Manufacturing Process of molasses based disttilery-converted.pptxArjunN51
The document describes the manufacturing process of molasses-based distillery. It involves two main sections - fermentation and distillation. In fermentation, molasses is diluted, yeast is propagated, and fermentation is carried out to produce fermented wash. In distillation, the fermented wash undergoes multiple distillation steps using various columns to produce final products like rectified spirit, extra neutral alcohol, fusel oil, and spent lees. Molecular sieve dehydration is also used to produce anhydrous ethanol.
1. Fermentation is a metabolic process where microorganisms like yeasts or bacteria produce chemical changes in an organic substrate through their enzymes.
2. There are different types of fermentation including batch, continuous, anaerobic, and aerobic fermentation. Batch fermentation uses a fixed volume in a closed container. Continuous fermentation removes products continuously.
3. The document provides details on the production processes for several pharmaceuticals using fermentation, including penicillin, streptomycin, vitamin B12, vitamin B2, and lovastatin. The processes involve inoculation, fermentation under controlled conditions, and product recovery methods.
This document discusses ethanol fermentation and production. Saccharomyces cerevisiae yeast is commonly used to ferment sugars like glucose and fructose into ethanol and carbon dioxide through anaerobic fermentation. The production of ethanol involves preparing nutrient solutions and inoculum from raw materials like molasses or grains, performing fermentation in large tanks, and recovering ethanol through distillation. Ethanol fermentation is an important industrial process used worldwide to produce biofuel from various plant materials.
This document summarizes the process of ethanol production. It discusses that ethanol is produced through the fermentation of sugars or starches by yeast into ethanol and carbon dioxide. The key raw materials for ethanol production are discussed as sugarcane, corn, and wheat. The document outlines the steps in ethanol production as milling, liquefaction, saccharification, fermentation, distillation, and dehydration. Yeast and bacteria are used in the fermentation process to convert sugars into ethanol. Byproducts of ethanol production like dried distillers grains and carbon dioxide are also mentioned.
This document summarizes the process of ethanol production. It discusses that ethanol is produced through the fermentation of sugars by microorganisms like yeast and bacteria. The key raw materials used are sugars, starches, and lignocellulosic biomass from crops like sugarcane, corn, and wheat. The production process involves milling and liquefying the raw material, saccharification to convert starches to sugars, fermentation of sugars to ethanol, distillation to separate ethanol from water, and dehydration to produce anhydrous ethanol. Byproducts like dried distillers grains and carbon dioxide are also discussed.
Whey is the byproduct generated during cheese and casein production. It is rich in minerals and vitamins but considered a pollutant due to its high biological oxygen demand. Various methods can bioconvert whey into saleable products like ethanol, yeast biomass, methane, organic acids, and lactic acid. These processes involve culturing microorganisms like yeast or bacteria using whey as a substrate, followed by separation and purification steps to isolate the final products. Bioconversion reduces the organic load of whey by over 75% while generating value-added goods.
This document summarizes the characteristics, physiology, production methods, and production process of baker's yeast. It describes yeast as unicellular fungi that are typically spherical or oval in shape. It also outlines various fermentation media used in yeast production, including grain wort, molasses salt, and glucose salt media. The production process involves preparing fermentation media, carrying out fermentation, harvesting yeast cells, and mixing, extruding and packaging the yeast.
Ethanol is nowadays is being regarded as a beverage as well as an important bio fuel. But how is it prepared? It's method of production i.e Fermentation is the key. This presentation has all what you need to know about ethanol fermentation.
Manufacturing Process of molasses based disttilery-converted.pptxArjunN51
The document describes the manufacturing process of molasses-based distillery. It involves two main sections - fermentation and distillation. In fermentation, molasses is diluted, yeast is propagated, and fermentation is carried out to produce fermented wash. In distillation, the fermented wash undergoes multiple distillation steps using various columns to produce final products like rectified spirit, extra neutral alcohol, fusel oil, and spent lees. Molecular sieve dehydration is also used to produce anhydrous ethanol.
1. Fermentation is a metabolic process where microorganisms like yeasts or bacteria produce chemical changes in an organic substrate through their enzymes.
2. There are different types of fermentation including batch, continuous, anaerobic, and aerobic fermentation. Batch fermentation uses a fixed volume in a closed container. Continuous fermentation removes products continuously.
