Ethanol From Sweet Sorghum - Compress
Ethanol From Sweet Sorghum - Compress
Ethanol From Sweet Sorghum - Compress
INTRODUCTION
Ethanol
The word alcohol derives from Arabic al-kuhul, which denotes a fine powder
of antimony produced by distilling antimony and used as all eye makeup. Alcohol
originally referred to any fine powder, but medieval alchemists later applied the
term to the refined products of distillation, and this led to the current usage Ethanol
is a clear liquid alcohol that is made by the fermentation of different biological
materials. This alcohol is known to have many uses, but one in particular is
becoming more popular. Ethanol, the most widely used biofuel, is made in a
process similar to brewing beer. The ethanol in the end is blended with gasoline to
improve vehicle performance and reduce air Pollution.
Sources of Ethanol
Unlike grain sorghum, Sweet sorghum or "Sorgo” or"kadwal" stalks are taller
and juicier and have high sugar content, similar to sugarcane. Conventionally, some
sweet sorghum varieties are grown for syrup production, while others are grown for
forage. The stem juice of sweet sorghum is rich in fermentable sugar and is useful
for alcohol production.
3. Harvesting & cultivation practices are easier and are identical to sugar cane.
5. Crop cycle is short- 3.5 to 4 months usually, two cycles are possible from same
piece of land annually, provided irrigation is possible.
This practically makes alcohol production free of energy cost and improves
possibility of operation in remote areas.(2)
Ethanol is made from agricultural crops, which "breathe" carbon dioxide and
give off oxygen. This maintains the balance of carbon dioxide in the atmosphere
Increased use of renewable fuels like ethanol. Will help counter the pollution and
global warming effects of burning gasoline. Under current conditions, use of
ethanol blended fuels as E85 can reduce the net emissions of greenhouse gases by
as much as 30-36% and can Further contribute by decreasing fossil energy use by
42-48%. Ethanol blended fuel as El0 reduces greenhouse gases by 2 4-2.9% and
fossil energy use by 3.3 -9%. The E10 blend reductions are lower because a smaller
fraction of the blend is ethanol. With improved technologies and use of ethanol
made from cellulose, these reductions in emissions will increase. (3)
Energy Value
Many have wondered whether ethanol makes sense, from an energy use
perspective. In fact, each liter of ethanol contains at least 2-4 times as much energy
as is required for inputs for crop production (fuel, machinery, fertilizers, etc), and
ethanol manufacture Although petroleum-derived energy is used in the manufacture
and transportation of inputs, this is more than offset by the solar energy captured
through photosynthesis. This positive energy balance is predicted to improve by up
to 25%, as more ever efficient crop and ethanol production becomes common over
the next decade. (4)
Health Effects
Ethanol, the active ingredient of' alcoholic beverages, has been part of the
human diet and the human environment for thousands of years. It is produced by
fermentation by fungi and other microorganisms, and is found at low levels in the
blood and breath of persons who do not drink alcohol. Ethanol is widely ingested in
alcoholic beverages, usually with only mild effects. However, at sufficiently high
doses, ethanol can cause toxic effects in humans, both short-term (such as
inebriation) and long-term (such as cirrhosis of the liver), If ethanol becomes a
common fuel additive, there may be opportunities for exposure by inhalation:
ethanol vapors might be inhaled at gasoline stations or in automobiles, for example
Thus, concern has been raised about the possible health consequences of using
ethanol for this purpose. The scientific literature contains virtually no reports of
injury to humans from inhaled ethanol. The apparent lack of harm may be
attributable to rapid metabolism of ethanol and the difficulty in significantly raising
blood ethanol concentration by inhalation exposure, which keep internal doses
extremely low except in unusual situations, such as heavy exercise in the presence
of concentrated vapors (4)
Demand of alcohol
Alcohol has assumed very important place in the country‟s economy. It has
potentially as fuel in the form of power alcohol for blending with petrol.
Fermentation alcohol has great demand in various countries. The synthetic alcohol
produced by these countries from Naphtha of petroleum crude is not useful for
beverages. (6)
There are about 322 distilleries in the country (1998-1999) with total installed
capacity of 2711 million lit per annum. It is however, disheartening to note that
inspire of' such abundant licensed and installed capacity and notwithstanding the
fact that there is a great demand for alcohol, both for chemical industries and
potable purpose, alcohol production in the country has being lagging behind and is
varying only around 1300 million liter the target of alcohol demand as projected in
the perspective plan for chemical industry, department of' chemical and
petrochemical is 2400 million lit pet' annual by year (2000). (6)
Now Indian government has been realized the importance of alcohol as fuel.
As India is agricultural country and has got large source of biomass which can be
used for production of alcohol and just now Indian government has passed the bill
of 5% blending of ethanol with petrol"(7)
One method to reduce air pollution is to oxygenated fuel for vehicle MTBE),
(MethylTert-btyl elher) is a member of a ,group of chemicals commonly known as
fuel oxygenates. It is a fuel additive to raise the octane number. But it is vary
soluble in water and it is a possible human carcinogenic. Thereby, it should be,
substituted for other oxygenated substances to increase the octane number of the
fuel. Presently, ethanol as an oxygen us biomass fuel is considered as a predominant
alternative to MTBE for its biodegradable, low toxicity, persistence and
regenerative characteristic. The United States gasoline supply is an ethanol blend
and the importance of ethanol use is expected to increase as more health issues are
related to air quality. Ethanol may be produced from many high energy crops such
as sweet sorghum corn, wheat, barley, sugar-cane, sugar beet, Cassava, sweet potato
etc.like most biofuel crops, sweet sorghum has the potential to reduce carbon
emissions. (7)
Sweet sorghum has the following characteristics
Therefore, based on the above characteristics, it seems that seems that sweet
sorghum is the most suitable plant for biofuel production than other crops under hot
and dry climatic conditions in addition, possible rise of' bagasse as a byproduct of
sweet sorghum include: burning to provide heat energy paper or fiber board
manufacturing, silage for animal feed or fiber for ethanol production. However,
since sweet sorghum is a relatively early stage of its Development, continued
research was needed to obtain better genetic material and match local agro-
economic conditions. The challenge is to harvest tile crop separate it into juice and
fiber and utilize each constituent for year-round production of ethanol. Sweet
sorghum juice is assumed to be converted to ethanol at 87 % theoretical, or 54.4 L
per 100kg fresh stalk yield Potential ethanol yield from the fiber is more difficult to
predict. The emerging enzymatic hydrolysis technology has not been proven on a
commercial scale. One ton of corn grain produces 387 L of 182 proof alcohol while
the same amount of sorghum grain produces 372 L Sorghum is used extensively for
alcohol production, where it is significantly lower in price than corn or wheat. The
commercial technology required ferment sweet sorghum biomass into alcohol has
been reported in china. One ton of sweet sorghum stalks has the potential to yield
74 L of 200- proof alcohol Therefore, it seems that because ethanol can be produced
from both stalk and grain of sweet sorghum, so it is tile most suitable crop for
ethanol production using for biofuel comparing to other crops such as corn or
sugarcane. (8)
Sweet sorghum juice content
Glucose Fructose sucrose content, starch and total sugar content, Amino acid
content Protein content by nitrogen, total Phosphorus content, mineral element
content.
This is the new bleed (R.S.S.V.9) cultured by Dr. Narkhede from rahuri krishi
vidyapeeth especially for production of ethanol This method gives equal yield of
ethanol as from molasses route and it is experimentally found that cost of ethanol
by sweet sorghum method is nearly same as by molasses, however cost of ethanol
by sweet sorghum method on commercial scale could be less than that by molasses
method. (9)
Project objective
Three main reasons led us to convert sorghum biomass into ethanol.
India has to face the significant problem of oil lacking. This energy resource is
very expensive and increases too much the cost of all industrials
transformations. Ethanol should be an alternative fuel or an additive.
An industrial outlet of this crop should open a new field for this culture and
encourage agriculturists. By this way agriculture economy should be
improved. The environmental point of view has to be considered. India is
LITERATURE SURVEY
Sorghum (Sorghum bicolor L.Moench) is one of the main course cereal crops
of India. India is second largest producer of sorghum in the world with production
of about 10–11 million t from a total area of 12 million ha. This crop is ideally
suited for semi-arid agro climatic regions of the country and, it gives reasonably
good yield with minimal requirement of irrigation and fertilizers (Maiti 1996). On
the other hand, cereals such as wheat (Triticum aestivum L.) and rice (Oryza sativa
L.) cannot withstand the harsh semi-arid climates. These crops also require fair
amount of water and other inputs such as fertilizers and pesticides. Therefore,
sorghum is one of the few cereals, which can be grown in semi-arid regions.
However, demand for sorghum for human consumption is decreasing with
enhanced socioeconomic status of population in general and easy availability of
preferred cereals in sufficient quantities at affordable prices. Since sorghum must be
cultivated in the semi-arid regions for fodder to feed the large cattle population of
the country, industrial applications for this grain are needed so that sorghum
cultivation becomes economically viable for marginal farmers.
The objective of this work was to find the best combination of different
experimental conditions during pre-treatment, enzymatic saccharification,
detoxification of inhibitors and fermentation of Sorghum bicolor straw for ethanol
production. The optimization of pre-treatment using different concentrations of
dilute sulfuric acid, various temperatures and residence times was achieved at
121°C, 1% acid concentration, 60 min residence time and enzyme saccharification
using cellulose (celluclast 1.5 L) and _-glycosidase (Novozyme 188) at 50°C and
pH 4.8 for 48 h. Different surfactants were used in order to increase the monomeric
sugar during enzymatic hydrolysis and it has been observed that the addition of
these surfactants contributed significantly in cellulosic conversion but no effect was
shown on hemicelluloses hydrolysis. Ferment ability of hydrolyzed was tested using
Saccharomyces cerevisiae Ethanol Red TM and it was observed that simultaneous
saccharification and fermentation (SSF) with both batch and fed batch resulted in
better ethanol yield as compared to separate hydrolysis and fermentation (SHF).
