Phn I: CNG NGH SN XUT BIO-ETHANOL

I.

TNG QUAN V CNG NGH SN XUT ETHANOL

1. Cng ngh sn xut Ethanol 1. nh ngha

Cng ngh sn xut ethanol l vic thc hin qu trnh chuyn ha cc nguyn liu cha tinh bt, ng, xenluloza thnh Ethanol (C2H5OH).
2. Cc phng php sn xut ethanol

Ethanol c th sn xut bng nhiu phng php khc nhau

Cng ngh sn xut ethanol tng hp:

Cng ngh sn xut ethanol tng hp sn xut ethanol bng nhiu phng php ho hc khc nhau. Trong cng ngh tng hp ho du, ethanol c sn xut bng dy chuyn cng ngh hydrat ho i vi kh etylen hoc cng ngh cacbonyl ho vi methanol. Hydrat ho: CH2=CH2 + H2O Cacbonyl:

C2H5OH C2H5OH + H2O

CH3OH + CO + 2 H2

Cng ngh sn xut ethanol sinh hc:

Cng ngh ny da trn qu trnh ln men cc ngun hydratcacbon c trong t nhin nh: nc ng p, ng, sn, mn, g... (C6H10O5)n + n H2O nC6H12O6 2C2H5OH + 2CO2 + Q

Trong qu trnh sn xut ethanol sinh hc c th phn thnh 2 cng on l cng on ln men nhm sn xut Bio-ethanol c nng thp v cng on chng ct - lm khan sn xut ethanol c nng cao phi trn vo xng. Hin nay sn xut cn ch yu l theo phng php sinh hc.
2. Cc ngun nguyn liu sn xut Bio-ethanol

Ngun nguyn liu sn xut Bio-ethanol ch yu t:

Cc loi nguyn liu cha ng: ma, c ci ng, tht nt Cc loi nguyn liu cha tinh bt: sn, ng, go, la mch, la m
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Cc loi nguyn liu cha cellulose

Tuy nhin, ty theo li th v ngun nguyn liu ca mi quc gia, ngi ta chn loi nguyn liu c li th nht sn xut Bio-Ethanol nhin liu. Vit Nam, cc ngun nguyn liu thch hp c th sn xut Bio-Ethanol l ma, sn, go, ng v r ng.
3. S khc nhau gia cng ngh xn xut cn thc phm v cn

nhin liu
1. Mc ch s dng

Cn thc phm:

Ngi ta sn xut cn thc phm l pha ch thnh ru v cc loi ung c cn. Cc loi ung ny c dng trc tip cho con ngi nn trong thnh phm ca cn thc phm ch bao gm ch yu l etanol. Cc loi cn u, du fusel, andehyt, axit, este c hi cho sc kho phi cng t cng tt v khng c vt qu ngng qui nh. Ngoi ra, do phi pha long khi pha ch, nn khng bt buc phi sn xut ra cn c nng cao.

Cn nhin liu:

Cn nhin liu c sn xut dng lm cht t. Khi sn xut cn nhin liu ngi ta khng cn phi tch b cn tp. Tri vi cn thc phm, cn nhin liu bt buc phi tch nc trit , v nu hm lng nc c trong cn cng cao th lm gim hiu qu ca qu trnh chy v nh hng n ng c thit b, ng thi khi pha cn vo xng s dn n s phn tch pha. Cng chnh v vy m khi sn xut cn nhin liu, ngi ta phi chn gii php cng ngh thch hp loi b nc trong cn, to ra cn c nng rt cao.
2. S khc nhau trong cng ngh sn xut ethanol thc

phm v ethanol nhin liu

S khc nhau trong cng ngh sn xut ethanol thc phm v ethanol nhin liu ch yu xy ra cng on cui: chng ct, tch nc: Cng on Ethanol thc phm Ethanol nhin liu

Phc tp hn do cn tch trit cc cht c hi cho Khng cn loi b cn

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Chng sc khe con ngi: cn u, du fusel, adehyte ct Tch Khng cn phi tch nc nng nng ethanol nc

tp Phi tch nc nng nng ethanol ln 99.8%

Ngoi ra, trnh s dng ethanol nhin liu cho cc mc ch khc, cn nhin liu sau khi tch nc c bin tnh bng cch thm vo 1,96 5%v/v cht bin tnh. Khi ethanol dng lm nhin liu c gi l ethanol bin tnh. Cht bin tnh c th dng l xng khng ch, naphta.
II.

