Final Year Project Report 4t1j2u

FINAL YEAR PROJECT REPORT

NATIONAL INSTITUTE OF TECHNOLOGY, DURGAPUR

BIOETHANOL F 3 -FUEL FOR FUTURE

BYAKASHDEEP SAH 07/BT/21 INTRODUCTION

Bioethanol is an alcohol made by fermenting the sugar components of plant materials and it is made mostly from sugar and starch crops. With advanced technology being developed, cellulosic biomass, such as trees and grasses, are also used as feedstocks for ethanol production. Ethanol can be used as a fuel for vehicles in its pure form, but it is usually used as a gasoline additive to increase octane and improve vehicle emissions. Bioethanol is widely used in the USA and in Brazil.

ABSTRACT

The purpose of this project is to produce ethanol from algae, as an environmentally friendly alternative to food crop-based fuels and petroleum-based fuels. Experimental data and results have been used to calculate the heat energy of ethanol produced from algae grown in different types of water - fresh water, river water and pond water. Relationship among the Laws of Thermodynamics has been used to analyze the results to show that: •

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Energy is freely available in our universe and tiny microorganisms called algae have been identified as being energy-rich. Specific gravity of the colourless liquid, produced by fermenting algae, was measured. When ethanol is burned, thermal energy is released.

This experimental effort was extended by burning ethanol produced from fruit, corn and yard-waste to determine the energy produced by these biofuels and comparing with the energy produced when algae ethanol was burned. Experimental data and results the hypothesis. Findings of this experiment show how the Laws of Thermodynamics help us understand the energies hidden in the smallest beings of Nature. This experiment clearly demonstrates "The Bug Power" of algae and demonstrates a process to develop a "low tech" and "low cost" solution to the energy crisis that the world is facing.

BIOALCOHOLS Biologically produced alcohols, most commonly ethanol, and less commonly propanol and butanol, are produced by the action of microorganisms and enzymes through the fermentation of sugars or starches (easiest), or cellulose (difficult). Biobutanol (biogasoline) is often claimed to provide a direct replacement for gasoline,because it can be used directly in a gasoline engine.

FIRST GENERATION BIOFUELS

'First-generation biofuels' are biofuels made from sugar, starch, vegetable oil, or animal fats using conventional technology. The basic feedstocks for the production of first generation biofuels are often seeds or grains such as wheat, which yields starch that is fermented into bioethanol, or sunflower seeds, which are pressed to yield vegetable oil that can be used in

biodiesel. These feedstocks could instead enter the animal or human food chain, and as the global population has risen their use in producing biofuels has been criticised for diverting food away from the human food chain, leading to food shortages and price rises. Ethanol fuel is the most common biofuel worldwide, particularly in Brazil. Alcohol fuels are produced by fermentation of sugars derived from wheat, corn, sugar beets, sugar cane, molasses and any sugar or starch from which alcoholic beverages can be made(like potato and fruit waste, etc.). The ethanol production methods used are enzyme digestion (to release sugars from stored starches), fermentation of the sugars, distillation and drying. The distillation process requires significant energy input for heat (often unsustainable natural gas fossil fuel, but cellulosic biomass such as bagasse, the waste left after sugar cane is pressed to extract its juice, can also be used more sustainably). Producing ethanol from cellulose is a difficult technical problem to solve. In nature, ruminant livestock (like cattle) eat grass and then use slow enzymatic digestive processes to break it into glucose (sugar). In cellulosic ethanol laboratories, various experimental processes are being developed to do the same thing, and then the sugars released can be fermented to make ethanol fuel. In 2009 scientists reported developing, using "synthetic biology", "15 new highly stable fungal enzyme catalysts that efficiently break down cellulose into sugars at high temperatures.

Ethanol from living algae

Most biofuel production comes from harvesting organic matter and then converting it to fuel but an alternative approach relies on the fact that some algae naturally produce ethanol and this can be collected without killing the algae. The ethanol evaporates and then can be condensed and collected. The company Algenol is trying to commercialize this process.

