Industry Overview
Ethanol is a versatile chemical produced through the fermentation of saccharine, starchy, and cellulosic raw materials. Historically, alcoholic beverages were discovered through the natural fermentation of materials such as honey and fruit juices. Ethyl alcohol is a volatile, flammable, clear and colorless liquid whose properties are strongly influenced by its hydroxyl group, which contributes to polarity and intermolecular hydrogen bonding.
The principal raw material categories for alcohol production include saccharine materials such as molasses, sugar beet and sugar cane; starchy materials such as potatoes and cereal grains; and cellulosic materials such as wood, agricultural residues and waste sulfite liquor. Starchy materials require conversion into fermentable sugars before fermentation.
The report focuses particularly on ethanol production from broken rice and other grains. The described technology can separate rice protein before utilizing the starch fraction for ethanol, maltodextrin and related products. This approach is intended to produce food-grade rice protein with purity of more than 80%, while utilizing the remaining starch for downstream processing.
The report covers ethanol properties, applications, Indian ethanol production and market conditions, ethanol blending, government initiatives and policies, grain-based and molasses-based distilleries, manufacturing processes, fermentation, distillation, biomass-based ethanol, pollution control, waste-water treatment, and suppliers of key raw materials and equipment.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 150 KL./MT./Day |
| Land & Building (80,000 sq.mt.) | Rs. 46.74 Cr |
| Plant & Machinery | Rs. 60 Cr |
| Working Capital for 2 Months | Rs. 30.44 Cr |
| Total Capital Investment | Rs. 141.63 Cr |
| Rate of Return | 37% |
| Break Even Point | 54% |
Content Index
- INTRODUCTION
- PROPERTIES OF ALCOHOL
- PHYSICAL PROPERTIES:-
- TABLE: PHYSICAL PROPERTIES OF ETHANOL:
- SOURCES OF ALCOHOL
- USES AND APPLICATION
- BROKEN RICE
- INDIAN SCENARIO OF ETHANOL
- TOTAL ETHANOL PRODUCTION CAPACITY IN INDIA
- IS 223.87 CR LT PER ANNUM
- ETHANOL CAPACITY BREAKUP BASED ON PRIVATE AND COOPERATIVE COMPANIES IS AS FOLLOWING:
- ETHANOL GENERATION FROM DIFFERENT SOURCES
- B HEAVY MOLASSES
- NATIONAL POLICY ON BIOFUELS
- GOING FORWARD
- ETHANOL PRODUCTION CAPACITY MAY INCREASE TO 375-400 CR LITRES: ISMA
- PRODUCTION VOLUME OF ETHANOL IN INDIA
- PRODUCTION VOLUME OF ETHANOL IN INDIA FROM 2011 TO 2020 (IN MILLION LITERS)
- MARKET OVERVIEW OF ETHANOL
- PETROL CONSUMPTION
- CONSUMPTION, PRODUCTION, IMPORT AND EXPORT OF ETHANOL
- INDIA – U.S. GRAINS COUNCIL
- KEY FACTS
- POLICY
- TRADE
- CHALLENGES
- MARKET OUTLOOK
- OVERVIEW OF DISTILLERY IN INDIA
- MANUFACTURERS/SUPPLIERS OF ETHANOL
- ETHANOL BLENDING IN INDIA
- PROCUREMENT OF ETHANOL
- GOVERNMENT INITIATIVES
- CCEA RECOMMENDATIONS
- 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
- ETHANOL POLICY AND PROGRAMS IN INDIA
- INDIA’S BIOFUEL POLICY: SALIENT FEATURES & RECENT DEVELOPMENTS
- ADDED FACTS:
- IMPEDIMENTS
- INSTITUTIONAL MECHANISM
- MARKET POSITION OF ETHANOL IN INDIA
- ETHANOL
- INDIAN 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:-
- CONTENTS OF THE CELL:-
- YEAST SPARES:-
- B.I.S. SPECIFICATION
- MANUFACTURING PROCESS OF ETHANOL FROM GRAIN
- LIQUEFACTION
- FERMENTATION
- DISTILLATION
- DISTILLERS DRY GRAIN & SOLUBLES (DDGS)
- PROCESS FLOW DIAGRAM
- SEQUENCES IN ETHANOL PRODUCTION
- PROCESS IN DETAILS FOR ALCOHOL PRODUCTION
- (A) ALCOHOL PRODUCTION FROM BROKEN RICE AND OTHER GRAIN
- 1) GRAIN HANDLING AND MILLING:-
- FERMENTATION:
- DISTILLAITON -
- TECHNOLOGY FOR ETHANOL FROM BROKEN RICE OR OTHER GRAIN
- 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
- ETHANOL FROM BIOMASS FEED STOCKS
- MANUFACTURE OF ETHANOL FROM BIOMASS
- PRETREATMENT OF LIGNOCELLULOSIC BIOMASS
- DETOXIFICATION OF BIOMASS HYDROLYZATES
- CELLULOSE HYDROLYSIS
- FERMENTATION STEP
- MOLASSES BASED DISTILLERY
- MANUFACTURING PROCESS OF MOLASSES BASED DISTILLERY
