Alcoholic Fermentation
With Temperature Controlled By
Ecological Absortion Chiller - Ecochill
Fernando C. Boscariol
Dedini S/A Indústrias de Base
[email protected]
1
Introduction
Several references in literature (Dias et al., 2007; Jones et
al., 1981; Prescott and Dunn, 1987; Yamakawa, 2008)
report a high concentration of ethanol in the fermentation
broth from most diverse sucrose feeds (sugarcane, wheat,
corn and rice).
Operating ethanol fermentation in high concentrations
fundamentally increases industrial productivity, reduces
steam and utilities consumption, and minimises losses with
contaminants and, especially, reduces the volume of
vinasse generated. Vinasse requires significant resources
for final disposal.
Justification 1 : Vinasse Volume
Reduction in Distillation
•Calculation Base – Direct Steam: 2,0 a 2,5 kg/ L Ethanol
Volume
of Vinasse
/ Volume of Ethanol
Relação
Vol. Vinhaça/Álcool
22
20
I:I:Borbotagem,
Vinhaça
e Flegma
Direct Steam,
Vinasse,
Lutter
18
II:Borbotagem
II: Direct Steam
III:
indireto
vinhaça
e flegmaça
III: Aquecimento
Indirect Steam,
Vinasse,
Lutter
16
IV: Indirect Steam
IV:Aquecimento
indireto
14
12
10,5
10
8
7,3
6
4
5
6
7
8
9
10
11
12
13
14
Grau
Alcoólico
Vinho(%(%)
Volume Vinhaça/
Volume
Álcool
em Função do Grau
Ethanol
on thedo
Beer
w/w)
Alcoólico do vinho
15
Absorption Chiller Cooling System
4
Absorption Cycles
3
1
1
Water is evaporated
under vacuum over the
chiller water pipe
2
•Produce water 16-20oC
•Controlling fermentation at 28-32 oC
2
Lithium bromide
absorb water vapor
3
Water is evaporated
using a heat source
and lithium bromide is
concentrated
4
Water is condensed
5
Absorption Chiller Cooling System

Heat Sources (reuse of non-thermal sources):
 Vinasse
 Flegmass (lutter water from B Column)
 Condensed steam
 Low pressure steam
VINHAÇA
VINHAÇA
ÁGUA TORRE
AGUA TORRE
AGUA PROCESSO
ÁGUA PROCESSO
Alcoholic Fermentation Process
•CO2
•PRE-FERMENTER
•WATER
•MUST
•WATER+ETHANOL
•WASHING TOWER
•FERMENTAÇÃO
•BEER
•36,27 C
•29 C
•HOT WATER
•COOLING TOWER
•CHILLER WATER
•DISTILLATION
•20 C
•BIOETHANOL
•85 C
•BEER
•75 C
•25 C
•K
•80,0 C
•VINASSE
•CHILLER
Demonstration Unit Plant
 Located at Bom Retiro
Sugar Mill – Cosan Group
(Capivari – SP – Brazil)
 Fermentation Capacity:
20.000 L de ethanol/day
 Operation 2008/2009
 Vinasse as heat source
 Saccharomyces cerevisiae
Raw Material Quality
2008: Mash from B and C Molasses
2009: Mash from Syrup
Brix %
Pol %
Purity %
TRS
%
B Molasses (2 massecuites)
80.40
52.15
64.86
62.50
C Molasses (3 massecuites)
79.80
46.68
58.80
59.56
Syrup
55.00
47.85
87.00
50.00
Results : Mash From Molasses (2008)
Controlled Temperature: 28 0C
12,0%
% EtOH v/v
11,0%
Average: 9.59 %v/v
SD: 1.1%
10,0%
9,0%
8,0%
7,0%
6,0%
Batches
Results : Mash From Molasses (2008)
Controlled Temperature: 30 0C
15,0%
14,0%
% EtOH v/v
13,0%
12,0%
11,0%
10,0%
9,0%
8,0%
7,0%
6,0%
Batches
Average: 11.98 %v/v
SD: 1.2%
Results : Mash From Molasses (2008)
Controlled Temperature: 32 0C
15,0%
14,0%
Average: 11.37 %v/v
