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Instruction Manual

CE 640 Biotechnical Production

of Ethanol

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i

CAD_9

05/2013

AllRightsReservedG.U.N

.T.

GertebauGmbH,

Barsbttel,Germany05/2013

Instruction Manual

Please read and follow the safety regulations before the first installation!

Publication-no.: 918.000 00 D 640 03 (A) CAD_9

CE 640 BIOTECHNICAL PRODUCTION OF ETHANOL

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Table of Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 Unit description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1 General view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.2 Process schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.3 Cooking tank for liquification / saccharification . . . . . . . . . . . . . . . . . 6

2.4 Fermentation tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.5 Distillation unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.6 Control cabinet and control technology . . . . . . . . . . . . . . . . . . . . . . 15

2.7 PLC controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.8 Compressed air diaphragm pump (P2 & P3). . . . . . . . . . . . . . . . . . 23

2.9 Diaphragm metering pumps (P1 & P4) with acid supply container (B3)and caustic supply container (B6) . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.10 Installation and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.11 Cleaning the tanks and supply lines with steam . . . . . . . . . . . . . . . 26

2.12 Maintenance / care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.13 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.1 Intended Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.2 Structure of the Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.3 Health hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.4 Hazards for unit and function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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4 Theory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4.1 Basics of alcohol creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4.2 Crushing the raw materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4.3 Liquification / saccharification of the raw materials . . . . . . . . . . . . . 38

4.4 Fermenting the mash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.5 Distillation of the mash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4.5.1 Basics of distillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4.5.2 Construction of a distillation . . . . . . . . . . . . . . . . . . . . . . . . 45

5 Notes on running experiments . . . . . . . . . . . . . . . . . . . . . . . . 47

5.1 Diagram of creating alcohol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.2 Liquification and Saccharification . . . . . . . . . . . . . . . . . . . . . . . . . . 49

5.3 Fermentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5.4 Distillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

6 Data acquisition software . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

6.1 Software installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

6.1.1 System requirements:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

6.1.2 Installation of software . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

6.2 Software operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

6.2.1 Menu point:Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

6.2.2 Menu point:File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

6.2.3 Menu point:View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

6.2.4 Menu point:Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

7 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

7.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

7.2 Process schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

7.3 Items supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

7.4 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

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1 Introduction

Alcohol is an important basematerial for the chem-ical industry. It is mainly obtained from food-stuffs

containing starch such as e.g. potatoes or cereal

products.

The experimental stand CE 640 Biotechnical

Production of Ethanol makes it possible to trace

and research the process of industrial alcohol pro-

duction from the liquification and saccharification

of the original materials to the conversion from

sugar into alcohol on to the distillation of the alco-hol.

The experimental stand uses two stainless steel

agitation vats for this. One is a cooking tank tem-

pered with steam and cold water and one is a fer-

mentation tank tempered with cold and hot water.

Distilling the alcohol is done witha completely inte-

grated distillation system.

Material transport through the system is done by

compressed air-driven conveyor pumps.

For optimal operating conditions, the cooking tank

and the fermentation tank have temperature con-

trols and rpm-regulated stirrers.

Control and monitoring on the system is done

on-site by an integrated PLC. Recording the mea-

surement data and monitoring can also be supple-

mented with a connected PC.

The experimental stand is used only for trainingstudents in the process-, bio- and food-stuffs tech-

nologyandis not intended for industrial purposes.

1 Introduction 1


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Learning Objectives / Experiments

Familiarization with the necessary individualsteps and system components for pro-

duction of ethanol:

gelatinisation by steam injection

liquefaction by use of alpha-amylase

saccharification by use of gluco-amylase

fermentation: conversion of sugar into

ethanol by yeast cultures under an-aerobic conditions

distillation: separation of ethanol fromthe mash

2 1 Introduction


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2 Unit description

2.1 General view

1 Steam pressure regulator valve (V1) 9 Mash pump (P3)

2 Cooking tank for liquification/ saccharification (B1) 10 Cold water control-valve (V2)3 Fermentation tank (B2) 11 Flow meter (F1)

4 Distillation unit (D1) 12 Mash pump (P2)

5 Control cabinet 13 Steam shut-off valve (V23)

6

7

Ethyl alcohol container (B4)

Mash container (B5)

14 Pressure regulator for cold watercontrol valve

8 Diaphragm metering pumps (P1 & P4) 15 Pressure regulator for steam-pressurecontrol valve

2 Unit description 3


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Fig. 2.1 General view

1 2 3 4 5

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14

13

11

12

10 8 9 8 7 6

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2.2 Process schematic

4 2 Unit description


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Fig. 2.2 Process schematic CE 640

CompressedAir

Water

Steam

WarmWater

Water

Water

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Individual components Measuring points

B1 Cooking tank (tank 1) V3 - V7 Solenoid valves

B2 Fermentation tank (tank 2) V8- V27 Ball valves, hand actuated

B3 Acid solution container V26 Steam pressure safety valve

B4 Ethyl alcohol container V28-V32 Ball valves, hand actuated

B5 Mash container T1 Mash temperature B1

B6 Caustic tank T2 Mash temperature B2

D1 Distillation unit T3 Cooling water drain temperature B2

P1 Diaphragm metering pump T4 Distillation unit water bath temperature

P2 Compressed air feed pump B1 - B2 T5 Mash temperature in distillation bubble

P3 Compressed air feed pump B2 - D1 T6 Gas temperature after bubble cap 1

P4 Diaphragm metering pump (caustic) T7 Gas temperature after bubble cap 2

R1 Stirrer geared motor B1 T8 Gas temperature after bubble cap 3

R2 Stirrer geared motor B2 T9 Gas temperature after dephlegmator

R3 Stirrer geared motor D1 Q1 pH value B1

H1 Water bath heater F1 Water flow to B1

V1 Steam control valve PI1 Steam pressure indication

V2 Cooling water control valve

The process diagram shows all components andmeasuring points on the CE 640 as well as all

required pipe connections and supply lines. There

are several ball valves to be opened or closed for

the individual operating states.

More detailed information on setting the individual

ball valves during the individual operating states

can be found in chapter 5 of these instruction.



