D2005061
INSTRUCTION MANUAL FOR
NORMAL STARTUP AND SHUTDOWN
OF
" 75 KLPD ENA PLANT "
CLIENT
: CNT WINE AND LIQUOR CO. LTD.
PLANT LOCATION
: KANCHANABURI,THAILAND
PROJECT CODE
: D2005061
DOCUMENT No.
: D2005061-4OPM403
PREPARED BY
Praj Industries Limited,
Praj House,
Mumbai - Bangalore Highway Bypass
Bavdhan, Pune - 411 021
www.praj.net
0
Rev. No.
Date
Prepd.
Chkd.
PPK
Apprd.
OPM/DIST/CNT WINE AND LIQUOR CO.LTD.KANCHANABURI,THAILAND
Page 1 of 19
For Operation
Purpose
D2005061
TABLE OF CONTENTS
Sr. No.
Description
1
GENERAL INSTRUCTIONS.
2
DISTILLATION
2.1
UTILITIES
2.2
NORMAL STARTUP
2.3
PROCESS PARAMETERS
2.4
NORMAL SHUTDOWN
2.5
CLEANING IN PLACE
2.6
TROUBLESHOOTING
OPM/DIST/CNT WINE AND LIQUOR CO.LTD.KANCHANABURI,THAILAND
Page 2 of 19
Page No.
D2005061
1. GENERAL INSTRUCTION
Operator must read and understand these instructions before
operating the plant.
a. The procedures and operating conditions listed here are guidelines
only and may be modified on start-up. The control system must be
flexible enough to accommodate these changes.
b. This does not cover peripheral equipment, which may affect the
plant.
c. It is expected that the operator may be required to take some
decisions and actions not covered by this manual. The operator will
be expected to monitor the system during operation, and may need
to intervene to assure safe operation of the plant as and when
required. The control system must be flexible enough to allow
operator intervention when necessary.
d. Operator should read the bought-out items operation manual /
safety procedures received from respective vendors and follow the
instructions as mentioned in their manual before starting / stopping
the respective item.
e. Operating personnel should follow the safety regulations as per
factory rules as well as factory acts and regulations in Thailand.
f. Before plant start it is necessary to make detailed schedule so as to
understand sequence of start-up of individual sections and their
synchronization.
g. AUTO mode means automatic operation and MAN mode means
manual operation.
OPM/DIST/CNT WINE AND LIQUOR CO.LTD.KANCHANABURI,THAILAND
Page 3 of 19
D2005061
2.
2.1
DISTILLATION
UTILITIES
Electrical
The Owner shall supply Power at following parameters to the plant:
Pumps
380 VAC / 3 phase / 50 Hz
Instruments
24 VDC
Actuated valves
24 VDC
Instrumental Air
This section requires approximately clean, condensate-free compressed
air at a minimum pressure of 7.5 bar (g) at the point of use. The air
should pass through an oil aerosol filter and particulate filter prior to
delivery to this section. The air should be dry to at least at -40C dew
point.
Cooling Water
The cooling water requirement for this section will vary according to
feedstock characteristics and plant turndown ration. To adequately meet
most anticipated situations, Owner should be able to supply
approximately 600 m3/hr of 32C (Max) cooling water.
To minimize maintenance and extend the life of the heat exchangers, the
cooling water should be treated with scale and corrosion inhibiting
chemicals, and purged to prevent dissolved solids concentration from
exceeding 30 PPM.
Steam
The steam rate will vary, depending upon the operating parameters. At
design conditions, the total direct requirement of condensate-free steam
at 3.5 bar (g) will be 10541 kg/hr (253 TPD).
OPM/DIST/CNT WINE AND LIQUOR CO.LTD.KANCHANABURI,THAILAND
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D2005061
2.2
NORMAL STARTUP
Follow all the steps explained in water trials for every fresh start-up without
alcohol in system. At the end of water trials ,plant will be running on water
with all stabilized conditions. Ensure fermented wash is ready in wash holding
tank to feed it to distillation. To take plant on alcohol, proceeds with following
steps.
1. Start plant on water as explained in water trials (Ref. document no. :
D2005061—4--OPM402: ) by putting water in wash charger.
