A

Project Phase- 1 Report

On

“MANUFACTURING OF ETHANOL”
Submitted by

Prathmesh Sunil Mawale

2030331527003

DEPARTMENT OF PETROCHEMICAL ENGINEERING

DR. BABASAHEB AMBEDKAR TECHNOLOGICAL

UNIVERSITY, LONERE
2022-23

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 Dr. BABASAHEB AMBEDKAR TECHNOLOGICAL
UNIVERSITY

Lonere 402103, Tal. - Mangaon, Dist. - Raigad, (M.S.)

DEPARTMENT OF PETROCHEMICAL ENGINEERING

CERTIFICATE

This is to certify that the Project Phase- 1 Report, entitled “Manufacturing of

Ethanol” have been duly completed by Prathmesh Sunil Mawale
(2030331527003) under the guidance of Prof. V.P. Jawanjal in satisfactory
manner for a fulfillment of Third Year Bachelor of Technology in Petrochemical
Engineering, of Dr. Babasaheb Ambedkar Technological University, Lonere in
academic year 2022-23.

Prof. V. P. Jawanjal Dr. S. S. Metkar

(Project Guide) (Head of Department)

Examiner
1.
2.

Place: Lonere
Date:

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 ACKNOWLEGDMENT
It is an incident of great pleasure for me submitting this Project Phase-1 Report.
I take this opportunity to express my deep sense of gratitude & great thanks to
my guide Prof. V. P. Jawanjal for giving her valuable guidance, inspiration &
encouragement to embark this project.

I also greatly acknowledge our Head of Department Dr. S. S. Metkar who has
been a constant source of guidance & inspiration throughout this project work.

I am also thankful to my friends, teaching staff whose encouragement &

suggestion helped me to complete my Project Phase-1 Report.

Last but not the least, I am thankful to my parents whose best wishes are always
with me.

Prathmesh Sunil Mawale

(2030331527003)
Final Year
B.Tech Petro-chemical Engineering

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 ABSTRACT
In ethanol production from sugarcane juice, sugarcane bagasse is used as fuel for the boiler, to
meet the steam and electric energy demand of the process. However, a surplus of bagasse is
common, which can be used either to increase electric energy or ethanol production. While the
first option uses already established processes, there are still many uncertainties about the
techno-economic feasibility of the second option. In this study, some key parameters of the
second-generation ethanol production process were analyzed and their influence in the process
feasibility assessed. The simulated process includes the enzymatic hydrolysis of sugarcane
bagasse pretreated with liquid hot water, and the analyzed parameters were the solid
consistency in the hydrolysis and pretreatment reactors and the hydrolysis reaction time. The
solid consistency in the hydrolysis reactor had the highest influence on the economic feasibility
of the process. For the economic scenario considered in this study, using bagasse to increase
ethanol production yielded higher ethanol production costs compared to using bagasse for
electric energy production, showing that further improvements in the process are still
necessary.

Keywords: Ethanol, Sugarcane, Molasses.

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 INDEX
Chapter Content Page
No No.
Title ⅰ
Certificate ⅱ
Acknowledgement ⅲ
Abstract ⅳ
Content (Index Page) ⅴ
1 Introduction 01
1.1 Ethanol
1.2 Physical & Chemical Properties
1.3 Occurrence
1.4 History
1.5 Uses of Ethanol
2 Process Description 11
3 Selection Process 16
4 Handling & Safety Precaution 19
5 Cost Estimate 21
Future Scope 23
Conclusion & Future Work 25
References

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 LIST OF FIGURES
Fig No: - Tittle of Figure Page No: -
1.1 Structural Formula of Ethanol 01
1.5.1 Personal Care Product 08
1.5.2 Household Products 09
1.5.3 Use of Ethanol in Food Additives 09
1.5.4 Ethanol Fuel 10
1.5.5 Medical Uses of Ethanol 10
3.1 18
Flowsheet for Ethanol Production from Molasses
using Fermentation Process
3.2 18
Flowchart for Ethanol Production from Molasses
using Fermentation Process

LIST OF TABLES
Table No. Tittle of Table Page No.
1 Physical Properties 02
2 Fermentation Condition 17
3 Technical assumptions of ethanol 22
production life cycle cost
calculation.

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 “Manufacturing of Ethanol”

CHAPTER 1
INTRODUCTION

1.1) Ethanol:

Ethanol or ethyl alcohol, CH3CH2OH, has been described as one of the most exotic synthetic
oxygen-containing organic chemicals because of its unique combination of properties as a
solvent, a germicide, a beverage, an antifreeze, a fuel, a depressant, and especially because of
its versatility as a chemical intermediate for other organic chemicals.

Ethanol is the IUPAC name for this chemical; the name ethyl alcohol is also correct. The name
alcohol is a generic name derived from two Arabic words, al and kohl, that described a finely
ground powder used by Oriental women to darken their eyebrows. The name, unqualified,
gradually became specific for ethyl alcohol, "spirits of wine rectified to the highest degree".
Ethyl alcohol is, of course, well known as a constituent of alcoholic beverages (see Beverage
spirits, distilled; Beer; Wine).

Ethanol is one of the largest volume organic chemicals used in industrial and consumer
products. The primary industrial uses of this aliphatic alcohol are as an intermediate in the
production of other chemicals and as a solvent. Ethanol is used in the manufacture of drugs,
plastics, lacquers, polishes, plasticizers, and cosmetics. Ethanol is used in medicine as a topical
anti-infective, and as an antidote for ethylene glycol or methanol overdose. Commercial
products containing ethanol include beverages, perfumes, aftershaves and colognes, medicinal
liquids, mouthwashes, liniments, and some rubbing alcohols.

