How Enogen and Cellerate can boost ethanol production?

With the growing significance of ethanol plants, newer and competitive ways are being explored to facilitate ethanol processes, making it more productive. Enogen Corn Enzyme is one of the latest in-seed techniques that is specifically designed to enhance the overall ethanol production. The modern biotechnology is directed towards infusing top-grade alpha amylase enzyme directly in the grain, eliminating the need to add liquid alpha amylase. This results in reduced production costs and improved process efficiency, thus adding value to ethanol plants and yielding desirable benefits to the corn ethanol producers.

How does Alpha-amylase enzyme work?

Alpha-amylase enzyme is a key ingredient in ethanol production. Corn seeds rich in this enzyme can be highly beneficial for ethanol plants.

The enzymes help ethanol plants reduce the viscosity of corn mash and eliminate the requirement of adding a liquid form of the enzyme. This yields incredibly high levels of solids loading in liquefaction and fermentation tanks, leading to increased throughput and yield. Use of Enogen technology with alpha-amylase enzyme also ensures a significant reduction in natural gas, electricity and water usage.

Cellerate Process Technology and Cellulosic ethanol

Cellerate process technology is a revolutionary procedure that helps ethanol producers to extract increased amount of ethanol from the same kernel of corn. It employs innovative procedure to convert corn kernel fiber into cellulosic ethanol. With cellerate technology installed in ethanol plant infrastructure, the biofuel industry can witness multifold increase in their produce.

The technique does not require any changes to be made in the conventional process of obtaining ethanol from molasses. It leverages the existing infrastructure and offers significant advantages to your plant. It allows pre-treatment in the fiber that facilitates whole stillage processing, eliminating the need to separate all the fiber and starch.

Benefits of Cellerate

Cellerate is a diverse process technology which significantly increases total production by utilizing pre-existing assets like feedstock receiving and storage, product separation and product storage. Besides enabling additional throughput from a dry grind ethanol facility, the process also offers the following benefits:

lAdds value to protein; feed co-products with higher protein content

lIncreases distillers corn oil production

lCreates cellulosic ethanol

lProduces low carbon intense ethanol

Cellerate and Enogen corn when used together can offer optimum benefits to Industrial production of ethanol, including increased throughput and yield with reduction in production cost.

In light of increased fuel prices, dependency on other countries for fuel needs and detrimental impact on the environment due to harmful emissions, ethanol industry needs a tremendous boost. Employing modern and innovative techniques like Cellerate and Enogen in ethanol plants can play an important role in addressing these issues.

An overview of Beer Fermentation Process !

The word Beer is derived from a Latin term called bibere which means ‘to drink’. It is an alcoholic fermented drink that is derived from malted grains like wheat, barley, etc. Fermentation is an important process that goes into the making of beer. Brewery plants widely use the fermentation process to create different flavors and styles of beer.

Role of Yeast in beer fermentation

Yeasts are micro-living organisms that have been used for preparing bread, brewing beer and more. They are a specific type of unicellular fungus that grows by splitting themselves in two. Yeast is largely used in beer fermentation for converting the glucose of the malted grains into carbon dioxide and ethanol. Brewery fermentation doesn’t require any oxygen.

For best results, it’s crucial for the yeast to thrive and grow. To achieve this objective you have to create the right environment for the yeast, this includes the right temperature and ample of food (glucose) for the yeast to do its work.

Yeast is categorically identified as either an Ale yeast or lager yeast. Depending upon the recipe or the style of beer to be prepared, the brew picker picks the yeast accordingly. Ale yeast is a top-fermenting strain that works at warm temperatures, while Lager yeast, is a bottom-fermenting strain, that performs best at lower temperatures. Due to temperature differences, each yeast strain imparts vastly different flavors and aromas to the final product, thus leading to different beer styles.

Beer fermentation Process

There are different steps involved in the making of beer like malting, mashing, boiling, etc. The first two steps, especially mashing and sparging, are essentially directed towards accumulating ‘food’ for the yeast.

