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  • Silver Trail Distillery Accident Investigation Response Report

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    State Fire Marshal releases findings of Silver Trail Distillery accident

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    State Fire Marshal releases findings of Silver Trail Distillery accident

    Copyright:

    © All Rights Reserved
    Scarica in formato PDF o leggi online su Scribd
    Segnala contenuti inappropriati
    5K visualizzazioni59 pagine

    Silver Trail Distillery Accident Investigation Response Report

    Caricato da

    WKYT
    State Fire Marshal releases findings of Silver Trail Distillery accident

    Copyright:

    © All Rights Reserved
    Scarica in formato PDF o leggi online su Scribd
    Segnala contenuti inappropriati
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    Public Protection Cabinet Housing, Bulag & Construction Divison of Fire Prevention 101 Sea Hero awd Suite 100 Franktory, Kentucky 40601-5405 none #5023!30582 Pax 03-93 1004 Tavest mn Response Report 1. Srwo case NunBER: 1oe2ain afer DAVOF Week: Fig. DATE: 22615, ‘TIME (MILITARY Ti 1OSES6TIME ZONE: BBCENTRAL CEASTERN wee NER CONDITIONS AT TIME OF INCIDENT: TEMPS9F_ IND DIRECTION ES mph 5. NAMIE(S)OF PERSON REFORTING INCIDENT: Shai aletn CAN BE REACHED AY TS ADDRES: 4 rr pay 1 SEMO RESPONSE REQUESTED BY Manta Co. EM Dieser Fook Murty ‘TIME OF REQUEST (MILITARY TIME} IZ0LEST DATEOP REQUEST: 42615, occurancy ty1 SINCLETAMILY OMULTLFAMILY (APARTMENT) EloUsiNEss HEALUCARE’ — EJINDUSTRIAL schoo. luNiveRsiry FL coRRECTIONS PLAce or worsiue MOBILESANUFACTURED HOME LJOTHER: | NOBILEMANUFACTURED HOME: [] DATA PLATE COULD YOT HE.LOCATED Year: MAKE ‘ove: 12. INCIDENT OCCUPANCY TYPE: BIFIXeD FACILITY TRANSPORTATION Clot 1 consmuucriontvee) 02 Os O4 Os HM Treornewen- rine Gexetosion riResXPLosion DSPILULEAKAGE JOTHER: alco! sill vent Oe %% umunigs | Beuscrmic Cnerumatcas Glenorane Corie UTILITIES DISCONNECTED: () YES C1NO O NAME: i Commun apoE NuMBER: 104 [RGUIELCATION MADE DAY OF WEEK: Fry DATE: (01% ‘TIME (MILITARY TIME 113 ARRIVED ON SCINE: DAN FainyDATE: (els TIME OmILITARY Tigh oat NAME: tay Man BADGE NUMER: 3 NOTIFICATION MADE DAY OF WEEK: Fray DATE: 4615 TIME (MILITARY TIMEy 1138 ‘ARRIVED ONSCENE: DAN: TadgDATE: cS TIME IILITARY TIMEy 128 (ste naRraTIvE FOR ADDITIONAL SPMO INVESTIGATORS NAME OF PRIMARY RESPONDING FIRE DEPARTMENT Ao fs Fre Dern HOW WAS FIRE DEPARTMENT NOTIFLED? Musa Couey is ARRIVED ON SCENE: DAY: dg DATE: 2043" TM (MILETARY TIME) 10:9 1 NAMEOF FinsTaN rREFICHTER: NAME OF FIRSTIN FIREFICHTER'S DEPARTMENT NAME. 22 ADDITIONAL RESPONDING AGENCIES: Oxenrucky starerouice se) Sisuenisr Boca rouice ners, ALCHOL TORACCO a FIREARMS VATA) *" EMERGENCY MEDICAL SERVICES 25) esTuck MeDicat EXaninTonsorriceaviua ” Clcounry cononed NATIONAL RESOURCES NB) BY OTHER: HS Maal ny De FD Fa "ant, Mash. 4D OF Hong ler Dato Rest OS Ose ist oF ovtstoe AGENCY INVESTIGATORS 2, OTHER: KUURY: VES JNO ——_NAMEIS: 1 Rapos OTHER: DEATIE. RIVES FINO NAMEIS} Kteflgo 1-15) ae SS TRFORRTTOR > (CAN BE REACHED AT THIS ADDRESS (INCLUDE STREET, CITY & COUNTY): S402 Awrom lighvay {OW LONG HAS THE OWNER OWNED THE PROPERTY? 17nd Atte mbit ose ino sce 198: Dac et 98M ar somped 010 Ras anes 2 NAME OF TENANT: Siler Tats Dilger __TENAST'S PHONE NO. 2704742052 CAN BE REACHED AT THs ADDRESS (INCLUDE STREET, CITY © COUNTY Sebo hr in @ StEWITNESS LOG FOR WITNESS INFORMATION. TAME OF INTERVIEWED PARTY: Spec: Baling Glownee Crenant C)omen recy DATEOF INTERVIEN, 42015 5 ANY KNOWN MECIIANICAL TROUBLE Wrri: C PLUME GD noTROUBLE KNOWN AT THE TINE INTERYTEW Ir ves, Desciin TAVEANY REPAIRS BEEN ADERECENTLY?LI VES 40 TEYES: WHEN AND Waitt WAS REPAIRED? Te Yes, WHOM MADE REPAIRS © DMeaTive Cevecrnicat, 28, HAVE VOU EXPERIENCED ANY OTHER Fis) ATTHIS FACILITY PROFERTYY?VES. NO Tes, WHEN HAT WABTHE CAUSE AD LOCATION SPFIRUGH 26 PROTECTION: SMOKE ALARM COFIRE ALARM SYSTEM CISPRINKLER {3 NONE ISSMOKE ALARM, DID SHOKE ALARM NOTIFY OCCUPANTS! VES "CIRO CIUNRNOWN 27, CINOINSURANCE ON FACILETVORERTY TSANES NSMARCE NAME: Ser Tr Dale hoor PHONE 0, 2704742152 [NAME OF INSURANCE COMPANY Chon Mul Azo Pe tons, AMOUNT OF INSURANCE COVERAGE: S20L00 cig ed cs NAME OF INSURANCE COMPANY: IASURANCE CO PHONE NO. AMOUNT OF INSURANCE COVERAGE: $ INVESTIGATION NARIATIVE, CONCLUSTION AND RECOMMENDATIONS ~~] ‘One moring of Fy: A243 (CST) eine cl fom Det Sine te Mal Ray “wanpson essing hat eer sn sel i epevan 9 asin a ape Thome ihe ‘vada epleestod been unas tah tn sd doen speed ra oon ses eve ated Dg) Thompson Ia en hed an wo ane gtd ta) renee ce ‘ego. 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Ada! nmin uy onteomng sas OF ‘orl sy the sil on nie eine ye nse copy fr a concsion Moonen hut melvsace™ | Sm Exton BRC —Cyuaruan, Cncennam Gitsoerenutven Gomer: 2. ANVFIRE ACCELLERANT DISCOVERED: CIYES INO IF VES. DESCRIRE WHERE: IF VES, DESCRIBE THE ENHANCERS DISCOVERED: 2 yiMlOTOSTAKES:EDVES CINO IF ES.ADOITIONAL MOTOS SUPLIED BY Fu Gesu 5 asawrrumgamoveneNomscenes Dyes ON sscurl lhl recs of 2039 (CST) ond raped th Mol County Shs pnd en ‘simple 9,80, IE FOLLOWING INFORMATION WAS SUBMITTED 10 THE DIVISION OF FIRE PREVENTION @ RECEIVED oY: DIGITAL CAMERA PICTURES (NUNBEROF CD'S) FIRE DEPARTAIENT RUN REPORT CoMPUTeR AIDED oiseaTcH /exD) SHEET EMERGENCY OPERATIONS CENTER C0) REPORT GkaPion onawtine WITNESS LOG SFMO CASE NUMBERS 1s0y2s111361RT v ‘RARE OF WITNESS: fy Ropes [ADDRESS OF WITNESS: £13 Cooperown Ra (CITY, STATE & ZIP CODE: Murty Ky. PHONE N z NAME OF WITNESS: a ADDRESS OF WITNESS: city, STATE & 21 coDt PHONENO! z NAME OF WITNESS [ADDRESS OF WITNESS: CciTy, STATE & 21 CODE: |__| Prono. re NAME OF WITNESS: [ADDRESS OF WITNESS: CrTy, STATE & Z1P CODr PHONE NO. = ‘NAME OF WITNESS: [ADDRESS OF WITNESS: CciTy, STATE & ZIP CODI I PHONE NO. ‘ NAME OF WITRESS: [ADDRESS OF WITNESS | cry, stares z1Pcone: PHONE NO: 7 NAME OF WITNESS: [ADDRESS OF WITNESS: iry, state & ziP cope: HONE NO. = NAME OF WITNESS: ADDRESS OF WITNESS: Civy, STATE & Z1P CODE. PHONE No. NAME OF WITNESS [ADDRESS OF WITNESS: Cry, STATE & ZIP CODE: PHONE NO: Te NAME OF WITNES [ADDRESS OF WITNESS: CCiTy, STATE & Z1P CODE: PHONE NO. - STUTMAN ee April 27, 2015 VIA E-MAIL TRANSMISSION AND US. CERTIFIED MAIL, Terry D. Wilhelm ‘The Revenoor Company, In. 20275 NW Bishop Scott Ré P.O. Box 602 ‘Yamhill, OR 97148 Re: Cincinnatt Insurance Company Insured: Balencorp, Inc. Cincinnati Insurance Company Claim No.: 243107 Date of Loss: 4/24/2015, 136 Palestine Read, Hardin, KY Dear Mr. Wilhelm: Please be advised that our offices represent Cincinnati Insurance Company, the insurance carrier for Baleneorp, Inc in connection with the above-referenced matter. On April 24, 2015, an explosion occurred at Balencorp's distiller, causing substantial damages and seriously injuring two employees. According o our prelininary investigation, the explosion may have occurred at still manufactured by and purchased from your company. Under the circumstances, Revenoot may be responsible for the damage sustained by Cincinnati's insured. Therefore, we are placing. you on notice ofthis potential claim. ‘We will be scheduling an inspection of te still and the explosion scene in the nea future. To this end, please immediately advise your company's liability insurance carier ofthe existence of Cincinnati's potential cleim against you and the need to investigate this laim, look forward to tearing from the appropiate represent of your company or insrance carer in the very near re, Very truly yours, Daniel Hogan |] Daniel Hogan Dinh Stutman Law [National Home Office $00 fee Cn, S301 For Wat, P1934: Phe 315991177: Fay 21528188 oon Sina ss Offices Nationwide = STUTMAN Een April 29, 2015 VIA E-MAIL TRANSMISSION AND U.S. CERTIFIED M; Terry D. Wilhelm ‘The Revenoor Company, Inc. 20275 NW Bishop Scott Rd P.O. Box 602, ‘Yamhill, OR 97148 Re: Cincinnati Insurance Company Insured: Balencorp, Inc. Cincinnati Insurance Company Claim No.: 2431075 Date of Loss: 4)24/2015 Loss location: 136 Palestine Road, Hardin, KY Dear Me. Wilhelm: Please find a copy of my prior notice letter directed to your company dated April 27, 2015. To date, [have not recsived a response ffom your company and/or its insurance carver. I is extremely important thal you notify your liability insurance carier about this loss as soon as possible. Your failure to do so may result in the denial of coverage by your insurance carrer. IF that occurs, then you may be solely and personally responsible for the damages sustained by Cincinnati's insured. Please tur this matter over to your insurance carrier immediately. If you do not have insurance, please contact me. ‘Thank you for your antic ted courtesy and cooperton Very rly yours, Daniet Hagan fo] Daniel Hogan Dinh Stutman Law [National Home Office 10 fe or ru 38, Fa Wading 241984 Phe 3E393117- Fe 2428 8 Simla omy Offices Nationwide STUTMAN May 12,2015 ‘VIA E-MAIL TRANSMISSION & FIRST CLASS MAIL Brook Laskey, Ese “Greg, Connor MeCoy Leavit Laskey LLC (Grey's Service 1805 Rio Grande Blvd. NW, Suite2 5338 Shamrock Lane Abaquerque, NM 87108 Deter, KY 42036 ‘Tem D. Wilhelm ‘The Revenoor Company, le. 20275 NW Bishop Scot Re, .0. Box 602 ‘Yamhill, OR 97148, Re: Cincinnati Insurance Company Insured: Balencorp, Inc, Clio Na 2431078 Date of Los: 4242015 ‘Loss location: 136Palesine Rocd, Hardin, KY Dear Al: ‘As you know, this office reresens Cincinat Insurance Company, the property insurance eae or Baleacop, Inc, in connection with the above referenced mate. all exploded on April 24,2015 causing substantial damages to Balencomy’sesiley ax well ae severely injuring two employes. We have placed ech of you onocice of potential bility forthe damages suslained by Cincinnati's insured. Please allo this corespondence to confirm tha the joint scene ingpetion is scheduled on Wednesday, ‘May 20, 2015 a 9:00am, s 136 Palestine Road, Hardin, Kentcky, Representatives of your companis andor ibility insurance cavers ar invited te aend and paripste in hs inspection. Pease be mindful ‘hat hs wil be the only opportunity you have inspect and document the lose see and to ientfy physical evidence tobe preserved. After the inspection, the scene wil be released for purposes of debris emoval, cleanup and repat and any identified evidence wil be retined. Ifyou wish tend andlor send a representative, pleas immediately contact me upoe recip ofthis earespondence. Very truly yours, Michael). Hopkins /s/ ‘Michel J. Hopkins Miitmme ce: BillCompton, Fre Marsal (a eal anamision) ‘Tm Fitz, Cinciant Insurance Company (ia email raeniscion) James M. Wells, Cincinnati Insurance Company (la e-nal ransmsion) ‘Dean Haris, Enpasering Design & Testing Corp (sa e-mail ranemision) Stutman Law National Home Office 00 en De, Se Fon Wagon a M4 Pon 28299 17 Pac 21599 18 se ela can Offices Nationwide SILVeRsTRAIL DISTILLERY JowT EXAMINATION SIGN IN SHEET ‘Addroas: 198 Passi Rod Faron, KY 4208 esting Date: 5208 Facilitator: 6 Cengton Fence Fre Maras Ose | Time: 08:00, ‘Waite ‘Companys _| Phone Eval Gea Ae Hie ny pak R026 [J com Phi god Akad Heck Depsy What ap) 270 2H Larry. Har Ofge Tlaneen Lochos! [oie | state lure evtere7 [janan lckanlO key. shu Chis WWWbins PSP her ost bro-azrgis dda nillisO Lym ver | patogee| Ware, |6o1 20 ts atuchonnauerssce Me Sain ola BIAS -AF 22) Spolowas Cesc ten Tin Midd ese, E pst _| gx- 79-200) middle do Cob ce a oe Danie Slack |founy | Slee Sip a70-437-H)| Sheksdady slarCeha/ 4 Brag meted 719-922617 IBEnaincaroaliehn Feb J ones Attornen |b i) ates | risbe rickyasclonael a , Vue. Foo sreustslpistucee [“Sratteccey| a717 _[paal@mbrdisbleny beees @%~ aav- Rae (eave: res Sete, aes Kal an0-85V arden avery STE cee. Za, ound” | divesscey |“ 9052 (2 breech Ve Gy Lap TOOL faaama | Harvey. Fauna! |ATY ised 4 met Laur | Page tort - HOWE GAN COMPANY PROPANE SAFETY CHECK ak€ous Hel0 560 are or service caus 20-05" CuomerNamispewrcrt fe SAvlue Redoutiuy Timeat Service Ct Arrived |S Ole Deprtd__ eee on HaedsY rama 0-254 2407 Perpsot Servis, _New Cason Change of Ocupney _Outef Gis Las Comparer ReguetX other Serve ee | set | net tana | oe | Gee | ome | =a = Bie" | meting | hie | cle cig] ants po sea [PY [iow ok [Guede ay Life i Teer anoow | mitt | sepa: | seater | Foe = ie | = | | wwe wwe wx [Reo ve | /ias_ 180 rT 0 [ro Loon aH Po lot pone | we] faze ewe LWWRRIO, |G qod | SUT [encase | sent iss satin [sete T 1 stalled Presto Tap Mv fo NG Did wot do Lok Cheek por oa Ne Me danasco be Fy AbahGad RUQOBIE Ts epcion cov up? Gu tena nee ie lace eee kph et en be oT wien abso cove ine oslo td he ra on fee ein ra compo ‘Some cnnrntsover deecsSnfreeon bape Caan TT = rar hava ien ald who oan a pada or otere mgs at ek ans iyo te ko ee tomes Oforte Yeu ave smela pope and can deet br eee ve ‘Tha scveheCone Sty noma avn re and ‘Shas th al oy Solvents nde mes boy owls Conner Say Ioan sped amar ie G Cl, ‘See Teaicen Sipe AEA Page 1 of 27 AE-117 Purdue University Cooperative Extension Service West Lafayette, IN 47907 ALCOHOL DISTILLATION: BASIC PRINCIPLES, EQUIPMENT, PERFORMANCE RELATIONSHIPS, AND SAFETY Erie Kvaalen, Doctoral Student in Chemical Engineering Philip C. Wankat, Professor of Chemical Engineering Bruce A. MeKenzie, Extension Agricultural Engineer, Pardue University ‘The purpose ofthis publication sto help you understand the distillation of ethyl alcool. It Fist presents ‘he basic principles involved in distillation and how the process works. The types of distilaion ‘equipment and systems that might be involved in a small fuel alcobol plant are then discussed, as ae the performance and control eriteria needed fora general evaluation ofeach. The publication concludes with discussion of safety, along with some general selection, operation and management criteria usefil in ‘evaluating alternatives, ‘The information presented here hopefully will help you decide if you want to get into alcohol production, and if so, wil help you evaluat the different options that are available to you. We will only cover those Aistlation processes and equipment capable of producing alcohol concentrations up to about 95.6 weight percent (wet basis) Remember, his publication is wot a design manual. Rather ts gol iso give a general understanding of| Aistilation processes and the performance of various equipment options inorder to aid you in evaluating alcohol production proposals and give a basis for more detailed self-study. We will not discuss fermentation processes and equipment, or uses of the finished alcohol concentrate ETHYL ALCOHOL—A VIABLE ALTERNATIVE FUEL ‘The idea of ethyl alcohol as aliquid fuel isnot new. It received considerable discussion and publicity in ‘he 1920's and 1930' asa motor fuel. Iwas used a a fuel in severl countries during World Wet Il Interest surfaced again in the U.S. inthe mid 1970s, with the advent ofthe ol embargo and cartel and the rapidly escalating oil prices that resulted fled Users bvomplon/ Documents Miy%20Documents/nspetion® avestigation... 75.2015 AELIT Page 2at'7 tthe ime ofthese rapid ol price increases, many people, particularly inthe faming community, began to look seriously at ethyl alcohol and gasoline alcohol blends as alternative fuels. However, by the ealy 1980, increased U'S. oil production plus significant drop in il consumption duc to high prices brought a corresponding world oversupply of oil and a marked drop in oil and gasoline prises. As a result interest im alcofl fuels diminished sharply. Interestingly, the increased use of unleaded fuels and subsidies for fuels using 10 percent alcohol caused man oil companies to add ety! alcohol to their gasoline asa non- lead octane improvement additive. Such fuels are not normally advertised as gasoline alcohol blends. Ione accepts, however, thatthe long range price of oil and energy will continue to increase, then ethyl alcohol as aliquid fuel, especially fr intemal combustion spark ignition engines, wil continue wo be a potentially viable alterative fuel source. The fet that alcohol may be profitably manufactured from a variety of cop and forest residues, as well as from grains themselves, enhances its appeal to farm producers. Ethyl Alcohol from "Beer" ‘Alcohol can be made fom variety of agricultural products bya three basic sep sequence: |. Breaking down the feed-stock (the rv material) chemically by a process which may involve ‘cooking and adding enzymes. Fermentating, i, the action of micro-organisms (usually yeast to produce a "beer" (The term "ber" describes the liquid traction ofa fermented mixture of water and ground or erushed grain that is usually no more than 10-12% alcohol, ence the similarity ofthe process and the final ‘alcohol content to that of domestic beer.) containing a small percentage of alcohol, along with the remains ofthe feedstock, the yeas cells and various other substances dissolved in water. 