BASIC SAFETY FOR POT STILL AND CONTINUOUS STILL SYSTEMS AMERICAN - - PowerPoint PPT Presentation

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BASIC SAFETY FOR POT STILL AND CONTINUOUS STILL SYSTEMS AMERICAN - - PowerPoint PPT Presentation

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BASIC SAFETY FOR POT STILL AND CONTINUOUS STILL SYSTEMS AMERICAN DISTILLING INSTITUTE 2016 CONFERENCE JOHN MCKEE CO-OWNER/DISTILLER, HEADFRAME SPIRITS CTO, HEADFRAME SPIRITS MANUFACTURING john@headframespirits.com *copy of this

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Headframe Spirits Manufacturing. www.headframes6lls.com

BASIC SAFETY FOR POT STILL AND CONTINUOUS STILL SYSTEMS AMERICAN DISTILLING INSTITUTE 2016 CONFERENCE

JOHN MCKEE

  • CO-OWNER/DISTILLER, HEADFRAME SPIRITS
  • CTO, HEADFRAME SPIRITS MANUFACTURING
  • john@headframespirits.com

*copy of this presentaLon available will beat www.headframesLlls.com aQer 4/6/16

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Headframe Spirits Manufacturing. www.headframes6lls.com

Me – a while ago

  • DisLllaLon Experience

Trayed and Structured Packing Systems

  • Atmospheric and

Vacuum DisLllaLon

  • Wiped Film

Evaporators

  • ConLnuous and Batch
  • Average operaLonal
  • utput of 2000-6000g/hr
  • f finished goods (*prior to

beverage alcohol producLon)

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Headframe Spirits Manufacturing. www.headframes6lls.com

20 MGY Caaish Oil Biodiesel Refinery 60 MGY High FFA Biodiesel Refinery

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SLIDE 4

Headframe Spirits Manufacturing. www.headframes6lls.com

Me – now

  • Co-Owner Co-Founder

Headframe Spirits

  • CTO Headframe Spirits
  • 2 DSPs
  • SLll Manufacturing Group

(*recently featured in Popular Mechanics)

  • Nerd
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SLIDE 5

Headframe Spirits Manufacturing. www.headframes6lls.com

My Wifey

  • Co-Owner Co-Founder

Headframe Spirits

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SLIDE 6

Headframe Spirits Manufacturing. www.headframes6lls.com

Regardless of size, “craQ”, “arLsan”…..

....you’re running an ethanol refinery

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Headframe Spirits Manufacturing. www.headframes6lls.com

The flow

  • Types of disLllaLon
  • How disLllaLon works
  • Incident map
  • Devices, Lps and tricks
  • Smiley face on disLllaLon column
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Headframe Spirits Manufacturing. www.headframes6lls.com

Types of Batch & Con6nuous Systems

Type Opera6onal Style Descrip6on Alembic & Pot SLll Batch Pot sLll with no trays, usually used to strip or produce low proof spirits Pot SLll w/ columns Batch Pot sLll with addiLonal trays and/or side columns, capable of producing low & high proof spirits Stripping SLll ConLnuous ConLnuous stripping sLll. Not capable

  • f producing beverage grade alcohol.

Output usually sent to a Pot SLll ConLnuous SLll ConLnuous ConLnuous disLllaLon system capable of producing finished beverage alcohol in a single pass.

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SLIDE 9

Headframe Spirits Manufacturing. www.headframes6lls.com

Other Dis6lla6on Systems & Styles

Type Opera6onal Style Descrip6on Wiped Film Evaporators ConLnuous Used in difficult to separate products, usually under vacuum to maximize deltaT Rotary Evaporators Batch & ConLnuous Vacuum based rotaLng disLllaLon. Usually lab scale. Vacuum vs Atmospheric DisLllaLon Batch & ConLnuous Lowering the vapor pressure via vacuum lowers the required heat, but increases the required cooling. Vacuum rated systems usually need to be stamped by a Professional Engineer.

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SLIDE 10

Headframe Spirits Manufacturing. www.headframes6lls.com

Alembic & Pot Dis6lla6on - Batch

  • Single Pot with a condenser.
  • OQen installed with a Lyne Arm of

various styles.

  • Capable of producing low proof

spirits in batch form

  • Direct fired or jacketed pots are
  • Qen the source of heat.

