Renuka Sugar Tech.pdf

KBK CHEM ENGINEERING PVT.LTD.

PROVIDING EPC SOLUTIONS AND TECHNOLOGY OF BIOETHANOL

www.kbk-chem.com

ABOUT US………. 

Established in 1997.



KBK is wholly owned subsidiary of Shree Renuka Sugars Ltd.(SRSL)



SRSL is a o gst the world’s leadi g co pa ies i area of Sugar, Power and BioEthanol



KBK has expertise in Distillery field for last 18 years.



Group turnover of company is $ 1.7 Bn.



KBK has executed about 50 projects across the Globe successfully

www.kbk-chem.com

GLOBAL GROUP BUSINESS OVERVIEW

Refineries

Integrated Sugar Mills

KEY BUSINESS PROCESS

Observations  Harvesting of owned cane in Brazil

Power Co-Gen Brazil

Raw Sugar

 Brazilian raw sugar primarily exported

White Sugar

 Indian sugarcane primarily converted to white sugar for domestic consumption

Sugar

Ethanol

India

Imported / Local Raw Sugar

Sugar / Ethanol Trading

India Sugar Refineries

 India-based sugar refineries can process imported raw sugar and re-export (tolling operation) Refined Sugar

KBK Chem-Engineering

 Physical trading of sugar and ethanol in Asian region enables better risk management

www.kbk-chem.com 3

MANAGEMENT Mr. Krishna Kumar Kumbhat

Director

Mr. Vijendra Singh

Director

Mr. S. Chandna

Head Marketing

Mr. R. Ramesh

Head Operations

www.kbk-chem.com

EPC AND TURN KEY SOLUTIONS 

Anhydrous Alcohol - Fuel grade (Ethanol)



Hydrated Alcohol Rectified Spirit Extra Neutral Alcohol Export Quality Rectified Spirit Industrial Grade Alcohol



Alcohol Allied Chemicals Ethyl Acetate Acetic Acid



Process plants using feedstock as… Sugar based Raw materials – Molasses, Sugar Cane, Sweet sorghum Starch based Raw material – Maize, Cassava, wheat ,Sorghum & other grains.

www.kbk-chem.com

BIO-ETHANOL 1. Sugar Based :  Cane Juice  Cane Syrup  Molasses  Beet sugar

2. Starch Based :  Corn  Maize  Wheat  Various Grains  Cassava

3. Sweet Sorghum based:  Sweet Sorghum Syrup

Continuous Research & Development is undergoing on other feed stocks for generation of 3-G bio-fuels. www.kbk-chem.com

STARCH %

ALCOHOL YIELD (LIT OF ALCOHOL/MT)

RICE

62-67

380-418

SORGHUM

62-65

380-410

WHEAT

62-65

380-410

POTATO

19-20

127-134

MALT

58-59

MAIZE

62-65

389-395

380-410

www.kbk-chem.com

ABOUT US………. 

Work shop certified with • ASME U-Stamp • R-Stamp

• ISO 9001:2008



Complete in-house Design, Engineering and Manufacturing Services



Professional and Experienced Engineering Team www.kbk-chem.com

ENGINEERING ACTIVITIES • Certifications ISO 9001: 2008 U “ta pi g R “ta pi g • Third Party Approvals Bureau Veritas TUV “G“ VSI • Fabrication codes ASME Section VIII Div. I. ASME Section II, Part A, B, C & D for Materials. ASME Section V for NDE ASME Section IX for Welding

• ASNT Qualified QC Team. Welding Inspectors. DP Level II. Radiography Level II. Visual Testing Level II. UT Level II. • Testing Facilities Radiography Room. Instrument Calibration PMI Testing Ultrasonic Testing

www.kbk-chem.com

MANUFACTURING CAPABILITIES

• • • •

51000 Sq. Ft. Work Area. Lifting Capacity of 25 MT. 40 ASME Qualified Welders Processing Cap. Per Month- 350 Tons www.kbk-chem.com

