grain based (maize, wheat) ethanol plant

GRAIN BASED (MAIZE, WHEAT) ETHANOL PLANT

[CODE NO.4406]  

Ethanol also termed as ethyl alcohol, grain alcohol, or simply liquid alcohol is abbreviated as EtOH; is an organic compound with molecular formula C2H5OH. Ethanol is a form of alcohol that is a renewable, domestically produced transportation fuelthat can be used to power automobiles like trucks, buses, boats, and motorbikes. Being apotent virucidal agent inactivating all of the lipophilic viruses, is utilized in manufacturing of drugs and cosmetics, plastics and plasticizers, lacquers and polishes.It can also fuel few farm equipment and tiny generators, being the best alternative fuel globally.Ethanol is the first generation biofuel. 

Production of Ethanol from Grains ( WHEAT, MAIZE ) :

Ethanol production plants are considered biorefineries, because they convert grain biomass into biofuel using enzymes and living microorganisms.It is produced commercially by breaking down grains like maize, sorghum, barley and wheat.Ethanol derived from grains, can convert agricultural waste items into fuel. This fuel can be used in gasoline or diesel-powered vehicles. Due to lower capital cost, over 90 % of the grain ethanol produced today comes from the dry milling process, while the remaining coming from wet mills and solvent refining.Ethanol can also be produced from cellulosic feed stocks—such as grass, wood, and crop residues—which is a more involved process than using starch-based crops. 

When ethanol is blended with 95% gasoline and other extravagant fuel additives, it can reduce about 90% CO2 and 60–80% SO2. This helps the world in solving many of the problems of air pollution, reducing the high levels of greenhouse gases that are causing drastic climate change while maintaining ecological security.

MARKET DYNAMICS:

The global ethanol market size was valued at USD 109 billion in 2022 and is anticipated to register an expansion at a compound annual growth rate (CAGR) of 4.8% from 2202 to 2032, to reach USD 170 billion. The demand for the product is driven by growing usage in the field of pharmaceuticals and antidotes and as a substance of a biofuel. Luxurious alcoholic beverages in every modern household is another major factor supporting market growth. To meet the market demand and supply, ethanol is manufactured by both natural as well as petrochemical feed stock.

The U.S. is the primary contributor in North America with a market share of over 18.6 %.However, Asia Pacific is estimated to register the fastest CAGR from 2020 to 2027 owing to growing fuel consumption, in pharmaceutical companies and increased industrial activities.Brazil in Latin America is second of the largest regional markets due to the abundant availability of raw material coupled with rising development in designing of compact and high efficiency motors from the automotive industry.  It was one of the first countries that experimented by replacing the crude oil with the blending of ethanol into gasoline, representing 26.7 % of the total ethanol production globally in 2020. Consumption in luxury beverages, household disinfectant and in other FMCG products is at its peak and the trend is expected to continue for the next few years at a rate of 5 to 6%. These applications of ethanol are the major market drivers. The automotive industry has grown rapidly over the past years despite numerous troubles.

FUTURE OUTLOOK: 

In terms of volume, the grain-based segment led the global market in 2020 with a share of 67.3%. Easy availability of food crops and development of efficient technologies day by day across the globe have boosted the segment growth significantly. Grain-based ethanol is majorly manufactured using the dry milling process where 1 bushel of maize can produce 2.86 gallons of denatured ethanol. World Corn production is expected to slow down by 4 % in 2022 -23 globally as manufacturers tackle problems associated with yields and saturation in demand.

India stands 6th among the leading ethanol producers in the world and still in 2020, it remained the biggest importers of the United States ethanol, with a market share of 99%. So far, in the country 196 grain- based projects with a combined capacity to annually produce 8.59 billion litres of ethanol per annum from food grains like rice and maize have been approved by the government since January 2021. Grain-based ethanol manufacturers have demanded that the Center follow dual pricing for the products made from maize and rice due to difference in realisation, potentially helping the government’s crop diversification plan.Oil marketing companies (OMCs) are offering to buy at ₹52.90/litre from grain-based ethanol plants,the government should offer to buy at ₹55/litre from those who are using maize as feed stock. Currently, India has 116 grain-based ethanol plants with an installed capacity of 268 crore litres, of which Punjab has the most –16 plants with a capacity of 61.67 crore litres. Till the end of 2020, there was no commercial cellulosic ethanol production in the U.S. Brazil—the world's second-largest consumer of fuel ethanol after U.S.—uses sugarcane to produce ethyl alcohol, which qualifies as an advanced biofuel for use in the country under the RFS. Argentina in 2020, was ranked 8th in the world with a contribution of just 1% toward the total global ethanol production. Colombia standing in 13th position in the world in 2020 with a contribution of 0.44% toward the total global ethanol production. And in the European Union in 2020,ethanol was 4.8% of the total global production.

