Industry Overview
Broken rice can serve as a valuable raw material for the production of ethanol, maltodextrin and food-grade rice protein. The described technology first separates rice protein from broken rice and subsequently uses the starch fraction for products such as ethanol and maltodextrin. The process can produce food-grade rice protein with protein content of more than 80%, while the material is described as non-allergenic and non-genetically modified. For a 300-ton-per-day broken rice processing line operating 300 days per year and 20 hours per day, the report indicates an hourly processing rate of 15 tons and a potential production of approximately 1.1 tons per hour of food-grade rice protein at the stated recovery and protein-content conditions.
Ethanol is a versatile oxygen-containing organic chemical and is the active constituent of alcoholic beverages produced through fermentation of saccharine materials. It is also used as a solvent, germicide, beverage ingredient, antifreeze, fuel and chemical intermediate. Ethyl alcohol is a volatile, flammable, clear and colorless liquid whose physical and chemical properties are strongly influenced by its hydroxyl group and associated hydrogen bonding. The report further examines ethanol production from broken rice, fermentation and distillation technologies, ethanol blending in petrol, biofuel policies, raw-material availability, market conditions, global outlook and the role of ethanol as both a fuel and industrial chemical.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 15000 Ltr/Day |
| Land & Building (12000 sq.mt) | Rs. 6.10 Cr |
| Plant & Machinery | Rs. 12 Cr |
| Working Capital for 2 Months | Rs. 2.66 Cr |
| Total Capital Investment | Rs. 21.66 Cr |
| Rate of Return | 23% |
| Break Even Point | 60% |
Content Index
- INTRODUCTION
- PROPERTIES OF ALCOHOL
- PHYSICAL PROPERTIES
- TABLE PHYSICAL PROPERTIES OF ETHANOL
- SOURCES OF ALCOHOL
- USES AND APPLICATION
- NEW POLICY ON BIOFUELS ALLOWS BLENDING OF ETHANOL
- DEFENCE SPECTRUM
- BROKEN RICE
- MARKET OVERVIEW OF ETHANOL IN INDIA
- SHORTFALL IN ETHANOL SUPPLIES
- FLUCTUATIONS IN SUPPLY OF RAW MATERIAL
- SECOND GENERATION ETHANOL PRODUCTION
- GLOBAL OUTLOOK
- CONCLUSION
- PETROL CONSUMPTION
- TOP THREE STATES DURING 2015-16 IN PRODUCTION OF ALCOHOL FROM MOLASSES
- MANUFACTURERS/SUPPLIERS OF ETHANOL
- ETHANOL BLENDING IN INDIA
- PROCUREMENT OF ETHANOL
- GOVERNMENT INITIATIVES
- CCEA RECOMMENDATIONS
- BENEFITS OF EBP
- CHALLENGES OF EBP
- PROBLEMS WITH DIVERTING CANE TO PRODUCE ETHANOL
- CRITICISM
- WHY ETHANOL BLENDING IN PETROL MIGHT NOT WORK FOR INDIA
- IMPACT ON NET SOWN AREA
- WAY FORWARD
- ETHANOL POLICY AND PROGRAMS IN INDIA
- INDIA’S BIOFUEL POLICY SALIENT FEATURES AND RECENT DEVELOPMENTS
- ADDED FACTS
- IMPEDIMENTS
- INSTITUTIONAL MECHANISM
- ETHANOL
- INDIA. ETHANOL PRODUCTION, SUPPLY AND CONSUMPTION
- PRODUCTION
- INDIA ETHANOL USED AS FUEL AND OTHER INDUSTRIAL CHEMICALS (MILLION LITERS)
- CONSUMPTION
- TRADE
- IMPORTS
- EXPORTS
- INDIA ETHANOL IMPORTS, IN MILLION LITERS
- INDIA ETHANOL EXPORTS, IN MILLION LITERS
- TRADE AND TECHNICAL NAMES
- UNITS OF MEASUREMENT
- ORGANISM USED IN THE PRODUCTION OF ALCOHOL
- TYPE OF YEAST
- SHAPE AND SIZE OF CELLS
- CONTENTS OF THE CELL
- YEAST SPARES
- B.I.S. SPECIFICATION
- MANUFACTURING PROCESS OF ETHANOL FROM BROKEN RICE
- PROCESS FLOW DIAGRAM
- PROCESS IN DETAILS FOR ALCOHOL PRODUCTION
- (A) ALCOHOL PRODUCTION FROM BROKEN RICE
- 1) GRAIN HANDLING AND MILLING
- FERMENTATION
- DISTILLAITON
- TECHNOLOGY FOR ETHANOL FROM BROKEN RICE
- ACID HYDROLYSIS OF DAMAGED RICE
- INCUBATION AT VARYING CONDITIONS
- ACID HYDROLYSIS AT VARYING TEMPERATURES
- ACID HYDROLYSIS AT VARYING PHYSICAL TREATMENT
- THERMO CHEMICAL PROCESS IN HYDROLYSIS
- PLANT LAYOUT
- SUPPLIERS OF RAW MATERIALS
- BROKEN RICE
- SUPPLIERS OF PLANT AND MACHINERY
- SILO
- HAMMER MILLS
- COOLING TOWER
- REACTORS
- D.G. SETS
- BOILERS
- CONDENSER
- DISTILLATION COLUMN
- SCRUBBER
Appendix
