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SIDDAPUR
DISTILLERIES
LIMITED
Post: Siddapur, Taluk: Jamkhandi, Dist: Bagalkot
State: Karnataka PIN: 587 302
PROJECT REPORT
FOR CAPACITY ENHANCEMENT FROM 60 KLPD TO 70 KLPD
BY KEEPING THE EFFLUENT GENERATION CONSTANT.
June, 2016
2
M/s. SIDDAPUR DISTILLERIES
LIMITED
Post: Siddapur, Tal: Jamkhandi, Dist.BagalkotState: Karnataka
CONTENTS
Chapter
No. Chapter Name Page No.
Board of Directors 1
Project Profile 2
I Introduction 3
II Project Concept and Justification 6
III Demand for Alcohol 9
IV Molasses Based Fermentation Technologies 28
V Manufacture of Alcohol by Multi-Pressure Vacuum
Distillation. 35
VI Distillery Specifications – 42
Basis of Project 42
Fermentation 44
Distillation – Rectified Spirit & Extra Neutral
Alcohol 45
VII Environmental Management Plan 53
3
BOARD OF DIRECTORS
Sr.No. Name Designation
1 ShriJagadeesh S.Gudagunti Chairman & Managing Director
2 ShriChandrashekharaiah G.Mathad Director
3 ShriMaharudrayya I.Ghanakumarmath Director
MANAGEMENT
Sr.No. Name Designation
1 ShriSudheer S.Gudagunti Vice President
2 ShriChandrashekar D.Haragapure Director (Operations)
3 ShriM.G. Alalalmath Distillery Manager
4 Shri K.I.Korti Sr.Manager (F&A)
5 Shri Jyothi K.M. Manager (Environment)
6 Shri D.I.Muchandi Civil Engineer
4
Project Profile for Enhancement of 60 KLPD Distillery to 70 KLPD
Distillery Plant Based on FED-Batch Fermentation & Multi-Pressure Vacuum
Distillation to Produce Rectified Spirit &Ethanol or Extra Neutral Alcohol& Ethanol.
1
Name and Address SIDDAPUR DISTILLERIES LTD.
Siddapur Village, Tal:Jamkhandi
Dist.Bagalkot (Karnataka State)
Ph.No.08353-238073, 238183
Fax No.08353-238063
2 Constitution and Type Public Limited Company
3 Project Concept
a) Products 1.Alcohol Conforming to I.S.I.
Grade – I, 323 (1959)
2. Extra Neutral Alcohol
I.S.I. Grade-I, 6613 (1972)
3. Head Spirit Conforming to I.S.I.
Grade – II, 323 (1959)
4. Bio-gas
5. Bio-Compost
b) Working days/Annum 270
c) Molasses required, 70,000 MT of Molasses/Annum
4 a) Alcohol production/Annum 94.50 Lac Ltrs. Rectified Spirit & Ethanol
or
94.50 Lac Ltrs. Extra Neutral Alcohol & Ethanol
b) Steam requirement MT/day Max. 216 MT
c) Electricity requirement,
(Distillery plant, ENA, Boiler,
Biomethanation, Bio-compost
and plant yard lightning etc.)
Max. 19200 KWH/day
d) Water requirement, M³/day 870
5 Staff and Labours 130Nos. for Distillery, Biogas and Bio-
composting unit.
5
CHAPTER – I
INTRODUCTION
Siddapur Distilleries Limited is a Public Limited Company registered under the
Company’s Act 1956 in the year 2003 bearing Registration No.08/32213 dated
07/07/2003 having its Registered Office at 2nd Block, 1st Floor, “Sukrut” Building,
Opp:K.C.Park Main Gate, P.B. Road, Dharwad and plant site at Siddapur Village,
JamkhandiTaluk, Bagalkot District. Siddapur Distilleries Limited has installed 60
KLPD Distillery Plant in the year 2004-05. Distillery plant is based on continuous
fermentation and multi-pressure vacuum distillation technology to produce good
quality potable grade Rectified Spirit, Extra Neutral Alcohol and Fuel Alcohol to meet
the requirements of Potable Alcohol Consumers, Pharmaceuticals Industries and Oil
Companies for blending with petrol. Distillery Plant was supplied by Mojj
Engineering System Ltd., Pune and started its trial and Commercial production on
11th November, 2004. The last 5 years performance of the distillery is given in the
Table 1.1.
LAST FIVE YEARS PERFORMANCE OF 60 KLPD DISTILLERY
Table 1.1
Sl. No
Year Molasses
Consumption
(MT)
Spirit production
(Lac BL) Total
Spirit
Production
(Lac BL)
Average
Alcohol
Recovery
(Ltrs./MT of
Molasses) Rectified
Spirit ENA
Impure
Spirit Ethanol
1 2011-12 41826 19.99 73.17 4.23 23.28 120.67 288.55
2 2012-13 43740 51.12 55.92 5.12 16.14 128.30 293.35
3 2013-14 35176 20.19 60.16 5.18 9.63 95.16 270.59
4 2014-15 48710 24.07 83.15 4.76 20.80 132.78 272.65
5 2015-16 46238 9.19 84.92 4.14 30.34 128.59 278.13
Siddapur Distilleries Limited is a sister concern of Shri Prabhulingeshwar Sugars &
Chemicals Limited,having 12000 TCD Sugar Plant at Siddapur Village,
Tq.Jamkhandi, Dist.Bagalkot having its Registered Office at 1st Floor, “Sukrut”
Building, Opp.K.C.Park Main Gate, P.B.Road, Dharwad.
6
Shri Prabhulingeshwar Sugars & Chemicals Limited is a Public Limited Company
consisting about 14000 members holding Equity &Preference shares. The Company
owns about 200 acres of land near Siddapur village, Tq.Jamkhandi, Dist.Bagalkot.
The Company has established its factory in the said area with all the infrastructure
facilities like Staff Quarters, Guest House, Workers Quarters, Canteen, School,
Medical and Bus facility etc. The initial crushing capacity was 2500 TCD. The
capacity was expanded from 2500 TCD to 8000 TCD during the year 2000-2010,
8000 to 10000 TCD during the year 2010-11 and finally to 12000 TCD in the year
2015-2016 with a view to crush all the available sugarcane in the area of operation.
In addition to industrial growth in the area, the factory is also involved in several
socio-economic developmental activities to help members, farmers and workers of
factory.
1. Staff Quarters: The Company has provided quarters to the Head of the Departments,
Chemists, Manufacturing Assistants and Engineers in the factory premises. There are
about 20 “B” type quarters, 12 “C” type quarters and 40 “E” type quarters. Apart from
this, about 100 residential quarters have been constructed for the Fitters, Helpers and
others. These quarters are provided with free water, dish antenna for entertainment
and electricity for their use. A telephone facility is also provided to “E” type quarters
along with a Security facility.
2. The Company has constructed a temple in the office premises. This allows the staff,
workers and their families to gather in the temple yard on festivals and other days.
3. The factory has a hospital facility consisting of a Doctor for treatment of the patients.
Apart from this the Company has also provided a mobile hospital van with all the
necessary equipments to attend emergency cases. This mobile Van is being used for
the workers, labours as well as by the farmers who are supplying cane to the factory.
To look after health of these people, Mobile Hospital Van is sent to all the villages
turn by turn and free medical assistance is provided to the needy patients.
4. To assist the general public of around the villages of the factory, the Company
organizes every year a “Free Health Camp” with the assistance from Walness Mission
Hospital, Miraj. About 2500 to 3000 villagers, farmers, workers and others are taking
advantage of this camp. Free health checkup, free distribution of medicines and free
food was also served to all the people who came to the camp. Apart from this, the
Doctors of the Walness Mission Hospital assisted some of the serious patients by
inviting them to their Miraj Hospital for providing further necessary treatments at
concessional charges.
7
5. Education Facilities:In the area of operation education facilities from primary to
graduation level are available, which take care of educational need of farmers and
employees.
6. The Company has provided a separate land of 3 acres named “Kailash” for
construction of various temples to create holy atmosphere in the factory premises.
There is a plan to plant 2000 Ayurvedic medicinal plants which will help for preparing
Ayurvedic medicines.
7. The Company is providing concessional rate bus/tempo fare to the workers who are
travelling from nearby places like Jamkhandi, Mudhol, etc., The Company has also
arranged transportation for children to go to Jamkhandi for attending the school.
8. For recreational purpose, 3 playgrounds are provided in the factory premises; for
playing Volleyball, Kabaddi,Football, Cricket and other games which are named as
“Nehru Maidan” and “Gandhi Maidan”. Further for children a separate playground is
provided. The Company has conducted competitions in volley ball and other games.
Players from nearby villages have participated in these competitions.
9. The Company has also developed greenery by planting various flower plants, trees,
etc., and has also developed lawns near the factory and residential premises. The lush
greenery has given a very pleasant look and soothing effect to the mind of everyone.
A rose garden has also been developed.
10. The Company has taken up and developed certain roads connecting the factory from
nearby villages as well as to Siddapur, etc., This has greatly helped in smooth
transportation of cane to factory.
11. The Company has contributed by providing free of cost sugar to some social
organizations who conducted mass marriages etc., likewise free of cost sugar was also
given to various temples and special organizations for assisting the social activities of
the public in nearby villages. The Company has also donated liberally for assisting
the educational institutions by contributing towards construction cost of school
buildings.
12. The Company is also distributing the bio-compost to villagers and cane growers at
concessional rates, which is used as manure to achieve “Zero Discharge” of spentwash
as per CREP norms.Factory has already installed bio-methanation plant as primary
effluent system, followed by secondary bio-composting as effluent treatment system.
The annual requirement of filler material like press mud cake (70,000 – 78,000 MT),
boiler ash etc., is available with factory which will be also sufficient for expanded
capacity of Distillery.In short, the performance of factory is quite impressive. To
exploit more benefit from this industrial complex, the management of the factory has
decided to enhancement capacity of existing 60 KLPD distillery unit to 70 KLPD
based on Fed-Batch fermentation and MPR distillation to produce industrial, potable
rectified spirit and potable extra neutral alcohol from molasses.
8
CHAPTER – II
PROJECT CONCEPT AND JUSTIFICATION
India is the largest producer of sugarcane as well as sugar in the world. The sugar
industry occupies a pride of place in rural economy. Most of the sugar industries are
located in rural areas providing employment to rural masses.
The molasses is used mainly for production of ethyl alcohol. There are more than 350
distilleries in the country with annual installed capacity 4.295 billion litres of alcohol
production and licensed capacity 4.527 billion litres. The alcohol production in the
year 2007 was 2.3 billion litres. At present the state of Karnataka is having 35
distilleries.
Molasses is considered as one of the valuable by-products of sugar industry. The total
molasses availability in the country was around 85.49 lac MT in 2005-06 and
increased upto 131.11 Lac MT in 2006-07 and to 113.11 Lac MT in 2007-08.
However, molasses produced in the country in the year 2008-09 was 65.42 Lac MT.
In the ensuing crushing season, the crushing of cane and molasses will be highest and
the required quantity will be available to all the distilleries in the state.
CAPACITY OF DISTILLERY:
Normally distilleries are expected to work for 270 days in a year and most of the
distilleries in India have adopted seasonal working of their distilleries in view of the
fact that they can receive surplus steam and power from their sugar factories. It is an
important consideration to keep the cost of production low. Some factories have
installed independent boiler and turbo-alternator to run the Distillery unit during off
season. This will help the distilleries to use all available molasses.
Following few suggestions shall be useful for proper designing of the distillery:
1) Management should take efforts to supply molasses in adequate quantity to the
distillery.
2) Both distilleries and sugar factories should have adequate molasses storage tanks
of mild steel.
3) As per the latest norms of CPCB, all distilleries are required to achieve “Zero
Discharge” of spentwash. Therefore, necessary measures should be taken by the
management to achieve Zero Discharge and prevent any kind of pollution in
surrounding area.
9
LOCATIONAL CONSIDERATIONS:
The important factors for expansion of distillery unit are,
a) Nearness to raw material.
b) Availability of utilities such as steam, electricity and water.
c) Adequate land for distillery and effluent treatment plant.
d) Avoiding likely odour nuisance to the residential colony and the public in general.
e) Availability of technical assistance in case of necessity.
f) Ease of control over both sugar factory as well as distillery by one management and
sharing common facilities like workshop etc.
MOLASSES STORAGE:
The total molasses requirement will be 70,000MT/annumfor 70 KLPD capacity. The
production of molasses is assumed to be 60,000-65,000 MT based on the cane
crushing during the years 2013-14 and 2014-15. Procurement of about 10000 to
15000MT of molasses will be procured from nearby sugar factories. At present the
distillery is having of one UCR Masonry tank of 1100 MT and three MS tanks for
molasses storage and capacity of each tank is 6000 MT.
Proper care should be taken by the sugar factory to cool down molasses before it goes
to molasses storage tank. The molasses storage tank should have a suitable pump for
recirculation of molasses. A two months stored molasses is ideal for fermentation.
The molasses can be pumped through pipeline, which can be laid down from the
storage tank to the distillery molasses tank.
WATER REQUIREMENT:
For Fed-batch fermentation based 70 KLPD distillery with integrated multi-product
system the maximum water requirement is about 870 KL/day. The factory is drawing
water from Krishna River, which is about 20 km. away from factory. Water storage
facility is available with the factory. The factory has constructed 2 Nos. water
reservoirs having total storage capacity of 54500M3. Thus, sufficient quantity of water
can be made available to the distillery from the factory water reservoir. To achieve
better efficiency and to maintain the plant and machinery in good condition, it is
necessary to have proper water treatment system. Process water will be treated with
chemicals and will be reusedfor the process or for the cooling tower.
10
STEAM REQUIREMENT & POWER GENERATION:
Steam Requirement:
The steam requirement of the proposed 70 KLPD distillery plant is 9 – 10 MT/hr. (for
Multi-pressure option). The sugar factory is having total three boilers, two boilers
having steam generation capacity of 60 MT/hr. at 66 Kg/cm2 pressure. The factory has
already installed a cogeneration unit of 36 MW, which was expanded upto 52 MW
capacity. Therefore, required steam at 3.5 Kg/cm2 pressure can be made available
from factory to distillery for 270 days/annum.
