60 KLPD GRAIN BASED DISTILLERY PLANT

60 KLPD GRAIN BASED DISTILLERY PLANT

 60 KLPD GRAIN BASED DISTILLERY PLANT

DESIGN BASIS
SR. DESCRIPTION SPECIFICATIONS
NO.
1. Capacity of the Plant- 60,000 Lit/Day Ethanol @ 99.8 % v/v
Raw Material :- Corn - 154 MT/Day @ starch 60% w/w
Corn Rice – 132 MT/Day @ starch 70% w/w
Water Quality Process water for Liquefaction & Fermentation
2. DM Water for Boiler make-up.
Soft water for cooling tower make up, and
vacuum pump sealing

3. Alcohol concentration in Wash 12% V/V Min

4. Steam Pressure (Dry &Saturated )

Liquefaction 0.7 kg/lit of alcohol – 1.75 MT/hrs
Distillation 1.8 kg/Lit of alcohol- 4.5 MT/hrs
MSDH 0.55 kg/Lit of alcohol-1.4 MT/hrs
Integrated Evaporation section By Analyzer vapor
Standalone Evaporation section 1.0 kg/lit of alcohol – 2.5 MT/hrs
DDGS Dryer 1.6 kg/Lit of alcohol -4.0 MT/hrs
Total steam consumption 14.05 MT/hrs

5. Condensate Polishing Unit Plant Capacity.-400 m3/Day

6. Water treatment Plat Plant Capacity.-1000 m3/Day
7. Reject water treatment plant Plant Capacity.-120 m3/Day
8. DDGS Product Corn - 42 TPD & Rice -28 TPD
9. Boiler Capacity- 15 TPH @ 45 Kg/Cm2(g)
10. Turbine Capacity-1.5 MW

11. Electrical
Motor Drives (LT) 415V AC
Rated Frequency 50 Hz + 5%
Lighting and Controls 220-250 V AC

12. Instrument Air Pressure :7 Kg/cm2 (g)

Temperature : 40 oC.
 60 KLPD GRAIN BASED DISTILLERY PLANT

Water Requirement-
Sr. Description Water Quality Fresh Water Fresh Water Remarks
No. Consumption Consumption
(without after recycle
recycle) m3/Day
m /Day
3

1. Liquefaction
& Fermentation Process
348 348
including CO2 Water
Scrubber water
2. Make-up water for After utilizing
Cooling tower 300m3/Day
Soft water 356 56 treated water
from condensate
treatment Plant.
3. Sealing water for Air 90% of sealing
blower in water is recycled
Fermentation, & balance
Soft water 70 7
Vacuum pump in through treated
Distillation water make-up
from CPU
4. Scrubbing water for No recycle
Alcohol Scrubber in Soft water 60 6
Distillation
5. DM water for boiler 85% Steam
water makeup & Jet condensate from
cooker DM water 96 96 plant shall be
recycled back to
Boiler.
Total Water 930 m3/day 513 m3/day
Consumption

Chemical Consumption-
Sr. No. Description Specifications
A. Sulphuric acid : Consumption 0.50 Kg / KL of total Spirit

B. Antifoam (Silicon) agent : Consumption 0.50Kg / KL of total Spirit

C. Urea : Consumption 4.5Kg / KL of total Spirit

D. Enzymes :
ENL (Alpha Amylase) : 0.8 Kg/KL of Alcohol
ENS (Gluco Amylase) : 1.30 Kg/KL of Alcohol
E. Yeast Consumption : 0.5 Kg / KL of Alcohol
F. Caustic (Sodium Hydroxide Concentration : 50% v/v
Solution) : 6 Kg/KL for CIP
Distillation & Evaporation:
: 300 Kgs/ CIP cycle
 60 KLPD GRAIN BASED DISTILLERY PLANT

PROCESS BLOCK DIAGRAM FOR GRAIN ETHANOL PLANT

 60 KLPD GRAIN BASED DISTILLERY PLANT

PROCESS DESCRIPTION
In grain-based distillery process have following steps.
• Grains receiving and storage
• Grains handling and milling
• Slurry preparation/liquefaction
• Saccharification and fermentation
• Multi-pressure distillation
• MSDH
• Decantation
• Multi-effect evaporation
• DDGS Dryer
• Alcohol storage

