Acerit Mamauag Sibal Soriano PED.

Republic of the Philippines
Cagayan State University

Carig Campus, Tuguegarao City
COLLEGE OF ENGINEERING
ETHANOL PRODUCTION FROM CORN
A Process Equipment Design Report
Presented to the Faculty of Department of Chemical Engineering
College of Engineering, Cagayan State University – Carig Campus
In partial fulfilment of the requirements for the degree of
Bachelor of Science in Chemical Engineering
Harvey O. Acerit
Aileen T. Mamauag
Arjanelle A. Sibal
Jonalbeth B. Soriano
January 2018
LETTER OF TRANSMITTAL
January 2018
Engr. CAESAR POBRE LLAPITAN
Instructor
Chemical Engineering Department
Cagayan State University
Dear Engr. Llapitan:
We are herewith submitting our report entitled “Ethanol Production from Corn” in partial
fulfillment for the requirement of the course Process Equipment Design.
The primary objective of this study is to present a complete and detailed process design for the
production of Ethanol. A concise overall process flow diagram, detailed Material and Energy
balance, Piping and Instrumentation Diagram (P&ID), Qualitative and Quantitative Block
Diagrams are included in this study. A discussion of the product safety, health and
environmental impacts is also included in this study. We hope that this will merit your approval.
Very truly yours,
Harvey O. Acerit
Aileen T. Mamauag
Arjanelle A. Sibal
Jonalbeth B. Soriano
i
Table of Contents
Title Page
Letter of Transmittal i
Table of Contents ii
Executive Summary iv
Chapter I Introduction 1
Product Information 1
Product Properties 6
Process Selection 7
Objective of the Study 11
Proposed Process 11
Chapter II Process Description 18
Reactor Feed Preparation 18
Reactor 20
Separator 20
Chapter III Material and Energy Balances 27
Material Balance 27
Energy Balance 35
Utility Requirement 40
ii
Chapter IV Process and Instrumentation Diagram 44
Symbols and Codes 45
ISA Identification Letters 46
Selection of Control Valves 46
Individual Control and Instrumentation of Equipment 49
Chapter V Health Safety and Environment 57
Risk Assessment 57
Government Regulations 61
HAZOP Studies 66
Pollution Prevention 69
Life Cycle Analysis 69
Equipment AutoCAD 76
Appendix 79
Material Balance 79
Energy Balance 89
iii
EXECUTIVE SUMMARY
The Philippines is a major and user of renewable energy and has for years required
biodiesel and ethanol in local petroleum diesel fuel and gasoline. Bioethanol production is one
of the most potential and realistic method for producing renewable energy source. Bioethanol
is produced mainly from sugar cane and corn. The design of a sustainable process for producing
bioethanol requires a methodological approach whereby economical, environmental and social
criteria are systematically integrated from the early stages of the process design.
Chapter 1 includes the product information and product properties. Process selection
is also shown in this chapter where it includes the comparison of the alternatives that are
commonly used in the manufacturing process and the anatomy of the new process design based
from these alternatives.
In Chapter 2, the technical study of the ethanol plant is presented. Block flow diagrams
are indicated to show the general flow of processes. Process topology is also included in this
chapter which shows the different streams and equipment used. Definitions of the process is
also discussed.
Chapter 3 discusses the material and energy balances accounted in the process of
ethanol production. The capacity of the product produced is 100000 kg per day of ethanol and
432320.24 kg per day of Dried Distillers’ grain and from this capacity, mass flow rates, material
and energy balance of equipment are calculated. Different utility requirements such as energy
consumption and water consumption were also elaborated.
Chapter 4 discusses the technical study of the banana production. This chapter shows
the process flow diagram and the Piping & Instrumentation diagram of the processes and
equipment used for the said product.
iv
Chapter 5 discusses the safety and health of workers and the environment. Risk
management and government regulations involved in the process were provided.
Environmental constraints like hazard and operability studies, pollution prevention, and life
cycle analysis were also discussed in this chapter
v
CHAPTER I
INTRODUCTION
A. Product Information
Ethanol (CH3CH2OH) is a clear, flammable, colorless and slightly toxic
chemical compound with acceptable odor. It can be produced either from petrochemical
feedstocks by acid-catalyzed hydration of ethane, or from biomass feedstocks through
fermentation. It is also known as ethyl alcohol, grain alcohol, and EtOH. On a global
scale, synthetic ethanol accounts for about 3-4% of total production while the rest is
produced from fermentation of biomass-mainly sugar crops. Ethanol has the same
chemical formula regardless of whether it is produced from starch-and sugar-based
feedstock, such as corn grain, sugarcane, or from cellulosic feedstock.
1. Technology
Ethanol or ethyl alcohol has existed since the beginning of recorded history. The
ancient Egyptians produced alcohol by naturally fermenting vegetative materials. Also
in ancient times, the Chinese discovered the art of distillation, which increases the
concentration of alcohol in fermented solutions. Ethanol was first prepared
synthetically in 1826, through the independent effort of Henry Hennel in Britain and
S.G in France. Michael Faraday prepared ethanol by the acid-catalyzed hydration of
ethylene in 1828, in a process similar to that used for industrial synthesis of ethanol
today. The face of ethanol production technology is old and ever changing. It is widely
noted that centuries ago man discovered and began employing fermentation technology
to produce alcohol/ethanol.
1
Feedstock for the ethanol production can be broadly classified into : (i)
Monomeric Sugars, these are substrates in which carbohydrate is present in the form of
simple, directly fermentable six-and twelve carbo sugar molecules such as glucose,
fructose, and maltose. Such feedstock include sugarcane, sugar beets, fruit (fresh or
dried), citrus molasses, and cane sorghum. (ii) Starch, contain slightly complex
carbohydrates and need to be enzymatically processed to yield simple sugars. Examples
of these are corn, grain sorghum, barley, and wheat and root/tubular crops such as
cassava, potatoes, cacti and arrowroot. (iii) Cellulosic Biomass, lignocellulosic biomass
such as that obtained from forest and agricultural residues, also serves as feedstock for
ethanol production.
2. Worldwide production of ethanol
Bioethanol and biodiesel are the most promising clean and alternative
renewable fuels. These can be used in the form of a gasoline/ diesel blend. Bioethanol
is currently produced mainly from corn (United States) and sugarcane in Brazil. The
United States and Brazil are the two major country in producing ethanol. There is also
growing interest in developing commercially viable cellulose to ethanol technology.
The use of ethanol as an alternative fuel source is presently a worldwide topic of
discussion and research. Through decades of research and development, the production
of fuel ethanol has been developing throughout the world. Conventional processes have
been maximized while advances continue to be made in lignocellulosic biomass
conversion. (Onuki; 2008)
2
3. Local production
The Philippines, Biofuels Act of 2006 (R.A. 9367) provides the legal basis for
the production in the country. Specifically for the Philippine sugar industry, ethanol
production for fuel will expand the market for sugar. The Republic Law No. 9367
enforces the blending of Bio-ethanol to Automobile Fuels. There are four feedstock
used in the production of ethanol in the country namely sugarcane, molasses, cassava
and sweet potato. But sugarcane and molasses are the most currently used as ethanol
feedstock in the country. (Survey; 2014)
4. Uses and Application of Ethanol
i. Medical
1. As an Antiseptic
Ethanol is used in medical wipes and in most common antibacterial hand
sanitizer gels.
2. As an Antitussive agent
Ethanol is also widely used, clinically and over the counter, as an antitussive
agent.
3. As an Antidote
Ethanol may be administered as an antidote to methanol poisoning.
ii. Recreational
Ethanol is commonly consumed as a recreational drug, especially while
socializing, due to its psychoactive effects.
3
iii. Fuel
1. Engine Fuel
The largest single use of ethanol is as an engine fuel and fuel additive. A
percentage of ethanol is combined with gasoline. This is beneficial because the ethanol:
a. decreases the fuel's cost
b. increases the fuel's octane rating
c. decreases gasoline's harmful emissions
Any amount of ethanol can be combined with gasoline, but the most common
blends are E10 and E85 in US and E25 in Brazil. More than 20% of Brazilian cars are
able to use 100% ethanol as fuel, which includes ethanol-only engines and flex-fuel
engines. Flex-fuel engines in Brazil are able to work with all ethanol, all gasoline or
any mixture of both. In the US flex-fuel vehicles can run on 0% to 85% ethanol (15%
gasoline) since higher ethanol blends are not yet allowed or efficient.
2. Rocket Fuel
Ethanol was commonly used as fuel in early bipropellant rocket (liquid
propelled) vehicles, in conjunction with an oxidizer such as liquid oxygen. The German
V-2 rocket of World War II, credited with beginning the space age, used ethanol, mixed
with 25% of water to reduce the combustion chamber temperature. The V-2's design
team helped develop U.S. rockets following World War II, including the ethanol-fueled
Redstone rocket which launched the first U.S. satellite.
3. Fuel Cells
Commercial fuel cells operate on reformed natural gas, hydrogen or methanol.
Ethanol is an attractive alternative due to its wide availability, low cost, high purity and
low toxicity.
4
4. Household Heating
Ethanol fuels flue-less, real flame fireplaces. It provides almost the same visual
benefits of a real flame log or coal fire without the need to vent the fumes via a flue as
ethanol produces very little hazardous carbon monoxide, and little or no noticeable
scent. An additional benefit is that, unlike a flue based fireplace, 100% of the heat
energy produced enters the room. This serves to offset some of the heat loss from an
external air vent, as well as offset the relatively high cost of the fuel compared to other
forms of heating.
iv. Feedstock
Ethanol is an important industrial ingredient. It has widespread use as a
precursor for other organic compounds such as ethyl halides, ethyl esters, diethyl ether,
acetic acid, and ethyl amines.
v. Solvent
Ethanol is miscible with water and is a good general purpose solvent. It is found
in paints, tinctures, markers, and personal care products such as mouthwashes,
perfumes and deodorants.
5
B. Product Properties
Ethanol, also called ethyl alcohol; can be used as fuel alcohol, drinking alcohol,
and grain alcohol. The common type of ethanol is the one found in alcoholic beverages.
It is also used as fuel for cars and often called alcohol or spirit. A fuel’s octane rating
is the measure of its ability to resist “knocking” or “pinging”. Ethanol has an octane
rating of 113 which offers more engine knock resistance at a lower cost than any other
gasoline additive on the planet. Ethanol is the lowest-cost octane source. Table 1 shows
the different property of ethanol.
Table 1.1 Property of ethanol
Ethanol
Chemical Formula C2H6O