- THE FERMENTATION CONSISTS OF FOLLOWING STEPS;
- DILUTION
- YEAST PROPAGATION
- AEROBIC FERMENTATION:
- ANAEROBIC FERMENTATION
- YEAST PROPAGATION
- FERMENTATION
- DISTILLATION
- POLLUTION CONTROL
- WASTE WATER TREATMENT
- SOLD / HAZARDOUS WASTE MANAGEMENT AND DISPOSAL
- 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
- 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)
Frequently Asked Questions
Ethanol can be produced from saccharine, starchy, and cellulosic raw materials. Saccharine materials include molasses, sugar beet and sugar cane, while starchy materials include potatoes and cereal grains such as rice. Cellulosic feedstocks include wood, agricultural residues and certain industrial waste streams. Saccharine materials can generally be fermented directly, whereas starch and cellulose require conversion into fermentable sugars before the fermentation stage.
Ethanol from broken rice is produced by converting the grain starch into fermentable sugars followed by fermentation and distillation. The process described in the report includes grain handling and milling, starch processing, fermentation and distillation. The technology also describes separating rice protein before utilizing the starch fraction, allowing the raw material to be processed into ethanol and other starch-based products. Process conditions and equipment selection depend on the feedstock characteristics and required product quality.
The major stages are grain handling and milling, starch liquefaction, fermentation and distillation. Grain is prepared for processing before its starch is converted into a form suitable for fermentation. Yeast then converts fermentable sugars into ethanol, after which distillation separates and concentrates the alcohol. Grain-based plants may also generate co-products such as Distillers Dry Grain & Solubles (DDGS), depending on the process configuration and downstream separation system.
Fermentation converts fermentable sugars into ethanol through the action of microorganisms, principally yeast in conventional alcohol production. For starchy feedstocks, starch must first be converted into fermentable sugars. The report discusses yeast propagation, aerobic and anaerobic fermentation, and fermentation as a core stage of both grain-based and molasses-based distillery processes. Control of fermentation conditions is important for maintaining process efficiency, product quality and consistent downstream distillation performance.
An ethanol plant can require grain-handling and milling equipment, silos, hammer mills, reactors, cooling towers, boilers, D.G. sets, condensers, distillation columns and scrubbers. The exact equipment configuration depends on the selected feedstock, process technology, plant capacity and product specifications. The report separately identifies suppliers of these equipment categories, reflecting their importance in establishing and operating a grain-based or distillery project.
Pollution control is essential because distillery operations can generate wastewater, process residues and other wastes that require appropriate treatment and management. The report includes dedicated sections on pollution control, waste-water treatment, and solid or hazardous waste management and disposal. A properly designed environmental management system helps control emissions and effluents, supports regulatory compliance and improves resource utilization through appropriate treatment, recovery and disposal practices.
The report provides extensive coverage of ethanol blending in India, including procurement, government initiatives, CCEA recommendations, benefits and challenges of the Ethanol Blended Petrol programme, policy and biofuel programmes, and issues associated with diverting sugarcane for ethanol production. It also examines market position, production, supply, consumption and trade. The report discusses both the potential benefits and the challenges associated with expanding ethanol use as a fuel component.
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