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Welcome
To
All India 2 Day Seminar Cum Exhibition
Organized By
All I dia Distille s’ Associatio
18th & 19th February 2016
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Thank you very much
for your Support & Continual Trust
on us
as your Technology Partner for
Ultra Modern & Energy Efficient Distilleries
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Deep sense of gratitude towards
Honorable Chairman of this technical session
Mr. K.P. Singh
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Maximization of Ethanol Production Using B-Heavy Molasses
as an Alternative Feed Stock – A Distillery Perspective
By
Sanjay Desai & Sandeep Chichbankar
Excel Engineers & Consultants, Pune INDIA
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Excel Engineers & Consultants
• Excel Engineers & Consultants, Pune INDIA is a technocrat driven
organization.
• A cumulative team experience of more than 2 decades and 150
distillery projects worldwide.
• A technology provider in Distillery, Biofuels, Sugar, Cogeneration,
Water, Waste Water, ZLD and Renewable Energy Industry.
• Excel is promoted by Mr. Sanjay Desai, a Chemical Engineer with a
clear vision to provide ultra-modern & state of art energy efficient
and sustainable futuristic technologies to the industry
• Fast growing technology and EPC company – 12 complete projects in
year 2015-2016.
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Area of Expertise
Distillery & Biofuels
Biomass Power & Waste to Energy
Sugar Industry & Cogeneration
Renewable Energy
Waste Heat Recovery & Recycle
Water & Waste Water Management
Zero Liquid Effluent Discharge Systems
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Strategic Alliance
Our strategic alliance with ISGEC
Heavy Engineering Ltd. has greatly
increased our strength to provide
a Complete, End to End
Technology Solution in Sugar
Industry, Cogeneration and
Distillery.
With this alliance, we are already
executing 4 big capacity distillery
projects along with Spent Wash
Incineration Boiler.
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State of Art Designing
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Excellence
Excelle ce is our Vision statement, a Mission statement & Quality policy.
• In house development E- ax Technologies for Grain and Molasses.
• Product ENA quality is accepted by all domestic & International Bottlers.
• Proven record of best Steam economy and energy savings.
• Execution of ZLD systems for both Molasses and Grain distilleries.
• Successful execution of single 300 KLPD Distillery in India.
• The best alternative & fastest growing technology company.
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E-max Range of Technologies
E- a Highl Efficie t Fe e tatio Tech olog
E- a E e g Efficie t “upe fi e G ade Distillatio Pla ts
E- a Multi Effect Evapo atio Pla ts
E- a D e a d DDG“ Pla t
E- a Ze o Li uid Efflue t Discha ge “ ste s
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E-max Fermentation Plants
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E-max Distillation Plants
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E-max Evaporation Plants
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E-max Dryer & DDGS Plants
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E-max ZLD Systems
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Manufacturing Facility
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EPC Capability
• House of single window innovative technologies and designs
• Concept to commissioning of custom built modern plants
• Highly professional project management team insuring project
completion well ahead of the project schedules.
• EPC services right from civil work to main process plant, boiler,
turbine and zero liquid effluent discharge.
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Esteemed Clientele
Repeat orders from satisfied customer is our strength, we are proud to be
associated with major players in industry for more than a decade.
• Globus Spirits Ltd., West Bengal, Complete Grain Distillery
• Globus Spirits Ltd., Bihar, Complete Grain Distillery
• CDBL, Chandigarh., I dia’s Largest Grain Distillery
• Oasis Group Punjab. – 3 Nos. DDGS Plants
• HLPL Karnal, Haryana, Grain Distillery
• Globus Spirit Ltd., Rajasthan, DDGS Plant with Zero Steam Evaporation
• San Carlos BioEnergy, Philippines, Cane/Molasses Distillery Expansion
• SSJD South Asia., IS to ENA Distillation Plant
• Hitech Engineers Ltd., KA, Complete Molasses/Juice Distillery – 2 Nos.
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Esteemed Clientele
• Shamanur Sugars Ltd., KA, Molasses /Grain Distillery Up-gradation
• Uttam Engineers Ltd., UP, Molasses/Grain Distillery – 2 nos
• Saipriya Sugars Ltd., (Nirani Group), KA, Complete Molasses Distillery
• Rana Sugars Ltd., Grain Distillery Modernization and Evaporation Plant
• Krishnaveni Sugars Ltd., (NSL Group), KA, Complete Molasses Distillery
• MRN Sugars & Power India Pvt. Ltd., KA, Complete Molasses Distillery
• Lorvin Industry Ltd., KA, Complete Molasses Distillery
• Rana Sugars Ltd., Fuel Ethanol Plant
• Tikaula Sugars Ltd., Evaporation Plants
• And Many More to come…
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Maximization of Ethanol Production Using B-Heavy Molasses
as an Alternative Feed Stock – A Distillery Perspective
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Background
• India is a fast growing economy and facing the challenges of increasing
energy demand.
• The Indian Sugar Industry is going through a very critical phase considering
excess sugar production compared to the present demand.
• At the same time, there is consistently growing awareness and necessity to
utilize Clea & Gree Fuel Ethanol in automotive / transportation sector.
• Govt. of India, realizing this potential, taking initiatives to promote utilization
of Fuel Grade Ethanol manufacture from Sugar Cane based feedstock
through its Ethanol Blending Programme (EBP).
• Ministry of Finance has exempted Central Value Added Tax (CENVAT) on
Fuel Ethanol manufactured from Molasses.
• Very attractive price for procurement of Fuel Ethanol for EBP.
