Industry Overview
The processing of broken rice can be integrated to produce ethanol, alcohol, maltodextrin and related products while first separating rice protein from the raw material. This approach enables recovery of high-quality food-grade rice protein with purity of more than 80%. The report describes the protein as non-allergenic and non-genetically modified, with good absorption characteristics compared with soy protein and other proteins.
Alcoholic beverages have been produced for a very long time, with early fermentation likely discovered accidentally when naturally occurring sugars in materials such as honey, fruit juice and tree sap fermented under suitable conditions. The term “alcohol” was initially applied to spirits of wine and ethyl alcohol and is now used for a broader series of substances with similar characteristics.
Ethyl alcohol is the active constituent of intoxicating liquor produced through fermentation of saccharine materials. It is also a versatile oxygen-containing organic chemical with applications as a solvent, germicide, beverage ingredient, antifreeze, fuel, depressant and chemical intermediate. Ethanol is the IUPAC name for the chemical, while the generic term “alcohol” has historical roots in the Arabic words “al” and “kohl.”
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 150 KL/Day |
| Land & Building (84,000 sq.mt.) | Rs. 31.08 Cr |
| Plant & Machinery | Rs. 223.98 Cr |
| Working Capital for 2 Months | Rs. 47.43 Cr |
| Total Capital Investment | Rs. 305.62 Cr |
| Rate of Return | 38% |
| Break Even Point | 50% |
Content Index
- INTRODUCTION
- PROPERTIES OF ALCOHOL
- PHYSICAL PROPERTIES
- TABLE: PHYSICAL PROPERTIES OF ETHANOL:
- SOURCES OF ALCOHOL
- USES AND APPLICATION
- OVERVIEW OF ETHANOL IN INDIA
- ENERGY SECURITY
- COMPATIBLE VEHICLES
- IMPACT ON EMISSIONS
- GLOBAL EVIDENCES
- POLICY OF ETHANOL IN INDIA
- ETHANOL SUPPLY PROJECTION IN INDIA
- ETHANOL PRODUCTION CAPACITIES
- MODIFIED INTEREST SCHEME TO ENHANCE PRODUCTION CAPACITY OF ETHANOL
- AVAILABILITY OF FEED-STOCKS FOR PRODUCTION OF ETHANOL
- TABLE: AVAILABILITY OF FEED-STOCK FOR ETHANOL IN THE COUNTRY (IN LAKH TON)
- ESTIMATION OF SUPPLY AND CAPACITY AUGMENTATION
- TABLE: YEAR WISE & SECTOR WISE ETHANOL PRODUCTION PROJECTIONS
- TABLE: ETHANOL CAPACITY REQUIREMENT BY YEAR AND RAW MATERIAL
- TABLE: ETHANOL CAPACITY AUGMENTATION (20% BLENDING BY 2025-26)
- FUEL ETHANOL DEMAND IN INDIA
- GROWTH IN VEHICLE POPULATION
- TABLE: PROJECTED ADDITION OF GASOLINE VEHICLES (IN LAKHS)
- DEMAND PROJECTIONS OF GASOLINE
- TABLE: GASOLINE DEMAND PROJECTIONS
- DEMAND PROJECTION OF FUEL ETHANOL
- TABLE: ETHANOL DEMAND PROJECTION
- ADDITIONAL MODELING OF ETHANOL DEMAND SCENARIOS
- 1. CONSERVATIVE (LOW EVS) –
- 2. BUSINESS-AS-USUAL (BAU, MEDIUM EVS) –
- 3. LOW CARBON (HIGH EV UPTAKE) –
- ETHANOL BLENDING PROGRAMME IN INDIA
- NODAL AGENCY FOR ETHANOL PRODUCTION
- TABLE: FEEDSTOCK COST AND ETHANOL YIELD
- TABLE: QUANTITY SUPPLIED (ETHANOL) AND %BLENDING TRENDS
- MANUFACTURERS/SUPPLIERS OF ETHANOL
- 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
- MASHING
- 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
- DETAILS OF PLANT AND MACHINERY
- AREA 1- GRAIN RECEIVING AND STORAGE SECTION
- AREA 2- GRAIN HANDLING AND MILLING SECTION
- AREA 3- LIQUEFACTION SECTION
- AREA 3- FERMENTATION SECTION
- AREA 4 – MULTIPRESSURE DISTILLATION SECTION
- REBOILERS
- CONDENSERS & COOLERS
- OTHER EQUIPMENTS
- AREA 5 – ETHANOL DEHYDRATION SECTION
- AREA 6- DECANTATION SECTION
- AREA 6.1: INTEGRATED EVAPORATION PLANT ON DISTILLATION COLUMN
- AREA 6.2: DRYER VAPOUR INTEGRATION EVAPORATION PLANT
- SCOPE OF SUPPLY: STEAM TUBE BUNDLE DRYER
- PARAMETERS:
- A) TUBE BUNDLE
- HOUSING PARTS
- DRIVING SYSTEM
- OTHER EQUIPMENT DETAILS
- DDGS DRYER EQUIPMENT SECTION
- VAPOUR DUCTING
- DRIVE ARRANGEMENT
- AREA 9 – UTILITIES SECTION –
- 1. COOLING TOWER FOR FERMENTATION
- 2. COOLING TOWER FOR LIQUEFACTION, DISTILLATION, MSDH AND INTEGRATED EVAPORATION SECTION
- AIR COMPRESSOR:
- DESIGN DATA & PERFORMANCE PROJECTIONS
- AREA 10: CONDENSATE POLISHING UNIT
- DETAILS OF TREATMENT UNITS
- LIST OF EQUIPMENTS
- RO PLANT -
- FILTER FEED TANK:
- FILTER FEED PUMP
- 1. PRIMING PUMP:
- ANTI-SCALENT DOSING UNIT:
- CARTRIDGE FILTER:
- HIGH PRESSURE PUMP:
- MEMBRANE SKID:
- ROCIP SYSTEM:
- SECTION 3
- SCOPE OF SUPPLY SCOPE OF SUPPLY
- AREA 11 – WATER TREATMENT PLANT: CAPACITY- 1500 M3/DAY
- AREA 12: PRODUCT RECEVING AND BULK STORAGE SECTION
- SECTION 15: ELECTRICAL SECTION
- STANDARD SPECIFICATIONS FOR ELECTRICAL
- MOTOR CONTROL CENTOR (MCC)
- EACH STARTER OF MCC WILL CONSIST OF:
- INCOMER OF MCC WILL BE:
- INTERNAL POWER WIRING
- FOR DOL STARTER
- FOR STAR-DELTA STARTER
- EARTHING
- POWER AND CONTROL CABLES
