Liquefaction

Liquefaction is the first step in processing starch-containing grains to alcohol. Here, the grain flour is mixed with
water and heated to break down the starch molecules into shorter dextrin molecules using enzymes. These
molecules can be further treated enzymatically to make glucose, which in turn is converted to alcohol by yeast.

Basic flow sheet of liquefaction section:-

Description of the process:The grain after milling is converted to flour and stored in flour silo. 6.25 ton/hour
of flour from four silo is weighed and mixed with water having a flow rate of
around 9300 LPH in a screw mixer. The slurry produced is temporarily stored in a
slurry tank where the temperature is maintained at around 80c to 85 c. The
slurry is pumped to ILT(initial liquefaction tank) where 30% alpha-amylase
enzyme is added to the slurry. The enzyme helps in the partial break down of
starch to dextrin by breaking the 1-4 carbon bond. The conditions maintained at
ILT are 90-95 c and 80% volume. The slurry from the ILT is moved to jet cooker
where it is brought in contact with steam. This results in the heating of the slurry
and thus the viscosity reduces. The slurry is passed to retention coil. The slurry is
heated to 113-114 c. The slurry is kept at retention coil for 10-15 minutes.
Retention coil acts as a pressure cooker and gives sufficient time for the grain to
breakdown. Before moving the slurry to FLT, the temperature must be reduced
for the amylase to act upon because at high temperature the enzyme gets
inactive. The slurry from retention coil (high pressure) is moved to flash tank
which is maintained at low pressure. The sudden reduction of pressure results in
flasing and the temperature of the slurry decreases. Slurry is then finally moved
to FLT(final liquefaction tank) where the complete dextrin production from starch
takes place. In FLT remaining 70% of amylase enzyme is added and the slurry is
maintained at 90% volume.