Industrial Alcohol
Industrial alcohol was an outgrowth of alcoholic
beverages, but now it has become important by
virtue of its economically useful properties as a
solvent and for syntheses of other chemicals.
The completely denatured formula are Admixtures
of substances which are difficult to separate from
the alcohol which smells and taste bad. All this
being designed to render the alcohol nonpotable.
A typical completely denatured alcohol formula
follows:
To every 100 gal of ethyl alcohol of not less than
160 proof add:
0.125 gal of Pyronate
.50 gal of acetadol
2.50 gal of methyl isobutyl ketone
1.0 gal of kerosene
The federal government has recognized the needs of
industry for alcohol in such form that it can be enter into
specialized manufacturing process where the denaturant
used in completely denatured alcohol would interfere.
Since 1906, when the first U.S. denatured alcohol law was
passed, many formulas for specially denatured alcohol
have been approved by the federal authorities. Such
special formula are limited to certain designed process
and are manufactured, stored, and used under bond to
prevent unlawful consumption. However , the 40 approved
special formulas under their authorized uses enter into an
exceedingly broad section of the entire industrial life of the
nation.
A proof gallon (tax gallon or 3.785L) signifies gallon containing 50% alcohol
by volume.
Ordinary alcohol of 95% strength is thus 190-proof alcohol, and pure
anhydrous alcohol is 200 proof.
Withdrawals of specially denatured alcohol in 1978 amounted 222.3X10^6
wine gallons and only 1.14X10^6 wine gallons of completely alcohol.
Typical specially denatured formulas are
To every 100 gal of 190-proof ethyl alcohol add:
SD No. 1. Approved wood alcohol. 5 gal. withdrawals for authorized uses:
plastics, dehydration, explosive, food products, chemicals, etc.
SD No. 2B. Benzene 0.5 gal. Withdrawal for authorized uses: plastics,
dehydration, explosive, food products, chemicals, etc.
SD No. 29. 100% acetaldehyde, 1 gal. or an alcoholic solution of
acetaldahyde(20%) 5 gal Withdrawal for authorized uses: manufacturing
acetaldehyde, acetic acid, aster ether, etc.
Making of Industrial Alcohol
MANUFACTURE
RAW MATERIALS
Alcohol from cellulosic materials, wood, wood waste, and
sulfite liquors is considered principally under wood
hydrolysis.
Corn is considered to be the most promising raw
materials for fermentation to alcohol, especially for
gasohol.
If sucrose is fermented it must first be inverted by the
enzyme invertase.
The fusel oil, obtained from yeast fermentations, is
thought to be furnished by the protein materials in the
mash fermented.
Comparison of Fermentation with direct
Hydration of Ethene
Fermentation
a batch process. everything is put into the
container and then left until fermentation is
complete.
very slow
uses gentle temperatures and atmospheric
pressure
uses renewable resources based on plant
materials.
Hydration of Ethene
a continuous flow process
a stream reactants is passed continuously over a
catalyst
very rapid
uses high temperature and pressures
uses finite resources
Requirements in Plant Procedures:
Steam Heating
Distillation
Power
pumping
Water
condensation
cooling
BEERS, WINES, AND LIQUORS
3 groups of alcoholic beverages
Malt liquors - Beer and Ale
Fermented wines - Wines
Distilled liquours - Distilled fermented
liquors
Raw materials - are grains or fruits with
carbohydrates.
Examples are: corn, barely, and rice, and
grapes
BEERS
-Low alcohol content
between 2%-7%.
-Brewing various
cereals with hops.
-For beers the most
important cereal is
barely.
Mashing. Extraction of the valuable constituents of
malt, malt adjuncts, and sugars by macerating the
fround materials with 190-230 L of water per 100
kg of materials and treating with water to prevent
too high pH, wich would tend to make a dark beer.
The flowchart for beer manufacture may be divided
into three groups of procedures:
1. Brewing of the mash through the cooled hopped
wort
2. The fermentation
3. Storage, finishing, and packaging for market.
Process:
Insoluble starch to liquefied starch by
pressure cooker and soluble malt starch to
dextrin and malt sugars.
Mixed with the rest of the malt.
Sparging for complete recovery.
Preparation of wort carried out in a mash
tub.
The wort is separated from the insoluble
spent grains.
Run into the copper wort cooker in
contact with the hops for the wort to get
concentrated, to sterilize it, to destroy all
the enzymes, to agulate certain proteins
by heat, etc.
Spent hops os separated from the wort
through a whrilpool separator.
Wort is then cooled in a plate heat
exchager and then aerated under
controlled conditions to facilitate the start
of fermentation.
Fermentation proceeds, initially at temperatures between
4-6 degrees celsius and then rises to 14 degrees celsius.
As the beer leaves the fermentors, it contains in
suspension hop resins, insoluble nitrogenous
substances, and a fair amount of yeast.
It is sent to the lagering tanks or aging tanks to
proceed in second fermentation.
For 4 months it is aged in about 0-2 degrees celsius.
Tannins and proteins are removed by settling.
Filtration through a pulp filter.
Bottling.
Pasteurization follows but some beers
are does not undergo on this process
instead, they are filtered through a fine
membranes which removes residual
yeasts and harmful bacterias.
WINES
Fermentation of the juice grape.
Classifications are:
1. Natural (7%-14%)
2. Fortified (14%-30%) sweet or dry, still or
sparkling.
PROCESS
Crushing of grapes via maceration, and removal
of stems.
The resulting pulp is pumped into a tank (11k 38k L).
Active culture of selected and cultivated yeast
is added.
