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Fermentation &
Distillation
3. ALCOHOLIC BEVERAGES:............................................................................................5
4. DISTILLED LIQUORS:.........................................................................................6
7. ALCOHOL YIELD.................................................................................................8
10. FERMENTATION............................................................................................................11
11. DISTILLERY....................................................................................................................13
12. DISTILLATION................................................................................................................14
13. EFFLUENT TREATMENT PLANT................................................................................15
14. CALCULATION OF COD...................................................................................18
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INTRODUCATION
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ALCOHOLIC BEVERAGES:
Alcoholic beverages vary considerably in their ethanol
content and in the foodstuffs from which they are produced. Most alcoholic beverages
can be broadly classified as fermented beverages, beverages made by the action of yeast
on sugary foodstuffs, or as distilled beverages, beverages whose preparation involves
concentrating the ethanol in fermented beverages by distillation. The ethanol content of a
beverage is usually measured in terms of the volume fraction of ethanol in the beverage,
expressed either as a percentage or in alcoholic proof units.
• Undistilled Beverages:
These are produced by fermentation process from fruit juice or
grains. The beverages prepared from grape juice are called wines. Wines contain 18-20%
alcohol and produced by natural fermentation are called “Natural wines”. Weak natural
wines are made stronger by addition of pure alcohol from outside and are named as
Fortified wines. e.g. beer, champaigne.
• Distilled Beverages:
If the fermented liquids are distilled, most of the alcohol along
with other volatile products like flavor, essential oils, esters and higher alcohol pass over
as distillate. The distiller liquors have a high alcohol content that may go up to 50% or
more. e.g. whisky, brandy, rum, gin etc.
It implies that pure brandy, whisky will be made strictly
from their raw materials, which are cherries, malt respectively. But in the case of
blended, some part of alcohol is supplied by genuine raw material while the rest is
supplied through the spirit manufactured. While in the case of essence, only the essence
of brandy or whisky is mixed in rectified spirit. This is usually cheap and low in quality.
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DISTILLED LIQUORS:
COUNTRY LIQUOR: - Single distilled spirit
FOREIGN LIQUOR: - Double distilled spirit
∗ Whisky:
Made from malt spirit (malt is the technical name of germinated and dried
barley), has 40-50% alcohol.
∗ Brandy:
Made from grapes, litchis, cherries, apple has 40-50%alcohol.
∗ Rum:
Made from molasses spirit has 45-55% alcohol.
∗ Gin:
Made from maize, barley has 40-45% alcohol.
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MANUFACTURE OF ALCOHOL
They are first treated to convert the starch or cellulose into the sugar’s that are then
fermented by yeast.
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ALCOHOL YIELD
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PRODUCTION OF ETHANOL BY FERMENTATION OF
SUGAR:
CHEMICAL REACTIONS:
invertase
C12H22O11 + H2O 2C6H12O6
invertase
C6H12O6 2C2H5OH + 2CO2
Side reaction
2C6H12O6 + H2O ROH + RCHO
(High mol. wt.)
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BY PRODUCTS OF ALCOHOL MANUFACTURE
ii) Fused oil: is a liquid with nauseating odour. It is used in confectionary and fruit
essences.
iv) Spent wash: the residual liquor from which ethyl alcohol has been removed by
distillation. It contains nitrogenous matter which can be used as manure and
fodder.
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FERMENTATION
It involves slow decomposition of big molecules of certain
organic compounds into simpler ones under the catalytic influence of non living complex
substances called ferments. The majority of process requires oxygen and is classified as
aerobic. A few processes carried out in the absence of oxygen are called anaerobic.
Fermentation is in two parts.
Part 1
Aerobic (Oxygen is present)
This is the initial rapid process where the yeast is doubling its colony size every 4 hours.
(Usually 24-48 hours)
Part 2
Anaerobic. (No oxygen present)
Slower activity and the yeast focus on converting sugar to alcohol rather that
increasing the number of yeast cells.
ALCOHOLIC FERMENTATION:
The chief ethanol producers are fungi especially strain of
Saccharomyces cerevisiae. The yeast respires aerobically but in the absence of air they
ferment carbohydrates to ethanol and CO2. The by-product, CO2, bubbles through the
liquid and dissipates into the air. The other by-product alcohol, remains in the liquid
which is great for us but not for the yeast, as the yeast dies when the alcohol exceeds its
tolerance level.
The fermentation process has other limits such as
temperature. Greater than 27C kills the yeast less and than 15C results in yeast activity
which is too slow.
The conversion of glucose to ethanol can be represented as:
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The ability of yeast cells to convert sugar into Carbon
dioxide and Alcohol is down to enzymes. Several enzymes are involved each does its
step in the process. The final step is Zymase reduction which takes the end product of the
other enzymes (acetaldehyde/glycerol), and turns this into good old ethyl alcohol. Sadly
alcohol actually destroys enzymes and kills the yeast cell if in high concentrations. This
happens at different levels for different strains of yeast.. Brewers yeast cannot withstand
much beyond 5 or 6% Alcohol by volume. Wine yeast is more tolerant at a range of 10-
15%. Specially cultured strains of yeast with the correct environment can withstand
alcohol levels up to 21% alcohol.
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DISTILLERY
1) Potable is prepared from raw material containing sugar. Firstly the alcohol is
produced from raw material and then liquor is prepared from alcohol.
