Plant Design for Production of 200 TPD Ethanol

from Organic Waste

A
Major PROJECT REPORT
Submitted by:
Hemant Khinchi
Kishore Kumar
Lokesh Mahala
INTEGRATED DUAL DEGREE
IN
PROCESS ENGINEERING WITH M.B.A.

Under the guidance

Of
Dr. Abhijit Maiti
(Assistant Professor)
Department of Polymer and Process Engineering

DEPT. OF POLYMER AND PROCESS ENGINEERING

INDIAN INSTITUTE OF TECHNOLOGY ROORKEE
SAHARANPUR CAMPUS
SAHARANPUR-247001, INDIA

pg. 1
 INDIAN INSTITUTE OF TECHNOLOGY ROORKEE
ROORKEE

CERTIFICATE

This is to certify that this project report entitled Plant Design for
Production of 200 TPD Ethanol from Organic Waste is submitted by
B.Tech 4th year students Hemant Khinchi, Kishore Kumar and Lokesh
Mahala who carried out the project work under my supervision. I approve
phase I of this project for submission of the Integrated Dual Degree in the
Department of Polymer and Process Engineering, Indian Institute of
Technology Roorkee, Roorkee.

Dr. Abhijit Maiti

(Project Supervisor)

pg. 2
Contents Page No.
1. Abstract 1
2. Introduction 2
3. Waste Segregation 7
Segregation of Organic Waste at Source
Storage of Organic Waste at Source
Storage of Yard Waste or Garden Waste
Collection and Transportation
Collection, Transportation and Disposal of Vegetable Market Waste
Current technique used for reducing municipal solid waste in India

4. Ethanol Production from Household Waste 16

Raw Material
Composition of Household Food Waste

5. Ethanol Production from Agricultural Waste 19

Raw Material
Chemical Composition of Agricultural Wastes

6. Pretreatment for Organic Waste 22

Physical Pretreatment
Physicochemical Pretreatment
Chemical Pretreatment
Biological Pretreatment

7. Fermentation of the Solid Residue 30

8. Hydrolysis Section 34

9. Enzymatic Hydrolysis 35
10. Fermentation 36
11. Plant Layout Draft 37
12. Reference 39

pg. 3
Abstract
Due to rapid growth in population and industrialization, worldwide ethanol demand
is increasing continuously. Conventional crops such as corn and sugarcane are
unable to meet the global demand of bioethanol production due to their primary
value of food and feed. Therefore, other options such as wood and household organic
waste as well as lignocellulosic substances such as agricultural wastes are most
sought after feedstocks for bioethanol production. These wastes are cost effective,
renewable and abundant. Bioethanol from these wastes could be a promising
technology though the process has several challenges and limitations such as
biomass transport and handling, and efficient pretreatment methods. Proper
pretreatment methods can increase concentrations of fermentable sugars after
enzymatic saccharification, thereby improving the efficiency of the whole process.
Conversion of glucose as well as xylose to ethanol needs some new fermentation
technologies, to make the whole process cost effective.
In this study, most efficient production method for bioethanol are discussed and a
layout for the plant design for bioethanol production is provided.

pg. 4
Introduction
The worlds present economy is highly dependent on various fossil energy sources
such as oil, coal, natural gas, etc. These are being used to produce fuel, electricity
and other goods. Excessive consumption of fossil fuels, particularly in large urban
areas, has resulted in generation of high levels of pollution during the last few
decades. The level of greenhouse gasses in the earths atmosphere has drastically
increased. With the expansion of human population and increase of industrial
prosperity, global energy consumption also has increased gradually. Import of
transport fuel is affected by limited reserves of fossil fuel. Annual global oil
production will begin to decline within the near future. In this scenario, renewable
sources might serve as an alternative. Wind, water, sun, biomass, geothermal heat
can be the renewable sources for the energy industry whereas fuel production and
the chemical industry may depend on biomass as an alternative source in the near
future. All petroleum-based fuels can be replaced by renewable biomass fuels such
as bioethanol, bio-diesel, bio-hydrogen, etc., derived from sugarcane, corn,
switchgrass, algae, etc. Requirements of electricity may be supplied by solar- and
wind-farms. The energy consumption rate includes each persons share of
electricity and fuel used in making foods and goods and their transport.
Countries across the globe have considered and directed state policies toward the
increased and economic utilization of biomass for meeting their future energy
demands to meet carbon dioxide reduction targets as specified in the Kyoto Protocol
as well as to decrease reliance and dependence on the supply of fossil fuels. Although
biomass can be a huge source of transport fuels such as bioethanol, biomass is
commonly used to generate both power and heat, generally through combustion.
Ethanol is at present the most widely used liquid biofuel for motor vehicles. The
importance of ethanol is increasing due to several reasons such as global warming
and climate change. Bioethanol has been receiving widespread interest at the
international, national and regional levels. The global market for bioethanol has
entered a phase of rapid, transitional growth. Many countries around the world are
shifting their focus toward renewable sources for power production because of
depleting crude oil reserves. The trend is extending to transport fuel as well. Ethanol
has potential as a valuable replacement of gasoline in the transport fuel market.
However, the cost of bioethanol production is more compared to fossil fuels. The