Power Generation:
The Distillery hasgiven on lease a 2.50 MW TG Set to Shri Prabhulingeshwar Sugars
& Chemicals Ltd. Therefore required power is available for distillery, bio-
methanitation, bio-composting plant & yard lightening etc., in season & off-season.
Necessary arrangement for the pressure reducing and de-supereheating (PRDS) of
steam has been made in the distillery. Based on the performance of the sugar factory
in last few years, the cost of steam is assumed at Rs600/MT.
The quarters of the technical staff of the sugar factory and distillery are at factory
campus & their services could be readily made available in case of necessity. The
nearness of the distillery to sugar factory is also of advantage from the point of
security.
11
CHAPTER – III
DEMAND FOR ALCOHOL
History of Ethanol:
Human have used ethanol since prehistory as the intoxicating ingredients in alcoholic
beverages. Dried residues on 9000-year-old pottery found in northern China imply
the use of alcoholic beverages even among Neolithic peoples. Islamic alchemists who
developed the art of distillation during the Abbasid Caliphate, the most notable of
whom was A1-Razi, first achieved its isolation as a relatively pure compound. The
writings attributed to Jabir IbnHayyan(Geber) (721-815) mention the flammable
vapours of boiled wine. A1-Kindi (801-873) unambiguously described the distillation
of wine. Distillation of ethanol from water yields a product that is at most 96%
ethanol, because ethanol forms an azeotrope with water. Johann Tobias Lowitz first
obtained absolute ethanol in 1796, by filtering distilled ethanol through charcoal.
Antoine Lavoisier described ethanol as a compound of carbon, hydrogen and oxygen
and in 1808 Nicolas Theodore de Saussure, determined ethanol’s chemical formula.
In 1858, Archibald Scott Couper published a structural formula for ethanol; this places
ethanol among the first chemical compounds to have their chemical structures
determined.
Ethanol was first prepared synthetically in 1826, through the independent efforts of
Henry Hennel in Britain and S.G.Serullas in France. Michael Faraday prepared
ethanol by the acid catalyzed hydration of ethylene in 1828.
Ethanol (Ethyl Alcohol):
The ethanol of commerce contains about five per cent water. Hence the term
“Hydrous (water-containing) alcohol”. If the last traces of water are removed,
“Anhydrous alcohol” (water-free or “absolute”) may be obtained. Ethanol which is
used for the production of sprits is usually heavily taxed, but it is also sold in an
untaxed “denatured” form, unfit for human consumption but suitable for many other
purposes. Denaturing is accomplished by the addition of a few percent of foreign
materials, which are not easily removed.
12
Non-denatured ethanol is the alcohol contained in beverages, thus the expression
“potable alcohol”. It also finds wide use as an industrial solvent. Furthermore, it is
the starting material for the preparation of a long list of industrial organic chemicals.
Alcohol has assumed very important place in the Country’s economy. It is vital raw
material for a number of chemicals. It has been a source of large amount of revenue
by way of Excise Duty levied by State Government on Alcoholic liquors. It has a
potentially as fuel in the form of power alcohol for blending with petrol in the ratio of
maximum 26:74. The characteristics of ethanol are given in Table 3.1 on next page.
Alcohol production from various feed stocks:
Ethanol can be produced from any biological feedstock’s that contain appreciable
amounts of sugar or materials such as starch or cellulose that can be converted into
sugar. Sugar beets and sugarcane are examples of feedstock’s that contain sugar.
Grain contains starch that can relatively easily be converted into sugar. A significant
percentage of trees and grasses are made up of cellulose, which can also be converted
to sugar, although with more difficulty than required to convert starch. The ethanol
production process, starts by grinding up the feedstock so it is more dissolved out of
the material or the starch or cellulose is converted into sugar. The sugar is then feed
to microbes that use it for food, producing ethanol and carbon dioxide in the process.
A final step purifies the ethanol to the desired concentration.
Fermentation alcohol may be produced from grain, molasses, fruit, wine, whey,
cellulose and numerous other sources. Synthetic alcohol may be derived from crude
oil or gas and coal. Both fermentation and synthetic alcohol are however, chemically
identical.
On a global scale, synthetic feedstock’s play a minor role. Only six percent of overall
output is accounted for by synthetic feedstock’s. Roughly 55% of world ethanol
production from sugar crops, both cane and beet. Most of the remainder comes from
grains, with maize playing a dominant role.
13
Table – 3.1 CHARACTERISTICS OF ETHANOL
Sl.
No. Description Unit
Characteristics of
Absolute Alcohol
A) General
1 Systematic Name Ethanol
2 Other Names Ethyl alcohol, grain
alcohol, Hydroxyethane
3 Molecular Formula g/mol C2H6O
4 Molecular Weight 46.07
5 Appearance Colorless liquid
6 CAS Number [64 – 17 – 5]
B) Properties*
1 Specific gravity at 15.6°/15.6°C Max. 0.7961
2 Phase Liquid
3 Solubility in Water Fully Miscible
4 Oxygen Content % 34.70
5 Latent vaporization heat KJ/Kg. 925
6 Lower calorific value KJ/Kg.
Kcal/Kg.
27723
6642
7 Boiling point °C 78.30
8 Melting point °C -114.3
9 Acidity PKa 15.9 (H+ from OH group.
10 Energy per unit and volume KJ/Kg 22012
11 Viscosity at 20°C Centipoise 1.192
12 Vapour pressure at 20°C Atm 0.058
13 Vapour pressure at 40°C Atm 0.177
14 Vapour pressure at 60°C Atm 0.463
15 Octane number (research) RON -- 106
16 Octane number (motor) MON -- 87
17 Stoichiometery mixture Air : Fuel 8.95:1
18 Dipole Moment 1.69 D (gas)
C) Hazards
1 Material Safety Data Sheet External MSDS
2 EU Classification Flammable (F)
Irritant (Xi)
3 Risk Phrases R 11
4 Safety Phrases S2, S7, S16
5 Flash Point 13°C (55.4°F
*For anhydrous (Fuel) alcohol
Source : - F.O. Licht’s World Ethanol and Biofuels Report, Vol8, No.16, 28/04/2010
14
Production of Ethanol from various feed stocks like sugarcane juice, molasses, grains and
other feed stocks and by synthetic route is stated in Table No.3.2
Table – 3.2World Ethanol production by feed stock
Sr.No. Feed stock Ethanol Production (%)
1 Sugar crops 55
2 Grains 37
3 Synthetic 6
4 Others 2
Following Table: 3.3 provides the details of crop wise starch content and estimated yield of
alcohol per tonne of starch content in feed stock.
Table – 3.3Alcohol yields from various renewable sources:
Crop Fermentable Carbohydrate
(Starch %)
Alcohol Yield
(Lit. of alcohol (94.68% v/v/MT) at
90% F.E & 98.5% D.E.
Potato 19-20 127.134
Tapioca 28-29 188.194
Sweet potato 30-31 201-208
Barley 50-51 335-342
Malt 58-59 389-395
Wheat 67-68 449-456
Maize 73-74 489-496
Rice 78-79 522-529
Sorghum 69-70 462-469
Ethyl alcohol is basically used for three purposes i.e. 1) Industrial alcohol for production of
downstream chemicals, 2) Potable Alcohol for manufacture of alcoholic beverages (Country
Liquor and IMFL) and 3) Fuel ethanol or Anhydrous alcohol, which can be blended with
petrol or diesel.
Table – 3.4Uses of Alcohol
Sr.No. Alcohol Consumption for (%)
1 Potable 11
2 Industrial 21
3 Fuel 68
15
Table 3.5 details the name of distilleries & their installed capacities in Karnataka State
Table 3.5 LIST OF DISTILLERIES IN KARNATAKA
Sr.No Name of the Distillery Installed Capacity
1 Athani Farmers Sugar Factory Ltd., Belgaum 90 KLPD
2 Bannari Amman Sugars Ltd., Mysore 60 KLPD
3 Chamundi Distilleries Pvt. Ltd., Mysore 54 KLPD
4 Gauri Industries (Karnataka) Pvt. Ltd.,
Chickballapur
RS-8100 KL
ENA – 5400 KL, CL
5 Khoday India Ltd., Bangalore 8000 KL, IMFL
6 Maruti Organics Ltd., Bidar 7200 KL, RS/ENA
7 The Mysore Sugar Co. Lltd., Mandya 10800 KL, RS/ENA/AA
IMFL, CL, SFU
8 Ravindra& Co., Ltd., Bidar 4500 KL, RS/ENA &IMFL
9 Sri Chamundeshwari Sugar Ltd., Mandya 5000 KL, RS / ENA
10 Shree Doodhaganga Krishna SSK Niyamit, BGM 30 KLPD RS/ENA/AA
11 NSL Sugars Ltd., Mandya 45 KLPD RS, ENA/AA
12 Samsons Distilleries (P) Ltd., Davanagere 18000 KL – RS, 9000 KL – ENA
16500 KL – AA
13 Shri Hiranyakeshi SSK Niyamit, Belgaum 16200 KL, RS/ENA/AA
14 Siddapur Distilleries Ltd., Bagalkot 60 KLPD, RS/ENA/AA
15 Shri Malaprabha SSK Niyamit, Belgaum 9000 KL, RS, Den. SpiritSFU
16 Sri LaxmiNarsimhan Distillery Pvt Ltd., Dharwad 12775 KL, RS, 7300 KL, ENA
17 SomaiyaOrgano Chemicals, Bagalkot 20000 KL RS, 15000 KL ENA
15000 KL AA
18 Satish Sugars Ltd., Belgaum 60 KLPD15 KL AA
19 The Ugar Sugar Works Limited, Belgaum 24369 KL, RS, 15 KL ENA &Ethanol
20 United Spirits Limited, Bellary 30 KLPD RS/ENA
21 Vishwanath Sugars & Distilleries, Belgaum 30 KLPD RS
22 Wilson Distilleries Pvt. Ltd., Mandya 9000 KL, RS/ENA
23 Sri Chamundeswari Sugars Ltd., Mandya 50 KL RS
24 Shree Renuka Sugars Ltd., Manoli, Belgaum 120 KLPD, RS & 60 KLPD AA
25 Shree Renuka Sugars Ltd., Athani, Belgaum 300 KLPD Rs
26 Shree Renuka Sugars Ltd., Athani, Afzalpur 150 KLPD
27 Nirani Sugars Ltd., Bagalkot 120 KLPD RS/ENA/AA
28 GMR Industries Ltd.,Uttar Kannada 45 KLPD RS
29 Jamkhandi Sugars Ltd. – Jamkhandi 60 KLPD
30 Nandi SSK-Bijapur 60 KLPD
31 Indian Sugar Manufacturing Ltd. – Bijapur 60 KLPD
32 Shamnur Sugar – Davanageri 60 KLPD
33 Kartik Agro Industries – Bagalkot 60 KLPD
34 JP Distillery Ltd. – Tumkur 30 KLPD
35 Vijaynagar Sugars – Gadag 120 KLPD
16
INDUSTRIAL ALCOHOL:
Ethyl Alcohol is an important feedstock for the manufacture of chemicals. These
chemicals are primarily the basic carbon based products like Acetic Acid, Butanol,
Butadiene, Acetic Anhydride, Vinyl Acetate, PVC etc. The following table 3.17, 3.18,
3.19 & 3.20 indicates different important chemicals that could be made from alcohol.
The existing plants such as synthetic rubber requiring large quantities of alcohol will
certainly grow to a large capacity. Acetic acid & Butanol, which are needed in
pharmaceuticals, paints & in many other areas are important industries as they are
value added products.
Ethylene, Ethylene oxide & Mono-ethylene glycol are also produced from
petrochemical route with latest technological development and taking into account the
increasing cost of petrochemical raw material, it is now possible to produce Ethylene
oxide, Mono-ethylene glycol, etc., starting from ethanol.
During the last 5-6 years, a number of alcohol-based industries have come up & the
existing has marginally expanded. The raw material needs of the alcohol based
chemical meet the domestic demands for the end products. These units are starving
for want of raw materials. The shortage is wide spread & it has hit most of chemical,
drug & other industries. The drug industry is also bedeviled by scarcity of industrial
alcohol. Producers of insulin, antibiotics, tonics & several other essential bulk drugs
& finished formulations are unable to obtain their quota of industrial alcohol, which is
a vital raw material for them.
It follows that the supply of industrial alcohol to chemical and drugs units in the
country will remain below normal for some more time.
In order to maintain proper rate of growth of Industries, production of alcohol must
increase.Denatured spirits are rectified spirit made unfit for drinking by addition of
chemicals, which have strong disagreeable odour and which cannot be easily
separated from spirit. The Denatured Spirits are taxed at a nominal rate so that their
use in industry becomes economical.