COST ESTIMATION

Plant Capacity                            120 KL/Day

Land & Building (1,20,000 sq.mt.)  Rs. 59.98  Cr

Plant & Machinery                        Rs. 157.56 Cr

Working Capital for 2 Months    Rs. 27.72  Cr

Total Capital Investment                  Rs. 260.26 Cr

Rate of Return                                     30%

Break Even Point                              56%

• INTRODUCTION
• PROPERTIES OF ALCOHOL
• PHYSICAL PROPERTIES
• TABLE: PHYSICAL PROPERTIES OF ETHANOL:
• SOURCES OF ALCOHOL
• USES AND APPLICATION
• OVERVIEW OF ETHANOL IN INDIA
• ENERGY SECURITY
• COMPATIBLE VEHICLES
• IMPACT ON EMISSIONS
• GLOBAL EVIDENCES
• POLICY OF ETHANOL IN INDIA
• ETHANOL SUPPLY PROJECTION IN INDIA
• ETHANOL PRODUCTION CAPACITIES
• MODIFIED INTEREST SCHEME TO ENHANCE PRODUCTION CAPACITY  OF ETHANOL
• AVAILABILITY OF FEED-STOCKS FOR PRODUCTION OF ETHANOL
• TABLE: AVAILABILITY OF FEED-STOCK FOR ETHANOL IN THE COUNTRY (IN LAKH TON)
• ESTIMATION OF SUPPLY AND CAPACITY AUGMENTATION
• TABLE: YEAR WISE & SECTOR WISE ETHANOL PRODUCTION PROJECTIONS
• TABLE: ETHANOL CAPACITY REQUIREMENT BY YEAR AND RAW MATERIAL
• TABLE: ETHANOL CAPACITY AUGMENTATION (20% BLENDING BY 2025-26)
• FUEL ETHANOL DEMAND IN INDIA
• GROWTH IN VEHICLE POPULATION
• TABLE: PROJECTED ADDITION OF GASOLINE VEHICLES (IN LAKHS)
• DEMAND PROJECTIONS OF GASOLINE
• TABLE: GASOLINE DEMAND PROJECTIONS
• DEMAND PROJECTION OF FUEL ETHANOL
• TABLE: ETHANOL DEMAND PROJECTION
• ADDITIONAL MODELING OF ETHANOL DEMAND SCENARIOS
• 1. CONSERVATIVE (LOW EVS) –
• 2. BUSINESS-AS-USUAL (BAU, MEDIUM EVS) –
• 3. LOW CARBON (HIGH EV UPTAKE) –
• ETHANOL BLENDING PROGRAMME IN INDIA
• NODAL AGENCY FOR ETHANOL PRODUCTION
• TABLE: FEEDSTOCK COST AND ETHANOL YIELD
• TABLE: QUANTITY SUPPLIED (ETHANOL) AND %BLENDING TRENDS
• MANUFACTURERS/SUPPLIERS OF ETHANOL
• 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 GRAIN
• LIQUEFACTION
• FERMENTATION
• DISTILLATION
• DISTILLERS DRY GRAIN & SOLUBLES (DDGS)
• PROCESS FLOW DIAGRAM
• SEQUENCES IN ETHANOL PRODUCTION
• PROCESS IN DETAILS FOR ALCOHOL PRODUCTION
• (A) ALCOHOL PRODUCTION FROM BROKEN RICE AND OTHER GRAIN
• 1)   GRAIN HANDLING AND MILLING
• MASHING
• FERMENTATION:
• DISTILLAITON -
• TECHNOLOGY FOR ETHANOL FROM BROKEN RICE OR OTHER GRAIN
• 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
• POLLUTION CONTROL
• WASTE WATER TREATMENT
• SOLD / HAZARDOUS WASTE MANAGEMENT AND DISPOSAL
• DETAILS OF PLANT AND MACHINERY
• AREA 1- GRAIN RECEIVING AND STORAGE SECTION
• AREA 2- GRAIN HANDLING AND MILLING SECTION
• AREA 3- LIQUEFACTION SECTION
