PROJECT

BRIEF
ON
BIOETHENOL
BY :

SHITAL URJA
(ISO 9001:2015 CERTIFIED COMPANY)
VADODARA , GUJARAT

www.shitalurja.in

M. 7574864477
 INDEX:

 BRIEF DETAILS ABOUT BIOETHENOL PROCESS

 USES OF BIOETHENOL
 FUTURE PROCESPECT OF BIOETHENOL INDUSTRY
 PLANT AND MACHINERY DETAILS
 LIST OF GOVERNMENT PERMISSION REQUIRED
 LIST OF RAW MATERIAL & LIST OF FINISHED GOODS
MANUFACTURED
 ABOUT SHITAL URJA
 CONTACT DETAILS
 NOTES
 PROCESS DESCRIPTION

Introduction

Broadly speaking, processes for making alcohol by fermentation include steps for
1) Preparing the feedstock,
2) Fermenting simple sugars,
3) Alcohol recovery and often
4) Recovery of residual on-alcohol materials.
The feedstock may already contain sugars as in the case of molasses, sugarcane juice
or whey; or it may contain sugar polymers such as cellulose, hemicelluloses or starch, which
can be depolymerised to fermentable sugars.

In brief, in this process the whole cereal, normally grains, corn (maize), is ground in a mill to
a fine particle size and mixed with liquid, usually a mixture of water and backset stillage.
This slurry is then treated with a liquefying enzyme to hydrolyze the cereal to dextrin’s,
which are oligosaccharides. The hydrolysis of starch with the liquefying enzyme, called “alfa-
amylase, is helped along by cooking the mash at an appropriate temperature to break down
the granular structure of the starch and cause it to gelatinize. Finally the dextrin’s produced
in the cooking process are further hydrolyzed to glucose in a saccharification process using
the exoenzyme glucoamylase and another enzyme (Rhizozyme.) that may be added to the
yeast propagation tank or the fermenter. These separate stages of milling, cooking and
saccharification will be explained.

Milling

The incoming cereal is usually inspected upon receipt. The distiller will check the grain for
bushel weight, moisture content, mold infestation, and general appearance. If the cereal
complies with the quality control standards, it will be unloaded into silos in preparation for
milling. The purpose of milling is to break up the cereal grains to as small a particle size as
possible in order to facilitate subsequent penetration of water in the cooking process.

Hammer Mill

With a hammer mill, the cereal grain is fed into a grinding chamber in which a number of
hammers rotate at high speed. The collision of the hammers with the grain causes a
breakdown to a meal. The mill outlet contains a retention screen that holds back larger
particles until they are broken down further so that there will be a known maximum particle
size in the meal. The screens are normally in the size range of 1/8-3/16 in. For efficient
processing of the cereal starch into alcohol, the particles should be as fine as possible.

Cooking and liquefying

Cooking is the entire process beginning with mixing the grain meal with water (and possibly
backset stillage) through to delivery of a mash ready for fermentation. Figure shows the
components that make up a typical milling and cooking system.

In the continuous cooking process meal, water and backset stillage are continually fed into a
premix tank at a temperature just below that of gelatinization. The mash is pumped
continuously through a jet cooker, where the temperature is instantly raised to 120 0C. The
retention time in the U tube is only three minutes, after which it is flashed into the
liquefaction vessel at 80-90Oc and the enzyme is added (high temperature-tolerant “-amylase
0.05-0.08% w/w cereal). The residence time in the liquefaction vessel is a minimum of 30
minutes. The main advantage of this system is the relatively short residence period in the U
tube. If properly designed there is no need to add any “-amylase enzyme in the slurring
stage. However, because of the relatively narrow diameter of the tubes, some distillers add a
small amount of enzyme to the slurry tank to guarantee a free flow. The gelatinized mash
from the Flash Tank is liquefied in the Final Liquefaction Tank where liquefying enzyme
(alpha-amylase) is added. The liquefied mash is cooled in Mash Coolers and transferred to
Fermentation section for further action.