CNG NGH SN XUT BIO-ETHANOL T TINH BT

1. Gii thiu v nguyn liu sn

V c ban cu sn gm 3 phn chinh: vo, thit cu va loi (ngoai ra con co cung va r cu). Vo sn gm co 2 phn la vo g va vo cui: Vo g co tac dung bao v cu va chng mt nc cua cu, tuy nhin vo g d bi mt khi thu hoach va vn chuyn. Vo cui la mt lp t bao cng phu bn ngoai, thanh phn chu yu la xenluloza ngoai ra con co cha polyphenol, enzim, va linamarin. Phn thit cu co cha nhiu tinh bt, protein va cac cht du, mt it polyphenol, c t va enzim. Loi sn nm tm cu doc sut chiu dai,thanh phn chu yu la xenluloza. Loi co chc nng dn nc va cac cht dinh dng gia cy va cu ng thi giup thoat nc khi phi hoc sy sn. Thanh phn sn ti dao ng trong gii han kha ln: tinh bt 20 - 34%, protein 0,8 - 1,2%, cht beo 0,3 - 0,4%, xenluloza 1 - 3,1%, cht tro 0,54%, polyphenol 0,1 - 0,3% va nc 60 - 74,2%. Ngoai ra trong sn con cha mt lng Vitamin va c t. Vitamin trong sn thuc nhom B. Cac Vitamin nay se bi mt mt phn khi ch bin va nht la khi nu trong san xut ru. c t trong sn co tn chung la phazeolunatin gm 2 glucozit Linamarin va Lotaustralin. Cac c t nay thng tp trung vo cui. Binh thng phazeolunatin khng c nhng khi bi thuy phn thi cac glucozit nay se giai phong axit HCN. Sn ti a thai lat va phi kh se giam ang k ham lng glucozit gy c k trn. c bit trong san xut ru, khi nu nhit cao a pha loang nc nn vi ham lng it cha anh hng n nm men. Hn na cac mui xyanat khi chng ct khng bay hi nn bi loai cung ba ru. Thi v thu hoch: Duyn Hi Min Trung: Vng ng bng, vng thp trng thu hoch vo ma h thu (khong thng 9 n thng 10) nhm trnh ma ma lt, min ni v nhng vng cao thu hoch thng 12 n thng 3. Ty Nguyn thi v thu hoch nguyn liu sn thng 12 n thng 3.
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Ngun thu mua: Petrosetco Trading s cung cp mt phn nguyn liu sn lt u vo. Bn cnh , Nh my s ch ng quy hoch vng nguyn liu ti mt s khu vc nh Qung Ngi, Bnh nh, Ph Yn v Ty Nguyn. Tiu chun sn lt s dng cho Nh my: Hnh dng lt sn: ng knh 30 70 mm, b dy: 20 30 mm m: 12 14 %kl Hm lng tinh bt: 70 75 %klg Protein: 1,5 1,8 %klg Hm lng tro: 1,8 3,0 %klg Lipid: 0,5 0,9 %klg x: 2,1 5,0 %klg Cc tp cht khc: 3,0 %klg
2. Cc nh cung cp cng ngh sn xut Bio-Ethanol nhin liu

trn Th gii

Trn th gii, hin nay c rt nhiu nh cung cp cng ngh sn xut Bio-Ethanol nhin liu. Mt s cc nh cung cp cng ngh sn xut Bio-Ethanol nhin liu hng u trn th gii nh:

Lurgi AG, Frankfurt, c Technip-Coflexip, Paris, Php Delta-T Corporation, Virginia, M Katzen International INC., Cincinnati, Ohio, M Tomsa Destil. S.L, Madrid, Ty Ban Nha Vogelbusch GmbH, Vienna, o

Ngoi cc nh cung cp bn quyn cng ngh k trn, trong lnh vc sn xut BioEthanol nhin liu cn c mt s cc nh cung cp cng ngh, thit b mua bn quyn cng ngh ca cc hng nu trn ri t nghin cu pht trin cng ngh, bao gm:

