WELCOMES ALL DELEGATES OF UPDA - Vapco Engineers · – Absolute Alcohol ... –Basic –Detailed...
Transcript of WELCOMES ALL DELEGATES OF UPDA - Vapco Engineers · – Absolute Alcohol ... –Basic –Detailed...
Confidential | Copyright © VAPCO Engineers Pvt. Ltd.
Building Energy Efficient Technology
VAPCO ENGINEERS PVT. LTD.
WELCOMES
ALL DELEGATES OF
UPDA
9th SEPTEMBER 2016
Confidential | Copyright © VAPCO Engineers Pvt. Ltd.
Content
VAPCO - INTRODUCTION
OFFERINGS & EXPERIENCE
CHALLENGES & OPPORTUNITIES
VAPCO SOLUTIONS
BUSINESS MODEL
RECENT CASE STUDIES
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VAPCO in a snapshot
• Provide sustainable & greener solutions in the form ofEngineering services & EPC solutions in the selectedprocess industries.
• Suggest solutions for enhancement of operationalefficiency.
• Offers Technologies & systems which are :
• more INCLUSIVE in nature.
• Provide RIGHT & SUSTAINABLE solutions & enhancegrowth of our CUSTOMERS
Genesis:
Explore, Develop & Design green ways of protecting ourSurroundings, People and The Nature.
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VAPCO in a snap shot
We aim to be recognized as CUSTOMER CENTRIC & FRIENDLY organization withgoal of moderate growth, profitability and maintaining our sense of humour.
To be recognized as important & preferred EPCplayer in the Ethanol, Starches and allied industries andcreate VALUE for our customers & employeesVISION
VAPCO is committed to provide sustainable & environmentfriendly 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.
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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 selecteddomains
Proven Project & Construction Management & implementation team
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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.
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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
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2016
2016 • Commissioning of 50 KLPD
MSDH Plant
• 170 KLPD Grain plant completed
• 40 KLPD MSDH plant under
execution
• Development of BSW
Evaporation process condensate
stripping unit – Under trial Run
• 2 BSW Evaporation plants :
Under Erection
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Content
VAPCO - INTRODUCTION
OFFERINGS & EXPERIENCE
CHALLENGES & OPPORTUNITIES
VAPCO SOLUTIONS
BUSINESS MODEL
RECENT CASE STUDIES
Confidential | Copyright © VAPCO Engineers Pvt. Ltd.
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
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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
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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
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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
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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
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Present experience…
DDGS Dryers
Supply of Rotary Steam Tube
Bundle Dryer at two Distilleries
Feed Stocks
HandledSyrup
Wet Cake
Operation at Steam Pressure
of 3.50 kg/cm2(g)
Features:Runs on conduction principle
Fixed shell & rotating tubebundle
- good material contact
- Better product
- Consumes less electricity
Properly sized and spacedbaffles provides proper supportto steam tubes
Provision for expansion of tubebundle prevents stress build-upand ensures longer life
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Content
VAPCO - INTRODUCTION
OFFERINGS & EXPERIENCE
CHALLENGES & OPPORTUNITIES
VAPCO SOLUTIONS
BUSINESS MODEL
RECENT CASE STUDIES
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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 vsAutomation
OPERATIONAL
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Specific Challenges & Opportunities
Grain Based Plants / Conversion
• Optimum usage of existing infrastructure
• Reduction in energy consumption in all unit operations
• No recycle of Thin slops in the Liquefaction
• Evaporation of thin slops without steam
• Maintaining higher solids in thick slops
• Use of 100% Syrup in Drying process
• Recycle of waste streams
• Minimum Hardware maximum efficiencies
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Specific Challenges & Opportunities
Molasses Based Plants
• Modification of distillation plant for Energy Reduction
• Reduction in effluent (spent wash or lees) at source
• Heat integration to reduce overall energy requirement
• Capacity enhancement with use of existing equipments
Effluent treatment:
• BSW Evaporation or RSW or RO Reject Evaporation
• Reduction in steam & overall energy – Additional energy is needed in BSW Degassification
• Recycle of waste streams
• Treatment of process condensate – BSW Evaporation
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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
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Content
VAPCO - INTRODUCTION
OFFERINGS & EXPERIENCE
CHALLENGES & OPPORTUNITIES
VAPCO SOLUTIONS
BUSINESS MODEL
RECENT CASE STUDIES
Confidential | Copyright © VAPCO Engineers Pvt. Ltd.
