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.

Thermal Vapour Recompression (TVR), Mechanical Vapour Recompression (MVR), and heat pump system

whisky distillery building model

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.

Starting a new project? Get in touch with our experienced team