After the boiling process is over, the wort is cooled, strained and filtered.  Yeast is then added to the fermenting vessel. At this point, the brewing stops and fermentation begins. Fermentation is an important part of brewing technology used in brewing plants. The beer is stored for a couple of weeks at desired temperature; at room temperature (in the case of ales) and at cold temperatures (in the case of lagers). During this period yeast consumes all the sugar in the wort and spits out CO2 and alcohol as waste products.

Carbonation of Beer

Once you are done with the fermentation process, you have a non-carbonated alcoholic beer ready. You can add desired carbonation to the bottled beer, either artificially through carbonation techniques or by simply allowing the beer to naturally carbonate by allowing further fermentation of the yeast, resulting in more carbon dioxide. When this bottled drink is allowed to sit for a period ranging from a few weeks to a few months you get to taste the delicious, fizzy drinks!

Know All About Ethanol-The Benefits and the Making

Rapid depletion of natural resources(petroleum, crude oil, gasoline etc,) their rising prices and harmful emissions are the concerns that set the momentum for alternative fuel. Ethanol has emerged as the right solution to the problem. Ethanol is now being viewed as the best substitute for petroleum that is largely used by vehicles across the globe. Hence,  endeavors are being directed towards enhancing ethanol production process in several bio-based industries. Ethanol can be used in its pure form or it can be blended with other gasoline constituents.

Why ethanol is the favored substitute for petroleum?

Ethanol is a highly preferred alternative to traditional gasoline fuels because it is economical and environmental-friendly. It is produced from agricultural waste products that are rich in sugar and starch. Coming from the surplus agricultural waste, ethanol extraction does not interfere with food production. Moreover, ethanol-fueled vehicles are considered to be more eco-friendly as they emit less carbon dioxide. Even the ethanol-blended fuels such as E10 (10% ethanol and 90% gasoline) can lead to reduced emissions of greenhouse gases by up to 3.9%.

Derived primarily as a result of conversion of the sun's energy, ethanol is also a renewable source. Ethanol formation starts with photosynthesis, when crops, like sugar cane, corn etc, grow using sunlight. These feedstocks are then processed into ethanol. When it burns as fuel it emits water and carbon dioxide. This is used in the next cycle of ethanol production.

Other applications of Ethanol

Apart from being used as biofuel, ethanol is also used in the production of beverages. It is the principal component of alcoholic beverages like whiskey, rum, vodka. Ethanol also finds application in the making of paints, varnishes, perfumes, pharmaceuticals, industrial solvent etc.

Ethanol Production

Ethanol is obtained from crops or plants that have large amount of sugar or constituents that can be converted into sugar. Plants like sugarcane, sugar beets and molasses, corn, wheat, grains etc are ideal raw materials for ethanol production.Fermentation process is the most widely used method for producing ethanol. Synthetic ethanol is created from non-renewable sources like coal and gas.

Ethanol from molasses and other feedstock can be obtained by two methods- dry milling process and wet mill process. Approximately 90 percent of the grain ethanol comes from the dry milling process and the remaining 10 percent is produced from wet mills.

Dry Milling Processes includes the following processes:

● The crops or plants are grinded up for easier processing .

● The sugar present in the ground feedstock is dissolved

● Next the sugar is fermented with yeast to produce ethanol.

● The ethanol is then distilled and dehydrated to attain a higher concentration.

● Gasoline or other additive(denaturant) is then added to the product to make it suitable for further use.

Due to the growing popularity of ethanol applications, researches are being conducted to develop more advanced techniques for ethanol production.  So, in the days to come, we can look forward to more dynamic roles of ethanol.

Understanding Shell and Tube Heat Exchangers

Shell and tube heat exchangers are one of the most effective heat exchangers employed in various industries such as refineries and chemical industries. These process equipment are widely used in applications, which require cooling or heating a large volume of process fluids or gases. Shell and tube heat exchangers comprise a cylindrical shell with a large number of small tubes. The tubes are positioned into the cylinder using a tube bundle or "tube stack" which can either have fixed tube plates. The tubes are constructed using thermally conductive materials, which enable the exchange of heat between the hot fluids flowing outside the tubes and the coolant flowing through the tubes. These heat exchangers offer an optimal cooling solution in different fields such as Industrial, Hydraulic, Marine, Railways, etc.

