INDIAN INDUSTRY

CHALLCHALL

Dr. S. KumaNATIONAL SUGNATIONAL SUG

KAN

National Sugar I‐OCT‐16

ALCOHOL Y – FUTURE ENGESENGES

ar & N Mohan GAR INSTITUTEGAR INSTITUTENPUR

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Indi is n f th l r st prIndia is one of the largest prinstalled capacity of 375 momillion litres.

The capacity utilization of di65% l d t th

p y65% only, due to the non amolasses and chances of its befuture are also remote.

Since ethanol is fuel of futui ifi d th tsignificance and the present

which are likely to be faced bcome.

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r duc r f lc h l in Asi & nnuroducer of alcohol in Asia & annuaolasses based distilleries is 4000

istilleries is in the range of 60il bilit f i t i

gavailability of main raw materiaeing available in large quantities i

ure, its production assumes great ti di h ll

, p gtation discusses some challengeby the distilleries in the years t

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INTRODUCTIONFast depleting fossiincrease in the demandincrease in the demandmatter of concern throuIn our country the situwe are importing mp grequirement and spendincurrency for the importy p

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N l fuels and continuousd of petro products is ad of petro products is aughout the world.ation is more serious sinceore than 70% of ourng huge amounts of foreignt of crude.

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Thus we must producedi till i t t th fdistilleries to meet the f

By doing so, the valuconverting molasses inconverting molasses inimprove the financialpindustry.

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e maximum alcohol byf t i tfuture requirements.

ue addition created bynto alcohol shall alsonto alcohol shall alsohealth of the sugarg

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Raw Materials foraw Mat r a s for

These include sucrose ccane, sugar beet, sweet sg

•Starch containing plantsg pcassava, sweet potato, m

•Cellulosic materials (sugacrop residues, switch grap , g

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r Alcohol Productior coho ro uct o

containing plants (sugarsorghum, fruits etc.)g

s (corn, wheat, potato,( pmillets etc).

ar cane bagasse, wood,ss, waste paper etc)., p p )

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RAWMATERIALS FOR ALCORAW MATERIALS FOR ALCO

SimpleSucrose

Single Stage Hydrolysis

Sucrose

Moderate Starch

Complexwo Stage Hydrolysis

Starch

Most Complex

reatment Followed by LiquefactionCellulose

H

OHOL PRODUCTIONOHOL PRODUCTION

Cane juice ; Beet juMolassesMolasses

Cassava; wheat ricsorghum; millets

Bagasse; heat &Lignin

Bagasse; wheat & straw; grass

6Hemicellulose

Out of these the most wOut of these, the most wmolasses in our countrycommonly used in Brazilcommonly used in Brazil.

Starchy raw materials arStarchy raw materials arproduction of grain spirit (ifermentative production of ffermentative production of f

In India utilization ofIn India, utilization ofproduction of alcohol is restfor the production of grainfor the production of grainwhen rates of ethanol were

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widely used raw material iswidely used raw material iswhile sugar cane juice is

re mainly utilized for there mainly utilized for thein USA corn is used for thefuel ethanol)fuel ethanol).

grains for fermentativegrains for fermentativetricted to some states mainlyspirit for IMFL (till recentlyspirit for IMFL (till recentlycomparatively less).

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Fermentation TeFermentation TeTh ti l d lThe conventional and olis batch fermentation

•Here each fermenter isHere each fermenter isyeast culture.

• After completion of fffi i t ti fsufficient time for

fermented wash is sent

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chnologieschnologiesd t f th t h l idest of the technologies.

s pitched separately withs pitched separately with

fermentation and allowingt ttli thyeast settling, the

for distillation.

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•This is the time testedp l nt in l n fprevalent in large no. ofof 225-230 l/ton ofcontent of about 47-48

•Continuous fermendeveloped in foreign codeveloped in foreign coadopted by Indian d

dcommon are cascade an

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d technology and is stillf distill i s i in i ldf distilleries giving yieldmolasses having TRSg%.

ntation technologiesountries have also beenountries have also beendistilleries, the mostd bi ilnd biostil.

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•The cascade system use•The cascade system useand Biostil uses singleSchizosaccharomyces pomSchizosaccharomyces pomyeast.

•It also involves weak washffl teffluent.

B th th t h l i h•Both the technologies hadistilleries but both of

i ll i i N th Iespecially in in Northern I

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es three to five fermenteres three to five fermenterlarge fermenter and use

mbe which is osmotoleranmbe which is osmotoleran

h recycle and generates les

b d t d b I diave been adopted by Indiathem are giving problem

I di di till iIndian distilleries.