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Ethanol production from broken rice uses the starch-rich material as a feedstock for fermentation and subsequent distillation. Broken rice is first handled and milled, after which the starch is converted into fermentable material and subjected to fermentation. The resulting alcohol-containing mixture is then processed through distillation to obtain ethanol. The report also describes a technology in which rice protein is separated before the starch fraction is used for ethanol or maltodextrin production, allowing the raw material to support multiple value-added products.
Broken rice is suitable for ethanol production because it contains starch that can be converted into fermentable sugars. As a by-product or lower-value fraction of rice processing, it can provide a useful feedstock for an integrated bioprocessing facility. The report considers broken rice for alcohol production as well as for the recovery of food-grade rice protein and production of maltodextrin. Proper milling, hydrolysis, fermentation and distillation are important process stages for converting the available starch into ethanol efficiently.
The main stages include grain handling and milling, starch hydrolysis, fermentation and distillation. Grain preparation makes the broken rice suitable for further processing, while hydrolysis converts starch into fermentable sugars. Fermentation uses microorganisms such as yeast to convert available sugars into ethanol. Distillation then separates and concentrates the ethanol from the fermented mixture. Depending on the process design, additional treatment and purification stages may be incorporated to achieve the required product quality and operating performance.
Fermentation converts fermentable sugars into ethanol through the activity of suitable microorganisms, commonly yeast. In a broken-rice ethanol process, starch must first be converted into sugars that the fermenting organism can utilize. Process conditions such as temperature, pH, nutrient availability and fermentation time influence microbial activity and alcohol formation. Effective fermentation is therefore an important stage between starch conversion and distillation, where the alcohol-containing fermented liquid is processed further to recover ethanol.
Ethanol is separated from the fermented liquid primarily through distillation. Because ethanol and water have different volatilities, controlled heating and condensation can be used to concentrate ethanol from the fermentation broth. Industrial plants use distillation columns and associated equipment to carry out this separation continuously or in a controlled process configuration. Depending on the required specification and final application, further dehydration or purification may be incorporated after conventional distillation.
Ethanol is used as a fuel, industrial chemical, solvent and ingredient in alcoholic beverages, among other applications. Its chemical properties also make it useful as a germicide, antifreeze and chemical intermediate. In fuel applications, ethanol can be blended with petrol as part of biofuel programs. Industrial demand may also arise from its use in chemical processing and formulations. The report examines ethanol both as a fuel and as an industrial chemical, including its production, supply, consumption, trade and blending applications.
Integrating rice protein recovery with ethanol production can improve the utilization of broken rice by separating valuable protein before processing the starch fraction. The approach described in the report is intended to produce food-grade rice protein while directing the remaining starch toward ethanol, maltodextrin or related products. This type of integrated processing can create multiple product streams from a single raw material and may improve overall resource utilization. Product quality, recovery efficiency, process integration and appropriate food-processing controls remain important considerations when developing such a facility.
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