Solutions from VAPCO……
MOLASSES MODULE:
• Forced circulation Reboilers for reduction in thespent wash quantity at the generation stage.
• Lower steam consumption models in distillation
• Integrated Evaporation Models with minimum addon energy for concentration of :
• RSW
• BSW
• RO Reject
• Maximum Evaporation through use of Alcoholvapours of distillation
• Process Condensate treatment
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Solutions from VAPCO……
GRAIN CONVERSION:
• 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
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Schemes Offered…..
GRAIN BASED DISTILLERY
Liquefaction Distillation Evaporation DDGS Dryer Total
Option I
Evaporator
Integrated
with
Distillation
0.3 Kg/Lit 2.7 Kg/Lit Nil 1.5 Kg/Lit 4.5 Kg/Lit
Option II
Evaporator
Integrated
with Dryer
0.3 Kg/Lit 2.2 Kg/Lit 0.3 Kg/Lit 1.5 Kg/Lit 4.3 Kg/Lit
- Option I offers flexibility in Dryer operations
- Boiler sizing in both the options will not vary significantly
- For new projects scheme needs to be chosen based on by product’s demand
- Distillation & Evaporation are must run sections & needs to be operated in case
of DWGS & DDGS.
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Schemes Offered…..
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MOLASSES BASED DISTILLERY
Distillation Evaporation Total
Option I
Integrated
Evaporation Section
2.9 Kg/Lit 0.9 Kg/Lit 3.8 Kg/Lit
Option II
Stand alone
evaporation Section
2.3 Kg/Lit 2.2 Kg/Lit 4.5 Kg/Lit
- Steam & Power balance needs to be evaluated in detail. Electricity
consumption points to be estimated & evaluated
- Significant difference in the boiler sizing, but Incineration boilers are sized as
per Concentrate Qty.
- CAPEX Driven decision for New projects
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Content
VAPCO - INTRODUCTION
OFFERINGS & EXPERIENCE
CHALLENGES & OPPORTUNITIES
VAPCO SOLUTIONS
BUSINESS MODEL
RECENT CASE STUDIES
Confidential | Copyright © VAPCO Engineers Pvt. Ltd.
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)
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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
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Content
VAPCO - INTRODUCTION
OFFERINGS & EXPERIENCE
CHALLENGES & OPPORTUNITIES
VAPCO SOLUTIONS
BUSINESS MODEL
RECENT CASE STUDIES
Confidential | Copyright © VAPCO Engineers Pvt. Ltd.
RECENT CASE STUDIES
Confidential | Copyright © VAPCO Engineers Pvt. Ltd.
Key Features
- One of the largest Integrated Evaporation plant in distillery in India
- 30 Ton/hr. evaporation with Alcohol Vapours, That is “ZERO” Steam
Consumption
Value deliveredSignificant reduction in overall energy consumption with better
quality of product & By product production in Grain based Distillery
Project : 170 KLPD Total Spirit Grain based distillery
Scope of Work :
A. Design & Supply of Liquefaction Section
B. Designing of Fermentation Section
C. Modification & Technology up gradation in Distillation
plant
D. Design & Supply of Integrated Evaporation Section for
Thin slop evaporation section
Client : Bihar Distillers private limited
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Key Features
- To produce Absolute alcohol as per Pharma & Aroma industry
- Customised plant design to suit existing civil structure
- Thermic fluid to be used as Heat source
Value delivered- Utility balancing as per existing infrastructure
- Compact plant with minor alterations in existing building
Project : 50 KLPD Molecular Sieve Dehydration Plant
Scope of Work :
A. Design, Engineering & Supply of MSDH plant
B. Design, engineering & Supply of SS Storage tanks as
per norms
Client : Sterling Chemicals Ltd.
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Project : Process Condensate treatment to remove Ammonia & H2S
Scope of Work :
Design, Engineering & Supply of treatment plant for removal of ammonia & H2S from
Biomethanated spent wash evaporator process condensate
Features :
- First of a kind unit with simple process
- Skid mounted Unit with just 3 days installation time
- Simple &
Client : United Spirit Ltd.
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Road Map Ahead……
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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 paybacks34
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VAPCO Engineers Private Limited
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