17
Table 3.6
DERIVATIVE OF ETHYL ALCOHOL
Acetic Acid, Acetic Anhydride n-Butnol, Butadiene, Chloral
Crotonaldehyde, GlyoxalPenterithritoal, Peracetic Acid Sorbic Acid
Ethyl Acetate, Ethyl Acrylate Ethyl Amine, Ethyl Anile
Ethyl Benzonate, Ethyl Bromide Ethyl Butyrate, Ethyl Caprate, Ethyl Caproale
Ethyl Caprylate, Ethyl Cellulose Ethyl Chloracetate, Ethyl Chloride, Ethyl Cinnamate, Ethyl Cyanoacetate
Ethyl Ether, Ethyl Formate Ethyl Heptanoate, Ethyl isovalorate Ethyl Propionate
Ethyl Salicilate, Ethyl Silicate Diethyl Aniline, Diethyl Maleate, Diethyl Malonate, Diethyl Oxalate
Diethyl phthalate, DietehylSulphate, Phenyl Ethyl Alcohol, Potassium Ethyl Xanthate, Sodium, Alginate
Ethyl Benzene, Ethylene Dichloride, Ethyl Oxide, Polyethylene
Ethylene
Acetaldehyde A
Ethyl Alcohol
Al
18
Table 3.7
DERIVATIVE OF ETHYL ALCOHOL
Chloroquin, Dithranon, Metronidazole, Phenacetin, Salbutanol-Sulphate, Trimethoprim
Drugs & Pharma
Direct Use
Acetates
Drugs & Pharma
Pigments
nts
Direct Use
Acetates
Drugs & Pharma
Other Chemicals
Preservatives
Jams, KetchupsPicles,
Syrups
Textiles
Dyeing Aid Printing Aid
Benzidine- Yellow 20
Diazo YellowTR
Lake Red C Red 2, Red C Red C12, Yellow-1
Ammonium Acetate, Amyl Acetate, Anisyl
Acetate, Barium Acetate, Benyl Acetate,
Butyl Acetate, Cadmium Acetate, Carbitol
Acetate, Cellosolve Acetate, Cellulose
Acetate, Cellulose Triacetate, Cobalt
Acetate, Copper Acetate, Ethyl Acetate,
Ferric Acetate, Ferrous Acetate, Isobutyl
Acetate, Isopropyl Acetate, Lead Acetate,
Magnesium Acetate, Manganese Acetate,
Methyl Acetate, Nickel Acetate, Potassium
Acetate, Sodium Acetate, Sodium Acetate,
Strontium Acetate, Terpinyl Acetate,
ThalliumAceteate, Vinyl Acetate, Zinc
Acetate
Acetamide, Acetanilide, Acetic Anhydride, Acetophenetidin, Acetyl Chloride, Carboxy Methyl Cellulose, Chloro Acetic Acid, Dimethyl Acetamide, Glodin Fungicide, Glycine, Per Acetic Acid, Phenoxy Acetic Acid PTA, Strychnine, Thio Acetic Acid
19
Table 3.8
DERIVATIVE OF ACETIC ANHYDRIDE
ACETIC ANHYDRIDE
Aromatic Compounds
Chemicals Dyes & Pigments
Polymers & Intermediates
Drugs & Pharmacy
Acetophenone Benzyl Acetate Geranyl Acetate Cinnamic Acid CitronellylAcetate DehydroPregenolone Acetate Linalyl Acetate Methyl Acetate P.Cresyl Acetate Phenyl Ethyl Acetate, Rose Crystals
Acetyl Chloride Dimethyl Acetamide EDTA/NTA Meta Amino Acetanilide Meta Nitro Aniline
FAST BASES
Bordeax Red B Scarlet R
REACTIC Orange 4 & 16 Red EP88, Red M88 Red VSB Supara Red
OTHERS
Disperse Dye Intermediates S.D.Dyes Bordeaux GP Base
Carboxy Methyl Cellulose Cellulose Acetate Cellulose Acetate Butyrate Cellulose Tri Acetate Vinyl Acetate Monomer
Acetyl Salicylic Acid AminophylineAnalgin, AsprinAstrapholaxineBisacodylCaffieneChloramplhenicol Ciprofloxacin Coumarin Ibuprofen Mesterolone Metronidazole Paracetamol Salbutamol TheophylineThiacetazone Vitamin E
20
Table 3.9
DERIVATIVE OF CHLOROACETIC ACIDS
CHLORO ACETIC ACID
Drugs & Pharmaceuticals
Chemicals Pesticides
Amino PhylineCaffine Folic Acid Ibuprofen Isoprotemol Naproxen OxyphenButazzonePhenBarbitone Phenyl Butazone Salbutamol Sulphate Theophylline Xylocaine
Carboxy Methyl Cellulose Chloro Acetyl Chloride EDTA/NTA Ethyl Chloro Acetate Glycine Glycolic Acid Indigo Malonic Acid Phenoxy Acetic Acid Polymethane Dyes QuinolineDereivativeThio Glycolic Acid
2, 4, 5T 2, 4D AlachlorButachlorDimethoateFormathionGlyhosPiroxycan Quinalphos
21
Potable Alcohol:
Manufacture of alcoholic beverages from alcohol is also an attractive diversification.
According to the policy of the Government and it is necessary to get license for
manufacture of potable liquor. There is large demand for alcoholic beverages.
Indian Distilleries produce mostly Grade-I of alcohol. For export purpose, the quality
of alcohol should be of superior standards comparable to that of major exporters to
world markets like Brazil, Mexico, Spain and France. The minimum standards of
alcohol prevailing in India, Brazil and Mexico are given in Table 3.21. There is need
to procure alcohol of better quality. Good quality alcohol has great potentiality for
export. The strength of alcohol produced should be 96% v/v. Specifications of
rectified spirit as laid down by Indian Standards: 323-1959 is given in Table No.3.10.
Table 3.10 MINIMUM STANDARDS OF ALCOHOL
Characteristics India Brazil Mexico
Grade-I
Specific Gravity at 15.6°C 0.8171 0.8093 0.8138
Ethanol Content, % v/v (at 15.6°C 94.68 96.60 95.50
Acidity, % by wt. 0.002 0.0037 0.0037
Aldehyde Content, % by Wt. 0.006 0.006 0.006
22
Table 3.11
SPECIFICATION FOR RECTIFIED SPIRIT
(IS : 323 – 1959)
Sl.
No.
Characteristic Requirement of Rectified
Spirit for
*Method of Test
(Ref. to
Appendix) Grade-I Grade-II
1. Specific Gravity at
15.6°C/15.6°C(60°/60°F)
0.8171 0.8171 B
2. Ethanol content:
a) Percent by volume at
15.6°C(60°F) Min.
94.68 94.68 C
b) Degrees Over-proof, Min. 66.0 66.0 C
3. Miscibility with water Miscible Miscible D
4. Alkalinity Nil Nil E
5. Acidity (as CH3 COOH)
% by Wt. Max.
0.002 0.01 E
6. Residue on evaporation
gms/100 ml. Max.
0.005 0.01 F
7. Aldehyde content
(as CH3CHO)
gms/100ml. Max.
0.006 0.10 G
8. Ester content
(as CH3COOC2H5)
gms/100ml. Max.
0.02 -- H
9. Copper content (as Cu)
gms/100 ml. Max.
0.0004 -- J
10. Lead content (as Pb)
gms/100 ml. Max.
0.0001 -- K
11. Methyl alcohol content To satisfy the requirement of
the test.
L
12. Fuel Oil content To satisfy the requirement of
the test.
M
13. Furfural content To satisfy the requirement of
the test.
N
These refer to methods described in IS 323-1959 for Rectified Spirit.
23
The ENA quality is judged primarily by taking P.P. Time test (Potassium
permanganate reaction time test) and the organoleptic test. The spirit, which takes
maximum time to fade the colour of Potassium permanganate added in the ENA at
15.6°C, is said to be good quality. For a good quality ENA, the P.P. time test should
not be less than 50 minutes. The BIS specification of ENA\is given on Table No.3.23.
Table 3.12
REQUIREMENT OF NEUTRAL SPIRIT FOR ALCOHOLIC DRINKS
(IS : 6613 – 1972)
Sr.
No.
Characteristic Requirement
Neutral Spirit
IS:6613-1972 ENA
Requirement of
Export Quality
Neutral Spirit,
EQENA
01 Relative density at 15/15°C 0.81245 to 0.81679 0.8118
02 Ethanol content per cent by Volume at
15.6°C
94 to 95 96.0
03 Miscibility with water Miscible Miscible
04 Alkalinity Nil Nil
05 Acidity (as CH3COOH)
Mg/100 ml. Max.
2.00 1.25
06 Residue on evaporation
Mg/100 ml. Max.
2.00 2.00
07 Esters (CH3COOC2H5)
Mg/100 Ml. Max.
10.00 2.00
08 Lead (as Pb) mg/100 ml. Max. Nil Nil
09 Methyl Alcohol Content To pass test 5 PPM
10 Furfural content To pass test To pass test
11 Aldehyde (as CH3CHO)
Mg/100 ml. Max.
4.0 0.5
12 Permanganate reaction time, minutes min. 60 60
13 Copper (as Cu), mg/100 ml. Max. 2.0 0.3
14 Fusel Oil content, mg/100 ml. To pass test 10.00
In addition to above, the ENA shall pass specific organoleptic test required for high
quality blends.
There is good market for Extra Neutral Alcohol for manufacture of good quality perfumes,
homeopathic medicines, tonics and other pharmaceutical products and potable liquor. The
BIS specification for perfumery grade alcohol is given on Table No.3.13.
24
Table 3.13
REQUIREMENT FOR ALCOHOL / PERFUMERYGRADE
(IS:1049:1962
Sr.
No.
Characteristics Requirement
01 Specific gravity at 15.6/15.6°C Max.
and at 15.0/15.0°C Max.
0.8337
0.8348
02 Ethanol content, percent by volume, at
15.6°C Max.
90
03 Miscibility with water 1:19 by volume Miscible.
04 Acidity (as CH3COOH) percent by weight
Max.
0.0020
05 Residue on evaporation, percent by weight
Max.
0.02
(The residue shall not produce any
brown or red colour when treated with
1 ml. of concentrated sulphuric acid
analytical reagent grade)
(Sec.IS:266-1961)
06 Fusel oil and allied impurities Pass the test.
07 Aldehydes and Oxidizable impurities Pass the test.
08 Isopropyl alcohol, acetone and other
ketones.
Pass the test.
Fuel Alcohol:
Alcohol has a great future as renewable source of energy. The latest trend for a fuel
in the world is use of alcohol as an alternative for mineral fuel oil, which is depleting as far as
fuel oil is concerned. During wartime (II World War) in India alcohol in the form of power
alcohol was used for blending with petrol in the proportion of 80% petrol and 20% power
alcohol. This continued till 1960 when demand of alcohol for chemicals and plastics came up
with establishment of alcohol based chemical industries. Because of shortage of alcohol, the
scheme of blending petrol with alcohol was given up. Brazil has developed technology,
which has made possible large-scale substitution of petroleum-derived fuel. Even hydrous
alcohol (Rectified Spirit) can be used as exclusive fuel for automobiles. Alcohol powered
vehicles has taken the first position in Brazil and now accounts for 80% of overall sales or
about 5,00,000 alcohol powered units every year. Alcohol can also be blended with diesel in
the proportion of 7-10%. The BIS specifications (BIS:321-1964, BIS: 15464-2004) of
anhydrous alcohol (or fuel alcohol) are given in Table 3.25 and 3.26 respectively.
25
Table 3.14
SPECIFICATION FOR ANHYDROUS (Fuel) ALCOHOL
(IS : 321 – 1964)
Sl.
No.
Characteristic Requirement of Anhydrous Alcohol
Requirement for
Special
Grade
Grade-I Grade-II
1. Specific Gravity at 15.6°/15.6°C Max. 0.7961 0.7961 0.7961
2. Ethanol Content:
% by volume at 15.6°C, Max.
99.60 99.60 99.60
3. Miscibility with water Miscible Miscible Miscible
4. Alkalinity NIL NIL NIL
5. Acidity (as CH3COOH)
% by weight, Max.
0.006 0.006 0.006
6. Residue on evaporation % by weight,
Max.
0.005 0.005 0.005
7. Aldehyde content (as CH3CHO)
gm/100 ml. max.
0.10 0.006 0.10
8. Ester content (as CH3COOC2H5)
gm/100 ml. Max.
0.02 -- --
9. Copper (as Cu), gm/100 ml. Max. -- 0.0004 --
10. Lead (as Pb), gm/100 ml. Max. -- 0.0001 --
11. Methyl alcohol content -- To satisfy the
requirement
of the test
--
12. Fusel Oil content -- To satisfy the
requirement
of the test
--
13. Ketones, isopropyl alcohol and tertiary
butyl alcohol
-- To satisfy the
requirement
of the test
--
14. Total sulphur and compounds of sulphur
(as S) % by weight, Max.
0.001 -- --
15. Sulphur dioxide (as SO2), %
by weight, Max.
0.00005 -- --
26
Table 3.15
Requirements of Anhydrous Ethanol For Use In Automotive Fuel
Sl.
No.
Characteristic IS:15464 (2004)
01 Relative density at 15.6/15.6°C, Max. 0.7961
02 Ethanol Content present by volume at 15.6/15.6°C
Min (excluding denaturant)
99.6
03 Miscibility with water Miscible
04 Alkalinity Nil
05 Acidity (as CH3COOH) Mg/lit., Max. 30
06 Residue on evaporation percent by mass, Max. 0.005
07 Aldehyde content (as CH3CHO) Mg/lit., Max. 60
08 Copper, Mg/kg., Max. 0.1
09 Conductivity, uS/m, Max. 300
10 Methyl alcohol, Mg/litre. Max. 300
11 Appearance Clear and bright
Anhydrous alcohol is water free ethyl alcohol and is generally used during World war-II in
our country and the same was continued until 1963. The anhydrous alcohol denatured with
0.5% Kerosene was used to blend with petrol in the production of power alcohol of 20%
alcohol and 80% petrol composition. Power alcohol act made it compulsory to supply only
such mixtures at certain places known as power alcohol zone. As the demand of alcohol
increased for manufacture of chemicals, the power alcohol act was abolished and production
of absolute alcohol was totally suspended.
Developments with Major Ethanol Players:
As fuel ethanol is dominating the production portfolio, the largest players are to be
found in those countries with a highly developed fuel ethanol programme.
The USA – a greater role for ethanol:
There were 184 plants in operation with total production reaching to 46.84 billion
liters. Many plants will be added in next two years e.g. Archer Daniel is putting up two
ethanol plants each of 500 million gallon per annum capacity.
As per the Department of Energy, US is proposing to produce 226.8 billion liters of
fuel ethanol by the year 2030. Of this, 50% has to come from corn and remainder from
cellulosic feedstock.
In State of Union address in January 2007, President Bush proposed to raise
consumption of renewable fuels to 132.3 billion liters by 2017, which indicates that ethanol is
going to be main pillar of future US energy policy.
27
Brazil-most economic ethanol producer:
In the year 2010 Brazil produced 27.52 billion liters out of which 3.1 billion liters was
exported. In the year 2012 Brazil produced 30.0 billion liters and in 2015 it exports 7.9
billion liters of fuel ethanol. Brazil is expected to require about 2.0 – 3.0 billion liters extra
ethanol each year.
Companies from Japan, India, France, Germany, USA and others are queuing to build dozens
of new distilleries in Brazil. 200 New mills, each costing about $ 200 m are planned for the
next few years, while area under sugarcane is expected to double or even triple.
