Raj Process Equipments designs and executes the state of art Industrial
Alcohol Plants Manufacturers in India for distilleries right from
fermentation, distillation and evaporation with unique zero liquid discharge
guarantee. Industrial Alcohol Plants Manufacturers in India are engineered
for high yield and low cost for optimizing the profits.
Raj
Process Equipments are ultimate in Potable Alcohol Plants Manufacturers
India for alcohols for human consumption. each stage is as sensitive and
volatile as other. The size and design of Potable Alcohol Plants
Manufacturers India are finalized after due consideration to every minute
detail.
Processes
- Fermentation processes for cane molasses, juice and grain.
- Distillation processes integrated distillation plant operating at
Atmospheric, Vacuum, Multi pressure for fuel alcohol, Potable alcohol,
Industrial alcohol Superior fuel Ethanol Plant.
- Evaporator and Dryer for distillery effluents.
Fermentation
Our Fermentation system design based on crucial parameters which helps to
reduce loses of alcohol in fer mentors and increase the yield of alcohol by
controlling the unwanted byproducts.
- Fermentation systems for alcohol production are designed to handle a
verity of feed stock.
- Sugarcane juice streams (primary, secondary, mixed, syrup, filtrate
etc.)
- Cane Molasses Grains, (Wheat, Rice, Corn, Millet, Sorghum, Rye, Bajra
etc.)
Features
- High Fermentation efficiency
- Minimal wastewater generation
- Yeast separation and recycle under gravity, eliminating need for
expensive yeast separators.
- Flexibility to operate continuous as well as synchronized mode of
operations, depending on characteristics of feed stock.
- Rugged operation
- Provision to tap high purity CO2
Synthetic detergents, which are also known as syndets, were developed to
overcome the difficulties faced while using soap as a cleaning agent. Soaps
when used in hard water precipitate the calcium and magnesium salts, due to
which it's effectiveness as a cleaning agent deteriorates.
Detergent
Slurry Formulation Detergent powder falls into four major groups :
- Heavy duty detergents (high and low foaming)
- Light duty detergents
- Soap powders
- Soda products.
- Normally active ingredients used for detergents are linear alkyl
benzyl sulphonates.
Applications
Washing Powders : (Detergents, Soaps, Surface Active Agents)The
free-flowing, non-dusty, non-caking products in bead form are produced in
counter-current flow dryers with nozzle atomization is the preferred layout
for high-bulk-density detergents. Feeds are homogenized and fine-filtered
prior to passing to nozzles operating at high pressure. Hot air from
direct-fired air heaters enters at the base of the cylindrical part of the
tower with slight rotary motion. The exhaust air is drawn from the top of
the tower. Inlet temperatures vary according to product. Up to 400°C
(750°F) is used for some detergents, but lower temperatures are used
for fine washing agents. Product recovery from the drying tower is high
(99%). The fines fraction is usually returned to feed preparation. Open -
cycle dryers are normally used, Co-current dryers are used for low - bulk -
density detergents.
Soda Products : Detergent formulations consist basically of (a) an
active ingredient (b) sodium tripolyphosphate, (c) silicates, (d) sodium
sulphate. Normally the active ingredients are fatty alcohol sulphates,
primary and secondary alkyl sulphonates and alkyl aryl sulphonates.
Synthetic detergents are currently based upon linear alkyl benzene
sulphonates. Formulations are with variations as decided by each company.
Detergent Allied Products : RAJ also provides state of art powder
technology for detergent allied products like Sodium Lauryl Sulphate (SLS),
Alfa Olefin Sulphonate (AOS), Optical Brightening Agents (OBA), Linear Alkyl
Benzyl Sulphonate (LABSA), Sodium Silicate, Sodium Tri-polyphosphate (STPP).
The technology or the manufacturing process of starch differs according to
the raw material used. One of the highlighted aspect of starch processing /
extraction is that starch is produced according to the requirement of the
end users depending upon changing reaction condition (Temp, pH2 additives)
and strict process control methods. To facilitate these aspects of starch
extraction or processing, we design & develop starch processing
equipment & starch processing plants that meet varied requirements in
starch & it's derivative manufacturing units.
Usage of Starch
Some
of most common industrial uses of starch is as follows:-
- Ceramics : Starch is also used to make some packing peanuts,
and some dropped ceiling tiles.
- Textile chemicals : To reduce breaking of yarns during
weaving, the warp yarns are sized. Starch is one of the main agents used
for cotton sizing. Starch is also used as printing thickener.
- Printing industry : In the printing industry food grade
starch is used in the manufacture of anti-set-off spray powder used to
separate printed sheets of paper to avoid wet ink being set off.
- Bioplastics : Starch is used to produce various bioplastics,
synthetic polymers that are biodegradable. An example is polylactic
acid.
- Oil Exploration : Starch is used to adjust the viscosity of
drilling fluid which is used to lubricate the drill head in (mineral)
oil extraction.
- Bio-Ethanol : Glucose from starch can be further fermented to
ethanol. Hydrogen production - Starch can be used to produce hydrogen,
using enzymes.
- Papermaking
- Adhesives
Raj Process Equipments are key player internationally for Manufacturer
of Fuel-Alcohol Plants and Turn Key Solutions for Distillery Plants. The
process of distillation is one with slow dynamics and is accompanied by side
streams, making it essential to have a carefully planned and designed
control system which is best handled by.
Product
Micro
Crystalline Cellulose is a mechanically disintegrated level of D.P.
Cellulose. It comprises purified, de-polymerized, Micro Crystalline sub
micron size colloidal particles. It is produced by treating Alfa Cellulose
obtained as a pulp from fibrous plants with minerals acid.