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2.3 Cooking tank for liquification / saccharification



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Fig. 2.3 Mash tank

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1 Shaft coupling 11 Supports

2 Geared motor 12 Water supply connection

3 Acid supply 13 Sealing plug

4 Cover flap 14 Drain valve

5 Overflow connection 15 Temperature sensor

6 Cover latch 16 Connection to feed-pump

7 Hand-hold for cover 17 Cooling water drain

8 Hinged cover 18 Cooling water feed

9 Inspection glass 19 Steam feed connection

10 pH measuring probe



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Fig. 2.4 Cooker tank / Mash tank

7 8

6

14 15 16 19

4

3

5

17

18

13

10

2

1

9

11

12

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The mash or cooking tank is used for liquefying

and saccharifying the initial materials. This pro-

cess is known as mashing. The container uses an

stirrer for this, consisting of a geared motor and a

pitched blade stirrer on the shaft.

Heating the original materials is done with a direct

hot steam line into the cooking tank through a jet.

This enables an increase in liquid by around 15%.

To prevent the mash from running back into the

steam feed line, it is built into a non-return valve.

This valve can be removed from the interior of thecontainer with the jet as a complete unit.

The container is equipped with a double-jacket,

through which water can be pumped for cooling

the mash if required. Temperature monitoring is

done by a temperature sensor built into its floor.

The tank also has a pH value measuring probe for

regulating the pH value.

For the required lowering of the pH value during

the process, the tank has an acid inlet with a dia-

phragm metering pump. For the required lowering

of the pHvalue during the process, the tank has an

acid supply with a diaphragm metering pump.This

measuring probe is only installed when the system

is to be operated.

The cooking tank is designed as an open con-

tainer. That means that steam will escape through

the openings in the cover while cooking. To fill the

containerwith rawmaterialsuch as grain,potatoes

or enzymes, the cover is made in two parts and

can be opened. It is secured by means of a

latch-pin.

The container, cover and all attachment parts are

made of stainless steel.



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2.4 Fermentation tank



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Fig. 2.5 Fermentation tank

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1 Sealing plug 10 Fill opening

2 Clean-out opening 11 Supports

3 Coupling 12 Cooling water outlet

4 Geared motor 13 Cooling water control valve

5 Cover 14 Drain valve

6 Mash feed 15 Connection to feed-pump

7 Temperature sensor for mash 16 Temperature sensor for cooling water drain

8 Inspection glass 17 Cooling water inlet

9 Fermentation lock 18 Double jacket container

19 Shut-off valve for cooling water



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Fig. 2.6 Fermentation tank (Tank 2)

3 4 9 10 11 12

13 14 15 18 19

2

1

17

19

6

7

8

5

16

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The fermentation tank converts the sugar con-

tained in the mash into alcohol. This tank can be

sealedair tight and temperedwithcold and hot wa-

ter using a water jacket. The cold or hot hot water

flows through a double jacket on the outside of the

tank. The fermentation tank is equipped with an

stirrer for optimal mash mixing. It consists of a

speed regulated geared motor and an stirrer with

two pitched blade stirrers. The temperature of the

mash is monitored with a temperature sensor.

To regulate the temperature more efficiently, an-other temperature sensor is located on the cooling

water drain.

The cover of the container is equipped with a

latched clean-out opening and a fill opening. The

stirrer shaft is run into the container through a fer-

mentation lock (see Fig. 2.7).

1 Geared motor

2 Coupling

3 O-ring

4 Divider

5 Stirrer shaft

6 Sealing liquid area

7 Cover

8 Sealing liquid

9 Spacer post for geared motor

10 O-ring

Thesealing liquid(normally water) in thefermenta-tion lock completely closes the interior of the con-

tainer off from the atmosphere. The CO2 gener-

ated in the fermentation process pearls up as gas

bubbles through the sealing liquid and escapes

into the atmosphere without the air from outside

being able to enter the container.

In order to improve monitoring, the fermentation

lock is made of transparent plastic.



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Fig. 2.7 Fermentation lock, cut-out view

1

2

3

4

5

6

7

8

9

10

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All other components of the fermentation tank are

made of stainless steel, as is the cooking tank.



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2.5 Distillation unit



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Fig. 2.8 Distillation unit

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The distillation unit is a modified boiler heater with

water bath (6). It contains bubble cap (1) tray col-

umn, dephlegmator (2) and condenser (4). T1 -

T10 indicate the positionsof the individual temper-

ature sensors in the system. For a detailed de-

scription of the individual components and mea-

surement connections, please read the attached

operating instructions of the manufacturer.



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Fig. 2.9 Distillation unit, overview

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2.6 Control cabinet and control technology

1 pH transducer

2 PLC controller (touch-screen)

3 Schematic diagram

4 EMERGENCY STOP button

5 Master switch

6 PC connection, USB

The control cabinet contains all required control

and regulating elements of the CE 640.

Control and regulation are carried out by the PLC

controller (PLC = programmable logic controller)

built into the side of the control cabinet. The con-

troller is menu guided. All entries and control in-

structions are entered via the touch screen. The

actual control of individual components such as

regulating valves, stirrer, pumps and heating con-



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Fig. 2.10 Control cabinet, overview

1

2

3

4

5

6

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trol is handled with the PLC installed in the control

cabinet.

All of the temperatures that are recorded in the ex-

perimental stand are shown on the touch screen.

The pH values and the temperature from the pH

measuring probe are shown on a separate mea-

suring device.

The entire system can be switched on or off with

the main switch.

Actuating the EMERGENCY STOP button switches

the electrical power off for the entire system.

The measurement data can be recorded and

saved through an interface on the side of the con-

trol cabinet using the respective data acquisition

software.

The measurement data can be recorded and

saved via a USB interface to the bottomright of the

side of the control cabinet using the associated

data acquisition software.



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2.7 PLC controller

The PLC controller is started automatically whenthe experimental stand is switched on and shows

the start menu (Fig. 2.11).

On the Start menu, you will find an operating hour

meter and some touch fields.

The sub-menus are reached by touching the indi-

vidual touch fields on the screen.

The screen offers choices between the parameter

settings for temperature control circuits in:

Mash (Cooking) tank (tank 1) with tem-perature- und pH-value control

Fermentation tank (tank 2) and

Distillation with temperature control

The parameters for the control circuit must match

the respective installation location and the respec-

tive environmental conditions. For details in this

regard, please refer to current technical literature

on control technology.

To change the user language go to sub-menuPa-

rameter (Fig. 2.12)

From here, the display language for the PLC con-troller can be changed.

The system time, date and the brightness of the

screen can also be set.

If an error has occurred on the PLC, a list of the er-

rors that have occurred will be displayed.