FUEL ETHANOL AS A OXYGENATE
Fuel-ethanol could be used in petrol as an oxygenate. This reduces emission of carbon
monoxide in the exhaust gases of vehicles, by taking combustion to completion. It is
necessary and advisable to reduce emission of carbon monoxide because it is toxic to human
beings. Completion of combustion also reduces emission of particulate carbon matter, which
could cause respiratory disorders. Oxygenate has ‘in-built’ oxygen molecule which helps in
completing combustion in a better manner. Oxygenates are organic compounds having
boiling point in the vicinity of the boiling point range of petrol. These compounds mix easily
and thoroughly with petrol.
Other compounds which are commonly used as oxygenates are tetraethyl lead, MTBE
(Methyl tertiary-butyl ether), ETBE (Ethyl tert-butyl ether), methanol etc., These compounds
also have oxygen molecules in them.Other function of the compounds added as oxygenates is
octane enhancer and anti-knocking agent. These compounds improve the octane number of
petrol, thus improving its combustion.
Tetraethyl lead is an oxygenate which is rich in oxygen. It has been traditionally used as an
oxygenate in petrol. However, it emits poisonous and dangerous fumes containing lead,
which are suspected to cause cancer. In order to replace tetraethyl lead, other substances are
added to petrol like the aromatics fraction from crude petroleum distillation. This fraction
containing BTX – benzene, toluene and xylene – is added to improve the octane number.
However, emissions from such a mixture are poisonous and require a catalytic converter to
prevent such emissions. Thus, vehicles using BTX fraction in petrol have to use a catalytic
converter on the exhaust of their vehicle. When MTBE is used as oxygenating agent, there is
a danger of it contaminating surface water making it unsuitable for use.
In order to get the required content of oxygen, various oxygenates have to be added in
different proportion to petrol, based on their content of oxygen.
28
‘Lead – Free’ Petrol:
Tetraethyl lead is commonly added to petrol as oxygenate and an antiknocking agent.
As its emissions are poisonous, substitutes have been developed. Either aromatic fraction of
petroleum, containing BTX (benzene, toluene and xylene) – or other agents like ETBE or
MTBE is added to make the petrol ‘lead-free’.
Oxygenates in India:
In India, MTBE is now used as oxygenate in petrol. ‘Lead-free’ petrol in India is now
added with MTBE in place of tetraethyl lead used normally. Various studies carried out in
the US have demonstrated that MTBE used in petrol gets settled onto surface water of lakes
and dams and reservoirs. This contamination of water is dangerous and could be harmful to
health.
Several States in the US have now banned use of MTBE as oxygenating agent in
petrol and have advocated used of fuel-ethanol as safe alternative.
In India there is scope to change from MTBE by employing the alternative and easily
available agent like ethanol. Ethanol is widely available in India and only needs to be
converted to anhydrous form before blending it into petrol.
Advantages of Fuel-Ethanol:
Addition of fuel-ethanol to petrol has several advantages, especially in a country like India.
Use of ethanol in place of tetraethyl lead or MTBE will prevent dangerous and poisonous
emissions containing lead or MTBE from petrol. It will not require any catalytic converter
for the vehicles.
Use of ethanol in petrol reduces emission of carbon monoxide. This will reduce pollution in
India, as this is the most major cause of environmental pollution in India.
Ethanol is made from renewable sources of energy i.e. based on agricultural products. Thus,
it is not a depleting resource like petrol. Ethanol is mainly produced from sugarcane
molasses. Sugarcane is a renewable source of energy. Sugarcane cultivation is an efficient
method of converting ‘solar energy’ into ‘stored energy’. Thus, use of ethanol as
oxygenating agent or fuel-extender would conserve fossil fuels and would reduce dependence
on fossil fuels.
Use of ethanol helps in maintaining the ‘carbon cycle’ of nature. Carbon dioxide in the
atmosphere is converted by agricultural crops like sugarcane or corn into carbonaceous
29
materials like sugar and starch using solar energy. This sugar or starch can be converted into
ethanol. This ethanol is used in vehicles to produce energy along with petrol. This
combustion in internal combustion engines converts ethanol into carbon dioxide. This carbon
dioxide can again be converted into sugar or starch. Thus, the ‘carbon cycle’ of nature
continues. This ‘carbon cycle’ uses solar energy, which otherwise would have been wasted.
Use of fossil fuels alone to generate energy only increases content of carbon dioxide in the
atmosphere, disturbing the natural balance. Sustaining the ‘carbon cycle’ reduces the
‘greenhouse effect’.
Use of ethanol, which is mostly a ‘home grown’ product reduces dependence on the
politically sensitive Middle – East region.
India has vast agricultural waste resources like sugarcane molasses to gainfully convert into
ethanol.
CONCLUSION:
The demand of alcohol for industrial, potable & fuel alcohol in Karnataka as well as in whole
country will increase significantly in coming years. The proposed enhancement /
modernization of Siddapur Distilleries Ltd., will contribute to fulfill the demand for Rectified
Spirit, ENA and fuel alcohol of Karnataka and neighboring states.
30
CHAPTER – IV
MOLASSES BASED FERMENTATION TECHNOLOGY
During the last decade, interesting developments have taken place in the field of technology
of fermentation of alcohol, which promise high yield of alcohol, economy in space, economy
in steam consumption and sizable reduction of quantity of effluent.
After the Second World War, considerable research and developments in the continuous
process for industrial fermentation have taken place and the processes have been perfected to
make them viable. Continuous processes for alcoholic fermentation are now commercialized.
This has been possible for the outstanding research and development work carried in Russia,
Sweden, Austria and U.S.A. etc., many processes have been patented.
There are variations in different processes of continuous fermentation. Some use only single
fermenter whereas some use two fermenters or battery of fermenters. The first fermenter
favours rapid cell growth and the second fermenter favours high rate of fermentation. Yeast
is recycled. The alcohol content in first fermenter is limited to not more than 4-6% v/v and
alcohol content in second fermenter is 8% v/v.
During the last two years interesting development taken place in the field of new technology
FED-BATCH fermentation, which promise high yield of alcohol, economy in space &
sizable reduction of quantity of effluent .
PROCESS FOR MANUFACTURE OF ALCOHOL
Molasses is the chief raw material used for production of alcohol. Molasses contains about
50% total sugars, of which 30 to 33% are cane sugar and the rest are reducing sugar. During
the fermentation, yeast strains to the species Saccharomyces Cerevisieae, a living
microorganism belonging to class fungi converts sugar present in the molasses such as
sucrose or glucose in to alcohol. Chemically this transformation for sucrose to alcohol can be
approximated by the equation:-
I) C12H22O11 + H2O 2C6H12O6 Invertase
Cane Sugar Glucose + Fructose
II) C6H12O6 2C2H5OH + 2CO2
180Zymase2 x 46 + 2 x 44
Glucose/Fructose Ethyl alcohol + Carbon di-oxide
Thus 180 gm. Of sugars on reaction gives 92 gms of alcohol. Therefore, 1 MT of sugar gives
511.1 kgs. of alcohol. The specific gravity of alcohol is 0.7934, therefore,
511.1 kg. of alcohol is equivalent to 511.1 / 0.7934 = 644.19 litres of alcohol. During
Fermentation of other by-products like glycerin, succinic acids etc. also are formed from
sugars. Therefore, actually 94.5% total fermentable sugars are available for alcohol
conversion. Thus, one MT of sugar will give only 644 x 0.945 = 608.6 litres of alcohol,
under ideal condition theoretically.Normally only 80 to 82% efficiencies are realized in batch
type plant. One MT of molasses containing 45% fermentable sugars gave an alcoholic yield
of 230 litres per MT.
31
For bringing out above biochemical reaction, we require proper and careful handling of yeast,
optimum parameters like pH, temperature control and substrate concentration, which results
into effective conversion of sugars to alcohol. For yeast propagation & multiplication
separate equipment is required. Initially yeast is developed in the laboratory from the single
cell yeast culture. In the laboratory, yeast is propagated in a test tube on 10 ml. Then it is
transferred to a bigger flask of 500 ml. flask are transferred to 5 liter flask containing the
sterilized molasses media solution. It is necessary to adjust the pH of the molasses solution
in the range of 4.5 to 5.0 add necessary nutrients such as ammonium sulphate or urea,
diammonium phosphate etc. Each stage of development of yeast from 10 ml to 500 ml and
500 ml to 5 litres requires 24 hours in the laboratory. On the plant side, there are again 3
stages of propagation namely 100 litres, 500 litres and 5000 litres. All these equipment’s are
designed so as to facilitate boiling molasses solution in order to sterilize it and also cooling to
bring it to the proper temperature of 33°C and letting in culture and taking out culture.
Boiling, cooling, introducing culture etc. are done in aseptic manner, i.e. Keeping the
fermentation medium free from any kind of infection. Further stages of yeast propagation are
done in open tanks. i.e. pre-fermenter requires about 8 hours in order to build up necessary
concentration of yeast in them. Finally pre-fermenter is emptied in an empty fermenter,
which is previously cleaned and kept ready. Dilute molasses solution is allowed to flow in
the fermenter so as to fill it to its working capacity say about one-lac litres.
Now a day, readymade compressed yeast is used directly in the pre-fermenters. Good quality
of yeast is available for use in distillery. The yeast is manufactured under strict controlled
conditions. This yeast is useful to obtain a good yield of alcohol by fermentation of molasses.
The stages of yeast propagation as described above for producing yeast from laboratory scale
to pre-fermenter stage may be totally eliminated. The fermentation of molasses in fermenters
take about 24 to 30 hours for completely exhausting the sugars in molasses.
The average efficiency of conversion of sugars from molasses to alcohol is 80 to 85% of
theoretical value in batch type distilleries. All the sugars are not converted to alcohol during
the process or fermentation because chemicals like glycerin, succinic acid, etc. are also
produced by yeast during their metabolic process. Therefore, it is not possible to have 100%
efficiency of conversion of sugars to alcohol. The average yield of alcohol from molasses is
about 230 litres from 1 MT of molasses in batch type distilleries.
Recently attractive developments have taken place in the field of fermentation and distilleries
whereby one can get high yield of 265 to 270 litres per MT of molasses.
TECHNOLOGY FOR CONTINUOUS FERMENTATION PROCESS:
The continuous fermentationtechnology as compared to the old batch fermentation
technology. It has many advantages like continuity of operation, higher efficiency and ease
of operation. Continuous fermentation also results into consistent performance over a long
period as compared with batch fermentation. Most modern ethanol production plants adopt
this continuous fermentation technology.
32
1) “K-SUPER” CONTINUOUS FERMENTATION (KBK):
K-Super proposed to adopt the efficient continuous fermentation in the distillery. The
fermentation process employs a special yeast culture, which can withstand variations in the
molasses equality, temperature and other shock loads. Fermentation plant consists of three to
four numbers fermenter tanks connected in series with all the accessories like plate heat
exchangers for cooling, air & CO2sparger, broth mixers and air blowers etc., The yeast is
immobilized using special media and it remains in the fermentation plant throughout and
hence it gives tremendous advantages in maintaining the yeast population and in combating
the bacterial infection. The technology is called continuous mixed bed fermentation (CMB)
and which is the latest technology available in the industry at present. Molasses after
weighing is diluted and also pre-treated to an appropriate sugar concentration while pumping
through molasses broth mixer into the fermenter. The partial pre-treatment of molasses is
required to reduce scaling of the equipment due to the sludge present in the molasses, which
is separated out very easily in this pre-treatment. The fermenters are then inoculated with
culture developed in the culture vessels. This culturing with suitable yeast is carried out only
during the start-up of the plant. The culture thus developed maintains itself in fermenters on
a continuous basis.
To help the fermentation sustain the assailable nitrogen are added in the medium in the form
of Urea and DAP as required. Temperature in the fermenters is maintained to an optimum
level as required for efficient reaction with the help of plate heat exchanger and recirculation
pumping system. This recirculation also helps in proper mixing of fermented wash. The
retention time for the reaction is about 24 to 32 hours. Air blower is provided to supply the
necessary oxygen required for the yeast and also for agitation. After completion of reaction
the fermented wash is delivered to wash settling clarifier. In Wash Settling Clarifier, settable
solids settle down. The supernatant goes to Buffer Wash Tank (BWT) and sludge from
bottom goes to Sludge Tank.
The CO2 which is liberated in fermentation is scrubbed in water, with the help of CO2
scrubber. This CO2 contains ethanol, which is recovered by collecting CO2 scrubber water
fed into sludge trough. The diluted sludge is pumped into Sludge settling clarifier. The
traces of ethanol present in diluted sludge are separated at the supernatant, which is collected
into BWT through overflow and washed sludge from bottom is drained off. The fermented
mash collected in the Clarified wash tank is then pumped to Mash or Primary column for
distillation.
A closed loop cooling tower system with an induced draft-cooling tower with
circulation pumps is also provided to ensure higher cooling efficiency and to minimize water
wastages.
2) CASCADE (HIFERM-GR) Continuous Process with yeast recycling (PRAJ):
M/s.PrajIndustries Ltd., Pune, supply complete plants for the fermentation industry. The
process is for continuous production of alcohol from sugar containing raw materials. The
process developed by them for continuous fermentation is adopted for production of alcohol
from raw molasses successfully in several countries like India, Thailand, Yugoslavia,
Australia, Ghana, Kenya, USA etc.
33
A set of four fermenters is required for this process. This wort enters the first fermenter and
is allowed to overflow to the second fermenter and the wash from 2nd fermenter goes to 3rd to
4th fermenter. The wash coming from the 4th fermenter, it contains 8-9.5% alcohol. Process
water is also added to first one or two fermenters. Water ring blowers sparged fermentation
air into first and second fermenters, carbon dioxide generated into the first and second
fermenter is collected and it fed into the third fermenter for proper mixing of the fermented
wash, while part of the carbon dioxide generated into the last fermenter is collected and it led
into the CO2 scrubber. The CO2 which is liberated in fermentation is scrubbed in water, with
the help of CO2 scrubber. This CO2 contains ethanol, which is recovered by collecting CO2
scrubber water fed into sludge trough.
The wash coming out last fermenter goes to yeast separator (yeast settling tank). In the yeast
separator yeast cream is separated by gravity settling from the wash and returned back to the
first fermenter by acidic treatment to avoid the contamination, nutrient dosing as well mixing
of molasses by broth mixer with yeast cream and sparging the air in yeast activation tank
(YAT), therefore yeast activity will be increases and it is fed to the fermenter No.1. The top
fermented wash overflow collected in the wash settling tank (WST).
