ETHANOL

PRODUCTON
Anaerobic Fermentation of alcohol
 Ethanol is used as
solvent
chemical intermediate
fuel
Solvent:-
Resins, pharmaceuticals , cosmetics ,household
cleaning products, industrial solvent
Fuel:-
Used as a bio fuel , In internal combustion engines
Chemical intermediate :-
• petroleum derived chemicals
• Butadiene production
Organisms for ethanol production:-
Bacteria:-
 Many bacteria can produce ethanol
 Many produce end products
• Other alcohol
• organic acids
• Polyols
• Ketones gasses
 Many bac metabolize glucose by EMP pathway
• Clostridium sps
• Spirochaeta sps
• Sarcina sps
• Streptococcus sps
Yeast
Primary interest are saccharomyces sps
Organisms are selected by
• High growth and fermentation rate
• High ethanol yield
• Osmotolerance
• Low PH
• High temp
• Hardiness under physical and chemical stress
• Ethanol and glucose tolerance(allows conversion of
conc feeds to conc products)
 RAW MATERIALS
Saccharine
Starch &
Cellulose materials
SACCHARINE:-
Simple, directly fermentable, 6 & 12 C molecules
Glucose, fructose, maltose
FRUITS:-
Grapes – 15%
Banana – 13.8%
Apples – 12.2%
Pineapples – 11.7%
Pears – 10%
Peaches – 7.6%
Oranges – 5.4%
Watermelon – 2.5%
MOLASSES:-
 Beet or cane molasses
 Contain 52 – 55 % fermentable
sugars
 Molasses with above 15 – 20 %
sugar cont will need to be dilute
 A ton yeild-70-80 gallons
CANE SORGUM :-
 14% fermentable sugar content
 Extraction requires heavy duty
 13-14 gallons of alcohol / ton
 Acidification is necessary
SUGAR BEET :-
Mostly preferred
15% sugar, 82% water, small amount of starch
Juice Is extracted by crushing
A ton yield 20 – 25 gallons of alcohol
Enzymes improve the alcohol yield
SUGAR CORN WASTE :-
7 – 15% sugar
Sugar is extracted as same as sorghum
8 – 18% gallons of alcohol per ton
Back slopping in the range of 20-25%
Acidification is necessary
Sugar beet sugar corn
Starchy materials:-
Materials that contain more complex carbohydrates
Grains :-
Grains must be milled, diluted & coked & fermented
Contain large amounts of fermentable materials
Alcohol yield is dependent on converted starch
Jerusalem artichokes :-
Abundant source of alcohol ( 16 – 18%) fermentable
material
A ton should yield about 25 gallons of alcohol
Material should be crushed to pulp & cooked for 2-
3 hrs, dilution is not necessary ( 79 – 80% water)
 grains artichokes

potatoes sweet potato

 PH is adjusted & fermentation is carried out
Potato:-
 15 -18% fermentable sugar
 A ton yield 20-25% of alcohol
 Cooked with steam under pressure
 After cooking mash is cooled to conversion for 15-20
min
 Once converted PH should be adjusted mash is
fermented
Sweet potato:-
 27-28% fermentable sugar
 A ton should yield 40 gallons of alcohol
 Similar manner to potatoes
 Dilution is required (66%water)
 Processing steps
Starchy materials are of 2 categories
1. Encased by grain hulls
2. Starch is readily available
Malting:-
Seeds are moistened & allowed to sprout
These seeds are powdered & the powder is called
malt
Milling:-
Grains are milled to expose the starch
Material is ground as fine as possible
But the fine flour is difficult to remove in distillation
process . Pot stills may reduce the problem
Cooking (preparation of mash):-
Starch is liquefied by boiling under pressure
To dissolve the water soluble starches
Always done with steam under pressure at 100°c
Use less water during cooking & water may be
added to dilute the mash
So cooling time may be saved
New method :- Milling & cooking in one operation
without use of water
 The cooked malt is called mash
Conversion :-
Conversion of starch to fermentable sugar (Maltose)
by certain enzymes in the malt or by acid hydrolysis
Enzyme extracts:-
Commercially available
3 basic types :
1. α amylase - produce dextrose
2. Β amylase - produce maltose
3. Gluco amylase – reduce the remaining starch
Acid hydrolysis:-
Conversion by the action of acid
Requires acid proof equipment and high temp
Dilute mineral acid(H₂SO₄) is added to grain slurry
Then immediately neutralized with calcium
hydroxide
Mash cooling:-
Mash is cooled after conversion & PH is checked
Cooling coils are used for cooling
Cooling time is reduced as much as possible
Fermentation
Batch fermentation is commonly employed.
Fermenter volume -- 600mᶟ.
3% inoculum(3×10⁶/ml)
With in 12 days yeast produce 10% ethanol
 when the process carried out at 35- 38°c , ph.4-4.5
max productivity was 1.9 g/h.
80%cells were removed in separator and brought
back again into fermenter.
When the high quality molasses is used, the max
yield is 95%.
Continuous fermentation not commonly used
In US 10 large scale plants among them 4 are used
con fermentation
Nutrient solution was molasses with di ammonium
phosphate
PH was adjusted to 5 with H₂SO₄
Fermentation temp -35°c
After fermentation cells were separated by
centrifugation and channeled back into the first
fermenter
 PRODUCT RECOVERY
Cell biomass is separated by centrifugation or
sedimentation.
M.o desired end product – heated ( aggregate)
readily separated from broth by sedimentation.
Desired end product metabolite.
intracellular - n.a , vit ,enz, a.b (gresofulvin)
extracellular - a.a, acitic acid, citric acid, alcohol,
[ penicillin, streptomycin]
 Separation of cell biomass
Flocculation flotation
Filtration centrifugation
flocculation:-
Flocculating agent is added
hydrocolloids
inorganic salts
organic poly electrolyte
 produce large aggregate which still settle more
readily
Flotation :-
by introducing gas into liquid
Cells gets adsorbed to the gas bubbles & rise to the
foam layer at the top of vessel
That can be collected & removed from the
bioreactor
Filtration:-
Bacterial cultures – absolute filters
 filamentous Fungi- depth filters
static & cross flow filtration
 Distillation
Separation for a mixture of liquids
It relies on differences in B.P of component liquids
to be separated
The mixture to be separated is added to the
distilled pot & is heated
Low B.P will vaporize first. this vapors passes into
distilling head & then into condenser.
With in the condenser the vapor is cooled & it
liquefies.
The resulting liquid is then collected in receiving
flask
 Ethanol B.P - 78.5°C
Water B.P - 100°C
Purification:-
By chromatography
HPLC
GLC
Applications
solvent in the manufacture of varnishes and
perfumes
Preservative for biological specimens
In the preparation of essence and flavorings
 In many medicines and drugs.
 As a disinfectant and in tinctures.
 Used as a biofuel (99.2%).
 Medically ethanol is soporific.
 Used as antiseptic.
 Fluid in many alcohol thermometer.
 92.4%ethanol is used as solvent in cosmetics
pharmaceuticals and chemical industry
Byproduct
 DDGS (distillers dried grain with solubles)
 Co₂– used for the production of dry ice and preparation
of soft drinks
 Yeast biomass- animal fodder (contains proteins &vit)