PPT Masterslides 03 2005 - Start · Nanofiltration Reverse osmosis ... Typical Novasep scope of...
Transcript of PPT Masterslides 03 2005 - Start · Nanofiltration Reverse osmosis ... Typical Novasep scope of...
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© Novasep
Vinasses/StillagesProcessing
Authors : Yvan BATHANY, Olivier PAUWELS, Robert POSSMANNDate : April 24th 2007
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© Novasep
Part 1 : Novasep Presentation
Part 2 : Vinasses / Stillages description
Part 3 : Applexion‘s answers to vinasses and stillages treatment
Part 4 : Water recovery- by evaporation,- by membrane
- NF/RO- BRM/RO
Part 5 : Suspended solids removal
Part 6 : Salt removal by crystallisation
Part 7 : Organic component recovery by chromatography
Summary
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© Novasep
⌧ Part 1 : Novasep Presentation
Part 2 : Vinasses / Stillages description
Part 3 : Applexion‘s answers to vinasses and stillages treatment
Part 4 : Water recovery- by evaporation,- by membrane
- NF/RO- BRM/RO
Part 5 : Suspended solids removal
Part 6 : Salt removal by crystallisation
Part 7 : Organic component recovery by chromatography
Summary
Novasep Group: Two Networks
APPLEXION SAS(Applexion-Epone/Orelis-SMB)
Buisness units PharmaBio-pharmaIndustrial biotech
NOVASEP SAS
Market :SweetnersNatural bio-moleculesDownsteam processing
Offer : Research & DevelopmentPurification technologiesEquipment & Systems
Offer :Research & DevelopmentCustom synthesisProprietary products (intermediates, APIs …)
Novasep Group
1’500 employees9 production sites5 main sales offices and global sales network
310 mio € sales300 mio € assets14% EBITDA/revenue10% R&D investment/revenue
NOVASEP Vision …
Develop new products and processes faster and cheaper by combining complementary technical expertise: chemicalengineering, chemical synthesis, separation technologies.
Develop as much as possible continuous processes for the pharmaceutical and nutraceutical industries.
Simplify the process to reduce operating cost for the biotech, food ingredient, dairy and sugar / sweetener market.
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© Novasep
Part 1 : Novasep Presentation
⌧ Part 2 : Vinasses / Stillages description
Part 3 : Applexion‘s answers to vinasses and stillages treatment
Part 4 : Water recovery- by evaporation,- by membrane
- NF/RO- BRM/RO
Part 5 : Suspended solids removal
Part 6 : Salt removal by crystallisation
Part 7 : Organic component recovery by chromatography
Summary
Vinasses and Stillages description1. Definition :
Leftover after the removal of alcohol out of an alcoholicsolution
Consequences :There are different types of vinasses depending :
On the substrate which has been fermentedRaw juice, Thin juice, Thick juice, Green syrup, Cane molasses, Beet molasses -------> VINASSESWheat, Barley, Corn substrate, Whole grain, Starch…- STILLAGES
On the process line to produce the alcoholic solution (type of acidification during fermentation, yeast cellremoval, recyclings, raw material pre-treatment…)
Vinasses and Stillages description2. Similar products :
Other products are not coming from alcoholic solution but have similar characteristics such as :
Vinasses from yeast production plant (same substratebut sugar is consumed to grow the yeast -> usually betterclarified solution, more diluted)Raffinate from molasses desugarization plant. Samesubstrate, but sugar removed by chromatography-> usually containing a little bit of sugar in it.Effluents from deashing plant : all the non sugar + chemicals used for regeneration of IX resins.
Vinasses and Stillages description3. Common characteristics :
Low value productDiluted productVery low sugar contentProduct difficult to discard because of the high COD and BOD.