Molar Mass 46.07 g/mol
Appearance Colorless liquid
Density 0.789 g/cc
Melting Point −114 °C
Boiling Point 78.37 °C
Flash point 14 ˚C
Other names Absolute alcohol/ Alcohol
Cologne spirit Drinking alcohol
Ethane monoxide
Ethylic alcohol EtOH
Ethyl alcohol
Ethyl hydrate
Ethyl hydroxide
Hydroxyethane
Methylcarbinol
6
C. Process Selection
The ethanol production process varies with the feedstock types. Depending on the
substrate complexity, various pretreatment methods are needed. For the production
from sugarcane, sugar beets and sorghum stalks, all of which contain simple sugars
such as glucose and sucrose, no pretreatment is needed except size reduction and
pressing. For starchy such as corn, sorghum and cassava, grinding or milling followed
by enzyme hydrolysis is needed to be obtain fermentable sugar. Lignocellulosic
biomass requires more comprehensive physical and chemical pretreatment to
enzymatic hydrolysis to release simple sugars.
1. Different processes use for the production of Ethanol
i. Wet milling process
The first step in the wet milling process is steeping, where the corn kernel is
placed in an aqueous solution of 0.1–0.2% SO2 and allowed to cook at 48–52◦C for
30–50 hours. This facilitates downstream fractionation by hydrolyzing disulfide bonds
in proteins so that they are more soluble. The corn is then ground in its wet state and
oil, fiber, and gluten are separated from the starch for further processing into value-
added co-products. During saccharification, enzymes break down the starch into
glucose. In the fermentation step, yeast grown in seed tanks is added to the corn mash
to ferment the simple sugars (glucose) to ethanol. Finally, ethanol is separated from the
water by means of distillation and dehydration. (Chaudhary;2012)
7
Gluten
Corn Fiber
(Gluten Meal)
(Gluten Feed)
Steeping
Starch/Gluten
Centrifugation
Separation
Starch
Grinding
Alpha-amylase/ Saccharification
Gluco-amylase
Germ (oil)
Yeast Fermentation
Germ Separation
Distillation
200 proof
Dehydration
Ethanol
Figure 1.1 Wet milling process for the production of ethanol
ii. Dry Milling process
In a dry mill, cleaned corn is first ground in hammer mills, which breaks the
tough outer coating of the seed and grinds the corn into a fine powder. During the
liquefaction process, water and enzymes are added to the ground corn in order to create
a slurry. The gelatinized starch feedstock is easier to hydrolyze into monomeric sugars
than uncooked corn, although processes that avoid the cooking step are being
considered for ethanol plants. Saccharification and fermentation are similar to the
processes performed in a wet mill. Ethanol is obtained from the water slurry via a
number of complex steps including distillation and dehydration. A co-product of the
dry milling process, heavy stillage, leaves the bottom of the first distillation column.
The heavy stillage is centrifuged to remove the majority of the solids. The thin stillage
is partly recycled to the liquefaction step. The centrifuged solids are referred to as wet
cake or wet distiller’ grain (35-40% solids). These are further dried to give DDGS.
(Chaudhary;2012)
8
Ethanol
Gluco-amylase Dehydration
Alpha-amylase,
Corn Yeast
water
Milling Liquefaction Saccharification Fermentation Distillation
Heavy
Stillage
Separation Centrifugation
Backset Thin Stillage
Wet cake
Dryer
Syrup
Dried Distiller's
Grain with
Solubles(DDGS)
Figure 1.2 Dry milling process for the production of ethanol
iii. Ethanol from Cellulosic Biomass
The difficulties of using cellulosic materials are there poor porosity, high
crystallinity, and lignin contents. Various kinds of pretreatment techniques have been
investigated, such as steam, acid and alkali treatments. In the ethanol production from
cellulosic material, the feedstock is delivered to the feed handling area for storage and
size reduction. From there, the biomass is conveyed to pretreatment and conditioning.
Pretreatment is used to reduce the crystallinity of cellulose and disrupt the
heterogeneous structure of cellulosic material and in this process detoxification is
applied. Enzymatic hydrolysis (or saccharification) coupled with co-fermentation of the
detoxified hydrolyzate slurry is carried out in a continuous hydrolysis trank and
anaerobic fermentation tanks in series. After several days of saccharification and
fermentation, most cellulose will have been converted to ethanol. Product recovery is
present after fermentation which involves distilling the beer to separate the ethanol from
the water and residual solids. (Farid;2008)
9
Ammonia
Steam Glucose Enzyme
Acid Production
Nutrients
Cellulase Enzymatic
Feedstock Feed chips Pretreatment/
Hydrolyzate Hydrolysis and
Handling Conditioning
Nutrients Fermentation
Recycle
Evaporation Water
Vent Beer Vent
Flash
Condensate
Distillation
Wastewater
Nutrients Steam Dehydration
Treatment
Solids Separation
Stillage
Lignin Ethanol
Product
Fuel Burner/Boiler Steam

Anaerobic Turbogenerator
Electricity Storage
iogas
Figure 1.3 Ethanol production from Cellulosic material
Table 1.2 Comparison of the tree alternatives method
Process Advantage Disadvantage

Wet milling process  More versatile  Higher cost of
construction and
operation
Dry milling process  More efficient  A need of

 A variety of high- sophisticated
valued coproducts marketing to dispose
are produced. of coproduct
Process using cellulosic  Greater ethanol  Conversion of
material production cellulosic biomass to
ethanol is more
difficult
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D. Objective of the Study
The objective of this study is to design a process where corn kernel can be
processed into a useful product which is ethanol and to reduce the waste of the primary
raw material which can also be process to produce a by-product of Distillers’ dried
grain.
This study will cover the processes involved in the production of ethanol. A
concise overall process flow diagram, detailed Material and Energy balance, Piping and
Instrumentation Diagram (P&ID), Qualitative and Quantitative Block Diagrams are
included in this study. A discussion of the product safety, health and environmental
impacts is also included in this study.
E. Proposed process of Ethanol Production
1. Anatomy of the process
The basic component of a typical chemical process of the ethanol production is
shown in the figure below. Each block represents a stage in the overall process a product
from the raw materials wherein the raw material used in the process is corn kernel. The
figure represents a generalized process; not all the stages will be needed for any
particular process and the complexity of each stage will depend on the nature of the
process.
11
Product Purification Product Sales
Raw Material Raw Material Product Separation Storage
Reaction
Storage Preparation
Dehydration
Feedstock Product
Milling Liquefication Saccharification Fermentation Distillation Distribution
Storage Storage
Centrifugation
Drying
Stage 1 Stage 2 Stage 3 Stage 4 Stage 6
Stage 5
Figure 1.4 Anatomy of the proposed process
i. Stage 1. Raw Material Storage
Corn kernels are stored in a storage room ready for the feed preparation
ii. Stage 2. Feed Preparation
The first process for the feed preparation involves milling wherein the size
reduction of corn kernels will happen. The feed preparation also involves
liquefaction and saccharification, conversion of starch to dextrin to glucose happens
respectively.
iii. Stage 3. Reaction
Fermenter is the reactor present in the process which is the heart of the process.
Fermentation is the most important part in the process.
iv. Stage 4. Product Separation
The product and by-product are separated using distillation. Ethanol is delivered
to a molecular sieve for the next stage which is dehydration and a stillage is also
delivered to a centrifuge ready for the next stage to produce a by-product of
distillers’ dried grain
12
v. Stage 5. Product Purification
The main product ethanol will undergo dehydration to produce a 99-100 %
ethanol. Centrifuge is used to purify the whole stillage removing the liquid phase of
the stillage which will be ready for drying to produce a dried distillers’ grain.
vi. Stage 6. Product Storage
The ethanol is the main product in the process which will be stored in tanks.
The distillers’ dried grain is the by-product in the process. Both products will be
stored in their respective storage ready for the distribution.
Below shows the general conversion of starch and its conversion rates to ethanol. A
detailed process of ethanol production from corn will be discuss in the chapter 2 of this
paper.
alpha- gluco- Yeast

amylase amylase
Starch
(C6 H10 O5 )n Dextrin Glucose Ethanol
+ 98% (C6 H12 O6 )10 99% (C6 H12 O6 ) 94% 2(C2H5OH)
Water (H2 O)
13
References
1. Acora, German, et al. (2013). Process design and sustainability in the production of
bioethanol from lignocellulosic materials. Electronic Journal of Biotechnology ISSN:
0717-3458 http://www.ejbiotechnology.info DOI: 10.2225/vol16-issue3-fulltext-7
2. Ajibola, F.O., Edema, M.O.and Oyewole, O.B. (2012). Enzymatic Production of
Ethanol from Cassava Starch Using Two Strains of Saccharomyces cerevisiae.
Official Journal of Nigerian Institute of Food Science and Techonology. NIFOJ Vol.
30 No. 2.
3. Basso, L.C, et al.(2010). Ethanol Production in Brazil: The Industrial Process and Its
Impact on Yeast Fermentation.
4. Bataller, B.G., Del Rosario, E., Demafelis, R. B., Ranola, R.F. (2009). Enchancing the
Viability of Cassava Feedstock for Bioethanol in the Philippine.
5. Bowen, Emily. Et.al. (2010). Ethanol from Sugar Beets: A Process and Economic
Analysis.
6. Cadavid, D.A et.al. (2014). Improvement in commercial scale dry mill corn ethanol
production using controlled flow cavitation and cellulose hydrolysis.
7. Chaudhary, D.P. et.al. (2012). Corn to Ethanol: Retrospect’s and Prospects. Maize:
Leading to a new Paradigm.
8. Convento, Divine Grace M., Abacan, Joel P., Acio, Finesse M. (2007). Biofuels: A
Review of Philippine Studies.
9. Cruz, Perfecto. (2013). Philippines Biofuels Situation and Outlook.
10. Bowen, Emily. Et.al. (2010). Ethanol from Sugar Beets: A Process and Economic
Analysis.
14
11. Ensinas, A.V., et al. (2009). Production of Bioethanol and other Bio-based materials
from Sugarcane Bagasse: Integration to conventional Bioethanol production process.
Chemical Engineering Research and Design, www.elsevier.com/cherd.
12. Farid, Talebnia (2008). Ethanol Production from Cellulosic Biomass by Encapsulated
Saccharomyces Cerevisiae.
13. Kumaresan, R., Meenakshi, A. (2014). Ethanol Production from Corn, Potato Peel
Waste and its Process Development. International Journal of ChemTech Research
ISSN: 0974-4290 Vol.6, No.5.
14. Liang, L., Zhang, Y., Liang S., et al. (2008). Study of sugarcane pieces as yeast
supports for ethanol production from sugarcane juice and molasses. Journal of
Industrial Microbiology and Biotechnology, 35, 1605-1613.
15. Mendoza, T.C. and R. Samson. The Energy Costs of Sugar Production in the
Philippine Context. The Philippine Journal of Crop Science 2002, Vol. 27 No. 2: 17-
26.
16. Patzek, Tad W. and Pimentel David. (2005). Ethanol Production Using Corn,
Switchgrass and Wood; Biodiesel Production Using Soybean and Sunflower.
17. Suthipong, Sthiannopkao. (2002). Ethanol Production Technology in Thailand. Asian
J. Energy Environ., Vol. 3 Issues 1-2, (2002)
18. Onuki, Shinnosuke, et.al. (2008). Ethanol production, purification, and analysis
techniques: A review. http:// lib.dr.iastate.edu/abe_eng_conf
19. Watanabe, M. (2009). Ethanol Production in Brazil: Bridging its Economic and
Environmental Aspects. International Association for Energy Economics. Brazil
15
RUBRIC FOR PROCESS EQUIPMENT DESIGN PROJECT EVALUATION
Name:
Title of Design Project:
EVALUATION CRITERIA 1 2 3 4
SCORE
Beginning Developing Proficient Exemplary
Identification of Problem or Definition Insufficient identification Partial identification of Adequate identification of Clear and complete
of Project of problem; inadequately problem; lack of specifics problem; any lack of identification of design
objectives. does impair solution of specifics does not impair goals and objectives.
(3 points) design. solution or design.
Alternative Designs Only one design Serious deficiencies in Alternative approaches Final design achieved
presented or clearly exploring and identifying identified to some after review of
(2) infeasible alternative alternative designs. degree. reasonable alternatives.
given.
One alternative At least two alternatives Three or more
No evidence of presented as the project presented alternatives presented.
alternative designs. solution.
Application of Engineering Principles No or erroneous Serious deficiencies in Effective application of Critical selection and
application of proper selection and use engineering principles application of engineering
(7) engineering principles of engineering principles. resulting in reasonable principles ensuring
yielding unreasonable solution. reasonable results.
solution.
Use of Computer–Aided Tools Serious deficiencies in Minimal application and Computer–aided tools Computer–aided tools
understanding the correct use of appropriate tools. used with moderate are used effectively to
(3) selection and/or use of effectiveness to develop develop and analyze
tools. designs. designs.
Meeting Design Requirements Few design requirements Only basic requirements Design requirements are All design requirements
are met. are met. met. are met and exceeded
(5)
16
Design Documentation Reports may have poor Reports attempts Reports use mostly Reports use appropriate
and Presentation quality writing and mix appropriate appropriate language/format for the
jargon with engineering language/format for the language/format for the engineering field.
language. engineering field. engineering field.
Reports are informative
(5 points) Reports miss many Reports are fairly Reports are mostly and easy to read.
important topics and are informative and generally informative and easy to
not easy to read. easy to read. read. Information in reports is
well organized so that
Information in report is Information in reports Information in reports is data or design feature
not organized. Data or organized into sections well organized. All data explanations are easy to
design features with data or design and design features can found.
explanations very difficult features explanation be found without
to locate. present. difficulty. Avoid plagiarism, does
not use information
Evidence of plagiarism. Evidence of plagiarism. Both positive and without giving credit to
negative results the appropriate source.
presented.
Punctuation, Capitalization & Spelling There are a number of There are 3 or 4 minor There are 1 or 2 minor There are no
(3) major errors in errors in punctuation, grammatical, spelling or grammatical, spelling or
punctuation, grammar grammar and/or spelling punctuation errors punctuation errors
and/or spelling which which do not break the
make it difficult to read flow for the reader
Sources Attempt to document All sources are All sources are All sources are
(2) source used is not accurately documented accurately documented accurately documented
completely accurate Only 1 or 2 sources were and in the desired format and in the desired format
Only 1 source was used used 2 or 3 sources were used
TOTAL SCORE
Rater: Engr. CAESAR P. LLAPITAN
17
CHAPTER II
PROCESS DESCRIPTION
A. Reactor Feed Preparation
1. Cleaning
The corn kernels must be cleaned prior to processing. The incoming stream of
corn kernels, as received, is typically passed through a screener or scalper or
multiple screeners or scalpers arranged to remove oversized materials (e.g., corn
cobs, husks, sticks) and smaller materials. The unwanted materials tend to account
for a very small portion of the incoming corn stream. The corn may also pass
through a destoner, which separates objects based on weight and can be used to
remove heavier objects (e.g., stones, glass) from the process stream. During the
cleaning process, pressurized air may be used to remove chaff and dust. In addition,
the process stream will usually pass through a magnetic separator to remove any
tramp metal that may be remaining.
2. Milling
Once the corn has been cleaned, the whole kernels are conveyed to a milling
operation typically a hammer mill or impact mill. A kernel of corn consists of a
fiber shell which contains starch, protein, gluten and germ. The shell needs to be
broken and the starch disrupted to enhance enzymatic hydrolysis during cooking.
This can be accomplished using a hammer or roller mill (with screens between 3.2
to 4.0 mm) to grind the corn into a fine meal.
3. Liquefaction
Corn Starch is composed of glucose units joined through a linkage in chains by
a 1-4 and in branches by a 1-6 glycosidic bonds. The linear starch molecules are
called amulose, whereas the branched on is called amylopectin.The whole milled

