Complete Technology Handbook on Ethanol, Biofuel and Bioenergy Based Products with Detailed Manufacturing Process (Activated Carbon, Ethanol as Biofuel, Biodiesel, Biogas, Bio-Chemical, Renewable Energy, Wood Wastes, Industrial Wastes)

Welcome to the comprehensive world of Ethanol, Biofuels, and Bioenergy-based products. This handbook is a vital resource for anyone seeking knowledge about these eco-friendly, sustainable, and innovative sources of energy. Within these pages, you will embark on a journey into the fascinating realm of renewable energy, exploring the science, technology, and economic aspects of these transformative fields.

The Eco-Friendly Revolution

In an era where environmental conservation and sustainability have become paramount, the quest for cleaner, greener energy sources is more critical than ever. Ethanol, Biofuels, and Bioenergy-based products have emerged as the embodiment of this global aspiration for a sustainable future.

Unraveling the Chapters

Throughout this handbook, you will traverse a diverse landscape, delving into the intricacies of ethanol production, the fascinating world of biofuels, and the promising realm of bioenergy-based products. From the inception of these innovations to their practical applications, this guide offers a comprehensive exploration of each subject.

Ethanol: Nature's Gift to Fuel

Chapter by chapter, you will journey through the various facets of ethanol, starting with its production. Ethanol's history and policy are illuminated, along with insights into its applications as both a fuel and a versatile raw material. You'll explore the chemistry that powers ethanol and understand its significance in various industries, from medical applications to rocket fuel and fuel cells. The extensive coverage ensures you grasp the economic and environmental implications of ethanol production.

Biofuels: Powering a Sustainable Tomorrow

Biofuels, another promising avenue of renewable energy, will captivate your curiosity as you progress through these pages. Discover how biofuels are made, the different production stages involved, and the specific types such as ethanol, biodiesel, and renewable hydrocarbon "drop-in" fuels. Dive deep into the classification of biofuels, which includes liquid and gaseous variants. Unravel their significance in the realm of green energy and understand the essential processes, including deconstruction and upgrading, that make biofuels a viable alternative to fossil fuels.

Bioenergy: Tapping Nature's Potential

Bioenergy, derived from biomass crops and waste materials, is a transformative force in the world of sustainable energy. This handbook explores its generation and applications, shedding light on energy crops, biomass energy, and the potential for various feedstocks in India. The process of pretreatment of lignocellulosic biomass is uncovered, addressing physical, chemical, physicochemical, and biological methods, paving the way for an extensive understanding of this eco-friendly energy source.

A World of Possibilities

The handbook's chapters also offer insights into the manufacturing of biomass-based activated carbon, biomass-based chemicals, and the unique potential of woody biomass fly ash in cement-based materials. Each section provides a comprehensive exploration of these eco-innovations and their practical applications in the energy industry.

The world of ethanol, biofuels, and bioenergy-based products is as promising as it is vast. Whether you are an academic researcher, an industry professional, or an environmentally conscious individual, the knowledge you gain from this handbook is invaluable. It equips you with the tools to appreciate, understand, and contribute to the ongoing transition to a more sustainable, eco-conscious future.

An Invitation to the Future

As you turn the pages of this handbook, consider it an invitation to a future powered by renewable and sustainable energy sources. We encourage you to explore each chapter with an open mind and a thirst for knowledge, for within these pages lies the promise of a greener, cleaner, and more sustainable world.

Welcome to a world where energy meets environmental responsibility, and innovation paves the way to a greener, more prosperous tomorrow. We hope that this handbook not only enriches your understanding but also inspires you to become an active participant in the transformative journey towards a world fueled by Ethanol, Biofuels, and Bioenergy-based products. Let the knowledge you gain here be a catalyst for positive change, as we collectively work towards a brighter, more sustainable future.

Chapter 1

Introduction 

Various Types of Biofuel 

Wood

Biogas

Biodiesel 

Ethanol 

Methanol 

Butanol 

Various Benefits of Biofuels 

They are renewable sources of energy 

Sovereignty 

Ensure sustainable economy 

Low costs 

Cleanest fuel 

Production of less smoke 

They help to reduce monopoly 

Lower toxicity in the atmosphere 

They are a source of employment for locals 

Contents-cum-Index They do not produce sulfur 

Promotion of agriculture 

Chapter 2

Ethanol  

Production 

Starch- and Sugar-Based Ethanol Production 

Cellulosic Production 

Ethanol applications as fuel and raw materials 

Chemistry 

Chemical formula 

Physical properties 

Solvent properties 

Flammability  

Uses 

Medical  

Anesthetic 

Antiseptic 

Antidote 

Medicinal solvent 

Pharmacology 

Recreational 

Fuel 

Engine fuel  

Rocket fuel 

Fuel cells 

Household heating and cooking 

Feedstock  

Solvent 

Low-temperature liquid 

Ethanol Technology 

Bio-Technologies Being Used 

Proprietary Technologies 

Integration of third party processes 

Thermal Integration of Plant 

Design Target 

Flexibility of process: 