THE SWOT ANALYSIS

Strengths • Potential to be carbon neutral on a lifecycle basis – meaning the carbon dioxide (CO2) emitted during its use is offset by the absorption from the atmosphere during its growth. • With emissions of CO2 and nitrous oxide taken into , some studies suggest that lifecycle

greenhouse gas emissions can be reduced by 90% with bioethanol compared to petrol. This is a bestcase scenario however, using sugar cane as the crop and large amounts of bagasse (the remaining wood fibres after the juice is extracted) used for heat energy. Nevertheless, even by current European standards the emission reductions are significant – around 35-65% depending on the processing method. • Bioethanol also has the advantage of lower taxation. The UK government has reduced fuel duty on bioethanol which offsets the higher production costs. The first supermarkets in the UK selling E85 offered it at around 2p cheaper than conventional petrol but typically you would use much more bioethanol per mile than traditional fuel – around 50% more if you’re using 100% bioethanol.

Weakness • Biodiversity – A large amount of arable land is required to grow crops. This could see some natural habitats destroyed including rainforests. • The food vs fuel debate – There is concern that due to the lucrative prices of bioethanol some farmers may sacrifice food crops for biofuel production which will increase food prices around the world.

• Carbon emissions – There is debate over the neutrality of bioethanol when all elements are taken into consideration including the cost of changing the land use of an area, transportation and the burning of the crop

Opportunities • The price of bioethanol-petrol fuels will be kept reasonable low due to government subsidies and lower taxes in order to encourage the use of a cleaner petrol alternative, assuming public interest is sufficient to create a significant market in the UK for bioethanol and alcohol fuelled cars. • Bioethanol produces only carbon dioxide and water as the waster products on burning, and the carbon dioxide released during fermentation and combustion equals the amount removed from the atmosphere while the crop is growing. • It is a renewable source • Can be used as an additive with petrol and water • Has a greater thermal efficiency due to a higher octane rating allowing greater compression ratios. • The price of bioethanol should be kept relatively low as governments encourage the use of more eco-friendly fuels.

Threats • Currently not carbon neutral • Cellulases do not work well in vitro • Predicted that hydrogen will be major fuel of future • For similar required energies, pure ethanol requires to be burnt for longer periods of time than regular petrol and therefore more fuelling facilities will need to be required if ethanol were to be used. • The production of bioethanol requires a significant amount of non-renewable fossil fuels so an alternative needs to be found. • Large areas of land is required in order to produce significant volumes bioethanol.

SITUATION IN INDIA India's biofuel strategy continues to focus on use of non-food sources for producton of biofuels: sugar molasses for production of ethanol for blending with gasoline, and non-edible oilseeds for production of biodiesel for blending with petro-diesel, according to the USDA Foreign Agricultural Service. The government's current target of five per cent blending of ethanol with petrol has been partially successful in years of surplus sugar production, but falters when sugar production declines.

Source: Petroleum Planning and Analysis Cell, GOI

Ministries Involved in the biofuels Sector India has been pursuing a two-fold strategy for promotion of biofuels by: a) providing budgetary for research, development and demonstration of technologies; and b) promoting private investment through fiscal incentives. Several ministries are involved in policymaking, regulation, promotion, and development of the biofuels sector in India.

In addition, various state governments [8] have drafted policies and set up institutions for promoting biofuels in their respective states. Several states have also formed rules for allocation of wastelands to various entities for the plantation of biodiesel feedstock crops.

biofuel MARKET CONDITIONS Motor Vehicle Petroleum Based Energy Market

India's petroleum-based energy demand by the transport sector is the fastest growing energy consuming sector and will continue to grow steadily in the coming years due to strong growth in the economy, rise in income levels, and an increase in the availability

and choice of vehicles. Petroleum product consumption has gone up from 100 million tons in Indian fiscal year (IFY) 2001/02 (April/March) to 134 million tons in IFY 2008/09 [9] . Energy demand by the transport sector is expected to grow by 6-8 per cent per year during the 11th five-year plan (2007-2012). Diesel and gasoline (petrol) contribute 98 per cent of the energy consumed in the transport sector.

Over 80 per cent of engers and about 60 per cent of freight are transported by road in India. With the growth in the economy and the rise in personal incomes there is increasing dependence on personal modes of transport such as cars and two wheelers. Industry sources report that that the total number of vehicles has increased more than five fold, from 21.3 million (including 14.2 million two-wheelers) in 1991 to 109 million in 2008 [10] . The motor vehicle population

grew by 10-12 per cent in the last few years, and is expected to continue to grow around eight-10 per cent in the next few years.

