CHE EL3

BioEthanol Manufacturing
Colegio San Agustin-Bacolod
Engr Nilo T. Aldon-Lecturer
2023

nilo t. aldon 1
Course Description:
• This course deals with the manufacture of bioethanol from
sugar cane and molasses.
• The students will be introduced to the different unit
processes, unit operations, equipment, utilities,
production/quality control, waste management, costing
and organization associated with bioethanol
manufacturing.

nilo t. aldon 2
Specific Objectives
At the end of the semester, the students will be able to:
1. describe the different processes and operations involved in the
manufacture of ethanol from sugar cane/molasses, and other alternative
raw materials
2. describe the operating principles and functions of the different equipment
and facilities, including their basic instrumentation & control,
3. perform calculations on material balances, energy balances as well as basic
equipment sizing and selection
4. demonstrate understanding of distillery management and control through
calculations of KPIs (key performance indicators), like fermentation
efficiency, distillation efficiency, yield, utilities and manufacturing costs
5. identify/describe the personnel, their respective duties and responsibilities
and the type of management suited to run a bioethanol distillery plant
6. learn from the actual operation and management practices of the various
efficient distilleries, and demonstrate this knowledge by comparing their
production processes/methods and organization
7. prepare and submit a study/evaluation of a specific distillery plant

nilo t. aldon 3
 Presentation Outline
1. Introduction/Overview
2. Distillery Plant Location, Layout
3. Molasses Receiving, Handling and Storage
4. Cane Receiving, Extraction and Preparation
5. Alcohol Handling, Storage and Dispatching
6. Fermentation
7. Distillation
8. Dehydration
9. CO2 Collection and Processing
10. Auxiliary Equipment/Utilities (Water Treatment, Boiler, TG, Cooling Tower)
(Water, Cooling Water, Air, Steam, Electrical Power)
11. Waste Management
12. Reporting: Production and Quality Control
13. Organization and Management
14. Project Presentation/Reporting nilo t. aldon 4
 MAJOR REFERENCES
• The Alcohol Textbook, 4th Edition, A reference for the beverage, fuel and industrial alcohol industries, K.A.
Jacques, PhD, T.P. Lyons, PhD

• ETHYL ALCOHOL HANDBOOK 6TH EDITION

• Handbook on Anhydrous Alcohol

• Cane Sugar Engineering, Handbook of Sugar Cane , Peter Rein

• Handbook of Sugar Cane engineering, E. Hugot, 3 Ed rd

• Biochemical Engineering, James Lee, Book Version 2.1

• Chemical Engineering Handbook, Perry
• BIOFUEL ACT IRR RA 9367-DC-2007-05-0006
• Distillery Journals of the Author.. Engr Nilo T.Aldon

nilo t. aldon 5
Grading Matrix
Term Grades
• Term Exam (50% of Term Grade)
• Quizzes (40% of Term Grade)
• Assignments, Class Participation/Attendance (10% of Term grade)

Final Grade
• 30% Prelim
• 30% Midterm
• 40% End-term

ntaldon 6
1. INTRODUCTION/OVERVIEW

nilo t. aldon 7
Alcohol: Realities
• Ethyl alcohol has probably been used by human beings as a beverage
for at least 300 centuries.
• Although ethyl alcohol had been known for a considerable time in a
crude state in wines and beer, it was not until 1796 that Johann
Tobias Lowitz first prepared it free of water.
• Its composition was determined in 1808 by Théodore de Sassure,
although
• Lavoisier had established its qualitative formula even earlier.
• Its structural formula was established by Sir Edward Frankland later
in the 19th century.
 Handbook on Anhydrous Alcohol-6th ed,

nilo t. aldon 8
Typical BioEthanol Plant

nilo t. aldon 9
nilo t. aldon 10
nilo t. aldon 11
What is Bioethanol?
• Bioethanol _refers to ethanol produced from
feedstock or biomass

• Bioethanol fuel_ refers to hydrous or

anhydrous bioethanol suitably denatured for
use as motor fuel, with quality specifications
in accordance with the Philippine National
Standard (PNS): ≥99.3%v/v AHA; ≤0.5% v/v
moisture nilo t. aldon 12
RA 9367-Biofuel Act Of 2006 Jul 24, 2006

An Act To Direct The Use of Biofuels Establishing for This

Purpose The Biofuel Program, Appropriating Funds Therefor And
For Other Purposes

(Prime raw materials Sugar Cane/Molasses, Also

sweet sorghum and cassava)

nilo t. aldon 13
ANNUAL ETHANOL PRODUCTION,
million gallons
% of World
Region 2015 2016 2017 2018 2019 2020
Production