Fermentation
The purpose of fermentation is to convert sugars into alcohol. Simultaneously Carbon
dioxide is produced in Stoichiometric proportions and is scrubbed before being discharged.
We employ closed top Fermenter with adequate external cooling system to maintain
optimum fermentation temperatures. Agitators are also provided to ensure mixing and
suspension of substrate in the tank. Anaerobic conditions are maintained to ensure high
reaction rates and CO2.
Fermenters are provided with Beer well of same capacity. Two fermenters will be taken for
distillation everyday. After transfer process is complete, empty fermenters will be put to CIP
cycle.

Distillation for Wash to Rectified Spirits

Distillation scheme has three distillation columns. These columns operate under different
pressure conditions. Energy from column operating under high pressure is reutilized by
column operating under low pressure to conserve energy.

The columns in order of flow are: -

 Analyser Column
 Aldehyde Column
 Rectifier cum Exhaust Column

Fermented wash is preheated in the Fermented Wash Pre heater and fed at the top of the
Analyzer column. Analyzer Column is heated with Low Pressure Steam
Top vapours of Analyser column containing all the alcohol in the wash are sent to
Analyzer Condenser. Rest of the fermented wash flows down the Analyser column and is
taken out as spent wash from Analyzer column bottom. Condensate of Analyzer is fed to
Aldehyde Column by pump. Aldehyde Column Top is Taken as Impure Spirits Draw.
Aldehyde bottoms are fed to Rectifier cum Exhaust Column.
In Rectifier Low boiling impurities are concentrated at top of Rectifier column. The
Rectifier/Exhaust column concentrates the ethanol . A top draw is taken out as impure
alcohol from the top of the Rectifier column. Draw is Cooled & stored in RS StorageTanks
A small head cut if required is removed from the overhead stream to withdraw
Impurities. Fusel oil build up is avoided in the Rectifier cum exhaust column by withdrawing
outside streams (fusel oils).

Storage
Product streams from the various sections are initially collected in respective daily receivers
and then transferred to bulk storage tanks. Separate vent condenser is provided for each
bulk storage tank.
Capacity of Storage tanks will be decided based on location requirements.
MOLECULAR SIEVE ETHANOL DE-HYDRATION (MSDH) PLANT:

The Dehydration system offered herein is configured as a stand-alone unit

and is capable of operating independently from any other process equipment,
once properly connected to the utilities. The unit basically consists of three
beds of desiccants along with regeneration,vaporization, and recovery system.
While one bed is under feeding condition second in de- pressured condition
while third is under regeneration condition for an equal period. In such
operational conditions sieve bed have some breath in between continuous
feeding and regenerating which enhances the continuous operation without any
pressure hiccups in sievebeds.
A computer-controlled Control System actuates the required valves
operation, switching the flow from one bed to the other in a continuous
operation, at the same time constantly monitoring all process, quality and
safety. The feed is pre-heated, with outgoing product and fed to the alcohol
drum which is situated above natural circulation evaporation. Such kind of
arrangement ensures that only rectified spirit vapours are entered in sieve
beds. The resulting overhead vapors send to Sieve Bed 1, where the vapour is
dehydrated i.e. moisture is adsorbed from feed alcohol and dry product
vapours come out from the bottom of sieve bed. Product vapors are then
condensed in reboiler of column, cooled, and pumped to storage. A portion of
the dry product vapour is purge through Sieve Bed 2, under vacuum, to
regenerate the bed in preparation for cycle changeover before Bed 2 goes
feeding it is ready with pressure condition which help bed to remove trapped
moisture due thermal swing operation, and Bed 3 having de-pressure
condition which is necessary to avoid sudden high-pressure shock load of bed
to vacuum conditions. The regeneration operation forces the release of the
moisture from the desiccant, making the next bed ready for the next cycle. The
recovered low strength vapours are evacuated with help of regen pump
condensing through regen condenser and collected and recycled back to
column.
The stream (Spent Water/Spent Lees) from the bottom of recovery column,
containing negligible ethanol.
BIOETHENOL USES

Fuel Ethanol:
Ethanol is a renewable fuel made from various plant materials
collectively known as "biomass." More than 98% of U.S. gasoline contains
ethanol, typically E10 (10% ethanol, 90% gasoline), to oxygenate the fuel,
which reduces air pollution.