H S E POLICY…. Health, Safety & Environment Health & Safety Policy Safety Manual Awareness Programs Training to Workmen Supervisors Regular Audits

SERVICES AND TECHNOLOGIES Distilleries

Ethanol Plants

Evaporation Plant

Equipment Business

Continue……

Bio-Gas Plant

Bio-Composting

www.kbk-chem.com

SERVICES AND TECHNOLOGIES Condensate polishing Unit

Water Treatment Plant

Dryers

Columns

Copper Pot Still

www.kbk-chem.com

POLLUTING STREAMS IN DISTILLERY

www.kbk-chem.com

1 liter of ethanol

Effluent Generation- 8.5 liter

www.kbk-chem.com

www.kbk-chem.com

Effluent Reduction At Source High alcohol concentration irrespective of quality of molasses

High alcohol production

No Contamination carryover to next fermentor

FED BATCH FERMENTATION PROCESS ...Leads to

Lesser generation of Effluent

Lesser cost of effluent treatment

Reduction in Process water consumption

Alcohol concentration can increase as per requirement with high brix feed

Less Power and steam consumption in distillation

Effluent Reduction At Source

Withstand high DS conc.

Recycling of spent wash

CONTINUOUS

High alcohol production

FERMENTATION PROCESS ...Leads to

Lesser generation of Effluent

Less chances of Contamination

Reduction in Process water consumption

Alcohol concentration can increase as per requirement with high brix feed

Less Power and steam consumption in distillation www.kbk-chem.com

ZERO LIQUID DISCHARGE OPTIONS

BIOMETHANATION

RAW SPENT WASH

SPENT WASH CONCENTRATION

SPENT WASH INCINERATION

COMPOSTING

STEAM & POWER GENERATION

www.kbk-chem.com

ZERO LIQUID DISCHARGE BY COMPOSTING

Spent wash

Distillery

Biogas

Biomethanation

Biomethanated Spent wash Boiler Process condensate

Condensate polishing Unit Concentrated spent wash Water Recycling

Composting

Evaporation

www.kbk-chem.com

ZERO LIQUID DISCHARGE BY SPENT WASH INCINERATION

Spent wash

Distillery

Evaporation

Steam & power for process

Concentrated Spent wash

Condensate polishing Unit Incineration Boiler Water Recycling

www.kbk-chem.com

Analyzer Column Bottom

Raw Spent Wash

8.5-9 lit / per lit of alcohol

13% Solids

Integrated Evaporation 30% Solids

3.5-4 lit / per lit of alcohol

Stand Alone Evaporation 60% Solids

1.5-1.7 lit / per lit of alcohol

Incineration

Bio-methanation

5% Solids

8.5-9 lit / per lit of alcohol

High Efficiency Degasser Column + Integrated Evaporation 10% Solids

3.5-4.25 lit / per lit of alcohol

Stand Alone Evaporation 30% Solids

1.5-2 lit / per lit of alcohol

Bio Composting www.kbk-chem.com

CIP – Once a Month 50 % Energy saving Low fixed and operating cost Good heat transfer coefficient System Operation At Optimum thermal Efficiency High Efficiency distributer for optimizing recirculation Optimization of tube size & passes for less power consumption High efficient vapor liquid separator avoids carryover and contamination High Efficiency degasser for effective removal of dissolved gases in Biomethanated spent wash www.kbk-chem.com

SALIENT FEATURES OF KBK BIODIGESTOR

Ease of operation

High methane content in biogas

Mesosphilic operation, hence no external steam

Long hydraulic retention time

60 to 65 % COD reduction

BIODIGESTER

Handles high COD feed

Equipment with Vacuum & pressure safety devices

High TSS handling capacity

SALIENT FEATURES OF KBK CPU

Lower capital cost

Higher BOD/COD removal efficiency

Colorless treated water

Less Operation Cost

CONDENSATE POLISHING UNIT

90% to 95% water to be reused for cooling tower makeup after treatment

Ease for operation

Less chemical consumption

Less power requirement www.kbk-chem.com

GENERAL STEPS IN BIOETHANOL PRODUCTION FROM GRAIN FEESTOCK - GRAIN STORAGE SILO

GRAIN HANDLING & MILLING (HAMMER MILL)