Molecular structure: -

Fig 1.1 Structural Formula of Ethanol

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Dept. of Petrochemical Engineering, Dr. BATU. Lonere
 “Manufacturing of Ethanol”

1.2) Physical and Chemical Properties

1.2.1) Physical Properties

Ethyl alcohol under ordinary conditions is a volatile, flammable, clear, colorless liquid. Its odor
is pleasant, familiar, and characteristic, as is its taste when it is suitably diluted with water.

The physical and chemical properties of ethyl alcohol are primarily dependent upon the
hydroxyl group. This group imparts polarity to the molecule and also gives rise to
intermolecular hydrogen bonding. These two properties account for the differences between
the physical behavior of lower molecular weight alcohols and that of hydrocarbons of
equivalent weight. Infrared spectrographic studies have shown that, in the liquid state,
hydrogen bonds are formed by the attraction of the hydroxyl hydrogen of one molecule and the
hydroxyl oxygen of a second molecule. The effect of this bonding is to make liquid alcohol
behave as though it were largely dimerized. This behavior is analogous to that of water, which
however, is more strongly bonded and appears to exist in liquid clusters of more than two
molecules. The association of ethyl alcohol, it should be noted, is confined to the liquid state;
in the vapor state it is monomeric.

A summary of physical properties of ethyl alcohol is presented in Table 1. Detailed information

on the vapor pressure, density, and viscosity of ethanol can be obtained.

Table 1 Physical Properties

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 “Manufacturing of Ethanol”

1.2.2) Chemical Properties

• The chemistry of ethyl alcohol is largely that of the hydroxyl group, namely, re- actions
of dehydration, dehydrogenation, oxidation, and esterification. The hydrogen atom of
the hydroxyl group can be replaced by an active metal, such as sodium, potassium, and
calcium, to form a metal ethoxide (ethylate) with the evolution of hydrogen gas (see
Alkoxides, metal).

2 CH₂H₂OH+2 M 2 C₂H₂OM+ H₂

• Sodium ethoxide can be prepared by the reaction of absolute ethyl alcohol and sodium,
or by refluxing absolute ethyl alcohol with anhydrous sodium hydroxide:

CH2CH2OH+ NaOH CH3CH₂ONa+ H₂O

• Commercially, water is removed by azeotropic distillation (qv) with benzene. Sodium

ethoxide precipitates upon addition of anhydrous acetone. This strong base hydrolyzes
readily to give ethyl alcohol and sodium and hydroxyl ions.

CH3CH₂O-Na++H₂O CH3CH₂OH+Na+ + OH-

• Sodium ethoxide can also be prepared by the reaction of sodium amalgam with ethyl
alcohol. Sodium ethoxide is used in organic synthesis as a condensing and reducing
agent. The reaction between sodium ethoxide and sulfur monochloride yields diethyl
thiosulfate.
• Esterification: -

Esters are formed by the reaction of ethanol with inorganic and

organic acids, acid anhydrides, and acid halides. If the inorganic acid is oxygenated (sulfuric
acid, nitric acid), the ester has a carbon-oxygen linkage that is easily hydrolyzed (24-26).

CH3CH3OH+H2SO4 CH3CH2OSO3H+H₂O

2CH3CH₂OH+ H₂SO4 (CHCH₂O) SO₂+2H₂O

CH2CH2OH + HONO2 CH3CH2ONO2+ H₂O

Organic esters are formed by the elimination of water between an alcohol and an organic acid2.

CH3CH2OH+RCOOH RCOOCH2CH3 + H2O

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Dept. of Petrochemical Engineering, Dr. BATU. Lonere
 “Manufacturing of Ethanol”

The reaction is reversible and reaches equilibrium slowly. Generally, acidic catalysts are used,
such as strong sulfuric acid, hydrochloric acid, boron trifluoride, and ptoluenesulfonic acid.
Batchwise and continuous processes are used for the esterification reaction.

Ethyl alcohol also reacts with acid anhydrides or acid halides to give the corresponding esters.

CH3CH2OH + (RCO)2O RCOOCH2CH3 + RCOOH

2CH3CHO CH3COOCH2CH3+ HCl

The direct conversion of ethyl alcohol to ethyl acetate is believed to take place via acetaldehyde
and its condensation to ethyl acetate (Tishchenko reaction).

CH3CH2OH CH3CHO+H2

2 CH3CH2OH CH3COOCH2CH3

An ethyl acetate yield of ca 24% is obtained using a copper oxide catalyst with 0.1-0.2%

thoria at 350°C.

• Dehydration

Ethyl alcohol can be dehydrated to form ethylene or ethyl ether.

CH3CH2OH CH2 = CH2+H2O

2CH2CHO CH3COOCH2CH3

Generally, both ethylene and ethyl ether are formed to some extent, but the conditions can be
altered to favor one reaction or the other.

• Dehydrogenation.

The dehydrogenation of ethyl alcohol to acetaldehyde can be affected by a vapor-phase reaction

over various catalysts.

CH3CH2OH CH3CHO+H2

• Haloform Reaction.

Ethyl alcohol reacts with sodium hypochlorite to give chloroform the haloform reaction.

CH3CH2OH+NaOCl CH3CHO+NaCl+H2O

CH3CHO+3NaCl CCl3CHO+3NaOH

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Dept. of Petrochemical Engineering, Dr. BATU. Lonere
 “Manufacturing of Ethanol”

CCl3CHO+NaOH CHCl3+HCOONa

Similarly, bromoform, CHBra, and iodoform, CHI, are obtained from sodium hypobromite and
hypoiodite, respectively. Ethyl alcohol is the only primary alcohol that undergoes this reaction.