3. The document provides details on the production processes for several pharmaceuticals using fermentation, including penicillin, streptomycin, vitamin B12, vitamin B2, and lovastatin. The processes involve inoculation, fermentation under controlled conditions, and product recovery methods.
This document discusses ethanol fermentation and production. Saccharomyces cerevisiae yeast is commonly used to ferment sugars like glucose and fructose into ethanol and carbon dioxide through anaerobic fermentation. The production of ethanol involves preparing nutrient solutions and inoculum from raw materials like molasses or grains, performing fermentation in large tanks, and recovering ethanol through distillation. Ethanol fermentation is an important industrial process used worldwide to produce biofuel from various plant materials.
This document summarizes the process of ethanol production. It discusses that ethanol is produced through the fermentation of sugars or starches by yeast into ethanol and carbon dioxide. The key raw materials for ethanol production are discussed as sugarcane, corn, and wheat. The document outlines the steps in ethanol production as milling, liquefaction, saccharification, fermentation, distillation, and dehydration. Yeast and bacteria are used in the fermentation process to convert sugars into ethanol. Byproducts of ethanol production like dried distillers grains and carbon dioxide are also mentioned.
This document summarizes the process of ethanol production. It discusses that ethanol is produced through the fermentation of sugars by microorganisms like yeast and bacteria. The key raw materials used are sugars, starches, and lignocellulosic biomass from crops like sugarcane, corn, and wheat. The production process involves milling and liquefying the raw material, saccharification to convert starches to sugars, fermentation of sugars to ethanol, distillation to separate ethanol from water, and dehydration to produce anhydrous ethanol. Byproducts like dried distillers grains and carbon dioxide are also discussed.
Whey is the byproduct generated during cheese and casein production. It is rich in minerals and vitamins but considered a pollutant due to its high biological oxygen demand. Various methods can bioconvert whey into saleable products like ethanol, yeast biomass, methane, organic acids, and lactic acid. These processes involve culturing microorganisms like yeast or bacteria using whey as a substrate, followed by separation and purification steps to isolate the final products. Bioconversion reduces the organic load of whey by over 75% while generating value-added goods.
This document summarizes the characteristics, physiology, production methods, and production process of baker's yeast. It describes yeast as unicellular fungi that are typically spherical or oval in shape. It also outlines various fermentation media used in yeast production, including grain wort, molasses salt, and glucose salt media. The production process involves preparing fermentation media, carrying out fermentation, harvesting yeast cells, and mixing, extruding and packaging the yeast.
Ethanol is nowadays is being regarded as a beverage as well as an important bio fuel. But how is it prepared? It's method of production i.e Fermentation is the key. This presentation has all what you need to know about ethanol fermentation.
The document provides information on the production of ethyl alcohol through fermentation. It discusses the raw materials and process, including fermentation in vessels and recovery through distillation. Key points include:
- Ethanol is produced through fermentation of sugars or starches from crops like sugar cane, molasses, or starch using yeast.
- The fermentation process involves adding yeast to a substrate in fermentation vessels to produce ethanol and carbon dioxide.
- Distillation is used to recover the ethanol, involving several columns like rectifiers to separate ethanol based on boiling points.
- Effluents from production are treated onsite through various steps like anaerobic treatment and aerobic treatment to allow for
Acetic acid, also known as ethanoic acid, is the principal constituent of vinegar. It can be produced through aerobic or anaerobic fermentation processes. Aerobic fermentation is a two-step process where yeast first produces alcohol from sugars, then acetic acid bacteria oxidizes the ethanol into acetic acid. Anaerobic fermentation directly converts sugars into acetic acid without an intermediate ethanol step using bacteria like Clostridium. Industrially, acetic acid is most commonly produced via submerged fermentation using acetic acid bacteria in large steel tanks, though surface and continuous fermentation are also used.
Ethanol, also known as alcohol, is produced through the fermentation of sugars by yeast. It has been produced for thousands of years and is used in alcoholic beverages as well as fuels. Ethanol is commonly fermented from sugars in grains like corn or from sugarcane. New technologies allow ethanol to be produced from cellulosic biomass as well through enzymatic or thermal processes. The fermentation process involves inoculating sugar-containing substrates with yeast, which converts the sugars to ethanol and carbon dioxide through a series of biochemical reactions. Proper fermentation conditions like temperature, pH, and nutrients maximize ethanol yield.
