Industry Overview
Ethanol is an alcohol compound containing a hydroxyl group bonded to a carbon atom and is widely produced through the fermentation of agricultural raw materials such as rice, corn, and sugarcane. It has antibacterial, antifungal, disinfectant, and antiseptic properties and is used in hand sanitizers, medical wipes, medicines, mouthwashes, analgesics, and as an antidote in certain poisoning cases.
Production of ethanol from broken rice involves the bioconversion of starch into fermentable sugars, followed by fermentation. In the conventional process, starch is liquefied using thermostable alpha-amylase and subsequently subjected to simultaneous saccharification and fermentation using glucoamylase and yeast such as Saccharomyces Cerevbisiae. Industrial processing generally includes grain crushing, mashing, cooking, scarification, fermentation, distillation, and molecular dehydration.
During fermentation, yeast metabolizes sugar under reduced-oxygen conditions to produce ethanol and carbon dioxide. The process is generally conducted under moderate temperature conditions of 35-40 degrees. Ethanol production from broken rice is an important application of agricultural starch conversion technology. The global ethanol market has experienced rapid growth, supported by biofuel initiatives and the use of ethanol as an alternative to gasoline. However, rising raw material prices remain an important constraint on market growth.
Cost Estimation
| Particulars | Cost / Value |
|---|---|
| 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% |
Content Index
- 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
- 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 production from broken rice is a fermentation-based process that converts the starch present in rice into ethanol. The process generally involves grain handling and milling, slurry preparation, cooking, liquefaction, saccharification, fermentation, distillation, and dehydration. Enzymes such as alpha-amylase and glucoamylase help convert starch into fermentable sugars, while yeast converts these sugars into ethanol and carbon dioxide.
Broken rice can serve as a starch-rich agricultural feedstock for ethanol production. Its starch can be converted into fermentable sugars through enzymatic processing before fermentation. Using broken rice provides an alternative feedstock for distilleries and supports the utilization of agricultural materials that can be processed into alcohol. The suitability of the raw material depends on its quality, starch characteristics, availability, and overall process economics.
The main stages are grain handling and milling, slurry preparation, cooking, starch liquefaction, saccharification, fermentation, distillation, and dehydration. During liquefaction, starch is broken down using enzymes such as alpha-amylase. Further enzymatic conversion produces fermentable sugars, which are metabolized by yeast during fermentation. The resulting fermented material is processed through distillation to separate ethanol, followed by dehydration when higher ethanol concentration is required.
Saccharomyces Cerevbisiae is identified in the report as the yeast used for ethanol fermentation. Yeast converts fermentable sugars into ethanol and carbon dioxide under reduced-oxygen conditions. Industrial yeast selection considers characteristics such as ethanol tolerance, fermentation performance, temperature tolerance, and ability to utilize available sugars. The report also notes that highly ethanol-tolerant yeast strains can survive up to approximately 18% ethanol by volume.
The report states that ethanol fermentation is conducted under moderate temperature conditions of 35-40 degrees. Maintaining suitable thermal conditions is important because yeast activity and fermentation performance are strongly influenced by temperature. Excessive temperatures can adversely affect yeast viability, while unsuitable low temperatures can reduce fermentation activity. Industrial fermentation therefore requires controlled operating conditions to support consistent conversion of fermentable sugars into ethanol.
A broken rice ethanol plant requires equipment for raw material handling, milling, slurry preparation, cooking, fermentation, distillation, and dehydration. The report specifically identifies silos, hammer mills, cooling towers, reactors, D.G. sets, boilers, condensers, distillation columns, and scrubbers among the plant and machinery supply categories. The final equipment configuration depends on process design, feedstock characteristics, production requirements, utilities, and the desired ethanol specification.
Ethanol is used in fuel, industrial, pharmaceutical, healthcare, and consumer applications. Its antibacterial and antifungal properties support its use in hand sanitizers, medical wipes, disinfectants, and antiseptics. Ethanol is also used as a solvent for certain medicines, mouthwashes, and analgesics. In the fuel sector, ethanol can be blended with petrol as an alternative fuel component. Its applications therefore extend beyond conventional industrial alcohol uses.
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