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Ethanol

Thai Roong Ruang Energy Co., Ltd.

Thai Roong Ruang Energy Co., Ltd. was founded in 2004 with the key objective to produce ethanol for selling to oil production companies for their production process of biofuel, including Gasohol E10, E20 and E85. In the ethanol production process, we mainly use by-products from sugar production (i.e. molasses and bagasse) as raw materials. Currently, our plant operates with a production capacity of 270,000 liters per day.

Additionally, Thai Roong Ruang Energy Co., Ltd., with the major support from both the Thai and Japanese governments represented through the Office of the Cane and Sugar Board (OCSB) and the New Energy and Industrial Technology Development Organization (NEDO) respectively and in collaboration with Japanese private enterprises (namely, Marubeni Corporation, Tsukishima Kikai Co., Ltd. and Sapporo Breweries Ltd.), has been engaged in The Model Project for Ethanol Production from Molasses and Bagasse in the Sugar Factory in Thailand in 2006 with the purpose to promote the ethanol plant of Thai Roong Ruang Energy Co., Ltd. as the first model plant for cellulosic ethanol production in the world, and subsequently The Model Project for Bioethanol Production from Bagasse using Enzyme Method in Thailand taken in 2014. The Japanese government fundamentally supports both new technology and machinery for producing ethanol from cellulose in bagasse (i.e. Cellulosic Ethanol) with the key purposes to lessen the dependency on imports of foreign oil (i.e. fossil fuels), which is the major cause of greenhouse gas emission, and to promote the sustainability of energy use and environment conservation (i.e. the so-called Green Partnership Program).

 
 

The Model Project for Ethanol Production from Molasses and Bagasse in the Sugar Factory in Thailand
and
The Model Project for Ethanol Production from Bagasse using Enzyme Method in Thailand

 
Objectives :
  1. To reduce dependence on the import of oils whose prices have been soaring continually.
  2. To generate sustainable income and occupation for cane farmers.
  3. To reduce the consumption of fossil fuels which cause greenhouse gas, contributing to mitigation of global warming.
  4. To support the policy of the government to use clean bio-alternative energy.
  5. To pioneer the use of a new technology for the production of fuel ethanol using molasses and bagasses as raw materials..


Project 1: The Model Project for Ethanol Production from Molasses and Bagasse in the Sugar Factory in Thailand
1.1 Bagasse Fermentation Process :
    MATERIAL PREPARATION PROCESS The bagasse is fed to the Bagasse Washer from Bagasse Yard by shovel loader and conveyor. By using water, sand and foreign materials are removed from bagasse and the Screw Feeder will compress it for dewatering before feed to the Hydrolysis Process.

    HYDROLYSIS PROCESS The clean bagasse is fed to the Hydrolyzer in order to decompose hemicellulose of the bagasse into C5 sugar. Steam and Sulfuric Acid are used in this process. The product of this process is C5 sugar and C5 residue which are separated in the next process.

    C5 RECOVERY PROCESS The solution from Hydrolysis Process, which contains C5 sugar and C5 residue, is fed into Belt Washer to filtrate the C5 sugar liquid away from the residue. The filtrated liquid will be neutralized by lime milk before fed to fermentation process. The residue from this process is burnt in the sugar factorys boiler as fuel or mix with filter cake from sugar factory as compost.

    KO11 PROPAGATION PROCESS KO11 is inoculated from the laboratory before further propagate in the Propagation Tank. Sterilized yeast from the Molasses process is used as nutrient for KO11 and after the desirable population of the microorganism is reached, it will be transferred to the fermentation process.

    FERMENTATION PROCESS KO11 is fed to the Fermentation tank after amount of C5 sugar liquid in tank is reach target. After fermentation process is completed, bagasse broth is fed to Storage Tank before continue to the Evaporation Process respectively.
1.2 Molasses Fermentation Process :
    MATERIAL PREPARATION PROCESS The purpose of this process is to analyze and use the material which is molasses, Ammonium Sulfate and sterile water to the calculated amount in order to reach the maximum efficiency of fermentation.

    YEAST PROPAGATION PROCESS The Propagation Process will start from sterilize nutrient which is molasses, Ammonium Sulfate, and condensate water in order to terminate other microorganism that can interrupt this process. After sterilization, the inoculated yeast from laboratory will be injected into the Starter Tank and Propagation Tank. When yeast reaches the desirable amount then it is transferred to the next process.

