03_ethanol_from_sugar cane.pdf

8/10/2019 03_ethanol_from_sugar cane.pdf

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300.000 Liter/day Fuel Alcohol

Production Of Ethanol From Sugar Cane

Milton Figueroa Bentez, Incauca S.A.


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300.000 LPD Fuel Ethanol

I N CAUCA S.A . is located in Cali, Colombia

Started operation inOctober, 2005

There are five Fuel Ethanol Distilleries inColombia ( 1,000,000 LPD)


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DISTILLATION

DEHYDRATION

FIREFIGHTINGSYSTEM WATERTANK

COOLING TOWER

CAUSTIC LYE,ACID TANKS

FEEDSTOCKPREPARATION AREA

TRUCK LOADINGSTATION

STORAGETANKS

GASOLINERECEIPT

INCAUCA S.A. DISTILLERY LAYOUTINCAUCA S.A. DISTILLERY LAYOUT

FERMENTATION


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DualDual SugarSugar//EthanolEthanol ProcessProcess

COMPOSTING PLANTCOMPOSTING PLANT

SUGAR FACTORYSUGAR FACTORY

ETHANOL PLANTETHANOL PLANT

VINASSEVINASSE

(STILLAGE)(STILLAGE)

PRESS MUDPRESS MUD

SUGAR CANESUGAR CANE


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6,000 liter/day IMPURE ALCOHOL

600 liter/day FUSEL OIL

600 m3/day SPENT LEES

500 Ton/day VINASSE 28 % w/w

300,000 liter/day FUEL ETHANOL 99.5% v/v

DistilleryDistillery ProductsProducts


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FermentationFermentation DistillationDistillation

EvaporationEvaporation

B-Molasses

JuiceSyrup

Fermented Mash8% v/v

DehydrationDehydration

CompostingComposting

PlantPlant

RectifiedEthanol96% v/v

WasteWaste WaterWaterTreatmentTreatment PlantPlant

Vinasse12 -16% w/w

Fuel Alcohol 99.5 %v/v

Vinasse24- 28 %

w/w

Press Mud

Fertilizer

FUEL ALCOHOL FLOW DIAGRAMFUEL ALCOHOL FLOW DIAGRAM

Fusel OilImpure Alcohol 96 % v/v

Yeast

ProcessCondensate

SpentLees


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TI

LI

TI

MIXED FEED PREPARATION

FeedTank

90

C

CoolingWater

Coolingwater

40 - 45

C

Mixed Feed tofermenters

Volatile Acidity

B-Molasses 5000 ppm

Syrup 2000 ppm

Juice 450 ppm

DensimeterJuice 14%

532 Ton/day532 Ton/day

Syrup 55%


B-Molasses63% w/w


MagneticFlow meter

CP

PHE90C

Steam

TI

1.25 kg/L45 % w/w

Fermentable sugar


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FEEDSTOCKFEEDSTOCK

10-100010-30001103 1104CFU/ml

6,96,26pH

57,781%Brix

45020005800ppmVolatile Acidity

1% w/wCalcium

0,070,61,3% w/wUnfermentable Sugar

13,95563% w/wFermentable Sugar

JuiceSyrupB-Molasses


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Acetic Acid

Butyric Acid

Propionic Acid

Valeric Acid

Iso Valeric Acid

Maximum in the fermenter 3000 ppm

COMPONENTS OF VOLATILE ACIDITYCOMPONENTS OF VOLATILE ACIDITY

Destroy yeast cellmembrane

Destroy yeast cellmembrane

Decrease AlcoholProductivity of Yeast

Decrease AlcoholProductivity of Yeast

Decrease YeastGrowth

Decrease YeastGrowth


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Volatile Acidity Effect on Relative Yeast Growth & Productivity

0

20

40

60

80

100

120

0 1000 2000 3000 4000 5000 6000 7000

Volatile Acidity (ppm)

RelativeSpecificG

rowthRate(%)

RelativeSpecificProductivity(%)

Relative Specific Productivity

Relative Specif ic Grow th Rate

R

EffectsEffects ofofVolatileVolatile AcidityAcidity


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Mixed FeedVinasse

Water

1000 m3

Mash

Charger

Mash toDistillery

Mash toDistillery

Air

Sulphuric Acid

Nutrients

Mixed Feed + Water

VINASSE RECYCLING 60 - 71%

FERMENTATION SECTIONFERMENTATION SECTION

Settlingtank

ActivationTank

R-1 R-2 R-3 R-4


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Temperature in fermenters: 31 32C

