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PROMOTING SUSTAINABLITY :
BIO ETHYL ALCOHOL PRODUCTION
1. RAW MATERIALS : PRE REQUISITE
CANE MOLASSES : BIO ETHANOL & CHEMICAL
CANE MOLASSES : PURITY TO BE NOT LESS THAN 30-35 %
GRAIN STARCH : POTABLE ALCOHOL
SWEET SORGHUM : INCENTIVIES /SECURITY TO FARMERS
2. TECHNOLOGY : UP GRADATAION
FERMENTATION, ZELD & BY PRODUCTS DEVELOPMENTS
4 YEARS DEGREE FOR FERMENTATION TECHOLGOY BY NSI/DSI
SET UP R & D CENTRE BY AIDA
PRIVATE R & D CENTRES, + J/V & GRANTS WITH NSI /DSI & DISTILLERY
4. POLICY : FINANCE / APPROACH
TDF TO BE CREATED FOR DISTILLERY INDUSTRY
UNIFORM POLICY – CENTRAL AND STATE
INTER STATE MOMENT - GST
REMUNERATIVE PRICE + + IVE APPROACH BY OIL COMPANIES
3. POLLUTION : PRAGMATIC + IVE APPROACH ( CLOSURE IS DISASTER )
LONG TERM SOLUTIONS BY ENVIRONMENT MINISTRY /CPCB / SPCB
PROMOTING SUSTAINABLITY : BIO ETHYL ALCOHOL
95% ETHYL ALCOHOL AS E5/E10 DOPPING IN PETROL
MOLASSES, GRAIN STARCH, SWEET SOGHUM
1. ALTERNATE RAW MATERIALS
GRAIN
RICE, WHEAT
SORGHUM,
MILLETS,
BARLEY,
CORN
RAW MATERIALS
CANE MOLASSES
AH / BH / C
RAW MATERIALS FOR ETHYL ALCOHOL
SUGAR CANE
SUGAR BEET
CASSAVA
CELLULOSE
POTATO
SWEET SORGHUM
JUICE
SWEET POTATO
AGRO RESIDUES 2NDGENERATION ETHYL ALCOHOL
ALGAE
.
.
RICE STRAW – SOFT CELLULOSE
SUGAR
CANE
PRESS MUD BIO COMPOST
MOLASSES
SUGAR CANE INDUSTRY
4-5%
JUICE ALCOHOL .
.
.
2.5-3.5%
CANE MOLASSES
BH / C
MOLASSES PURITY
32 – 35 %
QUALITY
HANDLING
PROCESSING
PREPARATIONS
PRE TREATMENT
SUGAR %
RESIDUE /
SLUDGE %
MICRO BIOLOGY
WY / TBC / MOLD
PROCESS WATER
WY / TBC / MOLD
PROCESS AIR
WY / TBC / MOLD
HARVESTING
STORAGE
TECHNOLOGY UP GRADATION
a solution
TASK
TO
GET
QUALITY
QUALITY OF RAW MATERIALS FOR ETHYL ALCOHOL
MOLASSES
TRANSIT
HEATERS
2 ½ - 3
BOILED
STORAGE
OPEN PITS
COVERED MS
TANKS
TRANSPORT
BY MS TANKERS
STORAGE
OPEN PITS
COVERED
MS TANKS
SUGAR
FACTORY DISTILLERY
PURITY 25 30 – 35
C
TIS 40 – 50%
HIGH UFS
HIGH SLUDGE
CONTENT
HIGH MICROBIAL
COUNTS
PENTOSES, TREHALOSE
MANNON, GLUCAN ETC.
MOLASSES : HANDLING, STORAGE AND QUALITY
AH
BH
???
.
INHIBITORS
FACTOR - 1 25,000 – 40,000 PPM
FACTOR – 2 2,700 – 3,500 PPM
FACTOR – 3 190 – 590 PPM
INHIBITORS IN MOLASSES
FACTOR 1 CONCENTRATION IS HIGHLY DETRIMENTAL TO GET
HIGH ALCOHOL % MORE THAN 10% IN WASH
FACTOR 1 PRESENT IN SPENT WASH IN CONCENTRATION OF
11,000 – 14,000 PPM RESULTS INTO INHIBITION OF YEAST
AND VERY POOR FERMENTATION, THEREFORE, SPENT
WASH CAN NOT BE RECYCLED AS IT IS.
GRAINS : POWDER QUALITY
GRAINS : MICROBIAL ANALYSIS
PARTICU-
LARS
UNIT RICE
RICE WHEAT
NOS/gm UN INCUBATED INCUBATED
INCUBATED
TBC
NOS/gm
2X104 ~ 2.1X106
1.7X108 ~ 1.3X109
2.1X108 ~ 1.3X1011
WY
NOS/gm
6X104 ~ 2.1X106
2.5X105 ~ 3.9X109
3.6X105 ~ 7.2X107
MOLDS
NOS/gm
1.4X105 ~ 3.3X109
1.3X105 ~ 2.4X108
INCUBATED 24 HRS IN YEPD BROTH & TOTAL PLATE
COUNTS ON NA, LYSINE, ASHA MEDIA
SWEET SORGHUM IN INDONESIA
HIGH IN CARBOHYDRATE CONTENT
SWEET POTATO - YAM
SWEET
SORGHUM
CANE
GRAIN
JUICE
BIO ETHANOL
JUICE
SYRUP
CANE TOP
LEAVES
ROOTS
BAGASSE STEAM FUEL
CO GENERATION
POWER
FILTER MUD
ANIMAL FODDER
SOIL
CONSERVATION
BIO MANURE
BY PRODUCTS
DDGS
DRY YEAST
CONCENTRATED
PROTEINS
SWEET SORGHUM : VALUABLE CROP FOR
ETHYL ALCOHOL / GREEN ENERGY / FEED / FOOD
COMPARISON : RAW MATERIALS
SUGARCANE, MOLASSES, CASSAVA, CORN & SWEET
SORGHUM FOR BIO ETHANOL
In terms of feedstock, sweet sorghum is an important
alternate raw material for bio ethanol production.