United States 14,807 15,413 15,936 16,091 15,778 13,941 53%

Brazil 7,200 6,870 6,760 8,080 8,790 8,080 31%

European
1,360 1,240 1,320 1,360 1,380 1,260 5%
Union

China 770 730 850 810 1,010 930 4%

India 190 270 210 420 470 510 2%

Canada 450 450 460 460 500 430 2%

Thailand 310 330 380 390 430 390 1%

Argentina 220 240 290 290 290 210 1%

Rest of World 393 627 664 729 682 659 2%

Total 25,700 26,170 26,870 28,630 29,330 26,410

nilo t. aldon 14
 2%
4%
5%

53%

United States
31%
Brazil

2020 (26,410 million gal)

nilo t. aldon 15
Million liters/y

nilo t. aldon 16
nilo t. aldon 17
SRA 2019-2020 Sugar Milling Data

• Cane Milled: 23,301,581 mt

• Raw Sugar:2,153,356 mt (1.85 LKgTC)
• Molasses; 994,104 mt (0.043 cane)
• Bagasse: 6,877,963 mt (0.295 cane)
• Filter Cake: 891,644 mt (0.0383 cane

nilo t. aldon 18
List of Distilleries in Negros Island
1. Asian Alcohol Corporation_ RS/Potable/AHA/Fuel
2. Distilleria Bago Inc_ RS/Potable
3. VMC Manapla Distillery_ RS/Potable/AHA/Fuel
4. URC Fuel Ethanol Plant, La Carlota_ AHA/Fuel
5. Kooll Distillery Inc_ AHA/Fuel
6. San Carlos Bioenergy Corporation_ AHA/Fuel
7. URC Fuel Ethanol Plant, Bais_ AHA/Fuel
8. Sagay Distillery_AHA/Fuel

nilo t. aldon 19
Fuel ethanol Timeline
• 2005_ SEAOIL Philippines Inc. pioneered the use of ethanol as
gasoline blend, E10
• 2008_ Pilipinas Shell and Petron Corp introduced 95 Octane E10
gasoline
• 2009_Implementation of 5% blend
• 2011_ Implementation of 10% blend

nilo t. aldon 20
 MAJOR REFERENCES
• The Alcohol Textbook, 4th Edition, A reference for the beverage, fuel and industrial alcohol industries, K.A.
Jacques, PhD, T.P. Lyons, PhD

• ETHYL ALCOHOL HANDBOOK 6TH EDITION

• Handbook on Anhydrous Alcohol

• Cane Sugar Engineering, Handbook of Sugar Cane , Peter Rein

• Handbook of Sugar Cane engineering, E. Hugot, 3 Ed rd

• Biochemical Engineering, James Lee, Book Version 2.1

• Chemical Engineering Handbook, Perry
• BIOFUEL ACT IRR RA 9367-DC-2007-05-0006
• Distillery Journals of the Author.. Engr Nilo T.Aldon

nilo t. aldon 21
Grading Matrix
Term Grades
• Term Exam (50% of Term Grade)
• Quizzes (40% of Term Grade)
• Assignments, Class Participation/Attendance (10% of Term grade)

Final Grade
• 30% Prelim
• 30% Midterm
• 40% End-term

ntaldon 22
nilo t. aldon 23
SRA 2019-2020 Sugar Milling Data

• Cane Milled: 23,301,581 mt

• Raw Sugar:2,153,356 mt (1.85 LKgTC)
• Molasses; 994,104 mt (0.043 cane)
• Bagasse: 6,877,963 mt (0.295 cane)
• Filter Cake: 891,644 mt (0.0383 cane

nilo t. aldon 24
List of Distilleries in Negros Island
1. Asian Alcohol Corporation_ RS/Potable/AHA/Fuel
2. Distilleria Bago Inc_ RS/Potable
3. VMC Manapla Distillery_ RS/Potable/AHA/Fuel
4. URC Fuel Ethanol Plant, La Carlota_ AHA/Fuel
5. Kooll Distillery Inc_ AHA/Fuel
6. San Carlos Bioenergy Corporation_ AHA/Fuel
7. URC Fuel Ethanol Plant, Bais_ AHA/Fuel
8. Sagay Distillery_AHA/Fuel

nilo t. aldon 25
Fuel ethanol Timeline
• 2005_ SEAOIL Philippines Inc. pioneered the use of ethanol as
gasoline blend, E10
• 2008_ Pilipinas Shell and Petron Corp introduced 95 Octane E10
gasoline
• 2009_Implementation of 5% blend
• 2011_ Implementation of 10% blend

nilo t. aldon 26
nilo t. aldon 27
nilo t. aldon 28
nilo t. aldon 29
 Product Classifications/Grades of Ethanol
• R.S. (Rectified Spirit)- is highly concentrated ethanol which has been
purified by means of repeated distillation, a process that is called
rectification. It typically contains 94.5-96.0 % alcohol by volume. Rectified
spirits are used in mixed drinks, in the production of liqueurs, for
medicinal purposes, and as a household solvent.