Chapter 3

Ethanol Production 

History of Ethanol Production and Policy 

Sugarcane Ethanol Production 

Ethanol Production from Corn 

The reaction of glucose to ethanol 

How Corn is processed to Make Ethanol 

Grinding 

Cellulose-to-Ethanol Process 

Cellulosic Production Process 

Pretreatment 

Distillation 

Dehydration 

Technology Applications for Bioethanol 

Bioethanol Production  

Benefits of Bioethanol  

Applications 

Environmental Impacts 

Ethanol and the Environment 

Ethanol, the Low Carbon Solution 

RFA Members Net Zero Pledge 

Ethanol’s Significant GHG Emissions Reductions 

Chapter 4

Ethanol Production Process from Sugarcane 

Sugarcane processing 

Cane reception 

Cane preparation 

Extraction of sugars 

Cogeneration systems 

Ethanol production  

Juice treatment 

Juice concentration 

Fermentation 

Distillation 

Downstream processing 

Vinasse and biogas 

Combined heat and power 

Second-generation ethanol 

Second-generation ethanol versus CHP 

Ethanol dehydration 

Heterogeneous azeotropic distillation with cyclohexane 

Extractive distillation with Monoethyleneglycol (MEG) 

Adsorption on molecular sieves 

Juice treatment 

Juice concentration 

Boiling, crystallization and centrifuging 

Chapter 5

Ethanol Production Process from Sugarcane Bagasse 

Introduction 

Pretreatment  

Chemical pretreatment 

Dilute acid pretreatment 

Alkali pretreatment 

Organosolv pretreatments 

Physico-chemical pretreatment 

Steam explosion pretreatment 

Liquid hot water 

Biological pretreatment 

Chapter 6

Producing Ethanol from Cellulosic Material 

Overview 

Summary of the Invention 

Detailed descriptions of the preferred embodiments 

Example 1 

Example 2 

Chapter 7

Biofuel 

How Biofuel is Made 

Production Stages 

Production of Common Biofuels 

Ethanol 

Biodiesel 

Renewable hydrocarbon “drop-in” fuels 

Biofuel Conversion Processes 

Deconstruction 

High-Temperature Deconstruction  

Low-Temperature Deconstruction  

Upgrading  

Classification of Biofuels  

Types 

Liquid biofuels 

Gaseous biofuels 

Chapter 8

Biofuel Production from Biomass Crops 

Biomass Production 

Direct Combustion for Heat 

Standalone Combustion 

Biomass Co-combustion 

Types of Combustion 

Pyrolysis 

Alcoholic Fermentation 

Application of Products 

Anaerobic Digestion of Biogas 

Biomass energy 

Why Biomass energy? 

Biomass Potential and Availability in India: 

Renewable Bio-Feed stocks in India and their Availability for Heat and Power Generation 

Potential of Various Cellulosic Feed stocks in India for Ethanol Production 

Potential of Different Oilseeds and Trees of India for biodiesel production 

Chapter 9

Pretreatment of Lignocellulosic Biomass to Biofuel 

Physical methods 

Milling 

Microwave 

Mechanical extrusion 

Pyrolysism 

Pulse electric field (PEF) 

Chemical pretreatments 

Acid pretreatment 

Alkali pretreatment  

Organosolv 

Ionic liquids 

Ozonolysis 

Physicochemical pretreatment 

Ammonia fiber expansion (AFEX) 

Steam explosion 

Carbon dioxide explosion 

Liquid hot water (LHW) 

Wet oxidation 

Biological pretreatment 

Chapter 10

Biofuel Briquettes from Biomass

Properties of Biomass Briquettes 

Binding Mechanisms of Densification 

Mechanism of Compaction 

Benefits & Uses of Biomass Briquettes 

Application & Uses of Briquettes 

Use of Briquettes in Various Industries 

Markets for Biomass Briquettes 

Adoption of Biomass Briquettes in the Developed Countries 

The Rising Need for Biofuel Alternatives 

During the Forecast Period, Europe is Likely to Lead the Global Biomass Briquette Market 

Market Segmentation 

Pre-processing of Biomass Residues 

Mechanical processing 

Energy densification 

Pelletisation 

Fractionation 

Steam explosion 

Alkaline hydrolysis 

Liquid hot water (LHW) 

Low Temperature Steep

Delignification 

Co-solvent Enhanced Lignocellulosic Fractionation CELF 

Organosolv process 

Pyrolysis 

Torrefaction 

Bio-briquette Manufacturing Process 

Manufacturing Process of Bagasse or Biomass Briquettes 

Major Equipment used in Biomass/Bagasse briquettes 

Why bagasse/Biomass Briquettes are preferred 

Application of Biomass briquettes 

Approximate Calorific values Biomass Briquettes of different types of raw materials 

