Detailed Project Report on ethanol from rectified spirit

ETHANOL FROM RECTIFIED SPIRIT
[CODE NO.3470]  

Ethyl alcohol

     Commonly called alcohol has been described as one  of  the most exotic oxygen containing organic chemicals known because  of its unique  properties as solvent, beverage, combustible liquid, germicide and as building  block or chemical intermediate for  a host of organic chemicals. As a beverage it has been produced and utilized unknowingly as early as 4000 years ago by Pharaohs in Egypt.

     In India ethyl alcohol has been conventionally and economically produced  by fermentation of a byproduct  of  sugar industry  i.e. molasses.  Although ethyl  alcohol  can  also  be produced   from  other  carbohydrate  containing   materials   by fermentation such  as sugar, cassava (tapioca), rice, wheat, barley and  other  grains,  the economics led  to  its  production  from molasses,  because  of its easy availability at a  low  price.  A flourishing distillery industry grew for production of  both potable and industrial alcohol from molasses.

     After price and distribution decontrol of molasses, its price shot up. The  price of molasses increased from Rs.200  per tone to anywhere between Rs.1500 to Rs. 4500 per tonne. However, the molasses price has come down.  The price of   molasses fluctuates now. The price came down to as low as Rs. 50 per tone and increased some times back during lean period to Rs. 1000 per tone.  The average molasses price however is around Rs.  200-300 per tone.

     Ethyl  alcohol  is  available  as  an  azeotropic   constant boiling  liquid in  which the content of ethyl alcohol  is  about 95%. Distillation of this 95%. Distillation of this 95%  alcohol can  not make it more concentrated as the boiling point  of  this mixture is less than that of 100% ethyl alcohol.


     Alcohol can be used as motor fuel with considerable success. For  all the  uses of ethyl alcohol mentioned above  95%  alcohol can be used except for as MOTOR FUEL. The ethyl alcohol should be anhydrous or 100% for its  use as a component for  blending  in motor fuel.

(a)  Product characteristics and specification
(b)  Market survey
(c)  Manufacturing process
(d)  Plant capacity, raw materials and utilities
(e)  Project implementation and schedule
(f)  Project economics including project cost, production  cost,      
     profitability,  cash  flow statements, breakeven  point,  payback      
     period and internal rate of return.


Ethanol is a generic name for Ethyl Alcohol which can be produced by fermenting sugarcane molasses or juice. It is a volatile, flammable and colourless liquid. Ethyl Alcohol has three principle usages:

1.    Portable – Portable alcohol is used in varying ratios and blends in the production of liquor. There are two main grades of portable alcohol and they are:
a)    Rectified Spirit or RS, which has a purity of 95%.
b)    Extra Neutal Alcohol is produced by redistilling RS and is used in the production of portable
2.    Industrial – Industrial Alcohol is produced by denaturing alcohol with bitterants and thereby making it unfit for human consumption. This form of alcohol is called Special Denatured Spirit.
3.    Fuel Ethanol – This grade of alcohol is also termed as Anhydrous Alcohol

Usage of ethanol-blended gasoline began in the late 1970s. Environmentally, the use of ethanol blends has assisted in reducing carbon monoxide emissions. In the United States, one out of every eight gallons of gasoline sold contains ethanol. Most of this ethanol is purchased as blends of 10% ethanol and 90% gasoline, known as E10, and is used as an octane enhancer to improve air quality.


COST ESTIMATION

Plant  Capacity                                                  :     30.00 KL/day                            
land & Building  (12000 Sq.Mtr)                     :    Rs. 8.95 Cr
Plant & Machinery                                             :    Rs. 7.00 Cr
Working Capital for 2 Months                         :    Rs. 7.00 Cr
Total Capital Investment                                 :    Rs. 24.55 Cr
Rate of Return                                                  :    15%
Break Even Point                                             :    66%