NOTE:
Before switching over from process water to fermented wash ensure wash is
ready in wash holding tank for steady and continuous supply.
2. Stop water and start wash to wash charger with the rate of 20 m3/hr at the
beginning. Go on increasing wash feed rate slowly with increment of 5m3
every 30 min. up to 30 m3/hr (Initially stabilize the plant at approximate 60%
capacity only. This feeding rate is to be calculated based on the alcohol
concentration in wash feed). Once plant is stable wash feed can be increased
to achieve full capacity.
3. As fermented wash is introduced in the Analyser column / degasifying
column, temperature at the top of the column will decrease and spent wash
will start coming out from bottom of Analyser column instead of water
4. Ensure all the Level controllers, Flow control valves and pressure control
valves are in AUTO mode. Ensure the operation of level controllers by
visually observing levels through sight glasses
5. Pre rectifier column will start getting mixture of alcohol water vapour instead
of water vapour. so temperature profile of the column will start changing.
6. Alcohol vapour will get condensed in overhead condenser and get collected in
pre-rectifier reflux tank (T-413)
7. Ensure R.S. Draw flow control valve (FCV-480) closed. As per the
calculations it should take around six to eight hours to get desired rectified
spirit concentration up to 95% v/v. Therefore right from fourth hour itself start
checking concentration of rectified spirit from T – 413 every hour. Until the
concentration of R.S. is less than 95%v/v, run the column on total reflux.
Column temperature profile start changing as the column gets loaded with
alcohol.
OPM/DIST/CNT WINE AND LIQUOR CO.LTD.KANCHANABURI,THAILAND
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D2005061
8. Once HFO/LFO zone temperatures are achieved as mentioned in Table for
temperature profile, open HFO/LFO tapings and start taking HFO/LFO draw
to fusel oil draw tank (T-412) at flow rate mentioned in table 2.3.Through FI 480 and FI-481 respectively. Start soft water at mentioned flow rate in the
table 2.3.to Fusel oil decanter (S 411).
9. Open R.S. Draw flow control valve (FCV-480) about 20% in Manual mode.
Set the flow about 2000 LPH in FIT-480 for 60% of the plant capacity and put
the valve in AUTO mode. Adjust the flow such a way that HFO/LFO and RS
draw plate temperature are stable as mentioned in table no. 2.3. That rectified
spirit will enter into purifier column.
10. Once Rectified spirit will enter into Purifier column for further purification,
Temperature profile of the column will change. Set the soft water and spent
lees flows as shown in the table, but for 60% of the capacity.
11. Once plant is taken on full capacity, increase the RS, spent lees and soft
water flows accordingly.
12. Alcohol water liquid from Purifier bottom enters into Rectifier column, which
will change the temperature profile of the column.
13. Ensure ENA draw flow control valve, HFO, LFO draw valves on flow meters
are closed. Column should run on total reflux until concentration of alcohol
reaches at least 95%v/v at the reflux tank.
14. As the alcohol will replace the water in the column, HFO/LFO temperature will
start decreases. Once these temperatures reaches desired value as given in
the table, start HFO/LFO draws at desired flow rates as given in the table,
through respective flow metres to fusel oil wash holding tank (T-463).
15. Start TA draw from reflux tank at desired flow as given in the table to purifier
column feed bottle.
16. Open RS/ENA draw flow control valve (FCV-576) to 20% in manual mode.
Adjust the valve such a way that HFO/LFO and RS draw plate temperatures
are stable as given in table.
17. Set the flow on FIT -576, as given in the table but for 60% of the capacity.
Then take control valve on AUTO mode. Increase the flow rate once plant
taken on higher capacity.
OPM/DIST/CNT WINE AND LIQUOR CO.LTD.KANCHANABURI,THAILAND
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D2005061
a. Check exhaust column bottom sample it should have zero alcohol present
in it at temperature given in table.
b. Check mash column bottom sample. It should have zero alcohol present in
it at given temperature.
18. Rectified spirit from rectifier column will enter into the simmering column. It
will gain the heat from top vapours of purifier column. The temperatures of
simmering column will start rising. Start T. A. cut from simmering column
condenser.