Return brings you back to the previous start

menu.



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Fig. 2.11 Start menu

Fig. 2.12 Parameter

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From the start menu (Fig.2.11), the Mash tank

B1 can betouched tochangeto the menurespon-

sible for the cooking tank.

This menu can be used to regulate the tempera-

ture T1 and to set the pH value in the container

(Fig. 2.13). In this instance (controlled operation)

the actual value is shown (1) and the set value of

the controller is displayed (2).

The pH value in the cooking tank is regulated by

adding acid and caustic using the diaphragm me-tering pumps.

To activate thesecontrollers, thebutton" Manual"

(3) is to be switched to " Auto".

On the display(4), the control valve set value can

beread for the temperature control for T1. If the set

value of the valves should be controlled manually,

the button (3) for temperature T1 must first be setto Manual. This activates field (5) and the set

value can bedefined between -100% and +100%.

-100% = Cooling water valve fully open

+100% = Heating steam valve fully open

The button"R1" can beusedtoswitchthe stirrer on

or off.

The following is standard for switch fields

Switch field is green : Element is switched on

Switch field is red : Element is switched off



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Fig. 2.13 Mash tank

1 3 2

4 5

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On button(7), the rpm of the stirrer can beset.The

rpm/speed can also be changed with the stirrer

running.

Using the buttons "V6", (8) und (9) , tank 1 can be

fed a defined volume of fresh water. Button (8) is

used for defining the volume in this case. Button

"V6" is used for activating a solenoid valve, which

opens the fresh water supply. A flow meter is used

to determine the quantity of water flowing and this

is displayed with display (9). After achieving the

present volume, the solenoid valve closes auto-matically.

Button "Pump P2 " is used for actuating a com-

pressed air-driven diaphragm pump, which feeds

the container contents from tank 1 to tank 2.

Return brings you back to the previous menu.

The "Next" button (Fig.2.15) can be used for set-

ting the control parameters Kp, Tn and Tv for the

heating steam and cooling water control valve.

The button " Graph " can be used to show the

progress of the temperature and the pH value over

time.

The control valves for the temperature control of

tank 1 is a consistent pneumatic control valve,

which is regulated with an analogue signal.



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Fig. 2.14 Mash tank parameter

Fig. 2.15 Mash tank

7 8 9

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The control menu of tank 2 is constructed the

same as the one for tank 1 (Fig. 2.13).

The difference is that tank 2 only has a tempera-

ture control for cooling.

The stirrer can berun either in temporal intervals or

continuously.

Following settings are possible:

stirrer speed in rpm

on-time in min off-time in min

With Buttons "Pump P2" and "Pump P2" both of

the compressed air-driven diaphragm pumps are

operated.

Pump 2 feeds the container content fromtank 1 to tank 2.

Pump 3 feeds the container content fromtank 2 into the distillation unit.

The settings for control parameters Kp, Tn and Tv

for tank 2 is made the same as for tank 1

(Fig.2.14).

Tank 2 has a solenoid valve as actuator. There-

fore, a minimum switch-on duration can be set forthe solenoid valve in the menu with parameter

minimum on period. The precision of the

controller can be set with the period parameter.

The greater the value of period in relation to

minimum on period, the more precise the

controller can work.

The actuator solenoid valve is activated by binary

switching signals.



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Fig. 2.16 Fermentation

Fig. 2.17 Fermentation parameter

Fig. 2.18 Fermentation

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In the menu for distillation, the temperatureT9 is

regulated as a command variable for the distillation

(Fig. 2.19). The function of the individual buttons

and displays are the same as for tanks 1 and 2.

An stirrer in the distillation bubble can be operated

from this page of the menu. The rpm of this stirrer

is not variable.

Pump 3 can be operated from here to fill the distil-

lationbubblewith thecontainercontent of tank 2.

On a diagram with the positions of the various sen-

sors all measured temperatures of the distillation

unit are shown.


The settings for control parameters Kp, Tn and Tv

for distillation are made the same as for tank 1

(Fig.2.14).

The distillation has a heater as an actuator. There-

fore, a minimum switch-on duration can be set for

the heater in the menu with parameter minimum

on period. The precision of the controller can be

set with the period parameter. The greater the

value of period in relation to minimum on pe-riod, the more precise the controller can work.

The actuator heater is activated by binary switch-

ing signals.

The parameter deviation for change over

describes the relationship between command

variable control and disturbance variable control.

Normally this parameter is set to 0




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Fig. 2.19 Distillation Parameter

Fig. 2.20 Distillation, over temperature

Fig. 2.21 Distillation

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From the start menu (Fig. 2.11), the Measure-ment button can be actuated to bring up an over-

view ofallmeasurement data from theentireunit.

An numerical input field (Fig. 2.23) appears forentering command variables or for changing

parameters or speeds (rpm).

Numbers are entered here without any delimiters

or separating characters of any kind and must be

confirmed with RET.

Example:

To enter a temperature of 40.5C, the numbers

405 must be entered and then the entry must be

confirmed with RET. The separation character is

inserted automatically and the value is accepted

as a new command variable.



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Fig. 2.22 Example for numerical input

Fig. 2.23 Measurement

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2.8 Compressed air diaphragm pump (P2 & P3)

To feed the container content from the cookingtank (B1) into the fermentation tank (B2) and then

on to the distillation unit (D1), the CE640 system is

equipped with two compressed air operated -

double diaphragm pumps. These pumps require a

compressed air supply to function. The maximum

air-pressure is set on a pressure regulator (1) on

the respective pump. The supply volume of the

pumpisset witha control valve (2). Air lines can be

removed from the threaded connections (3).

The compressed air diaphragm pumps are

designed for transferring liquids up to a viscosity of

10,000 mPas. Solid material particles having a

diameter of up to

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2.9 Diaphragm metering pumps (P1 & P4) with acid supply container (B3)

and caustic supply container (B6)

The mash must be acidified to optimise the

saccharification process. Acid is added using the

diaphragm metering pump (P1), while caustic is

added using the diaphragm metering pump (P2).

Both pumps (Fig. 2.27 & Fig. 2.28) are operated

using the PLC controller. The acid solution from

the supply container (B3) and the caustic solution

from the supply container (B6) are conveyed into

the cooking tank through a hose connection.The feed quantity can be set on the front of the

pump:

Adjusting the pump stroke and

Adjusting the stroke frequency

The pump stroke is set with a rotary knob be-tween 0 and 100%

The stroke frequency is set with the small ro-tary knob between 0 and 100%.