Praj Industries Limited, Pune, n Alfa Laval (India) Limited, Pune, n Filli impianti, Monteriggioni, Italia Kolon Engineering & Construction Co. Ltd., Kyunggi-Do, Hn Quc Changhae Engineering Co.Ltd, Jeonju, Hn Quc Rushan Risheng Machinery Manufacture Co., Ltd, Trung Quc

Trong phm vi ca cng ny, chng ti trnh by cc dy chuyn sn xut ca cc nh cung cp cng ngh trong cc H s cho thu i vi D n ny, c th:
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Vogelbusch GmbH, Vienna, o Katzen International INC., Cincinnati, Ohio, M Praj Industries Limited, Pune, n Delta-T Corporation, Virginia, M
1. Cng ngh Vogelbusch

2.1.1. Cng on nghin: Sn lt v n nh my bng xe ti c xung phu tip nhn. Sau sn c tch b tp cht kim loi ri n kho cha. T kho cha, sn c lm sch s b v cp cho thng cha trung gian trc khi vo my nghin ba. Sn phm sau nghin c phn loi bng sng phn loi, y nhng sn phm c kch thc cha t s c quay v li thng cha trung gian trc my nghin, bt sn vi kch thc t yu cu c cha thng cha bt. Bi sinh ra s c x l bng h thng lc c bit vi s h tr ca my thi kh. 2.1.2. Cng on h ha ng ha:

Bt sn s c ha trn vi nc sch, hi ngng v dch hm long sau ly tm. Tinh bt s c chuyn ha/ct mch thnh dextrin, ng a bi enzyme Alpha amylaza nhit , p sut v pH thch hp.

Qu trnh nu s s dng s phun hi trc tip. Dch sau khi h ha s c lm mt bi thit b lm lnh nhanh hot ng iu kin chn khng.

Dch sau khi lm lnh nhanh c cp cho thng ng ha. Ti y, mt phn dch hm long sau ly tm cng c b sung, dung dch H2SO4 iu chnh pH v enzyme Gluco-amylaza chuyn ha dextrin, ng a thnh ng Gluc. 2.1.3. Cng on ln men:

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Vogelbusch s dng cng ngh ln men lin tc. Kt qu ca vic s dng cng ngh nh vy s gim lao ng, gim lng dung dch CIP (kt qu l gim ha cht v chi ph), cng sut ln men tng khong 130% so vi h thng ln men theo m v lm tng sn lng ethanol.

Bn cht ca phng php ln men lin tc l ri u cc giai on ln men m mi giai on c thc hin trong mt hoc nhiu thit b ln men c lin h vi nhau. Dng dch s ln lt chy qua cc thng ln men v gim chn c ly ra t bn cui cng.

Trong thit k dy chuyn ny, qu trnh ln men c th thc hin gin on bng cch ng cc van kt ni gia cc thng ln men cch ly cc thng vi nhau. Khi tng thng s c np liu v ly gim chn ra mt cch c lp (ln men gin on tng thng). 2.1.4. Cng on chng ct tch nc:

S dng cng ngh chng ct a p sut, h thng chng ct h thng chng ct ny s dng nhit nng ti u hn v do gim lng hi tiu th.

H thng cc thp gm:

Thp ct I vi kh kh mt phn (MC 1) Thp ct II (MC 2) Thp kh Anehyt (AC) Thp ct tinh I (RC1) Thp ct tinh II (RC2)

Cc thp hot ng mc p sut khc nhau cc thp c th c gia nhit bi hi nh ca thp khc.

Hi cn t khu vc chng ct s c gia nhit siu tc nhm nng nhit ln khong 115oC v ha hi hon ton. Sau hi cn s c tch nc bng ry phn t 3A. Sn phm cn khan s c a i ngng t, lm mt v tn cha.
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Sau mt thi gian hp ph, thp hp ph b bo ha v thp c ti sinh bng mt phn dng hi cn khan i ra khi thp hp ph. Dng hi cn ti sinh c cha nc s quay tr li khu vc chng ct. 2.1.5. Cng on x l dch hm:

Dch hm thi t thp chng ct c a n my ly tm nhm tch b cc thnh phn rn l lng. Dch hm long sau ly tm, mt phn s hi lu li qu trnh cng ngh, phn cn li c a i c c bc hi.

B m tch ra t my ly tm s c trn vi phn cn y t thit b c c, sau c a i sy lm thc n gia sc.

Hi sinh ra t thit b sy, c c s c thu hi v quay tr li qu trnh cng ngh.