600g Alembic system, direct fired: Sonoma County Dis;llery

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Headframe Spirits Manufacturing. www.headframes6lls.com

Pot S6ll w/ Columns - Batch

  • Pot, with or without trays
  • Side columns with trays
  • Capable of producing a range of

spirits (depending upon the number of Lmes batches are re- run):

  • Stripped Low Wines
  • Low Proof Spirits (such as

whiskey, rum, etc)

  • High Proof Spirits (such as

grain whiskey, near neutral rum)

  • Neutral Spirits (NGS)

300g system, steam jacketed: Bozeman Spirits Dis;llery

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Headframe Spirits Manufacturing. www.headframes6lls.com

Stripping S6ll - Con6nuous

  • Usually single column
  • Capable of removing alcohol from

sLllage down to 0.5% ABV

  • Capable of producing Low Wines

for subsequent disLllaLon in a separate system 12” diameter, 24’ tall, steam injected stripping column, input 3-4 gpm. FEW Spirits

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Headframe Spirits Manufacturing. www.headframes6lls.com

Full Con6nuous S6ll - Con6nuous

  • Usually mulL-column
  • Capable of removing alcohol from

sLllage down to 0.5%

  • Capable of removing heads

compounds from finished spirit

  • Capable of producing a range of

spirits:

  • Stripped Low Wines
  • Low Proof Spirits (such as

whiskey, rum, etc)

  • High Proof Spirits (such as

grain whiskey, near neutral rum)

  • Neutral Spirits (NGS)

4 column, single-pass-to-finished goods con;nuous system. Headframe Spirits

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SLIDE 14

Headframe Spirits Manufacturing. www.headframes6lls.com

Differences between Batch & Con6nuous

Batch Con6nuous Volume Limited to Pot Volume Limited to Fermenter Volume

Major Variable to Product Type and Quality Time Temperature

Efficiency Greater man-hours and equipment hours as compared to conLnuous Fewer man-hours and equipment hours as compared to batch Output “average” of the hearts Specific locaLon in the “hearts”

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Headframe Spirits Manufacturing. www.headframes6lls.com

Boiling Points of Individual Compounds most

  • Zen found in dis6llery fermenta6ons

68 127 133 134 148 171 173 181 208 226 244 268 311

Boiling Point (F) HEADS HEARTS TAILS

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Headframe Spirits Manufacturing. www.headframes6lls.com

Proof goes down as temperature increases

68 127 133 134 148 171 173 181 208 226 244 268 311

Boiling Point (F)

Proof

HEADS HEARTS TAILS

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Headframe Spirits Manufacturing. www.headframes6lls.com

Opera6on of Batch S6lls

Batch Volume Limited to Pot Volume

Major Variable to Product Type and Quality Time

Efficiency Greater man-hours and equipment hours as compared to conLnuous Output “average” of the hearts

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Headframe Spirits Manufacturing. www.headframes6lls.com

Temperature

68 127 133 134 148 171 173 181 208 226 244 268 311

Boiling Point (F) HEADS

Time

Batch Dis6lla6on

Proof

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SLIDE 19

Proof

Headframe Spirits Manufacturing. www.headframes6lls.com 68 127 133 134 148 171 173 181 208 226 244 268 311

Boiling Point (F) HEADS HEARTS

Time

Batch Dis6lla6on

Temperature

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SLIDE 20

Proof

Headframe Spirits Manufacturing. www.headframes6lls.com 68 127 133 134 148 171 173 181 208 226 244 268 311

Boiling Point (F) HEADS HEARTS TAILS

Time

Batch Dis6lla6on

Temperature

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Headframe Spirits Manufacturing. www.headframes6lls.com

Opera6on of Con6nuous S6lls

Con6nuous Volume Limited to Fermenter Volume

Major Variable to Product Type and Quality Temperature

Efficiency Fewer man-hours and equipment hours as compared to batch Output Specific locaLon in the “hearts”

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Headframe Spirits Manufacturing. www.headframes6lls.com

Con6nuous Dis6lla6on – Stripping: Higher ABV

Temperature

68 127 133 134 148 171 173 181 208 226 244 268 311

Boiling Point (F) HEADS HEARTS

Proof

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SLIDE 23

Proof

Headframe Spirits Manufacturing. www.headframes6lls.com

Con6nuous Dis6lla6on – Stripping: Lower ABV

Temperature

68 127 133 134 148 171 173 181 208 226 244 268 311

Boiling Point (F) HEADS HEARTS

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SLIDE 24

Proof

Headframe Spirits Manufacturing. www.headframes6lls.com

Con6nuous Dis6lla6on – Full Con6nuous: Neutral

Temperature

HEARTS

68 127 133 134 148 171 173 181 208 226 244 268 311

Boiling Point (F)

