Why Ethanol is important

Ethanol is a primary biofuel produced through the fermentation of sugars by yeasts or through ethyl hydration. It is widely recognized as an alternative fuel source, contributing to a more sustainable energy future. Beyond its role as a fuel, ethanol is also utilized as an industrial solvent and has important medical applications, serving as an antiseptic and disinfectant. Its versatility makes it a valuable component in various industries.

The Government of India has set a target of 20% for ethanol blending which implies that the total demand for ethanol will rise to 18 Bn Litres, thus needing plants to operate at an 80% efficiency rate.

The Ethanol Production Process (Grain-Based)

Grain Milling

Grains like broken rice, wheat, corn, maize etc are milled and processed to be sent to the fermenter

Liquefaction

Water is added to dilute the starch content in the grains. This slurry is then sent to the fermenter

Fermentation

Yeast is added to the slurry to start the fermentation process

Distillation

Post fermentation, distillation is done to recover the ethanol

Inefficiencies in the Current Process

Slow Fermentation

Standard fermentation cycle lasts 3 days thus requiring more and large fermenters to accommodate daily production

Long Down-Time

Post every fermentation cycle, there is a 1-1.5 days of down-time required for maintenance of the fermenters (including acid wash)

Wastage

Yeast is removed post every fermentation cycle due to accumulation of dead yeast as well as reproduction

Yield

Conventional yeast provides a 90% yield of sugars from raw materials - both grains as well as molasses.