A. SILO & GRAIN HANDLING SYSTEM :-

System involved in Grain handling system:
Grains are received from trucks in gunny bags. These bags are unloaded manually on receiving
platform. From the platform Bags are dumped manually into the receiving hopper. Receiving hopper
is provided with aspiration system to avoid dusting in the receiving area. Hopper is equipped with
Safety Grill, Manual slide gate to control flow to elevator. The Bucket Elevator shall feed the grains to
the Pre-cleaner. The Pre-cleaner is provided of double deck type to remove oversize and undersize
impurities. The dust and light impurities are separated with blower and cyclone of the Pre-cleaner.
In the Pre-cleaner oversize, undersize impurities along with light dust and farm waste are removed.
From the Pre-cleaner, clean grains are further fed to Bucket Elevator to feed the silos. The Silo’s
diverter is provided at the outlet of elevator to feed the desired silo. Y chute is provided for feeding
the silo. The Bucket elevator is provided with supporting structure with ladder up to top and
intermediate platforms.

B. MILLING:- (Hammer Mill):-

Milling is required to reduce the particle size of raw material. The milling section of the plant has
the necessary equipment for cleaning of raw materials and screening the final floor to get the
desired particle size.
Grain Milling: Involves rotary feeder for controlled feed, hammer mill to achieve desired particle
size and capacity. Hammer mill discharge arrangement with screw conveyor, rotary screen for
coarse separation.
Flour handling: Involves mechanical or pneumatic conveying, screw conveyor, bucket elevator,
rotary valves with roots blowers.
Flour Storage: Flour storage silo is provided with bin activator for a smooth discharge. Silo is
provided with high & low level switches and load cells for weighing/automation.
Flour weighing and batching: Weight controller and Totalizer provided for automation to know
the flour consumption. Unique equipment called Pre-masher is used for metered feed of flour and
water to get uniform slurry for liquefaction.
 60 KLPD GRAIN BASED DISTILLERY PLANT

C. LIQUIFICATION SECTION:-
Liquefaction initiates the conversion of starch into simple molecules of dextrin. It is divided into
three sub processes.

In pre-masher, flour & required quantity of water are transferred by conveyer. Uniform grain
slurry is made and transferred to another low shear tank (slurry tank) for proper mixing. In slurry
tank required pH of 5 to 5.5 is maintained by using lime/sodium hydroxide if required and
temperature as 550C to 600C. An enzyme called α-amylase is added here in small (20-25%) dose
before the cooking process starts.

Cooking: The grain slurry is pumped from mixing tank (Slurry tank) to Jet Cooker (Hydro Heater)
through open impeller centrifugal pump. In jet cooker steam is applied at 3.5 kg/cm2 pressure to
cook the starch slurry to break down the chemical structure of starch in presence of enzymes. The
temperature of grain slurry at outlet of jet cooker is maintained between 105 to 120 0C, after
cooking the grain slurry is passed through the retention vessel to provide desired retention time
at a given flow rate to convert starch into dextrin. In this step slurry pressure & viscosity reduces.
The slurry which is hot is transferred into the flash tank to reduce the temperature of the slurry to
90- 950C before sending to final liquefaction tank. Flash tank is attached to flash condensers where
vapours are condensed and condensate is sent to slurry tank.

Liquefaction: Grain slurry is transferred to final liquefaction tank from flash tank where
remaining 75 to 80% of enzymes of α-amylase is added which convert starch to dextrin and 1-4 α-
glycosidase linkages are hydrolysed into amylase and amylo pectin. Enzymatic activities rapidly
break-down the starch molecules to soluble dextrin’s and Oligosaccharides. To have good
conversion of starch to dextrin retention time should be about 1 hr.
Saccharification: From the liquefaction chamber, the mash is pumped through a heat exchanger
to be cooled for simultaneous Saccharification. Simultaneous Saccharification is the formation of
fermentable glucose and the process is carried out in fermenter with fermentation process. The
breakdown of dextrin’s formed during liquefaction takes place with the help of a second enzyme,
Amylo-glucosidase. The pH is required to be adjusted in the range of 4.0 to 5.0 and the optimum
temperature for the Amylo-glucosidase enzyme is about 30-350C. The quantity of glucose
produced is monitored by measuring the Dextrose Equivalent (DE) of the mash.

D. FERMENTATION:
Fermenters are cylindrical & vertical with conical top & flat sloping bottom. Fermenters are
equipped with top entry agitators. Final liquefied slurry from final liquefaction tank is pumped
into fermenter and is diluted to appropriate sugar concentration with process water. During
fermentation process, Saccharification progresses further, and releases glucose required by yeast.