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DISTILLATION
Distillation is the process of separation of two miscible
volatile liquids by vaporization, given that both the liquids exist in both the phases.
Distillation of raw alcoholic brews concentrates the alcohol and leaves behind many
chemicals that are not volatile at distillation temperatures
In practices distillation can be carried out by either of two
principle methods. The liquid mixture to be separated and condensing the vapor without
allowing any liquid to return to the still, and then there be no reflux.
The second method is based on the return of the part of the
condense to the still under such conditioned that this returning liquid is brought into the
condenser. Either of these methods can be conducted as a continuous or batch process.
Distillation unit consist of an analyzer (23 plates), aldehyde column and rectifier (56
plates).
The analyzer and the rectifier are connected via the 13th
plate called the adjust plate. In the rectifier section the heat is provided from the bottom
to the condenser heat exchange takes place between the vapors entering the water
flowing through condenser.
PROCESS DESCRIPTION:
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EFFLUENT TREATMENT PLANT
The main raw material of distillery molasses and when it is
distilled after fermentation to get alcohol, produce large quantity of liquid effluent called
“spent wash”. This spent wash contains organic matter in the effluent is therefore
required to be remove so that it can be discharged safely into the environment.
In the effluent treatment plant, set up by Mohan
Meakin ltd in March 1988, the treatment of the effluent takes place in the following
steps:
1. Anaerobic treatment i.e., biogas generation, two stage
2. Aerobic treatment i.e., secondary treatment
3. Clarification unit with chemical treatment
4. Second stage aeration unit with chemical treatment
5. Sludge decanter machine
6. Clarification by two methane separator clarifier
7. Ferti irrigation in the zeal of zero discharge
8. Fountain with atomization technique
9. Flocculation unit with R.C.C. clarifier for chemical treatment
10. Recycling of treated trade effluent for cooling purpose
Spent wash rich in organic matter from the distillery
having a temperature of 100-1020C, is cooled through heat exchangers to bring the
required temperature of 400C. This effluent is fed into METHANE REACTOR. Methane
reactor is the heart of effluent treatment plant. The biological process which includes the
degradation of higher organic compounds and reduction of BOD take place in this zone.
The methane (8, 000-9,000 NM 3/day) is recovered as a by product during the course of
BOD reduction. The methane reactor has been designed for 90% reduction in BOD.
The overflow of the methane digester is sent to the
anaerobic filter clarifiers and then to aeration basin having 3 surface aerators of 50 HP
each, to provide sufficient oxygen for the growth of aerobic bacteria responsible for
further decomposition of pollutants. The effluent of the brewery directly comes to
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aeration basin along with the anaerobic stream. This basin has been designed for 90%
reduction in BOD.
Effluent is then sent to clarifier where the sludge is
separated and dewatered through sludge decanter machine previously, sludge was been
dried by press deg dewatering machine and sludge drying beds. A part of sludge as
required is recirculated to the aeration basin. Separated sludge is used as manure in the
lawns and agricultural farms. The overflow effluent from the secondary clarifier is
further taken to the secondary stage aeration unit and clarifiers for further reduction of
the BOD value.
In this, chemical treatment is also added for the further
reduction in BOD value. The supernatant treatment trade effluent coming out from
methane separator clarifiers is partially sent to the fountain having an atomization
technique fro more natural aeration and it is used for ferti irrigation partially.
The F.L.D. and brewery bottle washing water of low BOD
value is mixed in second stage aeration for treatment with the help of chemicals, i.e.,
flocculants and polyelectrolyte.
The treated trade effluent thus coming out from the
clarifiers or flocculation unit is taken into the cooling tower and used for cooling purpose
in distillery condenser before being discharged. Ultimately treated effluent being
discharged top river Gomti is within the norms (i.e., 30pm) values led down by the
pollution control board.
Not only this, Mohan Meakins has a substantial saving of
coal in the form of biogas and reduced the coal consumption which is in the tune of 85-
90%.
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P.I Diagram of E.T. Plant
2
Vat Washing, 1 4 6
Distillery & Vat 3
washing brewery
Secondary treatment i.e. two stages
Bottle Washing of I.M.F.L
Anaerobic treatment i.e. two
stage followed by ClarifierBottle Washing of Country Liquor
Bottling
15 14
12 10 9 8
11
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CALCULATION OF COD
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ENVIRONMENTAL SIGNIFICANCE OF DO
CALCULATING DO
COLLECTION OF SAMPLE - entry of air should be avoided.
STANDARED REAGENTS FOR MEASURING DO-
Reducing agent used is 0.025N sodium thiosulphate.
Starch solution determines end point.
Standard reagent used is iodine.
End point-blue turns colorless.
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EXPERIMENTAL DETAILS
Sugar testing:
In sugar testing two things are find out:
1) Brix:
It is the percentage of molasses solution in water by weight. Normally
available molasses has a brix is briolette. it consists of two parts, the upper part is
used to find brix, the bottom part gives the temperature, which is thus used to find
the correction to brix.
100gm molasses
900ml water
Mix
Check brix
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2) Total reducing sugar (TRS)
100gm molasses
900ml water
Mix
Check brix
Boil to 70oC
Cool
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BOTTLING UNIT
Rectified spirit
Filtration
Sealing
Packaging in cartons
Transportation unit
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