This document provides information on the process of beer production, including definitions, history, raw materials used, steps such as malting, mashing, fermentation and filtration. It describes the key components of beer like barley, hops, water and yeast. It also discusses the differences between top-fermenting and bottom-fermenting beers, and notes that dietetic beers contain low carbohydrates and protein.
Citric acid is produced through fermentation using the fungus Aspergillus niger. There are three main production methods - surface fermentation, submerged fermentation, and solid state fermentation. Surface fermentation involves growing A. niger as a mycelial mat on the surface of a molasses substrate, while submerged fermentation uses a liquid molasses substrate. Solid state fermentation uses a moistened solid substrate. Key factors that affect production include carbon source concentration, pH control, aeration, and trace element levels. Citric acid is recovered from the fermentation broth through precipitation or solvent extraction and purified for use as a food additive, preservative, and acidulant.
The document summarizes the production of acetone and butanol through anaerobic fermentation by Clostridium bacteria. It describes the key steps in the industrial process, including using molasses or corn as a substrate, fermenting the substrate anaerobically, and recovering acetone and butanol through fractional distillation. The typical ratios of acetone, butanol, and ethanol produced are also provided.
The document discusses the process of beer production. It begins with an introduction defining beer as an alcoholic beverage made by fermenting grains like barley with yeast. The main ingredients in beer are then described as barley, yeast, hops, water, and other adjunct grains or fruits. The document proceeds to explain the brewing process which involves steps like malting, milling, mashing, lautering, boiling, fermentation, lagering and bottling. Factors that affect fermentation and the four stages of fermentation are also outlined. Finally, the health benefits and risks of beer consumption are briefly mentioned.
1) Ethanol and butanediol are commonly used industrial solvents that can be produced through fermentation.
2) Ethanol is typically produced by fermenting sugars or starches with yeast, while butanediol is produced via bacterial fermentation of various substrates.
3) The production processes involve selecting microorganisms, preparing fermentation media and inoculum, carrying out fermentation, and recovering the solvent through distillation. Both ethanol and butanediol find various industrial applications.
Ethyl alcohol can be produced through two main processes: fermentation of carbohydrates or hydration of ethylene. Fermentation involves yeast cells like Saccharomyces cerevisiae transforming carbohydrates into ethanol and carbon dioxide. The fermentation of sugars like glucose occurs through an anaerobic biological process. Various raw materials like molasses, starch, and cellulosic waste can be used as substrates for ethanol fermentation by microorganisms like yeast under optimal temperature and pH conditions. The fermented broth is then distilled to recover 95% ethanol and byproducts are used in industries like perfume manufacturing.
This document discusses the production of lipases and cellulases. It describes that lipases are produced by microbes like bacteria, fungi and yeast through fermentation and are used in industries like food processing, detergents, and pharmaceuticals. Cellulases are enzymes that break down cellulose and are produced by fungi and bacteria through fermentation. They have applications in food, textile, pulp and paper industries. The document provides details on lipase-producing microorganisms, fermentation conditions, purification methods, and applications of both lipases and cellulases.
The presentation talks about the basics of bioprocess. Describes what is fermentation? Also lists the different modes of fermentation and the basis for selection of type of reactor. General requirements for a fermentation process. Components of a reactor
Ethanol can be produced through anaerobic fermentation of sugars and starches from various raw materials by yeast and bacteria. Saccharine materials like fruits, molasses, sugar beet and sugar cane directly provide fermentable sugars. Starchy materials like grains and tubers must be processed to break down starch into sugars through steps like milling, cooking, and conversion. The sugars are then fermented by organisms like Saccharomyces yeast to produce ethanol. The ethanol is recovered through distillation which separates ethanol (boiling point 78.5°C) from water (boiling point 100°C). Ethanol finds uses as a solvent, fuel, and chemical intermediate. Byproducts are also generated including
The document discusses the continuous production of ethanol from fermentation and purification in a single vessel. The key steps described are:
1) Milling and liquefaction of raw materials like corn to release sugars;
2) Fermentation of sugars to ethanol using yeast;
3) Distillation and rectification to separate and purify ethanol from byproducts; and
4) Possible further processing like evaporation of stillage to produce animal feed.
The overall process aims to efficiently produce ethanol fuel from renewable sources in a single continuous vessel.