• AREA 3- FERMENTATION SECTION
• AREA 4 – MULTIPRESSURE DISTILLATION SECTION REBOILERS
• CONDENSERS & COOLERS
• OTHER EQUIPMENTS
• AREA 5 – ETHANOL DEHYDRATION SECTION
• AREA 6- DECANTATION SECTION
• AREA 6.1: INTEGRATED EVAPORATION PLANT ON DISTILLATION COLUMN
• AREA 6.2: DRYER VAPOUR INTEGRATION EVAPORATION PLANT
• SCOPE OF SUPPLY: STEAM TUBE BUNDLE DRYER
• PARAMETERS:
• A) TUBE BUNDLE
• HOUSING PARTS
• DRIVING SYSTEM
• OTHER EQUIPMENT DETAILS
• DDGS DRYER EQUIPMENT SECTION
• VAPOUR DUCTING
• DRIVE ARRANGEMENT
• AREA 9 – UTILITIES SECTION –
• 1. COOLING TOWER FOR FERMENTATION
• 2. COOLING TOWER FOR LIQUEFACTION, DISTILLATION, MSDH 
•    AND INTEGRATED
• EVAPORATION SECTION
• AIR COMPRESSOR:
• DESIGN DATA & PERFORMANCE PROJECTIONS
• AREA 10: CONDENSATE POLISHING UNIT
• DETAILS OF TREATMENT UNITS
• LIST OF EQUIPMENTS
• RO PLANT -
• FILTER FEED TANK:
• FILTER FEED PUMP
• 1. PRIMING PUMP:
• ANTI-SCALENT DOSING UNIT:
• CARTRIDGE FILTER:
• HIGH PRESSURE PUMP:
• MEMBRANE SKID:
• ROCIP SYSTEM:
• SECTION 3
• SCOPE OF SUPPLY SCOPE OF SUPPLY
• AREA 11 – WATER TREATMENT PLANT: CAPACITY- 1500 M3/DAY
• AREA 12: PRODUCT RECEVING AND BULK STORAGE SECTION
• SECTION 15: ELECTRICAL SECTION
• STANDARD SPECIFICATIONS FOR ELECTRICAL
• MOTOR CONTROL CENTOR (MCC)
• EACH STARTER OF MCC WILL CONSIST OF:
• INCOMER OF MCC WILL BE:
• INTERNAL POWER WIRING
• FOR DOL STARTER
• FOR STAR-DELTA STARTER
• EARTHING
• POWER AND CONTROL CABLES
• PUSH BUTTON STATION
• CABLE TRAYS
• ERECTION MATERIAL
• PLANT LIGHTING:
• SECTION
• STANDARD SPECIFICATIONS FOR INSTRUMENTATION
• CONTROL SYSTEM
• COMMUNICATION SYSTEM
• PARTS INTERCHANGEABILITY
• SECURITY
• SPARE PHILOSOPHY
• SYSTEM SPECIFICATION
• COMMUNICATION HARDWARE
• POWER SUPPLY MODULE
• DIGITAL INPUT MODULE
• DIGITAL OUTPUT MODULE
• ANALOG INPUT MODULE
• ANALOG OUTPUT MODULE
• PROCESSOR MODULE
• OPERATOR INTERFACE
• OPERATOR CUM ENGINEERING STATION
• OTHER HARDWARE REQUIREMENT
• MOUNTING
• INTERIOR LIGHTING AND RECEPTACLES
• INSTRUMENT LIST
• LIQUEFACTION SECTION
• FERMENTATION SECTION
• DISTILLATION SECTION
• EVAPORATION SECTION
• DEHYDRATION SECTION
• DETAILS OF LABORATORY EQUIPMENTS
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF BROKEN RICE
• SUPPLIERS OF PLANT AND MACHINERY
• SUPPLIERS OF SILO
• SUPPLIERS OF HAMMER MILLS
• SUPPLIERS OF COOLING TOWER
• SUPPLIERS OF REACTORS
• SUPPLIERS OF D.G. SETS
• SUPPLIERS OF BOILERS
• SUPPLIERS OF CONDENSER
• SUPPLIERS OF DISTILLATION COLUMN
• SUPPLIERS OF SCRUBBER

APPENDIX – A:

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)