ETHANOL FROM RECTIFIED SPIRIT
[CODE NO.3470]
Ethyl alcohol
Commonly called alcohol has been described as one of the most exotic oxygen containing organic chemicals known because of its unique properties as solvent, beverage, combustible liquid, germicide and as building block or chemical intermediate for a host of organic chemicals. As a beverage it has been produced and utilized unknowingly as early as 4000 years ago by Pharaohs in Egypt.
In India ethyl alcohol has been conventionally and economically produced by fermentation of a byproduct of sugar industry i.e. molasses. Although ethyl alcohol can also be produced from other carbohydrate containing materials by fermentation such as sugar, cassava (tapioca), rice, wheat, barley and other grains, the economics led to its production from molasses, because of its easy availability at a low price. A flourishing distillery industry grew for production of both potable and industrial alcohol from molasses.
After price and distribution decontrol of molasses, its price shot up. The price of molasses increased from Rs.200 per tone to anywhere between Rs.1500 to Rs. 4500 per tonne. However, the molasses price has come down. The price of molasses fluctuates now. The price came down to as low as Rs. 50 per tone and increased some times back during lean period to Rs. 1000 per tone. The average molasses price however is around Rs. 200-300 per tone.
Ethyl alcohol is available as an azeotropic constant boiling liquid in which the content of ethyl alcohol is about 95%. Distillation of this 95%. Distillation of this 95% alcohol can not make it more concentrated as the boiling point of this mixture is less than that of 100% ethyl alcohol.
Alcohol can be used as motor fuel with considerable success. For all the uses of ethyl alcohol mentioned above 95% alcohol can be used except for as MOTOR FUEL. The ethyl alcohol should be anhydrous or 100% for its use as a component for blending in motor fuel.
(a) Product characteristics and specification
(b) Market survey
(c) Manufacturing process
(d) Plant capacity, raw materials and utilities
(e) Project implementation and schedule
(f) Project economics including project cost, production cost,
profitability, cash flow statements, breakeven point, payback
period and internal rate of return.
Ethanol is a generic name for Ethyl Alcohol which can be produced by fermenting sugarcane molasses or juice. It is a volatile, flammable and colourless liquid. Ethyl Alcohol has three principle usages:
1. Portable – Portable alcohol is used in varying ratios and blends in the production of liquor. There are two main grades of portable alcohol and they are:
a) Rectified Spirit or RS, which has a purity of 95%.
b) Extra Neutal Alcohol is produced by redistilling RS and is used in the production of portable
2. Industrial – Industrial Alcohol is produced by denaturing alcohol with bitterants and thereby making it unfit for human consumption. This form of alcohol is called Special Denatured Spirit.
3. Fuel Ethanol – This grade of alcohol is also termed as Anhydrous Alcohol
Usage of ethanol-blended gasoline began in the late 1970s. Environmentally, the use of ethanol blends has assisted in reducing carbon monoxide emissions. In the United States, one out of every eight gallons of gasoline sold contains ethanol. Most of this ethanol is purchased as blends of 10% ethanol and 90% gasoline, known as E10, and is used as an octane enhancer to improve air quality.