The pump cannot be started by hand (manually),

only by an external signal from the PLC.

Diaphragm metering pump



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Fig. 2.26 Diaphragm metering pump (P1)

Fig. 2.27 Diaphragm metering pump (P4)

Fig. 2.28 Tank (B3 & B6)

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2.10 Installation and commissioning

The installation and commissioning of the devicedemands a few prerequisites from the installation

location and the supply equipment:

Setting up the test stand. The front and theleft and right hand sides of the test stand

must be readily accessible. The room in

which the test stand is set up must be ade-

quately ventilated.

Connect the water supply to (4) cold waterand (5) hot water (Fig. 2.29)

Attach drain lines to (1).

Attach steam supply to (2), technical special-ist only.

Attach steam pressure-relief line to (3), tech-nical specialist only. The steam pressure-re-

lief line must end in a secure space or in theopen, outside.

Connect the compressed air supply for thesystem (6) (connection in the bottom right of

the left side).

Attach the power supply (ensure that the cor-rect voltage supply is used!).

Check the fuse in the control cabinet before

switching the unit on. Screw the pH measuring probe into tank 1

and make electrical connections.

Switch on the unit at the master switch.



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Fig. 2.29 Supply connections

1 2 3 4 5 6

Fig. 2.30 Supply connections

1 3 2 4 5 6

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2.13 Shutdown

When the system is to be shut down or anylength of time, all supply lines are to be dis-

connected and all liquids are to be drained

from the hoses and system components.

The pH measuring probe is to be removed,packaged and storage according to section

2.12.

All parts of the system and hoses are to be

cleaned thoroughly and any encrustationand solids are to be removed.

Completely emptyandrinse the container forthe acid solution.

Rinse out the diaphragmmetering pump withlotsofwater to removeany residualacid from

the pump and the hose connections.

Disconnect the system from the electrical

power supply.



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3 Safety

Before putting the device into operation, the

experiment instructions are to be read thor-

oughly and especially the safety notes

Prior to starting the experiments, all partici-

pants are to be briefed on the safety aspects

and the correct handling of the unit!

3.1 Intended Use

The unit is tobeusedonly for teachingpurposes.

3.2 Structure of the Safety Instructions

The signal words DANGER, WARNING or CAU-

TION indicate the probability andpotential severity

of injury.

An additional symbol indicates the nature of the

hazard or a required action.

Signal word Explanation

DANGER Indicates a situation which, if not avoided, will result in

death or serious injury.

WARNING Indicates a situation which, if not avoided, may result in

death or serious injury.

CAUTION Indicates a situation which, if not avoided, may result inminor or moderately serious injury.

NOTICE Indicates a situation which may result in damage to

equipment, or provides instructions on operation of

the equipment.

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Symbol Explanation

Hazardous Electrical voltage

Risk of burnshot surface

Toxic materials

Corrosive materials

Risk of entanglementrotating parts

Hand injuries

Notice

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3.3 Health hazards

WARNING

Electrical connections are exposed when the

control unit is open.

Risk of electric shock.

Disconnect from the mains supply beforeopening.

Work should only be performed by qualifiedelectricians.

Protect the control cabinet against water andmoisture.

WARNING

Hazardous electrical voltage

Risk of electric shock. Never operate the unit without a correctly in-

stalled earth wire.

Non-compliance with this requirementmeans that the operator and the unit are no

longer adequately protected.

Incaseofdanger, isolate the systemfromthemains by using the EMERGENCY STOP

button or unplugging.

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WARNING

The alcohol that is produced with this systemis raw alcohol and is not suitable for consump-

tion.

DANGER of poisoning!

Consumingrawalcohol, even in smalldoses,can lead to irreversible damage to health!

While operating the distillation, make surethat there is proper ventilation to prevent an

accumulationofalcohol ingredients in theair.

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WARNING

Steam lines and partsof the distillation unit getvery hot. Hot steam can escapeat the pressure

relief line.

DANGER of burning / scalding!

Tank 1 becomes very hot during the heatingoperation. Do not touch the jacket surface of

the tank during operation .

Neveroperate the steamheating for tank1with-

out a closed steam pressure-relief line.

Never operate the steam heating of tank 1without the water supply in tank 1.

While operating the distillation unit, much ofthe equipment will get very hot. Do not touch

the surface of the water bath, the distillation

bubble and the column.

Observe all safety notes for the distillation unit in

the attached operating instructions of the manu-

facturer. Non-adherence can lead to extensive

danger to health.

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WARNING

Handling acid and caustic carries a risk ofchemical burns.

DANGER of damage to health!

The hazards and safety information de-scribed in the safetydata sheets must be fol-

lowed closely when handling the acid and

buffer solutions used in the experiments.

WARNING

Rotating parts.

RISK of injury!!

Do not reach into the rotating coupling of thestirrer in tank 1.

Do not reach into the rotating coupling of thestirrer in tank 2.

Do not reach into the rotating stirrer of thedistillation bubble.

WARNING

Risk of crushing at hinged lid.DANGER of injuries !

When opening tank 1, always secure thecover with the latch-pin.

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3.4 Hazards for unit and function

NOTICE!

After completion of individual sections of theexperiment, always clean and rinse any sys-

tem parts and hoses/lines that have been

used, thoroughly.

NOTICE!

The pHmeasuring probe isnever tobeput intostorage dry. After using the measuring probe,

remove it, clean it and put in wet storage.

In addition, followthe instructionsof themea-

suring probe manufacturer.

NOTICE!

After the experiment, do not leave any acidicsolution in the acid container and acid supply

container. After using acid, remove all acid

from the acid container, diaphragm metering

pump and hose connections and rinse out

with water.

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4 Theory

4.1 Basics of alcohol creation

The foundation of alcohol creation is the alcoholic

fermentation through which glucose with the addi-

tion of yeast causes ethanol and carbon dioxide.

This happens according to the following formula:

C6H1206 -> 2 C2H5OH + 2 CO2

glucose + yeast -> ethanol + carbon dioxide

The yeast is used as a biological aid in creating al-

cohol, which starts the initial conversion of the glu-

cose into ethanol. Information on the precise prog-

ress during alcohol fermentation can be found in

popular literature on the subject.

To distil alcohol from high-starch content raw ma-

terials that normally have very low glucose or

sugar contents, the raw material must go through

various process steps in order to obtaina sufficientamount of alcohol.

