Project Synopsis
Provide process design services in the development of a simulation model, process flow diagram (PFD), and preliminary equipment sizing for an ethanol distillation process to produce vodka for a beverage OEM equipment fabrication company.
Project Summary
The client is a craft brewing original equipment manufacturer (OEM) specializing in custom-designed beer and distillery equipment. The client contracted Process Engineering Associates, LLC (PROCESS) to provide process design services in the development of a simulation model, process flow diagram (PFD), and preliminary equipment sizing for an ethanol distillation process. The work scope consisted of two phases: the first phase generated a base case material balance and equipment sizing while the second phase was an evaluation of the sensitivity of process variables to product composition and operating conditions.
Feed to the distillation system is finished beer from a typical industrial grain and syrup fermentation process. The finished beer is nearly 80 weight percent water and about 14 percent ethanol. Solids from the fermentation process are also in the beer along with fusel oils and light components such as carbon dioxide and aldehydes.
Beer from the fermentation process is preheated and then the stillage is removed via two beer columns. The beer columns are steam strippers that remove the ethanol and other volatile components and concentrate the solids from fermentation and a large amount of the water as a waste stream. The beer columns are equipped with a kettle reboiler but no condenser. The stillage waste stream also contains most of the dextrose and glycerol and lactic acid from the fermentation process.
Light end overheads from the beer columns are routed to a rectification column. The overheads are fed to the bottom of the column as vapor. The rectifier is equipped with a forced circulation reboiler and overhead partial condenser. Light ends are liberated as vapor from the partial condenser. Ethanol is recovered from a side-draw near the top of the column. Fusel oils are removed from a side-draw near the bottom of the column. Wastewater is removed from the bottom of the reboiler.
The purpose of the rectifier is to concentrate ethanol near the top of the column while driving the heavier and lower boiling fusel oils towards the bottom of the column along with the water. The reboiler temperature is key in maintaining this driving force across the column. The final ethanol product is 190-proof clear spirit (vodka). The ethanol is treated in an activated carbon bed prior to being sent to ageing tanks.
PROCESS modeled the separation process in CHEMCAD and then sized all the columns, exchangers, and vessels that comprised the system configuration. PROCESS performed sensitivity analysis on the distillation process to determine how it could also be used in the production of whiskey and rum. All equipment was sized and specified such that the client could perform an installed cost estimate and business plan to see if the approach was feasible. As of the writing of this document, the client is still evaluating their approach.
Industry Type
Alcoholic Spirits Production
Utilized Skills
- Process simulation
- Distillation system design
- Equipment sizing.