pg. 5
world bioethanol production in 2001 was 31 billion liters. It has grown to 39 billion
liters in 2006 and is expected to reach 100 billion liters in 2015. Brazil and the USA
are the two major ethanol producers accounting for 62% of the world production.
Large scale production of fuel ethanol is mainly based on sucrose from sugarcane in
Brazil or starch, mainly from corn, in the USA. Current ethanol production based on
corn, starch and sugar substances may not be desirable due to their food and feed
value. The green gold fuel from lignocellulosic wastes avoids the existing
competition of food versus fuel caused by grain based bioethanol production. It has
been estimated that 442 billion liters of bioethanol can be produced from
lignocellulosic biomass and that total crop residues and wasted crops can produce
491 billion liters of bioethanol per year, about 16 times higher than the actual world
bioethanol production. Lignocellulosic materials are renewable, low cost and are
abundantly available. It includes crop residues, grasses, sawdust, wood chips, etc.
Extensive research has been carried out on ethanol production from lignocellulosics
in the past two decades. Hence bioethanol production could be the route to the
effective utilization of agricultural wastes. Rice straw, wheat straw, corn straw, and
sugarcane bagasse are the major agricultural wastes in terms of quantity of biomass
available.

pg. 6
Waste Segregation
Segregation include sorting and separate storage of various components of solid
waste namely biodegradable wastes including agriculture and dairy waste, non-
biodegradable wastes including recyclable waste, non- recyclable combustible
waste, sanitary waste and non-recyclable inert waste, domestic hazardous wastes,
and construction and demolition wastes.
Segregating waste at source ensures that waste is less contaminated and can be
collected and transported for further processing. Segregation of waste also optimizes
waste processing and treatment technologies. It results in high proportion of
segregated material that could be reused and recycled, leading to less consumption
of virgin material.
segregate and store the waste generated by them in three separate streams namely
bio-degradable, non-bio-degradable and domestic hazardous wastes in suitable bins
and handover segregated wastes to authorized waste pickers or waste collectors as
per the direction or notification by the local authorities from time to time.
store horticulture waste and garden waste generated from his premises separately in
his own premises and dispose of as per the directions of the local body from time to
time.

google image for segregation

pg. 7
Segregation of Organic Waste at Source
a. Segregate and store the waste generated by them in three separate streams
namely bio-degradable, non -biodegradable and domestic hazardous wastes
in suitable bins and handover segregated wastes to authorized waste pickers
or waste collectors as per the direction or notification by the local authorities
from time to time.
b. Wrap securely the used sanitary waste like diapers, sanitary pads etc., in the
pouches provided by the manufacturers or brand owners of these products or
in a suitable wrapping material as instructed by the local authorities and shall
place the same in the bin meant for dry waste or non- bio-degradable waste.
c. Manufacturers or brand owners or marketing companies of sanitary napkins
and diapers shall explore the possibility of using all recyclable materials in
their products or they shall provide a pouch or wrapper for disposal of each
napkin or diapers along with the packet of their sanitary products.
The local community should be educated and encouraged to perform the following
actions to ensure collection of segregated waste:
At the household level, MSW should be segregated into wet, dry, and
domestic hazardous waste fractions, at a minimum, and stored in separate
containers.
Waste should be placed at the doorstep before the appointed time of
collection.
Domestic hazardous waste (e.g., batteries; used CFLs; tube lights; chemical,
paint, and insecticide containers; etc.) should be handed over separately to the
waste collectors or at the domestic hazardous waste deposition centers for safe
disposal as specified by the municipal authority or through the relevant retail
trade (e.g., for batteries).
Sanitary waste (e.g., diapers, sanitary napkins, tampons, incontinence sheets
and any other similar waste) should be wrapped securely in the pouches and
handed over separately to the waste collectors on a daily basis. Upon
collection of sanitary waste, it is should be preferably disposed in biomedical
or MSW incinerators, as applicable to the local context or as directed by the
SPCB.

pg. 8
 Basic segregation
Wet Dry waste Hazardous
waste waste
Food wastes Paper cardboard Containers & Rags Rubber Metals Glass E-waste
of all kinds, and cartons packaging of all Wood (all kinds) Hazardous
cooked and kinds excluding Discarded Inerts House waste
uncooked, those containing clothing sweepings Household
including hazardous Furniture and inerts medical waste
eggshells and materials (not garden, +Batteries
bones, Compound yard or street from
flower, fruit packaging sweepings) flashlights and
and waste (tetrapak, button cells.
including blisters etc.) Lights bulbs,
juice, Plastics tube lights and
vegetable Compact
peels and Fluorescent
household Lamps (CFL)
garden/plant Car batteries,
wastes. oil filters and
Soiled car care
tissues, food products and
wrappers, consumables
paper towels;
fish and meat
Adapted from Manual on Municipal Solid Waste Management (First Edition), Central Public Health and Environmental Engineering Organization
(CPHEEO), 2000, Ministry of Urban Development.