2. Cng ngh Katzen

Qu trnh cng ngh gm cc cng on chnh nh sau:

Chun b dch, nu v ha lng Ln men v h thng v sinh ti ch (CIP) Chng ct v tch nc Ly tm Hn hp sn phm

2.2.1 Chun b dch, nu v ha lng

Bt sn a vo thng ha trn cng vi nc pha long, bao gm nc cng ngh v dng dch hm tun hon (backset). Lu lng dng nc pha long c iu khin bi iu khin mc trong thng ha dch.

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Mc ch c bn ca qu trn bt l nng cng sut h thng nu. Dch bt c tun hon quanh thng trn bt nh bm tun hon ca thng trn bt.

Cc bm nguyn liu nu chuyn dch bt t thng trn bt n thit b nu phun c iu khin dng. Thit b nu phun s dng hi nc 10 bar. ng thi, nc t thp tinh c th c a vo thit b nu.

Dch bt i vo thng h ha v c tun hon trong thng h ha c iu khin dng bi bm tun hon thng h ha. Enzym h ha c a vo thng h ha v m bo thi gian lu cho enzym thy phn mt phn tinh bt thnh ng malto. iu khin pH, dung dch amoniac c bm vo ca ht ca bm tun hon thng h ha v c iu khin bng cch kim sot pH trong chu k tun hon.

Dch sau khi h ha c chuyn n thit b lm mt dch bt. Ti y, dng dch hm tun hon (backset) cng c thm vo v axit H2SO4 a vo. iu ny lm gim hm lng cht rn ca dch bt v gim pH, nu cn, m bo iu kin ln men.

Dch bt c qua mt h thng thit b lm mt h nhit xung nhit ln men. 2. Ln men v h thng v sinh ti ch

Cc b phn chnh ca h thng ln men bao gm thit b hp ph Ethanol, h thng nhn men, cc thit b ln men vi bm v thit b lm mt, h thng v sinh ti ch, h thng nh lng xt, v h thng lu tr, vn chuyn v nh lng enzym.

H thng ln men to mi trng ph hp cho vic thy phn dextrin thnh dextroza v maltoza v su hn.

Ln men dextroza v malto thnh Ethanol bi chng men saccharomyces cerevisiae. Sut trong qu trnh ln men, nm men tri qua qu trnh pht trin nhanh, v sinh ra Ethanol, CO2, cc sn phm ph khc v nng lng. Thng ln men xem nh l bnh
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phn ng trong xy ra cng lc thy phn dextrin (ng ha) v ln men. Bn thng ln men, TK-401A-D, mi thng c lm y trong 15 gi. Tng qu trnh ln men gin on bao gm lm y thng, x ra v lm v sinh trong mt chu k 60 gi.

Hu ht dch bt sau khi h ha a trc tip vo mt trong bn thng ln men. Tuy nhin, mt phn dch h ha c cp cho thng nhn men, y men ging c nhn ln v pha tng trng mnh t loi b s chm tr khi ln men bng men kh v gim lng men kh s dng.

Nc cng ngh c gia nhit t thng nc cng ngh c s dng ha tan cc thnh phn trong thng ha cht dinh dng. Men kh, enzym, nc, v bt k cc cht khng sinh c thm vo thng ny, c ha trn v sau chuyn n thng ha men. V c chuyn tr li dng dch bt cung cp cho thng ln men ang c lm y.

trnh cc cht rn kt ta trong thng ln men, dch trong thng c bm tun hon v loi b nhit sinh ra trong qu trnh ln men, duy tr nhit ln men khng i, dch bt c tun hon qua thit b lm mt bn ngoi thng ln men. Khi qu trnh ln men kt thc, dch sau khi ln men c a vo thng cha gim chn.

hn ch s nhim khun v tng hiu sut chuyn ha thnh Ethanol, cc thng ln men c lm sch ha hc v v sinh sau mi chu trnh. Qu trnh lm sch thc hin p sut cao, u phun quay c th ra cc cht rn trn thnh v y ca cc thng. Cc thit b lm mt dch bt c lm sch bng cch tun hon dung dch v sinh ti ch thng qua cc ng.
3. Chng ct v tch nc

H thng chng ct gm hai thp:

Thp tch gim chn Thp tinh ch

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Hi ethanol ra khi thp tinh vi nng cn ti thiu l 91.7%kl c gia nhit siu tc, s dng hi 10 bar ngn cn pha lng i vo h thng tch nc ry phn t, c th lm gim hiu sut hp ph.