19. Start ENA from bottom of simmering column. Maintain the temperatures of
simmering column as given in table 2.3.
20. Alcohol water liquid from T – 472 will enter into FOC column. The
temperatures of FOC column will start decreasing. Once temperatures of
LFO, HFO and RS draw plates achieved, start respective draws maintaining
stable temperatures.
Note:
1. Ensure T. A. cut flows.
2. Observe and maintain temperatures of all the columns.
3. Observe and maintain levels of all the column.
4. Frequently check qualities of RS, ENA, LFO, HFO, purifier bottom.
5. Frequently check losses from bottom of analyser column, rectifier
cum exhaust column and FOC column.
6. Observe perfoemance of all the control valves.
OPM/DIST/CNT WINE AND LIQUOR CO.LTD.KANCHANABURI,THAILAND
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D2005061
2.3
PROCESS PARAMETERS
Closed Control Loops
Flows:
Sr.
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Instrument
Tag No.
Description
Fermented
Wash
Degasifying Column
Unit
FQIC-400
46000
LPH
FQIC-403
gf
FQIC-402
df
FE - 404
dfb
FI – 426
93
FE - 426
ffg
to
Alcohol water vapours from
mash column to degasifier
column
Spent wash to fermentation for
recycle.
Spent wash to fermentation for
recycle.
T. A. cut from rectifier column.
Reflux to rectifier column
Pre rectifier column RS draw
T. A. cut from prerectifier reflux
tank
Prerectifier column HFO draw
Prerectifier column LFO draw
T. A. cut from aldehyde
column reflux tank
Alcohol water from bottom of
purifier column to rectifier
column
Heavy Fusel Oil from rectifier
cum exhaust column.
Quantity
FQIC - 480
3130
Kg / hr
kg/hr
FI – 479
fdb
FI - 480
ff
FI - 481
ffg
FI - 453
fgf
FE – 452
27147
kg/hr
FI – 502
fg
LPH
OPM/DIST/CNT WINE AND LIQUOR CO.LTD.KANCHANABURI,THAILAND
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D2005061
14.
15.
16.
17.
18.
Light Fusel Oil from rectifier
cum exhaust column
Spent lees from rectifier cum
exhaust column to purifier
column.
RS from FOC column
LFO from FOC column
HFO from FOC column
FI – 501
fg
FQIC 527
fgg
FI - 453
gfg
FI - 451
fgfdg
FI - 452
fgg
LPH
RS Feed to simmering column
FQIC – 576
3130
LPH
ENA from bottom of simmering
column
FI – 576
3125
kg/hr
T. A. cut after mixing bottle
FI – 578
88
LPH
22.
soft water feed to purifier
column
FI – 603
9827.31
LPH
FI - 581
13.33
LPH
23.
T. A. cut from simmering
column reflux tank
24.
Soft Water Feed to Fusel Oil
Decanter S - 411
FI – 601
fh
LPH
25.
Soft Water Feed to Fusel Oil
Decanter S - 471
FI – 604
437
LPH
26.
Steam to wash column (stand
alone)
FQIC – 401
5644
Kg / hr
27.
Steam flow rate to exhaust
column.
FQIC – 476
565
Kg / hr
steam to rectifier column
FQIC – 526
6855
kg/hr
19.
20.
21.
28.
OPM/DIST/CNT WINE AND LIQUOR CO.LTD.KANCHANABURI,THAILAND
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D2005061
Temperature:
Sr.
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Description
Analyser Column Bottom
Temperature
Analyser Column Top
Temperature
Degasifying Column top
Temperature
Temp. of Fermented Wash to
Degasifying Column
Simmering column bottom
temperature
Aldehyde column-top
temperature
Aldehyde column-bottom
temperature
Pre-rectifier column top
temperature
Pre-rectifier column bottom
temperature
Exhaust column top
temperature
Exhaust column bottom
temperature
Pre rectifier column Rum draw
plate temperatures
Pre rectifier column RS draw
plate temperatures
Pre rectifier column LFO draw
plate temperatures
Pre rectifier column HFO draw
plate temperatures
Purifier column top
temperature
Purifier column bottom
temperature
Instrument
Tag No.