- PUSH BUTTON STATION
- CABLE TRAYS
- ERECTION MATERIAL
- PLANT LIGHTING:
- SECTION 16
- STANDARD SPECIFICATIONS FOR INSTRUMENTATION
- CONTROL SYSTEM
- COMMUNICATION SYSTEM
- PARTS INTERCHANGEABILITY
- SECURITY
- SPARE PHILOSOPHY
- SYSTEM SPECIFICATION
- COMMUNICATION HARDWARE
- POWER SUPPLY MODULE
- DIGITAL INPUT MODULE
- DIGITAL OUTPUT MODULE
- ANALOG INPUT MODULE
- ANALOG OUTPUT MODULE
- PROCESSOR MODULE
- OPERATOR INTERFACE
- OPERATOR CUM ENGINEERING STATION
- OTHER HARDWARE REQUIREMENT
- MOUNTING
- INTERIOR LIGHTING AND RECEPTACLES
- INSTRUMENT LIST
- LIQUEFACTION SECTION
- FERMENTATION SECTION
- DISTILLATION SECTION
- EVAPORATION SECTION
- DEHYDRATION SECTION
- DETAILS OF LABORATORY EQUIPMENTS
- 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 is ethyl alcohol produced industrially by converting fermentable carbohydrates into alcohol and then separating and purifying the resulting ethanol.
For grain-based production, the report describes grain handling and milling followed by mashing, liquefaction, fermentation and distillation. Dehydration may subsequently be used where higher-purity or fuel-grade ethanol is required. The process can also generate distillers dried grain and solubles (DDGS) as a co-product, while utilities and effluent-treatment systems support plant operation.
Broken rice can serve as a starch-rich grain feedstock that can be processed into fermentable material for ethanol production.
The report specifically considers broken rice and other grains through grain handling, milling, mashing, liquefaction, fermentation and distillation. Its proposed integrated approach also separates rice protein before the starch fraction is processed into products such as ethanol and maltodextrin. This can support recovery of multiple product streams rather than relying solely on ethanol as the output.
The main stages are feedstock preparation, liquefaction, fermentation, distillation and, where required, dehydration.
The report also identifies supporting sections for grain receiving and storage, milling, evaporation, decantation, DDGS drying, utilities, water treatment, condensate polishing, product storage, electrical systems and instrumentation. Together, these systems provide the material handling, process control, heat management, water supply, product recovery and plant services required for continuous industrial operation.
Fermentation converts fermentable sugars into ethanol through the activity of microorganisms, typically yeast.
In a grain ethanol plant, starch must first be converted into fermentable sugars through appropriate upstream processing. The report includes dedicated sections on the organism used in alcohol production, yeast type, cell characteristics and fermentation. Controlled operating conditions are important because temperature, pH, nutrient availability, contamination control and residence time can influence fermentation performance and the quality of the resulting process stream.
A grain-based ethanol plant requires process equipment for feed preparation, conversion, fermentation, separation, dehydration and co-product handling, together with utility and control systems.
The report covers grain receiving and storage equipment, milling systems, liquefaction and fermentation equipment, multipressure distillation, reboilers, condensers and coolers, ethanol dehydration, decantation, evaporation, steam tube bundle drying and DDGS drying. It also includes cooling towers, air compressors, water-treatment equipment, electrical systems, instrumentation and laboratory equipment.
Wastewater management in an ethanol plant involves treatment, recovery and controlled disposal systems designed around the characteristics of the process effluent.
The report includes pollution control, wastewater treatment and solid or hazardous waste management and disposal. It also identifies a condensate polishing unit and a water treatment plant as part of the overall plant infrastructure. Effective treatment helps manage process water quality and supports compliance with applicable environmental requirements while enabling suitable water reuse or discharge practices.
DDGS stands for distillers dried grains with solubles and is a co-product associated with grain-based ethanol production.
After fermentation and ethanol recovery, the remaining grain-derived material can be processed to recover useful solids and then dried. The report includes a dedicated DDGS section covering dryer equipment, vapour ducting and drive arrangements. Proper drying and handling are important for obtaining a stable co-product and for integrating heat and vapour streams efficiently within the wider ethanol manufacturing process.
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