• Reactivity Parameters.

The reactivity of ethyl alcohol-water mixtures has been correlated with three distinct alcohol
concentration ranges. For example, the chromium trioxide oxidation of ethyl alcohol, the
catalytic decomposition of hydrogen peroxide, and the sensitivity of colloidal particles to
coagulation are characteristic for ethyl alcohol concentrations of 25-30%, 40-60%, and above
60% alcohol, respectively. The effect of various catalysts also differs for different alcohol
concentrations.

1.3) Occurrence
In India, ethanol is primarily produced using sugarcane molasses. This is an example of
first-generation biofuels that uses biomass containing large amounts of sugar or materials that
can be converted to sugar such as starch, for the generation of ethanol.

India Ethanol market stood at USD2805.38 million in 2021 and is expected to grow at a CAGR
of 12.68% during the forecast period. This can be attributed to the factors like administrative
support, government policies like new ethanol blending program (EBP) which makes
compulsory for oil manufacturing companies (OMCs) to blend 10% ethanol in petrol by end
of 2022 and 20% till 2025. Moreover, blending with gasoline over conventional unblended
petrol also drives the ethanol market. Apart from that ethanol’s demand is increasing
extensively as a solvent for the manufacturing of varnishes and perfumes, in the preparation of
essences and flavorings, and as surface disinfectant, the demand for which was at peak during
Covid time as it was used in hand sanitizers.

1.4) HISTORY

Ethanol’s first use was to power an engine in 1826, and in 1876, Nicolaus Otto, the inventor of
the modern four-cycle internal combustion engine, used ethanol to power an early engine.
Ethanol also was used as a lighting fuel in the 1850s, but its use curtailed when it was taxed as
liquor to help pay for the Civil War. Ethanol use as a fuel continued after the tax was repealed,
and fueled Henry Ford’s Model T in 1908. The first ethanol blended with gasoline for use as

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Dept. of Petrochemical Engineering, Dr. BATU. Lonere
 “Manufacturing of Ethanol”

an octane booster occurred in the 1920s and 1930s, and was in high demand during World War
II because of fuel shortages.

Ethanol is the IUPAC name for this chemical; the name ethyl alcohol is also correct. The name
alcohol is a generic name derived from two Arabic words, al and kohl, that described a finely
ground powder used by Oriental women to darken their eyebrows. The name, unqualified,
gradually became specific for ethyl alcohol, "spirits of wine rectified to the highest degree".
Ethyl alcohol is, of course, well known as a constituent of alcoholic beverages (see Beverage
spirits, distilled; Beer; Wine).

As a beverage ethanol had been prepared and used long ago by the Egyptian pharaohs. Some
indication of the antiquity of the knowledge of ethyl alcohol is the fact that Noah is believed to
have built for himself a vineyard in which he grew grapes that he fermented into a sort of
alcoholic beverage.

It was Michael Faraday who first prepared ethanol by the acid-catalyzed hydration of ethylene
in 1828, in a process similar to that used for industrial ethanol synthesis today. Ethanol served
as lamp fuel in pre-Civil War United States and helped power early Model T automobiles.

Since 1826, when it was first used to power internal combustion engines (ethanol timeline),
ethanol has been of interest to entrepreneurs and agriculturists as a possible alternate fuel. As
early as 1862, it was heavily taxed to pay for the Civil War. In 1908, Henry Ford produced the
flex-fuel Model T, although by then cheap oil took over the powering of the nation and ethanol
languished.

Fast-forward to 1974, when Archer Daniels Midland (ADM), the main producer of high
fructose corn syrup, found itself in a quandary. The wet milling process used to manufacture
corn syrup from corn grain created, in excess, a by-product known as ethanol, and ADM
launched a shrewd search to find or create a market for it. Capitalizing on the “Project
Independence” initiative started by the Nixon administration to reach total independence from
foreign energy sources, ADM began a political campaign promoting ethanol as an additive to
gasoline—and the current ethanol industry was born.

By 1988, states began to pass laws demanding that all gasoline contain some oxygenate during
the winter to enhance burning of the fuel and to lower smog. MTBE was the chosen oxygenate
until it was found to be toxic—and then ethanol was adopted as an octane booster. This created

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Dept. of Petrochemical Engineering, Dr. BATU. Lonere
 “Manufacturing of Ethanol”

an immediate government-mandated demand for ethanol that spectacularly increased the

market for ethanol. By 2003, very little MTBE was used.

Bio-fuels have caught global attention in the last decade. They are renewable liquid fuels made
from biological raw materials and have proved to be good substitutes for petroleum in the
transportation sector. Being environment friendly, bio-fuels like ethanol and bio-diesel can help
us to conform to stricter emission norms. Globally, several policies have given a fillip to bio-
fuel production, leading to an increase in ethanol and bio-diesel output.

In order to promote bio-fuels in India, a National Policy on Bio-fuels was formulated by the
Union Ministry of New and Renewable Energy in 2009. In January 2013, the Union
government launched the Ethanol Blended Petrol (EBP) programme, which made it mandatory
for oil companies to sell petrol blended with at least 5 per cent of ethanol. The government
initiated significant investments in improving storage and blending infrastructure. The National
Policy on Bio-fuels had set a target of 20 per cent blending of bio-fuel by 2017. But the ethanol
story has not yet succeeded in India. Let us examine why.

1.5) USES OF ETHANOL

• Owing to its antibacterial and antifungal properties, ethanol (also known as ethyl alcohol)
is used in many hand sanitizers and medical wipes.

• Ethanol is also used as an antiseptic and as a disinfectant.

• In cases of ethylene glycol poisoning or methyl alcohol poisoning, ethanol is often

administered as an antidote.