Yeast
C6H12O6 = 2 C2H5OH + 2 CO2 + Heat
Fermentation is initiated by inoculating with required quantity of yeast. The assailable nitrogen is
added in the medium in the form of urea and di-ammonium phosphate. Temperature in the
fermenter is maintained at 32 C with the help of external wide gap plate heat exchanger (PHE).
The fermented mash is re-circulated continuously through the PHE. Recirculation also helps in
proper mixing of fermented mash. The rate of fermentation reaction gradually increases and after
about 55 to 65 hours fermentation completes. After completion of fermentation the mash is
transferred to mash holding tank.
 60 KLPD GRAIN BASED DISTILLERY PLANT

The CO2 which is liberated during fermentation is scrubbed in water, in CO2 Scrubber. This CO2
contains alcohol, which is recovered by collecting CO2 scrubber water into mash holding tank.

E. DISTILLATION:-
Multi-Pressure Distillation system has Seven Distillation columns operating at various pressure
conditions. Heat energy from columns operating under high pressure is utilized for columns
operating under low pressure to optimize the operation for energy consumption.

Wash to ENA Mode:

Following Columns will be under operation:
• Analyser Column
• Degasser Column
• Rectifier cum Exhaust Column

Analyzer cum Degasser Column

Analyzer Column is operated under Vacuum Pressure. It is heated using the top vapors of the Rectifier
column. The benefits to operate the primary column under vacuum pressure are that firstly, it
decreases the overall energy requirement of column and secondly, due to vacuum, scaling problem
in the column and reboiler is reduced. Hence allow the column to be operate smoothly & continuously
for quite long.
The fermented wash (from Fermentation) is preheated by a Plate Heat Exchanger. Then it is fed at
the top of Degasser Column. The pre heating of fermented wash in two stages recovers energy and
saves steam requirement in the distillation section.
Based on the Boiling Point, Degasser Column separates the high volatile compounds, mostly
containing the Impurities. Alcohol and other volatile compounds are separated from the top of the
Primary Column & fed to Pre- Rectifier Column for increasing the further concentration and removal
of impurities.

The solid containing colored liquid waste in fermented wash moves towards the bottom of Primary
column. This liquid waste is called as spent wash & taken out from the column bottom to Effluent
treatment plant for further processing.

Rectifier Column
Primary Rectifier Column is heated on steam indirectly with the help of one reboiler. Analyzer column
vapors condensed and fed to Primary Rectifier column. This column is operated under pressure to
for enhanced quality. Heavy & Light Fusel Oils are extracted from this column & fed to De - fusel Oil
Column.
Impure spirit is also separated from the Vent Condenser of this column.
Alcohol concentration is increased in this column.
The liquid bottom stream of the column, containing no traces of alcohol, is discharged in the form of
spent lees, Rectified spirit, separated from this column, is cooled, and taken to receivers.
 60 KLPD GRAIN BASED DISTILLERY PLANT

F. DECANTATION SECTION: -
Spent Wash from Analyzer column Bottom of grain-based distillery plant is feed to continuous
Decanter centrifuge. Due to centrifugal action suspended partials get separated as a wet cake and
thin liquor out called as a thin slope.
Thin slops coming out of Decanter are collected in a tank and partly recycled into the process &
further for Evaporation for concentration up to 30-35 % w/w solids. The concentrated thin slops
called as Syrup is mixed with Wet cake and sold in wet form as cattle feed (DWGS) or the entire
mixture can be dried in a DDGS Dryer and then sold in dry form as Cattle feed (DDGS).

G. DDGS DRYER:-

Wet distiller’s grains shall be fed into the dryer housing at controlled rate through a suitable
feeding system. The Fluidised Bed Dryer is enclosed in an insulated dryer housing and its outer
flights are fixed. Dry saturated steam is to be supplied to the dryer through rotary joint at one end
& the condensate is discharged through joint mounted on another end.

During fluidization, these flights pick up the material and shower them on to the tube bundles. The
heat transfer is primarily by conduction. The water vapours are exhausted through an Exhaust
Blower & passed through a cyclone separator for separating fines.

Dry product partially recycled back to Feed conditioner for feed conditioning through Product
Screw & Recycle Conveyor.

Entire operation of the Dryer is controlled through Control panel

H. STAND ALONE EVAPORATION :-

Thin Slop out from decantation is concentrated in multiple effect evaporation system. Heating media
used for the evaporation is steam. Evaporation plant is designed to get maximum water evaporated.
The Total system is in under vacuum, and the vapor generated in this system is re-used for further
heating to save steam consumption. The concentrated stream out from the evaporation is mixed with
wet cake and process condensate generated from the evaporation is sent to condensate polishing unit
for further treatment& recycle back into process.