Hi ethanol sau khi c gia nhit siu tc c a n cc thp tch nc ry phn t. Nc c gi li trong cc mao qun ca ry phn t , hi ethanol khan thot ra.

Cc thp tch nc lm vic theo chu k, khi mt thp c ti sinh th mt thp thc hin hp ph nc. Qu trnh ti sinh c thc hin chn khng, nc c gii hp khi cc ry phn t.

Dng sau khi ti sinh bao gm ethanol v nc c a tr li khu chng ct. Dng ethanol khan c ngng t, lm mt v a i tn cha.
4. Ly tm

Hm thi (whole stillage) c a n thng cha hm thi, ti y hm thi cha trong thng cng c bm tun hon. Hm thi c a n h thng ly tm tch ra thnh 2 dng: b m (wet cake) v dch hm long. Phn b m (wet cake) c a n my sy lm thc n gia sc. Hm long s c tun hon mt phn tr li qu trnh cng ngh, phn cn li s c c c bc hi. 2.2.5 Phi trn sn phm

Ethanol khan thnh phm c chuyn n mt trong hai thng cha sn phm trung gian. Nu ethanol thnh phm t cht lng (on-spec) s c bm n khu b cha sn phm.

Trong trng hp sn phm khng t cht lng (off-spec), n s c a trc tip t mt trong hai thng cha sn phm trung gian n thng cha sn phm tun hon. Sau c bm dn dn tr li thp tinh ti sn xut nhm thu hi ethanol.

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Trong qu trnh chuyn ethanol n b lu tr sn phm, ethanol c bin tnh bng cch thm vo 2-5%v xng khng ch.
3. Cng ngh Praj

Qu trnh sn xut ethanol t sn lt da theo phng php chng ct bao gm nghin, loi b ct , h ho, ln men, v chng ct - tch nc. X l nc thi theo phng php gn lng, x l bio-gas nh l phng php x l c bn v xc kh nh l phng php x l ln hai.

Khu cng ngh chnh c th c chia thnh 5 mc chnh nh sau:

Nghin sn v tch ct: Trong khu vc ny, sn lt c lm sch, nghin v ho bt to thnh dch bt sn (slury). H ho: Trong khu vc ny, tinh bt c h ho khong 115oC vi s c mt ca enzym. ng ho v ln men HIFERM-NM: Trong khu vc ny, dch h ho u tin c chuyn ho thnh ng, sau ng ln men c c ln men ng thi bi nm men kh hot ng to thnh ethanol Chng ct ECOFINE MPR: Trong khu vc ny, dch bt sau khi ln men c chng ct trong hai h thng thp chng ct to thnh ethanol ngm nc 93%v/v. Trong trng hp cn tng nng ln 95% th s dng hi nhiu hn. Tch b v x l nc thi theo phng php x l methanol ECOMET XPD Dch hm c sn xut nh l mt sn phm ph ca khu chng ct, c tch trong my tch ly tm to thnh b m v dch hm long.

2.3.1. M t cng ngh cho ln men HIFERM-NM 2.3.1.1 H ha

Bt sn c x l trong khu vc x l s b sn to thnh dch bt. Ct cng c loi b trong giai on x l ny. Dch bt ny c s dng lm nguyn liu cho cng on h ha. Dch bt trong khu x l s b sn c ha vi dng ra khi y thp tinh.

Dng dch hm tun hon v dch bt c ha trn trong thng chun b dch. N c gia nhit n 105oC. Dch ny c a vo thng h ha u tin. Trong thng h ha ny, dch bt c duy tr 85oC.
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Enzym h ha c thm vo cng vi enzym gim nht. Sau khi h ha, dch bt c lm mt v bm n khu vc ng ha v ln men. 2.3.1.2 ng ho v ln men

Men ging c chun b trong bnh chun b men bi dch bt c tit trng vi men kh hot ha. Nhit ti u c duy tr bng cch tun hon qua thit b lm mt bng nc. Cc thnh phn ca bnh chun b men c chuyn n thng ln men s b.