The process of alcohol creation is divided into five

steps:

Crushing the raw materials

Condensation

Saccharification

Fermentation

Distillation

Each of these steps requires different process

conditions to achieve optimal yields of alcohol.

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4.2 Crushing the raw materials

The target of crushing is pulping the starch con-

tained in the raw materials. During this process,

ensure that the starch is not destroyed during the

crushing. Pulping is normally done with ham-

mer-mills or monopumps.

Crushing the raw materials is not a component of

the CE 640 experiment stand. Information on the

topic of crushing can be read in popular literature

on the subject.

4.3 Liquification / saccharification of the raw materials

The liquification / saccharification of the raw mate-

rials, so-called mashing, has the purpose of con-

verting the starch contained in the raw materials

into glucose.

For the liquification and saccharification, special

enzymes must be added to the raw mash that are

essential for the conversion from starch into glu-

cose. The advantage of enzymes, in comparison

to other catalysers, is their chemo-selectivity.

Therefore, perfectly suitable enzymes for the re-

spectivepairingof substrate/productareavailable.

The liquification is done while adding an enzyme (

in this case, alpha-amylase) at a temperature of

90- 95C.

Liquefying the raw mash is necessary since the

heating causes the enclosed starch to cluster into

long chains of molecules. This can make stirring

and feeding the mash mechanically impossible.

The enzyme alpha-amylase breaks the long

chains of starch molecules into short molecule

chains. This leads to a clear reduction in the vis-

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cosity of the mash and therefore to a higher flow

capability and better feeding capabilities.To achieve optimal enzyme activity, the ambient

conditions must be adapted to the respective type

of enzyme. For alpha-amylase, that means an am-

bient temperature of 90- 95C and a pH value of

> 6.5.

After the mash has been liquefied and the starch is

in short molecule chains, the starch must be con-

verted into glucose. This procedure is the saccha-rification. This requires adding another enzyme to

the mash. Prior to this however, the ambient condi-

tions mustbe changed again toachieve anoptimal

enzyme activity andtherefore a high percentage of

glucose in the mash. For the enzyme gluco-amy-

lase, the mashmust becooled to 55-60Cand the

pH value must be lowered to 4.5 - 5.5.

Theentireprocedure of liquification andsaccharifi-

cation of the mash takes about 2 to 3 hours includ-

ing the half hour resting time after liquification and

after saccharification.

After the completion of the saccharification, the

mash must be cooled before the next step in the

process.

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4.4 Fermenting the mash

Thefermentation converts theglucose in themash

into alcohol. Yeast must be added to the mash for

this. The yeast coverts the glucose into ethanol

and carbon dioxide.

Yeast is a livingmicro-organismthat belongs to the

fungus group. Unlike enzymes from the previous

process steps, yeast has the ability to reproduce.

The scope of reproduction depends on the appli-

cable ambient conditions. Yeast is very sensitive

to temperature, as are all organisms.

Temperature range 28 ... 32C :

Optimal, the conversion from glucose

into alcohol achieves a maximum.

Temperatures below 12C :

Yeast initiates activity.

Temperatures above 40C :

Yeast dies.Besides alcohol andcarbondioxide, heat is gener-

ated duringthefermentation process,whichslowly

heats the mash. Therefore, the temperature must

be monitored and the fermentation tank must be

cooled in some cases.

To achieve a good mixture between the mash and

the yeast during the fermentation process, an stir-

rer slowly mixes the mash. This mixing can carry

on continuously at low rpm or at high rpm inintervals.

The fermentation of the mash must be done in a

closed container that does not allow any contact

with the atmosphere. Otherwise, there is a danger

of a bacteria contamination that could result in

turning the alcohol fermentation into a vinegar

fermentation.

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During the fermentation process, carbondioxide is

produced, which escapes into the atmospherethrough a fermentation lock. This can be recog-

nized by the gas bubbles escaping in the sealing

liquid of the fermentation lock.

The duration of the fermentation depends on dif-

ferent factors:

Temperature

Type of yeast

Intensity of the mixingNormally, a fermentation experiment takes be-

tween approx. 68 - 72h. That makes regular moni-

toring of the processes necessary.

The following must be checked regularly:

Fermentation lock

Fermentation temperature:

Foam build-up and fill level in the fer-

mentation tank

During the fermentation, carbon dioxide foam

builds up on the surface of the mash. This is not

permitted to escapethrough thefermentation lock.

The height of the foam layer must be checked reg-

ularly through the inspection-glass therefore. The

build-up of this foam layer is a sign of active fer-

mentation in the mash.

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4.5 Distillation of the mash

After completed fermentation, the distillation is the

last step in creating alcohol. Thedistillationof alco-

hol from the mash is done with the help of a water

bath distillery. This system works in the same way

as large industrial systems.

4.5.1 Basics of distillation

Distillation and rectification are two important ther-mal separationprocedures. Thiscan obtainone or

more of the volatile components from a volatile

mixture with several volatile components with a

high degree of purity. This separation process

functions by means of the basic operations of

evaporation and condensation. The difference be-

tween distillation / rectification and the separation

process of evaporation is that in evaporation only

one of the components is volatile. In distillation /rectification the vapour phase has a different com-

position to the liquid phase. This fact is the basis

for distillation and rectification.

The difference between rectification and distilla-

tion is that in rectification the vapours emanating

from the recovered condensate are partially re-

turned to the column and made to perform materi-

als transfer with the risingvapours onor at suitable

column fitments.In distillation the rising vapours are immediately

condensed in a condenser and drawn off without a

return line.

Theconcentrations in thevapourphase(y)andthe

liquidphase (x) can becalculated for the ideal case

using RAOULTs Law and DALTONs Law, if the

vapour pressure curves of the respective compo-

nents are known. Normally however the molecular

proportions of the two phases at equilibrium are

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determined experimentally. The calculation of the

molecular proportions should for instance result inan ideal two partmixture benzene (A) / toluene (B).

An ideal two part mixture has been achieved when

the partial vapour pressure curves are linear and

the molecules of the components behave exactly

as the pure components on their own.

From RAOULTs law:

pA = P0A xA and pB = p0B xB

( in this case xA + xB = 1 and pA + pB = p )

and with DALTONs law :

pA

= yA

p and pB

= yBp

( in this case yA + yB = 1 and pA + pB = p )

the pressure diagram shown in figure 4.1 can becreated.The pressurediagram shows that the two

part mixture of benzene / toluene behaves ideally

based on the two straight line partial pressure

curves ( 1 + 2 ). Curve 3 shows the total vapour

pressure by molecular proportion xA.