• Several medications that are insoluble in water are often dissolved in ethanol. For example,
ethanol (in concentrations ranging from 1% to 25%) is used as a solvent for some
analgesics and mouthwashes.

• Ethanol is the primary ingredient in many alcoholic drinks that are orally consumed for
recreational purposes. It acts as a psychoactive drug by reducing anxiety and creating a
feeling of euphoria in Humans. However, it also impairs cognitive and motor functions
and acts as a central nervous system (CNS) depressant.

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 “Manufacturing of Ethanol”

• Ethanol is used industrially in the production of ethyl esters, acetic acid, diethyl ether, and
ethyl amines.

• This compound is widely used as a solvent due to its ability to dissolve both polar and
nonpolar compounds.

• Since it has a melting point of -114.1oC, ethanol is used as an ingredient in cooling baths
in several laboratories. It also serves as the active fluid in many spirit thermometers.

1. Personal Care Products

Ethanol is a common ingredient in many cosmetics and beauty products.1 It acts as an
astringent to help clean skin, as a preservative in lotions and to help ensure that lotion
ingredients do not separate, and it helps hairspray adhere to hair.

Because ethanol is effective in killing microorganisms like bacteria, fungi and viruses, it is a
common ingredient in many hand sanitizers. The U.S. Centers for Disease Control and
Prevention (CDC) recommends the use of hand sanitizers in situations where soap and water
are not available.2 Practicing hand hygiene is also an important part of helping to stop the
spread of COVID-19. Using hand sanitizers or alcohol-based hand rubs (ABHR) can help to
inactivate SARS-CoV-2, the strain of coronavirus that causes COVID-19.

Fig 1.5.1 Personal Care Product

2. Household Products
Ethanol mixes easily with water and many organic compounds and makes an
effective solvent for use in paints, lacquers and varnish, as well as personal care and household
cleaning products. As an additive to cleaning products, ethanol is also used as a preservative
because it is effective in knocking out organisms that could pose a danger to consumers.

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 “Manufacturing of Ethanol”

Fig 1.5.2 Household Products

3. Food Additives
As a food additive, ethanol can help evenly distribute food coloring, as well as enhance the
flavour of food extracts. For example, vanilla extract, a common food flavouring, is made by
curing and processing vanilla beans in a solution of ethanol and water. In the United States, the
Food and Drug Administration (FDA) only allows vanilla to be called “extract” when it has an
alcohol or ethanol base.

Fig 1.5.3 Use of Ethanol in Food Additives

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Dept. of Petrochemical Engineering, Dr. BATU. Lonere
 “Manufacturing of Ethanol”

4. Fuel
More than 98 percent of U.S. gasoline contains ethanol, typically in a mixture called E10, made
up of 10 percent ethanol and 90 percent gasoline, to oxygenate the fuel and reduce air
pollution.5) Ethanol has a higher-octane number than gasoline, providing premium blending
properties, according to the U.S. Department of Energy. Minimum octane number
requirements prevent engine knocking and maintain drivability.

Fig No: - 1..4 Ethanol Fuel

Medical: -
Ethanol is used in medicine as a topical anti-infective, and as an antidote for ethylene glycol
or methanol overdose. Commercial products containing ethanol include beverages, perfumes,
aftershaves and colognes, medicinal liquids, mouthwashes, liniments, and some rubbing
alcohols.
Antiseptic
Antidote
Medicinal solvent
Pharmacology

Fig 1.5.5 Medical Uses of Ethanol

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Dept. of Petrochemical Engineering, Dr. BATU. Lonere
 “Manufacturing of Ethanol”

CHAPTER 2
PROCESS DESCRIPTION

An ethylene-rich gas is combined with process water, heated to the desired reaction
temperature, and passed through a fixed-bed catalytic reactor to form ethanol. The vapor
leaving the reactor is slightly hotter than the feed because the reaction is exothermic. The
reactor product is cooled by heat exchange with the reactor feed stream and is separated into
liquid and vapor streams. The liquid stream goes to the ethanol refining system, and the vapor
stream is scrubbed with water to remove the ethanol. The washed gas, mostly unreacted
ethylene, is enriched with fresh ethylene feed and re- cycled to the reactor. A small vent or
purge stream is removed from the recycled ethylene to prevent buildup of impurities in the gas
cycle.

The liquid product streams are fed to a distillation system to remove the light impurities and to
recover the ethanol as a 95% volume ethanol-water azeotrope. To produce anhydrous ethanol,
the ethanol-water azeotrope is fed to a dehydration system.

An advantage provided by this process is the recycling of process water recovered in the
refining stills to the reaction system. This reduces the amount of boiler feed water to less than
one-fifth of the total amount of water fed to the reactor. The investment and operating cost
required for supporting boiler feed water facilities are correspondingly reduced. Recycling
process water also reduces the amount of water dis- charged to the sewer, thus decreasing the
ethanol losses and the load on pollution abatement facilities.

Several patents deal with methods for preventing the formation of deposits in heat exchangers,
reducing corrosion and avoiding the need for corrosion- resistant materials. Copper is widely
used for lining the reactors and for piping, and some heat exchangers are made of phosphor
bronze. Eastman Kodak Co. advocates the use of a stainless steel-clad reactor lined with
overlapping copper curtains or shingles for corrosion resistance. A Hibernia Chemie patent
claims that a copper lining in the reactor has a limited life and can promote the formation of
cuprene. They describe a porous carbon brick lining with a Cu-Ag alloy between the brick and
the reactor wall.