Value
Unit
TI – 400
81
Deg. C
TI – 409
70
Deg. C
TI – 402
68
Deg. C
TI – 404
70
Deg. C
TI – 576
81
Deg. C
TI-452
45
Deg.C
TI-451
67
Deg.C
TI – 484
45
Deg.C
TI – 490
70
Deg.C
TI – 477
70
Deg.C
TI – 476
82
Deg.C
OPM/DIST/CNT WINE AND LIQUOR CO.LTD.KANCHANABURI,THAILAND
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hfd
fh
fdhd
dfhf
hfd
ff
D2005061
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Rectifier cum exhaust Column
Bottom Temperature
Rectifier cum exhaust column
top temperature
Rectifier cum exhaust column
R. S. draw plate temperature
Rectifier cum exhaust column
HFO draw plate temperature
Rectifier cum exhaust column
LFO draw plate temperature
FOC Column Bottom
Temperature
TI – 530
126
Deg. C
TI – 541
98
Deg. C
80
Deg. C
88-92
Deg. C
82-86
Deg. C
TI – 551
126
Deg. C
FOC column top temperature
TI – 558
98
Deg. C
FOC column R. S. draw plate
temperature
FOC column HFO draw plate
temperature
FOC column LFO draw plate
temperature
Simmering column top
temperature
Simmering column bottom
temperature
TI – 557
80
Deg. C
TI – 553,554
88-92
Deg. C
TI – 555,556
82-86
Deg. C
77
Deg. C
TI – 538,
539, 540
TI –
532,533,534
TI –
535,536,537
TI – 578
TI – 576
Deg. C
Pressure:
Sr.
No.
1.
2.
3.
4.
5.
Description
Degasifying Column Top
Pressure
Rectifier column top pressure
Aldehyde column top pressure
Pre rectifier column top
pressure
Pre rectifier column bottom
pressure
Instrument
Tag No.
Value
Unit
PT-400
0.396
Bar (A)
PT - 526
2.2
Bar (A)
PT – 451
0.25
PT - 481
0.28
PI - 488
0.424
OPM/DIST/CNT WINE AND LIQUOR CO.LTD.KANCHANABURI,THAILAND
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Bar (A)
Bar (A)
Bar (A)
D2005061
NOTE:
Above parameters are only guidelines. Actual operating parameters
shall be fine-tuned at site during normal operation of commissioning.
2.4
NORMAL SHUTDOWN (LONG DURATION SHUTDOWN)
Long duration shut down is generally planned shutdown for any
reason. There are some planned maintenance jobs which are to be
carried out during shut down; jobs like hot jobs, vessel entries, and
cold jobs too. SAFETY point of view it is important; not to have any
alcohol traces in the plant while carrying out any hot job or for
vessel entries. Therefore it is important to make system alcohol free
before shutting down the system. This can be achieved by take water
boiling. Following are the steps involved while taking long duration
shutdown
1. First of all make shutdown planning with respect to fermentation,
distillation. This is important because after shutdown there should be
no fermented mash lying in the fermentation section. Fermented mash
should be consumed completely.
2. Once the complete fermented mash is exhausted and when level in
mash charger is 5% start process water make-up in it. Reduce FQIC400 set point to 30 m3/hr. This way water feeding will start to mash
column.
3. Take LCV-402 in MAN mode and close; spent wash transfer to
fermentation will be stopped. Stop pump P-401 A/B.
4. Keep close watch on R.S. strength. When top temperatures of the
rectifier cum mash column starts rising; strength of R.S. draw will start
dropping. When strength of R.S. drops below 80 % v/v; stop R.S. draw
and divert this to storage tank where dilute alcohol is stored.
OPM/DIST/CNT WINE AND LIQUOR CO.LTD.KANCHANABURI,THAILAND
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D2005061
5. Adjust rectifier cum exhaust column top draw in such a way that top
temperatures should start rising continuously but steadily.
6. When top temperature of rectifier cum exhaust column becomes equal
to bottom temperature; it signifies that alcohol concentration at top of
the column is almost zero. Note that this activity generally takes
minimum twenty four hours to make system alcohol free.
