A] GRAIN HANDLING AND MILLING SECTION

Grain is lifted and unloaded by bucket elevator into grain silos. Grain from hopper is
transferred continuously to feed bin of intermediate bucket elevator. This bucket
elevator lifts the grains and feeds to vibratory pre-cleaner. The Pre-cleaner removes
light impurities like Straws, Stem and fine dust. Grain from vibrator is fed by gravity
to magnetic separator to remove iron particles. From magnetic separator the grain is
fed by gravity to de-stoner. This machine removes heavier particles like stones and
supplies almost stone free grains.

From de-stoner the grain is fed by gravity to hammer mill. The milled flour from
hammer mill is fed by bucket elevator to a vibratory sifter from a small hopper. The
vent losses are minimized by a bag filter on vent lines. Flour is unloaded from
hopper to vibratory sifter through rotary valve. The sifter classifies flour into fine
and coarse. The coarse particles are recycled by gravity to mill through duct. A
specially designed of mill facilitates of air escaping through Aspiration Section.
Front opening of our Hammer Mill facilitates easy change of Screen & Hammers.
Provide versatility of this Mill for all types of grinding of grains like Maize,
Sorghum, Broken Rice & Millets.

The Flour coming from mill of desired size of particles is conveyed through Screw
Conveyor and Bucket Elevator is Stores is Flour Storage Silo. The avg. Bulk Density
of 0.5/0.6 Gm./Cc. and Capacity of Silo is around Four Hours production of
Hammer Mill. The flour bins are mounted on load cell for Weighment. Once the
flour bin is full the actuated diversion valve stops feeding, the bin under feeding and
diverts feed to other bin, which is empty. At a time one bin is getting filled and other
bin is feeding to further section. The flour from either of bin is fed to next section,
i.e., liquefaction section through a screw conveyor, which works through loss in
weight feeder.
B] SLURRY PREPARATION AND LIQUEFACTION

The flour from mill is mixed homogenously in blunging tank where process water
with process condensate from evaporator and thin Stillage is used for dilution. Some
quantity of Alfa amylase and viscosity reducing enzyme is also added here. The
slurry is then pumped from mixing retention tank thru jet cooker where steam is
added through for instantly raising the temperature of slurry to >1050 C. The slurry
is cooked for specific period by allowing specific retention time in coil by centrifugal
pump to liquefaction tank. The heat recovery is done by using heat in flash steam
from liquefaction tank. The blunging vessel is a very high flow and high shear mixer
ensuring no untreated mash clusters are passed to jet cooker. Efficient mixing is
done by using agitators in mixing and liquefaction tanks. Gluco amylase is added in
specific amount for Saccharification. After this it is cooled and sent to fermentation.

The whole process is well monitored via instrumentation to get high conversion
efficiency.

C] YEAST PROPAGATION AND FERMENTATION

In this process we propagate the genetically marked, highly efficient yeast strain
under aseptic conditions, in Yeast vessels.

The ready yeast Culture is then transferred from Pre-Fermenter to Fermenter. The
glucose in media gets converted to ethanol, in each of the 6 Fermenter operating in
batch mode for grain based fermentation. CO2 liberated during reaction is sent to
CO2 scrubber for recovery of ethanol before venting to atmosphere. The equipment
is well designed to achieve enhanced efficiencies through better sugar / yeast
contact by shearing and mixing, efficient oxygen transfer etc. Oxygen transfer at
optimum efficiency is ensured by jet educators inside fermenters.

D] MULTIPRESSURE DISTILLATION

The fermentation mash containing Alcohol, non-fermentable solids and water is

The system consists of 8 main columns, namely, CO2 Stripper, Stripper Column,
Prerectifier Column, Extraction Column, Rectification Column, Refining Column,
Fusel Oil Column and Heads Concentration Column.

Wash is fed to CO2 stripper column to remove CO2 gas present in wash. Alcohol is
stripped off water in stripper column. The top vapours from stripper column are fed
to Calendria 1 as heat source for concentrating spent wash. Distillate from Calendria
is fed to pre-rectifier column as feed and steam is supplied as heat source. Prerectifier remove most of the fusel oils. Top of the Pre-rectifier column are fed to
Reboiler of Refining Column and part of the distillate from pre-rectifier column is
fed to extraction column after dilution where process water is used as dilution water
and remaining return back as a reflux. In extraction column most of the high boiling
impurities separate from ethanol in presence of water. The bottom ethanol water
mixture is preheated by steam condensate and spent leese before being fed to
rectifier column. Top vapours of Rectifier column are fed to Stripper Reboiler as a
heat source. In rectifier column product rectified spirit is taken out from top tray and
fed to refining column where mainly methanol impurities are separated. Pure ENA
is obtained at bottom of Refining column, which is cooled and stored. The impure
spirit from top of CO2 stripper column, extraction column, rectifier column and
refining column are fed to FO column. The final impure spirit cut is taken out from
heads column top and balance alcohol is recycled to pre-rectifier column. The
alcohol containing fusel oil from prerectifier and rectifier column is fed to fusel oil
column.

The top vapours from stripper column and Fusel Oil column are condensed in
evaporator for spent wash concentration. The rectifier column, fusel oil column, HC
column and pre-rectifier column get heat from steam at 3.5 bar (g).

Rectification column and pre-rectifier column works under positive pressure. The
top vapours from rectifier column are condensed in stripper column for giving heat
to stripper re-boiler. Most of the other columns work under vacuum. The Distillation
process is operated through PLC.

D] STILLAGE PROCESSING

The Stillage from Distillation section is then passed through decanter where cake
and thin stillage are separated. The recovered thin stillage from decanter is
concentrated in the evaporator till 38% concentration. The evaporator uses heat from
stripper column, fusel oil column and DDGS Dryer vapours for desired final
concentration of stillage. The product from the evaporator is mixed with cake
recovered from decanter. The mixture is sent to the dryer and the dried product is
used as cattle feed. Part of the thin stillage [approximately 40% to 50%] is recycled to
liquefaction section and fermenters.
Flow chart of Manufacturing Process