Fermentation proceeds.
Slight rise in temperature. Cooling would be
necessary to keep the temperature below 30
degrees celsius.
CO2 is formed and extraction of the color and
the tannins from the skins and seeds.
Cellar treatment is given to the wine to clear it, improve
the taste, and decrease the time of aging. it is this time
where part of the matter in suspension is removed, and
the racked for clarification.
The wine is corrected to commercial standards by
blending it with other winess and by the addition of
sugar, acids, or tannins.
Several treatment to the wine, it is then aged quickly to
produce a good sweet wine in 4 months time.
Further treatment is carried out such as pasteurization,
refrigeration, sunlight, uv light, ozone, agitation, and
aeration before it is packed and traded.
DISTILLED SPIRITS
1. The Fermenter
2 .The Pot
3 .The Distillation
Column
4 .The Lyne Arm
5 .The Condenser
6 .The Distillate
7 .Aging Barrels
A modern
distillery
1. The Fermenter - turning the mash into a wash (10 or 12 percent
alcohol by volume)
2 .The Pot - The heat builds for a half-hour or so to raise the wash to its
boiling points. Ethanol boils at 173 degrees F; water at 212.
3 .The Distillation Column - As blended alcohol and water vapor rises
from the pot, it enters a cool copper column. Most of the vapor
condenses and falls back into the pot as reflux.
4 .The Lyne Arm - Concentrated alcohol vapor enters a horizontal pipe
called a lyne arm.
5 .The Condenser - As vapor cools, it condenses into liquid ethanol,
which drips from the condenser into a collection vessel.
6 .The Distillate - Head, Heart, Tail.
7 .Aging Barrels - Bourbon whiskey is aged in new but charred oak
barrels
Butyl alcohol and Acetone
In fermentation of corn using Clostridium
acetobutylicum bacteria it gave 2 parts
butyl alcohol to 1 part acetone
New cultures feeding on molasses were
developed which gave a more dynamic
solvent ratio 3 parts butyl alcohol to 1 part
acetone.
Acetonebutanolethanol (ABE)
fermentation is a process that uses
bacterial fermentation to produce acetone,
n-Butanol, and ethanol from carbohydrates
such as starch and glucose. It was
developed by the chemist Chaim
Weizmann and was the primary process
used to make acetone during World War I,
such as to produce cordite, a substance
essential for the British war industry.
The process may be like how yeast
ferments sugars to produce ethanol for
wine, beer, or fuel, but the organisms that
carry out the ABE fermentation are strictly
anaerobic. The ABE fermentation
produces solvents in a ratio of 3 parts
acetone, 6 parts butanol to 1 part ethanol.
It usually uses a strain of bacteria from the
Class Clostridia. Clostridium
acetobutylicum is the most well-studied
and widely used species.
ACETIC ACID AND VINEGAR
CITRIC ACID
one of the most versatile organic acid.
is a weak organic acid that is produced
as a white crystalline powder.
source:
produced naturally in citrus fruits
Uses:
an acidulent in carbonated beverages,
jams, jellies, detergents,cosmetics, etc..
manufactured by aerobic fermentation of
crude sugar or corn sugar by a special
strain of Aspergillus niger.
Production
First, separating off the mycelium from the
broth.
Second, filtering off and washing the
resultant calcium citrate
Finally, decomposing the citrate with
sulfuric acid.
The calcium sulfate formed from this
decomposation is filtered off as a waste
by-product.
MISCELLANEOUS
COMPOUNDS
Monosodium Glutamate
Monosodium glutamate (MSG) is a flavor
enhancer added to thousands of foods.
MSG is an excitotoxin
MSG is approximately 78 percent free
glutamic acid, 21 percent sodium, and up to 1
percent contaminants.
L-Glutamic acid can be obtained directly from
fermentation of carbohydrates with
Micrococcus gluamicus or Brevibacterium
divaricatum
L-Lysine
L-lysine may be formed by microorganisms acting
on carbohydrates.
The usal organisms are:
Micrococcus glutamicus
Brevibacaterium flavum
Corynebacterium acetoglutamicum
Microbacterium ammoniaphilum
Dihydroxyacetone
Dihydroxyacetone is made by the
action of sorbose bacterium
fermentaion of glycerin.
Dihydroxyacetone is a colorless
three-carbon sugar that causes a
chemical reaction resulting in a
tan.
Pharamaceutical Products
Microbial fermentation is the
basis for the production of a
wide range of pharmaceutical
products, targeting practically
any medical indication.
Fermentation might also be the
sole source for natural therapeutic
proteins exclusively expressed in
microbial systems.
Micro-organisms that are typically used within the pharmaceutical
industry include:
Prokaryotes such as bacteria
(e.g. Escherichia coli, Staphylococcus aureus)
Streptomycetes
(e.g. Streptomyces spp, Actinomyces spp),
Eukaryotes such as filamentous fungi
(e.g., Nigrospora spp, Aspergillus spp,)
Yeast
(e.g. Saccharomyces cereviciae,Pichia pastoris).
ENZYMES
Enzymes are organic catalysts form in the
living cells of plants and animals, which is
essential in bringing about specific
biochemical reaction in living cells.
Enzymes have one function only, and work
like a key that fits in a lock. Only when the
right enzyme finds the right material it can
work upon, does a biochemical reaction
occur.
Characterictics of Enzymes
First, they increase the rate of a natural
chemical reaction.
Secondly, they typically only react with one
specific substrate or reactant.
Thirdly, enzyme activity is regulated and
controlled within the cell through several
different means, including regulation by
inhibitors and activators.