MANUFACTURING
Unravelling our manufacturing excellence
Ramshy Bio is equipped with a 300 KLPD capacity grain-based distillery plant to manufacture Fuel Ethanol, along with a 7.25 MW steam turbine plant for captive consumption of the plant.
Located in Telangana, India our multi-product distillery plant is operational all year round, making the best use of the local agricultural potential.
It is designed to be eco-friendly with advance Waste Water Treatment Plant for complete recycling of waste water and re-usage of the treated water in the manufacturing process as per State and Central PCB norms and Zero Liquid Discharge (ZLD) approach.
MANUFACTURING UNIT
Key highlights
60 TPH Thermax Boiler and 7.25 MW Siemens Turbine for captive power co-generation plant
2 Storage Silos with storage capacity of 7500 MT
Dry milling section is equipped with 2 Bühler mills, each with a storage capacity of 16 MT
4 Fermenters, each with a capacity of 1600 KL
Advanced multi pressure vacuum distillation integrated with evaporation plant through complete DCS system with vacuum operation of analyser-degasser and pressure rectifier column, followed by Molecular Sieve De-Hydration (MSDH) plant
Alfa Laval Decanter and Steam Tube Bundle Dryer for effective DDGS production
Modern, state-of-the-art technology for raw water treatment plant for process water, RO water, soft water for cooling tower and de-mineralised water for distillation and boiler
33% of total project land is reserved for Green Belt & Advanced Effluent Treatment plant for recycling treated water back to process in order to reduce raw water consumption and avoid land pollution in and outside the premises as project plans for Zero Liquid Discharge (ZLD).
Spread across 32.625 acres of land and strategically located with excellent road connectivity, our facility is poised to meet the growing demand for ethanol sustainably and efficiently.
Committed to environmental stewardship, we embrace the latest Clean Development Mechanism practices, ensuring minimal ecological footprint while maximizing production output. Safety norms are paramount in our operations, with stringent measures in place to safeguard our workforce and surroundings.
OUR PROCESS
By integrating different stages of traditional ethanol production and using advanced technologies, our plant is designed to effectively manage waste streams, minimise water and energy consumption, and mitigate environmental pollution, aligning with sustainable and environmentally friendly practices.
In the first step of ethanol production, the selected grains are procured, cleaned, and stored in silos. Subsequently, the grains are further cleaned and milled with the use of de-stoner, magnetic separators and hammer mill. This helps break them down into smaller particles, increasing their surface area for efficient enzymatic action in the subsequent liquefaction step.
Liquefaction is a crucial step that involves breaking down the starch present in the ground grain into simpler fermentable sugars. The ground grain from the milling process is mixed with recycled liquids and/ or fresh water to make a slurry. Enzymes, such as alpha-amylase are used in this stage which break down the starch molecules into smaller fragments.
The liquefaction process occurs under controlled conditions of temperature and pH to optimise enzyme activity and sugar production.
The liquefied slurry from the previous stage is further converted into fermentable sugars, primarily glucose. This process, known as saccharification, involves the addition of additional enzymes, typically glucoamylase, which hydrolyzes the starches into glucose molecules. Subsequently, yeast is added to the sugar-rich grain mash, initiating fermentation wherein the simple sugars are converted to ethanol and carbon dioxide, along with heat and small amounts of other byproducts.
Once fermentation is complete, the resulting mixture, known as beer/ wash that contains 12-14%v/v alcohol is emptied from the fermenter into a beer well. The beer well stores the fermented wash between batches and supplies a continuous stream of material to the Multipressure Distillation process.
Multi-pressure vacuum distillation integrated with evaporation is an advanced technique designed to enhance efficiency and reduce energy consumption, making ethanol production more sustainable and cost-effective while maintaining high purity levels.
In this process, after fermentation, the ethanol-water mixture undergoes evaporation under reduced pressure at multiple stages, each stage operating at different pressures. This multi-pressure approach optimizes the separation of ethanol from water and impurities by exploiting the varying boiling points of different components.