Citric acid is a weak organic acid found naturally in citrus fruits. It is produced industrially via fermentation using fungi like Aspergillus niger. Citric acid was first isolated in 1784 and industrial production began in 1890 based on the Italian citrus industry. Today, around 70% of the 1.5 million tons of citric acid produced annually is used in the food industry as a preservative and flavor enhancer. Key factors that affect citric acid fermentation are the carbon source, pH levels, aeration, and nutrient limitations. Recovery methods include precipitation, solvent extraction, and electrodialysis before the citric acid is purified and crystallized. Its major applications are in food & be
The document describes the process of using molecular sieves to dehydrate alcohol and produce anhydrous ethanol. It involves passing vaporized 190 proof alcohol through a molecular sieve bed to adsorb water. The beds are regenerated under vacuum to release water. The beds alternate between online dehydration and regeneration modes to continuously produce 200 proof ethanol. The ethanol is then denatured by adding gasoline before storage to render it undrinkable.
This document provides an overview of fermentation technology and downstream processing. It defines fermentation as the production of a product by microorganism mass culture. It describes the basic stages of batch fermentation including lag, log, stationary and death phases. It then outlines the main steps in downstream processing including removal of insolubles, product isolation, purification, polishing and packaging. Specific unit operations used at each stage like centrifugation, filtration, chromatography are also explained. The document emphasizes that the level of downstream processing depends on the target product and its end use.
This document discusses the production of two industrial solvents - ethyl alcohol and butanediol. It describes the microbial production of ethyl alcohol from molasses using Saccharomyces cerevisiae yeast. Key conditions for fermentation are listed. Commercial production involves diluting molasses, adding nutrients and yeast, then distilling the fermented product. Butanediol is produced similarly using bacteria like Bacillus and Enterobacter. Its uses include fuels, chemicals and polymers. Production methods aim to optimize yields under aerobic conditions with controlled pH and sugar concentrations.
Industrial microbiology involves using microorganisms to produce commercially valuable products through fermentation under controlled conditions. Some key applications include using yeasts to produce alcoholic beverages like beer, wine and spirits through fermentation of sugars, and using bacteria or fungi to produce products like vinegar or antibiotics. Microbes are well-suited for industrial applications because they can rapidly grow and produce enzymes to carry out metabolic reactions. Common fermentation processes include batch and continuous cultures to optimize microbial growth and product formation.
This document discusses the industrial production of ethyl alcohol. It describes how ethyl alcohol is commonly produced from molasses or waste sulphite liquor through yeast fermentation. The key steps involve using selected yeast strains, preparing an inoculum and fermentation medium, maintaining optimal fermentation conditions of temperature, pH and aeration, and finally recovering the ethyl alcohol through distillation. Byproducts such as carbon dioxide, yeast, fusel oils and stillage are also discussed.
The document provides information on the production of ethyl alcohol through fermentation. It discusses the raw materials and process, including fermentation in vessels and recovery through distillation. Key points include:
- Ethanol is produced through fermentation of sugars or starches from crops like sugar cane, molasses, or starch using yeast.
- The fermentation process involves adding yeast to a substrate in fermentation vessels to produce ethanol and carbon dioxide.
- Distillation is used to recover the ethanol, involving several columns like rectifiers to separate ethanol based on boiling points.
- Effluents from production are treated onsite through various steps like anaerobic treatment and aerobic treatment to allow for
Acetic acid, also known as ethanoic acid, is the principal constituent of vinegar. It can be produced through aerobic or anaerobic fermentation processes. Aerobic fermentation is a two-step process where yeast first produces alcohol from sugars, then acetic acid bacteria oxidizes the ethanol into acetic acid. Anaerobic fermentation directly converts sugars into acetic acid without an intermediate ethanol step using bacteria like Clostridium. Industrially, acetic acid is most commonly produced via submerged fermentation using acetic acid bacteria in large steel tanks, though surface and continuous fermentation are also used.
Ethanol, also known as alcohol, is produced through the fermentation of sugars by yeast. It has been produced for thousands of years and is used in alcoholic beverages as well as fuels. Ethanol is commonly fermented from sugars in grains like corn or from sugarcane. New technologies allow ethanol to be produced from cellulosic biomass as well through enzymatic or thermal processes. The fermentation process involves inoculating sugar-containing substrates with yeast, which converts the sugars to ethanol and carbon dioxide through a series of biochemical reactions. Proper fermentation conditions like temperature, pH, and nutrients maximize ethanol yield.
This document provides information on the process of beer production, including definitions, history, raw materials used, steps such as malting, mashing, fermentation and filtration. It describes the key components of beer like barley, hops, water and yeast. It also discusses the differences between top-fermenting and bottom-fermenting beers, and notes that dietetic beers contain low carbohydrates and protein.