Can India Meet Policy Targets? Ethanol Policy Industry sources report that the EBP is not sustainable as the ethanol supply hinges on sugarcane and sugar production. Sugarcane and sugar production in India typically follows a six to eight year cycle, wherein three to four years of higher production are followed by two to three years of lower production (refer to Indian Sugar Annual Report IN9049 for more details). The Indian sugar industry crushes about 70-80 per cent of the sugarcane for sugar production, with the remaining cane used for local sweeteners (khandsari and gur), seed, feed and cane juice, chewing and waste. The byproduct of the sugar industry, sugar molasses, is used for production of alcohol and ethanol.

Since sugarcane and sugar production is cyclical, availability of sugar molasses and sugarcane juice for ethanol production varies depending on the sugarcane cycle. Lower sugar molasses availability and consequent higher molasses prices affect the cost of production of ethanol, thereby causing disruptions in the supply of ethanol for the EBP programme at prenegotiated fixed ethanol prices.

Note /1: Mill Sugar Production in Crystal Weight Basis. Source: FAS/New Delhi estimates based on information from trade sources India has about 320 distilleries, with a production capacity of about 3.5 billion litres of rectified spirits (alcohol) per year, almost all of which is produced from sugar molasses [11] , and not from sugar juice, food grains or other cellulose feed stocks. More than 115 distilleries modified their distillation facilities to produce ethanol with total ethanol production capacity of 1.5 billion litres per year. Current ethanol production capacity is enough to meet the estimated ethanol demand for the five per cent blending ratio with

gasoline. However, for a 10 per cent EBP programme, current ethanol production capacity have to be expanded by increasing the number of molasses-based ethanol plants, and by setting up sugarcane juice-based ethanol production units.

Current Ethanol Production The ethanol supply for the EBP programme during MY 2008/09 has been severely impacted by the short supply of sugar molasses and continued strong demand for alcohol from other competing industries. Consequently, ethanol for blending with petrol in Indian sugar marketing year 2008/09 (October/September) is estimated at 100 million litres, against the target of 600 million litres. With market prices of alcohol ranging between Rs. 26 to Rs. 30 per litre since October 2008, most ethanol suppliers preferred diverting their supplies to the potable liquor and chemical industries instead of supplying ethanol at the current price of Rs. 21.50 per litre for the EBP programme. Despite the forecast improvement in the sugarcane and sugar production in MY 2009/10, a sharp drawdown in carryover stocks and expected strong demand from the chemical and potable liquor industry will constrain alcohol supplies. Consequently, supply of ethanol for fuel is forecast lower at 50 million litres. However, ethanol supplies to the EBP programme may improve if petroleum companies agree to a major hike in the procurement price from the current negotiated price.

India’s biofuel Drivers • The cornerstone of India's energy security strategy is to focus efforts toward energy self-reliance and developing renewable energy options like biofuels vis-à-vis fossil fuels. • Adoption of environmentally friendly biofuels to meet improved vehicle emission norms. • Developing an alternative usage for crops like sugarcane and its byproducts as feedstock for biofuels to farm income. • Improve utilization of wastelands and other unproductive land for cultivation of biofuel feed stock. • Enhance rural employment and livelihood opportunities by promoting production and marketing of biofuel feed stocks.

Food vs. Fuel India's strategy for promoting biofuels is two pronged:  Promote the use of ethanol derived from sugar byproducts of molasses/juice for blending with gasoline.  Promote the use of biodiesel derived from nonedible oils and oil waste for blending with diesel.

LAB Production of bioethanol Preparation - Growing Algae 

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Obtain algae growing in fresh water from the local pet store or hatchery. Place a large glass container containing fresh water in the sunroom at home so that the algae receive sunlight for photosynthesis to take place. Algae will multiply easily and rapidly - within 24

hours and sink to the bottom of the glass container. 

Maintain room temperature between 20 to 40 degrees Celsius.