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 “Manufacturing of Ethanol”

Hydration of Ethylene

Using Dilute Acids. A review of the early work on the hydration of ethylene using dilute acids,
the weak acid process, is given by Ellis. The reaction is favored by the use of low temperatures
and high pressures. Temperatures in the range of 150-250°C are the most frequently quoted
(131-136), although temperatures as low as 80°C have been reported.

Equilibrium constants for the hydration of ethylene were measured using a 3 mol % sulfuric
acid solution at 176-307°C and 8.1-26.3 MPa (80-260 atm). Above 250°C and 20.3 MPa (200
atm) polymerization of ethylene became important, and below 220°C ethyl ether formation
was significant. Both high temperature and high acid concentration favor the reduction of
sulfuric acid to sulfur dioxide; 65% acid is reduced by ethylene at above 180°C. To control the
severe corrosion problems encountered, a tantalum-plated reactor has been recommended. Loss
of acid catalyst in the off-gas can be compensated by adding ethyl sulfate in the feed. Operation
at pressures from atmospheric to 2.5 MPa (25 atm) using a battery of reactors have been
described, Ethylene was absorbed in the acid solution during countercurrent passage through
the battery at 130°C.

Hydration of Ethyl Ether.

Using the same type of acid catalysts as in the hydration of ethylene to ethanol, ethyl ether can
be hydrated to the alcohol. Catalysts that have been used for the hydration of ether include
phosphoric acid, sulfuric acid, hydrochloric acid, metallic oxides and silicates. Sulfuric acid
concentrations ranging from 5-25% at 200°C (143) to 63-70% at 110- 135°C and 1.01-1.42
MPa (10-14 atm) have been claimed.

Aluminum oxide has been the most widely used catalyst. At 320°C and at 1.01-1.42 MPa, 50-
66% conversion to alcohol based on the ether was obtained. The ethanol produced by the direct
hydration of ether generally has a foul odor owing to the presence of polymeric hydrocarbon
material, which can be removed by washing the aqueous alcohol with ether.

Fermentation Ethanol

Fermentation (qv), one of the oldest chemical processes known to man, is used to make a
variety of products, including foods, flavorings, beverages, pharmaceuticals, and chemicals. At

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 “Manufacturing of Ethanol”

present, however, many of the simpler products such as ethanol, are synthesized from
petroleum feedstocks at lower costa The future of the fermentation industry, therefore, depends
on its ability to utilize the high efficiency and specificity of enzyme catalysis to synthesize
complex products and on its ability to overcome variations in the quality and availability of
raw mate rials Ethanol is made from a variety of agricultural products such as grain, molasses,
fruit, whey, and sulfite waste liquor. Ethanol production by fermentation, excluding that for
beverages, has been declining in the United States since ethanol was introduced in the 1930s,
because of the low cost and assured availability of ethylene. In 1975, only ca 76 x 10 L of 100
proof industrial ethanol were produced by fermentation, compared to 795 x 10 1. by synthesis.
Generally, most of the agricultural products mentioned above command higher prices as foods,
and others, eg, potatoes, are uneconomical because of their low ethanol yield and high
transportation cost. The energy crisis of the early seventies may have generated renewed
interest in ethanol fermentation, but its use still depends on the availability and cost of the
carbohydrate relative to the availability and cost of ethylene. Sugar and grain prices, like oil
prices, have risen dramatically since 1973.

In some European countries (eg, Belgium, France, Italy and the Netherlands) fermentation is
still important in producing ethanol. In others (eg, Denmark, England and Germany) synthetic
ethanol predominates. In Japan more ethanol is fermented than synthesized. The 1973 annual
capacity was estimated at ca 250 x 10 L for ethanol fermentation and only 76 x 10 L for
synthetic ethanol. Current U.S producers of fermented industrial alcohol include the Chemical
Division of Georgia- Pacific, Grain Processing Corporation, and Publicker Industries. Georgia-
Pacific is the only producer using sulfite waste liquor as the carbohydrate source. In addition,
alcoholic beverage producers cannot be ruled out as potential industrial 'ethanol manufacturers
(see Beverage spirits, distilled).

Ethanol can be derived by fermentation processes from any material that contains sugar. The
many and varied raw materials used in the manufacture of ethanol via fermentation are
conveniently classified under three types of agricultural raw mate- rials: sugar, starches, and
cellulose materials. Sugars (from sugar cane, sugar beets, molasses, fruit) can be converted to
ethanol directly (see Sugar). Starches (from grains, potatoes, root crops) must first be
hydrolyzed to fermentable sugars by the action of enzymes from malt or molds (see Beer;
Yeast). Cellulose (qv) (from wood, agricultural residues, waste sulfite liquor from pulp and
paper mills) must likewise be converted to sugars, generally by the action of mineral acids.
Once simple sugars are formed, enzymes from yeast can readily ferment them to ethanol.

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 “Manufacturing of Ethanol”

Because fermentation ethanol has been thoroughly and repeatedly discussed in the literature,
the coverage here is illustrative rather than comprehensive, with special emphasis on the
potential raw materials for ethanol production of the future.

Sugars

The most widely used sugar for ethanol fermentation is blackstrap molasses which contains
about 35-40 wt% sucrose, 15-20 wt% invert sugars such as glucose and fructose, and 28-35
wt% of no sugar solids. Blackstrap (derived from Java and the Dutch word "strop," meaning
syrup) is collected as a by-product of cane sugar manufacture (see Syrups). The molasses is
diluted to a mash containing ca 10-20 wt % sugar. After the pH of the mash is adjusted to about
4-5 with mineral acid, it is inoculated with the yeast, and the fermentation is carried out no
aseptically at 20-32°C for about 1-3 d. The fermented beer, which typically contains ca 6-10
wt % ethanol, is then sent to the product recovery and purification section of the plant.