3. Separating the alcoho! from the water and other components in the bee, usually by distillation, to obtain the alcohol ina pure enough form to be used a uel Fermenting grain (cooking it in water and treating it wth enzymes to break down the starch and convert it to sugars) results in an alcobol concentration of roughly 510 percent. The finished concentration oF "beet" depends onthe amount of water used, the grain and the quality of the fermentation. This beers so tow in alcohol conten that it is useless a a fuel and must be further concentrated o obtain mixtures that will ignite and burn. For this reason a distillation column is used to produce a higher alcohol ‘concentration, (Several publications that discuss fermentation in considerable detail are listed tthe end ‘ofthis publication under "References.") DISTILLATION--HOW IT WORKS. First of al, ets look at how distillation works. We are ll generally familie with how disilled waters, produced. The wateris heated, andthe steam or Water vapor conducted avay in tube. Ihe ube is looped downward and cooling is applied below the hump, the vapor is condensed and distilled water ‘biained. This is "simple" distillation, removing a volatile substance (water) from non-volatile substances (lime, impurities, et. "Fractional" distillation is used to separate mixtures of te liquide with diferent boiling points, such as alcohol and water, Ethyl alcohol with 4 percent water boils at approximately 173° F, while water boils at 212° . A mixture ofthe two liquids will boil at all temperatures between 173° and 212°, depending on file:'C /User/beompion/Ducuments My%20Documents/nspevion*s208%20investigation,.. 7/5201 ABUT Page3 of 27 the ratio of alcohol to water Considera beaker ora glass jug filled partially witha mixture of alcohol and water at some tempersture The top of the containers ciosed except fora small hoe, to which a balloon is attached © keep air Out ‘Thus, the vessel is at atmospheric pressure, but the enelosute above the liquid level i essentially undisturbed by ai currents crculting around the jug. ‘After period of time, the amount of water vapor and amount of alcohol vapor contanedin the gaseous mixture above the liquid in the container will each e constant value, depending on the temperature and pressure. The liquid and vapor mixtures each an “equilibrium,” a condition under which there is no net ‘change in the lquidvapor ratio or in the aleohoU water ratio within either the liquid or vapor mixture However, the ratio of alcohol 1 water in the vapor phase is generally greater than the rat in the Liquid phase, because alcohol is usually more volaile than water (see Figure I) I is this characteristic of @ liquid-versus-vapor state ofa substance that permits us fo distil off an increasing concenzation of alcohol fiom dhe alcohol water mixture By bringing about a controlled series of successive sequences re-evaportion, condensation, ‘evaporation and re-condensation), each re-condensation from the previous vapor state achieves a higher alcohol concentration. This is because the alcohol in the vapor is ata higher concentration than was the ‘concentration in the liquid mixture from which twas vaporized. Figure 1 shows the vapor-versus-iquid composition when the pressure is atmospheric, The dotted line in the figure represents an equal concentration of alcohol in both the liquid end the vapor st, Note tht the alcohol concentration is consistently higher inthe vapor phase than inthe liquid phase fo: most ofthe range ofthe graph. The axes are explained later. file:(C: User/bcornpton/Dacuments/My2420Dncuments Inspetion®208%420Investigaion... 7/5015 AE-UIT Page 4 0f27 oy 6 o 2® MOO. aes V-tR ie oo A = » ge 2 “ 2 al wf ‘a - i i I ow o a 6 aa yo ow AOL UO LE wane Ge Faas De ceo. ad wea Figure 1. Equilibrium relationship between gaseous and liquid alcohol-water mixtures (atmospheric pressure). Azeotropic Mixtures ‘The previous relationships of sleohol-water mixtures hold tue upto alcohol concentrations of about 95.6 peteent. At this concentration, the two substances quit boiling sepaately (the aleaho in the vapor pase is no longer more concentrated than inthe liquid phase), and fractional ditlaion no longer works. ‘A mixture ofthis composition sealed an “azeowopic mixture”. Generally, third substance must be introduced into the mixture to pert separation by disllaton, or some other separation scheme must be used. The dels of separating the azeotrope are discussed briefly later. ‘Types of Distillation Processes Most Applicable to the Farm ‘There are two general types of distillation processes that appear applicable to farm-size fuel alcobol production with present techuology. One ithe eontinions-fud dstltion column system, in Wich a beer containing a constant alcohol content is continuously purmped into a column. The other isa pot-ype dstllaion system, in which a batch of beer, wit the heavy solid (speatgrai) not removed, i simply, boiled in place to vaporize the aleabo, The aleabol-water vapor are then freed to flow through 2 {le-/1C: Userscomplon/Documents My20Decumensnspetion”.20&%:20Investgation..._ 1/7015 AB-LIT disillaion column to bring about concentration, ‘These two procestes ae discussed in dealin the following pages. There are other fractional distillation systems that may or may not use a column 8s we normaly think of such units. They include centrifugal techniques, mechanical rotating wipers in a ube, etc, and are not discussed here, CONTINUOUS -FEED DISTILLATION COLUMN PROCESS A simplified schematic ofa continuous distillation column is presented in Figure 2. The column consis (of long tube, which includes a stripping section (the lower portion) and 2 rectifying section (he upper portion). There isa condenser located on the top end of the column and an optional reboileron the bottom. | ome eT f_— asm son es we ae. ae = a oe s—L vm > 2 Figure 2. A contiauots distillation proce ‘The process involves «controlled flow of liquid beer (preferably preheated and with all solids removed), ‘which is fed int the top of the stripping portion of the column The liquid aleahol-water mixture (beet) trickles downward through the columa, is Tow impeded or slowed by either a series of plates of continuous packing. Itpasses vapor (a mixture of Water vapor and alcohol vapor, but no it) which moves up. The source ofthe water vapor is ether steam injected from a boiler or vapor produced inthe reboilr. ‘The plates or packing serve to cause good mixing ofthe vapor and liquid, allowing the alzoho to file:/'C:/Userscompton/Documents/My'420Documenisimpetion"<208"420Investigaion... 