It is a white, odourless, tasteless, extra free flowing powder which is
relatively free from organic and non-organic contaminants. It is
metabolically inert, and has excellent water absorptive, swelling &
dispersion properties, is insoluble in water, dilute acid, common organic
solvents and oils. It is partially soluble in dilute alkali.
Process
Rayon Grade wood pulp, the main raw material is hydrolyzed under very
carefully controlled conditions. After Hydrolysis, specific inclusion of
hydrophobic agents is done. This is followed by thorough washing with
de-mineralized water. The depathogenised slurry prepared is pumped for Spray
Drying and finally blended and packed.
Guar Gum Manufacturing Process
Raw
Material Conveying : On a pneumatic conveyor system Guar Gum Splits are
moved through various tubes via air pressure, allowing for extra vertical
versatility. This Pneumatic conveyor is used to carry raw material to raw
material storage hopper for further processing. The contact parts in Carbon
Steel.
Raw Material Storage : The material conveyed through pneumatic
conveying system is stored in Mild Steel hoppers. Further it is conveyed to
washing system using control valves.
Washing Conveyor : Guar splits are screened to clean and then soaked
to pre-hydrate in washing conveyor. Pre-hydrating stage is very important in
the process as it derives the rate of hydration of the final product. The
soaking and conveying of guar splits is totally depends upon the design and
manufacturing of hydration conveyor. So it plays very important role in
production of high viscous guar gum powder.
Raj Process can manufacture single, two, three, four deck hydration
conveyors as per process requirements and space available.
Double Cone/Plough Shear Mixer : Pre-hydrated Guar splits are
transferred to this mixer. With help of reacting chemicals the guar splits
are processed as per requirement. This is done to achieve high viscosity.
The plough shear has special design plough arms fixed on rotating shaft.
These mixers can be provided with the jackets for cooling or heating as per
process demand.
Flaker : Crushing of the material is done to meet requirement of
coarse material. Three hardened rolls rotate towards each other. They are
kept nearer to each other by means of thither mechanical devices or with
hydraulic system helps to create the pressure on the rolls and make the
crushing possible.
The larger particles of mass, cereals, pulses are pushed between the rolls
uniformly spread and with continuous rate through a separate device.
Flaker Dryer : Flakes are passed through a duct wherein excess
moisture is removed before grinding operation.
Ultra-fine Grinding : The crushed guar splits can be easily ground
in ultra-fine grinder this grinder grinds the material with low generation
of heat. The grinding rollers are sintered formation of coarse grain and
ultra-fine grains on metal surface.
Finally grinded material fed to the flash dryer for further drying.
Flash Drying : Flash drying is a continuous drying plant used for
drying of wet flakes of guar split by disintegrating it into fine powder by
hot air.
The short residence time of one to three seconds requires that the moisture
that should evaporate is truly surface water and that the particles in the
feed flakes are completely dispersed in the drying air.
Hot Air Generator : A direct fired or indirect fired air heater is
provided for heating the ambient air to the required air inlet temperature.
The fuel used can be either wood chips, coal or solid agro-waste.
Hot Air Ducting : The hot air ducting for conveying the hot process
air from outlet of air heater to the sling fan is provided. The hot air
ducting is made from Carbon Steel HRA painted material of construction.
Suitable insulation will be done at site for minimum heat losses.
Delivery Blower (FD) : A centrifugal blower driven by a TEFC motor
is provided as a delivery blower. The blower is statically and dynamically
balanced and is of robust construction. The blower is complete with flap
damper for regulating the flow of air. The blower is in Carbon Steel Epoxy
painted construction.
Exhaust Blower (ID) : A centrifugal blower driven by a TEFC motor
through V belt and pulleys is provided. The blower is statically and
dynamically balanced and is of Carbon Steel construction with epoxy painted.
The blower is complete with anti-vibration pads, air flow control damper for
regulating flow of air.
Cyclone : High efficiency Cyclone separator is provided for
collection of the product. The cyclone is provided in SS 304 and is complete
with a vortex breaker.
Rotary Air Lock Valve : A motorized rotary air lock valve is fitted
on the bottom of the cyclone to discharge the dry powder through the chute.
Bag Filter : Bag filter with top quality media is provided for
collection of dust. After collection of dust, dust free air is released to
air. Bag filter with Mild Steel construction is designed such a way that it
avoids channeling of air.
Roto-Shifter : Unbalances weight on the motor shaft rotates in a
plane close to the center of the mass of assembly. Rotation of the eccentric
weight causes vibration in horizontal plane which moves the material across
the screen cloth to periphery increasing the horizontal through thus
oversize material is discharged at faster rate. The Material of construction
for Roto-Shifter is Aluminum.
Blender : For homogeneous mixing of products Cone Screw Mixer or
Ribbon Blender is provided as per requirement. The material of construction
for blenders is Carbon Steel.
Zero liquid discharge systems are normally incorporated to treat R.O.
Reject streams.
Process
It
contains a combination of different types of evaporators depending upon the
nature of liquid and it's contents. The waste liquid is concentrated to the
maximum level in the evaporators which may be either falling film or forced
circulation or a combination of both. The number of stages depends upon the
quantity of liquid to be handled. The water evaporated from the evaporators
is condensed in the condenser and can be reused in the process.
The concentrated liquid is then dried in either a spray dryer or a agitated
thin film dryer. The dry product obtained in powder form can either be used
as a by-product or can be sent for land filling.
Features
- Higher steam and power economy.
- Simple construction which is easy to operate.
- Skid mounted units up to certain capacities.
- Capacity range from 1 kl per day to 1000 kl per day.
- PLC controlled systems.
Applications
They find applications in the following industries:
- Pharmaceutical industry
- Distillery Chemical and dyes industry
- Paper industry
- Steel industry
Distillery
Plant