The direct fermentation of sugar cane juice, sugar beet juice, beet molasses (a by-product in
the production of beet sugar), fresh and dried fruits, cane sorghum, whey. and skim milk had
been considered as a means of obtaining ethanol, but none of these raw materials could compete
economically with molasses. Although the manufacture of ethanol from the sugar-containing
waste products of the fruit industry appears to be a highly desirable operation, particularly as a
means of reducing stream pollution in the vicinity of canning plants, such production is costly
because of the need to re- move most of the water (as much as 97%) contained in the waste
product.

The quadrupling of the selling price of crude petroleum by the Organization of Petroleum
Exporting Countries (OPEC) in 1973 may have a profound impact on fermentation processes
for producing ethanol. A primary objective of the U.S. Department of Energy is to develop
methods to derive fuels economically from sugar crops and corn, to evaluate the potential
feasibility of the various methods, and to suggest means of practical application. The results of
the sugar crop research on agronomics and fuels conversion undertaken by Batelle's Columbus
Laboratories lists several merits of sugar cane as a candidate energy resource. Sugar cane, a
renewable raw material, is renowned for its agricultural productivity, and its juice is directly
fermentable to ethanol. On the other hand, sugar cane products are valuable in food and feed
applications and their conversion to chemicals and energy can be considered an
underutilization of their potential value. By the year 2000 the energy needs of the U.S.

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Dept. of Petrochemical Engineering, Dr. BATU. Lonere
 “Manufacturing of Ethanol”

are expected to exceed ca 10 kJ (100 quads or 101 Btu) and sugar cane is expected to contribute
to less than 2 x 101 kJ (2 quads) of energy. However, as is seen under Manufacturing Costs
below, the prospects for sugar cane as a raw material for industrial ethanol are much brighter.
The subject of fermentation alcohol has always been of considerable interest to several tropical
countries, but until the oil crisis of 1973, only India appeared to appreciate the importance of
fermentation alcohol as a strategic material in its economy. Ethanol prices in India have been
maintained at an extremely low level by processing cane molasses, which has been a waste
product of negligible value.

In 1975, Brazil embarked upon an ambitious program for fermentation ethanol manufacture
which could provide the necessary blueprint for similar pro- grams in other tropical countries.
The five-year project, which is expected to cost the government and private Brazilian investors
one billion dollars, involves the planting of "energy plantation" at the rate of an additional 8.1
x 10 m³ (2 x 10 acre) of sugar cane and other plants each year. If the national plan achieves its
goal, Brazil will be producing 3 x 10" L of ethanol a year by 1980, nearly equal to the current
worldwide consumption. By 1981, fully one-fifth of the gasoline used in Brazil is planned to
be replaced by alcohol which, with government price regulations, could cost ca one-half as
much to produce as the retail price of gasoline.

By 1977, annual Brazilian alcohol production had risen to a level of 1.6 x 10° L That is the
equivalent of 12 x 10 bags of sugar, more than 14% of the total Brazilian sugar harvest, itself
the largest in the world. In addition to sugar cane, for which the ethanol fermentation
technology is the simplest and best understood, the Brazilian government is actively pursuing
plans to cultivate the sugar-yielding tuber, manioc (cassava).

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Dept. of Petrochemical Engineering, Dr. BATU. Lonere
 “Manufacturing of Ethanol”

CHAPTER 3
SELECTION PROCESS
Process Selection:

The Production of Ethanol from Fermentation of Sugarcane Molasses Process is a widely

used method for the production of Ethanol from Sugarcane bagasse’s. There are several reasons
why the Fermentation of Sugarcane Molasses Process is the preferred method for producing
Ethanol:

• Molasses is generally used because it is rich in all salts except nitrogen which is
normally employed in the actual growth of yeast cells.
• Molasses is defined as waste product of sugar industry of which further extraction of
sugar is uneconomical, contains about 40– 50% fermentable sugars.
• Because of the ease with which this can be fermented into ethanol and its low price
have made this raw material ideal for ethanol production.

Method:

The basic five stages of this process are:

• A "pre-treatment" phase, to make the raw material such as wood or straw amenable
to hydrolysis,
• Hydrolysis, to break down the molecules of cellulose into sugars
• Separation of the sugar solution from the residual materials, notably lignin.
• Yeast fermentation of the sugar solution
• Distillation to produce 99.5% pure alcohol.

Fermentation process
The plant carbohydrates, the starting materials in the production of ethanol, typically come
from crops such as sugar cane or sugar beet. The yeast, which could be a species such
as Saccharomyces cerevisiae, contains enzymes responsible for converting the glucose in plant
carbohydrates into ethanol via anaerobic respiration. The reaction also produces carbon
dioxide (CO2).
Ethanol is toxic to yeast in high concentrations. Consequently, the yeast dies out when the
solution reaches levels of about 15% ethanol. This means that the production of ethanol by

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Dept. of Petrochemical Engineering, Dr. BATU. Lonere
 “Manufacturing of Ethanol”

fermentation is a batch process. Thanks to ethanol's boiling point, which is lower than that of
water, the ethanol can then be separated from the rest of the solution by fractional distillation.
You should also note that fermentation has a slow rate of reaction, especially when compared
to the hydration of ethene.
Fermentation word equation
The chemical equation for fermentation is shown below, alongside the word equation.
C6H12O6 → 2C2H5OH + 2CO2
Glucose → ethanol + carbon dioxide
Fermentation starting materials and by-products
We mentioned that fermentation requires plant carbohydrates. These frequently come from
crops such as sugar beet or corn. Crops are quick and easy to grow, and often just the discarded
part of the plant (such as the stem or husk) is used in fermentation, leaving the edible portion
for human or animal consumption.
You can see from the chemical equation that fermentation releases carbon dioxide (CO2),
a greenhouse gas. This may seem harmful from an environmental point of view. However,
fermentation itself is technically carbon neutral - all of the carbon released was taken in
via photosynthesis during the crop's lifetime, and we'll support this statement with chemical
equations later on in the article.
Fermentation doesn't break down all of the plant material and so we are left with a residual by-
product. The leftover matter makes a more-than-suitable cattle feed.
Fermentation conditions
Effective fermentation requires certain conditions. These are shown below alongside the
reasoning behind them.

