Welcome

To

All India 2 Day Seminar Cum Exhibition

Organized By

All I dia Distille s’ Associatio

18th & 19th February 2016
 Thank you very much
for your Support & Continual Trust

on us

as your Technology Partner for

Ultra Modern & Energy Efficient Distilleries

 Deep sense of gratitude towards

Honorable Chairman of this technical session

Mr. K.P. Singh

Maximization of Ethanol Production Using B-Heavy Molasses
as an Alternative Feed Stock – A Distillery Perspective

By

Sanjay Desai & Sandeep Chichbankar

Excel Engineers & Consultants, Pune INDIA

Excel Engineers & Consultants
• Excel Engineers & Consultants, Pune INDIA is a technocrat driven
organization.

• A cumulative team experience of more than 2 decades and 150

distillery projects worldwide.

• A technology provider in Distillery, Biofuels, Sugar, Cogeneration,

Water, Waste Water, ZLD and Renewable Energy Industry.

• Excel is promoted by Mr. Sanjay Desai, a Chemical Engineer with a

clear vision to provide ultra-modern & state of art energy efficient
and sustainable futuristic technologies to the industry

• Fast growing technology and EPC company – 12 complete projects in

year 2015-2016.
Area of Expertise

Distillery & Biofuels

Biomass Power & Waste to Energy

Sugar Industry & Cogeneration

Renewable Energy

Waste Heat Recovery & Recycle

Water & Waste Water Management

Zero Liquid Effluent Discharge Systems

Strategic Alliance
Our strategic alliance with ISGEC
Heavy Engineering Ltd. has greatly
increased our strength to provide
a Complete, End to End
Technology Solution in Sugar
Industry, Cogeneration and
Distillery.

With this alliance, we are already

executing 4 big capacity distillery
projects along with Spent Wash
Incineration Boiler.
State of Art Designing
 Excellence

Excelle ce is our Vision statement, a Mission statement & Quality policy.

• In house development E- ax Technologies for Grain and Molasses.

• Product ENA quality is accepted by all domestic & International Bottlers.

• Proven record of best Steam economy and energy savings.

• Execution of ZLD systems for both Molasses and Grain distilleries.

• Successful execution of single 300 KLPD Distillery in India.

• The best alternative & fastest growing technology company.

E-max Range of Technologies

E- a Highl Efficie t Fe e tatio Tech olog

E- a E e g Efficie t “upe fi e G ade Distillatio Pla ts

E- a Multi Effect Evapo atio Pla ts

E- a D e a d DDG“ Pla t

E- a Ze o Li uid Efflue t Discha ge “ ste s

E-max Fermentation Plants
E-max Distillation Plants
E-max Evaporation Plants
E-max Dryer & DDGS Plants
E-max ZLD Systems
Manufacturing Facility
EPC Capability
• House of single window innovative technologies and designs

• Concept to commissioning of custom built modern plants

• Highly professional project management team insuring project

completion well ahead of the project schedules.

• EPC services right from civil work to main process plant, boiler,
turbine and zero liquid effluent discharge.
Esteemed Clientele
Repeat orders from satisfied customer is our strength, we are proud to be
associated with major players in industry for more than a decade.

• Globus Spirits Ltd., West Bengal, Complete Grain Distillery

• Globus Spirits Ltd., Bihar, Complete Grain Distillery
• CDBL, Chandigarh., I dia’s Largest Grain Distillery
• Oasis Group Punjab. – 3 Nos. DDGS Plants
• HLPL Karnal, Haryana, Grain Distillery
• Globus Spirit Ltd., Rajasthan, DDGS Plant with Zero Steam Evaporation
• San Carlos BioEnergy, Philippines, Cane/Molasses Distillery Expansion
• SSJD South Asia., IS to ENA Distillation Plant
• Hitech Engineers Ltd., KA, Complete Molasses/Juice Distillery – 2 Nos.
Esteemed Clientele
• Shamanur Sugars Ltd., KA, Molasses /Grain Distillery Up-gradation
• Uttam Engineers Ltd., UP, Molasses/Grain Distillery – 2 nos
• Saipriya Sugars Ltd., (Nirani Group), KA, Complete Molasses Distillery
• Rana Sugars Ltd., Grain Distillery Modernization and Evaporation Plant
• Krishnaveni Sugars Ltd., (NSL Group), KA, Complete Molasses Distillery
• MRN Sugars & Power India Pvt. Ltd., KA, Complete Molasses Distillery
• Lorvin Industry Ltd., KA, Complete Molasses Distillery
• Rana Sugars Ltd., Fuel Ethanol Plant
• Tikaula Sugars Ltd., Evaporation Plants
• And Many More to come…
Maximization of Ethanol Production Using B-Heavy Molasses
as an Alternative Feed Stock – A Distillery Perspective
Background
• India is a fast growing economy and facing the challenges of increasing
energy demand.

• The Indian Sugar Industry is going through a very critical phase considering
excess sugar production compared to the present demand.

• At the same time, there is consistently growing awareness and necessity to

utilize Clea & Gree Fuel Ethanol in automotive / transportation sector.

• Govt. of India, realizing this potential, taking initiatives to promote utilization

of Fuel Grade Ethanol manufacture from Sugar Cane based feedstock
through its Ethanol Blending Programme (EBP).

• Ministry of Finance has exempted Central Value Added Tax (CENVAT) on

Fuel Ethanol manufactured from Molasses.

• Very attractive price for procurement of Fuel Ethanol for EBP.