Containing all the non sugars of the substrate of fermentation
Salts (Ca2+, K+, SO42-, Cl-)Valuable product such as betaine, raffinose, glycerol, pentose….Suspended solids
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© Novasep
Part 1 : Novasep Presentation
Part 2 : Vinasses / Stillages description
⌧ Part 3 : Applexion‘s answers to vinasses and stillages treatment
Part 4 : Water recovery- by evaporation,- by membrane
- NF/RO- BRM/RO
Part 5 : Suspended solids removal
Part 6 : Salt removal by crystallisation
Part 7 : Organic component recovery by chromatography
Summary
Applexion’s Applexion’s answersanswers to vinasses to vinasses andand stillagesstillages treatmenttreatment
Enhanced value
Waterback to process
Animal feed
Fertilizer
Betaine, glycerolraffinose
Animal feed
Typical vinasses composition
Water89%
Valuable organic component4%
Others4%
Suspendedsolids 1%Salts2%
WATER
Dry matter
Vinasses
Water Suspended solids Salts Valuable organic component Others
Evaporation,NanofiltrationReverse osmosisMembrane-bio reactor
Clarification, filtration
Crystallization
Chromatography
Process
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© Novasep
Part 1 : Novasep Presentation
Part 2 : Vinasses / Stillages description
Part 3 : Applexion‘s answers to vinasses and stillages treatment
⌧ Part 4 : Water recovery- by evaporation,- by membrane
- NF/RO- BRM/RO
Part 5 : Suspended solids removal
Part 6 : Salt removal by crystallisation
Part 7 : Organic component recovery by chromatography
Summary
Typical evaporation technologies used for Typical evaporation technologies used for vinassesvinasses//stillages stillages concentrationconcentration
EVAPORATORS•Falling film evaporators with / without integrated separators•Forced circulation •Plate evaporator
Thermic organisation•Multiple effects•Thermo compression•Mechanical vapour recompression
TypicalTypical exampleexample of of wheatwheat stillagesstillages concentrationconcentration((EuropeanEuropean customercustomer))
Project description :
Evaporator specification :
Evaporation rate : 78 000 kg/hConcentration from 7% to 35%Steam consumption : 22 000 kg/hPower consumption : 1 100 kwhDesign : 4 effects evaporator
Additionnal expectation :
Possibility to use other source of energy thansteamTo reduce stops for cleaning
TypicalTypical exampleexample of of wheatwheat stillagesstillages concentration concentration ((EuropeanEuropean customercustomer))
Process description
Falling film /forced circulation:
Compromise solution between investment cost andfouling
• Tubular evaporator(3FF+2FC)
•4 effects evaporator with 2 FC in parallel
•Counter current flow
•Energy recovery system
Steam
TypicalTypical exampleexample of of wheatwheat stillagesstillages concentration concentration ((EuropeanEuropean customercustomer))
Process description• Tubular evaporator (3FF+2FC)
•4 effects evaporator with 2 FC in parallel
•Counter current flow
•Energy recovery system
Multiple effect : reduce steam consumption, Thermo or MVR could have been used.
2FC in parallel : reduce stop time during cleaning firsteffect
TypicalTypical exampleexample of of wheatwheat stillagesstillages concentration concentration ((EuropeanEuropean customercustomer))
Process description
FEEDSyrup
Counter current flow : to keep viscosity low whenconcentration increases.
• Tubular evaporator (3FF+2FC)
•4 effects evaporator with 2 FC in parallel
•Counter current flow
•Energy recovery system
TypicalTypical exampleexample of of wheatwheat stillagesstillages concentration concentration ((EuropeanEuropean customercustomer))
Process description• Tubular evaporator (3FF+2CF)
•4 effects evaporator with 2 CF in parallel
•Counter current flow
•Energy recovery system
Source of recovered energy
Energy recovery system : different inlets depending on type of energy
TypicalTypical exampleexample of of wheatwheat stillagesstillages concentration concentration
Commercial conditions
1. Typical Novasep scope of supply• Process , basic and detailed engineering and corresponding
equipments.
2. Typical planning• Order : T0• Equipment delivery : T0 + 8 months• Test : T0+12 months• Commissionning : T0 + 14 months
3. Main figures• OPEX : 6 € / t of water evaporated (0.07€/kwh, 22€/t steam)
WaterWater recoveryrecovery usingusing membrane membrane Technologies (pilot trials)Technologies (pilot trials)
Diluted andclarified vinasse100 t @ 4% of DS
Salty permeate
ROSalty solution 50 to 60 g/l
Water (68 t) without potential inhibitor of fermentation
Concentratedvinasses (7 t @ 55% of DS)
20 t @ 20% of DS
Nanofiltration effluent treatment
Condensate(25t)
Evaporation
Capex : 50 000 €/t of water removed
Opex : 4.5 €/t of water
NF
WaterWater recoveryrecovery usingusing membrane membrane technologiestechnologies
Condensate
Bioreactor
Purifiedwater outlet
UF ROWaterwithoutpotentialinhibitor
Back to process
Sludge
air
Purpose :•reduce the size of the biological treatment ->capital cost reduction.•Reduction of component that inducefermentation inhibition in order to reusecondensate in the fermentation process.•Sludge volume reduction.