7. Check samples from bottom of all the columns, from all the tanks and
sample points for concentration of alcohol.
8. Once it is clear that system is free from alcohol start shutdown
procedure.
9. Take FCV - 426 in MAN mode and close; steam to rectifier cum
exhaust column will be stopped.
10. Take FCV - 476 in MAN mode and close; steam to exhaust column will
be stopped.
11. Take FCV - 502 in MAN mode and close; steam to purifier column will
be stopped.
12. Stop process water feed to mash column by taking FCV-400 in MAN
mode and close it. Stop mash feed pump P-334A/B.
13. Take FCV-480 in MAN mode and close; draw from prerectifier column
will be stopped.
14. Take FCV-576 in MAN mode and close; draw from rectifier cum
exhaust column will be stopped.
15. Stop soft water supply to alcohol scrubber.
16. Stop soft water supply to F.O. decanter S – 411 and S - 471.
17. Stop LFO and HFO draws of prerectifier, rectifier cum exhaust column
and FOC column.
OPM/DIST/CNT WINE AND LIQUOR CO.LTD.KANCHANABURI,THAILAND
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D2005061
18. Take LCV-404 in MAN mode and close, spent wash from flash tank will
be stopped. Stop flash tank bottom pump P-501 A/B.
19. Take LCV-426 in MAN mode and close. Reflux to rectifier column will
be stopped. Stop rectifier column reflux pump P-461A/B.
20. Take LCV-428 and LCV-427 in MAN mode and close. Spent lees from
rectifier cum exhaust column will be stopped. Stop rectifier cum
exhaust column bottom pump P-462 A/B.
21. Take LCV-451 in MAN mode and close, Reflux to Aldehyde column will
be stopped. Stop Aldehyde column reflux pump P-421 A/B.
22. Take LCV-452 in MAN mode and close. Alcohol water from Aldehyde
column will be stopped. Stop Aldehyde column bottom pump P-422
A/B.
23. Take LCV-501 in MAN mode and close. Alcohol water from purifier
column will be stopped. Stop purifier column bottom pump P-451 A/B.
24. Take LCV-476 in MAN mode and close. Alcohol water from exhaust
column will be stopped. Stop exhaust column bottom pump P-412 A/B.
25. Take LCV-552 in MAN mode and close. Spent lees from FOC column
will be stopped. Stop FOC column bottom pump P-472 A/B.
26. Take LCV-577 in MAN mode and close, Reflux to simmering column
will be stopped. Stop simmering column reflux pump P-491 A/B.
27. Take LCV-578 in MAN mode and close. ENA from reflux column will
be stopped. Stop simmering column bottom pump P-492 A/B.
28. Take LCV-478 in MAN mode and close. Feeding to S - 411 will be
stopped. Stop pump P -415 A/B.
29. Take LCV-479 in MAN mode and close. Flow of R. S. / rum will be
stopped. Stop R. S. intermediate tank pump P – 411 A/B.
OPM/DIST/CNT WINE AND LIQUOR CO.LTD.KANCHANABURI,THAILAND
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D2005061
30. Take LCV-529 in MAN mode and close. Flow of FO washing will be
stopped. Stop pump P – 416 A/B.
31. Take LCV-576 in MAN mode and close. Flow of alcohol water to FOC
column will be stopped. Stop pump P – 472 A/B.
32. Stop vacuum pump.
33. Cooling water supply system.
34. Stop process water and soft water pumps.
35. Mash column Reboiler H 402 A/B/C content will be water only. Drain
the content of Reboiler.
36. After draining contents of both the reboilers perform CIP as per
procedure in 2.5.2.
OPM/DIST/CNT WINE AND LIQUOR CO.LTD.KANCHANABURI,THAILAND
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D2005061
2.5
CLEANING IN PLACE (CIP)
CIP of H-401A/B is to be done by 3% w/w caustic solution, which is
prepared in T-902. Start CIP solution supply pump P-902 A / B.