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Present Scenario
• Huge Energy Demand for transportation and other sectors, is usually met by
Fossil Fuels such as coal, natural gas and crude oil.
• Annual global requirement of petro products is around 18000 MMT and
I dia’s requirement is only 130 MMT.
• However, the domestic production of crude oil and natural gas is only about
35 MMT i.e. around 25%. This huge demand-supply gap is met by import.
• Out of 6 billion litres of installed capacity of Ethanol in India at 50% utilization,
we are capable of producing about 2.5 to 3 billion litres per annum.
• 5% Ethanol Blending Programme requires about 0.8 million litres of Fuel
Ethanol and remaining can be diverted to distilleries and chemical industry.
• Our crude oil import bills have increased by 13 times in last two decades and
expected to increase upto 50 times by 2020.
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Need for B-Heavy Molasses
• B-Heavy molasses is generated by two massecuite boiling scheme comprising
of A and B massecuites.
• With present annual molasses production of around 11-12 MMT, the alcohol
production through molasses route shall remain around 2500 million litres.
• It is estimated that if we can divert B-Heavy Molasses containing 1 million
tones of sugar, as additional 600 million litres of alcohol can be produced.
• Switching over from existing C Molasses to B-Heavy Molasses is easy in
existing set up of sugar mills and distilleries.
• Additionally, there are many other advantages using B-Heavy molasses as an
alternative feedstock in distilleries.
• Hence; in order to give boost to Ethanol Blending Programme, diversion of B-
Heavy Molasses to ethanol production is sought as a Technology Solution.
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Feed Stock Options
Sugar Factory can offer following feedstock options for manufacture of Fuel
Ethanol_
C Molasses
B-Heavy Molasses
Syrup of 40 Brix
Juice +
Molasses
A-Heavy Molasses
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Composition of Feedstock
Parameters Production
% of Cane
Crushed
Brix
%
Purity
%
FS
%w/w
Final C Molasses 4.26 83 34 42-45
B-Heavy Molasses 7.00 85 58 50-65
A-Heavy Molasses 12.00 76 73 62
Secondary Juice 39.73 9.26 79.32 --
Concentrated
Secondary juice
9.19 40.00 -- 32.33
Syrup 37.76 40.00 83.61 33.54
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Advantages (B-Heavy Molasses)
• Reduced recirculation of non-sugars and low purity intermediate in
the pan floor will result in considerable improvement in Sugar Quality
• Capacity enhancement at Sugar Mill due to less load on pan station
• Reduction in power consumption as well as steam consumption in
sugar mill
• Approximately 25% higher recovery of Ethanol due to high
fermentable sugars
• Higher fermentation efficiency
• Higher distillation efficiency due to higher alcohol percentage in
fermented wash (high gravity fermentation)
• Considerable reduction in effluent spent wash generation
• Lesser steam requirement in distillation and spent wash evaporation
plants
• Capacity enhancement at distillery due to higher alcohol, higher yield,
lower spent wash generation and lower utility consumption
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C Molasses Vs B-Heavy Molasses
Sr.
No. Parameters Units
C
Molasses
B
Molasses Advantage
1 Average
Fermentable
Sugars
% w/w 43 56 Around
30% more
FS
2 Brix in Molasses % 80 85 Similar
3 Average TRS % w/w 49 59 20% more
TRS
4 Average F/N Ratio -- 1.16 1.93 65% more
F/N ratio
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C Molasses Vs B-Heavy Molasses
Sr.
No.
Parameters Units C
Molasses
B
Molasses
Advantage
5 Average
Fermentation
Efficiency
% 89 92 Cleaner and
more efficient
fermentation
6 Ethanol Yield
Litres/ MT @
99.8% v/v
Litres/
MT
242 325 35% more
ethanol yield
7 Average Alcohol
in Fermented
Wash
% 9 12 Ease in
targeting
higher alcohol
8 Steam
Consumption for
Wash to RS
Kg/litr
e of
spirit
2.10 1.70 20% less
steam
consumption i
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C Molasses Vs B-Heavy Molasses
Sr.
No.
Parameters Units C
Molasses
B
Molasses
Advantage
9 Spent Wash
Generation from
Distillation
Litres/Li
tre of
Spirit
9.57 7.07 Reduction in
spent wash
by 25%
10 Spent Wash
Solids
% w/w 14.04 11.88 Less solids in
spent wash
due to more
FS
11 Spent wash to
Boiler @60 brix
Kg/Litre
of Spirit
2.13 1.33 Less load on
boiler
12 Bagasse
Requirement in
Boiler
Kg/Litre
of Spirit
0.43 0.27 Less auxiliary
fuel
requirement
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Conclusion & Recommendations
• B-Heavy Molasses can be effectively utilized for fermentative
production of ethanol.
• It does not only result in better alcohol yield but capacity utilization
and efficiencies at distillery also increases.
• There is substantial reduction in steam(20%) and reduction in effluent
spent wash (25%)
• Excel Engineers & Consultants have relevant experience and offers
assistance to existing distilleries to switch over to B-Heavy Molasses.
• Excel offers Concept to Commissioning of Turnkey EPC distillery
projects suitable to operate on both B-Heavy as well as Final C
Molasses with maximized efficiencies.
• Excel offers technology for upto 25% capacity enhancement in existing
distillery set up using B-Heavy Molasses.
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Contact Us
Excel Engineering & Consultants
604-605, Pride Kumar Senate, Phase-I,
Senapati Bapat Road, Near ICC, Shivajinagar,
Pune – 411 016 (India)
Tel: +91 20 41070100 Cell: +91 9561096988
Email: [email protected] Web: www.regreenexcel.com
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