Solids DRYER

CATTLE FEED

Waste

LIQUEFACTION & SACCHARIFICATION

MULTI EFFECT EVAPORATION

DECANTATION

FERMENTATION

Spent Wash

Spent Wash Evaporated Water

MULTI PRESSURE DISTILLATION

Spent lees ENA

RS

CONDENSATE POLISHING UNIT

COOLING TOWER

IS Sludge for Composting

www.kbk-chem.com

EFFICIENCY FACTORS

LIQUEFACTION EFFICIENCY :

FERMENTATION EFFICIENCY :

97% - 99%

90% TO 91%

DISTILLATION EFFICIENCY : 98.5%

www.kbk-chem.com

ADVANATGES OF KBK’S DISTILLATION •

• • • • • • • • • •

Less Steam consumption per liter of alcohol produced RS- 2.2 KG/LIT ENA- 3.2 KG/LIT AA- 0.50 KG/LIT Integrated Evaporation- No steam consumption IG+SA Evaporation- 1.52 KG/LIT of Alcohol Spent wash reduction at source due to Reboiler system Export Quality of Rectified spirit Export Quality of Extra Neutral Alcohol Export Quality of Ethanol with 99.9 % Purity Less spent lees generation (50 % spent lees reused ) Less Technical alcohol generation, improves end product quantity Waste heat recovery Steam condensate recycle to boiler

www.kbk-chem.com

3D model of Distillery Plant for Layout Optimization.

3D MODEL OF DISTILLERY PLANT PIPING LAYOUT

KBK ADVANTAGES • EPC & Turn Key solution provider • Huge Global & Domestic experience • Experience of Plant Execution up to 300 KLPD Plant capacity • ZLD solution provider with Spent wash Incineration • Design on less steam pressure • Less Effluent Generation • 95 % waste water reused back to process • High version software's for Plant Design & Engineering • Concept to commissioning experience • Trusted name in Distillery Business www.kbk-chem.com

BULGARIA

MYANMAR INDIA VIETNAM SENEGAL

THAILAND

ETHIOPIA

PHILIPPINES MALAYSIA

BRAZIL

TANZANIA

www.kbk-chem.com

TECHNICAL ADVANTAGES

40% thin slop and 70% spent lees recycle Simultaneous saccharification and fermentation 14-15% v/v alcohol in fermented wash Optimised fermentation cycle Multi-feed plant configuration with wheat, rice, corn, sweet sorghum etc. Patented novel yeast strain DDGS dryer with LNG / Steam as heating source DDGS waste vapour recovery system Optimised consumption of additives and enzymes

Krishnaveni Sugars Limited, INDIA 60, 000 liters per day Grain Based Distillery

www.kbk-chem.com

www.kbk-chem.com

THE SANJIVANI SSK LTD,KOPARGAON MH. 60 KLPD Ethanol Plant

www.kbk-chem.com

Rajasthan State Ganganagar Sugar Mills Ltd. 30 KLPD Duel Feed EQRS Plant

www.kbk-chem.com

www.kbk-chem.com

KBL TANZANIA 20 KLPD Molasses

www.kbk-chem.com

Renuka VDI ,Sao Pedro,Brazil 300 KLPD Ethanol

www.kbk-chem.com

www.kbk-chem.com

TECHNICAL ADVANTAGES

Maximum vinasse recycle to reduce effluent generation at source Achieved lowest vinasse generation of 1.5 lit / lit of ethanol Maximum productivity with optimum utility consumption and low cost of production Novel yeast strain suitable for high osmotic pressure Optimised fermentation cycle No requirement of performance boosters No use of Bio-cides www.kbk-chem.com

www.kbk-chem.com

ESTEEMED CUSTOMERS

Metahara Sugar Factory

www.kbk-chem.com

www.kbk-chem.com