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Distillation TechDistillation Tech

•Though batch fermenIndia but distillation isIndia but distillation is

h d ll•Atmospheric distillarectifier columns is bf mefficient and less ensystemssystems.

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nologiesnologies

ntation is still common incontinuouscontinuous.

ation using analyzer andbeing replaced by moderng p y mergy consuming distillation

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•These include those usingMulti Pressure RedistTotal Vacuum System (TVSTotal Vacuum System (TVS

•The fermented wash in t•The fermented wash in tproduce ENA from washt ith littl f tisteam with little formation

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g partial vacuum columns,illation (MPR) columns,S) etc.S) etc.

these columns can directlythese columns can directlyand also consumes lessf ln of scales.

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Power AlcoholPower Alcohol

•The need of fuels othfirst felt during second

• Thus plants producingestablished throughout testablished throughout t(first plant was at Mand

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her than petro fuels wasworld war.

g absolute alcohol werethe world including Indiathe world including Indiadya near Mysore).

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•These plants preparedl i tmolasses in our country

after mixing with benzene

•These plants are now rsince these are more efsince these are more effree from toxic (carcinoge

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d rectified spirit fromd thi di till dand this was redistilled

e etc.

replaced by MSDH plantsficient at the same timeficient at the same timeenic) entrainers.

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B d f AlBy products of Alc

The distillation industryThe distillation industrypotential of utilization

d horder to improve thdistilleries and to maktrend in alcohol. These

h l F icohol Fermentation

y is able to exploit they is able to exploit theof its by products in

h f l h l h fhe financial health ofke up for any downwardp yby products are:

Carbon dioxideCarbon dioxide

•It is major by producproduced during anaerproduced during anaermolasses.

•Quantitatively the extycarbon dioxide is 95% of

YeastYeastGlucose------- ethyl a180 92180 92

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t of distillery which isrobic fermentation ofrobic fermentation of

tent of generation off ethanol.

alcohol + Carbon dioxide8888

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BiogasBiogas•Spent wash obtained af•Spent wash obtained affrom fermented wash bypolluting liquid and haspolluting liquid and has1,00,000 – 1,30,000 mg50,000 - 65,000 mg/l w, , g3.5.

Thi ll i li id•This polluting liquid neefactory premises to bpermissible limitspermissible limits.

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fter recovery of alcoholfter recovery of alcoholy distillation, is a highly

COD in the range ofCOD in the range ofg/l and a BOD of aboutwith a pH value of aboutp

d b d i heds to be treated in thebring pollution loads to

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•The most useful treatmeof spent wash with theof spent wash with thebiogas (1 kg decrease imeter)meter).

Thi bi d d•This biogas produced csteam requirement of dqtreatment in biodigester.

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ent is anaerobic digestionrecovery of methane richrecovery of methane richin COD gives 0.53 cubic

75% fcan meet up to 75% ofdistillery by spent washy y p

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Future ChallengeFuture Challenge

•The competition in dommarket and the awaremarket and the awareenvironment protection hab d i d d fbe modernized and eco fr

•It is likely to face someto come with regard to fog f

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eses

estic as well as globaleness with regard toeness with regard toas seen this industry toi dliendly.

e challenges in the timeollowing:g

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Raw MaterialsRaw Materials•The main raw materialThe main raw materialmolasses, the byproduct o

•The availability of molad d hdependent on the quantisugar factories.g

•In past few years moIn past few years, moremained quite insufficien

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used by distilleries isused by distilleries isof sugar factories.

asses to distilleries isf h d bty of cane crushed by

olasses availability hasolasses availability hasnt to the distilleries.

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•In future, availability will be symolasses is expected to be coare being installed especially atg p y

•Thus distilleries can not depepstock in coming years.

•To overcome the probable anear future, we must look infor alcohol production.

• Sugarcane juice is one such a

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scarcer since the production ofponstant though new distilleriesttached to sugar factories.g

end solely on molasses as feedy

acute shortage of molasses infor using other raw materialsg

alternate.

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•However, considering thegand the yield of alcoholviable alternative.viable alternative.

• But in future years it• But in future years itsugarcane juice is utilized

l id da mass scale providedincentives on its procuremewhere corn is utilized foalcohol.alcohol.

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present cost of sugarcanep gfrom it, it may not be

t is most probable thatt is most probable thatfor alcohol production on

d G t idd Government providesent as is the case in U.S.or manufacture of power

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Sweet sorghum is anothergwhich should be encouragedmaterial for distilleriesmaterial for distilleries.

Starchy materials like wheStarchy materials like whemillets, cassava, potato, swh i l f fhe raw materials of future

Since out of above many arhere shall always be ahere shall always be amportant or fuel since both

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r crop, the cultivation ofp,d to make it a future raw

eat rice corn sorghumeat, rice, corn, sorghum,weet potato etc. are alsof l h l d ifor alcohol production.

re also consumed as food,debate whether food isdebate whether food is

h are essential.

