Ethanol Blending

Part of Unit 2: Alcohol from molasses

Ethanol Blending:
 Primary automotive fuels are gasoline & diesel.

 Gasoline & diesel are hydrocarbons derived from crude oil.

 Ethanol blended into nearly all unleaded gasoline.

 Ethanol was used to power original Model-T Ford.

 Ethanol has been a gasoline additive since the 1980s.

 Primary role was air quality improvement

 Replace lead, benzene, toluene and xylene

 Secondary role was octane improvement.

 Current role is octane, air quality, & increase domestic energy production
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Ethanol Blending: Applications and Advantages
 As production grew, ethanol was added to gasoline supplies to replace the octane
enhancer’s lead, benzene, toluene, and xylene as they were being removed from the
gasoline supply due to toxicity concerns.

 The Clean Air Act of 1990 further increased the market share for ethanol-blended fuel due
to mandated usage of oxygenated fuels in reformulated gasoline (RFG) in certain areas of
the United States to help reduce carbon monoxide emissions.

 RFG refers to extensive changes in gasoline properties that reduce emissions of volatile
and toxic organic compounds in ozone non-attainment areas.

 Fuel oxygenates, such as ethanol, add chemical oxygen to the fuel, which promotes more
complete combustion thereby lowering CO emissions. 3
Ethanol Blending: Applications and Advantages
 Hydrocarbon exhaust emissions are also often reduced.

 Today, ethanol is the most widely used oxygenate for RFG.

 Ethanol has a blending octane of 113 and is widely used in creating regular octane
gasoline from sub-octane base stocks or raising regular octane fuels to the mid-octane
level.

 This addition of ethanol to gasoline to boost octane is an alternative to more severe

refining operations making ethanol one of the most cost-effective octane enhancers
available to the refiner and blender today.

4
Example 1:
Ethyl alcohol is blended with gasoline in 20:80
ratio on weight basis, then
i) Determine the calorific value of the blending mixture.
ii) Determine the rate of blending mixture consumed to rise the
temperature of water from 10 oC to 30 oC for water at flowrate of 2
kg/sec and combustion efficiency of 80 %.
iii) Assume C8H16 is the molecular formula of gasoline, determine the
air used for the combustion of 10 g of blending mixture.
 Solution: Example 1 (i)
 Calorific Value calculation:

Given fuel is a mixture of Ethanol (46 g/mol) and Gasoline C8H16 (112 g/mol) in a weight ratio
of 20:80 respectively.
(To calculate Calorific value (GCV and NCV) we need to find weight % elemental (C, H, O) composition)

Calculating elemental compositions

% C (by weight) = (24/46)*100*0.2 + (96/112)*100*0.8 = 79 % QC = 8137.5 Kcal/kg of C

QH = 28905 Kcal/Kg of H
% H (by weight) = (6/46)*100*0.2 + (16/112)*100*0.8 = 14.038 %
QS = 2181 Kcal/kg of S
% O (by weight) = (16/46)*100*0.2 + (0/112)*100*0.8 = 6.9565 %

% M (Moisture by weight) = 0 % (as blend doesn’t contain any moisture)

 Solution: Example 1
 Calorific Value calculation:

GCV/HCV of Fuel = QC*(%C/100)+ QS*(%S/100) + QH*2*(%H/2)/100 -[2*(%O/32)]/100

Kcal/Kg of fuel,

Then GCV = 8137.5*0.79 + 2181*0 + 28905*0.14038 – [2*.069565/32]

= 6428.625 + 0 + 4057.68 – 0.004347 = 10,486.3 Kcal/Kg of Fuel

NCV = GCV – 584 [(9 * H2%+M%)/100] Kcal/Kg of fuel

= 10486.3 – 584[(9*14.038+0)/100] = 10486.3 – 737.83728 = 9748.46 Kcal/Kg Fuel

 Solution: Example 1 (ii)
 Rate of blending mixture consumed

Temp to be raised (T)= 30-10 = 20 oC; Water flow rate (m)= 2 kg/sec; Combustion efficiency (e)
= 80%;

