K-SUPER Fermentation

The SIF fermentation proposed is the latest and proven technology as compared to the old batch fermentation technology. It has many advantages like continuity of operation, higher efficiency and ease of operation. Continuous fermentation also results into consistent performance over a long period as compared with batch fermentation. Most modern ethanol production plants adopt this continuous fermentation technology. Considering all the above advantages, we have proposed to adopt the efficient fermentation in the distillery

The fermentation process employs a special yeast culture, which can withstand variations in temperature and other shock loads. Fermentation plant consists of four fermenter tanks connected with all the accessories like plate heat exchangers for cooling, sparges, broth mixers and air blowers etc.

The yeast is a remains in the fermentation plant throughout and hence it gives a tremendous advantages in maintaining the yeast population and in combating the bacterial infection.

Saccharified slurry from Saccharification section is pumped into Fermenter and is diluted to appropriate sugar concentration by adding water. It is, then inoculated with required quantity of suitable yeast. The assimilable nitrogen are added in the medium in the form of urea and dap. Temperature in the Fermenter is maintained with the help of plate heat exchanger.

The fermented mash is recirculated continuously through PHE. Recirculation also helps in proper mixing of fermented mash. The rate of fermentation reaction gradually increases and after 50 to 55 hours, fermentation completes. After completion of reaction the fermented mash is delivered to mash holding tank. The fermented mash collected in the Clarified Wash Tank is then pumped to Mash or Primary column for distillation.

The CO2, which is liberated, is scrubbed in water, with the help of CO2 Scrubber. This CO2 contains ethanol, which is recovered by collecting CO2 Scrubber water.

A closed loop cooling tower system with an induced draft-cooling tower with circulation pumps is also provided to ensure higher cooling efficiency and to minimise water wastages.

Advantages of SIF Fermentation Process

    Starch Fermentation Process
  • Good ease of operation and easy way daily cleaning / filling required.
  • Consistency in plant operation and performance is very high.
  • Less operating manpower required.
  • The process can also be automated with less cost and great ease.
  • Easy to control & trouble shoot, as it is a continuous process.

    Culture Yeast usage
  • No fresh yeast dosage required. Yeast is present in its culture form and hence saving in cost of the yeast.
  • Elimination of other yeast related problems like wild yeast and contamination along with the fresh yeast.
  • Yeast culturing will also ensure optimum yeast concentration in the fermentors, even when there is some bacterial growth.

    Higher Alcohol Concentration in Wash
  • Less effluent volume and low cost of treatment.
  • Reduced steam consumption in Distillation.
  • Higher alcohol concentration ensures low bacterial activity in fermentors.

    Rugged Process based on culture Yeast Technology
  • Can handle varying quality raw material.
  • Easy to start and stop, as and when required.
  • Can take care of fluctuations like temperature and other conditions.
  • Good control and handling of bacterial contamination.

    Higher alcohol recovery per MT of Grain

    Yeast can withstand a temperature of up to 34 deg C
  • The process works at different climatic conditions i.e. at different locations and also in hot seasons without significant drop in performance.

    Lesser residence time of fermentation
  • Lower residence time also help to maintain low bacterial activity.
  • Lesser fermentor volumes and lower capital cost.

    No agitation is required in fermentors
  • Low electricity consumption

    Minimum and controlled air sparging is employed for fermenter
  • Low electricity consumption.
  • Maximum CO2 recovery of upto 80 to 85 % of the total CO2 production is possible.

Advantages of   K SUPER Continuous Fermentation Process

    Continuous Fermentation Process
  • Good ease of operation and easy way as no daily cleaning / filling required.
  • Consistency in plant operation and performance is very high.
  • Less operating manpower required.
  • The process can also be automated with less cost and great ease.
  • Easy to control & trouble shoot, as it is a continuous process.

    Culture Yeast usage. And recycle yeast
  • No fresh yeast dosage required. Yeast is present in its culture form and hence saving in cost of the yeast.
  • Elimination of other yeast related problems like wild yeast and contamination along with the fresh yeast.
  • Yeast culturing and activation will also ensure optimum yeast concentration in the fermentors, even when there is some bacterial growth.

    Higher Alcohol Concentration in Wash
  • Less effluent volume and low cost of treatment.
  • Reduced steam consumption in Distillation.
  • Higher alcohol concentration ensures low bacterial activity in fermentors.

    Rugged Process based on culture Yeast Technology
  • Can handle varying quality raw material.
  • Easy to start and stop, as and when required.
  • Can take care of fluctuations like temperature and other conditions.
  • Good control and handling of bacterial contamination.

    Higher alcohol recovery per MT of Molasses

    Yeast can withstand a temperature of up to 34 deg C
  • The process works at different climatic conditions i.e. at different locations and also in hot seasons without significant drop in performance.

    Lesser residence time of fermentation
  • Lower residence time also help to maintain low bacterial activity.
  • Lesser fermentor volumes and lower capital cost.

    Lesser residence time of fermentation
  • Low electricity consumption.

    Minimum and controlled air sparging is employed for fermenter
  • Low electricity consumption.
  • Maximum CO2 recovery of upto 80 to 85 % of the total CO2 production is possible