Detoxification of furan during SHF facilitated reduction in fermentation time from
96 to 48 h. 98.5% theoretical yield was achieved in SHF with detoxification
experiment attaining an ethanol concentration and yield of 23.01 gL-1 and 0.115
gg-1 DM respectively. During the SSF batch and fed batch fermentation, the
maximum yields of ethanol per gram of dry matter were 0.1257 and 0.1332 g
respectively.
S.C. May,R.A. Stenzel, M.C. Weekes J. Yu. Industrial Utilization of
Sorghum in India [3]
The research work on sweet sorghum carried out at the Nimbkar Agricultural
Research Institute (NARI) since 1970s has been summarized. American lines were
crossed with a local Indian fodder/grain variety to produce varieties with a juicy
stalk and good quality grain. Further breeding was carried out to produce varieties
and hybrids giving high yield of good quality grain while retaining the characteristic
of juicy stalks high in sugar. Complete development of indigenous technology for
fermentation of sweet sorghum juice, solar distillation of ethanol and finally its use
as a cooking and lighting fuel in new and improved stoves and lanterns was carried
out. The technology of producing jaggery (unrefined sugar) and syrup from sweet
sorghum was also developed. Consumer response to these products was assessed by
marketing them in limited quantities. A completely automated multifuel gasification
system capable of producing thermal output between 120-500 kW was developed
for direct heat applications such as those in jaggery and syrup making units. Sweet
sorghum bagasse was also tested in an existing paper mill to assess its suitability for
paper manufacture. Areas of possible research for better exploitation of sweet
sorghum have been suggested.
PROPERTIES OF ETHANOL
PHYSICAL PROPERTIES
Ethyl alcohol under ordinary conditions is a volatile, flammable, clear,
colorless liquid. Its odor is pleasant, familiar, and characteristic, as is its taste when
suitably diluted with water. The most amazing property of ethanol is the volume
shrinkage that occurs when it is mixed with water, or the volume expansion that
occurs when it is mixed with gasoline. One volume of ethanol plus one volume of
water results in only 1.92 volumes of mixture.
The physical and chemical properties of ethyl alcohol are primarily dependent
upon the hydroxyl group. This group imparts polarity to the molecule and gives rise
to intermolecular hydrogen bonding. These two properties account for the
differences between the physical behavior of lower molecular weight alcohols and
that of hydrocarbons of equivalent weight. Infrared spectrographic studies (5) have
shown that, in the liquid state, hydrogen bonds are formed by the attraction of the
hydroxyl hydrogen of one molecule and the hydroxyl oxygen of a second molecule.
This bonding makes liquid alcohol behave as though it were largely demonized.
Formula CH3CH2OH
CAS NO 64175
B=-3803.99
C=-41.68
CHEMICAL PROPERTIES
Ester formation
Dehydration
Strong acid desiccants cause the dehydration of ethanol to form diethyl ether
and other byproducts. If the Temperature of the ethanol being dehydrated exceeds
around 160 °C, ethylene will be the main product. Millions of kilograms of diethyl
ether are produced annually using sulfuric acid catalyst.
Combustion
Acid-base chemistry
2 CH3CH2OH + 2 Na → 2 CH3CH2ONa + H2
Or a very strong base such as sodium hydride:
The acidity of water and ethanol are nearly the same, as indicated by their of
15.7 and 16 respectively. Thus, sodium ethoxide and sodium hydroxide exist in an
equilbrium that is closely balanced:
Halogenation
Upon treatment with halogens in the presence of base, ethanol gives the
corresponding halo form (CHX3, where X = Cl, Br, I). This conversion is called the
halo form reaction. An intermediate in the reaction with chlorine is the aldehydes
called chloral:
Oxidation
There is semantic confusion with regard to the term ethanol. Very often the
term is used as a synonym for alcoholic beverages. This is misleading, even though
ethanol may be used as a raw material for the production of spirits. In order to avoid
misunderstandings we would like to define ethanol as a clear, colorless,' flammable
oxygenated hydrocarbon, with the chemical formula C2 H5 OH. Even though the
definition is fairly straightforward, there are various categories for describing a
particular type of ethyl alcohol that are not mutually exclusive:
By feedstock.
By composition.
By end use.
The feedstock and therefore the processes by which ethanol can be produced
are diverse. Synthetic alcohol may be derived from crude oil or gas and coal.
Agricultural alcohol may be distilled from grains, molasses, fruit, sugar cane juice,
cellulose and numerous other sources. Both products fermentation and synthetic
alcohol are chemically identical. Synthetic alcohol is concentrated in the hands of
a couple of mostly multinational companies such as Sasol with operations in South
Africa and Germany, SADAF of Saudi Arabia, a 50:50 joint venture between Shell
of the UK and Netherlands and the Saudi Arabian Basic Industries Corporation, and
BP of the UK as well as Equistar in the US However, on a global scale synthetic
feedstock plays a minor role. In 2003, less than 5% of overall output was accounted
for by synthetic feedstock. More than 95% came from agricultural crops and given
the strong interest in fuel ethanol production worldwide this share can be expected
to grow in the future. Another distinction that is of importance in the field of
ethanol is the one between anhydrous and hydrous alcohol. Anhydrous alcohol is
free of water and at least 99% pure.
This ethanol may be used in fuel blends. Hydrous alcohol on the other hand
contains some water and usually has a purity of 96%. In Brazil, this ethanol is being
used as a 100% gasoline substitute in cars with dedicated engines. The distinction
between anhydrous and hydrous alcohol is of relevance not only in the fuel sector
but may be regarded as the basic quality distinction in the ethanol market. The final
distinction that is necessary in order to understand the dynamics of the world
ethanol market is by end-use. Certainly the oldest form of use of alcohol is that of a
beverage. The most important market for ethanol as an industrial application is
solvent. Solvents are primarily utilized in the production of paints and coatings,
pharmaceuticals, adhesives inks and other products. Ethanol represents one of the
most important oxygenated solvents in this category. Production and consumption
is concentrated in the industrialized countries in Northern America, Europe and
Asia. It is the only market where synthetic ethanol producers hold a significant
market share. The last usage category is fuel alcohol. As mentioned before, fuel
alcohol is either used in blends, for example in gasohol or diesohol, or in its pure
form. However, at present Brazil is the only country that uses ethanol as a 100%
substitute for gasoline.
The history of ethanol as a fuel dates back to the early days of the automobile.
However, cheap petrol quickly replaced ethanol, as the fuel of choice and it was not
until the early 1980s, when the Brazilian government launched the Proalcool
program, that ethanol made a come back to the market place. It may be estimated
that fuel ethanol accounts for roughly 70% of world ethyl alcohol production in
2003. As can be seen from Chart 1, this share is forecast to rise to over 80% by the
end of the decade. However, this projection only holds if the sometimes-ambitious
fuel ethanol programs which have been proposed in the
Chart 1 shows, that the industrial alcohol market is the smallest of the three.
Moreover, it is showing a rather modest rate of growth, which is similar to the
increase in Gross Domestic Product, Demand for distilled spirits in most developed
countries is stagnating or even declining, due to increased health awareness. This is
unlikely to change in the future.
Ethyl alcohol as an automotive fuel can be used in two ways: First it replaces
gasoline outright in dedicated internal combustion engines and secondly it is an
effective "octane booster" when mixed with gasoline in blends of 5 to 30%. In this
case no engine modifications are required. These blends achieve the same octane
boosting or anti-knock effect as petroleum derived aromatics like benzene or
metallic additives like lead. Ethanol easily blends with gasoline but not with diesel.
If the diesohol blend is to obtain more than 3% ethanol special emulsifiers are
needed. if we look at the bio-fuel programs that are already in existence, there are
three key success factors that must be considered: first, the abundance and
cheapness of feedstock used for their production together with The technology
involved and last, but not least, A supportive political framework.
Let's look at the feedstock's issue fuel first. According to our 2003 survey,
around 61% of world ethanol production is being produced from sugar crops, be it
sugar beet, sugar cane or molasses, while the remainder is being produced from
grains and here maize or corn is the dominating feedstock. Feedstock‟s crucially
determine the profitability of fuel ethanol production. There are various ways to
look at the issue
CHART 2) the theoretical per ha ethanol yields of the three major feedstock’s
currently in use are plotted.
CHART 3
If we look at the gross feedstock costs per .qallon of fuel ethanol produced, it is
sugar cane grown in the Centre/South of Brazil, which clearly leaves the rest of
the competition behind (Chart 3).
Political support
Critics often ask why bio4uels must be supported by the state. If fuel ethanol
is such a great product, so they say, then it surely will gain market share without
any government help. This argument is very much dependent on the assumption
that the energy markets that we look at work perfectly. In the energy market, and in
fact, in almost any market, these conditions are insufficiently meet and, therefore,
an active policy approach may be justified.
There is growing consensus that fuel ethanol may serve a multitude of goals that are
socially desirable. At the same time, as a fuel, it is invariably more expensive to
produce than for example gasoline. Or looked at it from another angle, ethanol faces
an unfavorable opportunity cost structure. The opportunity costs for ethanol
production from, for example sugar crops like cane or beet, is the return otherwise
achievable if these feedstock‟s were used to produce sugar. So, if policy makers
decide that ethanol is a desirable, good, they have to find ways to bridge the gap
between the cost of ethanol and that of gasoline and they have to make ethanol
production more attractive as compared to the manufacture of, say, sugar.
