Fermentation - Product: Fermented wash with alcohol

and Alcohol Water Vapor

Invertase - Fermented wash undergoes vapor
liquid separator. Vapor will back to DG
- Found in periplasmic spores of yeast
column and Liquid will undergo mash
Exothermic reaction – Reaction in column.
fermentation
Retention Time Mash Column
- Fermentor at least 24 hours - Strips off alcohol from the fermented
- Yeast – 24 hours wash
- Molasses – 32 hours - Operated under vacuum
- Preheater of mash column used is
- Maximum 36 hours
steam from flash steam came from
100 kg sugar – 51.11% ethanol & 48.89% mash column reboiler Feedstock of
CO2 mash column reboiler is rectified vapor
Yeast Cycle from rectifier column.
1. Log – adaptation to environment - Product: Top trays – alcohol vapor
2. Exponential – Multiply of yeast Bottom – Spent Wash
3. Stationary – nutrient exhaustion - Alcohol Water vapor from DG column
will undergo DG condenser. Liquified
4. Death – depletion of nutrients
vapor is placed to Rectifier Feed
Alcohol in fermentation Tank. Incondensable vapor will
- Anaerobic process undergo alcohol scrubber. Gases
High Volatile Acid in Fermentor from scrubber is vented out. Alcohol
- Addition of Penicillin and Ephymole scrubbed is placed to rectifier feed
Nutrients dosing tank.
- Magnesium sulfate heptahydrate - Top Trays has alcohol vapor and will
undergo mash condenser 1,2 and 3.
4 main chemicals in fermenters Liquified alcohol is placed to rectifier
- Di-ammonium Phosphate feed tank and vapor is placed to vapor
- Urea bottle.
- Sulfuric Acid - Pressure: 0.40 – 0.42 bars
- Sodium hydroxide - Temp: Top – 69-72C
Bot – 80-83C
Standard RS
- 13.6% Rectifier Feed Tank
3000 Tons Cane per day – 200,000L/day - Feedstock: Condensed alcohol mash
condenser 1,2 and vent condenser, DG
Distillation condenser, and scrubbed water.
- Temp: 60 – 63 C
Yeast – Saccharomyces Cerevisiae - Will undergo to heater to increase temp
(budding yeast) to 80 – 90 C and fed to rectifier cum
exhaust
Fermented Wash
Rectifier Cum Exhaust Column
Mash Condenser 1 - Feed: Alcohol water liquid from rectifier
feed tank.
Fermented Wash Preheater (plate heat - Product: Alcohol water vapor, Rectified
exchanger) Spirit, Spent lees, Light fusel oil and
- Temp: 68 C Heavy fusel oil. Spent lees
- Alcohol water vapor is used on mash
De-gassifying Column column reboiler. Flash steam generated
- Remove dissolved gasses and high goes to mash column for heating. Rectified
volatiles from fermented wash feed will go to rectified reflux tank and will
- Operated under vacuum go rectifier cum exhaust.
 - Rectified Spirit will undergo RS cooler (94- 3. Fiber - 30%
95% alcohol content) and store to RS draw
Tank and will go to MSDH (molecular sieve Truck Tippler
dehydration) and Off Spec - Alpha and Bravo
- Light and heavy fusel oil will go to decanter - Capacity: 50 tons
and will go to fusel oil washing tank and to - Angle: 55ᵒ Max
canal and CIP tank.
- Spent lees is heated to become flash Auxiliary cane carrier
steam and is placed to mash column - Alpha and bravo
together with alcohol vapor. - Chain operated conveying system that
- Vapor bottles: serve as vapor lock to would direct the cane to the chopper
separate from condensate. - First to be started in milling and last in
- CIP solution: Nitric acid is used for shutdown
cleaning
- Pressure: 2 – 2.2 bars Cane Chopper
- Temp: Top – 96-98 C - Rotating equipment with blade installed
Bot – 123-126 C in auxiliary carrier
- It cut canes to 0.5 meters (pre cuttings)
MSDH
Cross cane carrier
Evaporator
- Belt type conveyer
- Used to evaporate water from alcohol
- Feed: Rectified Spirit, alcohol water
Main cane carrier
liquid
- Chain operated belt conveyer
- Can are received length wise
- Kicker, leveler and fiberizer are located
- Cane leveler: 36 cane knives
- CBLS (cane blanket levelling system) –
80% thickness of canes to avoid
choking leveler
- Fiberizer – 1.2 MW motor to fiberize
cane. Note: the finer the fiber, the
easier to mill
-
Cane Crushing
- Rake elevator
- Donnelly chute – trapezoidal bin type
connection between rake elevator and
belt carrier. Equip with 6 infrared level
sensors.
Mill 1
Mill and Boiling House
- 50 mm pitch
- Imbibition came from mill 3
Mill 2
Cane Preparation, Crane crushing and
- 50 mm pitch
Boiling
- Imbibition came from mill 4
Mill 3
Sugar milling capacity: 300 Tons Cane Day
- 30 mm pitch
(TCD)
- Imbibition source is condensate from
Pol% of cake: 12 – 16%
evaporator
Pol% final bagasse: 2.54% max
Mill 4
Pol% of filter cake: 1.5% max
- 30 mm pitch
- Product: Bagasse – 50% moisture
Cane Composition
(BB), 51-52% moisture test in QAQC
1. Cane Juice – 70%
2. Water
Note: All milled juice is placed to mixed juice - Product: Syrup
tank

Mixed Juice Tank

- Dosing of biocide

Rotary Juice screen Filter

- Initial screening of fine bagasse from
the raw juice

Tank

Juice Heater 1 and 2

- Preheating of juice at 75ᵒC for liming
preparation

Reactor Tank
- Addition of milk of lime to adjust pH
- Product: Lime juice

Defecator

Juice Heater 3 and 4

- Reheating of lime juice
- Temp: 90

Juice Clarifier
- Addition of flocculants 25-30 ppm
- AP273 magna floc and ET27A6 Magna
Floc
- Product: Clarified juice and Muddy
Juice
- Clarified juice is placed in 100 mm
mesh
- Muddy juice will add bagasse to solidify
and will undergo rotary vacuum filter.
RVF operated under negative pressure
to suck water out of the mud cake.

Juice Heater 4 and 5

- Reheating of clarified juice
- Temp: 105

Evaporator 1,2,3,4,5
- Operated under vacuum
- Condensate of evaporator will return to
mill for imbibition
- Evaporator 1 – semi crestner type:
Temp: 121 - 130
- Evap 2,3,4 – Robert type – Temp: 93 -
120
- Evap 5 – Robert type – Temp: 80 - 86
- Flash condenser is employed in
evaporator 5 to create vacuum on the
system.