There are three columns in the system. Primary column also called Primary cum Mash & Degasser column, Rectifier Column which produces 95-96% v/v alcohol and Molecular Sieve De-Hydration (MSDH) process where 95-96% v/v of alcohol is converted into 99.8% fuel grade ethanol.
During the decantation and drying stage, the focus is on separating solids from the liquid fraction of the waste stream. Decantation involves allowing the mixture to settle, allowing heavier solids to settle at the bottom, forming a sediment, while the liquid portion, which contains dissolved organic matter, is separated.
Multi Effect Evaporation (MEE) is a thermal separation, or thermal concentration technique that is used to remove a liquid from a solution, suspension, or emulsion by boiling off some of the liquid. This process starts with a liquid product and ends up with a more concentrated liquid called Syrup as the main product from the process. It is sent to the dryer for further drying up to 88% w/w solid which is called DDGS.
MEE utilizes the latent heat from the condensation of vapour in one effect to drive evaporation in the next, significantly reducing energy consumption compared to traditional evaporation techniques.
Parallel to the decantation and drying process, wastewater treatment using the Zero Liquid Discharge (ZLD) concept within the Effluent Treatment Plant (ETP) is implemented. ZLD aims to eliminate liquid waste discharge by recovering and reusing water and treating the remaining solid waste.
In this context, the liquid fraction separated during decantation undergoes treatment processes such as filtration, reverse osmosis, and evaporation, employing Multi-Effect Evaporation (MEE) technology to remove pollutants and concentrate the wastewater efficiently. The treated water, now significantly purified, is then recycled for various process needs within the ethanol plant, reducing freshwater intake and minimising environmental impact.
We are dedicated to producing biofuels that not only meet the country's energy needs but also reduce environmental impact.
Our company is committed to sustainability, rural development, and supporting local farmers. We utilise a wide range of agro-based raw materials including damaged grains that are available in different seasons for the production of ethanol and other related products through the non-molasses route.
BENEFITS
Fuelling the future with sustainable solutions
Under the Ethanol Blending Programme (EBP), the Government of India and Telangana State is encouraging the adoption of non-molasses routes for ethanol production.
Reducing food waste, positive economic impact
Damaged grains are often unsuitable for human consumption due to their quality or appearance. By utilising these grains, we help reduce food waste, and also provide farmers with additional income streams contributing to the economic development of agricultural regions.
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Under the Ethanol Blending Programme (EBP), the Government of India and Telangana State is encouraging the adoption of non-molasses routes for ethanol production.
Our company is committed to sustainability, rural development, and supporting local farmers. We utilise a wide range of agro-based raw materials including damaged grains that are available in different seasons for the production of ethanol and other related products through the non-molasses route.
BENEFITS
Fuelling the future with sustainable solutions
Conserving resources
By diversifying our feedstock sources to include damaged grains, we reduce the dependency on specific grain crops or regions for ethanol production. This helps reduce the pressure on agricultural land and water resources, promoting efficient use of natural resources throughout the year.
Lowering carbon footprint
Ethanol produced from damaged grains typically has a lower carbon footprint compared to traditional fossil fuels. By using these grains as a feedstock, we promote a more sustainable alternative to conventional gasoline, reducing greenhouse gas emissions and mitigating climate change impacts.
Reducing food waste, positive economic impact
Damaged grains are often unsuitable for human consumption due to their quality or appearance. By utilising these grains, we help reduce food waste, and also provide farmers with additional income streams contributing to the economic development of agricultural regions.
Lowering carbon footprint
Ethanol produced from damaged grains typically has a lower carbon footprint compared to traditional fossil fuels. By using these grains as a feedstock, we promote a more sustainable alternative to conventional gasoline, reducing greenhouse gas emissions and mitigating climate change impacts.
Conserving resources
By diversifying our feedstock sources to include damaged grains, we reduce the dependency on specific grain crops or regions for ethanol production. This helps reduce the pressure on agricultural land and water resources, promoting efficient use of natural resources throughout the year.