    FERMENTATION PROCESS The Fermentation Process starts from transfers the propagated yeast to the Fermentation Tank. After that molasses, Ammonium Sulfate, and water are fed in the right amount. In this process the Heat Exchanger is used to control the temperature. When fermentation process is finished, yeast can agglomerate by itself and settle down easily, so that yeast and broth can separate without centrifuge. The Molasses Broth is transferred into the Storage Tank before continue to the Evapoursation Process. The yeast/mud from this process can be reused up to 10-12 cycles before sending to Yeast/Mud Treatment Process.

    YEAST/MUD TREATMENT PROCESS After the last fermentation, yeast/mud which it is transferred to the Yeast/Mud Sterilized Tank is sterilized by steam and cooled down in the Cooling Yeast/Mud Tank. The yeast/mud is used as nutrient for KO11 in Bagasse Fermentation Process.
Project 2: The Model Project for Bioethanol Production from Bagasse Using an Enzyme Method in Thailand
2.1 Sterilization Process:

In this process, C5 residue, a raw material of ethanol, is derived from the C5 hydrolysis and C5 sugar recovery. C5 residue is transferred to demo plant area for biological use. It is continuously supplied to the sterilizer quantitatively, then is sterilized. Sterilized C5 residue is conveyed sterilely to both enzyme production process and saccharification and fermentation process.

Morever, bagasse (can be used instead of C5 residue for this process) is transferred to clean and remove the particles in bagasse washer. Then the cleaned bagasse is conveyed by bagasse conveyor to sterilizer for pretreatment and sterilization and used for raw material of enzyme production process and saccharification and fermentation process.

2.2 Enzyme Production Process:

In this process, enzyme producing microorganisms are propagated. The sterilized C5 residue and bagasse are transferred to enzyme production tank. The 1st step of propagation is conducted in laboratory and transferred to the 2nd and 3rd step in plant for enzyme production respectively. In enzyme production tank, microorganism consumes C5 residue or bagasse and produces enzymes. Enzyme in enzyme production tank is transferred to saccharification and fermentation process which is conducted in batch-wise process.

2.3 Saccharification and Fermentation Process:

In this process, sterilized C5 residue or bagasse from pretreatment process is transferred to C6 fermenter. After that enzyme and yeast culture are transferred. C5 residue is saccharified by produced enzyme. Glucose or saccharified C5 residue is fermented by yeast. Ethanol is produced with simultaneous saccharification and fermentation process which its concentration is 4%, and it is supplied to refining process.

Distillation and Dehydration Process:
    DISTILLATION PROCESS The Fermentation washed from Storage Tank from Project 1 and Project 2 are preheated by the alcohol vapours from Mash Column and heat transfer from wastewater discharged from Evaporator and fed into De-gassifying Column, link with the top of Mash Column operated under vacuum. The alcohol vapours from De-gassifying Column is fed to Aldehyde Column, to remove impurities and final product to Technical Alcohol. The fermentation liquor from Mash Column is fed to Mash Column continue, Mash Column is heated up with the alcohol vapours from the second effect of Evaporator by direct heat. The alcohol vapours from Mash Column is fed to condenser . Condensate from these condensers is collected in Rectifier Feed Tank. The alcohol concentration in Mash Column will be in the range of 40-55% , wait for feed into Rectify Column.

    In the other hand, the Spent Wash from bottom of Mash Column, no alcohol concentration, is fed to Rectifier Feed Tank wait for to feed into Evaporator next time. The alcohol from Rectifier Feed Tank concentration 40-55% is fed to Rectify Column and preheated by Spent Wash from bottom of Rectify Column. The alcohol vapours is released from the top of Rectify Column is condensed by Reflux condenser to Reflux Tank, The alcohol concentration will be in the range 93-95% (v/v). Part of ethanol from Reflux Tank is fed to the top of Rectify Column to control the quality of ethanol and other part of ethanol is transferred to Evaporator next process. The Spent Lees, which is released from bottom of Rectify Column, no ethanol concentration, is used in the Biogas producing process.

    DEHYDRATION PROCESS The moisture of Ethanol vapours from Distillation column is reduced by this process. The smaller molecules of water are absorbed by molecular sieves in Dehydration Unit while the larger molecules of ethanol pass through condenser and condense to daily tank. From this phenomenon the concentration of the ethanol is raised over 99.5%. The output of this process will therefore be ensured to the right quality before stored in the Product Tank to guarantee the customers satisfaction.

Contact
Thai Roong Ruang Energy Co., Ltd.

Head Office
794, Thai Ruam Toon Building, 7th Floor, Krungkasem Road, Wat Sommanas Sub-District, Pomprab District, Bangkok 10100
Tel:  02 282 2022 Ext. 384     Fax:  02 282 5123

E-mail :  chatchai@trrsugar.com

     
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