Components of Shell & Tube Exchangers

The shell-and-tube heat exchanger is named for its two major components – round tubes & cylindrical shell. The shell cylinder can be fabricated from a rolled plate or from piping while the tubes are thin-walled tubing manufactured specifically to facilitate heat exchange.

● Tubes: The tubing may be seamless or welded. Tubing may consist of ‘Finns’ to provide more efficient heat transfer surface. Fins are commonly found on the outside of the tubes but are also available on the inside of the tubes. Tubes with a special surface, called high flux tubes, are used to enhance heat transfer on either or both sides of the tube wall.

● Tubesheets: Tubesheets are plates or forgings drilled to provide holes (triangular or square) for holding and inserting the tubes. Tubes are properly secured to the tube sheet to prevent the fluid on the shell side from mixing with the fluid on the tube side. The distance between the tube holes, measured from their centers, is called the tube pitch. Triangular pitch provides higher heat transfer and compactness while square pitch facilitates mechanical cleaning of the outside of the tubes.

● Baffles: Baffles are used for 3 reasons

○ To support the tubes

○ To maintain spacing between them

○ To direct the flow of fluid through the shell.

A segment, known as the baffle cut, is chipped in a way so as to permit the fluid to flow parallel to the tube axis as it flows from one baffle space to another.  The spacing between segmental baffles, called as the baffle pitch, along with the baffle cut, is used to determine the cross-flow velocity and hence the rate of heat transfer and the pressure drop.

● Tie Rods and Spacers - Tie rods and spacers are used to hold baffle assembly together & maintain the selected baffle spacing. The tie rods are secured at one end to the tube sheet and at the other end, holding the assembly together.

● Front Header: Also referred to as a stationary header, is the section from where the fluid enters the tube end of the exchanger.

● Rear Header: Is a section from where the fluid from the tube end leaves the exchanger or returns to the front header.

Working of Shell and tube heat exchanger

There are two fluids of different temperatures involved in the cooling operation, one - the process and the other - the cooling medium. The process fluid to be cooled is generally run through small diameter tubes that are housed within the shell. The outer shell, on the other hand, circulates the cooling medium. Both process and cooling fluid are kept in continuous circulation for the heat exchanger to function properly.

Applications of Shell and Tube Heat Exchangers

Shell and tube heat exchanger is used in various industrial applications due to their expertise in performing tasks such as:

● Cooling of hydraulic and lube oil

● Cooling of turbine, compressor, and engine

● Condensing process vapor or steam

● Evaporating process liquid or steam

Benefits of using Shell and tube exchangers

Shell & Tube Heat Exchangers are used in a number of industries such as refineries because of their advantages on other types of heat exchangers. Their benefits include

● Increased efficiency of heat transfer

● Easy to dismantle, clean and repair

● Compact in size

● Capacity can be increased simply by adding plates in pairs

● Affordable as compared to plate type coolers

● Can be used in systems with high operating temperatures and pressures

Praj industries - one of the leading Heat Exchanger Suppliers in the country, offers Critical Process Equipment & Systems to various process industries such as Oil & Gas, Refining, Petrochemicals, Fertilizers, Chemicals, Food, Pharma and Biotech. Praj also offers a range of static equipment like pressure vessels, reactors, shell and tube heat exchangers, distillation columns and other proprietary equipment as per the client design. 

WHAT IS ULTRAFILTRATION IN WASTEWATER TREATMENT PLANTS

Ultrafiltration devices are used to recycle and reuse water that practically consists of no solid contaminants. Suspended solids and solutes of high molecular weight are retained in the ‘retentate’, while water and low molecular weight solutes pass through the membrane in the permeate. The membranes are superfine having around 0.001 microns for filteringorganic and inorganic polymeric molecules and colloidal materials. It has a high tolerance to feed water quality upsets, is an absolute barrier, and improves water quality. In this type of filtration, the osmotic pressure difference is quite negligible across the surface of the membrane as the filtration is done for high molecular weight particles. This helps in achieving high flux rates without applying high pressure.

