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INTRODUCTION
Located in Mehn village at a distance of 10 km from Patiala. Came into existence in 1978 and started production in 1979. Capacity of plant 60KLD Ethanol. Raw material used is molasses and grain (rice).
Inlet of Molasses Molasses Storage Grain Loading Steam Milling & Screening Husk Storage Chopper Rice Husk
Dilution Tank
Liquefaction
Blower
Prefermenter
pH Setting
30%
Flue Gases
Cooling Water
Fermenter
Cooling Water
D.M Water
Cyclone in series
Cooling Tower
Wash Holding
H.E
Turbine
Boiler Blowdown
Boiler
Distillation
Ash
Spirit Storage
Domestic Waste
70%
Tank
Biocomposting
Green Belt
Acidogenesis
Methanogenesis
Aeration
Settling
Aeration
Settling
LIQUEFACTION
In grain flour along with processed water, enzyme and stabilizing chemicals are added. Slurry is cooked with high pressure steam Liquefied mash is cooled in mash cooler and saccharifying enzyme is added which initiates the formation of sugar. Mash now sent to pre-fermenter.
YEAST PROPAGATION
Molasses is received into the yeast vessel and sterilized by steam.(mash is taken during fermentation by grain) Yeast seed material is prepared and added to the yeast vessels by inoculating molasses with yeast. Aeration is done for yeast activation
FERMENTATION
Convert fermentable sugars into alcohol and CO2 Significant heat released during fermentation but temp maintained at 35-37 deg C by use of forced recirculation plate type heat exchangers Aerated cell mass is transferred to the fermenter for maintaining critical growth rate.
DISTILLATION
Multipressure distillation is done to extract ethanol from wash. Wash is preheated with spent wash and fed into distillation column for distillation Here aldehyde column remove the aldehyde impurity. Ethanol thus collected stored in tank for further processing.
BOILER
Steam requirements of the industry are fulfilled by a boiler of capacity 8TPH operated on biogas(70%) and rice husk(30%). A turbo alternator of 600 KW is installed for cogeneration. Four cyclones in series are installed to take care of ash generated during combustion. R.C.C chimney of 50 m height, 2 m internal dia having efflux vel 9.5 m/s
Steam Biogas and Rice husk Turbine Alternator Steam F.D Fan External Boiler Furnace Fire Tube Boiler Steam
Flue Gas
APCD
I.D Fan
Boiler
Fermentation section Fermenter cleaning water Pump Sealing water Floor Washings water Process Air Blower Sealing water Distillation Section Molasses based Plant- Spent Wash Grain based plant Thin slops Spent Lees Vacuum Pump Sealing Water Other cleaning water Liquefaction Section (For Grain Plant) Pump Sealing water Floor Washing water Other cleaning water
ETP
Pretreatment involving bar screen, oil traps, catching of the grit or sludge. Equalization. Neutralization. 1st stage anaerobic digestion. 2nd stage aerobic oxidation. 3rd stage oxidation. Drying of sludge on beds. Channeling of clear water for irrigation.
ENVIRONMENTAL CONCERNS
Flue gases from boiler Water used per lt of alcohol is quite high 15-20 lt Boiler blow down containing TDS
SUGGESTIONS
Installation of flash tank to recover heat and water vapors from boiler blow down Indirect heating during distillation Flue gas heat can be used Installation of multi effect evaporation plant to achieve ZLD Adoption of thin slop treatment option for grain based distillery
Thank You