In wash settling tank sludge is settled at the bottom while top supernatant wash over flow to
the wash charger (wash holding tank), then it is pumped to Mash or Primary column for
distillation system to recover the alcohol.
The sludge drain from the bottom of WST is fed into sludge trough where it is diluted with
CO2 scrubber water. The diluted sludge is pumped into Sludge settling tank (SST). The
traces of ethanol present in diluted sludge are separated at the supernatant, which is collected
into wash charger through overflow and washed sludge from bottom is drained off.
Fermentation auxiliaries like nutrient preparation, sulfuric acid dilution and antifoam agent
dosing are prepared on the ground floor. Nutrient solution and dilute acid is fed to the first
fermenter by metering or dosing pumps. In this manner by controlling parameters like
molasses and water flows, pH, Nutrient and temperature, alcohol concentration between 5.5
and 9.5 % v/v is maintained in first and last fermenter respectively. Temperature of the
individual fermenters is maintained in the desired range of 30 to 32°C by recirculating the
fermenting wash through the individual plate heat exchangers. A separate cooling tower and
pump is used for recirculating the cooling water for fermentation.
All the fermenters are covered and connected to a scrubber in order to recover alcohol from
carbon dioxide. The yield of alcohol is 280 litres/MT of molasses containing 47% total
fermentable sugars. Stillage would be appreciably less as alcohol concentration by `12-14
litres per litre of alcohol produced depending on alcohol produced in the wash.
Average residence time is in fermenters is 24-30 hrs. with alcohol % in fermented wash in the
range 8-9% (v/v).
M/s.PLraj Ind. Ltd., Pune has introduced a system in the year 2001-02 in which a granulated
flocculating type yeast strain is being used which has a property to settle down by
gravitational force. This eliminates the use of yeast separators. The fermentation efficiency
is claimed as 89-90%.
34
3) MojjEngg. Systems Ltd:
Molasses after weighing is diluted and also pre-treated to an appropriate sugar concentration
while pumping through molasses broth mixer into the fermenter. The partial pre-treatment of
molasses is required to reduce scaling of the equipment due to the sludge present in the
molasses, which is separated out very easily in this pre-treatment. The fermenters are then
inoculated with culture developed in the culture vessels. This culturing with suitable yeast is
carried out only during the start-up of the plant. The culture thus developed maintains itself
in fermenters on a continuous basis.
Continuous yeast growth in yeast YV03 byadding pasteurized molasses and recycling partly,
the yeast separated in yeast separator after acidification and activation treatment, which helps
to avoid contamination and maintain consistency in operation.
To help the fermentation sustain, the nitrogen is added in the medium in the form of Urea and
DAP as required. Temperature in the fermenters is maintained to an optimum level as
required for efficient reaction with the help of plate heat exchanger and recirculation
pumping system. This recirculation also helps in proper mixing of fermented wash. The
retention time for the reaction is about 22 to 24 hours. Air blower is provided to supply the
necessary oxygen required for the yeast and also for agitation.
This fermentation technology use genetically marked high osmotoleant yeast strain.
The system uses the cooling system to maintain fermented broth temperature to 32-35°C,
which results in improve yeast cell mass activity.
The technology incorporated yeast recycle, which maintain high yeast concentration and
reduced fermentation time result in lower fermenter volume, saving in capital and operating
cost.
After completion of reaction the fermented wash is delivered to yeast separation centrifugal
machine to separate the yeast cream. The technology incorporates yeast acidification and
activation, which ensure the yeast, recycle in continuous propagation vessel and fermenter is
bacteria free and ensures no contamination.
In Wash Settling Clarifier, settable solids settle down. The supernatant goes to clarified wash
tank (CWT) and sludge from bottom goes to sludge tank. The fermented wash collected in
the clarified wash tank is then pumped to stripping column for distillation.
The CO2 which is liberated, is scrubbed in water, with the help of CO2scrubber. This CO2
contains ethanol, which is recovered by collecting CO2 scrubber water into sludge
decantation. The technology incorporated sludge decantation system, which consists of
specially designed lamella separator as against conventional, designed to settle the sludge.
The settled sludge after dilution, from CO2scrubber water pass through the decanter. This
ensures the clarified wash going to distillation is free from sludge, which results in clean
distillation column, re-boiler tubes and integrated spent wash evaporator tubes. This also
helps to maintain consistency in operation and avoid losses due to stoppages. Alternatively
the technology also offers pre-clarification of molasses for high sludge/VFA content in
molasses.
35
A closed loop cooling tower system with an induced draft-cooling tower with circulation
pumps is also provided to ensure higher cooling efficiency and to minimize water wastages.
The system incorporates mechanical ejector in place of air sparger, which results in increase
the dissolved oxygen level, facilitate better contact between yeast and fermentable sugar
avoid hydraulically dead zones, increase yeast cell mass activity for high efficiency and better
yield.
The technology achieved 8-9% v/v alcohol percentage in fermented wash.
BIOSTIL:
Process developed for Continuous Fermentation is Biostil process patented by Alfa-Laval of
Sweden. It has some special features. It is a very comprehensive and compact process aimed
at only high yield of alcohol but also reduction of effluent substantially.
In this process, concentrated substrate of 40-45% of final molasses is fed to the fermenter at a
constant flow rate. The process does not involve pretreatment or pasteurization of molasses.
It envisages recycling of stillage to the extent of 70% of total volume in order to eliminate
bacterial infection. The whole fermentation is carried continuously in two fermenters.
Molasses wortisfeeded at such a rate that the sugar percentage remains below 1.8 to 2 % w/w.
Ethanol concentration is controlled at 6 to 7% w/w. Special kind of yeast known as
Saccharomyces pombe is used in the process. The yeast propagates by splitting and not by
budding. It stands high osmotic pressure. The process requires yeast propagation vessels,
nutrient tanks and pumps, yeast separators, hydrocyclones, carbon dioxide scrubber to
recover alcohol and efficient plate heat exchangers for cooling recycled stillage and for
cooling fermented wash.
The distillation system differs from the conventional process as far as wash column is
concerned. Other equipment’s are same as conventional plant.
The wash column divided into two sections:-i)Vaporizer ii) Stripper.
The wash is de-yeasted and also free from sludge by yeast separators of suitable design, as
the wash is pumped from fermenter to wash feed tank. The wash is plreheated by plate heat
exchanger and outgoing stillage. It enters the top plate of vaporizing section of wash column.
The wash is boiled by vapours coming up from the stripper section,. About 90% of ethanol is
removed from the top through vapour pipe of the column. The concentration of alcohol in
the vapor is approx. 50% v/v. About 70% of weak wash is pumped from the bottom of
vaporizer through the regeneration heat exchanger to return to the fermenter via a trim cooler
in the form of heat exchanger.
A minor stream of 30% remaining weak wash flows to another section of distillation column
called as stripping column. This column is heated by re-boiler instead of heating by steam
sparger employed in conventional plant. The vapours going out consisting of steam and
weak ethanol enters the bottom of vaporizer and provides heat necessary for boiling the wash.
The spent-wash leaving the column is free from alcohol and is concerned to 25% solids. The
duel purpose of this column heated by re-boiler for evaporation and distillation lead to the
highest possible stillage concentration without increase in steam consumption.
36
The recycling of spent-wash for dilution of molasses is a novel idea in this technique. This is
useful to increase soluble salt concentration for optimum osmotic pressure, which is
necessary to limit the growth of fermentation organism yeast without affecting the rate of
fermentation and eliminate contamination.
2) Fed Batch Process:
Fermentation process in Fed batch mode is very feasible for the molasses having higher value
of V.A by using culture yeast. We have adopted hyper fermentation system which offers the
flexibility of running the process in Fed batch.
Process Description:
Inoculation of yeast culture is 20% filling of molasses for 13 hrs. Total fermentation period is
24 to 28 hrs. and residual sugars will be controlled at 1.20% to 1.30%and the average alcohol
content in wash is 10.50% to 11%.Yield per MT of Molasses will be 270 to 280 BL.
In Fed batch fermentation the alcohol % in wash will be 10.50% to 11% as compared to
8.50% to 9.50% in continuous fermentation and the plant capacity will be increased by 10 to
15%. However, the steam requirement remains same and the generation of spent-wash will be
reduced by 3 to 4%. By this process optimum efficiency can be achieved.
37
CHAPTER – V
MULTI-PRESSURE VACUUM DISTILLATION
After fermentation the next stage in the manufacture of alcohol is to separate alcohol from
fermented wash and to concentrate it to 95% alcohol called as rectified spirit. For this
purpose, method of distillation is employed.
The distillation column system consist of number of bubble cap plates where wash is boiled
and alcoholic vapours are separated according to their boiling point and concentrated on each
plate stage by stage.
Atmospheric Distillation:
The fermented wash first enters the beer heater, which is a condenser for condensing
alcoholic vapours by using wash as cooling medium. The objective of this beer heater is to
recover the heat from the hot vapours of alcohol. Fermented wash from the beer heater goes
to degasifying column, degasifying column bottom goes to the top plate of the wash column.
Thiscolumn consists of 18 plates. The steam is admitted through the steam sparger situated
at the bottom of the column. As the steam rises up, the wash descending from the top to the
bottom of the column gets heated and by the time it reaches to bottom plate, it consist
practically no alcohol. The wash going out is called spent wash, which is discharged to the
drainpipe. The vapours coming from wash column now consists approximately 50% alcohol
and 50% water with impurities such as higher alcohol’s, aldehydes, acids, sulphur dioxide
etc. Part of these vapours are led to Pre-rectifier column where low boiling impurities are
separated from spirit which is produced at the rate of total production depending on the extent
of purity required and stored separately. Other portion of the vapours, which is major
quantity, is led to rectifying column. This column consists of 44 plates, which helps the
removal of bad smelling fusel oil, which is a mixture of higher alcohol. As the vapours
coming from wash column rise to the concentration of 95.5% alcohol. The alcoholic vapours
from rectifying column are condensed in the beer heater, principle condenser using water as a
coolant and finally vent condenser. The condensates of all three condensers go back to the
top of the rectifying column and uncondensed gasses are let out from the vent pipe. Actual
product of rectified spirit is drawn from the 3rd plate from the top and cooled in alcohol
cooler and taken out as a product.
The fusel oil which is a mixture of higher alcohol is drawn from the 6th to 10th plate from
bottom of rectifying column as a stream of vapours, it is condensed, cooled & led into a
decanter where it is mixed with water. Fusel oil being immiscible with water collects at the
top and is decanted through a funnel and sent to storage. The lower portion contains water
and alcohol and is sent back to wash column for recovery of alcohol. Fusel oil is recovered at
the rate of 0.2% of alcohol produced.
The alcohol both pure and impure is first led into separate receivers. The quantity of alcohol
produced is assessed daily in the receivers and it is finally transferred to storage vats in the
warehouse. The spirit from storage vats could be issued for denaturation or for own
consumption, or directly to the tankers of the customer depending upon the type of
requisition.
38
MULTI-PRESSURE VACUUM DISTILLATION:
Multi-pressure vacuum distillation system for production of Rectified Spirit consists of
distillation columns namely –
For-Rectified Spirit:
1. Degasifying cum analyzer column – Operation under vacuum
2. Pre-rectification column – Operation under vacuum
3. Rectification cum Exhaust Column – Operated under pressure
4. Fusel Oil Concentration column – Operated under atmospheric
For-ENA:
5. Extractive distillation column – Operated under atmospheric
6. Simmering column – Operated under atmospheric.
Fermented wash is preheated in pre-heater and fed at the top of the Analyzer column,
Analyzer column is fitted with thermosyphonreboiler. Top vapours of analyzer column are
sent to pre-rectifier column. Rest of the fermented wash flows down and is taken as spent
wash from analyzer column bottom. Pre-rectifier/stripperbottom liquid is preheated with
thermosyphonreboiler and fed to rectifier cum exhaust column. Low boiling impurities are
concentrated in the pre-rectifier column. A top reflux draw of condenser is taken out as
impure alcohol from the top of the pre-rectifier column. Rectifier exhaust is operatd under
pressure and bottom liquid is preheated with thermosyphonreboiler. Alcohol is enriched
towards the top and is drawn out as Rectified Spirit. Fusel oil build-up is avoided in the
Rectifier column by withdrawing out side streams of fusel oil. These are sent to fusel oil
concentration column from where the fusel oil is sent to decanter for further separation. The
fusel oil wash water is recycled back to the column. A top draw is taken out as impure
alcohol from the top of fusel oil column.
The design of the re-distillation plant is made in such a way that the Extra Neutral Alcohol
quality and the production does not get disturbed due to varying quality of rectified spirit.
The plant may be preferably in copper. As the plant deals with the rectified spirit, there is no
risk of corrosion and the quality of spirit produced will be superior.
In the proposed project, ENA will be produced directly from wash. The concentrated
vapours from the rectification/exhaust column will be fed directly to the ENA section of
distillation columns (Extractive distillation and simmering column). The ENA-distillation
columns will work on multi-pressure principle so that maximum heat economy can be
achieved with improved quality of ENA.
39
Benefits of Pressure Vacuum Distillation:
Following are the advantages of pressure vacuum distillation.
Since the analyzer column operates under vacuum, the formation of by-products such as
acetal may minimize there by improvement in quality of alcohol.
Pre-rectification column ensure removal of sulphur compounds/mercaptans and also
reduces load of lower boiling volatile compounds passing on to Rectifier cum exhaust
column.
The changes of scaling due to invert solubility of certain precipitating inorganic salts are
minimized in vacuum distillation.
Vacuum distillation requires low steam consumption with reboiler i.e. 2.2 Kg/lit. of
Rectified Spirit & 3.2 Kg/lit. of ENA.
MANUFACTURING PROCESS FOR FUEL (ANHYDROUS) ALCOHOL
Anhydrous alcohol is an important product required by industry. As per IS Specification it is
nearly 100% pure / water free alcohol. Alcohol as manufactured by Indian Distilleries is
rectified spirit, which is 94.68% alcohol and rest is water. It is not possible to remove
remaining water from rectified spirit by straight distillation as ethyl alcohol forms a constant
boiling mixture with water at this concentration and is known as azeotrope. Therefore,
special process for removal of water is required for manufacture of anhydrous alcohol.