There are various ways to achieve that It may be useful to distinguish between
the various stages in the production and marketing process where subsidization may
occur. For this end one can distinguish between input subsidies and output
subsidies. Under the former category, one may summarize measures like feedstock
price support (which results in prices below the going market rate) capital cost
support (in the form of cheap loans and debt cancellations) and income tax
concessions. On the output side most widely employed forms of support are excise
tax concessions which make the product cheaper than would have been the case
otherwise, so-called captive or mandated markets which ensure sufficient demand
for the product, price guarantees and direct price support measures.
merits of ethanol compared to other oxygenates like methyl tertiary butyl ether
(MTBE), ethyl tertiary butyl ether (ETBE) and tertiary amyl methyl ether (TAME).
Demand for ethanol as fuel has been increasing since ages, in-spite of presence of
other oxygenates. This can better be understood by seeing examples of USA,
Basically early years USA also used both MTBE and fuel ethanol
The various tax incentives have certainly helped the ethanol industry in the US to
get off the ground. However, the real boost came with the introduction of mandated
or captive markets in the early 1990s. The Clean Air Act mandated the use of
cleaner burning fuels in the dirtiest US cities. In order to achieve that, the
legislation enforces the addition of oxygen to gasoline. For long time petrol derived
MTBE has been oxygenate of choice but this is likely to change now and this
explains the amazing growth in recent years. Starting in January 2004, US states
banned MTBE from its ~uel pool. This opened the way for ethanol.
CHAPTER 5
India's transport sector is growing rapidly and presently accounts for over half
of the country's oil consurnption whilst the country has to import a large part of its
oil needs. Hastening interest in an ethanol program was the country's sugar glut
(part of which the industry is now exporting to the world market) and burgeoning
supplies of molasses. The sugar industry lobbied the government to embrace a bio-
ethanol programmed for several years. The industry emphasized that producing fuel
ethanol would absorb the sugar surplus and help the country's distillery sector,
which is presently burdened with huge overcapacity, and also allow value adding to
by-products, particularly molasses.
India's Minister for Petroleum and Natural Gas gave his approval in December
2001 to a proposal to launch pilot projects to test the feasibility of blending ethanol
with gasoline. Mid-March 2002 the government decided to allow the sale of E 5
across the country. On 13 September 2002, India's government rnandated that refine
states and four federally ruled areas would have to sell E-5 by law from 1 April
2004. In response India's sugar producers reportedly planned to build 20 ethanol
plants before the end of the year in addition to 10 plants already constructed. Most
of the plants were being constructed in Uttar-Pradesh, Maharashtra and Tamil
Nadu, the key sugar producing states and will chiefly use cane sugar molasses as a
feedstock.
Estimated annual ethanol needs for a E-5 blend is 0.37 bln litres. A 10% blend
increases the need to 0.72bln litres. This is against installed annual production
capacity of 2.7bln litres/year and annual consumption of 1.5bin litres. These figures
have to be treated with some caution. The chemical industry, fearing higher ethanol
prices as a result of the fuel alcohol programmed, usually estimates the surplus to be
much lower or even non-existent.
The sugar industry, on the other hand, estimates capacity at 3.2bln litres
inflating the surplus. The success of ethanol in India will depend to a significant
degree on pricing The sugar industry originally claimed that it could provide
ethanol at 19 Rupee per litre ($0.38/litre), which is at a lower cost than the product
it would substitute, MTBE. which costs 24-26 rupees per litre ($0.49-0.53/litre).
The oil industry however is seeking parity between ethanol and the price of gasoline
on an ex-refinery or import basis. In April 2002 the government announced Rs0.75
excise duty exemption. Implementation of the excise duty for ethanol which,
however, was delayed however until February 2003, because the chemical industry
opposed it, fearing higher prices and shortages of alcohol.
ANHYDROUS ETHANOL POTENTIAL FOR GASOLINE BLENDING
This statistics show a direct potential. Due to govt. promoting ethanol to mix
in petrol there is drastic demand for ethanol, which could overcome the existing
unutilized capacity and thus creating an excess demand. However, pricing appears
to becoming a stumbling block and in June 2003 India's Petroleum Ministry
announced that it would appoint a Tariff Commission to fix an appropriate price for
ethanol sourced from sugar mills. Ethanol pricing in India is also complicated by
differences in excise duty and sales tax across states and the central government is
trying to rationalize ethanol sales tax across the country. More significantly
perhaps, there are still substantial differences in the profitability of potable alcohol
as against fuel alcohol and in several states. Consequently, insufficient fuel alcohol
is being produced to meet demand. Other states have yet to set up sufficient
production capacity. Analysts expect that there is a deficit of around 150 mln litres
under the current geographic base to the fuel ethanol program; a deficit that will
grow once the mandated blending requirement is extended to all states in India.
Consequently, there may be a short-term market for imported Brazilian ethanol. As
the use of fuel ethanol has just started it's export has not yet began but it has a great
scope The Centre's Gasohol Program' of blending 5% ethanol in petrol has given an
assured scope for ethanol industry in the country. The Centre's Kisan-friendly
imitative has definitely been a boost to the venture. Following statistics could show
how there is definite market potential for such industry.
PETROL CONSUMPTION
500000000 Ltrs.
In parts of 4 states of Andhra Pradesh, Maharashtra, Punjab, Uttar Pradesh & Goa
5% of ethanol blended petrol has already been started and till 30th June 2003, it will
be fully covered. Gujarat, Haryana, Karnataka, Tamilnadu and the Union
Territories of Chandigarh, Dadra & Nagar Haveli Daman and Div and Pondicherry
are also covered till end of July 2003.
The entire country will be covered in 2nd Phase and ethanol content to be
increased to 10% in 3rd Phase. Most important R & D Studies are successful of
blending ethanol with Diesel, which itself is a very significant point in developing
ethanol. All this significance shows a definite assured market for the industry
leading the project to most viable and safe for financial assistance.
IMPORT EXPORT DATA
India Minister for petroleum and natural gas gave his approval in December 2001 to
a proposal to launch a pilot project to test the feasibility of blending ethanol with
gasoline. Mid-march 2002 the government decided to allow the sale of E-5 across
the country. On 13 September 2002, India‟s government mandated that nine states
and four federally ruled areas would have to sale E-5 by law from 1 April 2004. As
Indian govt. gave for blending of ethanol around 2004, so India has not yet started
to import.
CHAPTER 6
MANUFACTURING PROCESSES
Industrial ethyl alcohol can be produced synthetically from ethylene, as a by-
product of certain industrial operations, or by the fermentation of sugar, starch, or
cellulose. Fermentation processes accounted for 83% of total production in the U.S.,
Western Europe and Japan in 1997. By 2001 fermentation increased to 90%. The
first synthesis of ethanol from ethylene occurred in 1828 in Michael Faraday‟s
laboratory in Cambridge. There are two main processes for the synthesis of ethyl
alcohol from ethylene.
The earliest to be developed (in 1930 by Union Carbide Corp.) was the
indirect hydration process, variously called the strong sulfuric acid–ethylene
process, the ethyl sulfate process, the esterification–hydrolysis process, or the
sulfation–hydrolysis process. This process is still in use in Russia. The other
synthesis process, designed to eliminate the use of sulfuric acid and which, since the
early 1970s, has completely supplanted the old sulfuric acid process in the United
States, is the direct hydration process. This process, the catalytic vapor-phase
hydration of ethylene, is now practiced in the U.S. only by Dow Chemical; Texas
City, Texas, Dow imports crude industrial ethanol, CIE, from Saudi Arabia in a
tolling arrangement with shell chemicals, and refines it to industrial grade.
Other synthetic methods have been investigated but have not become
commercial. These include, for example, the hydration of ethylene in the presence
of dilute acids (weak sulfuric acid process); the conversion of acetylene to
acetaldehyde, followed by hydrogenation of the aldehydes to ethyl alcohol; and the
Fischer-Tropsch hydrocarbon synthesis. Synthetic fuels research has resulted in a
whole new look at processes to make lower molecular weight alcohols from
synthesis gas.
Ethylene hydration
Ethanol for use as an industrial feedstock or solvent (sometimes referred to as
synthetic ethanol) is often made from petrochemical feed stocks, primarily by the
acid-catalyzed hydration of ethylene, represented by the chemical equation
Fermentation
Fermentation one of the oldest chemical processes known, it is used to make a
variety of products, including fuel, foods, flavorings, beverages, pharmaceuticals,
and chemicals. Most of the fermentation ethanol is made from corn even though
before World War II molasses was the chief feedstock. Ethanol can be made from a
variety of agricultural products such as other grains, sugar cane and beets, fruit,
whey, and sulfite waste liquor. Studies are underway to ferment garbage to ethanol.
Generally, most of the agricultural products mentioned command higher prices as
foods, and others, eg, potatoes, are uneconomical because of their low ethanol yield
and high transportation cost. The use of fermentation ethanol in the industrial
market depends on the availability and cost of the carbohydrate relative to the
availability and cost of ethylene, and the economics and government policies
relating to the fuel ethanol market.
Once simple sugars are formed, enzymes from yeast can readily ferment them
to ethanol. Because fermentation ethanol has been thoroughly and repeatedly
discussed in the literature, the coverage here is illustrative rather than
comprehensive, with special emphasis on the potential raw materials for ethanol
production of the future
Sugar
Prior to the late 1970s, the most widely used sugar for ethanol fermentation
was blackstrap molasses which contains about 35–40 wt % sucrose, 15–20 wt %
invert sugars such as glucose and fructose, and 28–35 wt % of no sugar solids.
Blackstrap (derived from Java and the Dutch word stoop, meaning syrup) is
collected as a by-product of cane sugar manufacture. The molasses is diluted to a
mash containing10 − 20 wt % sugar.
