KBK CHEM ENGINEERING PVT.LTD.

PROVIDING EPC SOLUTIONS AND TECHNOLOGY OF BIOETHANOL

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 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 Bio-
Ethanol

 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

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 GLOBAL GROUP BUSINESS OVERVIEW

KEY BUSINESS PROCESS Observations

 Harvesting of owned
Power cane in Brazil
Integrated Sugar Mills

Co-Gen
Raw  Brazilian raw sugar
Sugar primarily exported
Brazil
Sugar  Indian sugarcane
primarily converted to
White white sugar for
Sugar domestic
India Ethanol consumption

 India-based sugar
refineries can process
imported raw sugar
and re-export (tolling
Refineries

operation)
Imported / Local India Sugar
Refined Sugar
Raw Sugar Refineries  Physical trading of
sugar and ethanol in
Asian region enables
better risk
management
Sugar / Ethanol Trading KBK Chem-Engineering

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3
 MANAGEMENT

Mr. Krishna Kumar Kumbhat Director

Mr. Vijendra Singh Director

Mr. S. Chandna Head Marketing

Mr. R. Ramesh Head Operations

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 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 : 2. Starch Based : 3. Sweet

 Cane Juice  Corn Sorghum
 Cane  Maize based:
Syrup  Wheat  Sweet
 Molasses  Various Sorghum
 Beet sugar Grains Syrup
 Cassava

Continuous Research & Development is undergoing on

other feed stocks for generation of 3-G bio-fuels.

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 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 58-59 389-395

MAIZE 62-65 380-410

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 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

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 ENGINEERING ACTIVITIES
• Certifications
• ASNT Qualified QC Team.
ISO 9001: 2008
Welding Inspectors.
U “ta pi g
DP Level II.
R “ta pi g
Radiography Level II.
Visual Testing Level II.
• Third Party Approvals
UT Level II.
Bureau Veritas
TUV • Testing Facilities
“G“
Radiography Room.
VSI
Instrument Calibration
PMI Testing
• Fabrication codes
Ultrasonic Testing
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 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
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 H S E POLICY….
Health, Safety & Environment

Health & Safety Policy

Safety Manual

Awareness Programs

Training to Workmen
Supervisors

Regular Audits
 SERVICES AND TECHNOLOGIES
Distilleries Evaporation Plant Bio-Gas Plant

Ethanol Plants Equipment Business Bio-Composting

Continue…… www.kbk-chem.com
 SERVICES AND TECHNOLOGIES
Water Treatment Condensate
Plant polishing Unit

Dryers Columns Copper Pot Still

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POLLUTING STREAMS IN DISTILLERY

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 1 liter of
ethanol

Effluent Generation- 8.5 liter

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www.kbk-chem.com
 Effluent Reduction At Source

High alcohol No Contamination

concentration carryover to next Reduction in Process
irrespective of fermentor water consumption
quality of molasses

FED BATCH Alcohol concentration

High alcohol FERMENTATION
PROCESS
can increase as per
production requirement with
...Leads to
high brix feed

Less Power and

Lesser generation of Lesser cost of effluent
steam consumption
Effluent treatment
in distillation
 Effluent Reduction At Source

Recycling of spent
Withstand high DS wash Reduction in Process
conc. water consumption

CONTINUOUS Alcohol concentration

High alcohol FERMENTATION can increase as per
production PROCESS
requirement with
...Leads to high brix feed

Less Power and

Lesser generation of Less chances of
steam consumption
Effluent Contamination
in distillation

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 ZERO LIQUID DISCHARGE OPTIONS

SPENT WASH COMPOSTING

BIOMETHANATION
CONCENTRATION

SPENT WASH STEAM & POWER

RAW SPENT WASH
INCINERATION GENERATION

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 ZERO LIQUID DISCHARGE BY COMPOSTING

Spent wash

Distillery Biogas Biomethanation

Biomethanated
Spent wash

Boiler

Process condensate

Condensate polishing Unit

Concentrated
spent wash

Water Recycling Evaporation

Composting
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 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
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 Analyzer
Column Raw Spent Wash Bio-methanation
Bottom

13% Solids 8.5-9 lit / per lit of alcohol 5% Solids 8.5-9 lit / per lit of alcohol

Integrated High Efficiency Degasser Column

Evaporation +
Integrated Evaporation
30% Solids 3.5-4 lit / per lit of alcohol 10% Solids 3.5-4.25 lit / per lit of alcohol

Stand Alone Evaporation Stand Alone Evaporation

60% Solids 1.5-1.7 lit / per lit of alcohol 30% Solids 1.5-2 lit / per lit of alcohol

Incineration Bio Composting

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 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
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 SALIENT FEATURES OF KBK BIODIGESTOR

Long hydraulic 60 to 65 % COD

Ease of operation retention time reduction

High methane Handles high COD

content in biogas BIODIGESTER feed

Mesosphilic operation, Equipment with

High TSS handling
hence no external Vacuum & pressure
capacity
steam safety devices
 SALIENT FEATURES OF KBK CPU

Higher BOD/COD Colorless treated

Lower capital cost removal efficiency water

CONDENSATE 90% to 95% water to

Less Operation Cost POLISHING be reused for cooling
UNIT tower makeup after
treatment

Less chemical Less power

Ease for operation
consumption requirement

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GENERAL STEPS IN BIOETHANOL PRODUCTION FROM GRAIN

FEESTOCK
- GRAIN STORAGE SILO

GRAIN HANDLING & MILLING

(HAMMER MILL) Solids
DRYER CATTLE
FEED

LIQUEFACTION & Waste

SACCHARIFICATION

MULTI EFFECT
DECANTATION EVAPORATION
FERMENTATION
Spent Wash
Spent Wash Evaporated
Water
MULTI PRESSURE
DISTILLATION
Spent CONDENSATE COOLING
lees POLISHING UNIT TOWER

ENA RS IS
Sludge for
Composting
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 EFFICIENCY FACTORS

LIQUEFACTION FERMENTATION
EFFICIENCY : EFFICIENCY :
97% - 99% 90% TO 91%

DISTILLATION EFFICIENCY :
98.5%

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 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

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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

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 BULGARIA

MYANMAR
INDIA
VIETNAM
SENEGAL
THAILAND PHILIPPINES
ETHIOPIA
MALAYSIA
TANZANIA
BRAZIL

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 Krishnaveni Sugars
TECHNICAL ADVANTAGES Limited, INDIA
40% thin slop and 70% spent 60, 000 liters per day Grain
Based Distillery
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
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THE SANJIVANI SSK LTD,KOPARGAON MH.
60 KLPD Ethanol Plant

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

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 KBL TANZANIA
20 KLPD Molasses

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Renuka VDI ,Sao Pedro,Brazil
300 KLPD Ethanol

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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
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ESTEEMED CUSTOMERS

Metahara Sugar Factory

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www.kbk-chem.com