In order to extract water from alcohol it is necessary to use some dehydrant or entrainer,
which is capable of separating, water from alcohol.
Simple dehydrant is un slacked lime, Industrial alcohol is taken in a reactor and quick lime is
added to that and the mixture is left over night for complete reaction. It is then distilled in
fractionating column to get anhydrous alcohol. Water is retained by quick lime. This process
is used for small-scale production of anhydrous alcoholby batch process.
The various processes used for dehydration of alcohol are as follows:
I) Azeotropic Distillation
II) Molecular Sieves
III) Pervaporation / Vapour permeation system.
The salient features of each of the processes are given herewith:-
I) Dehydration with Entrainer Process (Azeotropic Distillation):-
For manufacture of anhydrous alcohol on large scale, Cyclohexane is used as entrainer.
When 94.68% alcohol is mixed with Cyclohexane and distilled a ternary azeotrope is formed
e.g. If a mixture of ethanol, water and cyclohexane as given below is distilled and condensed
then the condensate forms two layers with following composition.
Azetrope Composition (%) Decanter
Upper Layer (%) Lower Layer (%)
Alcohol 18.50 14.50 53
Cyclohexane 74.10 84.50 11
Water 7.40 1.00 36
40
The system consists of two to three columns. First is a dehydration column followed by
recovery column. The Rectified Spirit is fed into the dehydration column. Cyclohexane is
also introduced in this column. Vapour of ethanol, water and cyclohexane close to its
azeotropic concentration is collected from the top whereas anhydrous alcohol is collected
from the bottom of the column.
Ternary mixture of ethanol, water and cyclohexane is condensed and sent for decantation
where it forms two layers. Top one is cyclohexane rich layer whereas bottom one is water
rich layer. Top layer is refluxed back and bottom layer is sent to recovery column. Water is
collected from the bottom of the recovery column whereas ternary mixture of cyclohexane,
water and ethanol comes out of the top, which is condensed and partially sent to dehydration
column. Any cyclohexane lost in the system is taken care by adding make-up cyclohexane in
the system.
One thousand litres of industrial alcohol of 94% v/v contains 940 litres of anhydrous alcohol
and 60 litres of water. For a capacity of 20 KLPD anhydrous alcohol plant make-up
cyclohexane required shall be 90 Kg/day. The cyclohexane is continuously recovered in the
process and recycled as entrainer. About 20 to 30 litres of cyclohexane will be required
every day to meet losses of cyclohexane in process. The process is rather simple and well
established and given good quality of anhydrous alcohol.
In another method, glycerin is used as dehydrant. Glycerin is fed counter current wise to the
rising alcohol vapours in a column. Glycerin absorbs all the water and leaves from the bottom
of the column, which consists of glycerin, water and some amount of alcohol. Distillate at
the top is anhydrous alcohol. Glycerin water mixture is sent first to alcohol recovery column
and then to vacuum evaporator for recovery of glycerin and removal of water. Glycerin is
recycled. This process is also effective giving good quality of anhydrous alcohol.
The steam requirement in the above two processes is around 2.6% / litre of anhydrous alcohol
produced.
II) Dehydration with Membrane Process:-
A) Pervaporation:-
Introduction:-
The developmentof system of dehydration with membrane for bulk water removal has
advantage of very low operative cost. Continuously working Pervaporation units are fed with
wet feed and produces on sea product directly. The liquid feed mixture is continuously
pumped through a series of membrane modules. The number of modules depends on the
capacity and the required final water content. If necessary, a reduction in product water
content can be achieved by reducing the feed rate. Pervap SMS modules are heated and
facilitate continuous isothermal pervaporation. No heating is required between membrane
modules. This technology is not available commercially in India.
41
Unit Description:-
--- Perevap SMS modules, with membranes
R101 Recuperator
H101 Feed heater
C301 Permeate condenser
C302 Permeate cooler
VP401 Vacuum Pump
as well as all piping, valves, instrument and insulation. All parts in contact with feed and
product are in SS-304 (Options-other SS grades)
Membrane Modules:-
The Pervap SMS unit is equipped with tubular micro-porous membrane installed in
isothermal high flux modules. Ceramic membrane tubes are installed co-axially in the tubes
of the module, which is similar to a shell, and tube heat exchanger. Feed passes through the
annular passage and permeate is collected from the inside of the ceramic tubes and plassed to
the permeate condensation system. Steam is fed to the module shell to offset the heat of
Pervaporation.
This equipment has the following advantages:-
i) High operating temperatures and pressures can be accommodated and maintained
providing high driving forces for Pervaporation.
ii) High mass transfer rate is obtained.
iii) Stainless steel materials of construction with graplhitegaskeeting – compatible
with virtually all-solvent systems.
iv) Standard module geometry allowing for easy membrane replacement, spare
holdings etc.
v) Individual membrane tubes can be disconnected / replacement if required.
Process Description:-
Continuously operating pre-vaporation units run at steady state conditions. Feed is passed
continuously through the unit and product leaves the unit at the desired water content.
Refer to the flow sheet to follow the function of the various equipment items included in the
skid. Feed from pump is first passed through a double filter station to prevent any fine
suspended soils reaching the membranes. Feed flow is controlled by a throttle
valve/rotameter combination. Feed is then preheated in recupereate, heated to operation
temperature in heater and then passed to the first membrane module. As the solvent passes
across the semi-permeable membranes, contained water diffuses through the membranes and
exists as vapour which passes to the permeate condensation system.
42
Peremeate condensation and Discharge:-
Permeating water is condensed in condenser and collects in the built-in sump. Vacuum pump
continuously removes non-condensable from the system.
Permeate is continuously removed from by permeate pump. The discharge rate of this pump
is throttled to maintain the set liquid level in condenser. Recycle line with cooler is provided
to prevent overheating of the system at low permeates rates.
Nitrogen System:- A nitrogen system is installed to ensure trouble-free shutdown of the unit
and to facilitate draining and purging of the unit when solvents are changed.
B) Vapour Permeation System:-
In this system, the liquid is vaporized and the vapour as a feed is fed to membrane module.
The membrane selectively separates water molecules from alcohol. The vapourpermeation
system is preferred if the liquid contains some dissolved particles suspended.
The advantage of membrane system:-
i) Easy operation
ii) Very low energy requirement / litre of Anhydrous alcohol. Hence the operating
cost is least.
iii) No toxic or hazardous chemical required.
iv) The life of system may be around five to seven years.
In this industry, effluent produced is only water. Therefore, problems of pollution hazard
are nil. Consent from Environmental Department and Pollution Control Board can be
easily obtained as a matter of routine.
III) Dehydration with Molecular Sieve Process:-
The rectified spirit from the rectifier is superheated with steam in feed super heater.
Superheated rectified spirit from feed super heater is passed to one of the pair of molecular
sieve beds for several minutes. On a timed basis, the flow of superheated rectified spirit
vapour is switched to the alternate bed of the pair. A portion of the anhydrous ethanol vapour
leaving the fresh adsorption bed is used to regenerate the loaded bed. A moderate vacuum is
applied by vacuum pump operating after condensation of the regenerated ethanolwater
mixture. This condensate is transferred from recycle drum to the Rectified Column in the
hydrous distillation plant via Recycle pump. The anhydrous alcohol draw is condensed in
product condenser and passed to product storage.
The life of molecular sieve may be around five to seven years. However, the operating cost is
considerably less than azeotropic distillation.
43
Requirement of Input:-
Plant
Capacity
(KLPD)
*Cooling
Water
(M3/hr.)
Cooling Water
Make-up
(M3/day)
**Steam (RS to
Abs. Alc.)
(Kg/lit.)
*** Power
(KwH/hr.)
Connected Operaing
60 275-300 200-230 0.55 80 40
* Cooling water recirculation rate 200-230M3/hr for Molecular Sieve plant only @
30°C maximum and 4 Kg/Cm2 (g) pressure at cooling water header,
T=8°C
** Steam requirement will be at full capacity operation @ 3.5 Kg/Cm2 (g) pressure in
steam header.
*** Electricity will be 440 V, 3 ph, 50 Hz, AC Electric supply. The power requirement
will be for Molecular sieve plant only, which excludes utilities like boiler, cooling
tower, etc.
Integrated Multi-product Concept:-
It is now possible to install a distillation system, which can produce different products i.e. in
the proposed scheme; we have considered the 70 KLPD production of Rectified spirit or
ENA after enhancement of existing 60 KLPD plant and 55.20 KLPD Anhydrous alcohol
from existing molecular sieve plant. This will allow flexibility of operation and different
products can be produced depending on the market demand. This integrated multi-product
system involves less capital investment as compared to independent system and offers good
advantage of energy conservation.
In this type of system, switching over from one product to another is quite easy and there is
no chance of contamination of one product with another. The system can work under multi-
pressure principle with few columns operating under vacuum, atmospheric and few under
pressure. In the multi-product concept few columns are common and depending on the final
product required, additional columns are operated.
44
CHAPTER – VI
DISTILLERY SPECIFICATIONS
The factory management has proposed to expand existing Continuous Fermentation
with multi-pressure vacuum distillation of 60 KLPD distillery plant to 70 KLPD with
the same technology configurations. The proposed expansion includes addition of one
fermenter, wash holding tank, agitators for all fermenters with all auxiliaries in
fermentation section. In distillation section one De-Gasifier column with their
condensers.Overall efficiency of existing and new plant capacity to produce excellent
quality of R.S/ENA &55.20 KLPD Fuel alcohol. For 55.20 KLPD existing Ethanol
plant, modification is not required.
Alcohol Production:-
1) Rectified Spirit conforming to Indian Standards.
323/1959, Grade-I will be minimum 95% v/v strength
2) Extra Neutral Alcohol conforming to Indian Standards – 6613/1972
3) Anhydrous alcohol conforming to Indian Standards
321/1964, Grade-I will be minimum 95% of total (99.5% v/v at
15.6°C)/IS:15464 (2004)(99.5% v/v at 15.6°C)
4) Impurealcohol
5% during Rectified Spirit production
6% during ENA production
5% during fuel alcohol production
The impure alcohol is also marketable as such in the form of Ordinary denatured
spirit.It can be disposed off by blending it with Grade-I, Rectified Spirit in a
proportion, which will give Grade –II spirit. This can be sold as special denatured
Industrial Alcohol.
During the process of distillation, a by-product known as fusel oil separates out. It is a
mixture of higher alcohol’s. The production of fusel oil is in the range of 0.2 – 0.3%
of alcohol production depending upon quality of molasses and fermentation
operations.
45
EXISTING SET – UP FOR SIDDAPUR DISTILLERIES LTD.(60 KLPD Molasses
Based Distillery)
Plant Capacity – 60 KLPD Total Spirit
a. Fermentation Section:
1) Continuous Fermentation System with 3 fermenters
2) Alcohol content in fermented wash was around 8.5 % v/v – 9.5 % v/v
3) Fermented Wash – 640 m3/day
b. Distillation Section :
1) Type – Multipressure – 8 Columns
2) The generation of Spent Wash was around 520 m3/day (around 9 lit / lit of total
spirit).
c. Integrated Evaporator Section :
1) Evaporation System for Raw Spent Wash
2) Concentrated Spent Wash generation for 60 KL operation was around 420
m3/day (7 lit / lit of Total Spirit)
3) Type - Integrated & cross flow type with triple effects
4) Integrated with Analyzer column Vapours to concentrate the Spent Wash
d. Biomethanation Section :
1) Type – LESMAT (Fixed Film Media Reactor)
2) Digester – 1 No.
3) Biogas Generation
The total steam consumption for the 60 KLPD Distillery Plant was around 9 TPH
CALCULATIONS:
Fermented wash generated with continuous fermentation @ 9.5 % avg. alcohol in wash =
60000/0.094 = 640 m3/day
Alcohol in Fermented Wash = 60 m3/day
Spent Leese in Fermented Wash = 80 m3/day
Analyzer top vapours – 120 m3/day
Spent wash Generated at Analyzer = 640 – 120 = 520 m3/day
Evaporation Achieved – 80 m3/day
Conc. Spent Wash Generated - 420 m3/day
46
PROCESS DESCRIPTION
1. FEED PREPARATION AND WEIGHING
Molasses Stored in a storage tank is first weighed in a tank with load cells so that
accurate quantity can be fed to the fermentation section. The weighed molasses then
transferred from tank to the dilutor in fermentation section where it is diluted with
water and fed to the Fermenter.
2. YEAST PROPAGATION AND FERMENTATION
The Yeast from Slant is transferred to Shaker Flasks and grown to the required
volume.This “genetically marked” yeast strain is then further propagated, under
aseptic conditions, in yeast culture vessel. These vessels are equipped with eductors
which are designed to achieve enhanced efficiencies through better sugar / yeast
contact by shearing and mixing, efficient oxygen transfer etc.
The ready yeast “seed” is then transferred from culture vessel to fermenter. The
molasses is diluted by process water. The glucose in the Feed media gets converted to
ethanol, in each of the 3 Fermenters operating in Continuous mode. A plate heat
exchanger and a circulation pump are provided to each fermenter, which will
continuously re-circulate the Fermenting Wash through PHE for maintaining the
Fermenters at 30 deg C. The nutrients, biocide, acid and anti-foam agents are fed to
the fermenters as per process requirement. The CO2 liberated during fermentation is
sent to CO2 Scrubber for recovery of ethanol otherwise being lost in vent. The
Fermented Wash is then sent to the Clarification Tank equipped with Lamella
Separator. The settled sludge is sent to Sludge Washing Tank for recovery of alcohol.
3. MULTIPRESSURE DISTILLATION (RS)
The fermented wash is fed to CO2 stripper column to remove CO2 gas present in wash.
Alcohol is stripped off water in stripper column. Bottom of Stripper (Spent Wash) is
fed to Integrated Evaporator. Conc. Spent Wash is then fed to Biogas Plant. The top
vapours [alcohol + water] are fed to Calendria. Distillate from Calendria is pre-heated
before being fed to rectifier column. In rectifier column RS is taken out from top tray.