Heat of fuel combustion (GCV) = 10,486.3 Kcal/Kg of Fuel; Specific heat capacity of water (Cp)
= 1Kcal/kgK

Then total heat required to raise the desired temp Q = mCpT = 2*1*20 = 40 kcal/sec

So, the rate of blending mixture consumed will be = Q/(GCV*e) = 40/(10486.3*0.8)

= 0.00305 kg/sec = 3.05 gm of fuel/sec

 Solution: Example 1 (iii)
 Air used for combustion

Basis: 1 kg of blended fuel

Then weight of carbon (C)= 0.79 kg; weight of hydrogen (H)= 0.14 kg; weight of Sulphur (S)=
0 kg; weight of Oxygen (O) = 0.069 kg;

So total air required for complete combustion will be =

= 11.6*0.79 + 34.8 (0.14-0.069/8) + 4.35*0

= 9.164 + 4.57185 + 0 = 13.73585 kg air

Then, for complete combustion of 10 gm fuel air required will be = 13.73585*0.01

= 0.13735 kg air
 (Just for Information)
 Calorific Value: The calorific value of a fuel is the amount of heat it generates on its complete
combustion. For solid and liquid fuels, we express it in unit kJ/kg. For the gaseous fuels, this
expressed in as kJ/m3.
 The calorific value is the total energy released as heat when a substance undergoes complete
combustion with oxygen under standard conditions.
 Fuel consists of one or more combustible elements or compounds like carbon, hydrogen, carbon
monoxide, hydrocarbons, Sulphur, etc. Of the above mentioned combustibles, sulphur is not a
desirable ingredient due to corrosive properties of SO2 formed by its combustion.
 It is the measurement of the heat value or amount of energy released and is either measured in
GCV (gross calorific value) or NCV (net calorific value).
 Gross calorific value (GCV) that is Higher Heating Value (HCV) is the amount of heat that
complete combustion releases by burning a unit of fuel. It assumes all water vapor produced during
the combustion process is fully condensed.
 (Just for Information)
 Calorific Value: The calorific value of a fuel is the amount of heat it generates on its
complete combustion. For solid and liquid fuels, we express it in unit kJ/kg. For the gaseous
fuels, this expressed in as kJ/m3.
 Net Calorific Value (NCV) means lower heating value (LHV) i.e. lower calorific value
(LCV) is determined by the subtraction of heat of vaporization of the water vapor from the
higher heating value. We shall purchase Fuel on the basis of NCV.
 For the conversion of GCV to NCV, we can use the formula given as follows:-

GCV = NCV + (584 (9 * H2% + M%)/100)

Where, GCV in Kcal/Kg; NCV in Kcal/Kg; H2%, Hydrogen Percentage by Weight in the fuel; M% is the
moisture percentage by weight in the fuel; 584 is Latent heat corresponding to the partial pressure of water
vapor in Kcal/kg.
 Calculation of GCV of fuel (Just for Information)

 Calorific values of solid and liquid fuels are found experimentally with the help of Bomb Calorimeter.

 For theoretical calculation of GCV of fuel, we need to do an analysis of fuel and get the constituent of
fuel on a weight basis. Based on the enthalpy of formation of combustion products we can estimate
the calorific value of the fuel.