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However, surplus and partp pallowed for alcohol productiof energy.of energy.•The most abundant carbohare in the form ofrepresented by grass, treep y g ,

•Due to presence of lignin•Due to presence of ligninbeen successfully emplp d ti n f th n lproduction of ethanol.

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tially spoiled grains may bey p g yion to meet future demand

hydrates present on earthlignocellulosics and are

s, wood, grain stalks etc., , g

n these have so far notn, these have so far notoyed for fermentative

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•Need is to concentrate ourof removal of lignin by sconverting cellulose to fermconverting cellulose to ferm

•Attempts should also be•Attempts should also becultivate those plants onittl li iittle lignin.

•Canada is the land richestand they are planning to scand they are planning to scplants and to grow them ofuture demands of alcoholfuture demands of alcohol.

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r research in the directionimple procedures and for

mentable sugar.mentable sugar.

e made to produce ande made to produce andlarge scale which contain

t in lignocellulosic forestscreen less lignin containingcreen less lignin containingon massive scale to meet

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•The quality of molassesq ydeteriorating due to extrsugar by the sugar fasugar by the sugar faequipment, better technolochemicalschemicals.

A l B C•At present only B, C anavailable to distilleries. Slalso increasing and so iscontent of volatile fatty accontent of volatile fatty ac

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available to distilleries israction of more and moreactories by using betteractories by using betterogy and use of a variety of

d b l d l ind below grade molasses isudge content in molasses isgthe case with regard to

cids (VFA)cids (VFA).

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•Cases of molasses deteriobeing reported in large nos

•Molasses with high sludgfermentation process caufermentation process cauexcessive foaming, drop in

•Thus, fermentation procespmonitored / modified andminimum effect of preseminimum effect of presemicroorganisms.

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oration on storage are alsog.

ge and more VFA affectusing drop in recoveryusing drop in recovery,yeast cell count etc.

ss needs to be continuouslyysuitably adjusted to haveence of sludge, VFA &ence of sludge, VFA &

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FermentationFermentation

The fermentation of dilout using distillers yeout using distillers yedesirable characteristics

•Broad range of substrat•Fast rate of fermentat•High ethanol toleranceg•High osmotolerance

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luted molasses is carriedast S cerevisiae Theast S. cerevisiae. Thes of distiller’s yeast are:

te utilizationion

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• High temperature toler

• Genetic stability

• Flocculating nature

• High acid tolerance

• Low generation of bypr

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rance

roducts

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•Since yeast is a living orgeffects of temperature, pH,p , p ,substrate etc., it is likelyrepeated use for long periodsp g pthat it does not change its ch

•Yeast also suffers from tformation and less specificpbacteria.

•In coming years, distilleriemodified bacterial strains likespecific growth rate, high oslow pH.p

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ganism and is susceptible toosmolarity, concentration ofy,to change its behavior by

. Attempts should be made soparacteristics.

he drawback of high sludgegrowth rate as compared tog p

es may be using geneticallyZymomonas which have fastery

smotolerance and tolerance to

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Technology AdoptioTechnology Adoptio•The available technfermentation (which is coprocess) and continuous fprocess) and continuous f

• Continuous fermentatio• Continuous fermentatioprocess employing onel h l t t ith lalcohol content with slo

(biostil) or cascade systyfermenters in a seriesrecycling.recycling.

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on By Distillerieson By Distilleriesnologies are batchgonventional fermentationfermentation process.fermentation process.

on may be one stepon may be one stepreactor with constant

d t liop and yeast recyclingem using three to fourgor cascade with yeast

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•In batch fermentation procel dare low and manpower r

contamination control butf i ffi i lfermentation efficiency valuesachievable.

• On the other hand, installatiot isystem, manpower requiremen

automated and productivities hi diffi ltis difficult.

A l b f di till•A large number of distillerfermentation systems both cas

ess normally installation costsi irequirement is more, easy

productivity is low and90% ( i )s up to 90% (maximum) are

on costs are high in continuoust i l t i l lnt is less, system is largelyhigh but contamination control

i h d t d tiries have adopted continuouscade and biostil.

O t f th bi til•Out of these biostilsuccessful especially in Norp y

•Cascade process hasCascade process hassuccessful.

•Increased content of slul ff t f t tmolasses affects fermentat

a result of this, some facas batch or fed batch. Umay be in use later on.may be in use later on.