Citric acid is produced through fermentation using the fungus Aspergillus niger. There are three main production methods - surface fermentation, submerged fermentation, and solid state fermentation. Surface fermentation involves growing A. niger as a mycelial mat on the surface of a molasses substrate, while submerged fermentation uses a liquid molasses substrate. Solid state fermentation uses a moistened solid substrate. Key factors that affect production include carbon source concentration, pH control, aeration, and trace element levels. Citric acid is recovered from the fermentation broth through precipitation or solvent extraction and purified for use as a food additive, preservative, and acidulant.
The document summarizes the production of acetone and butanol through anaerobic fermentation by Clostridium bacteria. It describes the key steps in the industrial process, including using molasses or corn as a substrate, fermenting the substrate anaerobically, and recovering acetone and butanol through fractional distillation. The typical ratios of acetone, butanol, and ethanol produced are also provided.
The document discusses the process of beer production. It begins with an introduction defining beer as an alcoholic beverage made by fermenting grains like barley with yeast. The main ingredients in beer are then described as barley, yeast, hops, water, and other adjunct grains or fruits. The document proceeds to explain the brewing process which involves steps like malting, milling, mashing, lautering, boiling, fermentation, lagering and bottling. Factors that affect fermentation and the four stages of fermentation are also outlined. Finally, the health benefits and risks of beer consumption are briefly mentioned.
1) Ethanol and butanediol are commonly used industrial solvents that can be produced through fermentation.
2) Ethanol is typically produced by fermenting sugars or starches with yeast, while butanediol is produced via bacterial fermentation of various substrates.
3) The production processes involve selecting microorganisms, preparing fermentation media and inoculum, carrying out fermentation, and recovering the solvent through distillation. Both ethanol and butanediol find various industrial applications.
Ethyl alcohol can be produced through two main processes: fermentation of carbohydrates or hydration of ethylene. Fermentation involves yeast cells like Saccharomyces cerevisiae transforming carbohydrates into ethanol and carbon dioxide. The fermentation of sugars like glucose occurs through an anaerobic biological process. Various raw materials like molasses, starch, and cellulosic waste can be used as substrates for ethanol fermentation by microorganisms like yeast under optimal temperature and pH conditions. The fermented broth is then distilled to recover 95% ethanol and byproducts are used in industries like perfume manufacturing.
This document discusses the production of lipases and cellulases. It describes that lipases are produced by microbes like bacteria, fungi and yeast through fermentation and are used in industries like food processing, detergents, and pharmaceuticals. Cellulases are enzymes that break down cellulose and are produced by fungi and bacteria through fermentation. They have applications in food, textile, pulp and paper industries. The document provides details on lipase-producing microorganisms, fermentation conditions, purification methods, and applications of both lipases and cellulases.
The presentation talks about the basics of bioprocess. Describes what is fermentation? Also lists the different modes of fermentation and the basis for selection of type of reactor. General requirements for a fermentation process. Components of a reactor
Ethanol can be produced through anaerobic fermentation of sugars and starches from various raw materials by yeast and bacteria. Saccharine materials like fruits, molasses, sugar beet and sugar cane directly provide fermentable sugars. Starchy materials like grains and tubers must be processed to break down starch into sugars through steps like milling, cooking, and conversion. The sugars are then fermented by organisms like Saccharomyces yeast to produce ethanol. The ethanol is recovered through distillation which separates ethanol (boiling point 78.5°C) from water (boiling point 100°C). Ethanol finds uses as a solvent, fuel, and chemical intermediate. Byproducts are also generated including
The document discusses the continuous production of ethanol from fermentation and purification in a single vessel. The key steps described are:
1) Milling and liquefaction of raw materials like corn to release sugars;
2) Fermentation of sugars to ethanol using yeast;
3) Distillation and rectification to separate and purify ethanol from byproducts; and
4) Possible further processing like evaporation of stillage to produce animal feed.
The overall process aims to efficiently produce ethanol fuel from renewable sources in a single continuous vessel.