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SLIDE 25

Proof

Headframe Spirits Manufacturing. www.headframes6lls.com

Temperature

68 127 133 134 148 171 173 181 208 226 244 268 311

Boiling Point (F) HEARTS

Con6nuous Dis6lla6on – Full Con6nuous: High Proof

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SLIDE 26

Proof

Headframe Spirits Manufacturing. www.headframes6lls.com

Temperature

68 127 133 134 148 171 173 181 208 226 244 268 311

Boiling Point (F) HEARTS

Con6nuous Dis6lla6on – Full Con6nuous: Low Proof

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Headframe Spirits Manufacturing. www.headframes6lls.com

Micro Dis6llery Incident Map 2008-2015

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Headframe Spirits Manufacturing. www.headframes6lls.com

San Luis Spirits DisLllery Dripping Springs, TX 11/07/08

  • Facility Damage
  • Injury
  • Fire/Explosion

Micro Dis6llery Incident Map 2008-2015

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Headframe Spirits Manufacturing. www.headframes6lls.com

Palmero Moonshine Anderson, SC 05/10/12

  • Fire

Micro Dis6llery Incident Map 2008-2015

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Headframe Spirits Manufacturing. www.headframes6lls.com

Alchemical SoluLons Ashland, OR 07/14/12

  • Facility Damage
  • Fire/Explosion

Micro Dis6llery Incident Map 2008-2015

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Headframe Spirits Manufacturing. www.headframes6lls.com

Tuthilltown Spirits Gardiner, NY 09/25/12

  • Facility Damage
  • Fire

Micro Dis6llery Incident Map 2008-2015

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Headframe Spirits Manufacturing. www.headframes6lls.com

Twister DisLllery Moore, OK 06/13/14

  • Facility Damage
  • Injury
  • Fire/Explosion

Micro Dis6llery Incident Map 2008-2015

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Headframe Spirits Manufacturing. www.headframes6lls.com

Cinco Vodka New Sulfur Springs, TX 10/24/14

  • Facility Damage
  • Injury
  • Fire/Explosion

Micro Dis6llery Incident Map 2008-2015

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Headframe Spirits Manufacturing. www.headframes6lls.com

Silver Trail DisLllery Hardin, KY 04/24/15

  • Facility Damage
  • Injury & Death
  • Fire/Explosion

Micro Dis6llery Incident Map 2008-2015

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Headframe Spirits Manufacturing. www.headframes6lls.com

San Luis Spirits DisLllery, Dripping Springs, TX hrp://www.nbcdfw.com/news/local/Worker-Burned-in-Blast-at-Texas-Vodka-DisLllery.html Palmero Moonshine, Anderson, SC hrp://www.foxcarolina.com/story/18254056/sLll-explodes-at-anderson-moonshine-store Alchemical SoluLons, Ashland, OR hrp://www.mailtribune.com/arLcle/20120714/NEWS/207140309 Tuthilltown Spirits, Gardiner, NY hrp://www.dailyfreeman.com/arLcle/DF/20120925/NEWS/309259986 Twister DisLllery, Moore, OK hrp://newsok.com/arLcle/4907972 Cinco Vodka New Sulphur Springs, TX hrp://www.ksat.com/news/explosion-blasts-man-through-wall-at-vodka-disLllery Silver Trail DisLllery hrp://www.reuters.com/arLcle/us-usa-explosion-kentucky-idUSKBN0NG0XK20150425

Micro Dis6llery Incident Map 2008-2015 - References

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Headframe Spirits Manufacturing. www.headframes6lls.com

  • Big assed disclaimer here….use Professional Engineers to answer your

specific quesLons. The discussion following is to be considered suggesLons only, with proper final recommendaLons made by pros in the field.

  • Who are those Pros?
  • Engineering firms like Dalkita www.dalkita.com or Professional

Engineers like Steven Stretch EE, PE at www.coreyeng.com

  • Local Fire Marshal
  • Reference to get you close:
  • DISCUS, Recommended Fire ProtecLon PracLces for DisLlled Spirits

Beverage FaciliLes (referencing):

  • NFPA
  • NEC

Safety – Big Assed Disclaimer

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Headframe Spirits Manufacturing. www.headframes6lls.com

  • Why: Even though most disLllaLon systems are considered atmospheric,

pressure and vacuum relief are required.

  • General rules of thumb
  • Crack pressure less than 15 psi.
  • Relief outlet should be piped outside the producLon area, away from

the sources of energy.

  • Vacuum relief is just as crucial as pressure relief
  • Most of the rules included can also be applied to rupture or burst disk

soluLons.