18
grain is slurried with water, and thermo stable enzyme a-amylase is added which
breakdown the starch polymer (hydrolyze a 1-4 bond) and produce soluble dextrin.
The most effective use of alpha-amylase occurs when the pH of the slurry is
between 6.0 and 6.5, and the pH is kept in this range from the time the alpha-
amylase is added until liquefaction is complete. Anhydrous ammonia and various
other bases (e.g. lime) may be added if the pH falls below the optimal range,
whereas sulfuric acid might be added if the pH starts to exceed the optimal range.
Liquefaction is accomplished using jet-cookers that inject steam into the corn flour
slurry to cook it at temperatures above 100°C (212°F). The heat help reduce the
levels of bacteria in the mash by 90%.
Reaction:
amylase
(C6 H10O5 ) n  H 2 O a (C6 H12O6 )10
4. Saccharification
After liquefaction, the slurry, now called “corn mash,” is cooled to
approximately 30°C (86°F), and a second enzyme (glucoamylase) is added.
Glucoamylase breaks down the dextrins into glucose, which completes the
breakdown of the starch into simple sugars. The most effective use of glucoamylase
occurs when the solution pH is between 4.0 and 5.5, which is considerably lower
than the pH in the liquefaction process. Therefore, the solution pH must be lowered
to achieve optimal enzymatic activity. The pH reduction at this stage is typically
accomplished by blending in a lower pH stillage solution generated later in the
process or by adding sulfuric acid.
Reaction:
C6 H12O6 10 g

amylase
10C6 H12O6
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B. Reactor
1. Fermentation
Yeast is added added to the mash to ferment the sugars. During this process, the
yeast eat the sugars, and in the process produces heat, ethanol and carbon dioxide.
The whole process requires 48-72 hours and the liquid phase of the beer is typically
8 to 12 percent ethanol by weight. CO2 released can be captured and sold for the
use in carbonating soft drinks, dry ice and some beverages industries. Unlike the
upstream processes (milling, liquefaction, saccharification) that operate
continuously, fermentation typically operates as a batch process. Most facilities
have numerous tanks dedicated to fermentation and they typically operate in groups
of three: while one tank is being filled, another is fermenting, and the third is
emptying and made ready for filling. With this arrangement, upstream production
never needs to halt between batches. Larger facilities can have multiple groupings
of three tanks.
Reaction:
C6 H12O6  2C2 H 5OH  CO2

yeast
C. Separator
1. Distillation
The beer mixture is pumped into a beer column where the purified ethanol is
collected from the vapor portion of columns and spent solids (stillage) from the
bottom. The ethanol stream is further purified in an ethanol column. The columns
utilize the differences in the boiling points of ethanol (78oC) and water (100oC) as
a milestone to boil off and separate the ethanol. By the time the product stream is
ready to leave the distillation columns, it contains about 95% ethanol by volume
(190-proof).
20
2. Dehydration
The ethanol still contains about 5% water. Alcohol and water form an azeotrope
at this point and cannot be separated further. To carry out this operation, it is passed
through a molecular sieve to physically separate the remaining water from the
ethanol. The molecular sieve is a bed of specialized beads that selectively adsorb
water based on molecule size. The beads are commonly made from zeolite, a type
of aluminosilicate. Similar to fermentation tanks, facilities typically operate
multiple molecular sieves so that when one sieve needs to be regenerated another is
always available to handle the ethanol stream. This step produces 99-100% ethanol.
3. Centrifugation
The stillage collected from the beer column contains 66% liquid. Centrifuge is
used to separate the liquid and solid phase of the whole stillage. The Wet Distillers’
Grain with Solubles or WDGS (40% moisture) is transported into a dryer using a
conveyor while the thin stillage (93% moisture) is first sent to an evaporator. Some
of the thin stillage is routed back to the slurry tank as a make up water.
4. Evaporation
The evaporator concentrates the thin stillage from 93% to 40% moisture
content. The feed is heated up to 105oC and the water evaporated can be utilize in
the cooker reducing the amount of heat and fresh water required in the upstream.
5. Dryer
WDGS is often dried to 10-12 percent moisture. This can be done in a rotary
drum dryer or in a ring dryer to form dried distillers’ grain with solubles (DDGS).
Dryer temperatures can vary considerably (from 220oF to 380oF) depending on
many factors, such as the type of dryer used, the dryer residence time and feed rate,
and the target moisture content.
21
Steam
Thin Stillage
Fresh water Acid Gluco-amylase Yeast Water
CO2
Corn Hammer Milled Slurry Mash Saccharification Mash CO2

Cooker Fermentors CO2
Kernels Mill Grains Tank Slurry (Dextrin) Tank (Glucose) Scrubber
Alpha-amylase
Waste Water
Ammonia
Beer
Lime
EthanolWater
Wet Ethanol
Azeotropic Ethanol
Dehydrated Molecular Ethanol Beer

Ethanol Sieve Column Column
Process Water
Stillage
Steam
Evaporator Centrifuge
Thin Stillage
Conc.Thin Stillage Wet Distillers Grain

with Soluble (WDGS)
Water
Distillers' Grain
with Soluble
Dryer
Dried Distillers Grain
with Soluble (DDGS)
Figure 2.1 Block Flow Diagram
22
M-101 T-101 T-102 R-101 H-101 T-103 E-101 R-102 E-102 R-103 G-101 N-101
Hammer Weigh Slurry Steam Steam Cook Mash Saccharification Mash Fermentors Degasser Beer Degas
Mill Tank Tank Cooker Heater Retention Tank Pre-Cooler Tank Post-Cooler Vent Condenser
S-101 T-104 T-105 T-106 T-107 E-103 E-104 E-105 C-101 T-108 V-101 D-101
CO2 Beer Ethanol Adsorption Adsorption Anhydrous Ethanol Water Stillage Centrifuge Thin Stillage Stillage DGS
Scrubber Column Column Column 1 Column 2 Ethanol Cooler Cooler Cooler Tank Evaporator Dryer
G-AMYLASE
8
A-AMYLASE
4
WATER
3
CORN
1
H-101
2 M-101
R-102
E-101
6
5 7
R-101
T-101 T-103
T-102 E-102
9
WATER CO2
14 15
YEAST WASTE WATER
10 16
S-101
E-103
ETHANOL
21
13
18 19
R-103
N-101 T-104 T-105 T-106 T-107
11
12 17
G-101
E-105
22
E-104
23 PROCESS WATER
20
Figure 2.2 Process Topology 26
24
MOISTURE
V-101
23 28
T-108 27
D-101 DDGS
C-101 29
25
References
1. Singh, V. (2016). Innovative Technologies and Products for Dry Grind Ethanol Process.
Professor, Agricultural & Biological Engineering. Associate Director, Integrated
Bioprocessing Research Laboratory. University of Illinois at Urban-Champaign
2. Johnston, D. New Enzymatic Advances in the Dry Grind (Grain) Ethanol Process. Crop
Conversion Science and Engineering Research Unit, USDA-ARS-Eastern Regional
Research Center, Wyndmoor, PA
3. Dale, R.T., Tyner, W.E. (2006). Economics and Technical Analysis of Ethanol Dry
Milling: Model User’s Manual. Purdue University.
4. Sapna, et.al. Corn to Ethanol: Retrospect’s and Prospects, Maize: Leading to a new
Paradigm. Directorate of Maize Research, Pusa Campus, New Delhi -110 012 Technical
Bulletin 2012/7 pp.28
5. Mosier, N.S., Ileleji, K. How Fuel ethanol is made from Corn. Department of Agricultural
and Biological Engineering, Purdue University.
6. Singh, V. (2009). Dry Grind Corn Processing – New Technologies. Associate Professor,
Department of Agricultural & Biological Engineering University of Illinois at Urbana-
Champaign, Urbana, IL
7. Wrenn, B.A. (2008). Summary Report for Pursuit Dynamics. National Corn-to-Ethanol
Research Center
8. Onuki, S., et. al. (2008). Ethanol production, purification, and analysis techniques: a
review. Agricultural and Biosystems Engineering, Iowa State University.
9. Szymanowska, D., Grajek, D. (2009). Fed-batch Simultaneous Saccharificationa nd
Ethanol Fermentation of Native Corn Starch. Poznań University of Life Sciences, Poznań,
Polan
24
Name:
SCORE
given.
solution.
(5)
25
not use information
presented.
TOTAL SCORE
26
CHAPTER III
MATERIAL AND ENERGY BALANCES
A. Material Balance
For each of the block shown in the block flow diagram, the material balance is
written as:
Material in  Material out
or
Mi  Mo
m n
or  M i , j   M o ,k
j 1 k 1
Where j represents the type of material inputs with a total of m inputs, and k
represents the type of material outputs with a total of n outputs.
The plant is assumed to produce a 100 000 kg/day of 99.5% ethanol and DDGS
as a co-product in a dry mill process.
In the dry mill ethanol process, the whole grain is processed, and the residual
components are separated at the end of the process. The ethanol production facility
run continuously with scheduled shut down periods for maintenance.
The basic steps include milling, cooking, liquefaction, saccharification,
fermentation, distillation/dehydration, centrifugation, evaporation, and drying. If
the ethanol plant is taken as a single system, the inputs are corn and water plus
energy, while the outputs are ethanol, solids (by‐products), wastewater, and CO2.
Degrees of freedom analysis are used when the number of unknowns and
independent equations have been determined. It is an analysis whether a problem is
solvable or not.
27
The following tables of properties are used for the material balance calculations:
the grain composition, the solid/liquid percentage of every streams, the assume
ethanol content in the downstream, the theoretical conversion rates of the three main
reactions as well as the needed weight of enzymes.
Table 3.1 Grain Composition

Grain Percent Average (Dry matter)
Carbohydrates (Total) 84.1
Starch 72.0
Fiber (NDF) 9.5
Simple Sugars 2.6
Protein 9.5
Oil 4.3
Minerals 1.4
Others 0.7
TOTAL 100
The production starts with corn as input. Table 3.1 lists the composition of corn.
It is used mainly in the upstream material balance calculations especially
component balances.
Table 3.2 Dry Mill Process Solid/Liquid Percentages

Product Liquid (w/w%) Solids (w/w%)
Slurry 67.0 33.0
Mash 77.8 22.2
Beer 89.0 11.0
Whole Stillage 66.0 34.0
Thin Stillage 93.0 7.0
WDGS 40.0 60.0
DDGS 89.0 11.0
28
Table 3.2 is used along with the conversion rates in Table 3.3 to determine the
theoretical yield of co-products from grain and the water needed in the production.
Table 3.3 Conversion Rates as a Percentage of Theoretical Yield
Starch to Dextrin Conversion : 98.0%

amylase
(C6 H10O5 ) n  H 2 O a (C6 H12O6 )10
Dextrin to Glucose Conversion: 99.0%

C6 H12O6 10 g
amylase
10C6 H12O6
Starch 
Glu cose 97.0%
Glucose to Ethanol Conversion: 94.0%
C6 H12O6  2C2 H 5OH  CO2
yeast
Starch 
 Ethanol 91.2%
Ethanol and CO2 yields were calculated as function of the corn composition and
conversion rates The DDGS came from starch, dextrin and glucose that was not
converted to alcohol in the fermentation process.
Table 3.4 Ethanol Content of the Down streams

