Model-based workflow for sustainable production of high-quality spirits in packed column stills

Abstract

This study addresses water scarcity in Chilean distilleries by developing a model-based engineering workflow. Prolonged droughts, likely driven by global warming, have intensified this problem. The primary challenge is maintaining high-quality spirits while reducing cooling water and energy use during batch distillation in packed columns. This process was modeled using mass and energy balances, resulting in a system of partial differential algebraic equations (PDAE). Our workflow includes mechanistic modeling, disturbance modeling, multiobjective optimization, model predictive control, and Monte Carlo simulations. Our findings show that cooling water consumption can be reduced by up to 35 % and energy consumption by up to 14.4 % while maintaining product quality. The proposed system is robust against operational disturbances and model mismatch, ensuring consistent distillate quality. This research demonstrates the integration of model-based optimization and control strategies in batch distillation processes, which can be replicated in other fruit wine distillation processes for improved sustainability.