NO OBJECTION

CERTIFICATE

(NOC)

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)

OTHER DOCUMENTS