INTRODUCTION    
ETHYL ALCOHOL    
PRODUCT CHARACTERISTICS    
PRODUCT    
TABLE : PHYSICAL PROPERTIES OF ETHYL ALCOHOL    
TABLE : REQUIREMENTS FOR ABSOLUTE (ANHYDROUS)  
ALCOHOL (AS  PER BIS)    
TABLE : ALCOHOL CHEMISTRY    
MERCK INDEX ENTRY    
TABLE : SPECIFICATION OF ALCOHOL STANDARDS IN INDIA    
TABLE  : RESPECTIVE VOLUMES OF ALCOHOL AND WATER
AND  SPECIFIC GRAVITY    
TABLE  TYPICAL ETHYL ALCOHOL SPECIFICATIONS    
HEALTH AND SAFETY CONSIDERATION    
TABLE: ETHYL ALCOHOL VAPOUR CONCENTRATION AND ITS EFFECTS
   IN MAN*    
SPECIFICATION OF RECTIFIED SPIRIT    
EXPORT QUALITY OF RECTIFIED SPIRIT WITH STRENGTH    
MARKET POSITION OF ETHANOL    
GLOBAL MARKET POSITION OF ETHANOL    
MARKET SITUATION    
PROJECTION HIGHLIGHTS    
FIGURE. EVOLUTION OF ETHANOL BLENDING IN GASOLINE FUELS
   AND OF BIODIESEL BLENDING IN DIESEL FUELS    
FIGURE. ASSUMPTIONS CONCERNING THE US BIOFUEL MANDATES
   POST-2017    
FIGURE. BIOFUEL PRICES TO TREND UPWARD    
ETHANOL    
PRODUCTION    
FIGURE. DEVELOPMENT OF THE WORLD ETHANOL MARKET
FIGURE. SHARE OF FEEDSTOCK USED FOR BIOFUEL PRODUCTION
   BOOKMARK NOT DEFINED.    
FIGURE. EVOLUTION OF THE REGIONAL DISTRIBUTIONS
   OF WORLD ETHANOL USE    
BIODIESEL    
MANUFACTURERS/SUPPLIERS OF ETHANOL    
MANUFACTURING PROCESS OF ETHANOL FROM RECTIFIED SPRIT    
PROCESS FLOW DIAGRAM    
AZETRPIC DISTILLATION TO MANUFACTURE 100% ETHANOL    
OTHER PROCESS TO MANUFACTURE ETHANOL    
MANUFACTURING PROCESS FLOW DIAGRAM OF ETHANOL    
BIOETHANOL    
BIOMASS FOR BIO-ETHANOL    
FEEDSTOCK  GALLONS ETHANOL/DRY TON    
REVIEW OF TECHNOLOGIES FOR MANUFACTURE OF BIOETH    
DEVELOPMENTS IN BIOETHANOL PRODUCTION TECHNOLOGIES    
PROCESS STEPS    
TECHNOLOGIES    
1. CONCENTRATED ACID HYDROLYSIS    
2. DILUTE ACID HYDROLYSIS    
3.ENZYMATIC HYDROLYSIS    
CELLULOSE ENZYME RESEARCH    
BIOMASS GASIFICATION AND FERMENTATION    
DEVELOPMENT OF MICROBES    
RAW MATERIALS FOR MAKING BIOETHANOL    
ANHYDROUS ETHANOL POTENTIAL FOR GASOLINE BLENDING    
THIS STATISTICS SHOW A DIRECT POTENTIAL.    
GOVT. POLICY    
THE GAZETTE OF INDIA: EXTRAORDINARY [PART I- SEC. I] MINISTRY
OF PETROLEUM AND NATURAL GAS RESOLUTIONNEW DELHI, 3RD
SEPTEMBER, 2002 NO. P-45018/28/2000-C. C. -    62
LIST OF LICENSES & PERMISSIONS REQUIRED FOR ETHANOL PLANT    
MANUFACTURE OF ETHANOL FROM REACTIFIED SPIRIT IN DETAILS    
MATERIAL SAFETY DATA SHEET OF ETHANOL    
SUPPLIERS OF RAW MATERIALS    
RECTIFIED SPIRIT    
BENZENE    
SUPPLIERS OF PACKAGING MATERIALS    
SUPPLIERS OF PLANT & MACHINERIES    
DISTILLATION COLUMN    
CONDENSER    
STORAGE VESSELS
BOILERS    
MATERIAL HANDLING EQUIPMENTS    
INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS    
LABORATORY EQUIPMENTS    
COOLING TOWER    
PACKAGING MACHINE    
       
APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET