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

B-Heavy Molasses

Syrup of 40 Brix

Juice +

Molasses

A-Heavy Molasses

Composition of Feedstock

Parameters Production

% of Cane

Crushed

Brix

%

Purity

%

FS

%w/w

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

Secondary juice

9.19 40.00 -- 32.33

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.

No. Parameters Units

C

Molasses

B

Molasses Advantage

1 Average

Fermentable

Sugars

% w/w 43 56 Around

30% more

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.

No.

Parameters Units C

Molasses

B

Molasses

Advantage

5 Average

Fermentation

Efficiency

% 89 92 Cleaner and

more efficient

fermentation

6 Ethanol Yield

Litres/ MT @

99.8% v/v

Litres/

MT

242 325 35% more

ethanol yield

7 Average Alcohol

in Fermented

Wash

% 9 12 Ease in

targeting

higher alcohol

8 Steam

Consumption for

Wash to RS

Kg/litr

e of

spirit

2.10 1.70 20% less

steam

consumption i

C Molasses Vs B-Heavy Molasses

Sr.

No.

Parameters Units C

Molasses

B

Molasses

Advantage

9 Spent Wash

Generation from

Distillation

Litres/Li

tre of

Spirit

9.57 7.07 Reduction in

spent wash

by 25%

10 Spent Wash

Solids

% w/w 14.04 11.88 Less solids in

spent wash

due to more

FS

11 Spent wash to

Boiler @60 brix

Kg/Litre

of Spirit

2.13 1.33 Less load on

boiler

12 Bagasse

Requirement in

Boiler

Kg/Litre

of Spirit

0.43 0.27 Less auxiliary

fuel

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