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PLOT LAYOUT PLAN
MPCB CONSENT
ORDER
MANUFACTURING
PROCESS
Manufacturing process
Fermentation is bio chemical process in which organic compounds is converted in to
simple organic molecule with the help of microorganisms like yeast by specific type of
organisms.
For the fermentation process, most essential Yeast bio mass is required, this required
bio mass is firstly inoculated I laboratory under aseptic condition, this inoculated culture
transferred in to different capacities of culture vessels for the increasing the yeast bio mass as
per the required fermentation process.
This system consists of 4 No’s of fermenters having same capacity. The prepared
culture bio mass is transferred to fermenter No 1 and molasses feeding depending upon the
sugar concentration present in molasses continuously through broth mixers. Water is directly
added in fermenter. This fermenter is works under aerobic condition. In fermenter No 1 for
maintaining the bio mass air given through sparger for healthy growth for yeast cells. We are
adding the Urea & DAP as a nutrient. Fermentation process is exothermic process, at the time
of reaction temperature of the wash increases, this temperature is maintaining in between 30 to
320 C through plate heat exchanger using cooling water.
After sufficient level of Ist fermenter of overflow taken in IInd fermenter. IIIrd & IVth
fermenter visually. In fermenter process sugars converted to alcohol & CO2, that CO2 blower.
IInd, IIIrd & IVth fermenter works under anaerobic condition. This scrubbed CO2 is return feed to
IInd, IIIrd & IVth fermenter through sparger to control the multiplication of yeast & produce
maximum alcohol. We are giving molasses & water feeding to IInd, IIIrd fermenter as process
calculation. To maintain fermented wash temperature in between 30 to 320 C, each fermenter
provides plate heat exchanger. At the time of fermentation process inert pressure is produced
in fermenter, to release increased inert pressure safety pressure safety system for all four
fermenters is provided.
After completion of fermentations process fermented wash to YST to settle the sludge &
supernatant wash transferred to CWT. fermented wash is transferred to distillation for further
separation of alcohol from wash.
MULTIPRESSURE VACUUM DISTILLATION:
Distillation is physical process in which to separate the mixture of compounds by the
virtue of their different boiling points.
The distillation plant consists of four-column system having Analyzer, pre-rectified,
Rectified cum exhaust & Fusel oil concentration column.
The fermented wash from CWT tank is pumped to the & fermented wash preheater &
preheated to 68 to 700C. by circulating hot spent wash on other side. Incoming spent wash
temperature is 80 to 820C. & after exchanging heat with fermented wash outlet temperature of
spent wash remains at 350to 400C. This hot fermented wash is then fed at top of the Analyzer
column.
1)Analyzer column:
Analyzer column strips off the alcohol from the fermented wash before discharging the
rest of the material as spent wash.
Fermented wash is fed at the top of the Analyzer column. Feed flow to the column is measured
by using a magnetic flow meter. Analyzer column is operating under vacuum 380-390mm.Hg.
Vacuum is created by using water ring vacuum pump and vacuum in the column is maintained by
manual valve. Analyzer column is provided with thermosyphon reboiler is provided with a stand
by arrangement. Rectifier top vapours are condensed on the shell side & spent wash is getting
recirculated on tube side. Vapour generated from the boiler is used in the Analyzer column for
stripping the alcohol from the fermented wash. Analyzer column top temperature maintained 72
to 740C and bottom temperature 80 to 820C. The vapour draw from top of the column fed to pre-
rectifier column.
Spent wash from analyzer column bottom is sent for treatment to the Effluent treatment
plant. the level in the bottom of column is controlled by pneumatic control valve.
2)Pre-rectifier column:
Pre-rectifier column is used for removal of low boiling impurities.
Column is operating under vacuum 490-500 mm.Hg.The column top temp. is maintained 49-
500C.and bottom temp. 60-620C.The vapours coming out of the top of pre-rectifier column are fed
to the condenser – I where they are partially condensed by passing cooling water on the tube
side. Balance alcohols vapours passes through the condenser –II are condensed by cooling
water and then collected to the pre-rectifier reflux tank are pumped back to the column as reflux.
Impure spirit draw is taken from the reflux. Alcohol water mixture from the column bottom is fed
to the Rectifier cum exhaust column. The level in the bottom of column is controlled by
pneumatic control valve.
