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PROCESS : Introduction
Broadly speaking, processes for making alcohol by fermentation include steps for
1) Preparing the feedstock,
2) Fermenting simple sugars,
3) Alcohol recovery and often
4) Recovery of residual on-alcohol materials.
The feedstock may already contain sugars as in the case of molasses, sugarcane juice or whey; or it may contain sugar polymers such as cellulose, hemicelluloses or starch, which can be depolymerised to fermentable sugars.
In brief, in this process the whole cereal, normally grains, corn (maize), is ground in a mill to a fine particle size and mixed with liquid, usually a mixture of water and backset stillage. This slurry is then treated with a liquefying enzyme to hydrolyze the cereal to dextrin's, which are oligosaccharides. The hydrolysis of starch with the liquefying enzyme, called “alfa- amylase, is helped along by cooking the mash at an appropriate temperature to break down the granular structure of the starch and cause it to gelatinize. Finally the dextrin's produced in the cooking process are further hydrolyzed to glucose in a saccharification process using the exoenzyme glucoamylase and another enzyme (Rhizozyme.) that may be added to the yeast propagation tank or the fermenter. These separate stages of milling, cooking and saccharification will be explained
The incoming cereal is usually inspected upon receipt. The distiller will check the grain for bushel weight, moisture content, mold infestation, and general appearance. If the cereal complies with the quality control standards, it will be unloaded into silos in preparation for milling. The purpose of milling is to break up the cereal grains to as small a particle size as possible in order to facilitate subsequent penetration of water in the cooking process.
With a hammer mill, the cereal grain is fed into a grinding chamber in which a number of hammers rotate at high speed. The collision of the hammers with the grain causes a breakdown to a meal. The mill outlet contains a retention screen that holds back larger particles until they are broken down further so that there will be a known maximum particle size in the meal. The screens are normally in the size range of 1/8-3/16 in. For efficient processing of the cereal starch into alcohol, the particles should be as fine as possible.
Cooking is the entire process beginning with mixing the grain meal with water (and possibly backset stillage) through to delivery of a mash ready for fermentation. Figure shows the components that make up a typical milling and cooking system.
In the continuous cooking process meal, water and backset stillage are continually fed into a premix tank at a temperature just below that of gelatinization. The mash is pumped continuously through a jet cooker, where the temperature is instantly raised to 120 0C. The retention time in the U tube is only three minutes, after which it is flashed into the liquefaction vessel at 80-90Oc and the enzyme is added (high temperature-tolerant “-amylase 0.05-0.08% w/w cereal). The residence time in the liquefaction vessel is a minimum of 30 minutes. The main advantage of this system is the relatively short residence period in the U tube. If properly designed there is no need to add any “-amylase enzyme in the slurring stage. However, because of the relatively narrow diameter of the tubes, some distillers add a small amount of enzyme to the slurry tank to guarantee a free flow. The gelatinized mash from the Flash Tank is liquefied in the Final Liquefaction Tank where liquefying enzyme (alpha-amylase) is added. The liquefied mash is cooled in Mash Coolers and transferred to Fermentation section for further action.
The purpose of fermentation is to convert sugars into alcohol. Simultaneously Carbon dioxide is produced in Stoichiometric proportions and is scrubbed before being discharged. We employ closed top Fermenter with adequate external cooling system to maintain optimum fermentation temperatures. Agitators are also provided to ensure mixing and suspension of substrate in the tank. Anaerobic conditions are maintained to ensure high reaction rates and CO2.
Fermenters are provided with Beer well of same capacity. Two fermenters will be taken for distillation everyday. After transfer process is complete, empty fermenters will be put to CIP cycle.
Fermented wash is preheated in the Fermented Wash Pre heater and fed at the top of the Analyzer column. Analyzer Column is heated with Low Pressure Steam .
Top vapours of Analyser column containing all the alcohol in the wash are sent to Analyzer Condenser. Rest of the fermented wash flows down the Analyser column and is taken out as spent wash from Analyzer column bottom.
Condensate of Analyzer is fed to Aldehyde Column by pump. Aldehyde Column Top is Taken as Impure Spirits Draw.
Aldehyde bottoms are fed to Rectifier cum Exhaust Column.
In Rectifier Low boiling impurities are concentrated at top of Rectifier column. The Rectifier/Exhaust column concentrates the ethanol . A top draw is taken out as impure alcohol from the top of the Rectifier column. Draw is Cooled & stored in RS Storage Tanks
A small head cut if required is removed from the overhead stream to withdraw Impurities. Fusel oil build up is avoided in the Rectifier cum exhaust column by withdrawing outside streams (fusel oils).
Product streams from the various sections are initially collected in respective daily receivers and then transferred to bulk storage tanks. Separate vent condenser is provided for each bulk storage tank.
Capacity of Storage tanks will be decided based on location requirements.
The Dehydration system offered herein is configured as a stand-alone unit and is capable of operating independently from any other process equipment, once properly connected to the utilities. The unit basically consists of three beds of desiccants along with regeneration, vaporization, and recovery system. While one bed is under feeding condition second in de- pressured condition while third is under regeneration condition for an equal period. In such operational conditions sieve bed have some breath in between continuous feeding and regenerating which enhances the continuous operation without any pressure hiccups in sieve beds.
A computer-controlled Control System actuates the required valves operation, switching the flow from one bed to the other in a continuous operation, at the same time constantly monitoring all process, quality and safety. The feed is pre-heated, with outgoing product and fed to the alcohol drum which is situated above natural circulation evaporation. Such kind of arrangement ensures that only rectified spirit vapours are entered in sieve beds. The resulting overhead vapors send to Sieve Bed 1, where the vapour is dehydrated i.e. moisture is adsorbed from feed alcohol and dry product vapours come out from the bottom of sieve bed. Product vapors are then condensed in reboiler of column, cooled, and pumped to storage. A portion of the dry product vapour is purge through Sieve Bed 2, under vacuum, to regenerate the bed in preparation for cycle changeover before Bed 2 goes feeding it is ready with pressure condition which help bed to remove trapped moisture due thermal swing operation, and Bed 3 having de-pressure condition which is necessary to avoid sudden high- pressure shock load of bed to vacuum conditions. The regeneration operation forces the release of the moisture from the desiccant, making the next bed ready for the next cycle. The recovered low strength vapours are evacuated with help of regen pump condensing through regen condenser and collected and recycled back to column.
The stream (Spent Water/Spent Lees) from the bottom of recovery column, containing negligible ethanol.
SHITAL PROJECTS,
C 101 , FOUR SQUARE , BH. BILLABONG SCHOOL , NR VIVANTA HEIGHTS , VADSAR , VADODARA , GUJARAT
+91 7574864477
sitlanimaheshp@gmail.com ,
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