Benefits of Biomass Briquettes:

Pollution 

Efficiency 

Cost 

Quality & Clean Fuel:

Biomass Briquette Plant 

Slow Burning 

High Efficiency 

Smokeless 

Equipment Required to Build A Biomass Briquetting Plant 

Small Briquettes Production Line at Low Setup Cost

Biomass Materials Biomass Briquetting Machinery Can Process 

Significance & Benefits to Setup Biomass Briquetting Plants 

The Cost of Setting up a Biomass Briquetting Plant 

Performance Characteristics of Screw Briquetting Machine 

Screw briquette machine 

Homogeneity of briquettes homogeneous

Chapter 11

Biomass Renewable Energy 

Introduction 

Renewable energy from plants and animals 

Biomass sources for energy include 

Biomass Feedstocks 

Wood 

Energy Crops 

Algae 

Agricultural Wastes 

Animal Wastes 

Human Waste

Municipal Solid Waste (MSW) 

Converting biomass to energy 

How much biomass is used for energy? 

Biomass properties 

Moisture content 

Calorific value 

Proportions of fixed carbon and volatile matter 

Ash/residue content 

Alkali metal content 

Cellulose/lignin ratio 

Bulk density 

Bioethanol Production from Lignocellulosic Feedstocks 

Feedstocks for bioethanol production 

Lignocelluloses-to-bioethanol processes 

Pretreatment of lignocelluloses for enzymatic hydrolysis 

Physical pretreatment 

Milling 

Irradiation 

Chemical pretreatment 

Dilute acid pretreatment 

Alkaline pretreatment 

Ozonolysis pretreatment 

Physico-chemical pretreatment 

Ammonia fiber explosion (AFEX) 

Biological pretreatment 

Biomass Pyramid 

Examples of Biomass Pyramid 

Biomass Pyramid of a Grassland Ecosystem 

Biomass Pyramid of a Tree Ecosystem 

Biomass Pyramid of a Marine Ecosystem 

Compaction Characteristics of Biomass and Their Significance 

Effect of Particle Size 

Effect of Moisture

Effect of Temperature of Biomass 

Effect of Temperature of the Die 

Effect of External Additives 

Unit Operations 

Anaerobic Digestion 

Chapter 12

Biomass-based Activated Carbon 

Introduction 

Biomass pyrolysis and char activation 

Biomass properties 

Lab-scale pyrolysis 

Lab-scale activation 

Surface measurement – BET method 

Activation results 

Pore size distribution 

Generation of granular activated carbon 

Rotary kiln reactor for char activation 

Composition of biological activated carbon process 

Composition and application 

Basic principles of biological activated carbon technology 

Application fields and the typical process flow of biological activated carbon technology 

Basic operational parameters of BAC process 

O3-BAC process and the evaluation of ozonation 

Mechanism and characteristics of O3-BAC process 

Effect of ozonation on molecule weight distribution and the molecule structure of organic matters 

Effect of ozonation on molecule weight distribution of organic matters 

Effect of ozonation on the structure of organic matters 

Improvement of biochemical properties of organics by ozonation 

Improvement of ozonation on biodegradability of organic matters 

Chapter 13

Biomass Based Chemicals

Biorefinery platforms for chemicals production 

Pyrolysis Oil Platform 

CO2 Platform 

Syngas Platform 

Bio Oil Platform 

Production of Methanol from Biomass 

Introduction 

Molecular Formula 

Utilization 

Relevant fuel regulations

Main feedstocks 

Scale of Production 

Production Process 

Biochemical pathways 

State of the art 

Applications of Methanol 

Uses of Methanol in Fuel 

Wastewater Treatment 

Ethanol 

Sugarcane versus Other Feedstock for the Ethanol Production 

Physical and Chemical Compositions of Sugarcane 

Ethanol Production from Sugarcane Biomass 

Pretreatment of Sugarcane Biomass 

Raw Materials and Their Pretreatment for Bioethanol Production 

Raw materials that contain sugar 

Raw materials that contain starch 

Raw materials that contain lignocellulose 

Physical pretreatment of raw materials that contain lignocellulose 

Chemical pretreatment of raw materials that contain lignocellulose 

Physicochemical pretreatment of raw materials that contain lignocellulose

Biological pretreatment of raw materials that contain lignocellulose 

Bioethanol Production from Raw Materials That Contain Sugar 

Bioethanol Production from Raw Materials that Contain Starch 

Bioethanol Production from Raw Materials that Contain Lignocellulose 

Distillation and dehydration 

Fermentation 

Chapter 14

Biomass Gasification 

Biomass feedstocks includes 

Types of Gasification 

Entrained Flow Gasification 

Fluidized Bed Gasification 

Moving Bed Gasification 

Updraft Gasifiers 

Downdraft Gasifiers 

Crossdraft Gasifiers 

Advantages and Disadvantage of Biomass Gasification 

Processes of Gasification 

Pyrolysis 

Cracking 

Reduction 

Combustion and Drying: 

