1. Fermentation: Batch/Fed-batch/Continuous Marker: Higher fermentation efficiency, higher alcohol lower spent wash/stillage generation. 2. Distillation : Atmospheric/Multi-pressure Distilla Marker: Reduced steam consumption, improved alcoh formation, reduced spent wash/stillage generation. 3. Dehydration: Molecular Sieve De-hydration Preferred and usually employed in place of Azeotropic 4. Evaporation: Standalone/ Integrated Marker: Lower steam consumption. 5. Condensate Polishing & Water Management Marker: Lower fresh water requirement SELECTION OF BEST AV
% in wash, lower retention time, ation hol quality, reduced scale c Distillation. VAILABLE TECHNOLOGIES Back to Annexure
1. Conversion Efficiency : 97.0+ 2. Fermentation Efficiency : 92.5+ 3. Distillation Efficiency : 98.5+ 3. Dehydration Efficiency : 99.5+ 4. Steam Consumption : ˂ 4 K 5. Power Consumption : ˂ 0.4 6. Fresh Water Requirement : ˂ 6 K BENCHMARKING OF EF
+ + + + g./ liter of ethanol KwH/liter of ethanol L/KL of ethanol FFICIENCY PARAMETERS Back to Annexure
1. Carbon Di-oxide gas: Solid : Refrigerated dairy/meat products cooling agent for heat sensitive materi machinery parts. Liquid : As a refrigerant for food products, In fire extinguishing agent Gaseous : Carbonated soft drinks, soda wa blanket in metal welding, pH control, As a Fumigation- Pest Control, hardening mould clarification of sugarcane juice and sugar m BY PRODUCT
, frozen foods, as a ials, shrink fitting of n-transit refrigeration, ater/ beverages, Inert a food preservative / ds in foundries and in melt clarification. T UTILIZATION Back to Annexure
Efforts to improvise the quality of DD Although the quantity of the same is as compared to rice based DDGS (a because of lower protein content,28 based, it fetches lower price and acce DRIED DISTILLER’S GRAIN
DGS from maize based ethanol units. more (about 0.6 Kg/ liter of ethanol) about 0.40 Kg/ liter of ethanol), but 8-30%, compared to 42-45% in rice eptability is also comparatively lower. NS WITH SOLUBLES (DDGS) Back to Annexure
Pelleting can improve the utility of DDGS, as it may improve storage and handling characteristics, and may allow more effective use in dairy cattle feeding As hig be nu by de FUTURISTIC APPROACH FORDD
s a partial substitute for flour, gh-value DDGS protein can e used to improve the utrition of various baked foods y increasing protein levels and ecreasing starch content. R BY-PRODUCT UTILIZATIONDGS Back to Annexure
Corn oil which has been extracted from DDGS can be used to manufacture biodiesel & for other purposes. Crude co ethanol p thin stilla process. C occurs af before the FUTURISTIC APPROACH FORCOR
orn oil can be produced at corn plants by extracting the oil from the ge portion of the DDGS production Corn oil extraction from thin stillage fter fermentation and distillation, and e drying to produce DDGS. R BY-PRODUCT UTILIZATIONRN OIL Back to Annexure
Corn to Ethanol Date: 02/5/2023
© Praj Industries Ltd www.praj.net LEED Certified Platinum Green Building Mahesh Kulkarni Back to Annexure
FEEDSTOCK C Typical Com Type of Corn US(GMO) Starch 63-64% Protein 7-8% Fibre 8-9% Fats 3-4% Ash 1-1.2% Other 1-2% Total Solids 86-88% Moisture 12-14% Research work required on improvement of Corn qu Production
COMPOSITION position of Corn Indian(Sweet Corn) 60-62% w/w 8-9% w/w 7-8% w/w 4-5% w/w 1-1.2% w/w 4-5% w/w 86-88% w/w 12-14% w/w ualities in terms of compatibility for ethanol Back to Annexure
COMPARISON OF US AND INDI ETHA Sr. No. Parameters US 1. Average size of plant 700-800 KLPD 2 Type of Corn GMO (Speciall developed for Et production 3 Type of Yeast and enzymes used GMO 4 Alcohol in Fermented wash 12-13% 5 Steam consumption 2.4-2.5 Kg/lit 6 Power consumption 160-170 Kwh US Corn to Ethanol Plants are more effic
IAN PROCESSES FOR CORN TO ANOL India Remark D 100-150 KLPD ly) thanol n Sweet Corn Low wax corn Non-GMO 15-17% Higher in case of US due to Feed characteristics, use of GMO Yeast and Enzymes t 3.6-3.8 Kg/lit With conventional Technology 240-250 Kwh ient and Less on OPEX than Indian Plants Back to Annexure
TYPICAL NUMBERS W Sr. No. Details Numbers Unit 1. Yield of Ethanol per ton of Corn 360 - 380 Lit/ton of Corn 2. Steam Consumption 3.6 - 3.8 Kg/lit 3 DDGS Production 0.65 - 0.7 Kg/lit of Ethanol 4. Protein content in DDGS 38 - 40 % 5. Water consumption 5.5 - 6.0 Lit/Lit of Ethanol Selection of correct technology, enzymes and Fe Ethanol.