Diagram 4.2 shows the typical courseof the boiling

and condensation lines in the boiling diagram for

benzene / toluene at a pressure of p = 1.01 x105

Pa. From the boiling diagram,as shown in the dia-

gram, an equilibrium diagram can be created.

The quantitative determination of the equilibrium

condition is determined as follows:

y x

xA

A

A

1 1( )

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Fig. 4.1 Pressure diagrambenzene / toluene

Fig. 4.2 Boiling diagram / equilibriumdiagram benzene / toluene

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For this, is defined as relative volatility. This is

the relation between the molecular proportions atequilibrium of the vapour phase and of the liquid

phase.

y x

y x

A A

B B

For an ideal two part mixture by using RAOULTs

Law and DALTON Law it produces:

pp

A

B

0

0

The greater the amount of , the further the equi-

librium trend is from the diagonals and the easier

the distilling separation.

In diagram 4.3 for instance boiling diagrams and

equilibrium diagrams for non-ideal two part mix-

tures are shown.

Further information on these mixtures and thequantitative determination of equilibrium condi-

tions can be found in technical literature.

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Fig. 4.3 Boiling diagram / equilibriumdiagram for real mixtures

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4.5.2 Construction of a distillation

Each distillationdevice is basicallyconstructedac-

cording to Fig. 4.4 .

The batch evaporates in the distillation bubble (2).

In this instance, a sufficiently large evaporation

chamber must exist. The constant heating of the

batch mixture can be achieved by e.g. an stirrer in

the distillation bubble. The heating (3) of the batch

mixture can be done directly or indirectly through a

water bath with sensitive batch materials.

The isolation column (1) separates the parts of the

gas mixture with a low boiling point from those with

a highboiling point bycondensationof those witha

high boiling point on the isolation column fixtures.

Columns with filling materials or with bottoms can

be used as isolatingcolumns.Another possibility is

the dephlegmator. This is constructed as a water

container, throughwhich thegasis routedin tubes.

The water temperature of this container must be

slightly higher than the initial temperature of the

cooling water from the condenser.

The isolating columnof the CE640 is a bubble cap

tray column with 3 layers in combination with a

water-filled dephlegmator.

The last components of a distillation apparatus is

the condenser(4), in which the gas parts that have

a low boiling point are condensed and escape the

condenserandthedistillationprocess as liquid.

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Fig. 4.4 Distillation apparatus

4

1

2

3

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5 Notes on running experiments

5.1 Diagram of creating alcohol

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Condensation

Cooling

Saccharific

ation

Cooling

Fermentation

Evaporation

Cooling

Condensa

tion

Distillation

R

awalcohol

Distilleryyeastculture

Alp

haamylase

An

tifoamingagent

Wa

ter>5dH

Po

tatoes

Glucoamylase

Su

lphuricacid

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The diagram shows the principle of the process

with the respective conditions that must be at-tained for the respective process steps. This dia-

gram applies for the procedure used in creating

raw alcohol from potatoes.

The steps liquification > cooling > saccharification

> cooling are performed in tank 1.

The fermentation is performed in the fermentation

tank.

Evaporating > cooling > condensing is all done in

the distillation unit.

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5.2 Liquification and Saccharification

The liquification of potatoes begins outside of the

experimental stand. The potatoes must be

crushed into a mash. The amount of potatoes de-

pends on the desired fill level of the system. A ref-

erence value for the CE 640 is ~10...15 kg.

The hand valves are to be positioned according to

the following table for the liquif icat ion /

saccharification. The designations of the valves

can be seen in process image (see 2.2 or 7.2).

ValveSetting/function



V1 Control valve V11 omitted V21 Closed

V2 Control valve V12 Closed V22 Closed

V3 Closed V13 Closed V23 Open

V4 Closed V14 Closed V24 Closed

V5 Closed V15 Position 1 V25 Closed

V6 Solenoid valve V16 Position 1 V26 Safety valve

V7 Solenoid valve V17 Closed V28 Closed

V8 Open V18 Closed V31 Closed


V10 Closed V20 Closed

NOTICE! Before the experiment, the overflow

hoses must be connected to all overflow points of

the system.

The liquification process is as follows:

Set valves according to the previous table.

Close valve V23.

Fill theacid supplycontainerwith sulphuricacid solutionof concentration 0.5mole/litre .

Switch on system.



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Install the pH measuring probe and connect the supply

line.

Call up the control menu for tank 1.

Make steam supply.

Enter the water supply quantity (~ 5...10 litre) on thePLC controller and fill in tank 1.

Enter the set temperature 90...95C on the PLC control-ler.Steam will berouted through the water supplynow.

Switch on the stirrer for tank 1.

Slowly open valve V23.

After reaching the set temperature in tank 1 , add ~10%of the amount of crushed potatoes.

Add the enzyme alpha-amylase according to manufac-turers specifications.

Now, slowly add small portions of the potato mass untilthe fill level of tank 1 reaches the pH sensor.

After the potato mass and the enzymes have been com-pletely added, the temperature must be held at a con-

stant temperature higher than 90C for a minimum of

30 minutes.

Than cool the mash to a temperature of ~55...58C (Setthe temperature on the PLC controller). Cooling water

flows through the outer jacket of tank 1.

pH value drop to 4.5...5.5 ( Enter the pH value on the

PLC controller). The pump now feeds in the acid solu-tion to tank 1.

Add the enzyme gluco-amylase and the anti-foamingagent according to manufacturers specifications.

After this addition, the temperature must be held for aminimum of30minutes withina range from55...58C.

Cool the mash to a temperature of ~28...30C.



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5.3 Fermentation

After pumping from the cooking tank into the fermentation

tank, the fermentation portion of the experiment is begun.

The portion takes up the most time. The durationof this phase

normally takes several days. First, all required supplies must

be made ready for this long period. The hand valves are to be

set according to the following table for the fermentation

process.

ValveSetting/

functionValve

Setting/

functionValve

Setting/

function

V1 Closed V11 omitted V21 Closed

V2 Closed V12 Open V22 Closed


V4 Solenoid valve V14 Closed V24 Open


V6 Closed V16 Position 1 V26 Safety valve




V10 Closed V20 Closed

After pumping over, the distilling yeast must be added tothe mash. The metering is to be done according to man-

ufacturers specifications.