After the pH of the mash is adjusted to about 4–5 with mineral acid, it is
inoculated with the yeast, and the fermentation is carried out no aseptically at 20–
32◦C for about 1–3 d. The fermented beer, which typically contains 6 − 10 wt %
ethanol, is then sent to the product recovery and purification section of the plant.
The direct fermentation of sugar cane juice, sugar beet juice, beet molasses (a by-
product in the production of beet sugar), fresh and dried fruits, cane sorghum, whey,
and skim milk had been considered as a means of obtaining ethanol, but none of
these raw materials could compete economically with molasses. Although the
manufacture of ethanol from the sugar-containing waste products of the fruit
industry appears to be a highly desirable operation, particularly as a means of
reducing stream pollution in the vicinity of canning plants, such production is costly
because of the need to remove most of the water (as much as 97%) contained in the
waste product. The results of the sugar-crop research on agronomics and fuels
conversion undertaken by Battelle‟s Columbus Laboratories lists several merits of
sugar cane as a candidate energy resource. Sugar cane, a renewable raw material, is
renowned for its agricultural productivity, and its juice is directly fermentable to
ethanol. On the other hand, sugar cane products are valuable in food and feed
applications and their conversion to chemicals and energy can be considered an
underutilization of their potential value. In 1975, Brazil embarked upon the
ambitious pro Alcohol program for fermentation ethanol manufacture from sugar
cane to reduce the country‟s dependence on foreign oil, and to modernize and make
more competitive Brazil‟s sugar mills in a lagging international sugar market.
Gasohol‟s have been used in Brazil since the early 1930s. The number of
alcohol distilleries grew to over 500 while the number of big sugar plantations grew
to over 1000. Brazil is currently the world‟s largest producer of fermentation
alcohol. The subject of fermentation alcohol has always been of considerable
interest to several tropical countries, but until the oil crisis of 1973, other than
Brazil, only India appeared to appreciate the importance of fermentation alcohol as
a strategic material in its economy. Ethanol prices in India have been maintained at
an extremely low level by processing cane molasses, which has been a waste
product of negligible value.
Starch
In the United States, all potable alcohol, most fermentation industrial alcohol,
and most fuel alcohol is currently made principally from grains; corn is the
principal feedstock for fuel alcohol. Fermentation of starch from grain is somewhat
more complex than fermentation of sugars because starch must first be converted to
sugar and then to ethanol. This process was known to the ancient Egyptians and
Mesopotamians who brewed beer almost 5000 years ago. The simplified equations
for the conversion of starch to ethanol are
enzyme yeast
C6H10O5 + H2 C6H12O6 2 C2H5OH + 2 CO2
Starch is converted enzymatic ally to glucose either by diastase presents in
sprouting grain or by fungal amylase. The resulting dextrose is fermented to ethanol
with the aid of yeast, producing CO2 as a co product. Other byproducts depend on
the type of process. The basic process steps for converting corn into ethanol are
degermination, milling, and separation of starch bearing endosperm from hulls,
slurring–liquefaction, and hydrolysis of starch to sugar, fermentation, distillation,
and dehydration. The hydrolysis or saccharification is usually carried out with an
amylase enzyme and the fermentation is usually by the yeast Saccharomyces
cerevisiae.
The process takes about 40–50 hours. The mash is agitated and kept cool to
facilitate yeast activity. The fermentation product is agitated and is kept cool. The
ethanol is separated out. Ethanol is concentrated to 190 proofs by distillation and
then dehydrated to 200 proofs by a molecular sieve system. Ethanol is treated with a
denaturant to render it undrinkable, and thus, is not subject to beverage tax. A by-
product produced by centrifugation of coarse grain and soluble material is
Condensed Distiller‟s Syrup. This is used for livestock feed. In wet milling, the
grain is soaked or steeped in water and sulfurous acid for 24–48 hours to separate it
into components. After steeping, the corn slurry goes through grinders to separate
corn germ and fiber components. Corn oil is extracted. The steepage liquor is
concentrated by evaporation. Gluten is separated outland used in livestock feed.
Cellulosic Materials
Over 900 × 106 metric tons of carbohydrate-containing cellulosicwastes are
generated annually. The technology for converting this material into ethanol is
available, but the stoichiometry of the process is disadvantageous. Even if each step
in the process of the conversion of cellulose to ethanol proceeded with 100% yields,
almost two-thirds of the mass would disappear during the sequence, most of it as
carbon dioxide in the fermentation of glucose to ethanol. This amount of carbon
dioxide leads to a disposal problem rather than to a raw material credit.
Starch and cellulose are both polymers of glucose, but cellulose is much more
difficult to hydrolyze to the sugar. Its structure is more crystalline which protects
the internal bonds from hydrolysis, and cellulose in plants is protected by lignin, a
polyphenolic material that forms a seal around the cellulose for further protection
against hydrolysis. Cellulosic wastes also contain substantial amounts of
hemicellulose, which is a polymer of pentoses. The aqueous mineral acids used to
hydrolyze the cellulose to glucose destroy much of the sugars, particularly the
pentoses, in the process. Nevertheless, a 1978 study claimed that forests could
theoretically provide 50% of the oil and gas used by U.S. utilities, replacing 20% of
annual fossil fuel consumption. None of this has taken place, but research has
continued. A process utilizing low temperature hydrolysis to separate cellulose from
paper has been licensed, with plans to construct a plant in Germany. The process
uses electrodialysis rather than diffusion dialysis to recover hydrochloric acid for
reuse. Other new ways of reducing the cost of converting cellulosic wastes from
wood, newspapers, and municipal garbage into glucose include the use of less
corrosive acids and reduced hydrolysis time. One way of making cellulose wastes
more susceptible to hydrolysis is by subjecting them to a short burst of high energy
electron beam radiation. Hydropulping of cellulose feedstocks followed by a 10 μs
burst from a 3 × 106−eV electron-beam accelerator is claimed to reduce the time of
hydrolysis by dilute acid from hours to seconds. An alternative to acid hydrolysis is
the use of enzymes. Although they avoid the corrosion problems and loss of fuel
product associated with acid hydrolysis, enzymes have their own drawbacks
Enzymatic hydrolysis slows as the glucose product accumulates in a reaction vessel.
This end-product inhibition eventually halts the hydrolysis unless some way is
found to draw off the glucose as it is formed.
Azeotropic distillation
Molecular Sieve Technology
Per-vaporization technique
AZEO'I'ROPIC DISTILLATION
Distillation as ethyl alcohol forms a constant boiling mixture with water at this
concentration and is known as azeotropic. Therefore, special process for removal of
water is required for manufacture of absolute alcohol. in order to extract water from
alcohol it is necessary to use some dehydrate, which is capable of separating, water
from alcohol. Simple dehydrate is unslacked 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 absolute alcohol.
Water' is retained by quick lime. This process is used for small-scale production of
absolute alcohol by batch process.
The rectified spirit from the rectifier is superheated with steam in feed super-heater.
Super-heated 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 vapors is switched to the alternate bed of the pair. A portion of the
anhydrous ethanol vapors leaving the fresh adsorption bed is used to regenerate the
loaded bed.
MEMBRANE PREVAPORISATION
In this the overhead from preco Pervaporation differs from other membrane
processes in that the membrane constitutes the barrier between feed which is liquid
and permeate which is vapor The driving force for the process is the chemical
potential on the two sides of the membrane
In this the overhead from preconcentrator, which is a distillation column with 50-
60%ethanol is sent to another distillation column (known as stripping column)
giving 95% pure ethanol as top product (Rectified spirit). The vapors‟ are
condensed and collected in a buffer tank (accumulator), which feeds the
Pervaporation unit. The vacuum is maintained on the other side of the membrane at
which water is obtained as permeate in the vapor form. The membrane has higher
permeability towards water. it is condensed and recycled to the stripper column.
CHAPTER 7
SELECTION OF PROCESS
The choice of process for the production of any product must include
consideration of several factors:
Choice of Process:
Our basic aim can be divided in to two parts
Ethanol is produced mainly from black strap molasses in India, sugar juice in
Brazil, Corn in U.S.A and Beet in Europe. With abundant supply of sugarcane,
India has an advantage in switching to the fuel ethanol program by fermentation of
molasses.
Now for anhydrous ethanol we usually prefer for Molecular Sieve technology
than azeotropic distillation because of its (Molecular Sieve technology's)
advantages over azeotropic distillation.
ADVANTAGES OF MOLECULAR SIEVE TECHNOLOGY FOR ETHANOL
DEHYDRATION ARE AS FOLLOWS: -
1 The basic process is very simple, making it easy to automate which reduces
labour and training requirements.
2. The process is inert. Since no chemicals are used, there are no material handling
or liability problems, which might endanger workers.
4. The molecular sieve desiccant material has a very long potential service life, with
failure occurring only due to fouling of the media or by mechanical destruction. A
properly designed system should exhibit a desiccant service life in excess of 5
years.
6. If fully integrated with the distillation system, steam consumption rate only
slightly above the absolute theoretical minimum for the separation can be achieved.
7. Most of the ethanol dehydration plants for production of absolute alcohol are
based on Azeotropic distillation; it is a mature and reliable technology capable of
producing a very dry product. However, its high capital cost, energy consumption,
reliance on toxic chemicals like benzene and sensitivity to feedstock impurities, has
virtually eliminated the use of azeotropic distillation in modern ethanol plants.
Benzene has been used as entrained of choice of ethanol dehydration but it is now
known to be a powerful carcinogen.