Table: - 2 Fermentation Condition

Condition Reasoning

The temperature is kept at 35 oC Maximises product yield. A lower temperature

decreases the rate of reaction whilst a higher
temperature denatures the enzymes involved in
anaerobic respiration.

Oxygen is excluded from the reactor Prevents ethanol from oxidising into ethanoic
(anaerobic conditions) acid.

Yeast Provide enzymes to catalyse the reaction.

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Dept. of Petrochemical Engineering, Dr. BATU. Lonere
 “Manufacturing of Ethanol”

Fig 3.1 Flowsheet for Ethanol Production from Molasses using Fermentation Process

Fig 3.2 Flowchart for Ethanol Production from Molasses using Fermentation Process

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Dept. of Petrochemical Engineering, Dr. BATU. Lonere
 “Manufacturing of Ethanol”

CHAPTER NO: - 4
HANDLING AND SAFETY PRECAUTION
Safe Handling of Ethanol
As the use of ethanol-gasoline blends continues to grow, any perceptions that ethanol can be
handled any less cautiously than gasoline should be dismissed. Ethanol is a toxic substance
that when ingested by people in small amounts can have intoxicating effects similar to those
of alcohol. But larger amounts of ethanol in humans can cause coma and death. Additionally,
E85, the common ethanol blend, is potentially carcinogenic. And ethanol is flammable.
The safety standards for handling, dispensing, or transporting E85 are the same as those for
gasoline.
The following procedures should be taken if a person experiences symptoms of exposure.
For vapor inhalation, move away from the vapors to fresh air; contact medical personnel.
For skin adsorption, wash the exposed area with soap and rinse with large quantities of water;
contact medical personnel.
For eye adsorption, flush the eyes with water for at least 15 minutes; contact medical
personnel.
For ingestion, have the person lie down and keep him/her warm; do not induce vomiting;
contact medical personnel immediately.
Before constructing any refueling installations, consult the local fire marshal. Regulations
governing the safe handling of fuel ethanol may vary from area to area.
In case of a fire:
Use CO2, halon, or a dry chemical extinguisher.
Use the fire-fighting equipment and breathing apparatus.
For spills, disposal, and handling:
Spills: - Eliminate all sources of ignition.
Waste disposal: - Do not allow materials to enter sewers where vapors may be ignited.
Handling and storage: - Keep away from heat, sparks, and open flames. Keep container
closed. Use with adequate ventilation.
The following should be worn whenever using ethanol:
Respirator, Boots, Long rubber gloves, Industrial aprons, Overalls, Chemical safety goggles,
Face shield.

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 “Manufacturing of Ethanol”

Factors affecting Ammonia Production in India:

There are several factors that could impact the future scope of ethanol production in India,
including:

Government policies and incentives: The government can play a key role in promoting the
production and use of ethanol through policies and incentives. For example, the Indian
government has implemented a National Biofuels Policy, which aims to increase the
production and use of biofuels, including ethanol.

Feedstock availability: The availability of feedstocks such as sugarcane, corn, and molasses
for ethanol production could impact the future scope of ethanol production in India.

Technological advances: Advances in technology could improve the efficiency and cost-
effectiveness of ethanol production, making it more attractive as a source of energy.

Competition with other biofuels: Ethanol may face competition from other biofuels, such as
biodiesel, in the future.

Overall, the future scope for ethanol production in India is likely to be influenced by a
combination of these and other factors.

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 “Manufacturing of Ethanol”

CHAPTER NO: - 5

COST ESTIMATE

For the detailed cost breakdown analysis, all the costs associated with the fuel production
system at each stage within the ethanol production system are included for the estimation of
ethanol life cycle cost [35]. These cost components are mainly divided into four main cost
categories such as feedstock cost (CFS), operation and maintenance cost (CO&M), capital
investment cost (CI) and gains from by-product (CG).

Feedstock cost (CFS) Feedstock cost consists of the cost of molasses used for ethanol
production. Molasses prices are highly variable, depending on fluctuations in the local market’s
demand, seasons, and locations, etc. [26]. Pakistan has been exporting cane molasses to the
European Union (EU), Saudi Arabia, UAE and Afghanistan. Therefore, the demand and price
fluctuations in the international market also have a great influence on the local prices of
molasses.

Operation and maintenance cost (CO&M) Operation and maintenance (O&M) cost is an
aggregation of costs incurred during the production process due to the inputs of water, labor,
chemicals, enzymes (yeast), energy (steam and electricity), maintenance, administration,
insurance, and all the other miscellaneous overhead expenditures.

Capital investment cost (CI) Capital investment cost consists of the initial cost of all the
fundamental equipment, machinery and auxiliaries required for ethanol production. The
transportation and installation cost of the machinery etc. is also included. Other than plant
machinery and equipment, the land cost and construction cost of the building and other
production facilities are also a part of the initial investment. The indirect costs related to plant
such as consultancy fee paid to the consultant is accounted for in the capital investment cost as
well.

Table 2 Technical assumptions of ethanol production life cycle cost calculation.