Streams Weight Percent Ethanol
Beer 8.9
Wet Ethanol 60.0
Process Water 0.05
Azeotropic Ethanol 95.0
Ethanol Water (Recycle) 73.0
Dehydrated Ethanol 99.5
29
Aside from the main raw materials needed in the plant, the addition of enzymes
greatly contributes to the production process. Table 3.4 shows the corresponding
amount of enzymes needed for the three main reactions of the process.
Table 3.5 Theoretical Weight of Enzymes Needed in the Dry Mill Process
Estimated Weight
weight needed
Enzymes Unit Process needed
(kg)
(kg/kg corn)
A-Amylase Liquefaction 0.000811 per kg starch 0.000582
G-Amylase Saccahrification 0.000854 per kg dextrin 0.000680
Yeast Fermentation 0.000244 per kg glucose 0.000194
30
Steam
Fresh water Thin Stillage
605991.93 Gluco-amylase Yeast Water
kg/day
CO2
Milled Mash Mash
Corn Kernels Slurry Cooker Saccharification
Hammer Mill Grains Slurry Tank (Dextrin) (Glucose) Fermentors CO2 Scrubber
210 o C, 1atm Tank CO2
40 o C, 1atm 80 o C, 1atm 35 o C, 1atm 30 o C, 1atm
68 o C, 1atm
Waste Water
Beer
Alpha-amylase
Ethanol Water
Wet Ethanol
Azeotropic Ethanol
Dehydrated
Ethanol Molecular Ethanol Column Beer Column
Sieves 80 o C, 1atm 80 o C, 1atm
80 o C, 1atm
Process Water
Stillage
Steam
105 o C, 1atm Thin Stillage 70 o C, 1atm
Conc.Thin Stillage Wet Distillers' Grain

with Soluble (WDGS)
Water
Distillers' Grain with
Soluble Dryer
150 o C, 1atm
Dried Distillers' Grain
with Soluble (DDGS)
Figure 3.1 Qualitative Block Diagram
31
Steam
Fresh water Thin Stillage
605991.93 Gluco-amylase Yeast Water
208. 41 kg/day 58.95 kg/day 111073.00
kg/day
CO2 kg/day
Milled Mash Mash
Corn Kernels Slurry
Hammer Grains Slurry (Dextrin)Saccharification (Glucose) CO2
Cooker Fermentors CO2
312244.33 Mill 312244.33 Tank 953153.86 1415811.96 Tank 1415811.96 Scrubber
kg/day kg/day kg/day kg/day kg/day
Waste Water
Beer
Alpha-amylase
1304738.97
182.28 kg/day Ethanol Water
Wet Ethanol kg/day
20454.55 Azeotropic Ethanol
kg/day 165888.24
Dehydrated 120454.55
kg/day
Ethanol Molecular kg/day Ethanol Beer
Sieves Column Column
100000.00
kg/day Process Water
Stillage
65888.24 1138850.73
Steam kg/day 34917.59 kg/day
462658.11 kg/day
kg/day 523763.90
kg/day
Thin Stillage
580169.24
Conc.Thin Stillage Wet Distillers' Grain kg/day
61105.79 with Soluble (WDGS)
kg/day Water
208954.78
Distillers' Grain
kg/day
with Soluble
Dryer
Dried Distillers' Grain
432320.24 with Soluble (DDGS)
kg/day
Figure 3.2 Quantitative Block Diagram
32
A summary of flow rates table is established to show and to check whether the
sum of all input flow rates equals the sum of the output stream.
Table 3.6 Summary of Material Balance
Inflow Outflow
Equipment Streams
(kg/day) (kg/day)
Corn Kernels 312244.33
Hammer Mill Milled Grains 312244.33
Milled Grains 312244.33
Fresh Water 605991.93
Slurry Tank Recycle from
34917.59
Centrifuge
Slurry 953153.86
Slurry 953153.86
Steam from
Cooker 462658.11
Evaporator
Mash (Dextrin) 1415811.96
Mash (Dextrin) 1415811.96
Saccharification Tank
Mash (Glucose) 1415811.96
Mash (Glucose) 1415811.96
Fermentors Beer 1304738.97
Carbon Dioxide 111073.00
Beer 1304738.97
Beer Column Wet Ethanol 165888.24
Stillage 1138850.73
Wet Ethanol 165888.24
Ethanol Water
20454.55
Ethanol Column from Mol.Sieves
Process Water 65888.24
Molecular Sieves Ethanol Water 20454.55
33
Stillage 1138850.73
Thin Stillage
34917.59
(to Slurry Tank)
Centrifuge Thin Stillage
523763.90
(to Evaporator)
Wet Distillers' Grain
580169.24
with Solubles
Thin Stillage 523763.90
Steam to Evaporator 462658.11
Evaporator
Concentrated Thin
61105.79
Stillage
Wet Distillers' Grain
580169.24
with Solubles
Concentrated Thin
61105.79
DGS Dryer Stillage
Water 208954.78
Dried Distillers'
432320.24
Grain with Solubles
TOTAL 9428260.03 9428260.03
34
B. Energy Balance
Two heat balance equations were used in the calculations.
Q  mCpT
Q  mH
Where
m is the mass flowrate in kg/s,
Cp is the specific heat capacity in kJ/kgoC,
ΔT is the temperature difference in oC and
ΔH is the enthalpy in kJ/kg.
From Chemical Reaction Engineering by Octave Levenspiel, the energy balance
equation on reactor is:
Q  Cp 2 Tx A  Cp1 T (1  x A )  H r x A
Where
Cp2 is the mean specific heat capacity of the converted product,
Cp1 is the mean specific heat of unreacted feed stream,
xA is the fractional conversion and
ΔHr heat of reaction
Energy can be in the form of mechanical energy done on the system, a heat gain
or loss due to a change in temperature or work done. Data and assumptions
regarding the streams leaving and entering the equipment such as sensible heat, heat
of vaporization, heat capacity and mass flow rates and temperature of streams were
needed.
35
250
200
150
T(deg.C)
100
50
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13
Streams
Figure 3.3 Temperature Profile for Ethanol and DDGS Production
Table 3.7 Legend of Streams in Figure 3.3
Streams Black Blue Red

1 Corn Kernels
2 Milled Grains
3 Slurry
4 Mash (Dextrin)
5 Mash (Dextrin)
6 Mash (Dextrin)
7 Mash (Glucose)
8 Mash (Glucose)
9 Beer
10 Wet Ethanol Stillage
Azeotropic Thin Stillage(up)/
11
Ethanol WDGS(down)
Conc. Thin
Dehydrated
12 Stillage(up)/
Ethanol
WGDS(down)
Dehydrated
13 DDGS
Ethanol
36
Table 3.7 Specific Heat capacity of Streams
Streams Cp (kJ/kgoC)
Corn/Milled Grains 1.800
Slurry 1.218
Mash(Dextrin) 1.218
Mash(Glucose) 1.2552
Beer 0.805
CO2 0.9185
Wet Ethanol 3.055
Stillage/WDGS 4.184
DDGS 2.536
Ethanol Water 3.055
Process Water 4.188
Table 3.7 shows the different specific heat capacities used for the computation
of the sensible heat of streams or heat gain or loss of a stream.
Table 3.9 Summary of Energy Balance with Streams Temperature
Input, Output, Heat

Temp.
Equipment Streams Qin Qout Loss/Gain
(oC)
(kW) (kW) (kW)
Corn Kernels 25 162.63
Hammer Mill Milled 97.58
40 260.21
Grains
Milled
40 260.21
Grains
Fresh Water 25 790.83
Slurry Tank -10.59
Thin Stillage
70 118.65
(Recycle)
Slurry 80 1074.96
37
Slurry 80 1074.96
Steam 210 15516.84
Cooker -12400.33
Mash
210 4191.47
(Dextrin)
Mash
210 4191.47
Cook Retention (Dextrin)
-2594.72
Tank Mash
80 1596.75
(Dextrin)
Mash
Pre-cooler to 80 1596.75
(Dextrin)
Saccharification -997.97
Mash
Tank 30 598.78
(Dextrin)
Mash
30 598.78
Saccharification (Dextrin)
799.91
Tank Mash
68 1398.69
(Glucose)
Post-cooler Mash
68 1398.69
from (Glucose)
-781.62
Saccharification Mash
30 617.07
Tank (Glucose)
Mash
30 617.07
(Glucose)
Fermentors Carbon -150.26
35 41.34
Dioxide
Beer 35 425.47
Beer 35 425.47
Beer Column Wet Ethanol 38 222.89 4209.36
Stillage 80 4411.94
Wet Ethanol 38 222.89
Ethanol
Ethanol 35 25.34
Water 194.60
Column
Azeotropic
40 187.19
Ethanol
38
Process
80 255.64
Water
Azeotropic
40 187.19
Ethanol
Moecular Ethanol
80 57.92 22.25
Sieves Water
Dehydrated
80 151.52
Ethanol
Ethanol
80 57.92
Ethanol Water Water
-32.58
Cooler Ethanol
35 25.34
Water
Dehydrated
80 151.52
Dehydrated Ethanol
-85.23
Ethanol Cooler Dehydrated
35 66.29
Ethanol
Stillage 80 4411.94
Stillage Cooler -551.49
Stillage 70 3860.45
Thin Stillage 70 1780.35
Steam to
105 14336.53
Evaporator Cooker 12866.78
Conc. Thin
105 310.60
Stillage
WDGS 70 1966.69
Conc. Thin
105 310.60
DGS Dryer Stillage 6344.98
Water 150 6718.75
DDGS 150 1903.52
39
C. Utility Requirement
1. Water Consumption
The water used in the bioethanol pant can be city water, groundwater or
surface water. The type of water used depends on its application. Water is
recycled and re-used, after prior appropriate purification treatment, for specific
process applications such as liquefaction, cooking, steam generation, scrubbing
and cooling. Water treatment is used to provide the requisite quality of water to
a variety of different processes, many of which with have their own individual
technical requirements.
2. Energy Consumption
Ethanol production requires electrical and thermal energy at every step of the
process. Electricity is needed for lighting, for plant process control, for heating
and as driving power for machinery. It is usually generated and supplied by
utility companies. When steam and electricity are generated on-site the
efficiency factor can be considerably higher.
Table 3.10 Average Energy and Water Usage per gallon of Ethanol produced
Utility Unit Value
Energy (Ave Use per gal EtOH)
a. Thermal Mbtu’s 31 879
b. Electrical kWh’s 1.14
TOTAL Mbtu’s 31.879
Water (Ave Use per gal EtOH)
a. Fresh Gal 4.9
b. Recycled Gal 1.2
TOTAL Gal 6.1
40
References
1. Levenspiel, O. Chemical Reaction Engineering Third Edition. Department of Chemical
Engineering, Oregon State University. Copyright © 1999 John Wiley & Sons, Inc.
2. Green, D.W. & Perry, R.H. Perry’s Chemical Engineers’ Handbook Eight Edition.
Copyright © 2008 by The McGraw-Hill Companies, Inc.
3. Singh, V. (2016). Innovative Technologies and Products for Dry Grind Ethanol Process.
Professor, Agricultural & Biological Engineering. Associate Director, Integrated
Bioprocessing Research Laboratory. University of Illinois at Urban-Champaign
4. Dale, R.T., Tyner, W.E. (2006) Economics and Technical Analysis of Ethanol Dry Milling:
Model User’s Manual. Purdue University.
5. Sapna, et.al. Corn to Ethanol: Retrospect’s and Prospects, Maize: Leading to a new
Paradigm. Directorate of Maize Research, Pusa Campus, New Delhi -110 012 Technical
Bulletin 2012/7 pp.28
6. Source: Mosier, N.S., Ileleji, K. How Fuel ethanol is Made from Corn. Department of
Agricultural and Biological Engineering, Purdue University.
7. Singh, V.(2009). Dry Grind Corn Processing – New Technologies. Associate Professor,
8. Baccay, M. Jr., Catral, P., Martinez K., Ordillo, V. (2017). Bioethanol Production from
Corn Stover. Department of Chemical Engineering, Cagayan State University, Tuguegarao
City, Philippines.
41
Name:
SCORE
given.
solution.
(5)
42
not use information
presented.
TOTAL SCORE
Rater: Engr. CAESAR P. LLAPITA
43
CHAPTER IV
PROCESS AND INSTRUMENTATION DIAGRAM
Piping and Instrumentation Diagram (P&ID) is a detailed diagram that shows the piping
and vessels with its proper instrumentation and control devices. P and ID is foundational to the
maintenance of the process that it graphically represents. Also, it provides the basis for the
development of control schemes, like Hazard and Operability Study (HAZOP).
P and ID diagram is established thoroughly for the production of ethanol from corn kernel.
This diagram will show the complete details of instruments, piping requirement, different control
loops, control systems, signal lines, and different equipment/vessel comprising the facility.
Equipments use in the production of ethanol are carefully analyze in order to produce the expected
quality of ethanol. This will consider the preliminary treatment of the corn kernels, effectiveness
in conversion of starch to dextrin to glucose and into ethanol, temperature and concentration during
fermentation and distillation and nutrient amount necessary for cultivating microbes. These factors
need to be considered because it will greatly affects the flow of operation.
Piping and Instrumentation Diagrams entails with logical, concise and easy-to-understand
sequence of unit process equipments.
44
A. Symbols and Codes
Table 4.1 Control Element Symbols
Symbol Description
Gate valve
 Control valve
 Pneumatic valve
Table 4.2 Instrumentation Line Symbols
Symbol Applications
Process connection to instruments
Electrical signal
Table 4.3 Location of Instruments
Discrete Location and Accessibility
 Located in Field.
 Not panel, cabinet, or console mounted.
 Visible at field location.
 Normally operator accessible.
45
B. Instrumentation, Systems, and Automation (ISA) Identification Letters
Table 4.4 ISA Identification Letters