Thng ln men s b c lm y dch bt v np cc cht ca thng nhn men. Mc ch ca vic ln men s b c sc kh (aerated) cho php cc t bo nm men pht trin nhiu hn v gim s nhim khun ca thng nhn men. Khi cc cht trong thng ln men s b c chuyn n thng nhn men chnh, nng ca nm men cao v cn bn c th gim c thi gian tr lin quan n s pht trin ca nm men trong qu trnh ln men.

Enzym ng ha c thm vo trong thng ln men. Chng s chuyn ha tinh bt thnh ng. y c bn l s chuyn ha ca dextrin thnh dextroza. Mc ch ca qu trnh ln men l chuyn cc cht c th ln men c thnh cn.

pH ca dch bt c iu chnh c bn l nh dch hm tun hon (cng l cung cp cht dinh dng) hoc l thm axit vo. Nm men c hiu lc trong mt lng va khi u qu trnh ln men nhanh v kt thc trong vng 60 gi.

Ti giai on u ca chu k, thng ln men c np liu vi dch bt v cc cht ca thng ln men s b. Ln men l qu trnh sinh nhit. Nhit sinh ra c loi b bng cch tun hon lm mt qua thit b trao i nhit bn ngoi. Bm tun hon cng c cung cp bm dch ln men (gim chn) n thng gim chn. Sau thng ln men c lm sch vi nc v dung dch xt, v kh trng cho m tip theo. 2.3.1.3 Ra CO2

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CO2 rt ra trong sut qu trnh ln men s ko theo mt lng ethanol. CO2 ny c a vo thit b ra CO2 bng nc v thu hi lng ethanol b ko theo. 2.3.2 Chng ct

ECOFINE MPR l s cng ngh a p sut vi hai thp chng ct. Cc thp ny bao gm cc dng:

Thp th kt hp tch kh nh thp: vn hnh chn khng Thp tinh: vn hnh p sut d

Dch sau khi ln men c gia nhit trong thit b gia nhit s b v a vo nh ca thp tch kh nh ca thp th. Mt khu vc nh c cung cp nh ca thp th gi l thp tch kh. Dm chn c a vo thp ny v dng i xung thp th.

Hi nh thp th cha ethanol c chuyn n thp tinh sau khi ngng t. Mt phn nh ca dng hi ny c np vo thp tch kh. Trong thp tch kh cc kh ha tan cng vi mt s tp cht c tch ra nh ca thp. Hi ny c ngng t trong thit b ngng t ca thp tch kh v thnh phn ngng t c a n khu vc thp hn ca thp tinh thu hi ethanol.

Phn cn li ca dm chn tch ra khi dng ethanol i xung di thp th v ly ra nh dng nc thi t y ca thp th. Thp th vn hnh chn khng m bo nhit vn hnh thp. nhit thp, ha tan ca mui canxi cao hn nn chng khng kt ta trong thp. V vy thp th t ng cn hn.

Thp tinh c vn hnh p sut tng. Hi c a vo thit b un si y thp, c cung cp y thp.

Cn c lm giu i ra nh v c nng khong 95% v/v. Cn sau tinh ch i ra khi thp v c a i lu tr.
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Dng du fusel t thp tinh c a n thit b tch du fusel, c ho tan vi nc v lp giu du fusel c tch ra. Nc ra du fusel c tun hon tr li thp.

Dng nc tch ra t y thp th mt phn c tun hon li khu vc ln men nh l nc ho tan v phn cn li c a n phn xng x l nc thi. 2.3.3 Tch nc

Qu trnh to thnh cn tinh ch thng qua lp ht m. Hai thp ht m c cung cp cho php vn hnh lin tc: mt thp thc hin qu trnh hp ph trong khi thp kia tin hnh ti sinh.

Nguyn liu l hi qu nhit ca thp tinh, c gia nhit m bo nhit vn hnh, v tun hon n thp ry phn t 1 c gi nh l ang trong giai on tch nc. Sau khi i qua thit b lm kh, hi c ngng t, lm mt v a n b cha sn phm.

Mt phn nh ca hi sn phm c a n thp 2 ang trong giai on ti sinh, p sut chn khng, tin hnh ti sinh.