 Repeat steps 1 to 3 using river water and water from pond to grow algae. Ethanol Flame Test Take out the hydrometer and wrap cotton wool on a skewer. Dip cotton wool in the clear liquid. Hold the cotton wool against a flame of a lighter. The flame will be blue indicating again that the liquid collected in the second beaker is indeed ethanol produced by fermenting algae! Preparation - Making Ethanol from Algae 

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Algae multiply rapidly and sink to the bottom of the glass container. Wear rubber gloves and take out the algae. Put the algae in a glass flask in the same sunroom where the glass container is placed. Maintain room temperature between 20 to 40 degrees Celsius. Take a beaker and fill it with fresh water algae. Add 20 gm of yeast. Place the cork very tightly on it. Allow algae to ferment and produce ethanol. Put 100 mL of water in another beaker. Place the cork tightly on the beaker and connect it to the beaker containing algae.

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Label each flask clearly - Ethanol from Fresh water Algae, Ethanol from River water Algae; Ethanol from Pond water Algae.

 Repeat steps 1 to 3 for each type of algae.

Industrial production of bioethanol Sugar fermentation  Fermentation under anaerobic conditions uses microorganisms Saccharomyces cerevisiae to convert sugars to ethanol. Ethanol production process results in the production of ethanol and

CO2 and heat. One molecule of glucose yields 2 molecules of ethanol and 2 molecules of CO2. One kilogram of glucose will theoretically produce 0.51 kilogram of ethanol and 0.49 kilogram of CO2. C6H12O6 = CO2 + 2 C2H5OH Go= 85 kJ mol  In the fermentation step, yeast grown in seed tanks is added to the mash to ferment the simple sugars to ethanol. The other components of the grain kernel (protein, oil, etc.) remain largely unchanged during the fermentation process. E.g. corn oil helps to prevent foaming during the fermentation. Fermentation is a downstream process that occurs continuously.  Fermentation is a continuous process also in case of dry-grind facilities. While continuous fermentation has greater reactor productivity (one fermenting for approximately 46-48 hours) because it is continuously operating with high yeast loads, much more care needs to be exercised to prevent contamination with bacteria, especially species of Lactobacillus. These bacteria allow production of organic acids that lower ethanol yields (Graves, 2006), (Bayrock, 2001), (NL514253).  Ethanol production by yeast has high selectivity, low accumulation of byproducts, high ethanol yield, and high fermentation rate. Yeasts have to be viable and genetically stable, but also tolerant to high temperatures during the process.  In addition to ethanol, carbon dioxide (CO2) is also produced during fermentation. Usually, the carbon dioxide is not recovered as a sellable product. If recovered, this carbon dioxide can be cleaned, compressed and sold for carbonation of soft drinks or frozen into dry-ice for cold product storage, for sandblasting in car service and metal industry, etc.

If the carbon dioxide is not recovered, it is cleaned and vented to the atmosphere. Ethanol from Algae  Algae have a tendency to have a much different makeup than does most feedstocks used in ethanol, such as corn and sugar cane. Ethanol from algae is possible by converting the starch (the storage component) and Cellulose (the cell wall component). Put simply, lipids in algae oil can be made into biodiesel, while the carbohydrates can be converted to ethanol. Algae are the optimal source for second generation bioethanol due to the fact that they are high in carbohydrates/polysaccharides and thin cellulose walls  It’s not that it’s difficult to make ethanol from algae.  Veridium Corp is a subsidiary of GreenShift. (Mar 2006)  The real problem is that there are so many more valuable products to produce from it, such as carrageenan, agar, and dozens of valuable compounds. In comparison, alcohol is a low-priced product. Algae Species for Ethanol Production  Some prominent strains of algae that have a high carbohydrate content and hence are promising candidates for ethanol production.  Sargassum  Glacilaria  Prymnesium parvum  Euglena gracilis

Conclusion  Even with few challenges taken into consideration, the natural advantages of ethanol production from algae, look to make it one of the foremost players in the clean energy market.  Ethanol fuel production holds future promise for developing countries: ◦ More jobs; ◦ Energy independence. Unfortunately, due to some time constraints and unavoidable circumstances I have been unable to begin with my laboratory preparation of the bioethanol using algae. Hence I plan to begin it and complete it by the end of next semester.