7/5/2015 ABUT evaporate and the water to condense Atany piven point along the column, there is more aleohol in the vipr than in the liquid, but not ax ‘much as there should be according tothe equilibrium principle, Since the alcohol concentration in the vapor has not reached equilibrium, is vapor pressure causes ito evaporate out ofthe liquid, and water condenses out ofthe vapor, “These two processes must happen simultaneously, because the ist the vaporization) requires heat and te second (condensation) produces hea. Ina wel designed and insulated column all he beat supplied by the condensation goes into the evaporation ofthe sleokol ‘About the same amount of alcohol evaporates asthe amount of water that condenses. Thus, the vapor {moving up the column) constantly increases in alcohol content, whereas the liquid (owing down) ‘constantly loses alcohol This means thatthe top of the columa will have high alcohol content in both liguid and vapor, and the bottom low in alcohol content. ‘The column shown can be operated ether ina "continuous mode” ofa "batch mode similar to continuous versus bath grain drying processes. The next two paragraphs describe the differences between these modes. ‘In continuous operation, the column is brought toa balanced-opemation state. It consists ofa continuous feed input of bee, continuous outflow of "bottoms (Bottoms isa mixture of condensate water and some beer, in which not all alcohol was removed or éisilled), steam inp rom a boiler or reboilr (Tor process ‘heat nd to make up for inefficiencies) and an outpt of highly concentrated alcohol vapor. Alcohol vepor is condensed and larg fraction refluxed (recirculated) into the topof the column to contro the final concentration of the product output. This reflux fois required to produce a downward flowing liquid ‘ream in the top section ofthe column. Without the reflux steam, there can be no liquid inthe rectifying section ofthe column, which means no separation would then occur in the rectifying section. The ‘remaining highly-concentrated aleohol-vater condensate or distil is collected as product. Once the column is brought into a operating balance in "continuous mode,” he operation is ideally sustained night and day, week efter week, because each time i is shut down and must be restarted, the start-up and shut-down result in appreciable losses in encrzy and efficiency. ‘Ina batch operating mode, the column is started, brought toa balanced performance and operated until ‘the quantity (or batch) of beer on hand is distilled, The columa must then be shut down, cooled and cleaned, ready for tar-up forthe nex batch, Batch operation and performance wil be discuseed later Actual Operation in the Still Let us now describe the continuous fed distillation column processin the ail as sen in Figure 2. The “stripping” section and the "rctfying” section of the column are shown in the figure asa single vertical column unit, which is the prefered configuration, They may, however, be built side by side, interconnecied with tubing to return the output ofthe stripping unit the rectifVing section and vice versa. This makes the total height shorer, bat requires a pump o lif liquid fom te bottom ofthe second. column to the top ofthe first. Tubing must be quite large and well insulated. The vapor forthe stripping ‘ection is supplied either by stam injected atthe bottom of the column or by the reboier, which collects some ofthe liquid (mainly water) coming out the bottom ofthe columa and boils it to produce the vapor. As the vapor moves out ofthe stripper, the rectifying section increases the alcohol concentration by Ses: Users/bcompton/Documents’My*420DocumentsInspetion®20820invesigation... 7/5015 AE-LIT Page of 27 allowing the vapor flow to move p the columa against some of the final liquid product flow (reflux) ‘moving down. When the vapor finaly reaches the inp ofthe rectifying section, it should havea concentration of 80-95 percent alcohol, depending on te column length and the operating cenditions sed The concentrated aleohol-water vapor of 80-95 percent is then condensed to liquid in the condenser by cooling it. Roughly 23 to 3/4 ofthe final liquid is returned tothe rectifying section of the stil as “reflux” (a iguid ot high sleobol concentration) I provides a highly volatile source of alechl vapor to facilitate high final-productconceatration and wo condense out some ofthe remaining water vapor This reflux ts necessary o obiain a concentrated alcohol product. The remaining liquid flowing from the condenser (about 1/310 1/4 ofthe ttl) isthe finished product, ready for whatever use is intended. The ratio of amount of alcohol resumed to the column fo amount collected as product is called the "reflux rato." This ratio contols both product purity and amount of energy required forthe distillation, The higher the reflux rai, the purer the alcohol product and the more energy that is required for distillation. ‘The incoming beer feed, if wellfitered, may be used as pat ofthe cooling fluid in the condenser, This will bring sbout condensation ofthe reflux and