First we would discuss various raw materials and then later actual flow sheet
in detail
RAW MATERIAL
YEAST
Organism alternation: Yeast is the only Organism Currently used for large-
scale ethanol production· Yeast produces ethanol with very high selectively (only
traces of by products) is very hardy and large compared with bacteria (allowing
simplified handling). Clostridium thermosaccharolyticum, thermoanaerobactor
ethanolicus and other thermophilic bacteria as well as Pachysolen tannophilus yeast
are under intensive study for use in fermenting pentose sugars, which are non-
fermentable by ordinary yeast· These bacteria also convert hexos sugars and have
been considered as an alternative to yeast science very high temperature reaction
would allow simple continuous stripping of yeast from one of the
importantsubgroups of fungi like bacteria are widespread in the nature although
they usually live in the soil and in the region of very lower humidity than bacteria·
They are unable to extract energy from sunlight and usually free-living.
High growth and fermentation rate allows the use of smaller fermentation
equipment· Ethanol and glucose tolerance allows the conversion of concentration
feeds toconcentrated products, reducing energy requirements for distillation and
stilling handling· Osmotolerance allows the handling of relatively dirty raw
materials such as blackstrap molasses with its high salt cintent. Osmetolerance also
allows the recycle of large portion of stilling liquids, thus reducing stilling handling
costs. Low pH fermentation combats contamination by competing organisms· High
temperature tolerance simplifies fermenter cooling. General hardliness allows yeast
to survive both the ordinary stress of handling (such as centrifugation) as well as the
stresses arising from the plant upset.
FERMENTATION KINETICS
Glycolysis
Via this pathway, every gram of glucose converted will yield 0.511 g of ethanol.
Secondary reaction will consume a small portion of glucose feed, however, to
produce biomass and secondary products and Pasteur found that actual yield of
ethanol from fermentation by yeast in reduced to 95% of the theoretical maximum.
When complex substrates, typical of industries practice, are used, further by-
products and generated and the ethanol yield is reduced typically only to 90% of the
theoretical.
Via aerobic metabolism, sugar is converted completely to carbon dioxide, cell mass
and by-products, with no ethanol formed, and aerobic metabolism must be avoided.
EFFECT OF SUGAR CONCENTRATION
V = Vmax Cs
(Ks +Cs)
Where,
Ks = Saturation constant
At very Iow substrate concentrations (below about 3gl -1), the yeast is starved
and productivity decreases. At higher concentrations a saturation limit is reached, so
that, the rate to produce the ethanol per cell is essentially at its maximum up to
150g/I catabolite (sugar) inhibition of enzymes in the fermentative pathway
becomes important and the conversion rate is slowed. An important secondary
effect of sugar is catabolite repression of the oxidative pathways (the Crabtree
effect) At above 3.30 gl-1 sugar concentration (depending on yeast strain), the
production of oxidative enzymes is inhibited, thus forcing fermentative metabolism.
The catabolite repression is not found in all yeast and is a desirable property, which
is selected, in the industrial strains.
EFFECT OF ETHANOL
Ethanol is toxic to yeast and high tolerance is a desirable trait selection in the
industrial strains The inhibitory effect of ethanol is generally negligible a Iow
alcohol concentrations (20 gl-l) but increase rapidly at higher concentrations. For
most strains ethanol production and cell growth are halted completely at above 110
gl-1, although some very Iow fermenting sake yeast (saccharomyces sake) can
tolerate ethanol concentrations as high as 160/gl at Iow temperatures. Ethanol
inhibition is directly related to inhibition and denaturation of important glycolic
enzymes, as well as to the modification of cell membrane. It is important to avoid a
high degree of aerobic metabolism, which utilizes the sugar substrate but produces
no ethanol, it has been found ,however the trace amounts of oxygen may greatly
stimulate yeast fermentation. Oxygen is required for yeast growth, as a building
block for the biosynthesis of polyunsaturated fats and lipids required in aerobic
sugar consumption in yeasts, which slows the Crabtree effect. For other yeast or at
Iow sugar concentration, the oxygen supply should be limited. Trace amounts (0.7
mm hg oxygen tension) of oxygen are adequate and do not promote aerobic
metabolism.
Effect of pH:
Fermentation rate is sensitive to pH, but most distiller's yeasts show a broad
optimum from at least pH 4-6. Its range is lower than that for typical bacteria.
Further, rnost yeasts can tolerate exposure to acid solution of pH as Iow as 2
without permanent damage.
Effect of temperature:
Yeast extract is the water soluble extract of auto catalysed yeast and contains
all necessary yeast growth factors: amino-acids, pureness, pyrimidines and vitamins
as well minerals Phosphorus, potassium (from the yeast extract), magnesium and
calcium are incorporated into cell used is apparent from oura's (1974) comparison
of 12 of the best-known culture media.
Raw material selection
For production of ethanol, sweet sorghum can be best option over sugarcane
& molasses.
Juice extraction
Juice is extracted by series mills. The juice coming out of milling section is
first Screened, sterilized by heating up to 1000C and then clarified the muddy juice
is first sent to Rotary vacuum filter and the filtrate juice is sent to evaporation
section for concentration. The juice can also be directly sent to fermentation
section. depending on the scheme selected the juice can be concentrated using
evaporators to attend various brix. In case of juice to ethanol, it is advisable to
partially increase the concentration of juice to 16-18 brix. The syrup which needs
storage for using during off season needs to concentration to minimum 65 brix.
Fermentation
Distillation
Process description
The gradually cultured distillers yeast along with nutrient is poured rate the
tank Then in the proportion of 1 gm of yeast per lit juice of sweet sorghum that has
been heated and sterilized is introduced into the tank aerobic condition with 32oC
temperature is maintain in the tank, yeast completes the growth in 18-24 hr. after
the yeast has reproduced, open the valve of tank. Let juice of sweet sorghum and
yeast flows into the fermentation tank. Then nutrient in yeast provide for
saccharomicyne to reproduce it in a large quality anaerobic condition are
maintain here. This Produce takes about 24hr. and above 95% sweet sorghum juice
could fermented to become alcohol and CO2.
LEGENDS
Notation Description
C110 DISTILLATION COLUMN
D113 SETTLING DEVICE
D110A 1ST MOLECULAR SIEVE BED
D110B 2ST MOLECULAR SIEVE BED
E111,E113,E114,E115 HEAT EXACHANGER
E112 CONDENSER
E110 REBOILER
1) The feed (rectified spirit) pumped from the storage tanks, is heated through the
heat exchanger (El14) by dehydrated alcohol, then heated RS of 93% to 96% is
fed to the top of the distillation column Cl10.
2) The liquid passes through the distillation column where ethanol is stripped of,
The alcohol free liquid called spend lees is separated and discharged from the
bottom of distillation column and ethanol stream, with strength of about 96% by
volume, is removed as vapour, at the top section of the distillation column and
feed to the molecular sieve unit after a super heating about 1 15°C by steam in
the heat exchanger (El11).
3) Fusel oils are removed from an intermediate points of the column in order to
avoid any risk of flooding of the column and feed to the static setting device (D-
113) where they are separated from the weak water which are recycled to the
column.
4) The distillation column (C-110) has an operating pressure of about 160 kpa (A)
and is heated with low pressure steam by menace of reboiler (E-110).
5) The super heated ethanol stream removed at the top of the distillation column
feeds one of the two sieve beds (D-110A) is now in regeneration mode.
6) The second sieve bed (D-110OB) is now in regeneration mode under vacuum)
and receives a small amount of vapors from (D-110A) working in over pressure.
As soon as regeneration is finished ( a regeneration cycle lasts about 5 minutes),
an automatic control system changes the operating conditions of two sieve beds
in order to have the first sieve D-110A) in regeneration and the second one (D-
110B) in dehydration mode.
7) The dehydration process release a vapors ethanol stream with a very small
amount of water (500 p.p.m or less), which is condensed in the condenser E
113, cooled in the heat exchangers E-114 and E-115 and sent to the storage as
dehydrated alcohol.
8) The regeneration process releases a certain amount of absorbed water and
ethanol, which are condensed in the condenser E-112 and recycled to the
column.
9) Cooling media of the first cooling steps of the dehydrated alcohol is the
regeneration stream recycled to the distillation column and cooling media of the
second cooling step of dehydrated alcohol is the fed stock coming from the
storage tanks, which is preheated as hereinabove described.
10) Remaining vapors and liquid are condensed and cooled by cooling water in
S&T or P&F heat exchangers.
STORAGE AND HANDLING
Storage tanks are made of almost any structural material steel and reinforced
concrete are most widely used., resistance to corrosion, light weight and Iow cost
are taken into consideration while selecting the storage materials, plastic and glass
coating are also applied to steel plants. Aluminum and other non ferrous material
are used. Neopress tanks are best suited for ethanol storage. Since these chemicals
are flammable and leakage may cause 'nothing but death'The distance between two
tanks should be at least be 7-8 meters away from each other because of which
storage is more secure.
Ethanol is volatile liquid. These liquids are stored in specially designed tanks
which are capable of conserving the contents if these are stored in normal fixed bed
volume tanks a loss takes place due to the following causes.
Breathing losses
A space above the liquid level is filled with air and vapour mixture.
Vaporization increases with rise in temperature during the day. Increase in
temperature will there fore result in expansion of mixture and a loss of certain
volume through the vent. The temperature drops during the night and some
condensation takes place, the air-vapour mixture contracts and fresh air is sucked
into the tank.
Filling losses
When liquid is discharged from fixed volume tank the tank will be filled with
air vapor mixture, if the tank is then filled gain with the fresh batch of liquid certain
volume of air vapour will be vented and loss. This loss can be subtenant if such
filling takes place very frequently.
Waste Treatments
Any one of the above factors can have deciding effect on selection of the
wastewater treatment system. It is therefore essential to select the wastewater
treatment method depending upon above and choose the suitable fermentation and
distillation process accordingly.