2. TECHNOLOGY UP GRADATION
UNIQUE FERMENTATION ( UF )
YEAST STRAIN, CREST’S ADDITIVES, INTEGRATED FERMENTATION PROCESS & ENGINEERING
87% 95%
IMPROVING FERMENTATION EFFICIENCY
TOLERANCE TO HIGH TEMPERATURE ( 41- 43 0C )
HIGH ALCOHOL CONCENTRATION ( 10 – 17 %)
FAST FERMENTING ( 14 – 16 /
24 – 26 HRS)
CREST’S YEAST
CREST 1
CREST 2
CREST 3
CREST Z
BENZYL SEPTOL
CREST’S SPECIFIC ADDITIVES
with optimal Crest’s macro & micro nutrients
* CONTINUOUS ????
* CASKETING ????
* BIO STILL ????
* FED BATCH ????
systems need to be reviewed in
absolute terms ?
leads to poor and inefficient
fermentation due to various
reasons ??
FERMENTATION SYSTEMS
* CULTURE – CREST’S YEAST STRAIN * HIGH YEAST CELL CONCENTRATION-BUB
* 2 NOS FERMENTERS
* 1 NO. WASH OUT TANK
OPTIMUM DOSAGES OF MACRO, MICRO NUTRIENTS,
FERMENTATION ADDITIVES , OPTIMAL AERATION &
INTEGRATED PROCESS STEPS
ENGINEERING UPGRADATION OF EXISTING
FERMENTATION EQUIPMENTS
WELL DESIGNED FERMENTATION EQUIPMENTS
UF SYSTEM ( CANE MOLASSES – BATCH )
ENZYME +
YEAST +
NUTRIENTS +
DECONTAMINANT
PROCESS
ENGINEERING
AMBIENT TEMPERATURE
FERMENTATION
R.S.
ENA
A.H.
RICE
GRAIN
STARCH
ALCOHOL
RECOVERY
DISTILLATION
Crest’s Integrated Technology
GRAIN STARCH : CONTINUOUS FERMENTATION
UF : GOOD AND EFFICIENT FERMENTATION
ETHANOL YIELD
IMPROVED
TECHNOLOGY
250 LITERS
ALCOHOL/ TON
MOLASSES
220 LITERS
ALCOHOL/ TON
MOLASSES
CONVENTIONAL
TECHNOLOGY
465 LITERS
ALCOHOL/ TON
RICE
430 LITERS
ALCOHOL/ TON
RICE
UF : ADDITIONAL ALCOHOL YIELD
REDUCE EFFLUENT, CLEAR SPW, HIGH DM, MEE CONCENTRATE,
RECYCLE CONDENSATES & VALUE BY PRODUCTS
3. ZERO LIQUID EFFLUENT DISCHARGE ( ZELD )
but problem persists ?
1200 KLPD
700 KLPD
REDUCE SPENT WASH GENERATION
results in getting clean spent wash
CLEAN FERMENTED
WASH
( WITHOUT SLUDGE )
SEPARATE CALCIUM & YEAST AFTER
FERMENTATION
4-5% 12-15
HIGH DRY MATTER CONTENT CLEAN
RAW SPENT WASH FEED TO MEE
CLEAR RAW SPENT WASH FOR ETP SYSTEMS
CONTINUOUS FLUID BED DRYER
HORIZONTAL FLUID BED DRYER
•RECYCLE TOTAL VOLUME OF SPENT LEES
& MEE CONDENSATE FOR DILUTION OF
RAW MATERIALS FOR NEXT BATCH OF
FERMENTATION .
*NO EQUIPMENTS , ONLY SIMPLE
TREATMENT AND PROCESS STEPS .
RECYCLE MEE CONDENSATE
UTILIZATION OF MEE CONCENTRATE : VALUE
ADDED BY PRODUCTS
AN APPROACH TO ZELD
4. POLICY : FINANACIAL / APPROACH
POLICY FOR USE OF ALTERNATE RAW MATERIALS
* MOLASSES & PURITY– BIO ETHANOL/INDUSTRIAL ALCOHOL
* SWEET SORGHUM – BIO ETHANOL
* AGRO RESIDUE – BIO ETHANOL ( 2ND GENERATION )
* STARCH – POTABLE ALCOHOL
UNIFORM POLICY – CENTRAL AND STATE
INTER STATE MOMENT - GST
REMUNERATIVE PRICE + + IVE APPROACH BY OIL COMPANIES
95% ETHYL ALCOHOL USE FOR E5/E10 DOPPING IN PETROL
TDF TO BE CREATED FOR DISTILLERY INDUSTRY
Crest’s UF & ZELD (a net profit & sustainability for distillery industry )
READY TO TAKE UP TURNKEY PROJECT