C + O2  CO2 + 8137.5 Kcal/kg of carbon (QC)

H2 + ½ O2  H20 + 28905 Kcal/Kg of hydrogen (QH)

S + O2  SO2+ 2181 Kcal/kg of Sulphur (QS)

 GCV/HCV of Fuel = QC*(%C/100)+ QS*(%S/100) + QH*2*(%H/2)/100 -[2*(%O/32)]/100

Kcal/Kg of fuel

 NCV/LCV of Fuel = GCV – 584 [(9 * H2%+M%)/100] Kcal/Kg of fuel

 (Just for Information)
 Calculation of GCV of fuel: Example
 Suppose a fuel contains carbon, hydrogen, Nitrogen, Sulphur, Oxygen as 86.5%, 12%, 0.9%,
0.2%, 0.4% respectively, calculation of GCV and LCV
 GCV of Fuel = QC*(%C/100)+ QS*(%S/100) + QH*2*(%H/2)/100 -[2*(%O/32)]/100
 GCV of fuel
= 8137.5*(86.5/100)+ 2181*(0.2/100) + 28905*2*(12/2)/100 - [2*(0.4/32)]/100
= 7038.9 + 4.3 + 3468 – 0.00025 = 10511.2 Kcal/Kg of fuel
NCV of Fuel = GCV – 584 [(9 * H2%+M%)/100]
=10511.2 – 584[(9*12+0)/100]
= 10511.2- 630.7 = 11141.92 Kcal/kg
 (Just for Information)
 Air used for combustion
Industrial Alcohol
Part of Unit 3: Alcohol from substrates
 Industrial Alcohol
 Industrial alcohol is distilled ethyl alcohol (C2H5OH), normally of high proof,
produced and sold for other than beverage purposes.

 It is usually distributed in the form of pure ethyl alcohol, completely

denatured alcohol, specially denatured alcohol and proprietary solvent blends.

 The primary industrial uses of this aliphatic alcohol are as an intermediate in

the production of other chemicals and as a solvent.

 Industrial Alcohol is used in the manufacturing of drugs, plastics, lacquers,

polishes, plasticizers, and cosmetics.
16
Alcoholic Beverages
Part of Unit 3: Alcohol from substrates
Alcoholic Beverages
 Alcoholic beverages have been known since antiquity.

 These are judged in terms of flavor and stimulant effect and hardly at all as sources
of calories.

 However, the calorific value of alcohol in 7 Kcal/g and excess of alcohol consumed
could add to the total calorie intake of a person.

 In the case of distilled liquors (whisky, brandy, gin and rum), the calorific value is
only due to alcohol.

 Consumption of 10 ml of these, beverages would yield about 230 Kcal of energy.

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Alcoholic Beverages
 Wine contain some nutrients present in the original malted barley and the fruit juice used
in their preparation gives more energy than other distilled liquors naturally.

 350 ml of beer gives about 150 Kcal and 100 ml of wine about 80 Kcal.

 Alcohol is absorbed without prior digestion but the body has limited capacity to oxidize it.
That is the reason why alcoholic beverages are to be sipped instead of gulping them.

 As a drug the effects of alcohol vary from mild stimulation, when small amounts are
consumed, to loss of coordination and even death when large amounts are consumed.

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Alcoholic Beverages: Types
 There are three main classes of alcoholic beverages
1. Wines

2. Malted beverages (beer)

3. Distilled liquors.

 Different starting materials and different methods are used in their manufacture.

 But there is one common characteristic in all of them, namely, they are made by the process of fermentation.

 The essential step in all the fermentation processes is the conversion of glucose into alcohol by yeast.

 The enzymes present in yeast catalyze the breakdown of glucose.

20
Alcoholic Beverages: Beer
 Beer is an alcoholic beverage produced by the saccharification of starch and fermentation of the
resulting sugar.

 The starch and saccharification enzymes are often derived from malted cereal grains, most
commonly malted barley and malted wheat.

 Most beer is also flavored with hops, which add bitterness and act as a natural preservative, though
other flavorings such as herbs or fruit may occasionally be included.

 The preparation of beer is called brewing.

 Beer is the world's most widely consumed alcoholic beverage, and is the third-most popular drink
overall, after water and tea.

 It is thought by some to be the oldest fermented beverage. 21

Alcoholic Beverages: Beer
 Mainly two steps: 1. Malting; 2. Brewing

 MALTING is the process of controlled germination followed by controlled drying of barley.

