CHAPTER I

SUMMARY

Ethanol Processing Plant

In this design, the designers proposed the Ethanol

Processing Plant having a production capacity of 100 li/day

where the raw material to be used is sugar cane. In 2005,

the Philippines is the ninth largest sugar producer in the

world and second largest sugar producer among the

Association of Southeast Asian Nations (ASEAN) countries,

after Thailand according to Food and Agriculture

Organization.

PLANT LOCATION

The designers decided to construct the Sugar Cane

Ethanol Processing Plant near a sugar cane plantation

located near the river of Brgy. Pasol-o, Jamindan, Capiz.

The designers considered that location for the

availability of raw materials because of sugar cane

plantation and presence of water supply.

PRODUCT DESCRIPTION

Sugarcane ethanol is an alcohol-based fuel produced by

the fermentation of sugarcane juice and molasses. Because it

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is a clean, affordable and low-carbon bio-fuel, sugarcane

ethanol has emerged as a leading renewable fuel for the

transportation sector. Ethanol is produced from biomass

mostly via a fermentation process using glucose derived from

sugars (sugar cane, sugar beet, and molasses), starch (corn,

wheat, grains) or cellulose (forest products) as raw

materials. Synthetic ethanol can also be produced from non-

renewable sources like coal and gas.

MARKET FEASIBILITY

Approximately 60 percent of world ethanol product uses

sugar crops as the primary feedstock, with the remaining 40

percent using grain crops as the primary feedstock.

The majority of ethanol produced by other countries

around the world uses sugar crops as primary feedstock.

Sugarcane is the predominant feedstock in this country,

although several countries use sugar beets as the main

ingredient in ethanol production. Since the feedstock costs

are major cost item in producing ethanol, the relatively low

market prices for sugar crops in many countries, compared to

the United States, makes the production of ethanol from

sugar crops economically feasible.

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Market Projections

The emerging capacity of alcoholic beverages is also

stoking the demand for ethanol. The rising application of

ethanol in making premium quality alcoholic beverages is

boosting the market. The miscellaneous use of ethanol in

making explosives, paints and perfumes is also accentuating

in the global market.

Market Share

Global demand for ethanol has increased significantly

over the past few years, driven by concerns over energy

security, environmental sustainability, and the need to

mitigate climate change through the reduction of greenhouse

gas emissions.

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 TECHNICAL FEASIBILITY

Sugarcane ethanol is an alcohol-based fuel produced by

the fermentation of sugarcane juice and molasses. Pure

ethanol is a colourless liquid. It has a specific smell and

burning taste. Its boiling point is 351 K which is higher

than corresponding alkanes. It is soluble in water. Ethanol

has a density of 789 g/li. Ethanol can be used two ways: (1)

Blended with gasoline at levels ranging from 5 to 27.5

percent to reduce petroleum use, boost octane ratings and

cut tailpipe emissions; (2) Pure ethanol made up of 85 to

100 percent depending on country specifications can be used

in specially designed engines.

On arrival at the sugar processing plant, sugarcane is

loaded onto a conveyor table. It passed various sugar

equipments including a shredder which uses a series of

knives to chop the cane into smaller lengths and shred it

into finer pieces. This process exposes the inner material

of the sugarcane and prepares it for efficient juice

extraction. The shredded cane then proceeds to a crusher,

which uses a set of roller mills to extract the juice. A

counter current stream of maceration water is used to remove

the juice from the crusher. Sugarcane juice from the

extraction process contains many impurities. The juice is

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heated and purified by the addition of flocculation aids and

lime. Heat helps to kill natural enzymes in the juice, which

would otherwise break down the sucrose. Lime is a suspension

of calcium hydroxide in solution and increases the pH of the

juice from its natural acidic level to a neutral pH of 7.0.

The control of pH is critical throughout sugar processing.

Sucrose hydrolyzes to glucose and fructose at a pH less than

7.0 and all of these sugars decompose substantially at a pH

greater than 11.5.The neutralized juice is pumped to a

continuous clarifier where it is inoculated with

flocculants. Clear juice flows off the top part of the

vessel, while flocculated impurities, called muds, settle at

the bottom. Clarified juice is processed through evaporators

which are often comprised to concentrate the juice.

The designers decided that Sugarcane Ethanol Processing

Plant must operate continuously from February to early

December. The production is scheduled for 300 days of the

year, running continuously.

The estimated capacity of ethanol production is 100 li/

day. Therefore the annual production capacity of the plant

is 30,000 liters per year.

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Material Balance, Energy Requirement, and Normal Duration of

Ethanol Processing Plant with Equipments

Processes Equipment/s Material Energy Operating

Balance Requirement Hours

Conveying Belt 20 tons 4-7.5 KW 4 hrs

Conveyor Sugarcane

Milling Hydraulic 5 tons of 50 HP per 4 hrs

Sugarcane sugarcane Mill

Crushing per hour

Mill

Steaming Steam 3,000 kg of 1,600 kg/hr 2 hrs

Boiler Sugarcane of Steam

Juice
Evaporator

Fermentation Cylindrical 1,350 liters 42 48 hrs

-conical of Ethanol liters/hr

Fermentatio

n Tank

Distillation Rectifying 100 liters --

Column of Ethanol

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