Citric acid is a weak organic acid found naturally in citrus fruits. It is produced industrially via fermentation using fungi like Aspergillus niger. Citric acid was first isolated in 1784 and industrial production began in 1890 based on the Italian citrus industry. Today, around 70% of the 1.5 million tons of citric acid produced annually is used in the food industry as a preservative and flavor enhancer. Key factors that affect citric acid fermentation are the carbon source, pH levels, aeration, and nutrient limitations. Recovery methods include precipitation, solvent extraction, and electrodialysis before the citric acid is purified and crystallized. Its major applications are in food & be
The document describes the process of using molecular sieves to dehydrate alcohol and produce anhydrous ethanol. It involves passing vaporized 190 proof alcohol through a molecular sieve bed to adsorb water. The beds are regenerated under vacuum to release water. The beds alternate between online dehydration and regeneration modes to continuously produce 200 proof ethanol. The ethanol is then denatured by adding gasoline before storage to render it undrinkable.
This document provides an overview of fermentation technology and downstream processing. It defines fermentation as the production of a product by microorganism mass culture. It describes the basic stages of batch fermentation including lag, log, stationary and death phases. It then outlines the main steps in downstream processing including removal of insolubles, product isolation, purification, polishing and packaging. Specific unit operations used at each stage like centrifugation, filtration, chromatography are also explained. The document emphasizes that the level of downstream processing depends on the target product and its end use.
This document discusses the production of two industrial solvents - ethyl alcohol and butanediol. It describes the microbial production of ethyl alcohol from molasses using Saccharomyces cerevisiae yeast. Key conditions for fermentation are listed. Commercial production involves diluting molasses, adding nutrients and yeast, then distilling the fermented product. Butanediol is produced similarly using bacteria like Bacillus and Enterobacter. Its uses include fuels, chemicals and polymers. Production methods aim to optimize yields under aerobic conditions with controlled pH and sugar concentrations.
Industrial microbiology involves using microorganisms to produce commercially valuable products through fermentation under controlled conditions. Some key applications include using yeasts to produce alcoholic beverages like beer, wine and spirits through fermentation of sugars, and using bacteria or fungi to produce products like vinegar or antibiotics. Microbes are well-suited for industrial applications because they can rapidly grow and produce enzymes to carry out metabolic reactions. Common fermentation processes include batch and continuous cultures to optimize microbial growth and product formation.
This document discusses the industrial production of ethyl alcohol. It describes how ethyl alcohol is commonly produced from molasses or waste sulphite liquor through yeast fermentation. The key steps involve using selected yeast strains, preparing an inoculum and fermentation medium, maintaining optimal fermentation conditions of temperature, pH and aeration, and finally recovering the ethyl alcohol through distillation. Byproducts such as carbon dioxide, yeast, fusel oils and stillage are also discussed.
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2. Manufacturing Process of molasses
based distillery
Production of alcohol comprises broadly 3 sections, viz.
(i) Fermentation
(ii) Distillation and
(iii) Effluent treatment and disposal.
3. The fermentation consists of following steps;
1. Molasses weighing -Weighment of molasses will be carried
out either through a load cell based system or through a direct
flow meter system both with totalizing provisions.
2. Dilution
3. Yeast Propagation
4. Pre fermentation and
5. Fermentation
4. DILUTION
The first operation, which is carried out on molasses is dilution. In
dilution operation molasses, from the storage tank is diluted with
raw water. The diluted molasses is used for subsequent unit
operations i.e. yeast propagation & fermentation. The dilution ratios
required for yeast propagation and fermentation are different. For
requirement of yeast propagation, molasses is diluted to keep the
sugar percentage of 8 – 9% while for fermentation molasses is
diluted to keep the sugar 16-18%.
5. Sacchromyce ceriviseae sp is the yeast used for molasses fermentation.
Yeast is unicellular living organism. The growth of yeast takes place by
division of one cell into two, two cells into four and so on, if sugar solution
is provided for its growth. Two types of fermentation process are generally
observed during fermentation.
Aerobic Fermentation:
Aerobic fermentation takes place in presence of excess oxygen and in this
process, the yeast growth remains optimum. Ethyl Alcohol production is
less, because most of the sugar gets converted into water, carbon dioxide
and yeast during fermentation. Aerobic fermentation is suitable for yeast
propagation, with the main objective to achieve the growth of yeast cells.
Anaerobic fermentation
Anaerobic fermentation occurs in absence of Oxygen. Under anaerobic
condition the sugar gets converted into ethyl alcohol and carbon dioxide.
Yeast growth is less in the anaerobic process. Hence, this process is
suitable for ethyl alcohol production, but not yeast propagation.