finished product, while atthe same ime preheating the beer feed just befor it enters the stripper section. Thus, a minimum of added heat is needed to bring bout the inital alcohol vaporization (tipping) operation. When the relus liquid reaches the botom of the estifier, it enters the feed input level and joins the Fee, ‘which s prebeated beer. The mixture enriches the alcohol content ofthe hot beer and Facilitates the vaporizing (stripping) process asthe liquids flow down against the upward low of steam anc alcohol ‘vapor. As the steam moves upward, it causes the alcohol to vaporize from the liquid as some of the water ‘vapor condenses. Ifthe vapor composition at every point in the entire column is ploted versus the corresponding composition ofthe liquid, the result isthe two lines (operating lines) of Figure 3, shown superimposed on ‘he enuilibrium diagram of Figure 1. The axes are based on bow many alcobol molecules there are per Inundred molecules, rather than on a weight bass (This is because one alcohol molecule evaporates for ‘very water molecule that condenses: thus, the numiber of molecules of vapor passing a given point per second doesn! chenge as you move up the colum, andthe same goes forthe liquid. So ifthe stripper has, for instance, four times as many molecules of liquid as of gas passing some point near the top it will, also have four times as many molecules of liquid as of gas passing some other point near the botom This ‘ments tht if the molecular composition ofthe gas changes by pereat ina certain segment of the colums, then the molecular composition of the liquid has to change by percent inthe same segment, regaiess of where that segment is.) The two lines in Figure 3 are straight, having a constant slope when axes of molecular percent are used, (Weight percent is also shown onthe horizontal exis, so conversion canbe made very easily.) The slope of an operating line is directly related to the ratio of flows of liquid to vapor: the higher the slope, the more liquid flow to vapor flow there is, {le:CUserswomplow/Ducurmens My*<20Decumentsinspetion"s208%420Investigation... 75/2015 Figure 3. Operating lines for stripping and rectifying. ‘The Yoperaing line” of the rectifying section intersects the dottedine of equal vapor and liquid ‘compositions atthe high end. This is because the reflux (the liquif added athe top) was part of the vapor ‘hich has now beea condensed and now has the same compositca asthe vapor The higher the alcohol concentration inthe product, the smaller will be the slope ofthe operating lie (since operating and equilibrium lines cannot intersect) and the greater the reflux wil have tobe. ence, less product is bined per pound of vapor if te products higher in aleobol, ard more energy is used per pound of product. ‘The equilibrium curve inthe figure has a "sway-beck” at high coeceatrations. To get a product really close tothe azeotrope, the slope of the operating line must be increased to almost 4S degrees, Ths means increasing the amount of reflux liquid until it almost equals the amount af vapor owing up, thereby increasing the reflux ratio sharply. This procedure leaves less actual product, since most ofthe condensed ‘vapors have to be sent back down the column. Consequently it take about ivive as much energy to get a gallon of 95 percent aleabol (by weight) ait does to get a gallon of 8S percent alcohol Plate or Tray-Type Columns ‘The length of eolums necessary to bring about 2 given concentration of final product is determined from the operating relationships presented in Figure 3. Consider a column constructed with plates” along its entre length as shown in Figure 4. Liquid introduced into a platetype columa forms «skal pool on cach plate. The liquid flows across the plate, while the gas bubbles up through hols in the plate (called a sieve tray) Each plate or tray has a short section of tubing eut though the pate, fle:'C-AUsersbcompton/DocunentsMy*420Ducumentsinspetion*é2087420investigtion,.. 7/5/2015 wee = ours AENT Page 9 of STEW Figure 4. Sieve tray plate ofa staged column, Each plate retains aliquid layer the depth of which is controlled by the height ofthe weir. The holes in each plate are small enough thatthe vapor bubbles keep the liquid from passing through. The sight pressure of the alcohol-water vapor created by the reboller, or pot, frees the vapor to bubble chrough the holes, bi {intimate contact between the vapor (initially at lower aleohol concentrati {sat slightly higher concentration). Vapor of increased alcobol comceatration leaves the surface of each successive plate while traveling upward through the column. ‘The assembly is similar toa toadsto}, with the hollow stem positioned oft one side ofthe cap about 11 of the way in fom one edge, The top end of the tube projects above the plate surface the lower end stops just above the surface ofthe plate below. The tube is projected above the plate surface in onder fo form a miniature dam (called a "weir" to maintain a depth of liquid onthe plate. As the liquid level rises, overflow occurs into the downcomer pipe tothe next plate below. ‘The discharge end of each downcomer pipe must be positioned close tothe surface of the plate below, 0 that the fee end will be immersed inthe ligui level on tat plate. This forms liquid seal over the open end to keep vapor from entering the pipe. By positioning successive downcomer pipes on opposite sides ofeach sieve tay te liquid flows across each plat, minimizing any stagnate flow sections and helping ‘move any solids that might accumulate fom the distillation column, Sometimes the holes inthe sieve tay are covered with caps orcheckvalves to help prevent the liquid {fom coming down through the hole f the vapor Now remains strong, however, wil prevent counterlow ital Ideally, when the liquid lesves a plate in it Gow downward it should bein equilibrium withthe vapor flowing upwaed from te same plate [Now we have a theoretical basis to prediet the leahol content ofthe liquid and vapor at any plate or fie'C:Usersbcompton/Documents‘My*%20DocumentsInspeton® 208% DInvestigation... 