AlcoNCP’s audit results

AlcoNCP have two major audits each year. The IMS audit encompassing ISO 9001, 45001 and 14001, as well as the FSSC audit (food safety). This year’s IMS audit took place on 27 June and also served as the recertification audit, a process that happens every three years. According to compliance officer Dineshree Pillay, the recertification audit was a major event but AlcoNCP managed to secure it once again.

“There were nine minor findings that were noted and we’ve logged these onto our IO system to be addressed. ”

Projects: Multiple pump replacements

As a leading producer of high-quality neutral alcohol and Distillers of Dried Grains with Solubles, here at AlcoNCP we constantly strive to improve our performance. Process technician Lavania Govender and project manager Lumeshni Pillay report back on various pump upgrades, degassing and the copper pot installation in the setting of standards in service.

Pump upgrades

PMP530

The motor on the purified alcohol pump in the distillery was upgraded from 22kW to 37kW. This modification was required for debottlenecking as pump capacity was limited to 80% speed on the drive. Since this change, the pump speed has increased up to 85% on normal operation without concerns for trips.

PU014 and PU015

The acid condensate recovery pumps were replaced with larger DURCO models on a variable speed philosophy to maintain a level in the acid condensate tank. The old level control valve was removed as this posed a restriction on recovery flow rates. These pumps can recover up to 50m3/hr, which is double the original proposed duty. Increased recovery in acid condensate reduces the amount of fresh corporation water required to maintain levels in the acid condensate tank.

PMP490

The rinsing effluent pump was deemed inadequate to handle the solids in TNK490 and as a result, frequent blockages occurred. PMP490 was changed to a SAMCO pump with an open impeller and larger motor. The modification included a recirculation line to the tank and an isolation valve to effluent to ensure that solids remained in suspension. Since the change, callouts regarding ‘unblocking lines’ have decreased and solid recovery to TNK310 has been a priority.

Degassing and copper pot installation

Degassing in a distillery is essential for removing non-condensables. The lower degassing on TNK550A/B, HTR530 and HTR540A and B were ineffective due to a design flaw which caused reduced heat transfer efficiency in the reboilers hence more energy usage, and column pressurisation. A modification of the degassing system was done in August and October, resulting in degassing flows increasing by 5ton/h, and pressure reduction in all columns. The nosing results after the copper pot were installed were distinctly better and the nosing profile across the distillery has since changed to more sweet, fruity and pleasant odours.

Operator Training: AlcoNCP operators taking it all in their stride

It is said employees who are properly trained are more familiar with the requirements of their position resulting in increased productivity. This is exactly the feeling of the production specialist at AlcoNCP, Zinhle Mqadi. “Task books was an idea from the Ghent plant guys because it has helped them over the years to train their staff. There was quite a lot of translation that needed to be done and then we also had to adjust the task books to our plants. “In our task books, we have all these practical questions and theoretical questions that are relating to the different areas of the plant, to try and get a better understanding of certain areas of the plant and what would you do if something happens. It also tests whether you know what the parameters and specifications are.“It starts with practical issues but also covers the the oretical issues, like the formula of some of the chemicals that you use.”

Zinhle says operators and shift managers greatly benefit from these task books. “The biggest job for the shift managers is to do every part, which is all four parts of the plant. But the operators are only focussing on the areas that they are working on the front-end field operator, front-end panel operator, back-end field operator and back-end panel operator.”According to Zinhle in-depth training is of great importance at the AlcoNCP plant.

“The plant is larger and much more complicated and studying is therefore very important. Just opening and closing valves are not good enough anymore, you’ve got to understand why you have to do certain things, so training is essential. “Before we used to just make sure that people followed instructions, but now we want people to think, to sit and think about what is going on here and then make decisions. Avoiding breakdowns, mistakes and safety incidents are all included.” I’m very proud of the operators and the way that they’re taking everything on. “At AlcoNCP, we are here to build and motivate each other, you have to do that.”