -100 Under Engg

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 Thank you

Sustainability through Advanced Technologies

© Praj Industries Ltd www.praj.net