Giai on ti sinh ht hi nc t cc mao qun ca ry phn t, gip cho thp 2 sn sng cho chu k k tip. Nng dng hi thu hi thp, c ngng t v tun hon tr li thp tinh. 2.3.4 Ly tm tch b

Qu trnh tch c thc hin bi my tch ly tm lin tc tch b m. Dng cht lng l dch hm long t thit b tch c a qua phn hu k kh, theo sau l phn hu hiu kh. 4. Cng ngh Applied Process Technology International APTI (Delta-T):
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1. S khi cng ngh sn xut ethanol

Thuyt minh:

Cng ngh sn xut Bio-Ethanol vi nguyn liu l sn lt (cassava chip), sn lt c a n khu vc nghin, chun b dch v tch ct, y s to thnh dung dch bt ng nht (cassava slurry). Tinh bt trong dung dch bt c chuyn ha thnh ng c kh nng ln men da trn hot ng ca cc enzyme (cng on h ha v nu) v sau ng c chuyn ha thnh Ethanol v CO2 bi hot ng ca men (cng on ln men).

Kh CO2 th s c ra s b bng nc tch lng cn b cun theo, sau CO2 c a n phn xng thu hi v ha lng CO2.

Dch sau ln men (gim chn) c nng Ethanol thp (9 14%v/v), cn phi loi b ti a lng nc bng phng php chng ct, tinh luyn. Tuy nhin do hin tng im ng ph ca hn hp Ethanol v nc nn sau cng on chng ct Bio-Ethanol thu c ch t nng 95-96 %v/v. s dng lm nhin liu, Bio-Ethanol tip tc c a qua cng on tch nc t nng ti thiu 99,8 %v/v.

Dch hm thi ra t y ca hai thp chng ct th c a n Decanter (my ly tm) tch cc thnh phn rn c trong dch hm. Cc bc x l tip theo l sy b v x l nc thi c thu hi Mtan.

Hiu sut ca cc cng on chnh:

Hiu sut ln men: 94% Hiu sut chng ct: 99% Hiu sut tch nc: 99,5% Hiu sut tng ca nh sn xut chnh (t h ha n tch nc): 90,7%
2. S khi ca cm h thng tip nhn sn nghin

th - tn tr - nghin mn

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Cm h thng bao gm t khu tip nhn sn lt n khu vc nghin sn. Sn lt l nguyn liu ca nh my, sau khi ra khi cm ny, sn c nghin mn to thnh bt sn c kch thc t yu cu v chuyn ti cc cng on tip theo ca nh my. Cm h thng bao gm cc h thng nh sau:

H thng tip nhn sn lt H thng vn chuyn sn lt H thng lm sch s b v b gy s b sn Kho cha sn H thng lm sch H thng nghin v cha bt sn

3.2.1 H thng tip nhn sn lt

Sn c vn chuyn bng xe ti (khong 10-15 tn/xe) n nh my. Sau khi kim tra cht lng sn, sn c vo cc phu thu ca h thng tip nhn, sau sn s x t phiu cha n h thng vn chuyn nh trng lc vi lu lng n nh. Trong qu trnh tip nhn sn, s pht sinh rt nhiu bi, gy nhim mi trng, do , ti khu vc ny c trang b h thng khng ch v tip nhn bi, bt k bi pht sinh c thu nhn v tun hon li phu cha.

H thng c thit k vi cng sut 48,67 tn/h v hot ng lin tc 24h/ngy, 7 ngy/tun. 3.2.2 H thng vn chuyn sn lt

Sn c chuyn t khu ny n khu kia trong cm l nh h thng vn chuyn. Mc ch ca h thng ny nh sau:

Vn chuyn sn t h thng tip nhn sn n h thng lm sch s b v b gy sn s b Vn chuyn sn sau khi b gy s b n kho cha hoc h thng lm sch Vn chuyn sn t kho cha n h thng lm sch.

3.2.3 H thng lm sch s b v b gy s b sn

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Sn lt c thu nhn ti nh my c lm sch s b trc khi b gy s b. H thng lm sch s b c thit k phn tch kim loi, ct, t v cc thnh phn khc i theo sn. H thng b gy s b nhm gim kch thc ca sn lt, t kch thc ln thnh kch thc nh hn (khong 15 20mm). Sn sau khi b gy s b c th c vn chuyn n kho lu tr hoc chuyn trc tip vo sn xut. 3.2.4 Kho cha sn

Kho sn c thit k vi nhng yu cu sau:

L loi kho khp kn, c h thng thng thong Cng sut lm vic bng 70% cng sut cha ca ton b kho H thng tip nhn, vn chuyn, tho liu t ng Khng ch m thp hn 14% v nhit cao hn 35oC bng kh nng t nhin hay cng bc nhm m bo tn tht di 3% khi lng sau 6 thng tn cha.