Chapter 15

Biochemical from Biomass 

Biochemical Conversion 

Thermochemical Conversion 

Combustion 

Carbonization 

Pyrolysis 

Gasification 

Liquefaction 

Biofuel Production 

Ethanol Fermentation 

Sugar and starch fermentation to ethanol 

Sulfuric Acid Process

Uses of Sulphuric Acid 

In Domestic Environments 

As a Catalyst:

Acetone–butanol–ethanol fermentation 

Chemical Structure of Acetone and n Butanol 

Fermentation Process of Acetone-Butanol

Hydrogen Fermentation 

Chapter 16

Reuse of Woody Biomass Fly Ash in Cement-Based Materials 

Introduction 

Materials and Methods 

B loss on ignition 

Preparation of Hardened Cement Paste Specimens for Monolith Leaching Test

Monolith Leaching Test 

Chemical Characterization of WBFA 

Leaching Behavior of Blended Cement Pastes 

Utilization of Wood Biomass Ash in Concrete Industry 

Technical feasibility and valorization of WBA use as supplementary cementitious material 

Ecological feasibility of using WBA as supplementary cementitious material

Market readiness of the WBA use as Supplementary cementitious material 

Chapter 17

BIS Specifications 

Chapter 18

Plant Economics of Activated Carbon (From Coconut Shell)

Manufacturing Process 

Plant Economics 

Land & Building 

Plant & Machinery 

Fixed Capital 

Working Capital Requirement/Month 

Total Capital Investment 

Turn Over/Annum 

Chapter 19

Plant Economics of Bio-coal 

Manufacturing Process 

Process Flow Diagram of Biocoal 

Plant Economics 

Land & Building 

Plant & Machinery 

Fixed Capital 

Working Capital Requirement/Month 

Total Capital Investment 

Turn Over/Annum 

Chapter 20

Plant Economics of Bio-diesel Manufacturing Plant 

Biodiesel Production and Problems 

Manufacturing Process of Bio Diesel 

Process in Details 

Pretreatment 

Plant Economics 

Plant & Machinery 

Fixed Capital 

Working Capital Requirement/Month  

Total Capital Investment 

Turn Over/Annum  

Chapter 21

Plant Economics of Biogas Production & Bottling Plant 

The process of CBG production in the country 

Water Scrubbing Technology 

Pressure Swing Adsorption (PSA) Technology 

Internal structure of gobar gas plant 

Production 

Landfill gas 

Technical 

Process of bio gas production 

Bio gas bottling process 

Plant Economics 

Land & Building 

Plant & Machinery 

Fixed Capital 

Working Capital Requirement/Month 

Total Capital Investment 

Turn Over/Annum

Chapter 22

Plant Economics of Biomass Briquettes from Bamboo/Wood Chips

Manufacturing Process 

Moisture control prior to biomass processing 

Milling 

Typical Designs of bamboo/wood Chippers 

Briquetting 

Piston briquetting 

Extrusion matrix 

Packaging

Briquettes packing with thermo sealing 

Pallet wrapping machine 

Process Flow 

Plant Economics 

Land & Building 

Plant & Machinery 

Fixed Capital 

Working Capital Requirement/Month 

Total Capital Investment 

Turn Over/Annum 

Chapter 23

Plant Economics of Grain Based Ethanol 

Manufacturing Process 

Liquefaction 

Fermentation 

Distillation 

Distillers Dry Grain & Soluble (Ddgs) 

Sequences – Ethanol Production 

Plant Economics 

Land & Building 

Plant & Machinery 

Fixed Capital 

Working Capital Requirement/Month 

Turn Over/Annum 

Chapter 24

Plant Economics of Municipal Solid Waste Management 

Benefits of Bio-Gas Technology from MSW 

Output from MSW 

Non biodegradable or dry fractions 

Bio-degradable Fractions 

Biodegradable or wet waste 

Plant Economics 

Land & Building 

Plant & Machinery 

Fixed Capital 

Working Capital Requirement/Month 

Total Capital Investment 

Turn Over/Annum 

Chapter 25

Plant Economics of Pyrolysis Oil from Plastic Waste 

Pyrolysis Process Description 

Feed Preparation 

Biomass Heating 

Char Separation 

Liquids Collection 

Pyrolysis Products 

Pyrolysis Bio-Oil 

Plant Economics 

Land & Building 

Plant & Machinery 

Fixed Capital 

Working Capital Requirement/Month 

Total Capital Investment

Turn Over/Annum