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did tprocess did not proverthern India.

so far been partiallyso far been partially

udge as well as VFA inti i d ttion in cascade system asctories operate continuouspUse of immobilized yeast

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•In addition to above, newein molasses fermentation fon mo ass s f rm ntat on foincluding prohibition whichmany more states at the samany more states,at the samay also be slashed. Rs 3/

•Since new raw materials acoming years, problems aneed to be visualized.

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er problems may be addedor which we must be readyor wh ch w must r a yis likely to be extended toame time prices of ethanolame time prices of ethanol/ w.e.f. 13.10.16.

are likely to be utilized inassociated with them also

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DistillationDistillation•Atmospheric distillation is cby MPR (Multi Pressure Redisby MPR (Multi Pressure RedisSystem at low temperature.

•MPR is quite common whereindirectly ENA can be produceddirectly ENA can be produced

•It is expected that newer d•It is expected that newer dbe developed which will proENA of good quality at the eENA of good quality at the eof energy.

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continuously being replacedstillation) and Total Vacuumstillation) and Total Vacuum

n at low steam consumptiond from fermented washd from fermented wash.

distillation technologies maydistillation technologies mayoduce rectified spirit andexpense of less consumptionexpense of less consumption

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Efflu nt T tmEffluent Treatme•Keeping in view the recenreduce generation of spenreduce generation of spenproduced and to achieve ZRO incineration system etRO, incineration system et

Bi c mp stin is a ver n•Biocomposting is a very nobio treatment using pres

t t d t hconcentrated spent wash.

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nt S st msent Systemsnt guidelines from CPCB tont wash per litre of alcoholnt wash per litre of alcoholZLD for distilleries, MEE.tc are in usetc. are in use.

ble meth d f spent washoble method of spent washss mud and spent wash/

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Th j bl i h•The major problem withand disposal.p

•Another problem which isAnother problem which ispacking/sale of incompletelit so happens the processit so happens, the processscrutiny.

•Some foolproof arrangemep gto discourage incompletely

bi i ibiocompost is its storage

likely to be faced shall belikely to be faced shall bely composted fertilizer. Ifs itself will come to stricts itself will come to strict

ent needs to be developedpcomposted fertilizer.

•As regards use of inciit l t it f l lifcapital cost, its useful life

gases shall require an exha

•It is felt that collaboratifout to develop alttechnologies for handling stechnologies for handling sand also to get some usefu

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ineration boilers, besidesd i i th h fle and emission through flue

austive study.

ive studies may be carriedyternate techno-economicspent wash to achieve ZLDspent wash to achieve ZLDl by product.

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Some alternate technologies

•Drying of spent wash anobtained into potash rich fe

• One time land applicatio• One time land applicatiowash under controlled condi

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s may be:

nd to convert the powderertilizers.

on of biomethanated spenton of biomethanated spentition.

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Power AlcoholPower Alcohol•The major use of alcohhe major use of alcohthe energy sector especpetrol (EBP)petrol (EBP).

Th fi t itt•The first committee wexamine the use of alcowith gasoline followed byvehicle using 5-10 %ggasoline.

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hol in future shall be inhol in future shall be incially as ethanol blended

f d i 1979 twas formed in 1979 toohol as fuel in admixturey trials by IIT Delhi on

blends of ethanol inf

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•With Govt. making it mangin petrol from Octoberfurther raising the blendinfurther raising the blendinof ethanol is to rise furthe

•It is probable that suffiil bl f EBPmay not available for EBP.

•To overcome this, needland for sugarcane crop whland for sugarcane crop wh

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ndatory to use 10% blendy2015 and intending on

ng levels the requirementng levels, the requirementer.

icient quantity of ethanol

shall be to increase thehich is only 7%hich is only 7%.

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•An increase of 1 millionf mmillion ton of sugarcane thbillion liters of ethanolbillion liters of ethanol.

D t in in d m• Due to increasing demoincrease area may not bealso be achieved by raisingBiomass to ethanol cocommercialized which canbiofuelsbiofuels.

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hectare will produce 75phat can give additional 5.0

phi p hographic pressures, suchpossible. Thus, this can

g the yield to 100 T/ha.onversion needs to bebe a limitless source of

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• At present for the tarpthe requirement of poweestimated to be approximestimated to be approximwhich is equal to the totalin the country through molain the country through mola

Th f i h• Thus, after meeting thechemical industry, only 5%y ybe achievable through moladesired blending levels podesired blending levels postocks has be harnessed.

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rgeted EBP 10 programmeg p ger alcohol or Ethanol ismately 2680 million litresmately 2680 million litresalcohol production potentiaasses routeasses route.

i f bl drequirement of potable and% blending target seems tog gasses route and to meet theotential of alternate feedotential of alternate feed

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National Sugar Institute, 44, Kanpur

ThankThank

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k youk you

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