Flux rate is the number of permeate products that pass through the per unit area of membrane for a given time unit. This process is similar to reverse osmosis except that the liquid stream flows along the membrane surface tangentially, creating two streams. The stream which comes in contact with the membrane is called the ‘Permeate’. Permeation rate is affected by various factors such as quality of feed, characteristics of the membrane and the operating conditions. The other stream is called ‘Concentrate’ which gets dense further due to molecules and ions.

Where to use Ultrafiltration filters?

UltraFiltration equipment can be used to turn raw water into potable by removing particulates and macromolecules. These filters can effectively replace the existing industrial water treatment systems involving secondary and tertiary processes such as coagulation, flocculation, sedimentation, sand filtration, and chlorination generally employed in Effluent treatment plant. Ultrafiltration methods are favored over traditional treatment methods for the following reasons:

Reasons to use Ultrafiltration Units

• Compact plant size

• Exceeds regulatory water quality standards by achieving 90-100% pathogen removal.

• No chemicals involved during filtration except while cleaning

• Consistent quality regardless of feeds

The waster recycled from the UF units can be used for a number of industrial applications such as in boiler or cooling tower feed water supplementation, pH adjustment, washing equipment, fire protection, process rinse water or processing water for production lines in manufacturing industries, toilets, dust control, construction activities etc. Using recycled water saves a lot of energy and money by reducing freshwater water usage and wastewater treatment requirements.

Factors affecting the performance of UF

Velocity: The velocity of the flow across the surface of the membrane directly affects the permeate rate. Permeate rate is an important parameter in the case of high viscosity liquids such as suspensions and emulsions. The higher the flow the more the pumping required. Hence, in order to avoid loss of energy, it is required to restrict the velocity within the limits.

Pressure: The permeate rate is also affected by the pressure across the membrane. The structural limitations require the operating pressure to be kept at low especially for ultrafiltration using capillary technology. Higher pressures cause compaction and fouling.

Temperature: Another factor which affects the UF performance is the ambient temperature. The permeate rate increases with the increase in temperature.

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Zero Liquid Discharge System and Its Importance

Zero Liquid Discharge or ZLD is one of the industrial water treatment systems where all the contaminants are converted into solid waste while separating the water. This process helps to decrease the waste quantity & recover fresh water which can be reutilized. Although ZLD is a noble approach, it is not at all an easy process and requires a high investment of money & machinery. Extraction of water from waste means dealing with a higher concentration of salinity, scaling compounds, and organics, which means increased cost.  But there are various benefits of ZLD which makes it an optimum choice for an industrial facility.

Several methods of waste management are classified as zero liquid discharge, despite using different boundaries to define the point where the discharge occurs. Usually, a facility or site property line that houses the industrial process is considered the border or ‘boundary condition’ where wastewater must be treated, recycled, and converted to solids for disposal to achieve zero liquid discharge.

Certain facilities which send their liquid waste for off-site treatment, deep well disposal or incineration, consider this to be akin to zero liquid discharge. While this approach actually avoids discharge of liquids into surface water or sewers, it can significantly increase the cost.

Some designs describe themselves as near zero liquid discharge or minimal liquid discharge systems which do not completely eliminate complete waste but may be more economical than ZLD.

An optimum ZLD treatment system should be able to:

● manage fluctuations in waste contamination and flow

● support required chemical volumes adjustments

● recover about 95% of the liquid

● treat and retrieve valuable byproducts from your waste

● produce a dry, solid cake for disposal

What makes ZLD important

Undeniably, freshwater is a scarce yet important resource in the industrial processes. Reusing the water becomes highly beneficial and economical too. Not to mention additional benefits like less damage to the environment.  On a broader scale, heavy contamination of rivers and water bodies have forced the government to make regulatory reforms in wastewater treatment. The severe consequences of water pollution have led to the rise in consideration of methods like zero liquid discharge system to tackle the issue on a large scale. For example, The Gainesville Renewable Bioenergy plant which is expected to power 70,000 homes in Gainesville, required setup of a complete zero liquid discharge system before granting the permit. One more notable perk of considering zero liquid discharge is the scope to recover the lost resources from wastewater.