• ENA (Extra Neutral Alcohol) – Distilled spirits produced from any material
at or above 190o proof. In practice, neutral spirit is purified, odorless,
tasteless and colorless ethanol produced by distillation and rectification
techniques that remove any significant amount of congeners. It is used in
the production of beverages such as vodka, gin, cordials and cream
liqueurs.

• AHA (Anhydrous Alcohol) - Literally means alcohol without water. The

term used for an alcohol that contains 99.3-99.9 % v/v ethanol and less
than 0.5% water by volume. It is primarily used as additive for liquid fuels
(gasoline).
• Potable Alcohol_ alcohol that is drinkable, generally called rhum or rum
• Absolute Alcohol_ 100% alcohol
nilo t. aldon 30
• Whisky _ an alcoholic distillate from a mash of grain, produced at less than
190° proof, in such as manner that the distillate possesses the taste, aroma
and characteristics generally attributed to whisky. With the exception of
corn whisky, it should be stored in oak barrels.
• Bourbon whisky _ whisky produced at not more than 1600 proof from a
fermented mash of not less than 51% corn, and stored at not more than
1250 proof in charred, new oak barrels. In practice, the bourbon whisky
mash bill is frequently about 65% corn, 25% rye, and 10% barley malt.
• Brandy_ an alcoholic distillate from the fermented juice, mash or wine of
fruit, or from the residue thereof, produced at less than 1900 proof, in such
a manner that the distillate possesses the taste, aroma and characteristics
generally attributed to the product.
• Rum_ an alcoholic distillate from the fermented juice of sugarcane,
sugarcane syrup, sugarcane molasses, or other sugarcane by-products,
produced at less than 1900 proof, in such a manner that the distillate
possesses the taste, aroma and characteristics generally attributed to rum.
Unlike whisky, rum may not be aged in oak barrels.
• Neutral spirit _ distilled spirits produced from any material at or above
1900 proof.. In practice, neutral spirit is purified, odorless, tasteless and
colorless ethanol produced by distillation and rectification techniques that
remove any significant amount of congeners. It is used in the production of
beverages such as vodka, gin, cordials and cream liqueurs.

nilo t. aldon 31
ANHYDROUS ALCOHOL, Phil National Standard Specifications

Moisture,% v/v <0.5 PNS ASTM E-203

*Fuel Ethanol,% v/v >99.3 PNS ASTM D-5501
*Methanol,% v/v <0.5 PNS ASTM D-5501
Inorganic chloride
Content,mg/L <40 PNS ASTMD512-81(1985 ed)
*Copper,mg/Kg <0.1 PNS ASTM D1688
*Acidity (as acetic Acid)% w/w <0.007 PNS ASTM D1613
pH 6.5-9.0 PNS ASTM D6423

DENATURED BIOETHANOL, Phil National Standard Specifications

Denaturant_ gasoline (2% v/v of AHA)

% Fuel Ethanol 96.9 min Gas Chromatogram

Denatured
Per Tanker
Bioethanol % Moisture 0.5 max Karl Fischer Titration

Density 0.7880-0.7900 Density Meter

nilo t. aldon 32
 Pricing Formula For Ethanol
= Average Feedstock Price in Peso/liter + Conversion Cost /liter

Monthly Average Sugar Composite Price x 1.85 Lkg/MT cane x 70.0 % x0.5 +
70 liters/mt
Molasses Price + P450/mt x0.5 + P22.29/liter
245 liters/mt
1. Average Feedstock Price in Peso per liter is based on sugar cane price and molasses price given a certain
yield in liters per mt

1.1 Sugar cane price is based on sugar mill site price as published by SRA. Sugar price quoted is the
Philippine average monthly composite price of the various sugar classifications (A,B,C,D, etc.)
1.2 Sugar price is converted to sugarcane price using a 1.85 Lkg per ton cane Phil. average and a sharing of 70.0%; Lkg
stands for 50-kilo bag
1.3 Cost due sugar cane is converted to Pesos per liter by using an average yield of 70 liters bioethanol per ton cane
1.4 Molasses price is based on millsite prices of Negros bidding as published by SRA plus average transportation cost of
Php450/ton
1.5 Cost due molasses is converted to Pesos per liter by using an average yield of 245 liters bioethanol
per ton molasses
1.6 Average feedstock cost is based on a 50:50 ratio of molasses to sugarcane

2. Conversion cost/liter of bioethanol is definednilo = Interest + Manufacturing Cost + Profit

as:t. aldon 33
nilo t. aldon 34