Segregation transportation image from google

pg. 9
Storage of Organic Waste at Source
At the household level, dry waste, wet waste, and domestic hazardous waste should
be stored in separate garbage bins, of appropriate capacity and colour (Figure 2.3).
The colour of the garbage bins should be in accordance with the SWM Rules, 2016;
wet waste is to be placed in a covered green bin and dry waste in a covered white
bin. Because the rule does not specify the colour of the bins for storage of domestic
hazardous waste, urban local bodies (ULBs) should decide on an appropriately
coloured bin. For example, Coimbatore City Municipal Corporation uses red bins
for collection of domestic hazardous waste. Capacity of bins depends on frequency
of collection (daily, alternate day, or on demand) and quantity of waste generated.
A container of 1215l (0.015 m3 ) capacity for a family of five members should be
adequate for each dry and wet waste, if collection takes place daily. However, a
household may keep larger containers or more than one container for waste produced
in 24 hours, having a spare capacity of 100% to meet unforeseen delays in clearance
or unforeseen extra loads. If dry waste is not collected daily, container capacity has
to be enlarged accordingly. Wet waste collection bins should be washed by the
household each time they are emptied. It is not desirable to use plastic bags in waste
bins.

pg. 10
Storage of Yard Waste or Garden Waste
The SWM Rules, 2016 suggests that horticulture waste from parks and gardens
should be collected separately and treated on-site to make optimum use of such
wastes and also to minimize the cost of its collection and transportation. In large
cities, the municipal authority may provide large containers for storage of waste or
facilitate provision of large containers through private sector participation. In small
cities, such waste may be stored on-site and the municipal authority may facilitate
its periodic collection, either through the SWM department or by involving the
private sector. The skip bins or containers shall be of a standard design and amenable
to automatic hydraulic lifting and unloading by a transport vehicle. This waste
should not be mixed with domestic waste.

pg. 11
Collection and Transportation
Arrange for door to door collection of segregated solid waste from all
households including slums and informal settlements, commercial,
institutional and other non-residential premises. From multi-storage
buildings, large commercial complexes, malls, housing complexes, etc., this
may be collected from the entry gate or any other designated location.
Setup material recovery facilities or secondary storage facilities with
sufficient space for sorting of recyclable materials to enable informal or
authorised waste pickers and waste collectors to separate recyclables from the
waste and provide easy access to waste pickers and recyclers for collection of
segregated recyclable waste such as paper, plastic, metal, glass, textile from
the source of generation or from material recovery facilities; Bins for storage
of bio-degradable wastes shall be painted green, those for storage of
recyclable wastes shall be printed white and those for storage of other wastes
shall be printed black.
Ensure safe storage and transportation of the domestic hazardous waste to the
hazardous waste disposal facility or as may be directed by the State Pollution
Control Board or the Pollution Control Committee.
Collect waste from vegetable, fruit, flower, meat, poultry and fish market on
day to day basis and promote setting up of decentralised 156 Manual on
Municipal Solid Waste Management compost plant or biomethanation plant
at suitable locations in the markets or in the vicinity of markets ensuring
hygienic conditions.
Collect separately waste from sweeping of streets, lanes and by-lanes daily,
or on alternate days or twice a week depending on the density of population,
commercial activity and local situation.
Transport segregated bio-degradable waste to the processing facilities like
compost plant, biomethanation plant or any such facility. Preference shall be
given for on site processing of such waste.

pg. 12
Collection, Transportation and Disposal of Vegetable
Market Waste

Waste from vegetable market

PRIMARY COLLECTION
AND TRANSPORTATION

Biodegradable Non-biodegradable
Others
waste waste

SECONDARY COLLECTION
Metal dumper
AND TRANSPORTATION Metal dumper Metal dumper
bin (black)
bin (green) bin (white)

Dumper placer Dumper placer

Dumper placer
Compactors Skip loader
Compactors
PROCESSING SITE Refuse collector
Hook loader Hook loader
tractor

Processing plant
Composting
(RDF/WTE)

DISPOSAL SITE

Residue from processing plant

(not to exceed 15% of waste
delivered at processing facility)
and further to be reduced to
less than 5% within the
stipulated time frame. Inert
waste to be disposed at landfill

pg. 13
Current technique used for reducing municipal
solid waste in India
Incineration
Incineration is a waste treatment process that involves combustion of waste at
very high temperatures in the presence of oxygen and results in the production
of ash, flue gas, and heat. Incineration is a feasible technology for combustion
of unprocessed or minimum processed refuse and for the segregated fraction
of high calorific value waste.

The potential for energy generation depends on the composition, density,

moisture content, and presence of inert in the waste. In practice, about 65%
80 % of the energy content of the organic matter can be recovered as heat
energy, which can be utilised either for direct thermal applications or for
producing power via steam turbine generators.

Incineration is especially relevant for the dry bin content in a two-bin system.
For unsegregated waste, pre-treatment is necessary.

The supply of waste should be stable and amount to at least 500 TPD of
segregated waste.

The success of waste incineration projects depends entirely on incoming

waste feed characteristics and quantity.

Minimum gas phase combustion temperature of 850C and a minimum

residence time of the flue gases, above this temperature, of two seconds after
the last incineration air supply.