 Such conditions are provided so that the enzymatic requirements of raw material reaches to its
optimumum level.

 BREWING (production of malt beverages) is the combined process of preparing beverages from
grains that have undergone sproughting and fermentation of the sugar solution by yeast where a
portion of the carbohydrate is converted to alcohol and CO2.

 Raw materials used in beer manufacturing : cereal grains like barley, wheat, rice, maize etc.

 BEER CONSTITUENTS • water: 90% • Alcohol: vary from 4-8%, in general 2.5-5.0% • Carbohydrates
(unfermented): 4%, include mono, di or tri polysaccharides • Inorganic compounds: Chlorides, sulfates,
bicarbonates of Mg & Ca: 0.8% • N- compounds: 0.3% • Organic acids: 0.2% • CO2: 0.5% • Other
22
compounds: 0.2%
Alcoholic Beverages: Distilled liquors
 All spirits are produced by the distillation of alcoholic beverage.

 There are two methods of producing spirit.

 Pot still method: This is used for full and heavy flavored spirits such as brandy.

 The patent still method: This is produced the lighter spirits such as vodka.

 Raw materials and Alcoholic strength

 Whisky: Distilled from Beer. Alcoholic volume in whisky is between 40% and 46% abv.

 Gin: The word has been taken from french word Genievre. The meaning is Juniper. Juniper is the flavouring agent
used for the production of Gin. The minimum bottled alcoholic strength for gin is 37.5% ABV in the E.U., 40%
ABV in the U.S.

 Vodka: Vodka is a neutral spirit that traditionally contains no aroma, taste or color. It originated in Russia during the
14th century and its name is derived from Voda, the Russian word for water. Vodka’s alcoholic content usually
ranges between 35 to 50% by volume. 23
Alcoholic Beverages: Distilled liquors
 Raw materials and Alcoholic strength
 Whisky: Distilled from Beer. Alcoholic volume in whisky is between 40% and 46% abv.

 Gin: The word has been taken from French word Genievre. The meaning is Juniper. Juniper is the flavoring agent
used for the production of Gin. The minimum bottled alcoholic strength for gin is 37.5% ABV in the E.U., 40%
ABV in the U.S.

 Vodka: Vodka is a neutral spirit that traditionally contains no aroma, taste or color. It originated in Russia during the
14th century and its name is derived from Voda, the Russian word for water. Vodka’s alcoholic content usually
ranges between 35 to 50% by volume.

 Brandy: Brandy (burnt wine) is a spirit produced by distilling wine. Brandy generally contains 36-60% alcohol by
volume and is typically taken as an after-dinner drink. While some brandies are aged in wooden casks, most are
colored with caramel coloring.

 Cognac: is named after the town of Cognac.

 Armagnac is produced in the Armagnac region in Gascony.

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Alcoholic Beverages: Distilled liquors
 Raw materials and Alcoholic strength
 Rum: is a distilled beverage made from fermented molasses or sugarcane juice and is aged for at least three years.
Caramel is used for coloring. Rum contains 40-55% alcohol.

 Tequila: A Mexican spirit distilled from the fermented juice of the agave plant. It is traditionally drunk after a lick
of salt and a squeeze of lime or lemon. Tequila contains alcoholic strength 45-50.5%

 Liqueurs are defined as sweetened and flavored spirits. Most liqueurs contain 20-65% alcohol. They are usually
consumed in small quantities after dinner.

 Cider is a beverage made from apple juice.

 Perry is an alcoholic beverage made of fermented pear juice.

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Alcoholic Beverages: Wines

26
Alcoholic Beverages: Wines

27
Wines: Production Steps

28
Wines: Production Steps

29
Wines: Production Steps

30
Wines: Production Steps

31
Wines: Production Flow sheet

32
Wines: Types

33
Wines: Types

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Wines: Types

35
Wines: Health Benefits

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