Letter Position - (XYY)
First Letter (X) Succeeding Letters(YY)
A Alarm
C Controller
F Flow
H High
I Indicator
L Level Low
T Temperature Transmitter
C. Selection of Control Valve
The control valve manipulates a flowing fluid, such as gas, steam, water or
chemical compounds, to compensate for the load disturbance and keep the regulated process
variable as close as possible to the desired set point.
Table 4.5 Control Valve
Control
Equipment Name Operating Principle
Valve
Rate of flow control valve

Rate of Flow
Flow Control Valve prevents excessive flow by
Control Valve
limiting flow to a preselected
46
minimum rate, regardless of
changing line pressure. The pilot
control responds to the
differential pressure produced
across an orifice plate installed
downstream of the valve.
Accurate control is achieved as
very small changes in the
controlling differential pressure
produce immediate corrective
action of the main valve. (CLA-
VAL)
Modulating float valve will be
used in the production process.
Modulating float valves maintain
a constant liquid level in a
Modulating storage tank by compensating for

Level Control Valve
Control Valve variations in supply or demand
and are used to control the flow
into or out of a tank by either
opening or closing on a rising
level. (CLA-VAL)
47
G-AMYLASE
A-AMYLASE
WATER TI
FT
FT
CORN FT
TA FC
FC
FC H-101 TI TIH TIL
FT
2 TC
M-101 FC
FC
LA R-102
`
FC TI
Figure 4.1 Piping and Instrumentation Diagram for the Production of
FC E-101
LC
`
FC
`
R-101 ` ` FC
FC
FC T-103
T-101 TC TI E-102
T-102
FC FC `
WATER CO2
FC
YEAST WASTE WATER
Ethanol from Corn Kernel
S-101
FC FC
FC
FT FC ETHANOL
FC TT
E-103
TI
TT FC FC TT
TC
TI TI TI
R-103 FT
TI T-104 T-105 T-106 T-107
FC N-101
FC
FT FC FT
FC TT
FC
FC TI
FC
FC
FC
G-101
TI FC
FC FC
TI
E-104
PROCESS WATER
E-105
FC
FC LI FC FT
FC
MOISTURE
V-101
TC
T-108
FT FC
C-101
48 TI DDGS
D-101
D. Individual Control and Instrumentation of Equipment
1. Hammer Mill
CORN
FC
Figure 4.2 Control and Instrumentation of Hammer Mill
After the preliminary treatment of corn, flow controller is installed
after this equipment to control the flow of treated corn. This will help to prevent
choking in the next equipment which is the major cause of stopping the whole
operation.
2. Weigh Tank
LA
LC
Figure 4.3 Control and Instrumentation of Weigh Tank
Since the flow is controlled in hammer mill, it is necessary also to
control the level of weighing tank. Inside the tank, there is a level alarm which is
triggered when it meets the capacity of the tank. This alarm is connected to level
controller automatically.
49
3. Slurry Tank
A-AMYLASE
WATER
FT
FC
FT
FC
FC
FC
Figure 4.4 Control and Instrumentation of Slurry Tank
Water, A-amylase and the treated corn must in proper ratio. Therefore,
flow controller in each of them is installed. After mixing, another flow controller is
installed at the product stream in order to observe the amount that needs to be
processed further.
4. Steam Cooker
TI
TA
TC
Figure 4.5 Control and Instrumentation of Steam Cooker
50
Heat is very significant in this equipment. Cooking requires a specific
amount of heat to prevent over cooked. Hence, temperature control is necessary.
Manual controlling of heat is difficult and take a high risk in safety. So, temperature
control is installed to avoid accident and to easily control cooking the slurry.
5. Cook Retention Tank
TI TIH TIL
FC
FC TI
`
` `
Figure 4.6 Control and Instrumentation of Cook Retention Tank
Before entering in this equipment, flow and temperature of the mash
must be controlled. Cook retention tank is use as storage and use in lowering the
temperature of the mash. When the desired temperature of the mash is reach, the mass
out is also controlled by flow controller. After the heat exchanger, temperature
indicator is installed to verify the temperature of the mash.
51
6. Saccharification Tank
G-AMYLASE
FT
FC
FC
`
FC
TC TI
Figure 4.7 Control and Instrumentation of Saccharification Tank
Mash is charged into saccharification tank and mixed with G-amylase.
Starch content of the mash will be converted into dextrin in this equipment. Flow is
controlled in both mash stream and G-amylase so that proper ratio is secured.
7. Fermentor
YEAST
FC
FC TT FT FC
TI
TI
FC
Figure 4.8 Control and Instrumentation of Fermentor
The amount of inputs in fermentors must be controlled. The mash
temperature must also know in order to cultivate the yeast. The flow of yeast is also
controlled so that the volume requirement of fermentors must be maximized.
52
8. Beer Column
FT
FC
FT FC
FC
TI
Figure 4.9 Control and Instrumentation of Beer Column
Flow controllers are very necessary in this equipment. The formation
of beer takes place in this equipment.
9. Ethanol Column
FT
FC TT
FC
TI
PROCESS WATER
Figure 4.10 Control and Instrumentation of Ethanol Column
The beer formed will proceed to ethanol column. The flow and
temperature of the beer will tell the efficiency of the separation process. Ethanol is the
product of this scheme, therefore, it is very important to account the volume of
ethanol produced.
53
References
9. Source: Mosier, N.S., Ileleji, K. How Fuel ethanol is Made from Corn. Department of
Agricultural and Biological Engineering, Purdue University.
10. Singh, V.(2009). Dry Grind Corn Processing – New Technologies. Associate Professor,
11. Baccay, M. Jr., Catral, P., Martinez K., Ordillo, V. (2017). Bioethanol Production from
Corn Stover. Department of Chemical Engineering, Cagayan State University, Tuguegarao
City, Philippines.
12. Acora, German, et al. (2013). Process design and sustainability in the production of
bioethanol from lignocellulosic materials. Electronic Journal of Biotechnology ISSN:
0717-3458 http://www.ejbiotechnology.info DOI: 10.2225/vol16-issue3-fulltext-7
13. Cadavid, D.A et.al. (2014). Improvement in commercial scale dry mill corn ethanol
production using controlled flow cavitation and cellulose hydrolysis.
14. Chaudhary, D.P. et.al. (2012). Corn to Ethanol: Retrospect’s and Prospects. Maize:
Leading to a new Paradigm.
15. Onuki, Shinnosuke, et.al. (2008). Ethanol production, purification, and analysis
techniques: A review. http:// lib.dr.iastate.edu/abe_eng_conf
16. Watanabe, M. (2009). Ethanol Production in Brazil: Bridging its Economic and
Environmental Aspects. International Association for Energy Economics. Brazil
54
Name:
SCORE
given.
solution.
(5)
55
not use information
presented.
TOTAL SCORE
56
CHAPTER V
HEALTH, SAFETY AND THE ENVIRONMENT
A. Risk Assessment
An industry with its complex nature of activities involving various plant machineries,
raw materials, products, operations, and environmental discharge has a number of
associated hazards. A minor failure can lead to major failures resulting into a disaster
causing heavy losses to life, property, and environmental. A number of hazards associated
with the biofuel industry in each stage of the plant cycle from the concept selection through
to the discharging. There are many other challenges like engineering unknowns, lack of
reliable failure rate data, inconsistency in applicable regulations, low skills, and entry of
new manufacturers (Nair, 2011). Risk assessment is being conducted to guarantee safety
and reliability of any new plant. It is necessary to have a risk assessment studies as they
form an integral part of an occupational health and safety management plan. Risk
assessment in process design can be considered under the following broad headings:
i) Identification of hazards and risk factors.
ii) Analysis and evaluation of risk associated with the hazard.
iii) Elimination of hazard or control of risk.
1. HAZARD IDENTIFICATION
In process safety and loss prevention, it is said, ‘once the hazards have been identified, half
the battle is won’ (Mannan). A number of hazard identification methods and techniques are
available and have been practiced. Different methods are required at different stages of a
project and also the depth of the study depends on the complications and extent of risk from
the facility/operation.
57
Hazards associated with the biofuel industry are categorized as follows:
a) Hazards from Materials
The principal hazards from materials in the form of raw materials, catalysts, intermediates
and finished products include:
 Fire Hazards.
 Explosion hazards and overpressure releases.
 Runaway/uncontrolled reaction.
 Toxic hazards.
 Steam flashes.
b) Hazards from Operations and Handling
Operational accidents in the biofuel industry range from slips, trips, and falls to major
incidents like fire and explosion. Hazards, causes, hazardous events and related
consequences during operation and handling (storage, processing, handling etc.) are given
below:
i. Storage of Flammable and Toxic Materials
This includes raw materials, additives, intermediates, finished products and by-products in
different forms/phases, sizes, shapes, temperature, and pressure as required by the process.
ii. Processing of Hazardous Materials
One of the major hazards is the accidents that could result from biofuel manufacture is
release of flammables, toxics and corrosives. Some examples of hazards related to
processing is given below:
 High operating or storage temperature/pressure (e.g. leading to process runaway)
 Overflow of tank, vessel, reactor or tanker.
 Lower temperature (solidification of biodiesel often resulting in plugging).
58
 Improper selection of appropriate equipment/machinery/rated vessels/pipe work
suitable for the process.
 Inadequate installation, inspection and maintenance.
 Use of unclassified equipment and machinery in explosive atmosphere.
iii. Material Handling
A range of materials in solid form, liquid form and gaseous form are transferred between
equipment, process vessels, storage etc. This involves a number of tools and transfer system
from shovel to conveyor system to pipelines and pumps. Manual handling of hazardous
materials results in occupational injuries and sometimes fatalities. Some related hazards
are:
 Material loss, damage due to inadequate or improper conveyor system.
 Poor housekeeping leading to dust hazards and dust explosion hazards.
 Release from pipelines, vessels and valves.
c) Hazards from Design, Construction, and Commissioning
Typically, biofuel plants mainly small/medium scale and occasionally large scale plants are
built in an existing facility/building or near to an existing facility/building/plant. Some of
the hazards are very significant when the existing facility (old barn, garage or storage
deport) is modified and converted to a biofuel processing facility. One of the common
failures is failing to recognize the additional requirements to adhere to (e.g. building
regulation codes, electrical installation requirements etc). If the associated hazards in
conversion are not identified and addressed, the facility as such could pose high risk due to
operation.
59
The following are some of the causes associated to biofuel plant projects that may result
hazards and hazardous events:
i. Improper selection of:
 The technology or methodology for the manufacture.
 The chemical and raw materials used for the production.
 The location of the facility.
ii. Inadequate facility for the selected process:
 Land area.
 Nearby facility and effects from and on them.
 Proximity to utilities (water, steam, power etc.).
iii. Unsafe design and layout.
 Inadequate separation distances (to restrict the spread of fire etc.).
 Inadequate design specification (not for maximum design pressure etc.).
 No access for inspection, maintenance etc.
 No provision of emergency escape.
 Thermal radiation from open flames/flares or equipment/vessel operating at high
temperature (no or improper insulation etc.).
iv. Faulty construction and commissioning.
 Use of inappropriate material of construction of the facility (incompatible for the
material handled/processed).
 No/improper foundation.
 Inadequate strength of load bearing members.
v. No/inadequate provision for:
 Ventilation.
 Lighting.
60
 Rest and cleaning.
 Weather protection.
 Protection from external factors (vehicle collision, attacks from animals/pests etc.).
2. RISK MANAGEMENT
Risk management is the term used to cover the whole process of identifying and assessing
risk, setting goals and creating and operating systems for their control. Though the biofuel
manufacturing facility often does not come under major accident hazard regulations, it is
prudent that the risk from the biofuel industry is assessed and managed considering the
nature of hazards and the stakeholders involved. The depth of risk assessment should be
proportional to the extent of risk involved in the process and facility.
B. Government Regulations
The policy and legislative actions of any government, at national, state, and local levels,
have significant impacts on the management and control of risk in the biofuel industry.
Occupational Safety and Health Administration (OSHA) Compliance
Occupational safety and health administration ensures safety and healthy working
environment by enforcing workplace laws and standards. At the request of the Renewable
Fuels Association (RFA), the ERI Solutions, Inc. of Colwich, KS developed an outline of
the general plant and employee safety regulatory compliance requirements for the
bioethanol production industry.
a. Recordkeeping (OSHA 1904).
The Occupational Safety and Health Act of 1970 (OSHA) requires covered employers to
prepare and maintain records of occupational injuries and illnesses. OSHA also establishes
requirements and criteria for reporting work-related injuries, illnesses, and fatalities.
61
b. Walking/Working surfaces (OSHA Subpart D).
Establishes requirements concerning guarding floor & wall openings, stairs and ladders.
OSHA requires the use of a guardrail system to protect workers from falls of 4’ or more to
lower levels.
c. Exit routes (OSHA 1910.37).
Establishes requirements for the proper design and construction of exit routes.
Requirements cover construction materials, opening dimensions, accessibility conditions
and capacity.
d. Emergency Action Plan (OSHA 1910.38).
An Emergency Action Plan (EAP) must be developed and include procedures for reporting
emergencies, emergency evacuation, and for employees performing medical or rescue
duties. OSHA also establishes requirements for alarm systems and training personnel on
the EAP.
e. Fire Prevention Plan (OSHA 1910.39).
Establishes requirements for employers to identify flammable and combustible materials
stored in the workplace and develop ways to control workplace fire hazards. Completing a
fire prevention plan and training employees will reduce the probability that a workplace
fire will occur or spread.
f. Occupational Noise Exposure (OSHA 1910.95).
Requires employers to identify if any employees are exposed to noise levels at 85 decibels
or more over eight (8) working hours. A hearing conservation program must be
implemented if it is determined that employees may be exposed to levels above this
threshold.
62
g. Flammable and Combustible Liquids (OSHA 1910.106).
Establishes requirements for the handling, storage and use of flammable and combustible
liquids with a flash point below 200°F. Ethanol is considered a Class 1B flammable liquid
(Flash point 73°F).
h. Storage and Handling of Anhydrous Ammonia (NH3) (OSHA 1910.111).
Facilities that have anhydrous ammonia systems must comply with this standard. If the
process contains over 10,000 pounds of anhydrous ammonia, OSHA 1910.119 also applies
(see Process Safety Management (PSM) below).
i. Process Safety Management (PSM) (OSHA 1910.119).
The purpose of this standard is to prevent or minimize the consequences of a catastrophic
release of toxic, reactive, flammable, or explosive chemicals. Since ethanol is considered a
flammable liquid, ethanol production facilities are required to comply with this standard if
they process or store over 10,000 pounds of ethanol. OSHA also lists threshold quantities
for other highly hazardous chemicals that are covered under the PSM regulation. Other
common chemicals in use at ethanol production facilities that may fall under PSM
regulations are anhydrous (or aqueous) ammonia, hydrochloric acid, denaturant, and
chlorine dioxide. This is not an all-inclusive list, but if you have these chemicals at your
site, you should determine for sure whether or not you meet the threshold quantity for that
specific chemical.
j. Emergency Response (OSHA 1910.120).
Employers must address what action employees are to take when there is an unwanted
release of hazardous chemicals. Employers may decide to train and mobilize employees to
control or mitigate the release according to the requirements of 1910.120 the Hazardous
Waste Operations and Emergency Response (HAZWOPER) standard. Employers may also
63
decide to have employees evacuate the danger area and have local community emergency
response organizations respond to the release.
k. Personal Protective Equipment (PPE) (OSHA Subpart I).
Contains regulations for Personal Protective Equipment (PPE) selection and use concerning
eyes, face, head and extremities. All ethanol production facilities must perform and
document a workplace hazard assessment so the proper PPE can be designated and
communicated for all areas of your facility.
l. Permit Required Confined Spaces (OSHA 1910.146).
Requires employers to develop practices and procedures to protect employees working in
permit-required confined spaces (PRCS). The standard requires an evaluation to determine
the existence of PRCSs, the implementation of a written confined space program, and the
establishment of rescue/emergency procedures. The employer must decide either to train
employees on entry rescues or rely on available external sources to provide entry rescues.
Either method must be documented as to its availability and reliability to respond in the
event of an emergency. All PRCSs must be labelled or communicated according to the
requirements of the standard.
m. Lockout/Tagout (OSHA 1910.147).
Requires implementing practices and procedures to shut down equipment, isolate it from
energy sources and prevent the release of potential hazardous energy while maintenance
and service activities are being performed. Employers must develop and document specific
procedures for all equipment and machinery that may be serviced within their facility.
n. Medical Services and First Aid (OSHA 1910.151).
Employers must ensure that medical personnel and adequate first aid supplies are available
to workers to handle potential workplace injuries if a medical facility is not in near
proximity to the workplace.
64
o. Fire Protection (OSHA Subpart L).
Standards for portable fire extinguishers, fire brigades, and employee alarm systems,
automatic sprinkler systems and fixed extinguishing systems.
p. Powered Industrial Trucks (OSHA 1910.178).
Establishes requirements for powered industrial trucks and training requirements for
operators of powered industrial trucks.
q. Machinery and Machine Guarding (OSHA 1910.212).
General requirements for machine guarding.
r. Welding, Cutting and Brazing (OSHA Subpart Q).
Contains regulations for oxygen fuel cutting and welding, arc welding and cutting, and
resistance welding. The standards also contain training requirements for personnel who will
be performing welding, cutting or brazing.
s. Grain Handling (OSHA 1910.272).
Contains requirements for control of grain dust fires or explosions and other hazardous
associated with grain handling facilities.
t. Electrical (OSHA Subpart S).
Contains regulations regarding electrical hazards in the workplace. Subpart S is based on
older versions of the national consensus standard NFPA 70E. OSHA has proposed an
update to Subpart S to reflect the more current editions of NFPA 70E.
u. Access to Employee Exposure and Medical Records (OSHA 1910.1020).
This standard is triggered if an employee is exposed to toxic substances or harmful physical
agents in the workplace. These exposure and medical records must be retained in
accordance with this regulation. The records must also be made available to employees or
their designated representative.
65
v. Blood borne Pathogens (OSHA 1910.1030).
This standard applies to all possible occupational exposure to blood or other potentially
infectious materials (OPIM). Occupational exposure means reasonably anticipated contact
with blood or other potentially infectious materials that may result from performance of an
employee’s duties. Employees who are responsible for rendering first aid or medical
assistance as part of their job duties are covered by the protections of the standard.
w. Hazard Communication (OSHA 1910.1200).
Also, referred to as the “Right-to-Know” standard, Hazard Communication establishes
requirements for ensuring that chemical hazards and their associated protective measures
are disseminated to employees who could be potentially be affected by these hazards.
x. Occupational Exposure to Hazardous Chemicals in Labs (OSHA 1910.1450).
This standard requires a laboratory to develop a Chemical Hygiene Plan which addresses
specific hazards found in the laboratory. This standard does not apply to typical facility
laboratory, as they generally only perform quality assurance/quality control type laboratory
operations.
C. HAZOP Studies
Safety and reliability in the design of plant initially relies upon the application of various
codes of practice, or design codes and standards. These represent the accumulation of
knowledge and experience of both individual experts and the industry as a whole. Such
application is usually backed up by the experience of the engineers involved, who might
well have been previously concerned with the design, commissioning or operation of
similar plant. However, it is considered that although codes of practice are extremely
valuable, it is important to supplement them with an imaginative anticipation of deviations
which might occur because of errors in operation (e.g. equipment malfunction, operator
66
error etc.). The HAZOP Study is an opportunity to correct these faults before such changes
become too expensive, or impossible to accomplish.
A HAZOP study is a structured and systematic examination of a planned of existing process
or operation in order to identify and evaluate problems that may represent risks to personnel
or equipment, or prevent efficient operation. The basic concept of HAZOP study is to take
full description of the process and to question every part of it to discover what deviations
from the intention of the design can occur and what the causes and consequences of these
deviations may be. (Hazard Identification and Control, Sam Mannan, 2005)
Potential Hazards in Biofuels Production and Handling
 Fire and explosion Hazards of Biofuels
Employers producing biofuels may expose workers to potential fire and explosion
hazards, and protect them from these hazards by preventing releases, avoiding
ignition of spills, and having appropriate fire protection systems and emergency
response procedures.
Sufficient controls include:
 Good facility layout
 Proper design of vessels and piping systems
 Proper selection of electrical equipment for use in hazardous areas
 Adequate instrumentation with alarms, interlocks, and shutdowns
 Operating procedures
 Good maintenance practices
 Safe work procedures
67
 Chemical Reactivity Hazards in Biofuel Manufacturing
Biofuels manufacturing processes can present reactive hazards. The gases produced
during ethanol fermentation need to be properly vented to avoid over pressuring
equipment and piping.
Controls to keep the process within safe limits include:
 Controlling the rate and order of chemical addition
 Providing robust cooling
 Segregating incompatible materials to prevent inadvertent mixing
 Use of detailed operating procedures
 Toxicity Hazards in Biofuel Manufacturing
Biofuels and the chemicals used in the manufacturing process present toxic
exposure hazards that need to be carefully controlled to protect workers.
Controls needed include:
 Good engineering, design and fabrication
 Maintenance practices to prevent releases, ventilation, and drainage to
reduce exposures
 Appropriate use of personal protective equipment
These hazards are in addition to normal workplace hazards, such as walking/working
surface hazards, electrical hazards and other similar hazards.
68
D. Pollution Prevention
The increasing production of ethanol has been established as an important contributor
to future energy independence. But the waste streams from many varying processes that
are being developed contain a variety of components which could be potentially
harmful to the environment if adequate care is not taken to manage those risks
(Menetrez, 2010). Pollution prevention is needed to reduce risks and environmental
concerns. At production facilities, there are several points in the process that create the
possibility of release:
 Storage in tanks
 Movement in piping systems
 During transfer to trucks
E. Life Cycle Analysis
Life cycle analysis is used to quantify and evaluate the environmental
performance of a product, process or activity from cradle to grave, that is, considering
the whole life cycle of the process. It starts at the first step of the process being
investigated. For this proposed design, the first step is the transportation of corn kernels
to the mill. Additionally, this accounts all the wastes released to the environment and
the corresponding waste treatment the plant will put up to minimize the risk of the waste
in the environment and nearby community.
The LCA at the different stage of ethanol production methods and product
development is presented in the following illustration.
69
a. Inputs and Outputs of a System
INPUTS OUTPUTS
RAW EMISSIONS TO AIR