Seal the fermentation tank hermetically against the at-

mosphere.

Fill the fermentation lock with water.

Close the latches in the cover.

Check whether valve V21 is closed.

Set valve V15 so that the fermentation tank isenclosed from the atmosphere.



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Then switch on the stirrer of the fermentation tank to

achieve a good mixture.

NOTICE! The stirrer is not to be operated continually

during fermentation since the foam build-up would be

too great.

During fermentation, carbon dioxide builds up in the in-

terior of the fermentation tank. This escapes through

the fermentation lock on the head of the fermentationtank (canbe recognizedby gas bubbles in the fermenta-

tion lock). The development of gas bubbles only begins

after a fewhoursof thefermentation process,however.

During the fermentation process, perform the followingchecks regularly:

Temperature in the fermentation tank

Fill level in the fermentation tank

Fill level in the fermentation lock - refill if nec-essary

The temperature can be set and monitored on the PLC

controller.

Thetemperature in thefermentation tank is regulated by

feeding cold and hot water into the double jacket around

the fermentation tank.

NOTICE! During fermentation, the temperature in-creases slightly and then drops continuously after

~12 h.

After a mixing timeof~5h the stirrer shouldonlybeoper-ated in intervals. Interval operation supports the escape

of carbondioxide frommash. The durations for the inter-

vals can only be determined from trying it yourself.



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If the fill level in the fermentation tank is too highand fluid

is forced out the fermentation lock, some mash will haveto be drained out through valve V13.

During the fermentation process, mash samples canbe taken

andtested foralcohol andresidualsugarcontent. This is done

by separating the liquid from the floating particles and deter-

mining the alcohol content with an alcohol meter and the re-

sidual sugar content with a saccharimeter.

The fermentation process is completed after a period of~68...72 h. No more gas bubbles should be escapingthrough the fermentation lock then.

The mash must then be fed into the distillation unit. Thisis done by opening valves V21 and V17 and setting the

three-way valve V16 so that the feed is to the distilla-

tion unit. Open the filling opening in the cover of the fer-

mentation tank.

Afterwards, pump P3 can be switched on from the PLC

controller and the mash can be pumped into the distilla-

tion unit.

After pumping is complete, close valve V17.

The fermentation tank must be cleaned as soon as possible

after pumping the mash out to prevent any biological degrad-

ing of the residual mash.



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5.4 Distillation

The last process step is the distillation of the alcohol

fromthe mash. The valvesmust be set as follows for the

distillation process.




V1 Closed V11 omitted V21 Open


V3 Closed V13 Closed V23 ClosedV4 Closed V14 Closed V24 Closed


V6 Closed V16 Position 1 V26 Safety valve

V7 Closed V17 Open / Closed V28 Closed



V10 Closed V20 Open

Read the instructions by the manufacturer for an

exact description of the distillation unit.

WARNING

The alcohol that is produced with this system

is raw alcohol and is not suitable for consump-

tion.

DANGER of poisoning!

Consumingrawalcohol, even in smalldoses,can lead to irreversible damage to health!

While operating the distillation, make surethat there is proper ventilation to prevent an

accumulationofalcohol ingredients in theair.



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WARNING

Steam lines and partsof the distillation unit getvery hot. Hot steam can escapeat the pressure

relief line.

DANGER of burning / scalding!

Tank 1 becomes very hot during the heatingoperation. Do not touch the jacket surface of

the tank during operation .

Neveroperate the steamheating for tank1with-

out a closed steam pressure-relief line.

Never operate the steam heating of tank 1without the water supply in tank 1.

While operating the distillation unit, much ofthe equipment will get very hot. Do not touch

the surface of the water bath, the distillation

bubble and the column.

Trouble-free functionality of the cooling water system is

absolutely necessary for proper distillation operation.

The distillation occurs as follows:

Close valve V17.

Fill the water bath to the mark with water.

Fill the condenser and the dephlegmator with wa-ter.

Set the thermostat for the cooling water flow ac-cording to the manufacturers instructions.

Set the gas temperature T9 for control to78...79C.

Switch on the stirrer for the distillation unit.



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While heating, monitor the temperature and the

water pressure in the water bath continuously. Af-ter achieving the temperature set for T9, the heat-

ing is controlled by switching the heater. The con-

densing alcohol flows into the alcohol supply and

then into the ethanol container (B4) from there.

During the distillation procedure, slowly increasethe value for temperature T9 to 90...95C and set

the cooling water thermostat to a higher tempera-

ture at the same time.

After separating all alcohol, switch the distillationunit off according to the manufacturers instruc-

tions.

After the distillation unit has cooled to ~30...40C ,the residual mash can be drained through valve

V19 and can be disposed of. Clean the distillation

unit according to the instructions of the manufac-

turer. All liquids are to be drained and the system

dried.



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6 Data acquisition software

6.1 Software installation

6.1.1 System requirements:

PC with Pentium IV, 1 GHz

Minimum 1024 MB RAM

Minimum 11GB of availablehard disk space

1 CD-ROM drive

USB-port Graphics resolution min. 1024 x 768 Pixel,

True Color

Operating system:Windows XP / Windows Vista/ Windows 7

6.1.2 Installation of software

The following are needed for the installation: A fully operational PCwithUSB port (formini-

mum requirements see chapter 6.1.1).

G.U.N.T. CD-ROMAll components necessary to install and run

the program are contained on the CD-ROM

supplied by G.U.N.T.

Hardware driver installationWithout Internet

Set up USB connection to PC

Call up the Device Manager

Manually install the driver for "USB FAST

SERIAL ADAPTER"

Right-click on "USB FAST SERIALADAPTER"

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Update the driver software

Search the computer for driver soft-ware

Insert the CD-ROM in the drive (e.g.drive D)

Install the driver from D:\USB-COM-M

Restart the PC

Installation with Internet connection (Windows 7)

BWhen prompted to install new device driversoftware, download the driver from the

Internet. (The"Automatically install Windows

update" option may need to be activated.))

Install the driver from the Internet.

Restart the PC

Installing the CE 640 software

Insert the CD-ROMinthe drive (e.g. drive D)

Open EXPLORER under WINDOWS andselect the CD-ROM.

Open the subdirectory \installer\.

Run Setup.exe in D:\installer\setup.exe. (As-suming D is the CD-ROM drive.)

Follow the instructions in the dialog box.