In other words cane molasses based distillery and its wastewater treatment system
should be made for each other. With one or more options from the basket of
technologies available, a system can be conceptualized and designed for
requirement of distillery complex OR with resources available at distillery
site/location for disposal of final treated effluent
Brewery requires treatment before it can be used as water for irrigation. The
treatment method comprises of Bio-methanation followed by aeration or a two-
stage aeration system. The former method has advantage of less power consumption
and less sludge generation while the latter has advantage of easy start up and
operation. While Industries like PRAJ can provide both types of system,
considering the overall benefits bio-methanation followed by aeration system is
recommended.
THERMODYNAMIC FEASIBILITY
The enthalpy and Gibbs free energy data of the compounds are given below:
1) C12H22O11+H2O 2 C6H12O6
FOR REACTION 1)
C12H22O11+H2O 2 C6H12O6
= (2 X (-1274.45))-((-2222.12)+(-285.84))
= -40.94 KJ/GMOLE
NOW,
= (2 X (-910.52))-((-1544.65)+(-228.61))
= -47.78 K J/MOLE.
SINCE THE FREE ENERGY IS NEGATIVE, THE REACTION IS FEASIBLE
= (2 X (-276.98) + 2X(-393.51))-(-1274.45))
= -66.53 KJ/GMOLE.
NOW,
= (2 X (-174.38)+2X(-394.38)) - (-910.52)
= -226.576 KJ/GMOLE
∆S° = (∆G298+∆H298)/298
FOR Reaction 1
FOR Reaction 2
MATERIAL BALANCE
BASIS – 1100 Kg SWEET SORGHUM JUICE (1000 Lit)
(WATER)
OVERALL
SWEET SORGHUM
PLANT
JUICE (ETHANOL 100% PURE)
WASTES
CONTENTS WT %
SUCROSE (C12H22O11) 11.4
GLUCOSE (C6H12O6) 2.85
WATER (H2O) 83.79
OTHER 1.96
Our basic aim can be divided into two parts
CO2
FEED WATER
CRUSHER YEAST
3 DISTILLATION COLUMN
SORGHUM JUICE H2SO4 ETHANOL
NUTRIENTS
BOTTEMS
Feed is 1100 kg of sweet sorghum stem. A composition of which is given in the range
of percentage in table. For calculation purpose, it is assume fix value as shown in below
table.
CONTENTS WT %
SUCROSE (C12H22O11) 11.4
GLUCOSE (C6H12O6) 2.85
WATER (H2O) 83.79
OTHER 1.96
1.SUCROSE in feed = 1100 x 0.114 = 125.4kg.
= 921.69/18 =51.205kmol
So therefore, we can say total moles of feed on Mole percent calculation (waste free
basis): -
NUTRIENTS+H2SO4
FEED, M Hm
MIXER
REACTION
C12H22O11+H2O 2 C6H12O6
From reaction
= 915.09 Kg
= 163.332 Kg
=51.7454 kmole
Mole % of Hm (waste free basis)
Glucose=0.9074x100/51.7454=1.753%
Water=50.8383x100/51.7454=98.247%
Weight % of Hm
Glucose=163.332x100/1100=14.84%
Water=915.09x100/1100=83.19%
Waste=21.56x100/1100=1.96%
BALANCE ON FERMENTOR
(CO2+ETHANOL TRACES)
Hm Fm
FERMENTOR
Reaction
Ethanol in Fm=1.7240x46=79.3067 Kg
Water in Fm=50.8383x18=915.089 Kg
Waste in Fm=21.56 Kg
Ethanol=1.7240x100/52.562=3.279%
Water=52.562x100/52.562=96.72%
Weight %
Ethanol=79.306x100/1015.953=7.805%
Water=915.089x100/1015.953=90.07%
Waste=21.56x100/1015.953=2.122%
DISTILLATION COLUMN
D2 D3
L1
Fm D1 S1 S2
95% ETHANOL
W1 W2 W3
Let,
Overall Balance
Fm=D1+W1
Component Balance
FxXf=D1xXd1+W1xXw1
D1=16.5141 kmole
W1=36.0478 kmole
=647.562 Kg
Waste in Bottom=21.56 Kg
Composition of D1
= 75.964 Kg
= 267.52 Kg
Now in the aldehyde column, undesirable volatiles such as aldehydes are taken off
and azeotropic alcohol-water mixer are obtained from the rectification column
where 95% pure ethanol is taken off as a side stream, condensed and run to storage.
Aldehyde Column
Assuming
Xd2=0.9
Xs1=0.4
Xw2=0.01
Overall Balance
D1=D2+W2+S1
16.5141=D2+W2+3.0963
D2+W2=13.4178 ……..(3)
Component Balance
D1xXd1=D2xXd2+W2xXw2+S1xXs1
16.5141x0.1=D2x0.9+W2x0.01+3.0963x0.4
D2x0.9+W2x0.01=0.41289 …….(4)
D2=0.3131 kmole
W2=13.1046 kmole
S1=3.0963 kmole
= 56.971 Kg
Ethanol in D2=0.3131x0.9=0.28179
=12.96 Kg
Water in D2=0.3131x0.1=0.03131 kmole
= 0.56 Kg
Rectification Column
Assuming
Xd3=0.97
Xs2= 0.95
Xw3=0.01
Overall Balance
S1=D3+W3+S2
3.0963=D3+W3+1.2515
Component Balance
S1xXs1=D3xXd3+W3xXw3+S2xXs2
3.0963x0.4=D3x0.97+W3x0.01+1.2515x0.95
D3x0.97+W3x0.01=0.04959 …..(6)
D3=0.0324 kmole
W3=1.8124 kmole
S2=1.2512 kmole
=54.64 Kg
At D3
=1.445 Kg
=0.0174 Kg
F
PREHATER
MOLECULAR SIEVE
WATER
BEDS
W ETHANOL 100%
FUSEL OIL
STILLAGE
F=1.2515 kmole
Assuming
Xf = 0.95
Xd=0.98
Xs=0.5
Xw=0.001
F=D+W+S
Component Balance
FxXf=DxXd+WxXw+SxXs
1.2515x0.95=Dx0.98+Wx0.001+0.02376x0.5
D=1.2 kmole
W=0.0267 kmole
S=0.02376 kmole
=54.096 Kg
=0.432 Kg
So,
=67.62 Lit.
OVERALL MATERIAL BALANCE
B C D
A OVERALL PLANT F
J I
INPUT= 1100KG
B=YEAST + NUTRIENTS
OUTPUT = 1100KG
C=CO2 REMOVED=79.85 KG
I=WATER IN WASTE=913.33 KG
J=WASTE=21.56 KG
CHAPTER 10
ENERGY BALANCE
CONTENT OF FEED
T = 303 0 K, T0 = 298 0 K
∆ Hf (FEED) = m Cp ∆T = m Cp (T-T0)
= 980.277 kcal / hr
=83.48 x 15600 / 46
= 28649.739 kcal / hr
= 32817.462 kcal / hr
Therefore cooling water required = ∆H removed /Cp ∆ T
= 32817.462 / 1 x 2
= 16408.73 cal / hr
Avg Cp = 0.936
= 1.7240 kmol
M2 = 32.85 kg
M2 = 52.87 kg
De=D x Xd
Dw=D x (1-Xd)
Qc = Deλe + Dw x λw/D
λe=9218.21 kcal/kmole
λw=9668 kcal/kmole
λv=9720 kcal/kmole
λs=506.22 kcal/Kg
Qr=V x λv
Ws1=Qr (total)/λs
Now,
We will start directly from molecular sieve bed for better understanding of energy
balance.
6.48 = m x 1 x 10
m = 0.648 Kg
470.63 = M x Cp x ∆T
m x 1 x 15 = 313
5) In the final heat exchanger the heat content of ethanol (product) is same
M x 5 x 1 = 313
M = 62.6 Kg of water
6)Now moving to the preheater section, we have obtained fusel oil + stillage =
1.24 Kg
Therefore,
= 55.072 Kg
λs = 506.22 Kcal/Kg
7)The feed is preheated sent to the molecular sieve bed the preheated feed again
superheated By steam, now calculating steam reqired for that
DESIGN
Design for fermentation tank
Shell Design
Internal Design=1000 mm
M.O.C.=S.S.
Thickness of Shell
t=PDI/2fj-p
=13.28=15 mm.
=1178.09 lit.
= 0.085 x (1000)3
=85 lit.
= 1178.09+170
=1348.09 lit.
Considering the effect of combine loading stress in circumferential direction due to
internal.
Ft = P(Di+t)/2t
=0.0111(1000+15)/2 x 15
=0.187 Kg/mm2
F1= PDi/4t
= 0.0111 x 1000/4 x 15
= 0.185 Kg/mm2
Volume of total material= volume of total material shell + volume of material for 2
head
= (π/4) x (Do2-DI2) x L
=0.0713 m3
=0.085 (10303-10003)
= 7.88 x 10-3 m3
= 699.68 Kg
= 1799.68 Kg
= 359.93 Kg
= 2159.616 Kg
= 1.5 x 2159.616
= 3239.42 Kg
F2 = w/t (Di + t)
=0.14184 Kg/mm2
Fn =F1 + F2
= 0.185 + 0.14184
= 0.326 Kg/mm2
Fs = 0
= 0.2833 Kg/mm2
Head Design
Torrispherical head
Diameter = 1000 mm
M.O.C.=S.S.
Th = PRcW/2Fj
P=design pressure
Rc = crown radius
= 6% of crown radius
= 60 mm
Rc = 1000 mm
= 4.83
= 62.72 mm = 63 mm
Nozzles
M.O.C. =S.S.