Present Scenario
• Huge Energy Demand for transportation and other sectors, is usually met by
Fossil Fuels such as coal, natural gas and crude oil.

• Annual global requirement of petro products is around 18000 MMT and

I dia’s requirement is only 130 MMT.

• However, the domestic production of crude oil and natural gas is only about
35 MMT i.e. around 25%. This huge demand-supply gap is met by import.

• Out of 6 billion litres of installed capacity of Ethanol in India at 50% utilization,

we are capable of producing about 2.5 to 3 billion litres per annum.

• 5% Ethanol Blending Programme requires about 0.8 million litres of Fuel

Ethanol and remaining can be diverted to distilleries and chemical industry.

• Our crude oil import bills have increased by 13 times in last two decades and
expected to increase upto 50 times by 2020.
Need for B-Heavy Molasses
• B-Heavy molasses is generated by two massecuite boiling scheme comprising
of A and B massecuites.

• With present annual molasses production of around 11-12 MMT, the alcohol
production through molasses route shall remain around 2500 million litres.

• It is estimated that if we can divert B-Heavy Molasses containing 1 million

tones of sugar, as additional 600 million litres of alcohol can be produced.

• Switching over from existing C Molasses to B-Heavy Molasses is easy in

existing set up of sugar mills and distilleries.

• Additionally, there are many other advantages using B-Heavy molasses as an

alternative feedstock in distilleries.

• Hence; in order to give boost to Ethanol Blending Programme, diversion of B-

Heavy Molasses to ethanol production is sought as a Technology Solution.
Feed Stock Options
Sugar Factory can offer following feedstock options for manufacture of Fuel
Ethanol_

C
Molasses

A-Heavy B-Heavy
Molasses Molasses

Juice + Syrup of
Molasses 40 Brix
Composition of Feedstock
Parameters Production Brix Purity FS
% of Cane % % %w/w
Crushed

Final C Molasses 4.26 83 34 42-45

B-Heavy Molasses 7.00 85 58 50-65
A-Heavy Molasses 12.00 76 73 62
Secondary Juice 39.73 9.26 79.32 --
Concentrated 9.19 40.00 -- 32.33
Secondary juice

Syrup 37.76 40.00 83.61 33.54

Advantages (B-Heavy Molasses)
• Reduced recirculation of non-sugars and low purity intermediate in
the pan floor will result in considerable improvement in Sugar Quality
• Capacity enhancement at Sugar Mill due to less load on pan station
• Reduction in power consumption as well as steam consumption in
sugar mill
• Approximately 25% higher recovery of Ethanol due to high
fermentable sugars
• Higher fermentation efficiency
• Higher distillation efficiency due to higher alcohol percentage in
fermented wash (high gravity fermentation)
• Considerable reduction in effluent spent wash generation
• Lesser steam requirement in distillation and spent wash evaporation
plants
• Capacity enhancement at distillery due to higher alcohol, higher yield,
lower spent wash generation and lower utility consumption
C Molasses Vs B-Heavy Molasses

Sr. C B
Parameters Units Advantage
No. Molasses Molasses

1 Average % w/w 43 56 Around

Fermentable 30% more
Sugars FS
2 Brix in Molasses % 80 85 Similar
3 Average TRS % w/w 49 59 20% more
TRS
4 Average F/N Ratio -- 1.16 1.93 65% more
F/N ratio
C Molasses Vs B-Heavy Molasses
Sr. Parameters Units C B Advantage
No. Molasses Molasses
5 Average % 89 92 Cleaner and
Fermentation more efficient
Efficiency fermentation
6 Ethanol Yield Litres/ 242 325 35% more
Litres/ MT @ MT ethanol yield
99.8% v/v
7 Average Alcohol % 9 12 Ease in
in Fermented targeting
Wash higher alcohol
8 Steam Kg/litr 2.10 1.70 20% less
Consumption for e of steam
Wash to RS spirit consumption i
C Molasses Vs B-Heavy Molasses
Sr. Parameters Units C B Advantage
No. Molasses Molasses
9 Spent Wash Litres/Li 9.57 7.07 Reduction in
Generation from tre of spent wash
Distillation Spirit by 25%
10 Spent Wash % w/w 14.04 11.88 Less solids in
Solids spent wash
due to more
FS
11 Spent wash to Kg/Litre 2.13 1.33 Less load on
Boiler @60 brix of Spirit boiler
12 Bagasse Kg/Litre 0.43 0.27 Less auxiliary
Requirement in of Spirit fuel
Boiler requirement
Conclusion & Recommendations
• B-Heavy Molasses can be effectively utilized for fermentative
production of ethanol.
• It does not only result in better alcohol yield but capacity utilization
and efficiencies at distillery also increases.
• There is substantial reduction in steam(20%) and reduction in effluent
spent wash (25%)
• Excel Engineers & Consultants have relevant experience and offers
assistance to existing distilleries to switch over to B-Heavy Molasses.
• Excel offers Concept to Commissioning of Turnkey EPC distillery
projects suitable to operate on both B-Heavy as well as Final C
Molasses with maximized efficiencies.
• Excel offers technology for upto 25% capacity enhancement in existing
distillery set up using B-Heavy Molasses.
Contact Us

Excel Engineering & Consultants

604-605, Pride Kumar Senate, Phase-I,

Senapati Bapat Road, Near ICC, Shivajinagar,
Pune – 411 016 (India)
Tel: +91 20 41070100 Cell: +91 9561096988
Email: sales@regreenexcel.com Web: www.regreenexcel.com