Energy Reduction in Distilling – AspenTech Modelling of TVR, MVR & Heat Pump Integration

Client: Various Malt Whisky Distilleries
Focus: Energy Efficiency via Vapour Recompression and Heat Pump Technologies
Tools Used: Aspen Plus^®, Aspen EDR^®

Overview

In response to the growing need for decarbonisation in distilling, Allen Associates used AspenTech modelling tools to evaluate and optimise energy-saving technologies in both malt and grain distillation processes. The focus was on three key technologies: Thermal Vapour Recompression (TVR), Mechanical Vapour Recompression (MVR), and heat pump systems.

Objectives

Reduce thermal energy demand in the distillation process.
Evaluate the integration of low-carbon technologies (TVR, MVR, heat pumps).
Specify appropriate heat exchanger equipment based on updated energy profiles.

Approach

Using Aspen Plus and Aspen EDR, Allen Associates created detailed simulations of the distillation processes to:

Quantify energy consumption in baseline (traditional) systems.
Model alternative configurations incorporating TVR, MVR, and/or heat pump loops.
Evaluate heat recovery potential and efficiency impacts of each system.
Specify heat exchangers capable of operating under new thermal profiles, particularly where larger surface areas were needed to recover heat

Outcomes

Energy Savings Identified: Aspen simulations revealed configurations that reduced steam demand and condenser cooling requirements.
Custom Equipment Design: Heat exchangers and condensers were specified for enhanced heat recovery performance using Aspen EDR.
Carbon Footprint Reduction: The most efficient systems demonstrated significant reductions in scope 1 and 2 emissions.
Design-Ready Data: Clients were able to move directly from modelling to design with high-confidence outputs

Client Value

This modelling enabled clients to de-risk the integration of emerging technologies like vapour recompression and make evidence-based decisions about CAPEX vs OPEX trade-offs. Aspen tools provided a robust framework for identifying energy reduction pathways while preserving spirit quality and throughput.

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