Optimum oxygen content (lower than 6%) should be maintained to minimise

corrosion and ensure complete combustion. The carbon monoxide content of
the flue gas is a key indicator of the quality of combustion.

pg. 14
Landfilling
A landfill site is a site for the disposal of waste materials by burial and is the oldest
form of waste treatment. Historically, landfills have been the most common method
of organized waste disposal and remain so in many places around the world.
Allow only the non-usable, non-recyclable, non-biodegradable, non-combustible
and non-reactive inert waste and pre-processing rejects and residues from waste
processing facilities to go to sanitary landfill and the sanitary landfill sites shall meet
the specifications as given in however, every effort shall be made to recycle or reuse
the rejects to achieve the desired objective of zero waste going to landfill.

pg. 15
Ethanol Production from Household Waste
Raw Material
Utilization of house food waste as raw material represents a great challenge, as both
the collection of generated house food waste from multiple places and post-
collection treatment are difficult processes. Moisture and soluble sugars can make
house food waste an easy target for microorganisms, leading to their severe
degradation. Another challenge is the heterogeneity that house food waste present,
which is highly affected by the source from which the wastes are derived. Nutritional
habits and season of collection can also affect the composition of the house food
waste. Generally, fruits and vegetables represent a significant portion of the waste.
Finally, one important issue to be solved is the proper education of the public to
achieve low presence of contaminants (for example, plastics, metal et cetera) during
source separation of house food waste.

Composition of Household Food Waste

Fraction %w/w
Soluble 33.81
Glucose 4.39
Fructose 3.47
Sucrose 4.38
Sugar 12.54
Protein 0.54
Fats 11.91
Crude protein 10.51
Cellulose 18.3
Hemicellulose 7.55
Ash 11.03
Utilization of household food waste for the production of ethanol at high dry material content
Author :- Leonidas Matsakas,Dimitris Kekos,Maria Loizidou and Paul Christakopoulos
Matsakas et al.; licensee BioMed Central Ltd. 2014

pg. 16
 Ethanol Production from Household Waste

household waste Hydrolyzer

Pretreatment

Boiler
Water Tray dryer
reservoir

Water treatment plant Fermentation

Ethanol De-hydrolysis Distillation

pg. 17
 Ethanol Production from Agricultural Waste

Raw Material
The four major agro wastes are the most favorable feedstocks for bioethanol
production due to their availability throughout the year. Asia is the major
producer of rice straw and wheat straw, whereas corn straw. They also vary
in chemical composition, cellulose being the major component.

These agro-residues are also utilized as animal fodder, as domestic fuel, and
as fuel to run boilers. The utilization fraction of wheat straw, rice straw and
corn straw is too low and varies with geographic region. Each year a large
portion of agricultural residues is disposed of as waste. For instance,
approximately 600e900 million tons per year rice straw is produced globally.
The options for the disposal of rice straw are limited by the great bulk of
material, slow degradation in the soil, harboring of rice stem diseases, and
high mineral content. Only a small portion of globally produced rice straw is
used as animal feed, the rest is removed from the field by burning, a common
practice all over the world, increasing air pollution and affecting human
health.

Quantities of Agricultural Waste (million tons) for

Bioethanol Production

Agro waste Asia

Rice straw 667.6
Wheat straw 145.2
Corn straw 33.9
Bagasse 74.88

Bioethanol production from agricultural wastes: An overview

Author:-Nibedita Sarkar, Sumanta Kumar Ghosh, Satarupa Bannerjee, Kaustav Aikat*
Department of Biotechnology, National Institute of Technology, Durgapur 713209, West Bengal, India
journal homepage: www.elsevier.com/locate/renene

pg. 18
 Lignocellulose is a complex carbohydrate polymer of cellulose, hemicellulose
and lignin. Cellulose is linear and crystalline. It is a homopolymer of repeating
sugar units of glucose linked by b-1,4 glycosidic bonds. Hemicellulose is a
short and highly branched polymer. It is a heteropolymer of D-xylose, D-
arabinose, D-glucose, D-galactose, and D-mannose. Lignin is hydrophobic in
nature and is tightly bound to these two carbohydrate polymers. It thus
protects these polymers from microbial attack. It is a three-dimen-
sional aromatic polymer of p, hydroxyphenylpropanoid units connected by
CeC and CeOeC links. Sugar compositions of various agrowastes (rice straw,
wheat straw, corn straw, bagasse).

Lignocellulosics are processed for bioethanol production through three major

operations: pretreatment for delignification is necessary to liberate cellulose
and hemicellulose before hydrolysis; hydrolysis of cellulose and
hemicellulose to produce fermentable sugars including glucose, xylose,
arabinose, galactose, mannose and fermentation of reducing sugars. The non-
carbohydrate components of lignin also have value added applications.

Chemical Composition of Agricultural Wastes

Substrat Cellulose( Hemicellulose( Lignin(% Protein(% Ash(%

e %) %) ) ) )
Rice 32-47 19-27 5-24 - 12.4
straw
Wheat 35-45 20-30 8-15 3.1 10.1
straw
Corn 42.6 21.3 8.2 5.1 4.3
straw
Bagasse 65(total carbohydrate) 18.4 3 2.4

