ENERGY AND TECHNOLOGY AUDIT MEASURES RECOMMENDED FOR IMPLEMENTATION

The above mentioned results of enterprise investigation as well as of analyses of quality indicators of the main product and raw material, made it possible to formulate a range of energy and technology measures which will enable increasing the economical efficiency of enterprise operation. For the time of performing the 1st stage of the audit, triticale grain of 59% starch content has been processed; the actual ethanol output made up 612.3l out of 1 ton of relative starch. Theoretically possible ethanol output per 1 ton of relative starch makes up 644l of ethanol (see Appendix – RECORD OF DISCUSSING THE PRELIMINARY RESULTS OF THE FIRST STAGE OF ENERGY AND TECHNOLOGY AUDIT OF THE PLANT OF UAB “KURANA” DATED 10.07.2014). It made it possible to develop two major groups of measures:

• Measures for ethanol output increase per 1 ton of relative raw starch which is supplied for processing;
• Measures for increasing efficiency of enterprise operation.

Measures for ethanol output increase are mainly based on the use of existing technological cycles, existing technological metering units and existing technological equipment; the named measures refer to the first group.

The measures of the 1st group are mainly related to the change of operation modes and approaches to process measures implementation. Measures of the 1st group are offered to be implemented on the basic of the main production cycles. The following measures refer to the first group:

As for the grinding and batch preparation cycles:

• Revamping of the unit of mixing flour and water during mash preparation;
• Restoring of grinding plates;
• Revamping of the unit of mash heating (B-104 tank);
• Changing of the scheme of adding enzymes;
• Using of the new types of complex enzymes;
• Organization of local disinfection of mash mixer;

As for the cycle of hydro-heat fermentation treatment of raw material (Fermentation No1);

• Changing of operation scheme of HDFT units

As for the cycle of raw material alcohol fermentation (Fermentation No2);

• Changing of mass mixing scheme in fermenters;
• Changing of the scheme of adding industrial yeasts into fermenters;
• Reconstruction of the system of fermentation gases disposal from fermenters, alcohol scrubber reconstruction;
• The use of antiseptic in order to exclude the wort contamination.

As for the cycle of distillation and rectification:

• Reconstruction of contact devices in distillation column.

It is very difficult to determine the economical efficiency of each measure; the calculations will be very subjective. In order to estimate the measure efficiency, especially that involving additional investments, there has been made a decision to estimate their overall efficiency in alcohol output increase from the reached 612.3l of ethanol per 1 ton of relative starch up to 644l.

The increase in ethanol output within the stated limits enables to enhance its output up to 2833.8l per day under the unchanged raw material and energy resources consumption required by the process peration.

Providing the ethanol cost is 5.00 EUR per 1.0daL (0.50 EUR per 10l), implementation of the 1st group measures has to increase income and EBITDA by 1,420.00 EUR per day or under the recommended operating mode (330 days a year) by 467,577.00 EUR per year.