Yeast Propagation
6. Yeast Propagation
Yeast propagation is being done in aerobic condition and it is slated in the laboratory
strictly under hygienic conditions. To start with, a few yeast cells are added to the
sterilized diluted molasses the entire sugar contain in solution is exhausted. The contents
of test tube are then transferred to a volumetric flask and made up to 250 ml with
sterilized diluted molasses. The solution is left for further growth of yeast. After yeast
growth is achieved in 250 ml solution, it is further made upto 1 liter with sterilized diluted
molasses. The process is repeated till 20 liters of solution containing yeast biomass is
obtained.
Further, yeast propagation is carried out in the yeast vessel in the fermenter house. The
20 liter of yeast solution obtained from laboratory is propagated to required volume
through various stages in yeast vessels of capacities 100 l, 500 l, 2000 l and 5000 l from
the yeast vessels the yeast biomass is fed to the pre-fermenters, in which diluted
molasses is added in the pre-fermenters, aerobic conditions are maintained by means of
submerged aeration to maximize yeast production. The capacity of Pre-fementer vessels
ranges from 15000 L to 18000 L.
15-
18000L
2000 l 5000 l
7. Fermentation
Fermentation is carried out in the fermentation vessels under controlled conditions of
temperature and pH. The propagated yeast biomass is transferred to the main
fermenters keeping volume at 10 to 15% of the total fermenter volume. The rest is
filled with diluted molasses. After filling the fermenter, it is left for fermentation. This
process occurs under anaerobic condition. Under these conditions, the glucose
molecule breaks down to produce ethyl alcohol and carbon dioxide. The time required
for completion of the fermentation process is 15 – 20 hours. The fermentation process
is understood to be completed when the effervescence stops. Other measurement
like specific gravity etc., are also taken to assess the completion of fermentation
process.
Fermentation is an exothermic reaction. Hence, the temperature rises during the
fermentation process. To maintain the temperature at 36 degree C., the fermenter
vessels are required to be cooled with fresh water, through plate type heat exchanger.
The yeast sludge along with solids present in molasses is collected at the bottom of
the fermenter vessels. These solids need to be removed to make the fermenter
vessels ready for another batch of fermentation process. The sludge is washed off by
water. The washed sludge called fermenter washing constitutes a waste along with
some alcohol.
The fermenter washing is centrifuged in a high speed centrifuge machine, which
separates solid and liquid the liquid containing some alcohol is sent for distillation
while the solid contained biomass and other solid is sent for bio-composting.
9. Batch fermentation
o All necessary medium components and the inoculum are added at the beginning.
o The products of fermentation, whether intracellular or extracellular, are harvested
only at the end of the run.
o The concentration of medium components are not controlled during the process.
o As the living cells consume nutrients and yield product(s), their concentrations in
the medium vary along the process.
o The affecting factors, such as pH and temperature, are normally kept constant
during the process.
o The optimum concentration of raw materials can be decided only according to the
initial concentration.
10. Continuous fermentation
• One or more feed streams containing the necessary nutrients are fed continuously.
• The output stream containing the cells, products and residues is continuously
withdrawn.
• A steady state is established for the process.
• The culture volume is kept continuous by maintaining an equal volumetric flow rate
of feed and output.
• Need for cleaning is minimized as a continuous culture concentration is maintained
in the fermenter.
• Continuous fermentation systems require good quality of molasses and are
susceptible to contamination.
11. Fed-batch fermentation
Nutrient or raw material is fed intermittently.
After the first filling, the inoculum is added.
After a small retention time, filling is continued.
Fermentation starts right after the first filling and continues along
the process.
At the end of the process, fermenter is emptied and the product is
obtained.
It is currently the most popular mode of fermentation amongst the
distilleries in India.
13. Analyzer Column
•In this column preheated fermented wash is stripped
off from all volatile components, including ethyl alcohol.
•From bottom, spent wash is drained and sent to ETP.
•This column generally has a degasser section on the
top, which removes all dissolved gases in the fermented
wash.
•This column is generally operated under vacuum to
eliminate the chance of scaling and reduce energy
requirement.
•The vapors (45% to 55% ethanol vapors) of this column
are condensed and fed to prerectifier column.
Wash
Spent wash
Alcohol – water vapour
14. Pre-rectifier Column
•In this column the heavier alcohols (fusel oil) are
separated and collected from top middle draw.
•It is operated under vacuum.
•The main product is drawn off from the top side of
the column.
