Industry Overview
The ethanol industry has long been associated with the fermentation of saccharine materials to produce ethyl alcohol, a versatile chemical used as a beverage ingredient, solvent, germicide, antifreeze, fuel, depressant, and chemical intermediate. Ethanol is the IUPAC name for ethyl alcohol, while the term alcohol is used generically for a group of substances with similar characteristics.
This project focuses on the production of ethanol from broken rice and other grains, with an integrated approach that can first separate high-quality food-grade rice protein and subsequently utilize starch for ethanol, maltodextrin, and related products. The process is intended to produce rice protein with purity of more than 80%, while offering characteristics such as non-allergenicity and non-genetically modified origin. The project also covers grain handling, milling, liquefaction, fermentation, distillation, DDGS production, process technology, pollution control, wastewater treatment, plant layout, and equipment requirements.
The report further examines India's ethanol market, ethanol blending, biofuel policies, raw-material availability, second-generation ethanol, market outlook, procurement, government initiatives, and the potential economic, agricultural, environmental, and socio-economic benefits associated with ethanol production from broken rice.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 100 KL/Day |
| Land & Building (15 Acres) | Rs. 30.06 Cr |
| Plant & Machinery | Rs. 39.35 Cr |
| Working Capital for 2 Months | Rs. 21.95 Cr |
| Total Capital Investment | Rs. 94.29 Cr |
| Rate of Return | 41% |
| Break Even Point | 54% |
Content Index
- INTRODUCTION
- PROPERTIES OF ALCOHOL
- PHYSICAL PROPERTIES
- TABLE: PHYSICAL PROPERTIES OF ETHANOL:
- SOURCES OF ALCOHOL
- USES AND APPLICATION
- NEW POLICY ON BIOFUELS ALLOWS BLENDING OF ETHANOL
- BROKEN RICE
- OVERVIEW OF BIO ETHANOL IN CHHATTISGARH
- CHHATTISGARH’S PADDY PRODUCTION (LAKH TONNE):
- BENEFITS OF BIO ETHANOL IN CHHATTISGARH
- BOOST TO INDIAN ECONOMY:
- BENEFIT TO FARMERS:
- ENVIRONMENTAL BENEFITS WITH THE PROJECT:
- BOARD
- SOCIO ECONOMIC BENEFITS:
- INTEREST SUBSIDY
- FIXED CAPITAL INVESTMENT SUBSIDY
- ELECTRICITY DUTY EXEMPTION
- EXEMPTION IN LAND PREMIUM ON ALLOTMENT OF LAND IN INDUSTRIAL AREAS/INDUSTRIAL PARKS
- PROJECT REPORT SUBSIDY
- QUALITY CERTIFICATION SUBSIDY
- MARKET OVERVIEW OF ETHANOL IN INDIA
- SHORTFALL IN ETHANOL SUPPLIES
- FLUCTUATIONS IN SUPPLY OF RAW MATERIAL
- SECOND GENERATION ETHANOL PRODUCTION
- GLOBAL OUTLOOK
- CONCLUSION
- PETROL CONSUMPTION
- SCENARIO OF ETHANOL
- INDIA – U.S. GRAINS COUNCIL
- ETHANOL MARKET OVERVIEW
- KEY FACTS
- TARGET:
- CONSUMPTION:
- POLICY
- TRADE
- CHALLENGES
- MARKET OUTLOOK
- OVERVIEW OF DISTILLERY IN INDIA
- NEWS BRANDS IN PREMIUM CATEGORY TO DRIVE GROWTH MOMENTUM
- WHITE SPIRITS TO GAIN SHARE IN LONGER RUN
- INDUSTRY OUTLOOK
- 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
- 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
- INDIA. ETHANOL PRODUCTION, SUPPLY AND CONSUMPTION
- PRODUCTION
- INDIA: ETHANOL USED AS FUEL AND OTHER INDUSTRIAL CHEMICALS (MILLION LITERS)
- CONSUMPTION
- TRADE
- IMPORTS
- EXPORTS
- INDIA ETHANOL IMPORTS, IN MILLION LITERS
- INDIA ETHANOL EXPORTS, IN MILLION LITERS
- 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
- 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
- POLLUTION CONTROL
- WASTE WATER TREATMENT
- SOLD / HAZARDOUS WASTE MANAGEMENT AND DISPOSAL
- PLANT LAYOUT
- 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
- 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 production from broken rice is a grain-based process in which the starch present in broken rice is converted into fermentable sugars and subsequently fermented to produce ethanol. The process generally involves grain handling and milling, liquefaction, fermentation, and distillation. The project report also describes an integrated approach in which rice protein can be separated before the starch is utilized for ethanol and other starch-based products. This approach can support better utilization of the raw material and the production of additional value-added products.
The main stages in grain-based ethanol manufacturing are grain handling and milling, liquefaction, fermentation, and distillation. Grain is prepared to make its starch accessible, after which enzymatic or other suitable treatment converts starch into fermentable sugars. Yeast fermentation converts these sugars into ethanol and other products. Distillation then separates and concentrates the ethanol. Depending on the plant configuration, the process may also include DDGS recovery, wastewater treatment, pollution-control systems, and supporting utilities.
Broken rice can be suitable for ethanol production because it contains starch that can be processed into fermentable sugars. Using broken rice also provides an opportunity to utilize a lower-value grain fraction in an industrial process. In an integrated facility, the report proposes separating rice protein before using the starch for ethanol and other products. This can improve raw-material utilization and create additional value streams, provided that the process is technically and economically appropriate for the intended plant configuration.
Fermentation converts fermentable sugars into ethanol through the action of microorganisms, typically yeast. Before fermentation, the starch-containing raw material must undergo processing that makes suitable sugars available to the microorganism. Control of factors such as temperature, pH, nutrient availability, contamination, and fermentation time is important for consistent process performance. The resulting fermented material is subsequently sent to distillation, where ethanol is separated and concentrated for the required application.
A grain-based ethanol plant generally requires equipment for raw-material handling, milling, processing, fermentation, distillation, utilities, and environmental management. The report specifically identifies silos, hammer mills, cooling towers, reactors, D.G. sets, boilers, condensers, distillation columns, and scrubbers among the equipment and supplier categories. The final equipment configuration depends on plant capacity, process technology, raw-material characteristics, product specifications, energy integration, and environmental-control requirements.
Ethanol is used in fuel blending, alcoholic beverages, solvents, germicidal applications, antifreeze formulations, and as a chemical intermediate. Its combination of chemical and physical properties gives it broad industrial utility. In the context of the project, particular attention is given to ethanol as a biofuel and its role in ethanol blending with petrol. The report also considers industrial chemical applications, market development, procurement, trade, and the broader outlook for ethanol production in India.
Environmental considerations for an ethanol plant include wastewater treatment, pollution control, management of solid and hazardous waste, emissions control, and responsible handling of process residues. Grain-based ethanol production generates process streams that require appropriate treatment and disposal or recovery systems. The project report includes dedicated sections on pollution control, wastewater treatment, and solid or hazardous waste management and disposal. Proper plant design should integrate these systems with production operations to support regulatory compliance and efficient resource use.
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