Case Study: Enhancing Distillery Performance Through Process Re-Engineering

This case study details a comprehensive process optimisation initiative undertaken at a 150 KLPD ethanol distillery based on cane syrup and B-heavy molasses.

The plant, operated by NSL Sugars Ltd., was consistently operating below capacity at 90 to 100 KLPD due to multiple technical bottlenecks. Key challenges included spent wash loss at the analyser column bottom, mechanical seal failures in the analyser condensate pump, and carryover from the fermented wash to the pre-rectifier.

Through targeted engineering interventions—such as column internals redesign, heat exchanger integration, operating mode shifts, and piping modifications—plant capacity was successfully increased to 200 KLPD.

The revamp resulted in major energy and water savings, along with a dramatic improvement in equipment reliability.

This study serves as a benchmark for sustainable capacity augmentation and energy efficiency in ethanol distilleries utilising existing infrastructure.