CO2 (111, 072.9956 kg/day)
Corn Kernels (312, 244.3329 kg/day ),
Yeast (58.95 kg/day)
ENERGY USABLE PRODUCTS

SYSTEM
Ethanol (100, 000 kg/day),
stillage (1, 138, 850.728 kg/day)
WATER OTHER RELEASES

(Heat)
The figure shows the input materials necessary for the production of ethanol and
the corresponding emissions. CO2 emissions are subjected to treatment which is the
CO2 scrubber for recycle and industrial use. From the heat balance, there are less
amount of heat losses so there is no need for the tanks to be jacketed.
b. System Boundaries
INPUTS OUTPUTS
Raw Materials Atmospheric emissions

(Corn kernels, Enymes) Raw Material Acquisition (CO2 )
(Milling)
Material Manufacture
(Fermentation, Distillation)
Solid & Liquid wastes

Energy (dirt,water)
Final Product Collection
(Storing in Cylindrical Vessels)
Transportation/Distribution
(Trucks/ Alcoholic beverage
manufacturers, refueling stations)
Other Environmental Release
Water (Heat)
Consumer use and Final Disposal
(Fuel, Alcoholic beverages)
The corn kernels will be acquired from milling and fresh water will be used The
product which is the ethanol will be stored in a tank for distribution. For the whole
process, the atmospheric emissions will be a negligible amount of steam coming

70
out of the cooker. CO2 will be scrubbed in the process. The dried stillage will be
used as feed for animals.
c. Raw Material Acquisition
Inputs
(Corn Kernels)
Transportation
(Carrier trucks)
Outputs
Energy
(Milled Grains)
Equipment
(Hammer Mill)
The main raw material (corn kernels) will be harvested at different places and is
delivered to the milling stage through carrier trucks. The milling stage uses hammer
mill to produce the milled grains used for the processing of the ethanol.
d. Consumer Use and Final Disposal
USE
(Denaturing plants)
Point of Use MAINTENANCE