Uses:
Fuel ethanol is used principally for blending in low concentrations with
motor gasoline as an oxygenate or octane enhancer. In high concentrations,
it is used to fuel alternative-fuel vehicles specially designed for its use.

Ethyl Alcohol:
Ethanol, also called alcohol, ethyl alcohol and grain alcohol, is a clear,
colorless liquid and the principal ingredient in alcoholic beverages like beer,
wine or brandy. Because it can readily dissolve in water and other organic
compounds, ethanol also is an ingredient in a range of products, from
personal care and beauty products to paints and varnishes to fuel.

Uses:
Personal Care Products
Household Products
Food Additives
Fuel
PLANT AND MACHINERY DETAILS

DESCRIPTION OF SECTION

Boiler Section

Steam Turbine Section

Milling Section

Liquefaction Section

Fermentation Section

Distillation Section

Evaporation Section

Decanter & accessories, tanks with pumps

DDGS Dryer Unit (Rotary Dryer)

Alcohol Product receivers and Storage Section

Cooling Towers with pump and motor

Water Treatment Plant

Plant cabling with electric PCC panel and MCC

Plant, Equipment Electrical & Instrument Cabling
Piping for plant for Process Liquid, water, alcohol
transfer, cooling water piping with valves etc
GOVT. PERMISSION REQUIRED :

• Non Agriculture permission for land

• Construction permission for shade
construction.
• Pollution control board permission.
• Peso permission. ( Explosive
permission)
• Environment Clearance.
• Fire NOC.
• Prohibition and excise Department.
LIST OF RAW MATERIAL

 BROKEN RICE
 CLEANING REJECTED MAIZE
 ANY AGRI COMMODITY CONTAINING GOOD AMOUNT OF
SOLUBLE STARCH CONTENT

LIST OF FINISHED GOODS

BIO –ETHANOL And CATTLE FEEDSTOCK

In this process, we get 2 Productfrom our any given Raw material.

1. Bio –Ethanol
2. DDGS - Cattle feedstock Bioethanol

we get different ratio depends upon feedstock

ABOUT SHITAL Urja

• We at Shital Urja are dedicated with passion and

enthusiasm for helping young entrepreneurs is a real
encouragement to proceed with a business start-up right
from providing basic information , procurement of plant
and machinery , loans , subsidies , market research for
projects .

• Shital Urja is a well known technical company providing

focused turnkey solutions and we have been following
stringent system and procedure to ensure only top
quality strictly in conformity with delivering the needs of
our clients in this rapidly growing & changing market.
Our team is behind the success of many clients in their
investment.

• Over the years, SHITAL Urja has become a well known

name in the industrial and agriculture world for delivering
a wealth of technical services and solutions to clients,
both large and small. We provide the turnkey solutions
through comprehensive knowledge of equipment and
practices through our excellent team at a very
economical price.

• TYPES OF PROJECTS WE EXECUTE

 BIOETHENOL PLANTS
 BIOCNG PLANTS
 BIOMASS BRIQUETTING PLANTS
 BIOFERTILISERS PLANTS
 CONTACT US

SHITAL URJA
(AN ISO 9001:2015 CERTIFIED COMPANY)

REG. OFFICE : C 101 FOUR SQUARE , BH.

BILLABONG SCHOOL , NEAR VIVANTA
HEIGHTS , VADSAR , VADODARA,
GUJARAT,INDIA

M. 7574864477 , 7574864480

EMAIL : [email protected]
www.shitalurja.in
Notes: