1)Objectives:

2)Introduction:
Ethanol also known as ethyl alcohol, drinking alcohol or grain alcohol, it is a
flammable, colorless, mildly toxic chemical compound, and is best known as the
alcohol found in alcoholic beverages. Its molecular formula is variously represented
as ETOH, CH3CH2OH and CH2CH5OH or as its empirical formula c2h6o (which it
shares with dimethyl ether). on industrial scale, ethanol can be prepared by the
formation of molasses. Its alcoholic content is usually increased above that of the
original fermented mixture by distillation. The types of pre-treatment a raw material
receives depends on its nature but generally the fermentation process follows the
general pattern of growth, harvest and delivery to a distillery, conversion of the raw
materials to hydrolysable substrate suitable for fermentation to ethanol, fermentation
and purification by distillation. Ethanol production from molasses is not new, but
some areas are to be researched to increase fully awareness. In Pakistan 22
distilleries were operating using molasses for ethanol production, there is need to be
increase the number of distillery plant in order to utilize molasses fully and get
benefit from that. Numerical simulations give the opportunity to utilize the process
in a proper manner, because in this we can calculate any parameter or optimize
without any pilot plant. Numerical methods are available to carry out numerical
simulation. MATLAB software has many applications regarding to solve any
differential equation, ethanol production from molasses has getting attention

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regarding its usage and other type of application to overcome the problem of energy
crises. Zygomas mobiles used for ethanol production. Zygomas mobiles has many
favorable conditions regarding its utilization. Zygomas mobiles give maximum
production of ethanol compared to other yeast like Saccharomyces cerevisiae
and leucomycins Marxian us, some researcher still working to get more
other yeast for production of ethanol . A cell reactor (ICR) under study to carry out
the fermentation process using molasses as substrate and yeast Saccharomyces
cerevisiae were under investigation. He used packed bed of immobilized cell for
fermentation process. The works were carryout by using Saccharomyces cerevisiae
to enhance the productivity of immobilized cells. The fermentation of ethanol was
carried using 24 hr. for growth to carry out the fermentation process. Ethanol
fermentation model were proposed by him to carry out the fermentation process of
ethanol. Zygomas mobiles as a yeast for process of Fermentations to convert the
sugars into alcohol different cultures of Zygomas mobiles were analyzed under this
study. The conditions that increase ethanol production were given by this researcher
temperature of 30°C and static culture and time of fermentation of 48 h, achieving
55.8 g L-1 it shows that Zygomas mobiles has getting attention now days due to its
availability and getting part of research in the area of biotechnology. Preliminary
tests carried out in glucose (50 g/L) fermentation medium showed that high enzyme
amounts (2.5–3.5 FPU/mL) could cause a negative effect on K. Marxian us growth
rate and viable cells number. However, the maximum ethanol production was not
affected and about 86% of the theoretical (22 g/L) was reached in all cases
independently of the enzyme dosage. In SSF experiments, cell viability was always
affected by enzyme loading. Nevertheless, slight differences observed on cell
viability during glucose fermentation processes with the detected concentrations of
the additives did not justify the negative effect observed in SSF experiments. To
produce ethanol from final sugar cane molasses and to evaluate its quality. Urea was
used as nitrogen source and added at different concentrations 0.15%, 0.5%, and
0.25% (w/v) to the molasses mash. Experiments were conducted using four
treatments depending upon molasses sugar concentration which was calculated as
percentages 10, 15, 20 and 25(w/v). The pH of the mash was adjusted to 4.8 using
concentrated Sulphur acid. 5% (w/v) baker’s yeast was added. The fermentation was
conducted for 72 hours at 33°C. The microbiological analysis revealed absence of
bacteria, yeasts and molds in dilutions 10-3, 10-4, 10-5 of molasses samples. The
yield of ethanol obtained was 20 ml per 100 g of molasses, and ethanol with 96%
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purity could be obtained when the main medium of production (molasses) includes
0.25% (w/v) urea and 20% (w/v) sugar concentration. Zygomas mobiles using
soybean molasses as substrate for ethanol production under controlled conditions.
Ethanol now days getting interested due to friendly effects on environment, different
yeasts were under investigation for ethanol production from molasses. Soybean
molasses as substrate in this study. The conditions that were used to maximize
ethanol production from soybean molasses were 200 g L-1 of soluble solids, pH
between 6.0 and 7.0, in this work Saccharomyces cerise were also tested to see the
behavior that on ethanol production. Bag gaze and trash after getting juice from
sugar cane the material were obtained to use it in proper way co-generation of bag
gaze and trash elements were carried out the researcher also studied different
lignocelluloses material for ethanol production different parameter for ethanol
production were under study to carry out process of ethanol. There are also different
feedstock’s available for ethanol production. But as for lignocelluloses material is
concerned give maximum ethanol production regarding other source for ethanol
production.