Bioethanol production from agricultural wastes: An overview

Author:-Nibedita Sarkar, Sumanta Kumar Ghosh, Satarupa Bannerjee, Kaustav Aikat*
Department of Biotechnology, National Institute of Technology, Durgapur 713209, West Bengal, India
journal homepage: www.elsevier.com/locate/renene

pg. 19
Ethanol Production from Agricultural Waste

Agricultural Pretreatment hydrolysis

waste

Acid Enzymatic

Concentrated acid Dilute acid

Fermentation

Bioethanol Distillation

pg. 20
 Pretreatment for Organic Waste
The most important processing challenge in the production of biofuel is
pretreatment of the biomass. Lignocellulosic biomass is composed of three
main constituents namely hemicellulose, lignin and cellulose. Pretreatment
methods refer to the solubilization and separation of one or more of these
components of biomass. It makes the remaining solid biomass more accessible
to further chemical or biological treatment. The lignocellulosic complex is
made up of a matrix of cellulose and lignin bound by hemicellulose chains.
The pretreatment is done to break the matrix to reduce the degree of
crystallinity of the cellulose and increase the fraction of amorphous cellulose,
the most suitable form for enzymatic attack. Pretreatment is undertaken to
bring about a change in the macroscopic and microscopic size and structure
of biomass as well as submicroscopic structure and chemical composition. It
makes the lignocellulosic biomass susceptible to quick hydrolysis with
increased yields of monomeric sugars.

Goals of an effective pretreatment process are:

(i) formation of sugars directly or subsequently by hydrolysis
(ii) to avoid loss and/or degradation of sugars formed
(iii) to limit formation of inhibitory products
(iv) to reduce energy demands and
(v) to minimize costs. Physical, chemical, physicochemical and biological
treatments are the four fundamental types of pretreatment techniques
employed. In general, a combination of these processes is used in the
pretreatment step.

pg. 21
Physical Pretreatment
Mechanical size reduction:
The first step for ethanol production from agricultural solid
wastes is comminution through milling, grinding or chipping. This reduces
cellulose crystallinity and improves the efficiency of downstream processing.
Wet milling, dry milling, vibratory ball milling and compression milling are
usually done. The power input for mechanical comminution of agricultural
materials depends on the initial and final particle sizes, moisture content and
on the nature of waste (hardwood, softwood, fibrous, etc) being handled. Size
reduction may provide better results but very fine particle size may impose
negative effects on the subsequent processing such as pretreatment and
enzymatic hydrolysis. It may generate clumps during the subsequent steps
involving liquid and may lead to channeling. Specific energy consumption
also increases. The specific energy consumptions for grinding wheat straw
with hammer mill screen sizes of 0.8 and 3.2 mm were 51.6 and 11.4 kW h
t_1, respectively. It is advisable to use hammer mill or ball mill for hardwood
and cutter mill for softwood. Ball milling (BM) and wet disk milling (WDM)
are other processes which can be used for comminution.

Pyrolysis:
Pyrolysis is an endothermic process where less input
of energy is required. In this process the materials are treated at a
temperature greater than 300 C, whereby cellulose rapidly
decomposes to produce gaseous products such as H2 and CO and
residual char. The decomposition is much slower and less volatile
products are formed at lower temperatures. The residual char is
further treated by leaching with water or with mild acid. The water
leachate contains enough carbon source to support microbial growth
for bioethanol production. Glucose is the main component of water

pg. 22
 leachate. An average of 55% of total weight of biomass is lost during
water leaching. Fan et al. have shown 80e85% conversion of
cellulose to reducing sugars with more than 50% glucose through
mild acid leaching (1 N H2SO4, 95 C, 1 h).

Microwave oven and electron beam irradiation

pretreatment:
Pretreatment of lignocellulosic biomass in a microwave
oven is also a feasible method which uses the high heating efficiency
of a microwave oven and it is also easy to operate. Microwave
treatment utilizes thermal and non-thermal effects generated by
microwaves in aqueous environments. In the thermal method,
internal heat is generated in the biomass by microwave radiation,
resulting from the vibrations of the polar bonds in the biomass and
the surrounding aqueous medium. Thus a hot spot is created within
the inhomogeneous material. This unique heating feature results in
an explosion effect among the particles and improves the disruption
of recalcitrant structures of lignocellulose. Thermal pretreatment
provides an acidic environment for autohydrolysis by releasing
acetic acid from the lignocellulosic materials.

Physicochemical Pretreatment:

Steam explosion or autohydrolysis:

Steam explosion is a promising method of pretreatment
which makes biomass more accessible to cellulase attack.
This method of pretreatment without the use of any catalyst
is promising and the biomass fractionates to yield levulinic
acid, xylitol and alcohols. In this method the biomass is
heated using high-pressure steam (20e50 bar, 160e290 C) for
a few minutes; the reaction is then stopped by sudden

pg. 23
 decompression to atmospheric pressure. When steam is
allowed to expand within the lignocellulosic matrix it
separates the individual fibers. The high recovery of xylose
(45e65%) makes steam-explosion pretreatment
economically attractive.

Liquid hot water method:

The liquid hot water method uses compressed hot liquid
water (at pressure above saturation point) to hydrolyze the
hemicellulose. It is a hydrothermal pretreatment method
which releases high fraction of hemicellulosic sugars in the
form of oligomers. The treatment generally occurs at
temperatures of 170e230 C and pressures above 5 MPa for
20 min. It, however, also contributes to the production of
small amounts of undesired degrading compounds such as
furfural, carboxylic acid, that are very toxic to ethanol
fermentation as they inhibit microbial growth. As xylose
recovery is relatively high (88e98%), and no acid or
chemical is required, it is an environmentally attractive and
economically interesting method. Yu et al. studied two step
liquid hot water treatment of Eucalyptus grandis and
obtained a xylose recovery of 86.4%. Maximal glucose yield
of 70e76% corresponding to 80% of xylan removal from
soybean straw was obtained through combined liquid hot
water and alkaline treatments.