pH in Activation Vessel: 3.5 - 4

Antibiotic Addition: 2 3 ppmOperation Volume: 750 m3

Yeast Population / Viability in Fermenter : 450-350 million cel/ml ~ 49 % - 60 %

Free Asimilable Nitrogen: 250 ppm

Maximum Slugde: Lower than 16 % w/w

Vinasse Recycled to fermenter: 60 71 %

Volatile Acidity: Maximum 3000 ppm

Contamination: Lower than 106 CFU/ml

Ethanol Concentration: 7.5 8 % v/v

Residual Sugar last fermenter: 0.75 % w/v

FermentationFermentation OperationOperation ConditionsConditions


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DISTILLATION SECTION

Degassifyng

Column

MashColu

mn

RectifierColum

Aldehy

deColumn

Vinasse toComposting

Vapor

RectifiedAlcohol

Impure Ethanol

Fusel oilMash

CoolingWater

OH

Vinasse

Steam

Waste Water

Treatment Plant

FlubexEvaporator

Steam

Energy recovery

From MolecularSieve

60-71% Vinasseto Fermentation

Spent Lees

OH

Process Condesate


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RECTIFIER COLUMN 56 BUBBLE CAP TRAYSRECTIFIER COLUMN 56 BUBBLE CAP TRAYS


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Rectifier Column 56 bubblecap trays - Vacuum

Mash Column 24

Grid trays -Vacuum

Aldehyde Column 24 bubble

cap trays -Vacuum

INCAUCA S.A. DISTILLERY

Distillation Efficiency : 99 -99.5%

Steam Consumption : 2.9 3.0 kg /liter Ethanol

Dehydration Efficiency : 99.5%

Fermentation Efficiency : 88- 90 %

Fuel Alcohol Cost : US 1.48 / liter


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RECTIFIEDRECTIFIED

ALCOHOLALCOHOL

96 % V/V96 % V/V

FUELFUEL

ALCOHOLALCOHOL

99.5% v/v99.5% v/v

DEHYDRATION SYSTEMDEHYDRATION SYSTEM MOLECULAR SIEVESMOLECULAR SIEVES


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Condenser

Fuel Alcohol Cooler

Spent Lees

Superheater

VacuumSystem

FeedPreheater

Steam

EV

A

P

O

R

A

T

O

R

C

O

L

U

M

N

94 oC 120 oC 25 psia

Alcohol 96 % v/v

RegenerationPreheater

Regeneration Liquid 80 % v/v

DEHYDRATION FLOW DIAGRAMDEHYDRATION FLOW DIAGRAM


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WASTE WATER TREATMENT PLANTWASTE WATER TREATMENT PLANT

EQUALIZINGEQUALIZINGLAGOONLAGOON

AEROBIC DIGESTERAEROBIC DIGESTER

ANAEROBICANAEROBIC

DIGESTERDIGESTER

CLARIFYERCLARIFYER

COD = 4000 mg/LpH = 4 - 4.2Q = 53 m3/h

COD = 150-200 mg/LpH = 7 - 7.5Q = 53 m3/h

COD = 40-60 mg/LpH = 7 - 7.5Q = 53 m3/h


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CONVENTIONAL DISTILLERIES PRODUCECONVENTIONAL DISTILLERIES PRODUCE1010 -- 16 LITERS VINASSE/LITER ALCOHOL16 LITERS VINASSE/LITER ALCOHOL

INCAUCA S.A. DISTILLERY PRODUCESINCAUCA S.A. DISTILLERY PRODUCES2 LITERS VINASSE / LITER ALCOHOL2 LITERS VINASSE / LITER ALCOHOL

RECIRCULATION 60RECIRCULATION 60 --71 % VINASSE TO71 % VINASSE TOFERMENTATIONFERMENTATION

INCAUCA S.A. DISTILLERYINCAUCA S.A. DISTILLERY -- VINASSE PRODUCTIONVINASSE PRODUCTION

TWO FLUBEX EVAPORATORS TO CONCENTRATETWO FLUBEX EVAPORATORS TO CONCENTRATE

THE VINASSETHE VINASSE


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Hot fluid

Condensate

Distributor

Plates

Downcomer-Tube 4

Bottombonnet

Bottom

bonnet

Distributor

Caps

TopBonnet

TopBonnet

Cold fluid

Steam

Tube 2

Full ViewFull View

Separator

Flubex


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5 mm

ONE MONTH - CONTINUOUS OPERATIONDUE TO SELF-CLEANING MECHANISM FROM

WIRE BIT ACTION

ONE MONTHONE MONTH -- CONTINUOUS OPERATIONCONTINUOUS OPERATIONDUE TO SELFDUE TO SELF--CLEANING MECHANISM FROMCLEANING MECHANISM FROM

WIRE BIT ACTIONWIRE BIT ACTION

WIRE BITS ARE POURED INTO FLUBEXWIRE BITS ARE POURED INTO FLUBEX

Compared Size Scouring Action

Scaling Wire Bits


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COMPOSTING PLANTCOMPOSTING PLANT

VINASSEVINASSE

PRESS MUDPRESS MUD

BAGASSEBAGASSEASH FROM BOILERASH FROM BOILER

AFTER 65 DAYSAFTER 65 DAYS WE OBTAIN AWE OBTAIN AFERTILIZERFERTILIZER


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FoamFoamrearea

WATER TANKWATER TANK

FIRE PROTECTION SYSTEMFIRE PROTECTION SYSTEM


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Thank You

03_ethanol_from_sugar cane.pdf

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