752015 AELIT Pauc 10 of 37 stage along the column, If we want an alcohol content inthe final product of 85 percent (moles per mole), ‘hen we ean read from Figure 5 what ligud concentration would be in equiliorum withthe final vapor concentration (Remember, his isthe same asthe product concentration) This liquid concentration is that which is on the surface ofthe tp plate If we know the composition of the liga flowing down the downcomer between the top plate and the second one, we can look atthe operating line on Figure Sto determine the vapor composition flowing up between the two plats, Because the liquid descending from the second plate must bein equilibrium withthe por ising from it, we can now determine te liquid composition below the second plate ffom the equilibrium curve 0, «| 2 «| 9 ela ez | mom ne 50/8 o| fuumwone Sn Ey E ey a|* 3 «| a 2 alo i v oe ee ee ce, LL W808 Tee =O Figure 5. Stepping-off procedure to determine the necessary numberof ideal plates. ‘This procedure, shown on Figure 5, isthe method used to determine te ideal number of stages > plates needed fora given set of operating conditions. In actual practice it usualy takes roughly 1 12102 times as many actual sages as this theoretical analysis predicts, Calculations for the column design need to be precise and are usually done by computer (Column length depends on feed concentration and desired product purity, but not on amount of feed column diameter depends on feed flow rate and reflux rato Column cross Sectional area is controlled bythe allowable vapor flow tate. Since vapor Flow rate i Aivectly proportional to feed cate, the column area is directly proportcnal othe feed rato, Double the foad ‘ate and the columa area must double, columa diameter will be proportional to the square rot ofthe feed rate. Vapor flow rate also increases a the reflux ratio increases Thus, the required columa diameter will also increase when the reflux ratio s increased) (Column design is usally done by the column ‘manufacturer, not by the user.) file.//Cserstbcomptow Documents My%420Ducumenisinspeion?4208"420Invesignion... 7/5/2013 AE-LIT Page 11 0f27 Packed Columns Analterative w 2 plate-ype units the packed column. In distillation columns lrg than 4 feet in siametr, trays or plates have been found generally more economical fr alcohol production. Bu in small columns, the costo fabrication, installation and maintenance of plates often makes a packed unit less expensive and more workable, ‘Another consideration isthe ease of cleaning deposits that may form in the courte of time. In the case of| plate-type columns, deposits can sometimes be removed with a chemical rns: other times trays may have to be scrubbed (through potholes) or packing taken out and cleaned, Small-diameter plate columns are difficult t clean inside, since port holes are quite small, ‘A packed column s filed with solid objects witha relatively large amount of open space fo liquid and ‘vapor flow. The objective of a packed column, as with a plate column, is o bring about intimate contact betwoon the liquid end the vapor without too much flow resistance. Packing objects should stack loosely in the columa, having a relatively large amount of exposed surtace area, providing many surfaces for liquid and vapor ow to intermingle Packing material may range in size from 1 inch for small columns (2-4 inch diameter) o 2 inches in leagtts and/or breadth fr large columns (2 fet in diameter o more). Several examples of commeria] pockings are shown in Figure 6, For alcohol production, ceramic, polypropylene plastic of stainless steel packings may be desirable. The important criteria are: (1) efficiency of contact between the liquid and the ‘por, (2) amount af resistance to flow, (3) flow capacity (amount of vapor low per square foot of area that can occur before the vapor will prevent the liquid from coming down), () resistance ofthe packing to cortosion or dissalving and (3) cost 20investigation... 7/5015 AE-IIT Page 120627 uo en ame Figure 6, Four common types of packing. ‘The efficiency of contact between the liquid and the vapor determines a factor known asthe “height equivalent oa theoretical plate” or HETP. A HETP is estimated a follows: * Firs, find the actual alcohol separation curring in atest section of height h + Next, use an analysis lke Figur Sto determine the numberof equilibrium sages required to give the separation observed. * Then divide height of test section by numberof stages. “Marbles are poor packing. They donot spread the liquid coming down the column enough to get an efficient exposure of lquid-gs interaction, Marble packing, therefore, gives a large HETP value, requiring a tall column. Als, the inside ofthe marble isnot available Fr flow, so large diameter columns are required Another important consideration in deciding on packing material is how long the packing will old up in thot alcohol solution, Durable packing like stainless steel may lst indefinitely but i expensive iil ‘Thus, cost-benefit ratio must be considered, Some general estimates of packing properties are commonly wed, The size of the packing should ‘normally be less than 18 of the diameter ofthe column. The HETP varies with the size of packing, ftom out 1 12 feet (for I-inch packing) to about 2 1/2 feet (for 2-inch packing). Below | inch in size, the ‘e:'C-/Usersbcompton/ Documents My*%20DocumentsTnspetion=208%20Iavestigation... 