Ammonia fiber explosion:

Ammonia fiber explosion (AFEX) pretreatment involves

liquid ammonia and steam explosion [21]. AFEX is an
alkaline thermal pretreatment which exposes the

pg. 24
 lignocellulosic materials by high temperature and
pressure treatment followed by rapid pressure release.
This method does not produce inhibitors of the
downstream processes and small particle size is not
required for efficacy. This pretreatment has the drawbacks
of being less efficient for biomass containing higher
lignin contents (e.g. softwood newspaper) as well as of
causing solubilization of only a very small fraction of
solid material particularly hemicellulose [28,29]. The
advantages are that it is simple and has a short process
time. It is more effective for the treatment of substrates
with less content of lignin compared to sugarcane. This
system does not directly liberate any sugars, but allows
the polymers (hemicellulose and cellulose) to be attacked
enzymatically which break down to sugars.

CO2 explosion:
CO2 explosion acts in a manner similar to that of the
steam and ammonia explosion techniques. However, CO2
explosion is more cost effective than ammonia explosion
and does not cause the formation of inhibitors as in steam
explosion. Conversion yields are higher compared to the
steam explosion method.

pg. 25
Chemical Pretreatment
Acid pretreatment: Acid pretreatment is considered as one of the
most important techniques and aims for high yields of sugars from
lignocellulosics. It is usually carried out by concentrated or diluted
acids (usually between 0.2% and 2.5% w/w) at temperatures
between 130 C and 210 C. Sulfuric acid is widely used for acid
pretreatment among various types of acid such as hydrochloric
acid, nitric acid and phosphoric acid. Acid pretreatment can utilize
either dilute or concentrated acids to improve cellulose hydrolysis.
The acid medium attacks the polysaccharides, especially
hemicelluloses which are easier to hydrolyze than cellulose.
However, acid pretreatment results in the production of various
inhibitors like acetic acid, furfural and 5 hydroxymethylfurfural.
These products are growth inhibitors of microorganisms.
Hydrolysates to be used for fermentation therefore need to be
detoxified. Moiser et al. reported higher hydrolysis yield from
lignocellulose pretreated with diluted H2SO4 compared to other
acids. A scarification yield of 74% was obtained from wheat straw
when subjected to 0.75% v/v of H2SO4 at 121 C for 1 h.

Alkaline pretreatment: Alkaline pretreatment of lignocellulosics

digests the lignin matrix and makes cellulose and hemicellulose
available for enzymatic degradation. Alkali treatment of
lignocellulose disrupts the cell wall by dissolving hemicelluloses,
lignin, and silica, by hydrolyzing uronic and acetic esters, and by
swelling cellulose. Crystallinity of cellulose is decreased due to
swelling. By this process, the substrates can be fractionated into
alkali-soluble lignin, hemicelluloses and residue, which makes it
easy to utilize them for more valuable products. The end residue
(mainly cellulose) can be used to produce either paper or cellulose

pg. 26
 derivatives. Hydroxides of sodium, potassium, calcium and
ammonium are used in this process. Alkaline pretreatment
processes utilize lower temperatures and pressures than other
pretreatment technologies. Sun et al. studied the effectiveness of
different alkaline solutions by analyzing the delignification and
dissolution of hemicellulose in wheat straw. They found that the
optimal process condition was that using 1.5% NaOH for 144 h at
20 C, releasing 60% and 80% lignin and hemicellulose
respectively. NaOH has been reported to increase hardwood
digestibility from 14% to 55% by reducing lignin content from 24-
55% to 20%.

Wet oxidation: In wet oxidation, the feedstock material is treated

with water and either by air or oxygen at temperatures above 120
C. The water is added to the biomass at a ratio of 1 L per 6 g of
biomass. The transfer of hemicelluloses from solid phase to the
liquid phase is promoted in this technique. It does not hydrolyze
the liberated hemicellulose molecules. The products of
hemicellulose hydrolysis during wet oxidation are sugar
oligomers. There have been several studies on wet oxidation as a
pretreatment strategy using different substrates. Pedarson et
al.obtained yields of 400 and 200 g/kg of wet oxidation treated
wheat straw for glucose and xylose respectively after 24 h at 50 C
using an enzyme mixture of 36 FPU/g celluclaste1.5 L and 37
CBU/g of Novozyme-188.

pg. 27
Biological Pretreatment
Degradation of the lignocellulosic complex to liberate cellulose can be brought
about with the help of microorganisms like brown rot, white rot and soft rot fungi.
Biological pretreatment renders the degradation of lignin and hemicellulose and
white rot fungi seem to be the most effective microorganism. Brown rot attacks
cellulose while white and soft rots attack both cellulose and lignin. Cellulase-less
mutant was developed for the selective degradation of lignin and to prevent the loss
of cellulose but in most cases of biological pretreatment the rate of hydrolysis is very
low. This method is safe and energy saving due to less mechanical support. It needs
no chemicals but low hydrolysis rates and low yields impede its implementation.
Biological pretreatment of bamboo culms with white rot fungi has been performed
at low temperature (25 C). In the case of a marine microorganism Phlebia sp. MG-
60, it was seen that when the substrate was supplemented with a nutrient medium
such as Kirks Medium, better delignification was observed compared to sterilized
water. Bio-delignification generally needs long periods of time. In a biological
pretreatment study with an aim to release the sugars from the lignocellulosic matrix
of sugarcane trash using a number of microorganisms it was observed that both
cellulose and lignin contents of the raw material can be drastically reduced.
Reduction in the cellulose content by Aspergillus terreus was about 55.2% while
delignification was found to be about 92% .