J = 0.85
Th = PDin/2fj – P
= 13.15 mm = 15 mm
A= (DIN + 2C) Tr
Tr = PDI / 2 FJ + P
= 12.93 = 15 mm
= 0.4 x 46 +0.6 x 18
=29.2
= 0.98 x 46 + 0.02 x 18
= 45.44
= 0.02 x 46 +0.98 x 18
= 18.56
= 3.605 KJ/Kg.K
=5052.76 KJ/Kg.K
Take α = 2.5
= 0.217
X 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Y 0 0.217 0.385 0.517 0.625 0.714 0.789 0.854 0.91 0.957 1.0
Intercept of q line = XD / R + 1
L=RxD
= 2.5 x 58.32
=145.8 Kg
G=L+B
= 145.8 + 58.32
= 204.12 Kg/h
q=1
L1 – L /F =q
L1 = q x F +L
= 1 x 90.41 + 145.8
= 236.21 Kg/kmole
G1 –G/F= q – 1
G1 = (q – 1) x F +G
= 294.53 Kg/kmole
= 0.4 x 46 +0.6 x 18
=29.2
= 1.174 Kg/m3
Liquid Density = ethanol density x mole % of ethanol in feed + water density x mole % of
water
= 893 Kg /m3
= 19.69 Kg mole/h
= 0.037 N/m
= 0.865 m/s
We can take 80% of Unf= 0.6924 m/s
An = Ac – Ad
Where,
An = volumetric flow rate of vapour / vapour velocity through net area at flood
= 0.04846 /0.6924
= 0.0699 m2
= 0.0699/ (1-0.088)
= 0.07664 m2
Therefore,
Ac = (π/4) x D2
0.07664= (π/4) x D2
D = 0.312 m
D = 32 cm
Aa = active area
Aa = Ac - 2Ad
= 0.0582 m2
= 0.24 m
= 0.256 m
Area of coming zone (Acz) = 2 x (Lw + Hw)
= 2 x( 0.24 + 0.256)
= 0.122 m2
Area of periphery waste (Awz) = 2 x (π/4 x Dc2 x α/360) – (π/4 x (Dc2 – 0.12)) x α/360
Θ = 2 sin-1(Lw/Dc)
A = 180 - 97.180
= 82.81o
= 3.61 x 10-3 m2
Perforated area Ap
= 0.067 m2
Ah = hole area
Ap = perforated area
Ah/Ap = 0.1
Ah = 0.1 x Ap
k2 = 90.113
hd = [0 + 90.113(1.174/893) 148.582]
= 105.91 mm
= 6 x 100 = 600 mm
= 8 x 100 = 800 mm
= 1400 mm
= 1.1 x 101.3
= 0.113 N /mm2
= 2.1418
But minimum thickness required for construction is 6 mm. so the minimum required
thickness of the cover is taken as 6 mm.
For stability of shell the column is divided into five parts and thickness is increased
from top to bottom of shell as 6,8,10,12,14 mm. for all other calculation thickness is used
the average thickness is 10 mm.
fap = PiDi/4(ts - C)
= 1.13 N/mm2
= 1600 mm
= 1.1 x 101.3
= 0.113 N /mm2
= 2.1418
But minimum thickness required for construction is 6 mm. so the minimum required
thickness of the cover is taken as 6 mm.
For stability of shell the column is divided into five parts and thickness is increased
from top to bottom of shell as 6,8,10,12,14 mm. for all other calculation thickness is used
the average thickness is 10 mm.
Axial stress due to pressure
fap = PiDi/4(ts - C)
= 1.13 N/mm2
= 1600 mm
= (320+10)
= 330 mm = 1.33m
= 169.77 N = 17.30 Kg
Ap = plate area
= (π/4) x Di2
= (π/4) x 0.322
= 0.0804 m2
Weight of plate = ρm x t x Ap
= 3.762 kg
Total weight of no of plate = no. of plate x weight of one plate
= 14 x 3.762
= 52.67 Kg
Stress due to weight of plate (fp) = (weight of plate)/plate thickness x (Di + ts)
= 0.0377 N/mm2
= 80.504 Kg
Stress due to total dead weight of vessel (fdw) = (Wt)/ts x (Di + ts)
= 80.504 / 10 x (320+10)
= 0.293 N/mm2
σL = Longitudinal stress
σh = circumferential stress
σL = Pi Di / 4 t
= 0.133 x 320 / 4 x 12
= 0.7533 N/mm2
σh = Pi Di / 2 t
= 0.133 x 320 / 2 x 12
= 1.506 N/mm2
D0 = Di + 2 x t
= 320 + 2 x 12
= 344 mm = 0.344 m
A flange at the bottom of the skirt transmits the load to the foundation. Skirt support is
Recommended for vertical vessel, as they do not impose concentrated loads on the shell;
They are particularly suitable for use tall columns subjected to wind loading. The skirt
Thickness must be sufficient to withstand the dead-weight loads and bending moments
Imposed on it by the vessel; it will not be under the vessel pressure. The maximum weight
= 833.128 N
= 833.128 / 14
= 59.509 N
= 59.509 x 0.8
= 47.6 N-m
= 4 x 47.6 / π x (50+12) x 12 x 50
= 0.356 N/mm2
CHAPTER
13. Site layout plans approved from State excise / central excise / MIDC if existing
All large sized plants to produce ethanol commissioned in Colombia. All plants are
on stream for commercial production.
1. Incauca S.A.
Turnkey design and supply of 250,000-1itres/day fuel ethanol plant using cane
molasses B+, juice and syrup.
It has an initial capacity of 600,000 tones a year or 2.5 rain liters per day.
Potential final capacity can be raised to 800,000 tones per year. Ground breaking
took place in September 2001 and by late 2003 the first trials had started.
5. Saj Globex, Mumbai Exporters of tomato paste, dairy products and also fuel
grade Ethanol. Location: 6, Rajgir Court, Kohinoor Road Dadar East, Mumbai,
Maharashtra, India, 400 014
NOTE: - Apart from these industries there are other industries in India, which
produces ethanol, but they are hydrous one so they are not mentioned
CHAPTER 9.
FAQ's-FUEL Ethanol
Fuel ethanol or anhydrous alcohol is produced by dehydration of spirit or extra
neutral alcohol. Ethanol used as part of the fuel, by with petrol, for a motor vehicle
is called fuel-ethanol. Rectified blending with petrol, for motor vehicle is fuel
ethanol.
What is an oxygenate?
Oxygenates are hydrocarbons that contain one or more oxygen atoms. The
primary oxygenates are alcohols and ethers, including: fuel ethanol, methyl tertiary
butyl ether (MTBE), ethyl tertiary butyl ether (ETBE), and tertiary amyl methyl
ether (TAME). Oxygenates are added to motor vehicle fuels to make them burn
more cleanly, thereby reducing toxic tailpipe pollution, particularly carbon
monoxide. Oxygenates are favoured not only for their vehicle emission benefits but
also their blending properties in motor gasoline (e.g., octane).
Many states in the US have been using 10% ethanol blend in gasoline (petrol)
for use in their cars. Brazil has been using up to 24 % ethanol in petrol. Engines of
cars do not need any change to use petrol with up to 24 % ethanol in it.
Ethanol has, apart from carbon and hydrogen, oxygen in it. This oxygen acts
as oxygenating agent during combustion in the IC engine of petrol cars, two-
wheelers and three wheelers thus preventing formation of carbon monoxide.
Gasoline with ethanol as anti-knocking agent will not cause any damage to the
engine.
Can it be used in Two-wheelers/Three-wheelers without any change in
vehicles?
Which are the other countries, which have promoted fuel ethanol?
Many states in the US have been using 10% ethanol blend in gasoline (petrol)
for use in their cars. Brazil has been using up to 24 % ethanol in petrol. Engines of
cars do not need any change to use petrol with up to 24 % ethanol in it. Fuel ethanol
programs have now been initiated in countries like Australia, Nepal, Columbia,
Poland, and Sweden etc.
Success factors
Fuel ethanol production and use is expected to rise strongly and it will go
along with an ever wider geographical spread. Ten years ago, there were only a
handful of countries producing ethanol. The largest was Brazil, where ethanol is
produced from molasses and sugar cane juice. The US produces mostly corn
alcohol and in France, sugar beets are being used. In some African countries, sugar
cane was processed into fuel alcohol.
In 2003, we there were some 13 countries spread over all five continents that
actually use ethyl alcohol as a fuel component. Looking into the future, the world
fuel ethanol map may look like this in ten years time: the Americas are likely to be
almost completely covered by fuel ethanol programs. Moreover, the green fuel will
likely be established in the European Union as well as in India, Thailand, China,
Australia and possibly Japan to name the largest nations.
Ethanol has been promoted because it has a positive net energy balance, which
means that the energy contained in a tonne of ethanol is greater than the energy
required to produce this tonne. Moreover, it has been demonstrated that it has a less
severe impact on the environment than conventional gasoline or other petroleum
derived additives. As such it is also less dangerous to health.
PLANT LOCATION
The location of plant can have further expansion a crucial effect on the
profitability of a product and the scope for further expansion. Many factors must be
considered selection a suitable site.
Marketing area
From material that are produced in bulk quantities where a cost of product is
relatively low and cost of transport is significant fraction the sale price the plant
should be located nearer to primarily market. This consideration will be less
important for low value production high price product.
Raw materials
Plant producing bulk chemicals is best located close to the source of major
raw materials.
Transport
Utilities
Plant must be located near a source of suitable quality. Process water may be
drawn from river, from wells or purchased from a local authority. General cooling
tower is used for process water cooling electrical power will be needed at all site
and can be taken fr.om electricity board For steam and power generation a
competitive price fuel must be available.