The present average alcohol production from molasses in the country

is around 2500 million liters per arum. However wide variation in ethanol production
is observed over the last few years, due to the fluctuation in sugarcane production.
In India alcohol is largely produced in the form of ether-

1. rectified spirit (Rs) (95 to 96% v/v ethanol) which is mainly used for industrial
applications in the form of ordinary denatured spirit(odds)or spherical de-natured
spirit(suds).

2. Extra neutral alcohol (ENA) (96% v/v ethanol) mainly used for manufacture of
portable liquors

3. Fuel ethanol or absolute alcohol (AA) (99.8 v/v) mainly used for blending with
petrol.

We have planned to establish 100 ton/day molasses-based

ethanol plant spread over a land of 175 acres in Haldia, West Bengal.

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2)Demand:
The gap between the availability of alcoholic and the requirement by the industry
has been winding. The existing requirement of alcohol by the industries is around
450 crore liters annually 10% fuel ethanol blending, industrial alcohol and potable
alcohol and the production is around 285 crore liters. The trend is increasing as the
blending increases. The govt. of India has set an indicative target of 25% blending
of ethanol with petrol also for diesel with bio-diesel across the country by 2019.
ethyl is commonly known as ethyl alcohol.it is mainly uses to produce alcoholic
drink such as beer, brandy or whisky, medical field and as a solvent. There are lot of
industries which is require ethanol like-

1. HICE PRODUCT LTD

2. HPCL BIOFUELS LTD

3.XL ENERGY LTD.

4. GODAVERI-BIO-REFINERIES

5. AMINES & PLASTISIZERS LTD

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3)Raw material:
The ethanol industry of today utilizes raw materials rich in saccharides, such as sugar
conc. Or sugar beets and raw materials rich in starch such as corn and wheat.

Baker’s yeast saccharomyces cerevisiae’s is the preferred fermenting

micro-organisms for ethanol production because of its superior and well documented
industrial performances. It is decided that the alcohol, there is going to be produced
from sugar conc. which will work sugar conc. which will work via producing
molasses.

4)Availability
In India sugarcane molasses are the major resource for ethanol production and
inconstancy of raw materials supply is the major cause behind the sluggish response
to blending targets, since sugarcane production is cyclical, ethanol production also
varies accordingly and does not optimum apply levels needed to meet the demand at

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any given time. Drastic fluctuation in the pricing of sugarcane farming and sugar
milling has resulted in mill owners being hotly indebted to farmers. We have decided
to get raw materials from a nearby sugar industry in Haldia, West Bengal.

5)Ethanol production from molasses

Ethanol can be produced from different source but in India ethanol produced from
molasses as a feed stock. There are verities of yeast which are used to convert
molasses into ethanol and co2, like saccharomyces services, thermoptometry
keyframes is diluted with water in water to maintain its brix and sugar percentage,
if there is increase percentage of sugar occur there would be problem of yeast death
rate increasing so that’s why we maintain sugar percentage. After that dilute
molasses is sent to fermenter in which yeast are getting sugar as substrate from
molasses and produce ethanol.

Percentage for ethanol production varies by varying the percentage of parameters.

For that concern there is necessary to study the various parameters used for carried
out the fermentation process, parameters under study are ph., oxygen, flowrate,
agitational intensity(rpm) and temperature. For that case different parameters had
effect on ethanol production yeast is involve converting sugary materials into
ethanol.

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6)Chemical reaction
Main reaction:

C12H22O11+H2O ---- 2C6H12O6

C6H12O6 ---- 2C2H5OH+2CO2

Side reaction:

2C6H12O6+H2O ----ROH+R’CHO

The production of ethanol by fermentation involves four major steps:

(a) the growth, harvest and delivery of raw material to an alcohol plant;
(b) the pre-treatment or conversion of the raw material to a substrate suitable for
fermentation to ethanol;
(c) fermentation of the substrate to alcohol, and purification by distillation; and
(d) treatment of the fermentation residue to reduce pollution and to recover by-
products.

Fermentation technology and efficiency has improved rapidly in the past decade and
is undergoing a chain of technical innovations aimed at using new alternative
materials and reducing costs. Technological advances will have, however, less
overall impact on market growth than the availability and costs of feedstock and the
cost-competing liquid fuel options.

The many and varied raw materials for bioethanol production can be conveniently
classified into three types:

(a) sugar from sugarcane, sugar beet and fruit, which may be converted to ethanol
directly;

(b) starches from grain and root crops, which must first be hydrolyzed to fermentable
sugars by the action of enzymes; and

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(c) cellulose from wood, agricultural wastes etc., which must be converted to sugars
using either acid or enzymatic hydrolysis.

FIG1: EQUIPMENTS IN ETHANOL PRODUCTION PLANT

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 FIG 2: ETHANOL PRODUCTION PROCESS

7)Functional role of various units

(a) Molasses storage tank:

• Molasses is liquor obtained as by product of sugar industries.

• Molasses is a heavy viscous material, which contains sucrose, fructose and glucose
(invert sugar) at a concentration of 50-60(wt./vol).

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(b) Sterilization tank:

• Yeast is sterilized under pressure and then cooled.

(c) Yeast cultivation tank:

• Yeast grows in the presence of oxygen by budding.

• Yeast is cultivated in advance.

(d) Yeast storage tank:

• Yeast are unicellular, oval and 0.004 to 0.010mm in diameter.
• PH is adjusted to 4.8 to 5 and temperature up to 32°C.

(e)Fermentation tank:

• Chemical changes are brought by the action of enzymes invertase and zymase
secreted by yeast in molasses.
• Fermentation is anaerobic,

• Heat is evolved which is removed by cooling coils.

• Residence time is 30-70 hours and temperature are maintained at 20-30°C

• 8-10%alcohol by volume(beer) is produced by fermentation process.

• HCl or sulfuric acid is added to obtain 4.5 PH.

(f) Diluter:

• Here molasses is diluted to 10 to 15% sugar solution.

(g) Scrubber:

• Carbon dioxide is released and utilized as by product.

• By-product CO2 contains some ethanol due to Vapor liquid evaporation and can
be recovered by water scrubbing.

• Water is sent back to continuous diluter stream.

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(h) Beer still:

• 50-60% concentration alcohol and aldehyde are produced.

• Slops are removed as bottom product.

• Slop is concentrated by evaporation for cattle feed or discharged as waste.

• Slop contains proteins, sugar and vitamins.

(I) Aldehyde still:

• Undesirable volatile liquid; aldehyde is taken off from the top of the still.
• From the side stream alcohol is feed to the decanter.

• It is extractive distillation column, and operates at a pressure of

around 0.6-0.7 MPa.

(j) Decanter:
• Fuel oil which is high molecular weight alcohol is recovered by decantation.
• Fuel oil is fractionated to produce amyl alcohol or are sold directly.

• The principle behind extraction of- fuel oil from ethanol is that higher alcohols are
more volatile than ethanol in solution containing a high concentration of water.

(k) Rectifying column:

• In the column, azeotropic alcohol- water mixture of 95% ethanol is withdrawn as

side product.

• This 95% ethanol is condensed in condenser and stored in storage tank.

• Side stream is withdrawn and sent to decanter.

• At the bottom, water is discharged.

• Here, alcohol – water mixtures are rectified to increase the strength of alcohol.

(l) Storage tank:

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• From storage tank, three streams are evolved:

• Direct sale as portable.

• For industrial use.

• To anhydrous still to produce 100% ethanol.

(m) Mix tank:

• For producing denatured alcohol, denaturant is mixed with the 95% ethanol
produced from rectifying column.

• Denaturant is normally methanol (10vol%)

(n) Ternary Azeotropic distillation:

• The product from rectifying column is a ternary minimum boiling azeotrope of

ethanol, water and benzene.

• Benzene is an azeotropic agent.

• Here mainly two units are present; anhydrous still, decanter, stripper and few heat
exchangers.

• Anhydrous motor fuel grade ethanol (100% ethanol) is produced as product.

• Heat integration and energy recovery plays a vital role in reducing energy
requirements

8)Parameters for ethanol production:

During the process of fermentation different parameters were used to study the
effects on ethanol production by varying the percentage of parameters. For that
concern there is necessary to study the various parameters used for carrying out the
fermentation process. Parameters under the study are

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  pH
 oxygen flow rate
 Agitational intensity (rpm)
 temperature.
For that case different parameters had effect on ethanol production, because during
ethanol production yeast is involved converting sugary material into ethanol.

