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Corporate Ethanol Plant



Contact Us

Praj Industries Limited,
"Praj Tower" 274 & 275/2,
Bhumkar Chowk-Hinjewadi Road,
Hinjewadi,
Pune : 411057, INDIA.
Phone : 020-71802000 and
020-22941000

Email:

Featured Sections

Cassava to Ethanol


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Know-how, Technology, Plant & Equipment

The Cassava Chips/Tubers are treated in pretreatment section. Cassava Tubers having soil, sand and peels are subjected to dry cleaning/wet cleaning , washing and root peeling. After cleaning, the roots are subjected to chopping and rasping process to make slurry. In case of dry chips, the chips are sent to milling section for making flour. Thus, prepared flour is then mixed with fresh water and recycle stream to prepare slurry. Praj patented degritting system is used to remove sand from slurry. The degritted slurry is then fed to the liquefaction section.


In Liquefaction process, starch in cassava is hydrolyzed into dextrins . The dextrins are converted into glucose which is further converted into alcohol through Saccharification & Simultaneous Fermentation by the action of enzymes and chemicals. Active dry yeast or wet compressed yeast is used which is scaled up in the yeast activation vessel. The fermenters are equipped with agitators for efficient mixing and coolers to maintain optimum temperature.


The application of a steam cooker is governed by type and composition of feedstock, its particle size and recycle streams used in slurry preparation.


Fermented mash is sent to the distillation plant to produce Hydrous Ethanol which can then be sent to dehydration section to produce Fuel Ethanol


Multi-feed systems can also be designed.


Skid Mounted Dehydration System


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To minimize on-site work and project execution time, Praj has introduced a unique concept of skid-mounted, modular dehydration units. All equipment (duly insulated), skid structure and piping are fabricated at Praj's manufacturing shops. The units are assembled and hydro tested prior to despatch. These systems help reduce cost of erection and shipping where these cost form a substantial part of the total cost. Being modular, capacity addition is also easier.


CO2 Recovery System


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PRAJ offers state-of-the-art CO2 Recovery Plants all over the world. PRAJ offers recovery plants to produce liquefied food grade and industrial grade CO2. The CO2 can be recovered from the fermentation plants in distilleries and breweries. Food grade CO2 is used in carbonated beverage industries. Industrial grade CO2 can be used in welding in the automobile industry and as fire extinguisher. PRAJ can offer these systems as standalone skid mounted units.


Bionutrient – EffyTone Fermentation Performance Enhancer


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EffyTone is a bionutrient with complete yeast nutrition for enhancement of fermentation performance in distilleries. While ensuring high rate of yeast metabolism during fermentation, EffyTone also provides vital micro nutrients which facilitate healthy yeast growth to achieve highest product efficiency. It also results in rapid conversion of sugars to alcohol, ensuring higher yields and minimal bacterial contamination and by- product formation, thereby enhancing yields. Praj offers variants based on feedstock and application.


Corn Slop Oil


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The economic value of a 'corn ethanol plant' can be further enhanced by extracting corn oil from Evaporated Thin Stillage. This proprietary technology offers additional revenue stream through flexibility in production of corn oil and DDGS depending upon market conditions. Process entails partial separation of corn oil from thin stillage which can be used as feedstock for various applications. Praj provides CSO system on skids as a single point supply.


Corn Wet Milling


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The following steps are involved in the wet milling process for separation of starch & other by-products from corn starch. Following are the main process steps for alcohol and other useful products.


  • Maize Cleaning
  • SO2 Water Preparation
  • Maize Steeping
  • Coarse Milling, De Germing, Germ separation, Germ drying.
  • Fine milling, Fibre removal.
  • Separation of Starch and Gluten.
  • Gluten refining and drying.
  • Starch A refining & drying.
  • Starch B slurry for Alcohol production.
Malt Spirit Plants


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PRAJ offers malt spirit plants including technology, plant & equipment and water and wastewater treatment solutions. Malt Spirit plant include the following sections :-

  • Malt Storage, Handling and Milling
  • Mashing
  • Fermentation
  • Pot Distillation
  • Storage
  • Effluent and Water & Wastewater Treatment

The quality of Malt Spirit is ensured through proper hygienic equipment and piping, especially in mashing and fermentation sections. To maintain the congener profile during the distillation, PRAJ has designed a special Pot Distillation which is constructed in DOW copper. Praj has supplied two Malt Spirit Plants with capacities of 60 m3 /day and 100 m3/ day.


Grape to Grape Spirit Plants


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PRAJ offers Grape to Grape Spirit plants on turnkey basis. This spirit is mainly produced to make brandy and other alcoholic beverages. Specially designed copper Pot Still-cum-Rectifier is used to maintain the congener profile as well as to get desired alcohol concentration of 70% v/v.


For the spirit production, the following operations are involved:

  • De stemming
  • Dipping
  • Juice Extraction
  • Fermentation
  • Pot Still-cum-Rectifier
  • Storage
  • Effluent and Water & Wastewater Treatment

Sweet Sorghum to Ethanol


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Praj has pioneered the use of Sweet Sorghum or "Sorgo" or "Kadval" for Ethanol production due to its high sugar content similar to sugarcane. This has been the result of extensive research on sweet sorghum, establishing its advantages as a raw material for ethanol production. Sweet Sorghum is a viable alternative for a variety of reasons as below:

  • Known crop for farmers.
  • Harvesting & cultivation practices are simple and identical to sugar cane.
  • Requires less water and fertilizers compared to sugarcane.
  • Crop cycle is short - 3.5 to 4 months. Usually, two cycles are possible from same piece of land annually provided irrigation is possible.
  • Generates bagasse as co-product which can be a principal source of energy for operation of distillery in the form of boiler fuel.
  • In addition to bagasse, sweet sorghum also gives sufficient quantity of green foliage which is useful as fodder for cattle.
  • Sugar Cane machinery can be used for extracting sugars from the stalk
  • Cost of production of sweet sorghum is comparatively less as compared to sugar cane.
  • Can be uniformly grown in warm, sunny weather.

Distilleries can be designed to operate on sweet sorghum between 6 to 10 months the year. Where cultivation season is 6-8 months, distilleries would require additional feedstock such as syrup/molasses or sugar cane / sugar beet to operate distilleries round the year.


Wastewater from the distillery can be composted using press mud produced from clarification of juice. There is also the possibility of excess electricity (co-generation) generation for commercial sale. These factors reduce cost of production of alcohol.


Advantage of PRAJ technology and plant design :
  • Complete know-how for developing a sweet sorghum project
  • Can undertake project for development of sweet sorghum crop with Agricultural back up.
  • Backed up by data generated on pilot and plant level.
  • High efficiency of sugar extraction systems.
  • Add-on module for existing sugar factory unit.
  • Virtually no liquid waste.
  • Negligible requirement of process water during steady state of distillery operation
  • Complete reuse of water.

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