PLANT LAYOUT
A preliminary site layout has been sketched. The layout of the plant is decided
keeping the following factors in mind:
The Process units and ancillary buildings should be laid to give the most
economical flow of materials and personnel around the site. Hazardous processes
must be located at a safe distance from the buildings. Consideration must also be
given to future expansion of plant. The ancillary buildings and services required are
storage, maintenance, workshops, stores for maintenance, laboratories for quality
control, fire station, utilities, offices for general administration, canteens and car
parks.
When roughing the preliminary site layout the process units will normally be
cited first and arranged to give a smooth flow of materials through the various
processing steps from raw materials to final product. Storage process units are
normally placed at least 30m apart.
The cost of construction can be minimized by adopting a layout that gives the
shortest run of connecting pipe between equipment, and the least amount of
structural work.
Considerations In Layout:
1. Operation:
Equipments that need to have frequent operator attention should be near to the
control room The main plant also has access to road on three sides for safety
reasons.
2. Plant expansion:
3. Administrative Office:
They are close to the roads connecting main roads.Weigh bridge is located on
the road connecting the storage buildings.
They are located in the vicinity of the main plant so that they can be easily
accessed when required.
It is located on that side of the plant such that effluent water can be directly
discharged into the drain.
ENVIRONMENTAL EFFECT
Carbon Dioxide
Carbon dioxide from the burning of' fossil Fuels is the largest single source of
greenhouse gases from human activities, representing about half of all greenhouse
gas emissions. Use of 10% ethanol-blended Fuels results in a 6-10% CO2 reduction
and higher levels of ethanol can further reduce the net quantity of CO2 emitted into
the atmosphere. More CO2 is absorbed by crop growth than is released by
manufacturing and using ethanol. The carbon dioxide produced during ethanol
production and gasoline combustion is extracted from the atmosphere by plants for
starch and sugar formation during photosynthesis. It is assimilated by the crop in its
roots, stalks and leaves, which usually return to the soil to maintain organic matter,
or to the grain, the portion currently used to produce ethanol. Only about 40 percent
or less of the organic matter is actually removed from farm fields for ethanol
production. The rest is returned to the soil as organic matter, increasing fertility and
reducing soil erosion. With modern conservation farming practices, this soil
organic-matter will build up, representing a net removal of carbon dioxide from the
atmosphere, An increase by l% in the soil organic matter means atmospheric
reduction of over 40 tones of CO2 per hectare of farmland.
Carbon Monoxide
Because of its high octane rating, adding ethanol to gasoline can permit the
reduction or removal of aromatic hydrocarbons (such as benzene), and other
hazardous high-octane additives commonly used to replace tetra-ethyl lead in
Canadian gasoline.
Ozone
The alcohol has its origins in the Middle East. The Arabs said to have made
cosmetic. Paints by heating and vaporizing a mixture of compounds .The residue
was tested to paints eyelids and 'KOHL'. When they later heated wines, they gave
the same name as the cosmetic "KOHL" or "ALCOHOL" It was the genius of Louis
Pasteur, who showed the world, the scientific understanding of fermentation, the
action of all microorganism and hence the, economic control. He showed that life
process of minute organism and hence their economic control. He showed that life
processes of minute organism directly cause fermentation.
Environmental impacts
Quantitative evaluation
4. Eutrophication- diffuses aerial input of nutrients into soils and water bodies
caused by Eutrophication substances such as nitrous oxide or ammonia.
6. Ozone depletion- Loss of the protective ozone layer in the stratosphere through
certain gases such as chlorofluorocarbons (CFCs) or nitrous oxide.
7. Soil erosion / soil compaction- Soil erosion describes the soil transport caused by
water, wind and temperature influence
and causes the reduction of soil fertility. Soil compaction increases erosion and is
caused by the use of heavy agricultural machinery. It further more leads to a decline
of soil microorganisms and oxygen content and eventually decreasing bodies by the
input of nutrients and pesticides.
8. Impact on soil organic mailer- A positive soil organic matter balance is crucial
for the long-term preservation of soil fertility.
9. Resource depletion (water)-The total water consumption of a crop during its
cultivation influences above and below ground water reserves, which is important
in arid areas and areas with water shortages.
10. Impact on ground and surface water- pollution of ground and surface water.
APPENDIX
2)Hazchem code: 2 SE
1) IMDG code: 30
3)Class: 3.2
4)Packaging group:II/III
2)Class: 3
3) Packaging group:II/III
4)Packaging instructions:
- Cargo: 307
- Passenger: 305
- Cargo(max. capacity): 60
- Passenger(max. capacity): 5 L
2.Chemical hazards:
Ethanol is a flammable liquid and whose vapors can form ignitable and
explosive mixtures with air at room temperature. Thus an aqueous mixture
containing 30% ethanol can produce a flammable mixture of vapors and air at 29°C
and even one containing 5% alcohol can produce a flammable mixture at 62 °C.
Ethanol reacts vigorously with wide range of oxidizing materials and other
chemicals.
3.Biological hazards:
The liquid can affect the skin producing a dermatitis characterized by drying
and fissuring.
(d) Swallowing:
Large doses lead to alcoholism. Alcohol abuse and dependence can have
profound effect on workplace performance and tendency to accidents at work. The
presence of denaturants in industrial alcohol greatly increases the toxicity ingestion.
4.Carcinogenicity:
5.Mutagenicity:
7.First aid:
(a) Eyes:
Flush immediately with water or neutral saline solution for at least 10 mins.
Seak medical attention.
(b) Lungs:
Remove the victim to fresh air. If breathing is weak, irregular or has stopped,
apply artificial respiration. Oxygen may be beneficial.
(c) Mouth:
Do not induce vomiting. Avoid alcoholic drinks, as this will enhance toxic
effects. Seek immediate attention.
(d) Skin:
Remove contaminated clothing, rinse contaminated area with soap and water.
If skin irritatation persists, seek medical attention.
9.Disposal
Shut off all sources of ignition and wear protective clothing. Absorb small
spills onto paper and remove to safe area for burning or burying. Flush the
contaminated area with plenty of water. For large spills, absorb with water and
vermiculate and remove to a safe place for burning or burying. Incineration is the
recommended method of disposal
INDIAN STAANDARD 321 OF 1964
REQUIRMENTS FOR ABSOLUTE (ANHYDROUS) ALCOHOL
*For test methods, reference should be made to the appendix of the Indian standard
323 of 1959 for rectified spirit, (with the expansion of item marked ***as noted
below ).
** Test method c should be used, with the modification of Indian standard 323 of
1959.
*** Reference should be made to test method A of this standard.
Please note: The figures in parentheses for parts per million (ppm) do not appear in
the original standard, but have been added here to facilitate comparison with
standards of countries.
CHAPTER
COMPARISON
Yield of sweet sorghum per hectare is good than both i.e. 54-69 tons per ha.
And the sugar content is 7-12 % wt basis.
So we used sweet sorghum juice as raw material for production of ethanol and
our production cost of ethanol is comparatively less than others i.e. only 25 Rs/lit
and calculated market cost of ethanol is 17 Rs less other general market cost of
ethanol.
CHAPTER
CONCLUSION
Ethanol was initially used for potable purpose and as solvent in chemical
industries.After few, decades ethanol is started to use as fuel to fulfill the increasing
demand of fuel. The crude oil resources are not renewable and will exhaust within
next few decades, so ethanol can be used as renewable energy resource due to its
nonpolluting properties obtained from biomass. The ethanol in tile end is blended
with gasoline to improve vehicle performance and reduce air pollution. As India has
to face the significant problem of oil lacking Ethanol should be an alternative fuel
or additive.
Ethanol is best produced from lower value grains such as barley, corn and
feed wheat from this we conclude that there are number of method of production of
ethanol of which fermentation is the best one. As the biomass as raw material of
method of production is available in abundant quantity, locally which is cheaper
and renewable also. Production cost is low and cost of ethanol in market is 17 Rs
also less than general ethanol cost of market. Between calculated market cost of
Ethanol is nearly 25 Rs. This ethanol can be used various purposes as solvent
intermediate of other chemicals or fuel.
Fuel ethanol will not go away in the foreseeable future. On the contrary, world
production is set to continue to grow vigorously. There are various fuel ethanol
projects in the pipelines around the world and, even though their implementation
may be delayed, there is enough momentum in the political arena to push them
through. Political support is there and in many instances the industry and the
authorities are very close to reaching an agreement over a viable framework of
support for fuel ethanol. World trade is likely to grow as well but the rate of growth
will depend on several factors. First of all, the sugar and alcohol economics as has
been illustrated in the case of Brazil. Unless the strong link between sugar and
alcohol production can be severed an additional element of volatility will be in the
equation.
The same applies to the corn and corn products market in the United States,
even though this relationship is not very obvious at present because of the depressed
state of the corn sweeteners market. Of course, such a strong increase in import
requirements would have to be preceded by an increase in output. Indeed there are
several projects under way which could facilitate such a development. From above
Chart it may be gleaned that most of the growth will happen in the United States
under the renewable fuels standard. Growth would also be strong in Brazil, mostly
because of the promises in the export market
The EU will be the third largest producer of fuel ethanol by 2005 and the rates
of growth would be considerably above those seen in Brazil and the United States.
India on other hand is developing on this field to great height.
Farmers are part of the ethanol gold rush. But now, the field is dominatedby
heavyweights, including agribusiness giants such as ADM and Cargill and hungry
corporate upstarts such as Vera Sun and US Bio Energy. Even ethanol novices are
getting in, from billionaire Bill Gates to hot-money Wall Street investors.
All this has made the outlook for fuel ethanol bright, and strong rates of growth in
both production and trade can be expected for the next several years.