WITH INDIAN CORN Indian Corn is more complex to process in to Ethanol due to wax matter present in the Corn. Yields are low due to lower Starch content in the Corn as compared to Rice (68-72% w/w) Though the DDGS quantity produced is more, protein content in the DDGS is lesser than Rice DDGS (42-45%) and hence fetch lower rate per kg. Utility consumption is more as compared to International norms due to use of conventional technologies and lower size plants eedstock Knowledge is key to success of Corn to Back to Annexure
PROCESS OF CO 1. Wet Milling 2.Dry Milling 3.Dry Fractiona
ORN TO ETHANOL ation Back to Annexure
WET M
MILLING 1. Mainly used for Corn to Starch Process. 2. More effluent gets generated. 3. Economical viability of this process needs to be established against the zero liquid discharge norms in Indian industry. Back to Annexure
DRY MILLIN Mill Liquefaction Fermentation Distillation+ MSDH Decantation Evaporation Dryer Dry Mill Process Ethanol DDGS Dry mill Grain to In India and the Rice pla operate Major d a. Grain H b. Liquific c. Decant Only by Back en Industri
G PROCESS ing process is broadly used worldwide for production of o Ethanol. Majority of plants are designed for Rice as feedstock en capacity is calculated for Corn in same plant. ant can operate at around 25-30% lower capacity when ed on Corn. ebottlneck sections are Handling and Milling ation and Fermentation tation and Dryer y-product which is possible in this process is DDGS nd Corn oil can be recovered but it can be used only for al purpose. Back to Annexure
DRY FRACTIONA Dry Fractionation Germ Fiber Corn Oil extraction Starc Food Grade Oil Deoil Cake CPT: Technology partner for Dry Fractionation
ATION PROCESS ch Stream Liquefaction Fermentation Distillation +Dehydration Decantation Drying Evaporation Wet Cake Thin Slop Corn Oil Extraction DCO Fuel Ethanol Hi Protein DDGS Back to Annexure
DIFFERENT PROCESSES USED F ETHA • Now • Hi-Pr • Food • No Se • Redu • Lowe Advan Dry Fractionation Process Dry Fractionation Liquefaction Fermentatio n Distillation+ MSDH Decantation Evaporation Dryer DCO Centrifuge/ Tricanter Ethanol Hi Protei n DDGS Germ Fiber Oil
FOR PROCESSING OF CORN TO ANOL used by many of the Corn to Ethanol Manufacturers in US otein DDGS production (44-50%) Grade Corn oil production eparate mill (Part of Dry Fractionation Unit) uction in dryer steam consumption by 30% er cost of production due to higher revues from By-Product. ntages of Dry fractionation unit Back to Annexure
MODERN TECHNOLOGIES Corn Fiber to Ethanol & High Protein DDGS MVR Based Technology for reduction in Water and Carbon
S FOR CORN TO ETHANOL 1. 6-7% higher yield of Ethanol per ton of Corn 2. Generation of high Protein DDGS (44- 50%) 3. Higher Operating Margins 1. Reduction in Steam consumption by 50% 2. Reduction in water consumption by 50% 3. Higher operating margins Back to Annexure
SUMM Proven Technologies for Corn to Eth from Praj For increasing viability of the Corn development of Corn varieties wit lower wax to be developed. In order to cater the logistical chal is required all across the country By-product valorization will be a ke viability of corn based plants
MARY hanol are available to Ethanol, th higher starch and lenges, corn cultivation ey to increasing Back to Annexure
C2H5OH
Back to Annexure
“E-max” Te Low Ene High Quality Low Water Footprint
echnology ergy Practical ZLD High Efficiency Back to Annexure
FEED STOCKS FO
OR BIO-ETHANOL Back to Annexure
MAIZE TO ETHANOL PRESENT CHALLENGES AND SOLUTIONS High Feed Stock costs – Improvement Process optimisation / equipment des (Yield increase from 385 litre/MT at 60 High /Steam costs – Heat Integration Mechanical Vapour Compression / C (Reduction from 5 kg/litre to 3 kg/litre High Water requirement – Steam/Hea through biological and membrane bio (Reduction from 1:6 to 1:4 times) High Fixed costs – Mechanisation and
– OPEX REDUCTION t in efficiency – Enzymes / Yeast / signing 0% starch to 395 litres/MT) distillation / DDGS Dryer / Cold Mash cooking technology e steam) at reduction/ Water recycle o reactor / Air cooled condensers Automation in all sections Back to Annexure
MAIZE TO ETHANOL – FEAS Short term and Long term Solution – Value a Dry Milling process High value added by products Corn Germ / Oil from dry degermin Corn Oil using Tri cantor after proce Wet Milling process Gluten high protein and low protein Germ and Corn Oil Fibre / cattle feed CBG Water recycle
SIBILITY & SUSTAINABILITY added By-products nator ess Back to Annexure
MAIZE TO ETHANOL – D
DRY MILLING PROCESS Back to Annexure
MAIZE TO ETHANOL – W
WET MILLING PROCESS Back to Annexure
MAIZE TO ETHANOL – FEAS Long term Solution – Wet milling 1 MT of Maize @ 60% starch content Germ – 60 to 65 kg Gluten – 55 to 60 kg Fibre – 20 to 25 kg Ethanol – 390 - 395 litre CO2 / CBG
SIBILITY & SUSTAINABILITY Back to Annexure