The impure spirit from top of CO2 stripper column, rectifier column, fed to fusel oil
column. The final impure spirit cut is taken out from the fusel oil column and partly
alcohol is recycled to rectifier column. The alcohol containing fusel oil from rectifier
column is fed to fusel oil column.
Rectification column works under pressure. The CO2 stripper, stripping column,
works under vacuum and fusel oil column works under atmospheric condition.
The top vapours from rectifier column are condensed in Stripper Reboiler. The
alcohol water vapours from stripping column are partly sent to CO2 stripper bottom
for heating. The Rectifier column and fusel oil column gets heat from steam.
47
4. MULTIPRESSURE DISTILLATION (ENA) WITH ETHANOL
The fermentation mash containing Alcohol, non-fermentable solids and water is
supplied to Distillation to separate the alcohol and other impurities, as a continuous
flow. The Distillation system is designed for premium quality extra neutral alcohol.
The system details are as below:
The system consists of 8 main columns, namely, CO2 Stripper, Stripper Column, Pre-
rectifier Column, Extraction Column, Rectification Column, Refining Column, and
Fusel Oil Column.
Wash is fed to CO2 stripper column to remove CO2 gas present in wash. Alcohol is
stripped off water in stripper column. Bottom of Stripper (Spent Wash) is fed to
Integrated Evaporator. Conc. Spent Wash is then fed to Biogas Plant. The top vapours
from stripper column are fed to Calendria. Distillate from calendria is fed to pre-
rectifier column as feed and steam is supplied as heat source. Pre-rectifier remove
most of the fusel oils. Top of the Pre-rectifier column are fed to Reboiler of Refining
Column and part of the distillate from pre-rectifier column is fed to extraction column
after dilution where process water is used as dilution water and remaining return back
as a reflux. In extraction column most of the high boiling impurities separate from
ethanol in presence of water. The bottom ethanol water mixture is pre-heated before
being fed to rectifier column. Top vapours of Rectifier column are fed to Stripper
Reboiler as a heat source. In rectifier column product rectified spirit is taken out from
top tray and fed to refining column where mainly methanol impurities are separated.
Pure ENA is obtained at bottom of Refining column, which is cooled and stored. The
impure spirit from top of CO2 stripper column, extraction column, rectifier column
and refining column are fed to FO column. The final impure spirit cut is taken out
from FO column top and balance alcohol is recycled to pre-rectifier column. The
alcohol containing fusel oil from pre-rectifier and rectifier column is fed to fusel oil
column.
The rectifier column, fusel oil column, HC column and pre-rectifier column get heat
from steam at 3.5 bar (g). Rectification column and pre-rectifier column works under
positive pressure. The top vapours from rectifier column are condensed in stripper
column for giving heat to stripper re-boiler. Most of the other columns work under
vacuum.
The Distillation process is operated through PLC.
The distillation system also is operated with Ethanol (Fuel Alcohol) mode with feed to
fuel alcohol plant given directly from the pre – rectifier column
48
MODIFICATIONS TO BE DONE FOR CAPACITY
ENHANCEMENT(60 KLPD TO 70 KLPD Molasses Based Dist illery)
Plant Capacity – 70 KLPD Tota l Spirit
a. Fermentation Section: 1) To convert the existing “Continuous Fermentation System” into “Fed Batch
System” 2) Alcohol in Fermented Wash – 10.5 % to 11 %. 3) Fermented Wash Generation - 660 m3/day.
b. Distillation Section :
1) Type – Multipressure – 8 Columns
2) The generation of Spent Wash will bearound 520 m3/day (around 7 lit / lit of total spirit).
c. Biomethanation Section :
1) Type – LESMAT (Fixed Film Media Reactor)
2) Digester – 1 No.
3) Biogas Generation
d. Integrated Evaporator Section : 1) Concentrated Spent Wash generation for 70 KL operation will be around 420
m3/day (6 lit / lit of Total Spirit) 2) Evaporation System for Biomethanated Spent Wash installing Degasifying
section to existing system.
3) Type - Integrated &Feed Forward flow type with triple effects
4) Integrated with Analyzer column Vapoursto concentration of Spent Wash
The total steam consumption for the 70 KLPD Distillery Plant would be around 9 TPH
CALCULATIONS:
Fermented wash generated with Fed - Batch fermentation @ 11 % avg. Alcohol in Wash =
70000/0.106 = 660 m3/day
Alcohol in Fermented Wash = 70 m3/day
Spent Leese in Fermented Wash = 70 m3/day
Analyzer top vapours – 140 m3/day
Spent wash Generated at Analyzer = 660 – 140 = 520 m3/day
Evaporation Achieved – 100 m3/day
Conc. Spent Wash Generated - 420 m3/day
PROCESS DESCRIPTION
1. FEED PREPARATION AND WEIGHING
Molasses Stored in a storage tank is first weighed in a tank with load cells so that accurate
quantity can be fed to the fermentation section. The weighed molasses then transferred from
tank to the dilutor in fermentation section where it is diluted with water and fed to the
Fermenter.
49
2. YEAST PROPAGATION AND FERMENTATION
The Yeast from Slant is transferred to Shaker Flasks and grown to the required volume.
This “genetically marked” yeast strain is then further propagated, under aseptic conditions, in
yeast culture vessel. These vessels are equipped with eductors which are designed to achieve
enhanced efficiencies through better sugar / yeast contact by shearing and mixing, efficient
oxygen transfer etc.
The ready yeast “seed” is then transferred from culture vessel to fermenter. The molasses is
diluted by process water. The glucose in the Feed media gets converted to ethanol, in each of
the 4 Fermenters operating in Batch mode. A plate heat exchanger and a circulation pump
are provided to each fermenter, which will continuously re-circulate the Fermenting Wash
through PHE for maintaining the Fermenters at 30 deg C. The nutrients, biocide, acid and
anti-foam agents are fed to the fermenters as per process requirement. The CO2 liberated
during fermentation is sent to CO2 Scrubber for recovery of ethanol otherwise being lost in
vent. The Fermented Wash is then sent to the Clarification Tank equipped with Lamella
Separator. The settled sludge is sent to Sludge Washing Tank for recovery of alcohol.
3.MULTIPRESSURE DISTILLATION (RS)
The fermented wash is fed to CO2 stripper column to remove CO2 gas present in wash.
Alcohol is stripped off water in stripper column. Bottom of Stripper (Spent Wash) is fed to
Integrated Evaporator. Conc. Spent Wash is then fed to Biogas Plant. The top vapours
[alcohol + water] are fed to Calendria. Distillate from Calendria is pre-heated before being
fed to rectifier column. In rectifier column RS is taken out from top tray. The impure spirit
from top of CO2 stripper column, rectifier column, fed to fusel oil column. The final impure
spirit cut is taken out from the fusel oil column and partly alcohol is recycled to rectifier
column. The alcohol containing fusel oil from rectifier column is fed to fusel oil column.
Rectification column works under pressure. The CO2 stripper, stripping column, works under
vacuum and fusel oil column works under atmospheric condition.
The top vapours from rectifier column are condensed in Stripper Reboiler. The alcohol water
vapours from stripping column are partly sent to CO2 stripper bottom for heating. The
Rectifier column and fusel oil column gets heat from steam.
4. MULTIPRESSURE DISTILLATION (ENA) WITH ETHANOL
The fermentation mash containing Alcohol, non-fermentable solids and water is supplied to
Distillation to separate the alcohol and other impurities, as a continuous flow.
The Distillation system is designed for premium quality extra neutral alcohol. The system
details are as below:
50
The system consists of 8 main columns, namely, CO2 Stripper, Stripper Column, Pre-rectifier
Column, Extraction Column, Rectification Column, Refining Column, and Fusel Oil Column.
Wash is fed to CO2 stripper column to remove CO2 gas present in wash. Alcohol is stripped
off water in stripper column. Bottom of Stripper (Spent Wash) is fed to Integrated
Evaporator. Conc. Spent Wash is then fed to Biogas Plant. The top vapours from stripper
column are fed to Calendria. Distillate from calendria is fed to pre-rectifier column as feed
and steam is supplied as heat source. Pre-rectifier remove most of the fusel oils.
Top of the Pre-rectifier column are fed to Reboiler of Refining Column and part of the
distillate from pre-rectifier column is fed to extraction column after dilution where process
water is used as dilution water and remaining return back as a reflux. In extraction column
most of the high boiling impurities separate from ethanol in presence of water. The bottom
ethanol water mixture is pre-heated before being fed to rectifier column. Top vapours of
Rectifier column are fed to Stripper Reboiler as a heat source. In rectifier column product
rectified spirit is taken out from top tray and fed to refining column where mainly methanol
impurities are separated. Pure ENA is obtained at bottom of Refining column, which is cooled
and stored. The impure spirit from top of CO2 stripper column, extraction column, rectifier
column and refining column are fed to FO column. The final impure spirit cut is taken out from
FO column top and balance alcohol is recycled to pre-rectifier column. The alcohol containing
fusel oil from pre-rectifier and rectifier column is fed to fusel oil column.
The rectifier column, fusel oil column, HC column and pre-rectifier column get heat from steam
at 3.5 bar (g).
Rectification column and pre-rectifier column works under positive pressure. The top vapours
from rectifier column are condensed in stripper column for giving heat to stripper re-boiler.
Most of the other columns work under vacuum.
The Distillation process is operated through PLC.
The distillation system also is operated with Ethanol (Fuel Alcohol) mode with feed to fuel
alcohol plant given directly from the pre – rectifier column
51
Raw materials and other products use in proposed distillery
(Existing 60 KLPD & after expansion to 70 KLPD)
BLOCK DIAGRAM of 70 KLPD PROPOSED PLANT
Steam 216 MT
CO254 MT
Process Fresh
Water 245 KL
Molasses Fermented
260 MT Wash 660 KL
Alc + Water Vap
Biogas to Boiler Spent Leese 70 KL
Spent Wash
520 KL Spent Wash
Process Condensate Water 100 KL
TRSW 420 KL
Treated Water Used for Process (170 KL)
Fermentation
Bio-Gas Plant Evaporator
Ethanol
Bio-Composting
Processing
Treated with
Physiochemical
treatment
Distillation
RS ENA
52
ADDTION OF EQUIPMENTS FOR CAPACITY ENHANCEMENT ARE AS FOLLOWS:
I. Fermentation Section:
To convert the existing “Continuous Fermentation System” into “Fed Batch System” to
increase Alcohol content in Fermented Wash from 10.5 % to 11% v/v
1. Supply & installation of 1 No. of Pre-Fermenter with a capacity of 60 m³ and increasing
the capacity of existing Pre-Fermenter from 30m³ to 60m³.
2. Supply & installation of 1 No. New (4th) Fermenter capacity of 362 m³
3. Supply & installation of new PHE
4. Supply & installation of 1 No. Clarified Wash Tank (CWT) with capacity of 100 m³
5. Supply of all required pipe fittings, valves & flow meters etc. to convert Continuous
Fermentation System” into “Fed Batch System”
“Advantages of Fed Batch Fermentation”
High Brix fermentation & more Alcohol % in wash i.e 11% to 12% v/v, when compared to
Continuous Process 8% to 9% v/v.
For every batch fresh culture is to be added. This will avoid bacterial contamination.
Changing process parameter for every batch depending on the Molasses characteristic.
Minimize the acid formation in Fermentation Media for getting good quality of Alcohol &
to increase the yield.
Due to increase in the Alcohol % in wash, the plant capacity will be increased by 10 to
15%. However the steam requirement remains same.
The generation of spent wash will be reduced by 3 to 4%.
The term fed signifies that fed is provided at a required rate to fermentation system
without getting accumulated.
Simple to operate.
Proper control on operating parameters.
Optimum efficiency can be achieved.
II. Distillation Section:
1. Supply & installation of Reboiler for existing refining column to increase the heating
Surface area.
2. Increasing 4 Nos of trays in existing stripper column.
3. Supply & installation Reboiler for existing stripper column.
4. Supply of new pump to transfer the existing CO2 stripper to stripper column due to
increase in height of stripper column.
5. Supply condenser on stripper vapours to maintain the stripper vacuum.
6. Pre-rectifier top vapor ducting to be changed to handle the increased alcohol vapours.
53
7. New pump unit installation for stripper column to handle the increased volume due to
increase in capacity.
8. Supply & installation of 1 No Vacuum pump & motor for higher capacity.
III. Evaporator: Addition of degasifying section to handle the Biomethanated spent wash.
1. Supply & installation of De-Gasifier column for the purpose of removal of dissolved
gases.
2. Supply & installation of BMSW feed pump & motor to existing degasser column.
3. Supply & installation of piping, valves, ducting, flow meter, LT etc.
4. Supply & installation of Condensers of 60m² & 25m²
5. Supply & installation of PHE 2 Nos one for Biomethanated spent wash Pre-Heater &
another one for Re-Boiler.
6. Supply & installation of vacuum pumps (2 Nos) with a capacity of 725 m³/hour
IV. Distillation Cooling Tower: Supply & installation of new pump unit capacity from 950 to 1200 m³/hour
Conclusion:
Presently you are preparing fermented wash and distilling 640000 liters per day to
produce 60000 liters. However after caring out all necessary additions, alterations &
modification in the plant as stated above, SDL will be able to produce as per below
production combinations;
ENA + FA = 70000 liters/day
RS + FA = 70000 liters/day
Apart from this generation of spent wash per liter of spirit will be around 6 liters
instead of 7 liters by making the existing evaporator operation system in series.
Presently 60 KL plant is generating 420 m³/day spent wash whereas after addition &
modification for 70 KL plant capacity, the spent wash generation will be 420m³/day same
as previously 60 KLPD plant.
