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    Present Status of Feedstock Management & Technology Developments in Ethanol Sector

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    song Li
    This document discusses the present status of feedstock management and technology developments in the ethanol sector in India. It covers the various feedstocks used for ethanol production in India including molasses, sugarcane, sweet sorghum, and grains. It also outlines India's ethanol production potential from these feedstocks and discusses the Indian ethanol blending program. The document provides an overview of the key ethanol production technologies used in India and how they have improved over time to become more efficient.

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    Present Status of Feedstock Management & Technology Developments in Ethanol Sector

    Uploaded by

    song Li
    157 views22 pages
    This document discusses the present status of feedstock management and technology developments in the ethanol sector in India. It covers the various feedstocks used for ethanol production in India including molasses, sugarcane, sweet sorghum, and grains. It also outlines India's ethanol production potential from these feedstocks and discusses the Indian ethanol blending program. The document provides an overview of the key ethanol production technologies used in India and how they have improved over time to become more efficient.

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    1_Jai_Uppal

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    This document discusses the present status of feedstock management and technology developments in the ethanol sector in India. It covers the various feedstocks used for ethanol production in India including molasses, sugarcane, sweet sorghum, and grains. It also outlines India's ethanol production potential from these feedstocks and discusses the Indian ethanol blending program. The document provides an overview of the key ethanol production technologies used in India and how they have improved over time to become more efficient.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    157 views22 pages

    Present Status of Feedstock Management & Technology Developments in Ethanol Sector

    Uploaded by

    song Li
    This document discusses the present status of feedstock management and technology developments in the ethanol sector in India. It covers the various feedstocks used for ethanol production in India including molasses, sugarcane, sweet sorghum, and grains. It also outlines India's ethanol production potential from these feedstocks and discusses the Indian ethanol blending program. The document provides an overview of the key ethanol production technologies used in India and how they have improved over time to become more efficient.

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    Present Status of Feedstock

    Management
    &
    Technology Developments in
    Ethanol Sector
    Jai Uppal, Consultant
    B.Sc. Chem. Engg., M.S.E. (Michigan, USA)
    F.I.E.. L.M.I.I.Ch.E., L.M.I.M.A.
    Sr. Advisor, Center for Alternate Energy Research (CAER),
    (University of Petroleum & Energy Studies)
    Email: jaiuppal@gmail.com; M: +919811171121

    New Delhi, September 25, 2007


    Feedstocks For Ethanol
    Production
    ‹ Sugars: –
    – Sugarcane,
    – sweet sorghum,
    – sugar beet,
    – molasses (by-product of sugar
    production) - ‘A’, ‘B’ & ‘C’ heavy molasses
    – fruits etc
    ‹ Starches: –
    – Grains (Corn, wheat, rice, barley,
    sorghum) etc
    – Tubers (Cassava, potato etc)
    ‹ Cellulose – Grass, wood, MSW etc
    Indian Feedstocks
    ‹ Molasses – main raw material + 90% of
    Ethanol/Alcohol Production
    ‹ Sugarcane – technology available and
    tested but cannot be used as sugarcane
    price very high – unviable for Ethanol
    ‹ Sweet Sorghum – high yielding variety
    being developed. Production technology
    being tested – one plant set up – This year
    commercial production.
    ‹ Tropical Sugar Beet – high yielding variety
    being tested – plant set up – trials taken -
    This year commercial production
    Indian Feedstocks
    ‹ Fruits – only for wine
    ‹ Grains used for potable alcohol
    production as it is costly – rice,
    sorghum, barley, malt
    ‹ Damaged/unusable grain – sorghum

    ‹ Tubers – Cassava has been used in


    south India for potable Alcohol
    ‹ Cellulose – Technology not yet
    developed
    Indian Feedstocks
    ‹ Molasses most economical feedstock
    ‹ Sugarcane most energy efficient crop
    - hard to beat.
    ‹ However, water intensive & one year crop.
    ‹ Negative impact in draughts and cost of
    production rises dramatically by up to
    30% but not as volatile as crude oil
    ‹ During drought, less water intensive crops
    may be economical
    – Sweet sorghum/tropical sugar beet – about
    4/6 months crop water intensity 1/3
    Indian Ethanol Potential
    ‹ This year’s 12 mill T of Molasses
    availability (for Ethanol). Can
    produce 2.7 bill L of Ethanol
    ‹ Surplus Sugar produced this year 9
    mill Tonnes – no where to sell as
    surplus in the world – glut !
    ‹ 5 mill tonne of sugar/ can be
    converted to 2.8 bill L of Ethanol
    ‹ E10 Blending Program requires 1.2
    bill L of Ethanol
    Indian Ethanol Potential
    ‹1 mill ha (of 60 mill ha) of irrigated
    land can produce 5 bill L of Ethanol
    ‹ 5% damaged grain – 11 mill T can
    produce – 4 bill L of Ethanol
    ‹ Surplus Biomass of 500 mill T can
    produce 100 bill L per year
    ‹ Or 50% of 120 mill T of Bagasse
    from sugar mills can produce 12 bill
    L of Ethanol
    Indian Ethanol Blending Program
    (EBP)
    ‹ Ethanol Used in WW II – ‘Power
    Alcohol’ in UP
    ‹ Technology Azeotropic distillation
    using benzene
    ‹ Stopped after the War

    ‹ R&D & Trials in 1979-80, 91-92,

    ‹ Pilot projects in 2002 – 3 locations,


    300 dispensing stations
    Indian EBP
    ‹ E5 blending made mandatory in 9 states
    & 4 UTs from Jan 1, 2003
    ‹ Made conditional from Oct 2004

    ‹ Resumed in 2006 & picks up momentum in


    2007 – E5 introduced in Delhi 1st time !
    ‹ Announcement to introduce E5 in all India
    except J&K, NE and Islands
    ‹ Intention to introduce E10 by Nov 2008

