MORYA GRAIN Distillery unit at Plot No A- 96 MIDC Paithan, Tal - Paithan, Dist. Aurangabad utilize sorghum or corn as the basic raw material to produce potable quality super fine Extra Neutral Alcohol (ENA). The distillery have capacity of 33 KLPD production of ENA+IS. Along with the main product the distillery will also produce animal feed called as Distillers’ Wet Grain with Solubles (DWGS), which will fetch additional income. The whole integrated approach and production of DWGS will result in zero discharge of effluent or there will be no effluent coming out of the distillery as in the case of conventional distilleries based on molasses. The process will be based on Dry Milling concept.

The incoming corn grains is inspected upon receipt. Inspection is carried out to determine the bushel weight, moisture content, mold infestation and general appearance. The accepted quality corn grain is unloaded into silos for storage before milling. The stored grain is weighed to determine the incoming quantity.

Conventionally, Extra Neutral Alcohol is manufactured from Rectified Spirit. The impurities in Rectified Spirit are reduced to considerable extent by properly diluting and redistilling the spirit. The impurities like aldehydes, acids, esters, higher alcohols are minimized by controlled condition and tapping impurities at appropriate points during distillation.
The material of construction used for entire distillation column and condensers is deoxidised red copper. Copper has special properties to react with some impurities, particularly sulphur containing compounds, and prevent their distillation with top product.

The distillation columns requiring steam for heating are provided with reboilers so that direct mixing of steam is avoided. For dilution of alcohol soft water is used in order to take special care regarding the quality of final product. The diluted and treated Rectified Spirit is pumped to overhead tank from where it is fed through a rotameter to the purifying column.

In the system employing reboiler, the hydrated rectified spirit is fed to the purification column where most of the low boiling components are removed as the top product. The bottom of the purification column is heated indirectly by steam through a thermosyphon reboiler. From the bottom of the exhaust column spent lees is removed which preheat alcohol water mixture in a plate type heat exchanger before being discharged. The vapours from the exhaust column rise to the top of the rectification column, which are condensed and refluxed. Extra Neutral Alcohol is drawn near the top of the rectification column (3 to 4 trays below top). The ENA is cooled in a cooler and taken to storage. Fusel oil is drawn near the bottom of the rectification column, decanted, cooled and sent to storage.

In another modification of the above system an additional refining column is added. The liquid from the top of the rectifying column is fed to the refining column and heated indirectly through a thermosyphon reboiler. Extra Neutral Alcohol is removed from two to three plates above refining column. In this system the quality of ENA obtained is of high grade.

In the five-column system apart from purification, rectifying and exhaust columns two additional column are employed. The fusel oil concentration column is heated directly with steam and fusel oil are tapped near the middle of the column. Fusel oil is separated and the alcohol containing water mixture is feed back to the column. The low boiling impurities from the purifying and rectification column are collected and after proper dilution with water are fed to the heads concentration column for final separation of Impure Spirit. The advantage of five column is the reduction in percentage cut of Impure Spirit to 5 percent as compared to 25 percent cut in three column system. The quality of spirit produced in five-column system will be also be superior to spirit produced in three-column system as it achieves better separation of impurities. However, the requirement of steam in five columns system is higher than the three-column system.

ENA plant can be also integrated with primary distillation plant in such a way that with addition of just two columns to the primary distillation system can give superior quality of ENA. For example, the primary Distillation System will have....

This will further reduce the steam consumption. Whenever required the plant can be switched over from RS mode to ENA mode.

The alcohol stripped whole stillage is subjected to centrifugation to separate the suspended fibrous mass and the thin stillage. This thin stillage is concentrated in the multi-effect evaporation system, which is supplied with steam. Part of the thin stillage is recycled back to be used in the process as backset. The water vapours coming out of evaporator are condensed and sent back to be used as recycle condensate. The concentrated thin stillage in the form of syrup is taken to the drying section where it is mixed with the fiberous mass and subjected to drying in the decanter-dryer system to produce DWGS. This also requires additional steam. The final moisture content of DWGS is about 8.0 to 9.0 %. The quantity of DWGS produced is around 950 to 1000 kg per MT of corn or sorghum processed.