pg. 28
Fermentation of the Solid Residue
Fermentations at 35% and 45% (w/v) DM(dry material) of non-sterilized liquefied
household food waste or pretreated residue were performed in 100-mL Erlenmeyer
flasks in an orbital shaker at 30C with an agitation of 100 rpm. The fermenting
microorganism was dry bakers yeast (Yiotis, Athens, Greece), which was added at
a concentration corresponding to 15 mg/g of initial DM. To evaluate the importance
of the separate liquefaction/saccharification step, untreated HFW were fermented
under the same conditions. Samples were taken at certain time intervals, centrifuged
and analyzed for ethanol. All trials were carried out in duplicate.

When the fermentation process was completed, the broth was filtrated under vacuum
in order to remove the solids which were further washed with distilled water. The
solids (residue) were dried at 60C until constant weight reached and were further
utilized for ethanol production after being hydrothermally pretreated.

pg. 29
Ethanol Fermentation

Fermentation image from google

Fermentation Section

pg. 30
Hydrolysis Section
Several plants are rich in starch and generally these plants have a certain amount
of sugar in its composition. Some vegetables rich in starch are, for example the corn,
the potatoes, the rice and the cassava. The hydrolysis is the breakdown of starch
molecules into smaller molecules, sugars, which may then be fermented by the
traditional process. The process of hydrolysis is not modern and is used in the
production of fuel ethanol from corn in the United States for a long time.

The hydrolysis process can be divided into two categories: the enzymatic hydrolysis
and the acid hydrolysis. In the acid hydrolysis, one uses a strong acid such as sulfuric
acid (H2SO4) or the hydrochloric acid (HCl), for the disruption of chemical bonds.
This process is performed at relatively high temperatures, approximately 120C and
1 atm pressure. The acid hydrolysis has the following disadvantages: high energy
consumption, waste generation and low chemical selectivity. This low selectivity
means that not only links between monomers are broken, but many sugar molecules
are also destroyed in this process. This turns the acid hydrolysis unattractive
commercially.

The process of enzymatic hydrolysis employ enzymes to break the chemical bonds
of the starch molecules. The enzymes are chosen according to the vegetable source
to be used in order to make them highly selective, i. e., acting almost exclusively on
the links between the monomers that compose the starch. The most widely used
commercial enzymes are the alpha-amylase of fungal origin and/or glucoamylase
and/or the enzyme pupullase. The major disadvantage of this process is the high cost
of the commercial enzyme, corresponding to about 50% of the total cost of the
process.

pg. 31
 Hydrolysis Section

pg. 32
Distillation Process
Distillation is a process of separating the component or substances from a
liquid mixture by selective evaporation and condensation. Distillation may result in
essentially complete separation (nearly pure components), or it may be a partial
separation that increases the concentration of selected components of the mixture.
In either case the process exploits differences in the volatility of the mixture's
components. In industrial chemistry, distillation is a unit operation of practically
universal importance, but it is a physical separation process and not a chemical
reaction.
Distillation means taking the fermented ethanol and water mixture and adding heat
to separate them -- typically in a still. Since ethanol evaporates faster than water, the
ethanol rises through a tube, collects and condenses into another container. The
water is left behind.
There are a lot of different kinds of stills, including pot stills, vacuum stills, reflux
stills and solar stills, which differ in setup and the way you heat your product. The
two most widely used in-home ethanol production units are solar stills and reflux
stills. Designs for all of these can be found online, and there are as many different
variations for all of them as human innovation will allow. If you have any doubts
about the safety or credibility of a particular still, do not attempt to use that design.

