Advanced Column Design – Aspen Modelling for Grain Distillation and Co-Product Treatmentn

Client: Confidential
Focus: Process Simulation of Grain Whisky Columns and Co-Product Systemss
Tools Used: spen Plus®, Aspen EDR®

Overview
Allen Associates applied AspenTech software to simulate and benchmark the performance of grain whisky columns, including a world-first model of a Coffey still. In parallel, they used Aspen to evaluate co-product treatment systems for water recovery, organic load reduction, and solvent reuse.

Objectives

• Develop accurate performance models for high-throughput grain distillation systems.
• Benchmark energy consumption, separation performance, and throughput across multiple configurations.
• Optimise column-based co-product recovery systems.

Approach

The Allen Associates team built Aspen Plus models to:

• Simulate multiple configurations of grain whisky columns.
• Evaluate energy efficiency, product separation, and system stability.
• Compare real-world plant data to validate the model outputs.
• Perform scenario analysis for co-product treatment to assess the sustainability impact of different process designs.

Notable Achievement:
Modelling the Coffey Still

Aspen was used to simulate a Coffey still for the first time. Due to the complexity of congener interactions and separation dynamics, the project required the collaboration of several AspenTech engineers during key stages to ensure convergence and accuracy.

Outcomes

• Validated Column Models: Enabled benchmarking, specification of optimal operating conditions and energy recovery strategies.
• First-of-its-Kind Modelling: The Coffey still simulation and benchmarking sets a precedent in digital distilling design.
• Sustainable Co-Product Treatment: Improved design of recovery systems for water, solvents, and organic by-products.
• Decision Support: Clients used model outputs to guide investment and system selection.

Client Value

Aspen modelling allowed clients to move forward with confidence in high-value capital projects by ensuring their grain distillation systems were energy-efficient, scalable, and compliant with modern sustainability expectations. It also enabled better use of by-product streams, supporting circular economy principles.