SD: 1.2%
% EtOH v/v
13,0%
12,0%
11,0%
10,0%
9,0%
8,0%
7,0%
6,0%
Batches
Results : Mash From Molasses (2008)
 The results show the feasible to obtain level above traditional 9% v/v
 Tendency of an optimum temperature at 30 0C
Temperature [C] Fermentation yields [%]
28
84.02
30
32
86.79
85.05
Results : Mash From Syrup (2009)
 Controlled Temperature: 30 0C
 Mash at 28% Reducing Sugar
Average: 13.82 %v/v
SD: 0.7%
16,0%
15,0%
14,0%
13,0%
% EtOH v/v
12,0%
11,0%
10,0%
9,0%
8,0%
7,0%
6,0%
Batches
Fermentation time: 11:30h
Results : Mash From Syrup (2009)
 Controlled Temperature: 30 0C
 Mash at 35% Reducing Sugar
Average: 15.45 %v/v
SD: 1.2%
18,0%
17,0%
16,0%
15,0%
14,0%
% EtOH v/v
13,0%
12,0%
11,0%
10,0%
9,0%
8,0%
7,0%
6,0%
34
35
36
37
39
42
43
Batches
48
49
50
51
Fermentation
time:5214:50h
CASE: Fermentation to 500.000 l EtOH/day
 Cooling the Fermentation and the Must
 Two sources of heat (vinasse + condensate)
RESFRIAMENTO MOSTO E FERMENTAÇÃO – 500 MLD
FONTE QUENTE: VINHAÇA E CONDENSADO
ÁGUA TORRE
25 ºC
1.800 m3/ h
29 ºC
240 t/ h
FERMENTAÇÃO
FE-101
ÁGUA TORRE
36,4 ºC
CONDENSADO
100 m3/ h
98 ºC
TANQUE COLETOR
602 m3/ h
20 ºC
MOSTO
191 t/ h
32 ºC
25 ºC
CONDENSADO
61 ºC
VINHAÇA
118 m3/ h
86 ºC
TANQUE PULMÃO
588 m3/ h
TANQUE PULMÃO
20 ºC
25 ºC
VINHAÇA
55 ºC
MOSTO ALIMENTADO
MOSTO
CONDENSADO
VINHAÇA
ÁGUA DE CONDENSAÇÃO
ÁGUA FRIA
CASE: Fermentation to 500.000 l EtOH/day
CONVENTIONAL FERMENTATION
Temperatures
• Feed must: 32ºC
CONTROLED FERMENTATION
Temperatures
• Feed must: 25ºC
• Fermentation: 34ºC
Ethanol % on the Beer
• Average: 8.5 %v/v
• Fermentation: 30ºC
Ethanol % on the Beer
Fermentation Yield
• Average: 13.0 %v/v
• Average: 91%
Fermentation Yield
Vinasse
• Average: 91.50%
• Generation: 9.8 l/l ethanol
Vinasse
Steam
• Generation: 5.7 l/l ethanol
• Distillation: 2.60 kg steam/l ethanol
Steam
• Distillation: 2.13 kg steam/l ethanol
CASE: Fermentation to 500.000 l EtOH/day
Cost Reduction: -34,3% (R$ 3.781.431)
Ecochill System
Conventional System
14.000.000
11.031.720
U$ 2.044.017
189.800
142.350
90.312
189.000
33.867
0
94.500
2.000.000
632.000
4.000.000
4.086.963
2.919.744
6.000.000
2.458.109
8.000.000
434.500
R$R$/
/ Season
safra
10.000.000
7.250.289
12.000.000
7.010.864
Pay Back
4 years
Conclusions
 The demonstration results was succeeded well, and the results
obtained at low temperature are promising for very high gravity
fermentation.
 The chiller worked in very stable operation.
 The results with molasses indicate a optimum temperature at 300C.
 Vinasse reduction can reach 40% ( 6 liters/l ethanol ).
 The reduction of the vinasse transportation is the great benefit in the
production cost.
 The cost reduction can reach 2 million dollar/season
 The steam consumption can reach 1.9 kg steam/liter ethanol (27%
reduction), providing more steam to electricity co-generation.
Thank You!
ALCOHOLIC FERMENTATION WITH TEMPERATURE
CONTROLLED BY ECOLOGICAL
ABSORTION CHILLER - ECOCHILL
CONTACT
Fernando C. Boscariol
Dedini Indústrias de Base
[email protected]