In evaporation inlet concentration will be 2-3% W/W solids and after evaporation It will increase up
to 35 % solids., which means about 80% water is removed from Evaporation and send to condensate
polishing unit for further treatment& recycle.
 60 KLPD GRAIN BASED DISTILLERY PLANT

PROFITABILITY PROJECTIONS
Cost of production and profitability sheet - An estimate for grain-based alcohol plant in India
Basis Notes
No of working days 330 Ethanol price/lit when produced from surplus grain procured from
Starch content 68 % FCI = ₹ 56.87
Recovery/ton 439.2Lit/Mt Ethanol price/lit when produced from damaged grain procured from
Plant capacity 60000Lit Per Day market = ₹ 51.55
CO2 production 45.9MT/day Selling price for DDGS and impure alcohol varies.
Recoverable CO2 27.5MT/day
VARIABLE COSTS
Cost Per
Raw Material Consumption Consumption Rate Cost/yr. liter
per day per year (Rs/unit) (Rs/unit) (Rs/unit)
Rice 136.6 MT 45085 MT ₹ 18,000.00 ₹ 811,530,000.00 ₹ 40.99
Steam 330 tons 108900 tons ₹ 480.00 ₹ 52,272,000.00 ₹ 2.64
Power-Cogen Plant 40020 kW 13206600 kW ₹ 1.57 ₹ 20,734,362.00 ₹ 1.05
Yeast 30 Kg 9900 Kg ₹ 900.00 ₹ 8,910,000.00 ₹ 0.45
Antifoam 30 kg 9900 kg ₹ 80.00 ₹ 792,000.00 ₹ 0.04
Sulphuric Acid 30 kg 9900 kg ₹ 22.00 ₹ 217,800.00 ₹ 0.01
Caustic 900 kg 297000 kg ₹ 22.00 ₹ 6,534,000.00 ₹ 0.33
NaOH 30 kg 9900 kg ₹ 22.00 ₹ 217,800.00 ₹ 0.01
Urea 270 Kg 89100 Kg ₹ 30.00 ₹ 2,673,000.00 ₹ 0.14
Alpha Amylase 60.4 Kg 19928 Kg ₹ 950.00 ₹ 18,931,600.00 ₹ 0.96
Amyloglucosesidase 88.3 Kg 29125 Kg ₹ 950.00 ₹ 27,668,750.00 ₹ 1.40
Process water 240 m3 79200 Lit ₹ 15.00 ₹ 1,188,000.00 ₹ 0.06
Soft water 295.2 m3 97416 Lit ₹ 15.00 ₹ 1,461,240.00 ₹ 0.07
DM water 72 m3 23760 Lit ₹ 25.00 ₹ 594,000.00 ₹ 0.03
Alcohol transport 60000 Lit 19800000 Lit ₹ 1.00 ₹ 19,800,000.00 ₹ 1.00
TOTAL VAR. COST(A) ₹ 953,130,552.00 ₹ 49.17
FIXED COSTS
Cost Per
Fixed costs Cost/yr. liter
Salaries and wages 60000 19800000 Lit ₹ 1.00 ₹ 19,800,000.00 ₹ 1.00
Repairs and
maintenance 60000 19800000 Lit ₹ 0.50 ₹ 9,900,000.00 ₹ 0.50
Insurance 60000 19800000 Lit ₹ 0.1 ₹ 1,980,000.00 ₹ 0.10
Interest on long term
loan ₹ 50,000,000.00 ₹ 2.53
TOTAL FIXED COST(B) ₹ 81,680,000.00 ₹ 4.13
TOTAL PRODUCTION COST(C = A+B) ₹ 1,034,810,552.00 ₹ 53.29
ESTIMATED INCOME FIGURES
Estimated Income
Ethanol 59400 19602000 Lit ₹ 51.55 ₹ 1,010,483,100.00
Impure Alcohol 600 198000 Lit ₹ 35.00 ₹ 6,930,000.00
DDGS 34155.21 11271217.82 Kg ₹ 21.00 ₹ 236,695,574.24
TOTAL ESTIMATED INCOME(D)
₹ 1,254,108,674.24
NET PROFIT PER YEAR(D-C) ₹ 219,298,122.24
NET PROFIT PER LIT OF ALCOHOL ₹ 11.08
PROFITABILITY PROJECTION
Sr. No. Particular Value Period
1 Plant Capital Investment ₹ 600,000,000.00
2 Estimated net profit per year ₹ 219,298,122.24
3 Payback period 2.74 Year