COST ESTIMATION
Plant Capacity : 30.00 KL/day
land & Building (12000 Sq.Mtr) : Rs. 8.95 Cr
Plant & Machinery : Rs. 7.00 Cr
Working Capital for 2 Months : Rs. 7.00 Cr
Total Capital Investment : Rs. 24.55 Cr
Rate of Return : 15%
Break Even Point : 66%
INTRODUCTION
ETHYL ALCOHOL
PRODUCT CHARACTERISTICS
PRODUCT
TABLE : PHYSICAL PROPERTIES OF ETHYL ALCOHOL
TABLE : REQUIREMENTS FOR ABSOLUTE (ANHYDROUS)
ALCOHOL (AS PER BIS)
TABLE : ALCOHOL CHEMISTRY
MERCK INDEX ENTRY
TABLE : SPECIFICATION OF ALCOHOL STANDARDS IN INDIA
TABLE : RESPECTIVE VOLUMES OF ALCOHOL AND WATER
AND SPECIFIC GRAVITY
TABLE TYPICAL ETHYL ALCOHOL SPECIFICATIONS
HEALTH AND SAFETY CONSIDERATION
TABLE: ETHYL ALCOHOL VAPOUR CONCENTRATION AND ITS EFFECTS
IN MAN*
SPECIFICATION OF RECTIFIED SPIRIT
EXPORT QUALITY OF RECTIFIED SPIRIT WITH STRENGTH
MARKET POSITION OF ETHANOL
GLOBAL MARKET POSITION OF ETHANOL
MARKET SITUATION
PROJECTION HIGHLIGHTS
FIGURE. EVOLUTION OF ETHANOL BLENDING IN GASOLINE FUELS
AND OF BIODIESEL BLENDING IN DIESEL FUELS
FIGURE. ASSUMPTIONS CONCERNING THE US BIOFUEL MANDATES
POST-2017
FIGURE. BIOFUEL PRICES TO TREND UPWARD
ETHANOL
PRODUCTION
FIGURE. DEVELOPMENT OF THE WORLD ETHANOL MARKET
FIGURE. SHARE OF FEEDSTOCK USED FOR BIOFUEL PRODUCTION
BOOKMARK NOT DEFINED.
FIGURE. EVOLUTION OF THE REGIONAL DISTRIBUTIONS
OF WORLD ETHANOL USE
BIODIESEL
MANUFACTURERS/SUPPLIERS OF ETHANOL
MANUFACTURING PROCESS OF ETHANOL FROM RECTIFIED SPRIT
PROCESS FLOW DIAGRAM
AZETRPIC DISTILLATION TO MANUFACTURE 100% ETHANOL
OTHER PROCESS TO MANUFACTURE ETHANOL
MANUFACTURING PROCESS FLOW DIAGRAM OF ETHANOL
BIOETHANOL
BIOMASS FOR BIO-ETHANOL
FEEDSTOCK GALLONS ETHANOL/DRY TON
REVIEW OF TECHNOLOGIES FOR MANUFACTURE OF BIOETH
DEVELOPMENTS IN BIOETHANOL PRODUCTION TECHNOLOGIES
PROCESS STEPS
TECHNOLOGIES
1. CONCENTRATED ACID HYDROLYSIS
2. DILUTE ACID HYDROLYSIS
3.ENZYMATIC HYDROLYSIS
CELLULOSE ENZYME RESEARCH
BIOMASS GASIFICATION AND FERMENTATION
DEVELOPMENT OF MICROBES
RAW MATERIALS FOR MAKING BIOETHANOL
ANHYDROUS ETHANOL POTENTIAL FOR GASOLINE BLENDING
THIS STATISTICS SHOW A DIRECT POTENTIAL.
GOVT. POLICY
THE GAZETTE OF INDIA: EXTRAORDINARY [PART I- SEC. I] MINISTRY
OF PETROLEUM AND NATURAL GAS RESOLUTIONNEW DELHI, 3RD
SEPTEMBER, 2002 NO. P-45018/28/2000-C. C. - 62
LIST OF LICENSES & PERMISSIONS REQUIRED FOR ETHANOL PLANT
MANUFACTURE OF ETHANOL FROM REACTIFIED SPIRIT IN DETAILS
MATERIAL SAFETY DATA SHEET OF ETHANOL
SUPPLIERS OF RAW MATERIALS
RECTIFIED SPIRIT
BENZENE
SUPPLIERS OF PACKAGING MATERIALS
SUPPLIERS OF PLANT & MACHINERIES
DISTILLATION COLUMN
CONDENSER
STORAGE VESSELS
BOILERS
MATERIAL HANDLING EQUIPMENTS
INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS
LABORATORY EQUIPMENTS
COOLING TOWER
PACKAGING MACHINE
APPENDIX – A:
1. COST OF PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET
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