Type Assumption

Feedstock Sugarcane molasses

Plant type Single feed & adjacent to the mail
Location Punjab, Pakistan

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 “Manufacturing of Ethanol”

Annual production (1000L) 14,250

Operating days 330
Plant life (years) 30
Discount rate 10.5%
Base year for Cost Estimate 2019

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Dept. of Petrochemical Engineering, Dr. BATU. Lonere
 “Manufacturing of Ethanol”

FUTURE SCOPE

Ethanol production has the potential to play a significant role in meeting India's energy needs
and reducing its dependence on fossil fuels. Ethanol can be blended with gasoline to create a
fuel blend that can be used in gasoline-powered vehicles, and it can also be used as a feedstock
for the production of chemicals and other products.

There are many potential areas for future scope on the manufacturing of ethanol. Some
potential directions for research include:

1. Improving the efficiency of the fermentation process: There are many ways that
researchers are trying to improve the efficiency of the fermentation process used to produce
ethanol. This could include developing new yeast strains that are more efficient at converting
sugars to ethanol, or optimizing the conditions in which the fermentation takes place (such as
temperature, pH, and nutrient availability).

2. Developing new feedstocks: Currently, ethanol is mostly produced from corn, wheat,
and other grains. However, researchers are exploring the use of other feedstocks such as woody
biomass, agricultural waste, and even algae as a source of sugars for ethanol production.

3. Improving the distillation process: The distillation process used to separate ethanol
from the fermented feedstock can be energy-intensive and expensive. Researchers are looking
for ways to improve the efficiency of this process, such as by using alternative separation
technologies or developing more efficient distillation columns.

4. Reducing the environmental impacts of ethanol production: Ethanol production can

have significant environmental impacts, including greenhouse gas emissions and water
pollution. Researchers are working on ways to reduce these impacts, such as by finding ways
to use renewable energy sources in the production process or by developing more sustainable
feedstocks.

5. Developing new uses for ethanol: Ethanol is currently used mainly as a fuel additive,
but researchers are exploring other potential uses for this chemical, such as in the production
of chemicals and plastics.

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Dept. of Petrochemical Engineering, Dr. BATU. Lonere
 “Manufacturing of Ethanol”

There are several potential areas of growth and development for the manufacturing of
ethanol from sugarcane molasses in India. Some of these include:

Increasing production: India has a large sugarcane industry and produces a significant amount
of molasses as a byproduct. There is potential to increase the production of ethanol from
molasses by building more distilleries and improving the efficiency of the production process.

Developing new uses for ethanol: Currently, ethanol produced from sugarcane molasses is
mostly used as a fuel additive in India. However, researchers are exploring other potential uses
for this chemical, such as in the production of chemicals and plastics. Developing new markets
for ethanol could create new demand for this product.

Reducing the environmental impacts of ethanol production: The production of ethanol from
sugarcane molasses can have environmental impacts, such as water pollution and greenhouse
gas emissions. Researchers are working on ways to reduce these impacts, such as by finding
ways to use renewable energy sources in the production process or by developing more
sustainable feedstocks.

Improving the efficiency of the production process: There are many ways that researchers are
trying to improve the efficiency of the ethanol production process. This could include
optimizing the conditions in which the fermentation takes place, developing new yeast strains
that are more efficient at converting sugars to ethanol, or improving the distillation process.

Developing new feedstocks: In addition to sugarcane molasses, there are other feedstocks that
can be used to produce ethanol. Researchers are exploring the use of other agricultural waste
and woody biomass as feedstocks for ethanol production.

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Dept. of Petrochemical Engineering, Dr. BATU. Lonere
 “Manufacturing of Ethanol”

CONCLUSION & FUTURE WORK FOR PHASE 2

In conclusion, the Fermentation process is an essential and widely-used method for the
manufacturing of Ethanol. It involves the combination of sugarcane molasses to produce
Ethanol under low pressure and temperature conditions. The process has several advantages,
including high efficiency, low cost, and the ability to use readily available feedstocks.

However, the Fermentation process also has some limitations, including the Ethanol yield is
limited by the amount of sugar present in the molasses. The more sugar present, the more
ethanol can be produced.

The fermentation process is sensitive to temperature and pH. If the temperature is too high or
the pH is not within a certain range, the fermentation process can be disrupted. These issues
can be addressed through the use of advanced technologies and more sustainable production
processes.

Overall, the manufacturing of ammonia through the Fermentation process will continue to be
an important part of the chemical industry, providing a vital raw material for a range of
applications including, personal care, food additives, Bio-fuel and pharmaceuticals. As the
world's population and demand for food and fuels continues to grow, the production of Ethanol
will become increasingly important for meeting these needs.

Future Work

In this project phase 2, I would be Manufacturing Ethanol from Sugarcane Molasses.

I would also be working on its: -

• Overall Material Balance

• Material Balance
• Energy Balance
• Reactor Design
• Plant layout, Plant Location

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Dept. of Petrochemical Engineering, Dr. BATU. Lonere
 “Manufacturing of Ethanol”

REFERENCES

1. “Encyclopedia of Chemical Technology, Vol 08” by Raymond Eller Kirk, Donald

Othmer.
2. “Bioethanol Production from Sugarcane Molasses with Simultaneous” Audiananti
Meganandi Kartini and Yeny Dhokhikah 2018 IOP Conf. Ser.: Earth Environ. Sci. 207
012061.
3. Sugarcane as a Bioenergy Source: History, Performance, and Perspectives for Second-
Generation Bioethanol in Bioenergy Research · March 2014.
4. Ethanol from sugarcane in GCB Bioenergy · January 2012

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Dept. of Petrochemical Engineering, Dr. BATU. Lonere