7/5/2015 AE-IT Page 13 0f 37 HETP usually emains above I foot. ‘The HETP usually gets worse (larger) i the flow is either too high or too low. If exbilty in operation rate is desired, a packing should bs chosen that has alow HETP over a large range of flows. The approximate rato ofthe highest w the lowest flow rates which yield good HETP values is known a the “turndown ratio", Pall rings and Intalox sed are good in this eapect, with tumdown ratios above 6 If we know the HETP, we can estimate the required column length. Withan assumed HETP of 1/2 feet, and an ideal numberof ways inthe rectifying section often, we need a rectifying section 15 fet all, The HETP will determine the actual number of plates needed; the number should nor be doubled, All ofthe previous discussion has considered distillation proceses in terms ofa constant feed of beer of ‘uniform alcohol content. Such processes canbe operated either as a continuous o a & batch procedure POT-TYPE DISTILLATION PROCESS Inthe pot distillation process, the entire batch of beer is hented to boiling in a large container, and the alcohol-vater vapors are collected snd channeled into a dsilltion column, Such a process will always bea batch procedure and involves only the use of a roctifying caluma, since the Stripping is done as the alcohol vapors are boiled off fom the vat. A pot distillation process i illustrated in Figure 7 Sle:(C:AUsers/ocompton/Documents My*20DocumentsTnspetion®4208%20Investigation... 1/5/2015 we ABSIT NSE ( ene TAL son Figure 7. A pot-ype batch distillation process. ‘The process has the characteristic that, as alcohol vapor s boiled off from the beer, the concentration of | alcofiol in the beer becomes less and less. As the beer loses its aleahol content, the alcohol produc also ‘decreases in concentration. To prevent this, the reflux ratio must be raised. Recall chat higher reffux ratios usually mean higher proof Raising the reflux ratio means geting lest product from a given amount of vapor produced, hence a greater energy cost. When almost all the aleobot ts been boiled out ofthe beer, the process is topped and the spet silage (formerly beer) is removed The basic advantage of this pot distillation process i its simplicity. Te does not require a constant supply ot beet, which is often not available in minimum-labor fuel alcohel processes. I also provides avery simple equipment system. with cooking, fermentation and boiling for distillation carried out inthe same file: /Useribcomptor/Documents’My*420Doeuments/Inspetion™:208%,20Investiganon... 752015: we ABT Pau 13 of 2¢ vessel. This procedure may aid in sterilizing equipment between successive batches, since cooking and fermenting inthe same vessel tends to heastrilize. Separation ofthe spent grain and large slid from the beer prior to heating fr distillation isnot necessary, an added advantage Its possible to approach a continuous batching operation ina three-vessel, one-column pot stem. A ‘batch of grain would be cooked and fermented every 72 hours, with one batch ready for dstilation every 2 hours The disadvantage ofthe pot distillation process and its systema simplicity is lower distillation efficiency, ‘because ofthe diminishing alcohol concentration in the beer under continuous boiling. Typically, a pot distillation unit requires about thee times as mach energy as an equivalent continuous distillation system, ‘based on (by weight) fod 8 percent, sillage 0.4 percent and produet 90 percent. Less stored heat may be sed a the end of cooking when the slur is rapidly cooled for fermentation; and heat losses during cooking and distillation heating cannot be minimized as readily as with the constant feed press Insulation applied tothe pot to conserve heat during cooking and distillation heating may hiner cooling ‘necessary to fermentation inthe summer. Thus, amount of energy required per gallon of alcool forthe pot distillation process is high. OTHER DISTILLATION METHODS Vacuum Distillation Carrying out distilation using a vacuum (low pressure) allows use of lower temperatures andatiains higher aleotol concentrations. For instance, at 42 mm Hg pressure (about 6 percent of atmospheric pressure (Normal atmospheric pressure is 760 mm He (aillimeters of mercury columa), equivalent to 30 inches of Hg or 14.7 psi Thus, 6 percent of 14.7 psi is approximately 0.88 pi), the temperatie tthe bottom ofthe column need only be about 35°C (95° F) andthe top about 20° C (68°F). This makes it hard to condense the vapor, since there isa smaller temperature diference between the vapor and the coolant (whether ar or water). But this pressure may be advantageous if heat ie supplied at only 35° C Here, waste heat om other machinery or solar heat might be exploited. In the vacoum proces, the zeotrope (or point where distillation ceases to work) moves toward 100 percents the pressure is lowered. Ata pressure below 1/10 atmosphere, the azeotrope disappear, ‘enabling distilling al the way to 100 percent alcobol. However, the difference in volatility (aporizabilty between the water and the alcohol is silvery small, requiring a high reflux ratio (more than 20). The amount of energy used is around 15,000 BTU/pound alcobol produce, which compares to ‘combustion energy of around 11,500 BTU/pound alcohol By holding the condenser near O° F, vacuum of around 4 mm Hg could be created, The volality difference would be great enough that the energy cost would be about 6000 BTUipound. Thecolumn, however, would have to be very large to accommodate te large volume of low-pressure vaper. Vacuum

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