ETHANOL FROM BROKEN RICE
[CODE 4036
Ethanol is one of the group of chemical compounds with molecules that contain a hydroxyl group bonded to a carbon atom. Ethanol is manufacturing through the fermentation process of agricultural products such as rice, corn, sugarcane, and others. Ethanol is known to have antibacterial and antifungal properties, and thus is used in many hand sanitizers and medical wipes. Ethanol is also used as a disinfectant and an antiseptic. In cases related to methyl alcohol poisoning and glycol poisoning, ethanol is used as an antidote. There exist various medicines that are insoluble in water and these are dissolved in ethanol. Ethanol is also used as a solvent for mouthwashes and analgesics.
The bioconversion of starch from rice is a two-step process. The involved primary step is scarification, where the starch is converted into sugar using amyl lytic microorganism or enzymes such as amylase and glucoamylase. The second step is fermentation where sugar is converted into ethanol using Saccharomyces Cerevbisiae. The direct fermentation process involves the use of amyl lytic yeasts, and this offers poor economic feasibility. The use of amyl lytic yeast species for the industrial use is indeed restricted because of the low ethanol tolerance.
The involved manufacturing process has to do with crushing of grains which are then mashed with water. This is then boiled for the scarification to filter and separate the available sugar. This is then followed by the second step which involves adding the yeast for the fermentation which is then maintained for four days. The produced ethanol is then separated using the distillation tower system. The distilled ethanol is then dehydrated by the molecular dehydration system. When certain species of yeast (such as Saccharomyces Cerevbisiae) metabolize sugar in reduced oxygen conditions, they are known to then produce carbon dioxide and ethanol.
The process of fermentation involves culturing yeast under favorable thermal conditions to produce alcohol. This process involves moderate temperature conditions of 35-40 degrees. It is known through research that the most ethanol tolerant strains of yeast can survive up to approximately 18% ethanol by volume.
It should be therefore understood that the conventional process for ethanol production involves liquefaction followed by simultaneous fermentation and saccharification under the yeast fermentation conditions. The liquefaction is carried out using the thermostable alpha amylase and the SSF with the glucoamylase with additional side activities of protease and pullulanase under the yeast fermentation conditions. It is also important to measure the enzyme efficacy in the liquefaction process which deals with fermentable sugar and liquefact solubility which is measured at the end fo the liquefaction process. Thus, the conventional process for manufacturing ethanol from broken rice is indeed an important process.
It is well understood that that global ethanol market is highly diverse and has witnessed rapid growth over the past 10 years due to rapid funding for biofuel by the regulating bodies. Biofuel is considered to be eco-friendly and is an alternative to gasoline. Furthermore, ethanol is also responsible for reducing the carcinogenic and particulate emissions by 65%-70% . However, the rising raw material prices are the most important factors that bar the growth of the ethanol market at a global level.
COST ESTIMATION
Plant Capacity 50 KL./Day
Land & Building (24,000 sq.mt.) Rs. 14.14 Cr
Plant & Machinery Rs. 27.38 Cr
Working Capital for 2 Months Rs. 8.85 Cr
Total Capital Investment Rs. 56.37 Cr
Rate of Return 30%
Break Even Point 51%
INTRODUCTION
PROPERTIES OF ALCOHOL
PHYSICAL PROPERTIES
TABLE: PHYSICAL PROPERTIES OF ETHANOL
SOURCES OF ALCOHOL
USES AND APPLICATION
BROKEN RICE
MARKET OVERVIEW OF ETHANOL IN INDIA
ETHANOL MARKET (FUEL AND INDUSTRIAL)
ETHANOL MARKET (MILLION LITERS)
TRADE
SHORTFALL IN ETHANOL SUPPLIES
FLUCTUATIONS IN SUPPLY OF RAW MATERIAL
SECOND GENERATION ETHANOL PRODUCTION
GLOBAL OUTLOOK
CONCLUSION
PETROL CONSUMPTION
OVERVIEW OF DISTILLERY IN INDIA
NEWS BRANDS IN PREMIUM CATEGORY TO DRIVE GROWTH MOMENTUM
WHITE SPIRITS TO GAIN SHARE IN LONGER RUN
INDUSTRY OUTLOOK
ALCOHOL BASED INDUSTRY IN INDIA
MANUFACTURERS/SUPPLIERS OF ETHANOL
LIST OF FEW DISTILLERIES IN INDIA
MANUFACTURERS/SUPPLIERS OF ETHANOL
ETHANOL BLENDING IN INDIA
PROCUREMENT OF ETHANOL
GOVERNMENT INITIATIVES
CCEA RECOMMENDATIONS
NATIONAL POLICY ON BIOFUELS 2018
BENEFITS OF EBP
CHALLENGES OF EBP
PROBLEMS WITH DIVERTING CANE TO PRODUCE ETHANOL
CRITICISM
WHY ETHANOL BLENDING IN PETROL MIGHT NOT WORK FOR INDIA
IMPACT ON NET SOWN AREA
WAY FORWARD
INDIA’S BIOFUEL POLICY: SALIENT FEATURES & RECENT DEVELOPMENTS
ADDED FACTS:
IMPEDIMENTS
INSTITUTIONAL MECHANISM
SUPPLY AND DEMAND OF ETHANOL
INDIA. ETHANOL PRODUCTION, SUPPLY AND CONSUMPTION
PRODUCTION
INDIA: ETHANOL USED AS FUEL AND OTHER INDUSTRIAL
CHEMICALS (MILLION LITERS)
CONSUMPTION
TRADE
IMPORTS
EXPORTS
TRADE AND TECHNICAL NAMES
UNITS OF MEASUREMENT
ORGANISM USED IN THE PRODUCTION OF ALCOHOL
TYPE OF YEAST
SHAPE AND SIZE OF CELLS
CONTENTS OF THE CELL
YEAST SPARES
B.I.S. SPECIFICATION
SEQUENCES IN ETHANOL PRODUCTION FROM BROKEN RICE
BROKEN RICE HANDLING SYSTEM
FLOUR WEIGHING AND BATCHING
SLURRY PREPARATION
COOKING
ETHANOL FRODUCTION FROM BROKEN RICE/GRAIN
PROCESS FLOW DIAGRAM
PROCESS IN DETAILS FOR ALCOHOL PRODUCTION
(A) ALCOHOL PRODUCTION FROM BROKEN RICE
1) GRAIN HANDLING AND MILLING
FERMENTATION:
DISTILLAITON-
TECHNOLOGY FOR ETHANOL FROM BROKEN RICE
ACID HYDROLYSIS OF DAMAGED RICE
INCUBATION AT VARYING CONDITIONS
ACID HYDROLYSIS AT VARYING TEMPERATURES
ACID HYDROLYSIS AT VARYING PHYSICAL TREATMENT
THERMO CHEMICAL PROCESS IN HYDROLYSIS
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF BROKEN RICE
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF SILO
SUPPLIERS OF HAMMER MILLS
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF REACTORS
SUPPLIERS OF D.G. SETS
SUPPLIERS OF BOILERS
SUPPLIERS OF CONDENSER
SUPPLIERS OF DISTILLATION COLUMN
SUPPLIERS OF SCRUBBER
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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