Fig 3: Graph showing worldwide Ethanol production

9)Simulation of ethanol production from molasses

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Simulation is technique in which we solve many mathematical models into
simulation by using different software package. Simulation has many advantages
regarding money saving, time saving regarding huge experiment conducted in the
laboratory or using any pilot plant. Different models using MATLAB software. In
this research Saccharomyces service were used to carry out the numerical simulation
by using eleven models, he suggest that Monod and Henwood model give the good
results against fermentation process for ethanol production .A mathematical model
of direct ethanol production from molasses in immobilized yeast culture. He also
developed the model that will predict the dynamic behavior of cell
growth, starch degradation and some other process. He compared the model and
experimental results for ethanol production. The mathematical model to predict the
temperature effect on ethanol production. Saccharomyces cerevisiae were under
study during his research. Because as we know that in mainly different country for
ethanol production Saccharomyces cerevisiae were used to carry out the
fermentation process using molasses as substrate. Due to this reason he developed
the mathematical model for temperature effect on ethanol production due to different
region of the world. Different temperature occurs so that’s why temperature has
important parameter for ethanol production. Phenomenological and empirical
nonlinear models were built for describing experimental data of Kluyveromyces
cicerisporus batch fermentation on whey, at different temperature and pH levels. The
phenomenological model is based on cell death; substrate consumption due to
product formation, cell growth and maintenance; substrate/product inhibition and
growth-associated/ non growth associated product formation. The parameters
estimation of the phenomenological model was carried out using the maximum
likelihood estimation method. The empirical nonlinear neural network model
identification employed traditional and the dynamic simulation analysis as the
validation procedures. The ethanol production improvement is important task to
improve its production. It is really thankful that we have to work on different tool to
optimize the production of ethanol. There are various numerical technique or we
can say that different software were available to do work on different process
engineering software to optimize different parameter to increase the production of
ethanol from molasses. Some researchers also working on different model to
improve the production because if we increase the production of ethanol from
molasses, there is chance to overcome the problem of energy crises . The simulation
on superpose software for an automatic sugarcane industry to work on ethanol
production. He did also work on the improvement on cost of ethanol. He also
predicts the costs of ethanol production from molasses. Because due to energy crises
facing world today’s scenario. There is need to explore the technique which will
improve the cost of ethanol production, because as chemical engineer is concerned
that should be economically.
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10)COST ESTIMATION :
For 100-ton production/day= 100000/46.07= 2170. 6099 kmole/day

For 70% efficiency = 2170.6099/0.7= 3100.871 kmole/day.

C12H12O11= 3100.871*342.3 = 558640.51 kg/day

H2O = 3100.871*18.015= 55862.191 kg/day

Density of glucose p= 1.54kg/cm2

Volume of glucose = 558640.51/1.54= 351346.23 L

Cost of glucose = Rs. 10.22/kg

Cost of H2O= Rs. 1/L

Total cost of H2O=55862.191*1= 55862.191/day

Total cost of glucose = 558640.51*10.22= 5709306.012/day

Zymase requirement is 2mg/L per day

Price of zymase/lit =Rs. 350

To produce 1 ton/day we require 2 kg zymase.

Price of 2 kg zymase= Rs. 700/day

To produce 100 ton, we require = Rs. 70000/day

Total cost of raw material= Rs. 5716306.012/day

1. minimum required land = 2 lactose and it cost depends on location it around 30 to

35 lacs.

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2. cost for civil work (like level, plant base, foundation, office, building, ETP, boiler
house, work house, god owns, boundaries, etc.) with construction material is around
8.4 cr.

3.cost for structure with material and construction is around 8.4 cr.

4. cost for complete equipment and plant (milling, process section, distillation plant,
evaporation, dryer, storage) is around 420000000.

5.cost for required high pressure boiler with turbine 50.4ton capacity is around
166666666

6. cost for all electronics instrumentation and automation is around 63000000.

7. working capital and other is around = 90000000. The complete project cost is 91
crores.

11)ADVANTAGES:

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  As the raw material is taken from nearby company the transport
cost is comparatively less.
 The rail-road transport system is well developed in the area.
 Availability of labors
 The river is nearby for which the supply of water is abundant.

12)DISADVANTAGES OF THE PROJECT:

 Release gases into the air.

 Causes water pollution


13)DISCUSSION:
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Our benefit from the project is Rs 26 crores and our total expenditure is
Rs 91 crores which will take nearly five years to cover up. Thus, we can
say that our report is feasible.

14)REFERENCES:

1. Akpa J (2012) Modeling of a Bioreactor for the Fermentation of Palm wine

by Saccaharomycecerevisiae(yeast) and lactobacillus (bacteria). Bioresource
Technology 3: 231-240.

2. Ana M, Viorel T, Calin M (2012) Simulation of Fermentation Bioreactor

Control for Ethanol Production.11th International Conference on
Development and Application Systems, Romaina.pp: 17-20.

3. Aziz S,Memon H, Shah F, Rajoka I, Soomro S (2009) Production of ethanol

by indigenous wild and mutant strain of
thermotolerantKluyveromycesMarxianusunder optimized fermentation
conditions. Pak Journal of Environmental Chemistry 10: 25-33.

4. Bai F, Anderson W, Young M (2010) Ethanol fermentation technologies

from sugar and starch feedstock’s. Biotechnology Advances 26: 89-105.

5. Carlos A, Cardona O (2007) Fuel ethanol production: Process design trends

and integration opportunities. Bioresource Technology 98: 2415-2457.

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