1 Alcoholic Fermentation With Temperature Controlled By Ecological Absortion Chiller - Ecochill Fernando C. Boscariol Dedini S/A Indústrias de Base fernando.boscariol@dedini.com.br
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 22 Calculation Base Direct Steam: 2,0 a 2,5 kg/ L Ethanol Volume Relação of Vinasse Vol. Vinhaça/Álcool / Volume of Ethanol 20 18 16 14 12 10 8 6 10,5 7,3 I: I: Borbotagem, Direct Steam, Vinhaça Vinasse, e Flegma Lutter II:Borbotagem Direct Steam III: Aquecimento Indirect Steam, indireto Vinasse, vinhaça Lutter e flegmaça IV:Aquecimento Indirect Steam indireto 4 5 6 7 8 9 10 11 12 13 14 15 Volume Vinhaça/ Ethanol Grau Volume Alcoólico on the do Álcool Beer Vinho (%(%) w/w) em Função do Grau Alcoólico do vinho
Absorption Chiller Cooling System 4 1 2 3 1 2 Absorption Cycles Water is evaporated under vacuum over the chiller water pipe Lithium bromide absorb water vapor Produce water 16-20 o C Controlling fermentation at 28-32 o C 3 4 Water is evaporated using a heat source and lithium bromide is concentrated 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 ÁGUA TORRE VINHAÇA AGUA TORRE AGUA PROCESSO ÁGUA PROCESSO
Alcoholic Fermentation Process PRE-FERMENTER CO2 WATER MUST WATER+ETHANOL WASHING TOWER FERMENTAÇÃO 36,27 C BEER HOT WATER CHILLER WATER 29 C COOLING TOWER DISTILLATION BIOETHANOL 20 C BEER 85 C 75 C VINASSE K 80,0 C 25 C 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 0 C 12,0% 11,0% Average: 9.59 %v/v SD: 1.1% % EtOH v/v 10,0% 9,0% 8,0% 7,0% 6,0% Batches
Results : Mash From Molasses (2008) Controlled Temperature: 30 0 C 15,0% Average: 11.98 %v/v SD: 1.2% 14,0% 13,0% % EtOH v/v 12,0% 11,0% 10,0% 9,0% 8,0% 7,0% 6,0% Batches
Results : Mash From Molasses (2008) Controlled Temperature: 32 0 C 15,0% 14,0% 13,0% Average: 11.37 %v/v SD: 1.2% % EtOH v/v 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 0 C Temperature [C] Fermentation yields [%] 28 84.02 30 86.79 32 85.05
Results : Mash From Syrup (2009) Controlled Temperature: 30 0 C 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 0 C Mash at 35% Reducing Sugar 18,0% Average: 15.45 %v/v SD: 1.2% 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% Fermentation time: 14:50h 34 35 36 37 39 42 43 48 49 50 51 52 Batches
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 1.800 m 3 / h 29 ºC 240 t/ h FERMENTAÇÃO FE-101 25 ºC ÁGUA TORRE 36,4 ºC CONDENSADO 100 m 3 / h 98 ºC TANQUE COLETOR 602 m 3 / h 20 ºC MOSTO 191 t/ h 32 ºC 25 ºC CONDENSADO 61 ºC VINHAÇA 118 m 3 / h 86 ºC TANQUE PULMÃO 588 m 3 / h 20 ºC TANQUE PULMÃO 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 Fermentation: 34ºC Ethanol % on the Beer Average: 8.5 %v/v Fermentation Yield Average: 91% Vinasse Generation: 9.8 l/l ethanol Steam Distillation: 2.60 kg steam/l ethanol CONTROLED FERMENTATION Temperatures Feed must: 25ºC Fermentation: 30ºC Ethanol % on the Beer Average: 13.0 %v/v Fermentation Yield Average: 91.50% Vinasse Generation: 5.7 l/l ethanol Steam Distillation: 2.13 kg steam/l ethanol
CASE: Fermentation to 500.000 l EtOH/day Ecochill System Conventional System Cost Reduction: -34,3% (R$ 3.781.431) U$ 2.044.017 14.000.000 12.000.000 Pay Back 4 years 11.031.720 R$ / Season R$/ safra 10.000.000 8.000.000 6.000.000 4.000.000 2.000.000 0 434.500 632.000 94.500 189.000 33.867 90.312 142.350 189.800 2.458.109 2.919.744 4.086.963 7.010.864 7.250.289
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 30 0 C. 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 fernando.boscariol@dedini.com.br