The Digital Sugar Mill

Seminar on Sugar & Ethanol Automation

Distillery Operations Automation

Mr. Rafique Ahmed Mangi

Director Operations

Habib Distillery

Distillery Operations Automation

Agenda

Pakistan’s Ethanol Industry

Habib Distillery (Molasses Consumption)

Habib Distillery (Ethanol Production)

Habib Distillery (Alcohol Yield %)

The Ethanol Distillation Process

Optimization of an Ethanol Plant

System Architecture

Trend History – Case Study

Achievements through Automation

Future Goals for the Distillery Industry

3

Pakistan’s Ethanol Industry

• No. of Distilleries: 7

• Capacity: 1 million ltrs.Sindh

• No. of Distilleries: 10

• Capacity: 1.3 million ltrs.Punjab

• No. of Distilleries: 3

• Capacity: 0.3 million ltrs.

Khyber Pakhtun Khwa

Habib Distillery (Molasses Consumption - Tonnes)

156000

158000

160000

162000

164000

166000

168000

170000

172000

174000

176000

2010~11 2011~12 2012~13 2013~14 2014~15

171468

163559

171468

175382

163845

Habib Distillery (Ethanol Production - Tonnes)

27000

28000

29000

30000

31000

32000

33000

2010~11 2011~12 2012~13 2013~14 2014~15

29303 29307

30464

32768

30681

Habib Distillery (Alcohol Yield %)

17.20

17.40

17.60

17.80

18.00

18.20

18.40

18.60

18.80

2010~11 2011~12 2012~13 2013~14 2014~15

17.80

17.92

18.25

18.70 18.73

The Ethanol Distillation Process

DILUTOR

YEAST PROPAGATIONFERMENTATIONCARBON DIOXIDE

DISTILLATION

RECTIFICATION

ALCOHOL

BIOGAS

WASTE WATER

SLOP TREATMENT

BOILER

TURBO GENERATOR

POWER

WATERMOLASSES

TREATED WATERFEED WATER

Optimization of an Ethanol Plant

Key Challenges to Reduce:

Contamination during Fermentation

Distillation Losses

Energy Consumption

Variability of Process Parameters

Variability in Production and Quality

Optimization of an Ethanol Plant

Why is this important?

Every change has to be assessed for the following:

Quality Control and Monitoring

Utilization of Non

Fermentable parts

Increase in Productivity

Consistency in Quality

Return on Investment

(ROI)

Optimization of an Ethanol Plant

How do we achieve this?

Provide Technology and Training

to the Industry

Selection of Appropriate

Control System

Selection of Appropriate Automation

Service Provider

Advanced Control

System to Optimize Process

Parameters

System Architecture

Trend History – Case Study

Trend History – Case Study

Trend History – Case Study

Achievements through Automation

16

Reduced Energy Cost (est. 3 - 5 %)

Increased Ethanol Yield (est. 2 - 4 %)

Consistency in Quality and Production

Reduced Cost of Production (est. 10 %)

Future Goals for the Distillery Industry

Enhanced Production of Biogas and Concentration of Methane

Zero Liquid Discharge

Reduction in COD content of Ethanol Waste Water, by more than 90-95 %

• National Environmental Quality Standards allow a COD value of 150 mg/l

• Existing COD value is around 32,000 – 35,000 mg/l

Question & AnswersThank You for Your Valuable Time