Computer Controlled Bioethanol Process Unit (EBEC)
PL-112452
The Computer Controlled Bioethanol Process Unit, referred to as "EBEC," is crafted for in-depth study and control of bioethanol production on a laboratory scale. This unit enables comprehensive monitoring and examination of essential stages, from the liquefaction and saccharification of raw materials to the sugar-to-ethanol conversion and distillation.
The setup is composed of three main sections: a mash tank, a fermentation tank, and a distillation unit. All components in contact with process materials (except the distillation unit) are made from stainless steel, while the distillation unit uses borosilicate glass, and sight glasses are crafted from Neoceram glass.
The mash tank has an inlet on its upper cover for adding water, starch, and enzymes. Its base is slightly sloped toward a port for draining the mixture or transferring it to the fermentation tank. During the mashing stage, starches are converted into glucose, facilitated by the addition of the alpha-amylase enzyme for liquefaction. Next, saccharification begins with the addition of glucoamylase. The tank includes sensors to monitor temperature and pH, which can be adjusted by adding acid or base through a dedicated circuit system.
After saccharification, the mixture moves to the fermentation tank, which has a similarly inclined base for easy draining or pumping into the distillation unit. Fermentation occurs when yeast is added, resulting in the production of ethanol and CO2. A sensor measures the temperature of the fermentation mixture.
Both tanks are indirectly heated by hot water in a jacket and continuously stirred. Sight glasses on both tanks allow real-time observation. The temperature in the tanks is maintained by a PID controller, which uses two temperature sensors at the jacket outlet to achieve the target temperature.
Thermal control of the mash and fermentation tanks is provided by a hot water system consisting of a thermostatic bath and a pump, with an additional temperature sensor placed in the bath.
Following fermentation, the mixture is transferred to the distillation unit. This unit contains a heating mantle, a stirrer, a distillation column, a cold finger (or dephlegmator), a condenser, and a decanting funnel, with four temperature sensors positioned at various points.
The Computer Controlled Unit includes the EDIBON Computer Control System (SCADA), comprising the main unit, a Control Interface Box, a Data Acquisition Board, and software for computer control, data acquisition, and data management to oversee the process and parameters.
- EG5C. Unit:
- Anodized aluminum frame and panels made of painted steel.
- The unit includes wheels to facilitate its mobility.
- Main metallic elements made of stainless steel.
- Diagram in the front panel with distribution of the elements similar to the real one.
- All the vessels, valves and other accessories in contact with process materials (except the distillation unit) are made of stainless steel. The distillation unit is made of borosilicate glass. Sight glasses are made of Neoceram glass.
The “EBEC” unit mainly consists of:
- Mash tank.
- Fermentation tank.
- Distillation unit.
- Two computer controlled diaphragm pumps to introduce the solution into the fermentation tank and the distillation unit.
- Temperature sensors.
- pH sensor measures the pH of the mash inside the mash tank.
- Hot water circulation system.
- Acid/base circuit system.
- Seven valves
The complete unit includes as well:
- Advanced Real-Time SCADA.
- Open Control + Multicontrol + Real-Time Control.
- Specialized EDIBON Control Software based on LabVIEW.
- National Instruments Data Acquisition board (250 KS/s, kilo samples per second).
- Calibration exercises, which are included, teach the user how to calibrate a sensor and the importance of checking the accuracy of the sensors before taking measurements.
- Projector and/or electronic whiteboard compatibility allows the unit to be explained and demonstrated to an entire class at one time.
- Capable of doing applied research, real industrial simulation, training courses, etc.
- Remote operation and control by the user and remote control for EDIBON technical support, are always included.
- Totally safe, utilizing 4 safety systems (Mechanical, Electrical, Electronic and Software).
- Designed and manufactured under several quality standards.
- Optional ICAI software to create, edit and carry out practical exercises, tests, exams, calculations, etc. Apart from monitoring user’s knowledge and progress reached.
- This unit has been designed for future expansion and integration. A common expansion is the EDIBON Scada-Net (ESN) System which enables multiple students to simultaneously operate many units in a network.
- EBEC/CIB. Control Interface Box.
- EBEC/CCSOF. PID Computer Control + Data Acquisition + Data Management Software
- Cables and Accessories, for normal operation.
- Manuals: This unit is supplied with 8 manuals: Required services, Assembly and Installation, Interface and Control software, Starting-up, Safety, Maintenance, Calibration and Practices manuals.
EXERCISES AND PRACTICAL POSSIBILITIES TO BE DONE WITH THE MAIN ITEMS
- Familiarization with the individual steps required for bioethanol production.
- Familiarization with the plant components required for bioethanol production.
- Study of the effect of temperature on bioethanol purity.
- Study of the effect of pH on bioethanol yield.
- Study of the effect of mashing time on bioethanol yield.
- Study of the effect of fermentation time on bioethanol yield.
- Study of the use of different raw materials to produce bioethanol.
- Study of the effect of adding different types of yeast to the fermentation.
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