Transportation/Distribution Waste
(beverages, fuel) (Stored before Disposal
(Trucks) Management
distribution)
Recycle
RE-USE
(by-products: DDGS,
CO2 )
The final product which is 99.5 % ethanol has a variety of uses. In its denatured
state, it is used as the main element of biofuels. It can also be used as solvent in
chemical solutions. For distribution, the product will be contained in a rigid and
sealed containers to avoid losses due to leakage or evaporation since the product is
71
volatile. As long as there is no contamination of the final product, no amount is
wasted and disposed.
e. Recycling
CORN CORN
KERNELS KERNELS
ETHANOL CO2
Stillage, DDGs CO2
Drying Scrubbing with water
Feed stocks and CO2 scrubbed

fertilizer
Recycling is made in order to minimize the harmful effects of ethanol plant
emissions into the environment and it is also of great effect on the profitability of
the plant. Thus, the stillage removed from the beer column is recovered and is dried
for use as feed stocks. As for the carbon dioxide, it will be scrubbed with water
using the CO2 scrubber to produce carbonic acid.
72
References
1. Muñoz, I. et al., (2013). Life Cycle Assessment of bio-based ethanol produced from
different agricultural feedstocks. LCA for Renewable Resources.
2. Han, J. (2015). Life Cycle analysis of ethanol: Issues, results, and case simulations.
3. Menetrez, M. (2012). The Potential Environmental Impact of Waste from Cellulosic
Ethanol Production. Journal of the Air & Waste Management Association.
4. Mohammadfam, I. et al., (2012). Application of Hazard and Operability Study
(HAZOP) in Evaluation of Health, Safety, and Environmental (HSE) Hazards.
International Journal of Occupational Hygiene.
5. Nair, S. (2011). Identifyig and Managing process Risks Related to Biofuel Projects and
Plants.
73
Name:
SCORE
given.
solution.
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not use information
presented.
TOTAL SCORE
75
Equipment AutoCAD
A. Hammer Mill
B. Centrifuge
C. Saccharification Tank
D. Beer Column and Ethanol Column
76
E. Molecular Sieve Dehydration
F. Evaporator
77
G. CO2 Scrubber
78
APPENDIX
A. Material Balance Calculations
1. Adsorption
Basis: 100 000 kg dehydrated ethanol /day
Ethanol Water
m2 (recycle to Ethanol Column)
73 wt% EtOH
Azeotropic Ethanol Molecular

m1
95 wt% EtOH Sieves
m3 Dehydrated Ethanol
99.5 wt% EtOH
Overall Mass Balance:
m1 = m2 + m3
m1 = m2 + 100 000 (1)
Ethanol Balance:
0.95m1 = 0.73m2 + 0.995m3
0.95m1 = 0.73m2 + 0.995(100 000) (2)
Degree of Freedom analysis: 2 unknown variables – 2 equations = 0
The problem is solvable.
Solving Eq. 1 and 2:
m1 = 120 454. 5455 kg azeotropic ethanol/day
m2 = 20 454. 5455 kg ethanol water/day
79
2. Ethanol Distillation
Ethanol Water
(from Molecular Sieves)
m4 = 20 454. 5455 kg/day
Azeotropic Ethanol
73 wt% EtOH
m2 m2 = 120 454. 5455 kg/day
95 wt% EtOH
m4
Wet Ethanol Ethanol
m1
60 wt% EtOH Column
m3 Process Water
0.05 wt% EtOH
m1 + m4= m2 + m3
m1 + 20 454. 5455 = 120 454. 5455 + m3 (1)
Ethanol Balance:
0.50m1 + 0.73m4 = 0.95m2 + 0.0005m3
0.60m1 + 0.73(20 454. 5455) = 0.95(120 454. 5455) + 0.0005m3 (2)
m1 = 165 888. 2402 kg wet ethanol/day
m3 = 65 888. 24022 kg process water/day
80
3. Beer Distillation
Wet Ethanol
m2 m2 = 165 888. 2402 kg/day
70 wt% EtOH
Beer
11 wt% Solid
m1 Beer Column
89 wt%Liquid with
10 wt% Ethanol
Stillage
m3 34 wt% Solids
66 wt% Liquid with
negligible EtOH content
m1 = m2 + m3
m1 = 165 888.2402 + m3 (1)
Ethanol Balance:
(0.10)(0.89)(m1) = 0.70m2
0.089m1 = 0.70(165 888.2402) (2)
m1 = 1 304 738. 968 kg beer/day
m3 = 1 138 850. 728 kg stillage/day
81
4. Centrifugation
25% of m2
(routed back to Slurry Tank)
m4
Thin Stillage
7 wt% solids m2 m5
Stillage
m1 = 1 138 850. 728 kg/day m1 Centrifuge
34 wt% solid
WDGS
m3
60 wt% solid
m1 = m2 + m3
1 138 850. 728 = m2 + m3 (1)
Solid Balance:
0.34m1 = 0.07m2 + 0.60m3
0.34(1 138 850. 728) = 0.07m2 + 0.60m3 (2)
Splitter:
m2 = m4 + m5 (3)
0.25m2 = m4 (4)
Solving Eq. 1, 2, 3 and 4:
m2 = 558 681. 4892 kg thin stillage/day
m3 = 580 169. 2388 kg WDGS/day
m4 = 34 917. 59308 kg/day
m5 = 523 763. 8961 kg/day
82
5. Evaporation
Steam
m2
(to Cooker)
Thin Stillage
m1 = 523 763. 8961 kg/day m1 Evaporator
7 wt% solids
Conc. Thin Stillage

m3
60 wt% solids
m1 = m2 + m3
523 763. 8961 = m2 + m3 (1)
Solid Balance:
0.07m1 = 0.60m3
0.07(523 763. 8961) = 0.60m3 (2)
m2 = 462 658. 1082 kg H2O/day
m3 = 61 105. 78788kg conc. thin stillage/day
83
6. Distillers’ Grains with Solubles (DGS) Drying
Conc. Thin Stillage

m2 = 61 105. 78788 kg/day
60 wt% solids
m3 H2O
m2
WDGS
m1 = 580 169. 2388 kg /day m1 DGS Dryer
60 wt% solids
m4 DDGS
11 wt% moisture
m1 + m2= m3 + m4
580 169. 2388 + 61 105. 78788 = m3 + m4 (1)
Solid Balance:
0.60m1 + 0.60m2 = 0.89m4
0.60(580 169. 2388) + 0.60(61 105. 78788) = 0.89m4 (2)
m3 = 208 954. 784 kg H2O/day
m4 = 432 320. 2427 kg DDGS/day
84
7. Fermentation
Yeast
my mCO2
Beer
m2 = 1 304 738. 968 kg/day
Mash (Glucose) m1 Fermentors m2 11 wt% Solid
89 wt%Liquid with
10 wt% Ethanol
Glucose to Ethanol Conversion: 94.0%
C6 H12O6  2C2 H 5OH  CO2

yeast
180 kg 92 kg 88 kg
0.0002 kg of yeast is needed for every 0.82 kg of glucose feed.
m1 = m2 + mCO2 (1)
CO2 produced:
88
mCO2 = (0.10) (0.89) m2 × (2)
92
Glucose in the feed:
180
m1glucose = (0.10) (0.89) m2 × (3)
92(0.94)
Yeast needed:
0.0002
my = m1glucose × (4)
0.82
85
Solving Eq. 1, 2, 3 and 4:
m1 = 1 415 811.964 kg mash(glucose)/day
mCO2 = 111 072. 9956 kg CO2/day
m1glucose = 241 696. 5572 kg glucose/day
my = 58.95 kg yeast/day
8. Saccharification
g-amylase
mg
Mash(Glucose)
Saccharification
Mash (Dextrins) m1 m2 m2 = 1 415 811. 964 kg/day
Tank
mglucose = 241 696. 5572 kg/day
Dextrin to Glucose Conversion: 99.0%
C6 H12O6 10 g

amylase
10C6 H12O6
0.0007 kg of g-amylase is needed for every 0.82 kg of dextrin feed.
m1 = m2 (1)
Dextrin in the feed:
1
m1dextrin = 241 696. 5572 × (2)
0.99
G-amylase needed:
0.0007
mg = m1dextrin × (3)
0.82
86
Solving Eq. 1, 2 and 3:
m1 = 1 415 811.964 kg mash(dextrin)/day
m1dextrin = 244 137. 9366 kg dextrin/day
mg = 208. 41 kg g-amylase/day
9. Liquefaction
Makeup water from Centrifuge Steam from Evaporator

Fresh Water m3 = 34 917. 59308 kg/day m4 = 462 658. 1082 kg/day
m2 m3 m4
Milled Grains
72 wt% Starch Mash(Dextrin)
m1 Slurry Tank Slurry Cooker m5 m5 = 1 415 811. 964 kg/day
mdextrin = 244 137. 9366 kg/day
ma
a-amylase
Starch to Dextrin Conversion: 98.0%
amylase
(C6 H10O5 ) n  H 2 O a (C6 H12O6 )10
0.74 kg 0.82 kg
0.0006 kg of g-amylase is needed for every 0.74 kg of dextrin feed.
m1 + m2 + m3 + m4 = m5 (1)
Starch in the feed (milled grains):
0.74
m1starch = 244 137. 9366 × (2)
0.82(0.98)
m1starch = 0.72m1 (3)
87
A-amylase needed:
0.0006
ma = m1starch × (4)
0.74
Solving Eq. 1, 2 and 3:
m1 = 312 244. 3329 kg milled grains/day
m1starch = 224 815.9197 kg starch/day
m2 = 605 991. 9298 kg H2O/day
ma = 182.28 kg a-amylase/day
10. Milling
Corn Kernels m1 Hammer Mill m2 Milled Grains

m2 = 312 244. 3329kg/day
m1 = m2 (1)
Degree of Freedom analysis: 1 unknown variable – 1 equation = 0
Solving Eq. 1:
m1 = 312 244. 3329 kg corn kernels/day
88
B. Energy Balance Calculations
1. Heat Gained During Milling
Corn Kernels, 25oC Hammer Mill Milled Grains, 40oC

m = 312 244. 3329kg/day m = 312 244. 3329kg/day
Given:
m = 3.614kg/s ; Tin = 25oC ; Tout = 40oC ; Cp = 1.800kJ/kgoC
Where:
m = mass flowrate
Cp = specific heat
The energy required
Q  mCpT  3.614(1.800)(40  25)
Q = 97.58 kW
2. Slurry Tank
Fresh Water, 25oC Thin Stilage from Centrifuge, 70oC

m2 = 605 991. 9298 kg/day m3 = 34 917. 59308 kg/day
Milled Grains, 40oC Slurry, 80oC

Slurry Tank
m1 = 312 244. 3329kg/day m4 = 953 153. 8558kg/day
Stream Mass Flowrate Temperature Cp H

(kg/s) (oC) (kJ/kgoC) (kJ/kg)
Milled Grains 3.614 40 1.800 -
Fresh Water 7.014 25 - 112.75
Thin Stillage 0.404 70 - 293.69
Slurry 11.032 80 1.218 -
89
Input:
Sensible Heat of Milled Grains
Q  mCpT  3.614(1.800)(40)
Q  260.21kW
Sensible Heat of Fresh Water
Q  mH  7.014(112.75)
Q  790.83kW
Sensible Heat of Thin Stillage
Q  mH  0.404(293.69)
Q  118.65kW
Output:
Sensible Heat of Slurry
Q  mCpT  11.032(1.218)(80)
Q  1074 .96kW
Q  output  input
Q  1074 .96  (176.07  790.83  118.65)
Q = -10.59 kW
90
3. Steam Cooking
Steam, 210oC
m2 = 462 658. 1082 kg/day
Slurry, 80oC Mash(Dextrin), 210oC

Cooker
m1 = 953 153. 8558kg/day m3 = 1 415 811. 964 kg/day

(kg/s) o
( C) (kJ/kgoC) (kJ/kg)
Slurry 11.032 80 1.218 -
Steam 5.355 210 - 2897.64
Mash(Dextrin) 16.387 210 1.218 -
Input:
Sensible Heat of Slurry
Q  mCpT  11.032(1.218)(80)
Q  1074 .96kW
Sensible Heat of Steam
Q  mH  5.355(2897 .64)
Q  15516 .84kW
Output:
Sensible Heat of Mash
Q  mCpT  16.387 (1.218)(210)
Q  4191 .47 kW
Q  4191 .47  (1074 .96  15516 .84)
Q = -12400.33 kW
91
4. Cook Retention Tank
Mash(Dextrin), 210oC Cook Retention Mash(Dextrin), 80oC

m = 1 415 811. 964 kg/day Tank m = 1 415 811. 964 kg/day
Heat Lost on the Retention Tank
Q  mCpT  16.387 (1.218)(80  210)
Q = -2594.72 kW
5. Pre-Cooling to Saccharification Tank
Cooling Water, 25oC
Mash(Dextrin), 80oC Mash(Dextrin), 30oC