    ‹ Alcohol capacity of +3.5 bill L

    ‹ Installed Ethanol capacity of about 1.5 bill L


    Ethanol Requirement for EBP

    Year % Ethanol Gasoline


    Blend Requirement Demand
    (MMT) (MMT)
    2006/07 5 0.5 10.07

    2011/12 10 1.29 12.85

    2011/12 25 3.21 12.85


    Feedstocks for Ethanol Production
    CANE
    CANE JUICE GRAIN GRAIN BEET
    MOLASSES

    WET MILLING
    DRY MILLING
    GLUTEN

    FIBRES
    SLURRY
    PREPARATION SLURRY
    PRE -
    DILUTION PREPARATION JUICE
    CLARIFICATION
    EXTRACTION
    LIQUIFACTION
    LIQUIFACTION

    CONCENTRA-
    TION SACCHARIFI SACCHARIFIC
    CATION ATION

    FERMENTATION FERMENTATION FERMENTATION FERMENTATION FERMENTATION

    Distillation

    HIGH QUALITY- ENA DEACTIVATED SPIRIT

    AZEOTROPIC MOLECULAR SIEVE


    DISTILLATION(HEXANE)

    ANHYDROUS ANHYDROUS
    ALCOHOL/ETHANOL ALCOHOL/ETHANOL
    Status of Indian Ethanol
    Technology
    ‹ Average capacity of plant 40 KLPD as
    against 300 to 1000 KLPD in USA/Brazil
    ‹ Level of average technology improving
    ‹ Cost of production – economies of scale
    will be achieved as EBP progresses
    ‹ Some Plants converting to multi feedstock
    plants
    ‹ Price around Rs 21.50 per L can be
    brought down if blending program is
    expanded
    ‹ Small inefficient plants will die !
    Ethanol Process Technology
    ‹ Process steps in Ethanol Production
    Technology:
    1. Convert starch to sugar
    2. Ferment Sugar using yeast to produce weak
    solution of Alcohol (7% to 9%)
    3. Distill alcohol to around 95% V/V
    4. Dehydrate Alcohol using Mol. Sieve to +99.7%
    ‹ For Molasses step 1 is avoided – Technology
    using Molasses and some grains is well
    established
    ‹ However technology being commercialized
    to handle sugar beet and sweet sorghum
    ‹ Continuous fermentation technology
    becoming popular especially larger Plants
    Simplified Ethanol Process
    Flowsheet

    Alcohol Production
    Simultaneous
    Grain crushing Mashing Sacchrification Fermentation Distillation

    Molasses

    Cane juice
    Fermentation Technology
    ‹ Batch Fermentation – being phased out
    ‹ Continuous Fermentation:-
    – without yeast recycle
    – or with yeast recycle
    ‹ Theoretically yield (fermentation efficiency
    in ascending order but in actual practice
    may not be so)
    ‹ Effect of quality of molasses & control of
    operation
    Fermentation Technology
    ‹ Higher efficiencies being attained
    despite the molasses quality
    deteriorating
    ‹ Ethanol from ‘A’ heavy molasses and
    ‘B’ heavy molasses no problem
    ‹ Ethanol from Sugarcane juice not in
    use but feasible by adding clarifying
    and evaporation equipment
    Distillation Technology
    ‹ Atmospheric Distillation being phased out
    ‹ Multi pressure (pressure-Vacuum)
    technology becoming popular
    ‹ lower steam consumption & downtime

    ‹ Introduced much earlier in India – ahead


    of Brazil in energy efficiency
    ‹ Reboilers instead of direct sparging of
    steam
    ‹ Lower water consumption
    Dehydration Technology
    ‹ Ethanol Production
    – Technologies
    ‹ Molecular Sieve (MS) - Technology of 90s
    ‹ Azeotropic Distillation(AD) - Old Polluting Technology
    ‹ Membrane - Yet to be stabilized - Membrane life

    ‹ Molecular Sieve technology under license


    from US firms – Pressure Swing
    Adsorption (PSA) process
    ‹ Low steam consumption of 0.6 kg per L of
    Ethanol & long life of Mol sieve established
    – ahead of Brazil
    ‹ Higher level of Instrumentation and
    DCS/PLC systems being introduced in
    almost all in new plants
    Effluent Treatment & Utilities
    ‹ Distillery Effluent very rich in organic matter
    – very high BOD and COD
    ‹ Major Issue & also an opportunity to use rich
    humus and nutrients in effluent
    ‹ Zero effluent discharge
    ‹ Primary Effluent Treatment Bio-methanation
    ‹ Bio-composting using press mud from sugar
    mills and distillery effluent
    ‹ Reverse osmosis/Evaporation being used to
    reduce quantity of effluent, increase DS and
    reduce water consumption by recycling
    ‹ Incineration in Boilers or spray drying
    ‹ High Water use issues –being addressed
    Effluent Treatment & Utilities
    ‹ Efficient Bio-methanation provides up to
    90 to 100% of Fuel for steam for
    distillation and dehydration
    ‹ Increasingly Ethanol plants are integrated
    with sugar mills and have their own high
    pressure boilers and turbines with
    alternators to generate power not only for
    the Distillery / Ethanol plant but also for
    the offices and residences or other
    industrial uses such as Alcohol based
    chemicals etc.
    Technology & Plant Sourcing
    ‹ All Alcohol/Ethanol Plants made in
    India
    ‹ Indian Alcohol/Ethanol technology
    and plant suppliers have arrived on
    the world stage !
    ‹ Plants being sold in all most all
    continents
    ‹ Indian Alcohol technology and plants
    being sold all over the world because
    it is efficient and with lower capital
    costs
    Thank You !

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