•Bottom product of the column is called spent lees.
Feed
Vapour
FO
Spent lees
15. Rectifier Column
•This column operates under elevated pressure.
•Rectified spirit, the first alcoholic product, is drawn
from this column.
•The bottom product, spent lees, is used in the process
of fermentation.
•Fusel oil and technical alcohol are also drawn from
this column.
Feed
Vapour
FO
Spent lees
RS
16. Extractive Distillation Column
•In this column DM water is used as an extractant to
dilute the rectified spirit.
•Water is added to change the relative volatility of the
undesirable components to obtain a product clear of
smell.
•Water is added in the ratio of 1:9.
•It is operated at atmospheric pressure.
•Bottom product is fed to the simmering column for
further concentration.
RS
Water
Dilute alcohol
Vapour
17. Simmering Column
•This column is operated under high reflux and vaccum
•Methanol, diacetyl and mercaptans are separated from
the top of the column.
•The final product, i.e., extraneutral alcohol (ENA) is
obtained as bottom product.
Feed
Vapour
ENA
18. Recovery Column
•Fusel oils along with the condensates of analyzer and
ED column are fed to this column for concentration.
•A technical alcohol is taken out from the top of the
column.
•Fusel oils are drawn off from upper trays
•Bottom lees is drained off.
•It is operated at atmospheric pressure.
Feed
FO
TA
Spent lees
19. Molecular Sieve Dehydration System
• Molecular sieve technology works on the principle of pressure swing adsorption.
• Molecular Sieve is nothing but synthetic Zeolites typically 3 Angstrom Zeolites. This material
has strong affinity for water.
•They adsorb water in cold condition and desorbs water when heated. This principle is used to
dehydrate ethanol.
•The crystalline structure of zeolites is complex and gives this material the ability to adsorb or
reject material based on molecular sizes.
•The molecular sieve adsorbents developed for vapour phase, Ethanol dehydration are metal
alumino-silicate with effective pores size opening of 3 Angstrom.
•During dehydration of ethanol, the water of hydrolysis fills the cavities or pores in the
molecular sieve. The potassium form of molecular sieve has pore size of 3 Angstrom, the critical
diameter of water molecules is 3.2A and Ethanol is 4.4 A.
20. Contd…
• In vapor phase, the gaseous water molecules are strong dipoles.
They are drawn in to the pores and condense at the wall of pores,
while ethanol being bigger in size passes through the bed without
getting in to pores of molecular sieve.
• The life of molecular sieve is 5 to 7 years.
• RS is fed to the column for concentration and heating.
• The superheated vapour is fed to one of the sieve columns for
adsorption of moisture.
• When the first sieve column gets saturated, the second is under
operation.
• The first sieve column is cleared of the accumulated moisture by
vacuum.
• Ethanol (99. 6 %) is obtained from the sieve column and is
cooled.
21. Molasses from sugar section
Molasses pit
Molasses Bulk Storage Molasses day tank
Process water
wort
Laboratory yeast culture
Yeast vessel series
Pre-fermentors
Air sparging system
Fermentors
Fermented wash tank
CO2 Scrubber
Yeast sludge CO2
Fermented wash
Sludge settling tank
To distillation section Recycled or sent to poultry feed/bio-
compost
Compressed/solidified for sale
or released into the atmosphere
Air
22. Fermented wash Analyser
Spent wash
Pre-rectifier
Fusel oil
Aldehyde column
Extractive distillationcolumn
Soft water
Rectifier
Spent lees
Steam through re-boiler
Fusel oil column
Impure spirit vapours*
Simmeringcolumn
Vapours
Rectified spirit vapours
Extra neutral alcohol
vapours
Vapours
Steam through re-boiler
Soft water
Vapours
Spent lees
Steam through re-boiler
Spent lees
Impure spirit vapours*
Condensers
Impure spirit
Rectified spirit
Extra neutral alcohol
Impure spirit tank
ENA receivers
RS receivers
Rectified spirit re-drawn To Ethanol section
Fusel oil tank
To evaporator section
Fusel oil
23. Rectified spirit
Weak spirit
Evaporator
column
Steam through re-boiler
RegenerationDrum
Super-heater
Vacuum pump
Molecular Sieve bed 1
Molecular Sieve bed 2
Condenser
Rectified spirit vapours
Steam through re-boiler
Ethanol vapour
Super-heated vapours
Condenser
Ethanol
Ethanol receivers
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