Cooler
m = 1 415 811. 964 kg/day m = 1 415 811. 964 kg/day
Cooling Water, 50oC
Given:
Where:
m = mass flowrate
Cp = specific heat
The energy required
Q  mCpT  16.387 (1.218)(30  80)
Q = -997.97 kW
92
Enthalpy of Water at 1atm (Perry 8th)
T = 25oC ; H = 112.75 kJ/kg
T = 50oC ; H = 209.83 kJ/kg
ΔH = 97.08 kJ/kg
Required Cooling water Flowrate
Q 997.97
m 
H 97.08
m = 10.28 kg/s
6. Saccharification Tank
Mash(Dextrin), 30oC Saccharification Mash(Glucose), 68oC

m = 1 415 811. 964 kg/day Tank m = 1 415 811. 964 kg/day
99.0% Conversion of Dextrin to Glucose
68oC conversion Temperature
From Chemical Reaction Engineering by Octave Levenspiel, the energy
balance equation on reactor is:
Q  Cp 2 Tx A  Cp1 T (1  x A )  H r x A
Where:
Cp2 = mean specific heat capacity of completely converted product
Cp1 = mean specific heat of unreacted feed stream
ΔHr = heat of reaction

93
Data:
Cp2 = 1.2552 kJ/kgoC
Cp1 = 1.200 kJ/kgoC
ΔHr = 0.722 kJ/kg
Substituting the data,
Q  1.2552 (68  30)(0.99)  1.200(68  30)(1  0.99)  0.722(0.99)
Q = 48.391 kJ/kg
At feed mass flowrate of 16.387kg/s, the heat required is
Q  16.378(48.391)
Q = 792.55 kW
For Heat Loss Calculation
Input:
Q  mCpT  16.387 (1.218)(30)
Q = 598.78 kW
Output:
Q  mCpT  16.387 (1.2552 )(68)
Q = 1398.67 kW
Q  1398 .67  598.78
Q = 799.91 kW
94
7. Post-Cooling after Saccharification Tank
Cooling Water, 25oC
Mash(Glucose), 68oC Mash(Glucose), 30oC

Cooler
m = 1 415 811. 964 kg/day m = 1 415 811. 964 kg/day
Cooling Water, 50oC
Given:
The energy required
Q  mCpT  16.387 (1.2552 )(30  68)
Q = -781.62 kW
Q 781.62
m 
H 97.08
m = 8.05 kg/s
95
8. Fermentors
CO2
Beer, 35oC
m2 = 1 304 738. 968 kg/day
Mash(Glucose), 30oC 11 wt% Solid
Fermentors
m1 = 1 415 811. 964 kg/day 89 wt%Liquid with
10 wt% Ethanol
Stream Mass Temperature Cp

Flowrate(kg/s) (oC) (kJ/kgoC)
Mash 16.387 30 1.2552
CO2 1.286 35 0.9185
Beer 15.101 35 0.805
Input:
Sensible Heat of Mash
Q  mCpT  16.387 (1.2552 )(30)
Q  617.07kW
Output:
Sensible Heat of CO2
Q  mCpT  1.286(0.9185)(35)
Q  41.34kW
Sensible Heat of Beer
Q  mCpT  15.101(0.805)(35)
Q  425.47 kW
Q  (41.34  425.47)  617.07
Q = -150.26 kW
96
9. Beer Column
Wet Ethanol, 38oC

m2 = 165 888. 2402 kg/day
70 wt% EtOH
Beer, 35oC
m2 = 1 304 738. 968 kg/day
11 wt% Solid Beer Column
89 wt%Liquid with
10 wt% Ethanol
Stillage, 80oC
m3 = 1 138 850. 728 kg/day
34 wt% solid
Stream Mass Flowrate Temperature Cp

(kg/s) (oC) (kJ/kgoC)
Beer 15.101 35 0.805
Wet Ethanol 1.920 38 3.055
Stillage 13.181 80 4.184
Input:
Sensible Heat of Beer
Q  mCpT  15.101(0.805)(35)
Q  425.47 kW
Output:
Sensible Heat of Wet Ethanol
Q  mCpT  1.920(3.055)(38)
Q  222.89kW
Sensible Heat of Stillage
Q  mCpT  13.181(4.184)(80)
Q  4411 .94kW
Q  (222.89  4411 .94)  425.47
97
Q = 4209.36 kW
10. Ethanol Column
Ethanol Water, 35oC

(from Molecular Sieves)
m2 = 20 454. 5455 kg/day
Azeotropic Ethanol, 40oC
73 wt% EtOH
m3 = 120 454. 5455 kg/day
95 wt% EtOH
Ethanol
Wet Ethanol, 38oC
Column
m1 = 165 888. 2402 kg/day
70 wt% EtOH
Process Water, 80oC
m4 = 65 888. 2402 kg/day
0.05 wt% EtOH

Ethanol Water 0.237 35 3.055
Wet Ethanol 1.920 38 3.055
Azeotropic Ethanol 1.394 40 3.357
Process Water 0.763 80 4.188
Input:
Sensible Heat of Wet Ethanol
Q  mCpT  1.920(3.055)(38)
Q  222.89kW
Sensible Heat of Ethanol Water
Q  mCpT  0.237(3.055)(35)
Q  25.34kW
Output:
Sensible Heat of Azeotropic Ethanol
Q  mCpT  1.394(3.357 )(40)
Q  187.19kW
Sensible Heat of Process Water
Q  mCpT  0.763(4.188)(80)
98
Q  255.64kW
Q  (187.19  255.64)  (222.89  25.34)
Q = 194.60 kW
11. Molecular Sieves
Ethanol Water, 80oC

(recycle to Ethanol Column)
m2 = 20 454. 5455 kg/day
73 wt% EtOH
Azeotropic Ethanol, 40oC
Molecular
m1 = 120 454. 5455 kg/day
Sieves
95 wt% EtOH
Dehydrated Ethanol, 80oC

m3 = 100 000 kg/day
99.5 wt% EtOH

Azeotropic Ethanol 1.394 40 3.357
Dehydrated Ethanol 1.157 80 1.637
Ethanol Water 0.237 80 3.055
Input:
Sensible Heat of Azeotropic Ethanol
Q  mCpT  1.394(3.357 )(40)
Q  187.19kW
Output:
Sensible Heat of Ethanol Water
Q  mCpT  0.237(3.055)(80)
Q  57.92kW
Sensible Heat of Dehydrated Ethanol
Q  mCpT  1.157(1.637 )(80)
99
Q  151.52kW
Q  (57.92  151.52)  187.19
Q = 22.25 kW
12. Cooling of Ethanol Water (Recycle to Ethanol Column)
Cooling Water, 25oC
Ethanol Water, 80oC Ethanol Water, 35oC

(recycle to Ethanol Column) Cooler (recycle to Ethanol Column)
m = 20 454. 5455 kg/day m = 20 454. 5455 kg/day
73 wt% EtOH 73 wt% EtOH
Cooling Water, 50oC
Given:
The energy required
Q  mCpT  0.237 (3.055)(35  80)
Q = -32.58W
Q 32.58
m 
H 97.08
m = 0.34 kg/s
100
13. Cooling of Dehydrated Ethanol
Cooling Water, 25oC

Cooler m = 100 000 kg/day
m = 100 000 kg/day
99.5 wt% EtOH
99.5 wt% EtOH
Cooling Water, 50oC
Given:
The energy required
Q  mCpT  1.157 (1.637)(35  80)
Q = -85.23W
Q 85.23
m 
H 97.08
m = 0.88 kg/s
101
14. Cooling of Stillage
Cooling Water, 25oC
Stillage, 80oC Cooler Stillage, 70oC

m = 1 138 850. 728 kg/day m = 1 138 850. 728 kg/day
34 wt% solid 34 wt% solid
Cooling Water, 50oC
Given:
The energy required
Q  mCpT  13.181(4.184)(70  80)
Q = -551.49W
Q 551.49
m 
H 97.08
m = 5.68 kg/s
102
15. Evaporator
Steam (to Cooker), 105oC

m2 = 462 658. 1082 kg/day
Thin Stillage, 70oC

m1 = 523 763. 8961 kg/day Evaporator
7 wt% solids
Conc. Thin Stillage, 105oC

m3 = 61 105. 78788 kg/day
60 wt% solids

Thin Stillage 6.062 70 - 293.69
Steam 5.355 105 - 2677.22
Conc. Thin Stillage 0.707 105 4.184 -
Input:
Sensible Heat of Thin Stillage
Q  mH  6.062(293.69)
Q  1780 .35kW
Output:
Q  mH  5.355(2677 .22)
Q  14336 .525kW
Sensible Heat of Conc. Thin Stillage
Q  mCpT  0.707 (4.184)(105)
Q  310.60kW
Q  (14336 .525  310.60)  1780 .35
103
Q = 12866.775 kW
16. DGS Dryer
Conc. Thin Stillage, 105oC

m2 = 61 105. 78788 kg/day
60 wt% solids
H2O, 150oC
m3 = 208 954. 784 kg/day
WDGS, 70oC
m1 = 580 169. 2388 kg /day DGS Dryer
60 wt% solids
DDGS, 150oC
m4 = 432 320. 2427 kg /day
11 wt% moisture

Conc. Thin Stillage 0.707 105 4.184 -
WDGS 6.715 70 4.184 -
Steam 2.418 150 - 2778.64
DDGS 5.004 150 2.536 -
Input:
Sensible Heat of Conc. Thin Stillage
Q  mCpT  0.707 (4.184)(105)
Q  310.60kW
Sensible Heat of WDGS
Q  mCpT  6.715(4.184)(70)
Q  1966 .69kW
Output:
Q  mH  2.418(2778 .64)
Q  6718 .75kW
Sensible Heat of DDGS
Q  mCpT  5.004(2.536)(150)
Q  1903 .52kW
104
Q  (6718 .75  1903 .52)  (310.60  1966 .69)
Q = 6344.98 kW
105

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Republic of the Philippines

Cagayan State University

ETHANOL PRODUCTION FROM CORN

A Process Equipment Design Report

Presented to the Faculty of Department of Chemical Engineering

College of Engineering, Cagayan State University – Carig Campus

In partial fulfilment of the requirements for the degree of

Bachelor of Science in Chemical Engineering

Engr. CAESAR POBRE LLAPITAN

Chemical Engineering Department

Cagayan State University

Dear Engr. Llapitan:

fulfillment for the requirement of the course Process Equipment Design.

Very truly yours,

Objective of the Study 11

Chapter II Process Description 18

Reactor Feed Preparation 18

Chapter III Material and Energy Balances 27

Symbols and Codes 45

ISA Identification Letters 46

Selection of Control Valves 46

Individual Control and Instrumentation of Equipment 49

Chapter V Health Safety and Environment 57

Life Cycle Analysis 69

bioethanol requires a methodological approach whereby economical, environmental and social

from these alternatives.

consumption and water consumption were also elaborated.

equipment used for the said product.

management and government regulations involved in the process were provided.

cycle analysis were also discussed in this chapter

Ethanol (CH3CH2OH) is a clear, flammable, colorless and slightly toxic

feedstocks by acid-catalyzed hydration of ethane, or from biomass feedstocks through

chemical formula regardless of whether it is produced from starch-and sugar-based

feedstock, such as corn grain, sugarcane, or from cellulosic feedstock.

ancient Egyptians produced alcohol by naturally fermenting vegetative materials. Also

concentration of alcohol in fermented solutions. Ethanol was first prepared

S.G in France. Michael Faraday prepared ethanol by the acid-catalyzed hydration of

carbohydrates and need to be enzymatically processed to yield simple sugars. Examples

2. Worldwide production of ethanol

growing interest in developing commercially viable cellulose to ethanol technology.

The use of ethanol as an alternative fuel source is presently a worldwide topic of

been maximized while advances continue to be made in lignocellulosic biomass

conversion. (Onuki; 2008)

feedstock in the country. (Survey; 2014)

4. Uses and Application of Ethanol

Ethanol is used in medical wipes and in most common antibacterial hand

Ethanol may be administered as an antidote to methanol poisoning.

Ethanol is commonly consumed as a recreational drug, especially while

socializing, due to its psychoactive effects.

a. decreases the fuel's cost

b. increases the fuel's octane rating

c. decreases gasoline's harmful emissions

Ethanol was commonly used as fuel in early bipropellant rocket (liquid

Redstone rocket which launched the first U.S. satellite.

Commercial fuel cells operate on reformed natural gas, hydrogen or methanol.

Ethanol is an important industrial ingredient. It has widespread use as a

acetic acid, and ethyl amines.

in paints, tinctures, markers, and personal care products such as mouthwashes,

perfumes and deodorants.

the different property of ethanol.

Table 1.1 Property of ethanol

Chemical Formula C2H6O

by enzyme hydrolysis is needed to be obtain fermentable sugar. Lignocellulosic

biomass requires more comprehensive physical and chemical pretreatment to