H-401A CIP
i. Take change over from H-401A to H-401B.
ii. Take H-401A off line and H-401B on line.
iii. Ensure that fermented wash inlet valve, fermented wash outlet
valve, spent wash inlet valve and spent wash outlet valve is
closed.
iv. Drain H-401A by opening respective drain valves for both the
sides.
v. Open 2 numbers of valves on CIP return line first and then open
2 numbers of valves on CIP supply line. This way H-401A will
go under circulation.
vi. Continue circulation of CIP solution through H-401A for two
hours.
vii. At the end stop the circulation pump and drain the PHE hold-up
completely.
H-401B CIP
i. Take change over from H-401 B to H-401A.
II. Take H-401B off line and H-401A on line.
III. Ensure that fermented wash inlet valve, fermented wash outlet
valve, spent wash inlet valve and spent wash outlet valve is
closed.
IV. Drain H-401B by opening respective drain valves for both the
sides.
V. Open 2 numbers of valves on CIP return line first and then open
2 numbers of valves on CIP supply line. This way H-401B will
go under circulation.
VI. Continue circulation of CIP solution through H-401B for two
hours.
VII. At the end stop the circulation pump and drain the PHE hold-up
completely.
OPM/DIST/CNT WINE AND LIQUOR CO.LTD.KANCHANABURI,THAILAND
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D2005061
NOTE:
CIP of PHE should be performed once in a week.
heat transfer effects.
It also depends upon
2.6 PROCESS TROUBLE SHOOTING
Sr.No.
1.
Trouble
Low Wash Feed
Indication
Corrective Action
Cause
Low level in
Wash Tank
Clarified Check and maintain level in
Clarified Wash Tank.
Improper functioning of Check
functioning
of
Clarified Wash Feed Clarified Wash Pump with
pump.
reference to priming and
discharge pressure
2.
3.
High analyser
column bottom
pressure
Low analyser
column bottom
pressure
High liquid
column
level
in Check and maintain level of
analyser column.
Scaling of trays
Check scaling of column
tray visually and if required
clean the column internals.
Higher Wash Feed rate
Check
and
maintain
required flow rate.
Vacuum pump operation
Check operation of vacuum
pump
Low wash feed flow
Check and adjust Wash
Feed flow
Low steam Pressure
Check bottom temperature
and pressure, adjust steam
flow to column.
OPM/DIST/CNT WINE AND LIQUOR CO.LTD.KANCHANABURI,THAILAND
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D2005061
4.
Low reflux to
columns
(Rectifier)
Low steam flow
Check steam pressure and
adjust steam flow.
High
water
temperature
condensers
outlet Check and adjust cooling
from water
supply
to
condensers.
Lower
level
in
the Maintain the level of water
Analyser Flash Tank
in the Analyser Flash Tank
Sr.No.
5.
6.
7.
8.
Trouble
Corrective Action
Cause
Low Wash Feed
Refer Point No. 1
High temperature
and Pressure of
Rectifier cum
Exhaust Column
bottom
High steam flow
Adjust steam
check steam
Scaling in condenser
Check
and
condenser
High Fusel Oil
Plate temperature
on Rectifier
Column and FOC
Column
Low temperature
of Fusel Oil Plate
on Rectifier
Column and FOC
Column
Low strength of
Rectified Spirit
Higher
temperature
flow
and
clean
bottom Check and adjust steam
flow
Higher draw of spirit
Check and adjust draw
Lower Bottom
temperature
Same as above.
Lower Spirit draw
Same as above
More
Rectified
Spirit Reduce draw. Close the
draw
from
Rectifier draw for sometime and
Column
operate under total reflux.
Low reflux in Rectifier Refer Point No. 4.
Column
9.
Loss through
Check analyser Column Check and adjust steam
OPM/DIST/CNT WINE AND LIQUOR CO.LTD.KANCHANABURI,THAILAND
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D2005061
spent wash
10.
Losses through
spent lees in
Exhaust, Rectifier
and FOC Column
bottom Pressure
flow to column
Higher wash feed
Check
and
maintain
required wash feed.
Check exhaust
temperature
bottom Increase steam flow to
column
and
maintain
bottom pressure.
Low Rectified Spirit draw
Increase draw.
OPM/DIST/CNT WINE AND LIQUOR CO.LTD.KANCHANABURI,THAILAND
Page 19 of 19