pg. 33
Distillation System vapor

Condenser Cooling water

Rectifying

Feed mixture
Reflux Low boiling product

Steam
Steeping

High boiling product

pg. 34
Enzymatic Hydrolysis
Saccharification is the critical step for bioethanol production where complex
carbohydrates are converted to simple monomers. Compared to acid hydrolysis,
enzymatic hydrolysis requires less energy and mild environment conditions. The
optimum conditions for cellulase have been reported as temperature of 40-50 C and
pH 4-5. Assay conditions for xylanase have also been reported to be 50 C
temperature and pH 4-5. Therefore, enzymatic hydrolysis is advantageous because
of its low toxicity, low utility cost and low corrosion compared to acid or alkaline
hydrolysis. Moreover, no inhibitory by-product is formed in enzymatic hydrolysis.
However, enzymatic hydrolysis is carried out by cellulase enzymes that are highly
substrate specific. Here cellulase and hemicellulase enzymes cleave the bonds of
cellulose and hemicellulose respectively. Cellulose contains glucan and
hemicellulose contains different sugar units such as mannan, xylan, glucan, galactan
and arabinan. Cellulase enzymes involve endo and exoglucanase and b-glucosidases.
Endoglucanase attacks the low crystallinity regions of the cellulose fiber,
exoglucanase (1,4-b-D glucancellobiohydrolase) removes the cellobiase units from
nthe free chain ends and finally cellobiose units are hydrolysed to glucose by b-
glucosidase. Hemicellulolytic enzymes are more complex and are a mixture of at
least eight enzymes such as endo-1,4-b-D-xylanases, exo-1,4-b-D xylocur-onidases,
a-L-arabinofuranosidases, endo-1,4-b-D mannanases, b-mannosidases, acetyl xylan
esterases, a-glucoronidases and a-galactosidases. Cellulose is hydrolysed to glucose
whereas hemicellulose gives rise to several pentoses and hexoses.
Various factors influence yields of monomer sugars from lignocellulose.
Temperature, pH and mixing rate are the main factors of enzymatic hydrolysis of
lignocellulosic material. Other factors that affect yield are substrate concentration,
cellulose enzyme loading, and surfactant addition. High substrate concentration may
lead to substrate inhibition. Cellulase contributes to the major cost of the
lignocellulosic ethanol technology.Therefore, an efficient pretreatment is to be
selected to decrease cellulose crystallinity and to remove lignin to the maximum
extent, so that hydrolysis time as well as cellulase loading will be minimized.

pg. 35
Fermentation
The saccharified biomass is used for fermentation by several microorganisms. But
the industrial utilization of lignocelluloses for bioethanol production is hindered by
the lack of ideal microorganisms which can efficiently ferment both pentose and
hexose sugars. For a commercially viable ethanol production method, an ideal
microorganism should have broad substrate utilization, high ethanol yield and
productivity, should have the ability to withstand high concentrations of ethanol and
high temperature, should be tolerant to inhibitors present in hydrolysate and have
cellulolytic activity. Genetically modified or engineered microorganisms are thus
used to achieve complete utilization of the sugars in the hydrolysate and better
production benefits.
The processes usually employed in the fermentation of lignocellulosic hydrolysate
are simultaneous saccharification and fermentation (SSF) and separate hydrolysis
and fermentation (SHF). Conventionally or traditionally the SHF process has been
employed but SSF is superior for ethanol production since it can improve ethanol
yields by removing end product inhibition and eliminate the need for separate
reactors. It is also cost effective but difference in optimum temperature conditions
of enzyme for hydrolysis an fermentation poses some limitation. The higher ethanol
yield coefficient from SSF would be partially due to more conversion of xylose to
xylitol under the SSF conditions. A comparative study between the two processes
(SHF and SSF) is presented.
Studies have shown that SSF is a better alternative to SHF. The slow xylose
consumption during fermentation in SHF may be due to the presence of toxic
compounds which inhibit the growth and fermentation activity of the
microorganism. The drawback of SSF can be removed by using thermo-tolerant
microorganisms like Kluyveromyces marxianus which has been developed to
withstand the higher temperatures needed for enzymatic hydrolysis.

pg. 36
Plant Layout Draft:

pg. 37
 Phase 2 Work:
1. Mass and Energy balance for plant.
2. Equipment design.
3. Instrumentation and piping.
4. Control system design.
5. Economic efficiency calculations.

pg. 38
References
1.Utilization of household food waste for the production of ethanol at high dry
material content
Author :- Leonidas Matsakas,Dimitris Kekos,Maria Loizidou and Paul
Christakopoulos
Matsakas et al.; licensee BioMed Central Ltd. 2014

2 . Hydrolysis of lignocellulosic materials for ethanol production: a review

Author :- Ye Sun, Jiayang Cheng

3 .Bioethanol production from agricultural wastes: An overview

Author:-Nibedita Sarkar, Sumanta Kumar Ghosh, Satarupa Bannerjee, Kaustav
Aikat*
Department of Biotechnology, National Institute of Technology, Durgapur 713209,
West Bengal, India
journal homepage: www.elsevier.com/locate/renene

4. Ethanol production from concentrated food waste hydrolysates with yeast cells
immobilized on corn stalk
Author:-Shoubao Yan & Xiangsong Chen & Jingyong Wu & Pingchao Wang

5. Ethanol production Using Organic Waste

Author :-Daewon Pak, Jun Cheol Lee, Jae Hyung Kim
Graduate School of Energy and Environment Seoul National University of
Technology

6. Converting lignocellulosic solid waste into ethanol for the State of Washington
An investigation of treatment technologies and environmental impacts
School of Forest Resources, University of Washington, Box 352100, Seattle, WA
98195, USA
Department of Mechanical Engineering, University of Washington, Seattle, WA
98195, USA
Author:-Elliott Schmitt ,Renata Bura , Rick Gustafson , Joyce Cooper , Azra
Vajzovic
journal homepage: www.elsevier.com/locate/biortech

7 Municipal Solid Waste Mangement Manual

Government Of India,Swachh Bharat Mission

pg. 39
8.Composition and Characterization Study of Solid Waste from Aurangabad City
Universal Journal of Environmental Research and Technology
Author:-Amul Late and M. B. Mule

9.htt://en.wikipedia.org

10.Making Ethanol from Wood Chips

Author :-Kevin Bullis November 16, 2006One startup is scaling up
experimental techniques to demonstrate the commercial potential of cellulosic
ethanol.

pg. 40