Proper Pressure & Vacuum Relief (part 1)

Loca6on Pressure Relief Vacuum Relief Pot X X Pot Jacket X *dimpled vs open jacket Column X X RecirculaLon Pumps X

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Headframe Spirits Manufacturing. www.headframes6lls.com

  • Design & selecLon by someone, with a PE, who can do the calculaLons for:
  • Size
  • Throughput required
  • Temperature required
  • PRVs from the hardware store are not appropriate for these
  • applicaLons. *excepLon for PRVs used in steam jackets.

Safety – Pressure & Vacuum Relief (part 2)

Pressure Relief Suitable for Water only Rupture disk and collar

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Headframe Spirits Manufacturing. www.headframes6lls.com

Safety – Pressure & Vacuum Relief (part 3)

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Headframe Spirits Manufacturing. www.headframes6lls.com

  • Why:
  • Standard OperaLon: A disLllaLon system will vent dissolved CO2 from

the fermentaLon and other non condensable volaLles.

  • Emergency CondiLon: Loss of water to condensers all for vapor

release from the sLll equipment.

  • LocaLon:
  • The final system vent can usually be found on the final condenser. It

should be vented:

  • Outside the enclosed producLon area
  • Use only hard piping, rated for temperature and flow
  • Piping should have no dips or low areas to collect liquid
  • Flame arrestors should be installed on the outlet

Safety – Ven6ng

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Headframe Spirits Manufacturing. www.headframes6lls.com

  • Why: Basic safety for systems includes integraLng safety interlocks

(automaLc shutdowns) for certain systems when certain condiLons occur.

Safety – Devices & Interlocks

Interlock Condi6on Ac6on Result

  • Loss of cooling water

to sLll system

  • VolaLle Sensor detects

alarm condiLon

  • DisLllaLon system

pressure exceeds 15 psi Shutdown signal sent to boiler or natural gas supply shutoff valve (same circuit as E-Stop) Energy shutdown to disLllaLon system Loss of power Area air exchange system conLnues to run for 1 hr

  • n backup power

Ensure volaLles cannot build up in disLllaLon area

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Headframe Spirits Manufacturing. www.headframes6lls.com

Safety – Preventa6ve Maintenance

Preventa6ve Maintenance Ac6on Schedule Batch Con6nuous PRV cleanout: Remove and inspect PRV for solids blocking the inlet to the PRV or blocking the valve seat in the open posiLon Semi annually

  • r aQer any

“burp” condiLon. X X Vacuum relief: Remove and ensure clear of debris or

  • bstrucLons

Semi annually X X CIP checkvalve inspecLon: (Tuthilltown) Inspect checkvalve spring or “flapper” for proper acLon

  • r erosion.

Semi annually X X

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Headframe Spirits Manufacturing. www.headframes6lls.com

Preventa6ve Maintenance Ac6on Schedule Batch Con6nuous Sight Glass seal inspecLon:

*get rid of them

Remove and inspect seals for erosion, cracks, or incomplete seals. Replace chipped or cracked Sight Glasses Semi annually X X Flame arrestors and final vents Inspect for

  • bstrucLons (bird’s

nests for instance) Quarterly X X Double mechanical seals

  • n agitators

Inspect per OEM instrucLons Quarterly X

Safety – Preventa6ve Maintenance (cont.)

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Headframe Spirits Manufacturing. www.headframes6lls.com

Safety – S6llhouse

  • Electrics area rated Class 1, Group D, Zone 1
  • VenLlaLon and 5X air exchange/hr and conLnues during a power
  • utage
  • Sprinkler system with at least 0.20 gpm/Q2
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Headframe Spirits Manufacturing. www.headframes6lls.com

Item Ac6on Condensing Water Interlock boiler operaLon against cooling water flow. Unarended (remote offsite)

  • peraLon

Never, ever appropriate. Even with automaLon and remote monitoring capabiliLes a disLllaLon system should never be run without trained personnel onsite. HAZOP Perform a Hazard and OperaLon Summary, even a basic run through can provide a lot of insights. (repeat annually) hrps://en.wikipedia.org/wiki/ Hazard_and_operability_study SLllage Temp Proper PPE should be used around spent sLllage which has not been cooled. Heads collecLon Sealed container, Cornelius kegs Storage Tanks Grounded

Safety – Opera6onal

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Headframe Spirits Manufacturing. www.headframes6lls.com

Safety - Common Equipment Failures

  • PRV:
  • Oversized
  • Not operaLonal due to blockage
  • Leaking seals, gaskets, broken check (flapper) valves which allow

volaLles into the disLllaLon room

  • VenLng not directed away from the disLllaLon room, for either final

vent or Pressure Relief devices

  • Double Mechanical seal faillure on agitator failing allowing for volaLle

release from pot

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Headframe Spirits Manufacturing. www.headframes6lls.com

Thanks…Ques6ons?