The computer must be restarted after completing

the installation.

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6.2 Software operation

After starting the program for the first time, the lan-

guage must be selected once.

The program has three tasks:

Clear representation of the current mea-sured values in the system diagram

Plotting of measured values (x,t)

Graphical display of values

Program structure

The menu items are context-specific, i.e. not all

menu items are always enabled. The menu bar

contains 5 options with the following sub-items:

Start

File

View

Language



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Fig. 6.1 Measurement value recordingsettings

11

12 13 14 15

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System diagram

This view shows the current measured values in aclear process diagram. The measurement values

are temperature and pH value in tank 1

About GUNT

Shows information about GUNT.

EXIT

Exits the program.



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Fig. 6.3 About GUNT

Fig. 6.4 System Diagram

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6.2.2 Menu point:File

New

(Charts only)

Creates a new data set.

Open

(Charts only)

Opens a saved data set and allows the data to be

viewed in a Measurement diagram or measured

values to be added.

Print

(Charts only)

Prints out the time lapse graphs on the default

printer.

Print window

(with Charts) Prints out a hardcopy on the stan-

dard printer.

(with System diagram) Prints out the system dia-gram currently displayed on the standard printer.

6.2.3 Menu point:View

Clear graph

(Charts only)

Clears the graph on the screen.

Play / pause

(Charts only)

Starts / stops the advance of the display.

6.2.4 Menu point:Language

German

English

French

Spanish

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7 Appendix

7.1 Technical data

Apparatus Complete L x W x H: 3400 x 1200 x 2000 mm

Weight: approx. 500 kg

Electrical supply: 3 x 400 V/ 50 Hz

alternative 3 x 220 V/ 60 Hz

Compressed air requirements: 1,5 ... 6 bar

Steam requirements: Q 15 kg/h

pmin 3 bar

Cooling water requirements: min. 400 litre/h

via fresh water connection

Mash tank Capacity: 60 litre

x h 341 x 675 mm

Material: Stainless steel

Inspection glass: DN 50, DIN 28120

Temperature measurement probe PT 100

Fermentation tank Capacity: 48 litre

x h 341 x 675 mm


Inspection glass: DN 50, DIN 28120

Temperature measurement probe PT 100

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Diaphragm feed pump L x W x H: 190 x 140 x 200 mm

Max. head 72 m

Max. capacity 27 litre/min

Max. suction lift wet 7 m

Max. particle size 4 mm

Max. air consumption: 12 m/h

Connections: Intake side 3/8

Delivery Side 3/8

Air intake 1/8

Material: Diaphragm: EPDM

Sphere: EPDM

Housing: PP

Diaphragm metering pump L x W x H: 262 x 102 x 186 mm

Max. operating pressure: 16 bar

Max. capacity 2.1 litre/h

Max. suction lift wet 6 m

Connection: 6 x 4 mm

Connection voltage: 100...230 VAC

Connection frequency: 50...60 Hz

Materials Metering head: PP

Valves: PP

Seals: EPDM

Balls: ceramic

Control valve steam Nominal size: DN 15

Pressure stage: PN 40

Kvs value: 0.4

Characteristic curve: linear


Max. supply air pressure: 4 bar

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Control valve cooling water Nominal size: DN 20

Pressure stage: PN 16

Kvs value: 4.0

Characteristic curve: linear

Material: Cast iron

Nominal signal range 0,4...2,0 bar

Solenoid valve Nominal size: DN 4

Pressure Range: 0...6 bar

Kv value 0.5

Connection: G3/8

Connection voltage: 24 VDC

Ethyl alcohol container Capacity: 10 litre

Material: PE

Mash container L x W x H: 600 x 400 x 165 mm

Capacity: 30 litre

Material: HDPE

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7.2 Process schematic

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7.3 Items supplied

1 System complete in steel trolley on castors

1 pH-measuring probe

1 Ethyl alcohol container

1 Mash container, portable

1 Set of water hoses with sleeve material

1 Steam hose, stainless steel mesh-wound

1 Alpha amylase, 0,5 litre1 Gluco amylase, 1 litre

1 Antifoaming agent, 1 litre

1 Distilling yeast, 500 gr

1 Software on CD

1 Data transmission cable

1 Instruction manual

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7.4 Index

AAlpha- Amylase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38, 50

B

Boiler heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Bubble cap tray column . . . . . . . . . . . . . . . . . . . . . . . 14, 45Buffer solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

C

Carbon dioxide . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 40 - 41Chemo- Selectivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Compressed air diaphragm pump . . . . . . . . . . . . . . . . . . 23

Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 45, 56Control cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Cooking tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Crushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

D

Damage to health . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Data acquisition software. . . . . . . . . . . . . . . . . . . . . . . . . 16Dephlegmator . . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 45, 56Diaphragm metering pump . . . . . . . . . . . . . . . . . 24, 28, 35

Diaphragm pump . . . . . . . . . . . . . . . . . . . . . . . . . 19, 23, 36Distillation . . . . . . . . . . . . . . . . . . . . . 17, 21, 32, 42, 45, 55Distillation unit . . . . . . . . . . . . . . . . . . . . . 13, 20, 36, 48, 54

E

Enzymes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 38Ethanol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

F

Fermentation . . . . . . . . . . . . . . . . . . . . . . . . 37, 40 - 41, 48Fermentation lock . . . . . . . . . . . . . . . . . . . . . . . . 11, 41, 53Fermentation tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9, 11

Flow meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Fresh water supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19G

Gluco- Amylase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Gluco-Amylase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Glucose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 - 38

I

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Installation of software. . . . . . . . . . . . . . . . . . . . . . . . . . . 59

L

Liquification. . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 38 - 39, 49

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M

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Maintenance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Mash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Mash tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Mashing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 38

P

PLC controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17, 53Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Pitched blade agitator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Pitched blade agitators . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Poisoning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32, 55

Process diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5R

Raw alcohol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32, 55S

Saccharification . . . . . . . . . . . . . . . . . . . . . . . 1, 38 - 39, 49Saccharimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Safety notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Sealing liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Software operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Starch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Stirrer . . . . . . . . . . . . . . . . 8, 11, 18, 20 - 21, 40, 50, 53, 56System diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63System time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

T

Temperature control . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 19W

Water bath distillery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Y

Yeast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 40

PpH measuring probe . . . . . . . . . . . . . . . . 16, 25, 28, 35, 50pH reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50pH value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39


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