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© Novasep
Part 1 : Novasep Presentation
Part 2 : Vinasses / Stillages description
Part 3 : Applexion‘s answers to vinasses and stillages treatment
Part 4 : Water recovery- by evaporation,- by membrane
- NF/RO- BRM/RO
⌧ Part 5 : Suspended solids removal
Part 6 : Salt removal by crystallisation
Part 7 : Organic component recovery by chromatography
Summary
SuspendedSuspended solidssolids removalremoval : : Vinasses clarificationVinasses clarification
Decanters
Precoat filters
plate filters
Cross-flow filtration
It can be done :
before vinassestreatment by filtration(precoat filters, plate filters, cross-flow filtration)
After vinasses concentration by clarification on centrifuge decanter
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© Novasep
Part 1 : Novasep Presentation
Part 2 : Vinasses / Stillages description
Part 3 : Applexion‘s answers to vinasses and stillages treatment
Part 4 : Water recovery- by evaporation,- by membrane
- NF/RO- BRM/RO
Part 5 : Suspended solids removal
⌧ Part 6 : Salt removal by crystallisation
Part 7 : Organic component recovery by chromatography
Summary
Preconcentrationwith Falling film up to 25%DS
Depotassified
vinasses
Steamvacuum
Vinasse
(NH4)2SO4
K2SO4
Crystallization steps
SaltsSalts removalremoval : : typicaltypical crystallizationcrystallization unitunit
SaltsSalts removalremoval : : typicaltypical crystallizationcrystallization unitunit
Depotassified
vinasses
Steamvacuum
Vinasse
(NH4)2SO4
K2SO4
Crystallization steps
Forcedcirculation for crystallizationsteps
SaltsSalts removalremoval : : typicaltypical crystallizationcrystallization unitunit
Depotassified
vinasses
Steamvacuum
Vinasse
(NH4)2SO4
K2SO4
Ammonium sulfate addition for K2SO4 crystallization
Continuous pushercentrifuge for crystals removal
Decanter centrifuge for vinasse clarification
Crystallization steps
Hydrocyclonefor intermediateclarification
SaltsSalts removalremoval : : typicaltypical figures figures (For 50 000tDS/Y of (For 50 000tDS/Y of beetbeet vinasses)vinasses)
K2SO4 (fertilizer) : 12 000 to 15 000 t/an
-Concentrated vinasses (animal feed) : 59 000 t/y
Final concentration 70%-72% of DSPotassium content: K2O <2,5% of concentrate Nitrogen content (N) : 7% of concentrate
-Power consumption (with MVR) : 2 400 kwh-Steam consumption : 2000 kg/h - (NH4)2SO4 consumption : 5000 t/an
-OPEX : 4.5-6 €/t of diluted vinasses
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© Novasep
Part 1 : Novasep Presentation
Part 2 : Vinasses / Stillages description
Part 3 : Applexion‘s answers to vinasses and stillages treatment
Part 4 : Water recovery- by evaporation,- by membrane
- NF/RO- BRM/RO
Part 5 : Suspended solids removal
Part 6 : Salt removal by crystallisation
⌧ Part 7 : Organic component recovery by chromatography
Summary
OrganicOrganic component component recoveryrecovery : : By By ChromatographyChromatography
Vinasses Water Water Water
Water
Raffinate(salts)
Raffinate(salts)
Raffinate(salts)
Raffinate(salts)
Betaine/glycerol
•Raffinate : lowaffinity with resin
•Betaine andglycerol : highaffinity with the resin
Bed Volume
conc
entr
atio
n (g
/L)
Bet/glyRaffinate
OrganicOrganic component component recoveryrecovery : : typicaltypical processprocessline on vinasses line on vinasses comingcoming fromfrom beetbeet
Dilutedvinasses
Pre-Concentration
Crystallization
Filtration
Chromatography
Betaine/glycerol RaffinateConcentrationConcentration
Condensatetreatment
RO/BRM
Condensates
K2SO4 (fertilizer)
Clarification
recoveredwater
Potassium free vinasses for animal feed
Concentration
Chromatography
Betaïne 98%
Crista
Glycerol
OrganicOrganic component component recoveryrecovery : : By By ChromatographyChromatography
CONCLUSIONCONCLUSION
Applexion can provide a custom-made design for evaporation, crystallization, filtration, chromatography, clarification using a wide range of technologies in order to meet our client expectation.
Applexion brings innovative and adapted solutions combining all these processes, in order to make a source of profit out of wastes.
Condensate recovery thanks to Orelis BRM technology and RO.
Betain or glycerol recovery thanks to chromatography technology and partnership with the main betain customer.
Current development on cane vinasses concentration
Thank you for your attention!Presenter:
Yvan BATHANY, Yvan BATHANY, Olivier PAUWELS, Olivier PAUWELS, Robert POSSMANNRobert POSSMANN
Email : [email protected]