3) Rectifier cum exhaust:
Rectifier cum exhaust column is consisting of eighth segment upper three are copper
metal & remaining remaining is S.S. having 66 bubble cap trays.The column operating under
pressure 2.2-2.5 bar (A). Top temperature maintained 33-1000C & bottom is 125-1270C. Steam is
applied to bottom valve having temp. 200-2500C.& pressure 2.2-2.5kg/cm2. The column feed
given from pre-rectifier bottom is pre heated through spent less. Rectifier spirit vapours coming
out from top of the column are partially condensed to the shell side of analyzer reboiler vent. The
totally condensate alcohol -water mixture collected in rectifier reflux tank & then circulated the top
of rectifier column by pumps. LFO & HFO draw temp. maintained between 101-1030C & 109-
1030C resp. these draw are taken to the fusel oil column. Rectified spirit draw collected from
upper tray of the column sent to R.S storage through R.S cooler.
Spent lee coming out of the exhaust column bottom is used to pre heat rectifier feed
then drained. The level in the bottom of column is controlled by pneumatic control valve.
4)Fusel oil conc. column:
The column is operating under atmospheric pressure. Steam is applied to the bottom.
The top & bottom temp. of column maintained 76-780C & 100-1020C resp. The alcohol vapours
condensed in I & II condenser are again refluxed to column. The impure alcohol draw taken from
I & II condenser bottle & cooled in the impure cooler & then collected in receiver. The
concentrated fusel oil recovered from column through decanter & collected to tank. Spent lees
coming out of the F.O.C. column from bottom & then drained to gutter.
FLOW CHART OF ETHANOL MANUFACTURING FROM MOLASSES
Molasses from the Sugar Factory
Weighing of Molasses
Dilution of Molasses
Prefermenter
Culture Yeast
Fermentation
Distillation
Ethanol
WATER BUDGET &
WATER PERMISSION
LETTER
DAILY WATER BUDGET FOR 45 K.L.P.D. MOLASSES BASED DISTILLERY
BY
JAYWANT SUGARS LTD.,
TAL. - KARAD, DIST. - SATARA
Daily Requirement of Water is 455 KL/Day (*232+ #223)
15 M3/day to CPU
Sewage Generated 4.5 K.L.
The sewage shall be treated in STP
Total Wash 480 KL (360 K.L. + 120 K.L. = 480 K.L.)
Fermentation
32 MT/ Day CO2
Plus Molasses 165 M.T. (Vol. 120 KL)
Yeast Sludge 10 KL
To incineration in the incinerator
boiler
Effluent 8.5 K.L.
Effluent Generated 6.5 KL
Fermenter Cooling *5 KL
Condenser Cooling Replenishment *60 KL
Fermentation Dilution 360 KL (*150 +
#210)
For Washing and Laboratory
# 7 KL
Domestic #6 KL
Distillation
472 KL
Steam from Boiler, 27 MT (1.6 T/KL of Alcohol) Condensation Water
337 K.L Spent wash (12%Solid) 45 K.L. Alcohol 90 KL Spent Lees
Steam Condensate 27 KL
Gardening *5 KL
Standalone
Evaporation system 76 KL
Condensate
114 KL Spent Wash Contains 60% Solids
331 KL
to CPU
Incineration
232 KL used for Fermentation process & cooling towers, boiler, gardening
Reject 99 KL
Note : * Recycled water from CPU unit. # Fresh water
Boiler
*10KL
Integrated
Evaporation System 150 KL
Condensate
226 KL Condensate
190 KL Spent wash (22 % Solid)
* 2 KL Water for Alcohol vapour scrubbing
15 KL other effluent
0.5 K.L. 2 KL.
6 KL
CPU FLOW Diagram
CPU Flow Diagram
Aeration Tank-I (10 X15 X 4M)
(10 M3/Hr)
PST (4Mø X 3.5M)
Excess Sludge
PSF ACF Treated Water Tank (8 X12 X 3.5M)
Treated Effluent
SST -II (4Mø X 4M)
Collection Tank-II (8 X12 X 3.5M)
SDB
Return Sludge
Aeration Tank-II (8 X12X 4M)
SST-I (6MøX4M)
Influent 331CMD
PSF-Pressure Sand Filter ACF-Activated Carbon Filter PST-Primary Settling Tank SST- Secondary Settling Tank SDB- Sludge Drying Bed
Return Sludge
Collection Tank-I (8 X12 X 3.5 M)
Flash Mixer
(2M X 2M X 1.5M)
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