4.0 Makes of bought out items (under R.S./ENA)
D.O Copper - Alcobax / Multimetal
SS & MS Sheet - SAIL/Tata/Jindal
SS Tubes - Ratnamani/Divine
GI nut & bolt - Tata / GKW
MS channel, beams, angles - SAIL/Tata
HDPE pipes - Hasti/Nocil
C.S.Pipes - Tata
PHE - Alfa-Laval/GEA/Tranter
Centrifugal Pumps - Microfinish/Kirloskar/KSB
54
Motors - Crompton/Siemens
Valves - Audco/intervalve/Saunder/Aqua
(Ball/butterfly/Gae/Globe
Control Valves - Keystone/Dembla/RK
Air blower & vacuum pump - PPI
PRDS - Forbes Marshall/Arca/Precision controls
Rotameter - Eureka
Temp. sensors - Eureka/Radix/Pyro
Pressure Indicator - H. Guru/Wika
Pressure, Temp.level, flow
Transmitter - Emersion/E.&H
Flow meter (Turbine) - Toshniwal/Rockwin
PLC - Allen Bradlley/Siemen/ABB/Microset
PC with monitor printer - IBM/HP/Compaq
Variable frequency drive - Hitachi/ABB/Toshiba/L & T
Electrical cable - Finolex/CCI/Polycab
Instrument Cable - Polycab/Gemscab
*Supplier will submit & get approval of makes from sugar factory/its inspection agency.
55
Project Cost for expansion of Distillery Plant capacity from 60 KLPD to 70 KLPD.
I - Fermentation House Expansion Work
Sl
No Description
Approx Value of
Project Cost (`) Remarks
1 SS 304 Fermenter Tank Capacity -350 m³ 2220000.00
2 Fermenter tank Centrifugal Pumps with Motor
Model: 150/26N (2 Nos) 315000.00
3 Fermenter & Pre - Fermenter Plate Heat Exchanger 1000000.00
4 Magnetic Flow Meter for F3, F4 & pre - Fermenter
tank 3150000.00
5 Digital Variable Area Flow Meter for pre -
Fermenter Tank 20000.00
6 Consumable Materials including Welding Rod &
Gas 150000.00
7 Pipe & Pipe Fittings including Butterfly Valves &
Ball Valves 600000.00
8 SS 304 Ejector 180000.00
9 SS 304 Pre-Fermenter Tank Capacity -60 m³ 325000.00
10 Pre - Fermenter Tank Pump with Motor 350000.00
Total- A 4575000.00
II - Distillation Plant Expansion Work for De-Gasifier Column Sl
No Description
Approx Value of
Project Cost (`) Remarks
1 Civil Foundation for De-Gasifier Column 2000000.00
2 De-Gasifier Column & Vent Condenser
MOC:SS 304 2100000.00
3 SS 304 Re Boiler with Pipe Ducting 1050000.00
4 SS 304 Ducting Pipe 250000.00
5 Kirloskar make centrifugal Pumps with Motors 650000.00
6 Pipe & Pipe Fittings including Butterfly Valves &
Ball Valves 3500000.00
7 De-Gasifier Column Plate Heat Exchanger 500000.00
8 Vacuum Pumps with Motors 750000.00
9 De-Gasifier column control Valves
Make :Samson (3 Nos) 350000.00
10 Level Transmitter Make : Yokogowa (2 Nos) 260000.00
11 PLC Materials 175000.00
12 Temp Gauge, Pressure Gauge, Diapram Gauge &
Vacuum Gauge etc 40000.00
13 De-Gasifier Column Structure Building work 1500000.00
Total -B 13125000.00
Total (A+B) 17700000.00
56
EXISTING & PROPOSED ENVIRONMENTAL MANAGEMENT PLAN (EMP)
Treatment of Distillery Spent Wash
The existing Distillery plant capacity is 60KLPD and the spent wash generated per
liter of alcohol is maximum 7.0-7.5 liters. However with the changes / optimization made in
our fermentation & Evaporation plant we are generating about 6.0 liter of spent wash per liter
of Alcohol.
We have changed the Continuous fermentation process to Fed Batch system where the spent
wash generation is reduced, further to this we are concentrating the Biomethanated spent
wash in distillation column re-boiler so there will be further reduction in the spent wash
generation. The process condensate generated will be treated through Physio Chemical
treatment and recycled back to process plant.
We propose to increase the Distillery capacity from 60 KLPD to 70 KLPD and we have
adequate Spent wash treatment facility in existing Effluent treatment Plant.
The spent wash is Anaerobically treated in the digester. During this anaerobic
degradation, the organic matters are converted into Bio-gas (55% contains methane) which
brings down the BOD value to 7000 – 8000 mg/lit, from the original level of about 45000 –
50000 mg/lit. The generated Bio-gas is used as fuel in the boiler of our parent sugar factory.
Further, the concentrated spent wash is utilized for Bio-composting using sugar
factory press mud, boiler ash and other waste bagasse to produce useful organic manure.
Bio-composting Process:-
In the Bio-composting system, the process is carried out on a concrete floor yard by
aerobic windrow technology using special aerobic microbial culture. The sugar industry
press mud, boiler ash, waste bagasse and yeast sludge from the distillery are mixed suitably
and bio-activated on the concrete floor. The reaction is an exothermic one which helps to
evaporate the water content and gasses. The necessary windrow moisture for the process is
maintained by spraying of concentrated treated RSW through tanker on the windrows
uniformly and aerotiller machine is used to turn the material, the composting process is
aerobic condition. The Bio-composting process would take about 60 days for completion and
the ready Bio-compost manure is enriched and distributed to the farmers.
Thus, the entire spent wash generation during the alcohol production will be converted into
valuable Bio-compost manure. This environmental management plan is of “ZLD” (Zero
Liquid Discharge) Environmental concept of Pollution Control Boards.
57
Spent Lees & Process Condensate Water Treatment Plant System
Spent lees and the process condensate water is generated in the range of 200m3/day
we are treating this effluent through the most advanced treatment technique i.ephysio-
chemical treatment and treated water is reused in the process plant.
Waste Water Generation From Existing & Proposed Distillery
The source of waste water generation from the existing and proposed distillery unit is
as below:
Sl.No. Waste Water Source Qty. in
(M3/day)
Mode of Disposal
01 Sewage water Domestic 3.20 Fed to Septic tank &
soak pit
02 Spent wash Process 420.00 Bio-metehanization
followed by
Bio-composting
03 Spent lees Process 80.00 Treated with physio-
chemical treatment
reused in process plant
04 Process condensate process 120.00 Treated with physio-
chemical treatment
reused in process plant
Note :- There is no difference b/w Existing and proposed waste water generation.
Solid Waste Generation from the Existing & Proposed Distillery
Sl.
No.
Solid Waste in MT
Mode of Disposal Existing 60 KLPD Proposed 70 KLPD
01 20 .0 26 .0 Mixed with Bio-composting
58
EXISTING AND PROPOSED ENVIRONMENT
MANAGEMENT PLAN (EMP) FLOW DIAGRAM
Raw Spent Wash
Anaerobic Digester
Storage Lagoon
Treated with Physio-chemical Treatment
Re-Boiler/ Evaporation
Concentrated Spent Wash
Process Condensate
Reused in Process Section
Press Mud from Sugar Factory
Bio-Composting Process
Compost Manure to Farmers
59
PANEL ROOM
COOLING TOWER
(1100MT)
03
13900
21000
512500
115900
10000147000
36500
24000
22000
18000
PLANT
18000
Ø 2100X324010 CU.MTR1 NOTRO STORAGE TANK04
04
02
01
TRO
STO
RAG
E TAN
K
20000
35000
74000
19500
FE
RM
EN
TA
TIO
N
FA-03
IS -T414
T-402
T-414
T-422
T-403
CODE NO.
T-412
T-413 A
T-404
32100 dia, 9000 liquid height, 11000 Total height
MCC Room/ Lab10
10000x4000
NORTH
SMAT Reactor
Buffer Tank (2 Nos)
Pre-aeration Tank
Biomethanated Effluent Sump
Blower Room9
8
7
6
Clarifier
5
4
4000x5000
5000x5000x2000 SWD+500 FB
7100 Ï x3000 SWD+500 FB
4400 Ï x3500 SWD+500 FB
12500x8000x3000 SWD+500 FB
Channel (2 Nos)
Name of Units
Aeration Fountain
No.
Unit
2
3
Feed Tank
1
Size
750 Wide
11500 Ï x1500 SWD+500 FB
4100 Ï
ENA TANK
TANK CAP.
70 CU.MTR
60 CU.MTR
20 CU.MTR
20 CU.MTR
150 CU.MTR
DAILY STORAGE TANK
10 CU.MTR
T-411
T-424
T-413
T-405
T-423
IS TANK
RS TANK
FUSEL OIL TANK
ENA TANK
IS TANK
3 NOS
1 NO
1 NO
3 NOS
3 NOS
T-401A RS TANK
FLUID CODE NO. QTY
3 NOS
Ø 3000x3000
Ø 5100x7500
Ø 2100x3000
Ø 3600x6000
Ø 3000x3000
IS TANK
DS TANK
IS TANK
FA TANK- A
ENA TANK EXISTING- 2Nos.AØ 4000x6000
DIMENSIONS FLUID
RS TANK
OFFICE FOR DISTILLERY
TREE
SHAMY
10 MTR WIDE ROAD
A
RS
TANK
TANK
STORAGE
F.A.DAY
Ø 5500x10500 1 NO 249 CU.MTR
1 NO 100 CU.MTR
2 NOS
1 NO
70 CU.MTR
150 CU.MTR
1 NO
3 NO
850 CU.MTR
950 CU.MTR
Ø 4600x6000
Ø 4000x6000
Ø 5100x7500
Ø 9000x13500
Ø 9500x13500
BULK STORAGE TANK
QTY
1 NO
TANK CAP.
950 CU.MTR
DIMENSIONS
Ø 9500x13500
COOLING
TOWERS
Fountain
Aeration
IS-02
IS-03
ENA-3DS-2 RS-3
Existing Drain
C h a n n e l
TANK
Ho
use
Pu
mp
Buffer Tank-II
Effluent Sump
Buffer Tank-I
Pad
Pump
Pump
Pad
Biomethanated
DAY STORAGE
R.S.& ENA
IS-01T-405,
IS- 403
T-413,
IS-03
IS-01
IS-02
T-404
ENA-2
DS-1
RS-2
ENA-1ENA-1
T-411
RS-1
T-401
DISTILLATION
T-423
FO TANK
RS
TANK
T-424
OFF.
KSBCL
SECURITY CABIN
MAIN GATE
FA-02
T-421 A
T-422
TANK
FA
T-421 A
FA-01
T-421 A
ST
OR
E
STORAGE
MOLS.
SMAT Reactor
BLOWER
20000
20000 15000
15000
General S
tore
30000
Godow
n
RECEIVING
MOLASSES
TANK
GARDEN
350 CU.MTR
550 CU.MTR(800MT)1 NO
4 NOS
Ø 9700x7500
Ø 7850x7750
FLUID TANK CAP.QTY DIMENSIONS
01
02
MOLASSES DAY STORAGE
FERMENTER TANKS
SL.NO
OTHERS TANKS
REC. MOLASSES TANK03 800 CU.MTR1 NO 20000x20000x2000
FENCING LINE
FENCING LINE
6000
25000
RAMP
RAMP
RAMP
LOADING
PLAT FORM
COLUMN
DE-GASSEFIER
GATE
DIS
PE
NS
IN
G
U
NIT
40 KL DIESEL
STORAGE TANK
NEEM TREE
DRAINAGE
COLLECTION
PIT
DRAINAGE
RAMP
PLAT FORM
FA TANK 3 NO 60 CU.MTR
EACH
ENA TANK 2 NOS 190 CU.MTR
DISTILATION
FERMENTATION
VEHICLE SHED
EXE.
OFF.
TANK
43000
Ï
3
5
2
2
0
3
7
6
3
8
3
8
6
1
3
2250
10000
CABIN 2000 x 3000
40 MT WEIGH BRIDGE
12000
6000
2000
600x 600 DRAINAGE
CHAMBER
5000
WEIGH BRIDGE CABIN
4500
MOLASSES STORAGE TANKS05 2 NOS 6000 MT Ø 24000X10000
TOTAL
T-421 A
17 NOS 850 CU.MTR
Ø 3600x6000
TOTAL NOS OF TANKS 14 NOS 7569 CU.MTR
T-413 B Ø 4800x10500
OFFICE
STORE GODOWN
B
BENA
TANK
ENA
TANK
A
2440044000
ENA
TANK
ENA
GARDEN
SHED
377999
14700
10000
2500x2500
1500
1500
15000
10000 1
500
DG SET
18500
8500
MOLASSES
STORAGE TANK
19518
10000
8600
Ï
2
4
0
0
0
05
Capacity
6000 MT
Capacity
6000 MT
Lab
Room
MC
C
10000
Effluent Sump
Pad
Pump
Clarifier
Biomethanated
Pre-aeration
Tank
4000
Ï
2
4
0
0
0
ELE ROOM
DYKE WALL
3 MTR HEIGHT
28000
2100
4000
All Dimensions Are in mm
Checked
PRECIDENT
Drg. No.
SHEET NO -
Master Plan of Distillery Plant (60 KLPD)Revision
Drawn
SIDDAPUR DISTILLERIES LIMITED
SIDDAPURTitle
Scale
1 : 500
APPROVED
DISTILLERY & ETHANOL PLANT ( 60 KLPD )Project :-
SDL/DSTL/002 - R1
DateName
VICE
R 1
NO OF SHEET
10 MTR WIDE ROAD
D D D
T-422
TANK
FA
B
A
TANK
TANK
ENA
ENA
T412
T402
T412
T412
PROPOSED -1No.B
HO
US
E
CAR WATER
SERVICE POINT
COMPRESSOR
SHED
ROOM
MOLASSES
STORAGE TANK
06
Capacity
6500 MT
Ï
2
4
0
0
0
DYKE WALL
3 MTR HEIGHT
16500
8500
2350
06 1 NO 6500 MT Ø 24000X10000
T-422
TANK
FA
B AC
T-422 2 Nos 950 CU.MTR Ø 9000x15000
PLAT FORM
LOADING
FITTERS ROOMS
FA TANK- B & C
Annexure - I (c)Annexure - I (c)
MOLASSES STORAGE TANK
Rain Water Harvesting Pit
Rain Water Harvesting Pit
General Store
Godown
WATER
TANK
01/05/03
GARDEN
GARDEN
GARDEN
GARDEN
GARDEN
GREEN BELT PLANTATION
GARDEN
GARDEN
GARDEN
GARDEN
GARDEN
GARDEN
GREEN BELT PLANTATION
10 MTR WIDE ROAD10 MTR WIDE ROAD
10 MTR WIDE COMPOST ROAD
FEED
General Store
Godown
Dayanand