3.2.5 H thng lm sch

H thng s nhn sn t kho cha hoc t h thng b gy s b. Mc ch ca h thng ny l loi b cc tp cht c mt trong sn lt nh t , ct, kim loi trnh gy nguy hi cho cc ba nghin trong h thng nghin. Sn sau khi lm sch s vn chuyn n h thng nghin. H thng lm sch c thit k vi cng sut 37,31 tn sn lt cho 1h hot ng v hot ng lin tc 24h/ngy, 7 ngy/tun. 3.2.6 H thng nghin v cha bt

H thng nghin c thit k vi cng sut 36,22 tn bt sn/h v vi mc ch l nghin sn lt thnh bt t kch thc yu cu cho cc cng on sn xut tip theo. Kch thc v phn trm ht bt c th hin trong bng di y: STT 1 2 3 4 5 Kch thc (micron) <250 >250 >1000 >1180 >1400 Bt (% khi lng) 70 95% 13 20% 2 4% 1 4% 1 2%

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Bt sn sau nghin c cha ti sil trung gian, ti y bt s c cn t ng v chuyn n khu vc chun b dch bt. Sil trung gian c thit k vi sc cha 2h (tc cng sut lm vic l 63 tn) nhm m bo cc cng on pha sau hot ng lin tc trong qu trnh thay li sn hoc cc s c ca my nghin.
3. S dng ca khu vc chun b dch v tch ct

Thuyt minh:

Bt sn sau nghin c ha trn cng vi dng dch t thng TK-1101 gm nc cng ngh, dch hm long v dng dch Grits hi lu t nh h thng cyclone cp 2 ca h thng cyclone tch ct. Dch bt sau c a n thng TK-1102. C 2 thng TK-1101 v TK-1102 u c trang b cnh khuy.

Dch bt t thng TK-1102 c gia nhit ln 40 - 50oC bng dng nc ngng cng ngh ti E-1102 trnh tinh bt l lng trong nc. Sau c dn qua thit b ng nht v n h thng cyclone 3 cp tch ct trit .

H thng cyclone cp 1: Dng nh cha 23%khi lng tinh bt v tch sch ct, c cha thng TK-1110 v c bm PC-1110A/B vn chuyn n cng on h ha. Dng y c bm qua h thng cyclone cp 2. H thng cyclone cp 2: Dng nh l dng dch bt c hi lu v thng TK1101 (dng ny vn cn ln mt s tinh bt b khng ha tan v ct hay cn c gi l Grits). Dng y c bm qua h thng cyclone cp 3. H thng cyclone cp 3: Dng nh c quay v ti u ht ca bm cp dch cho h thng cyclone cp 2. Dng y ch yu l nc v ct tip tc c phn tch ti thit b lng v tuyn ni ng thi hi lu trit lng tinh bt b cun theo.
4. S dng ca khu vc h ha v nu

Thuyt minh:

Dch bt t cm cng ngh chun b dch v tch ct tip tc c ha trn vi nc ngng cng ngh ti thng ha trn dch TK-2101. Thng ny c duy tr nhit khong 82oC. Thi gian lu ca dch trong thng l 30 pht. Enzyme Alpha-amylaza c a vo nhm b gy tinh bt thnh ng c kh nng ln men. NH3 c thm
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vo iu chnh pH, ng thi cung cp dinh dng cho men. Mt phn dch hm long c th c b sung vo thng ha trn.

Dch sau ha trn c bm n thng h ha TK-2201. Thi gian lu ca dch thng h ha l 120 pht thi gian cho enzyme Alpha-amylaza tip tc b gy nhng chui tinh bt thnh ng n. Sau dch c gia nhit bng hi ti thit b trao i nhit nhm chuyn ha tinh bt trit v tit trng dng dch. H thng gm 3 ni nu dng ng c cung cp nhm to thi gian lu cn thit (15 pht) tit trng. Sau khi nu, dch c lm lnh 2 cp bng gim chn v nc lm mt n nhit 32oC v cung cp cho khu vc ln men.

Dung dch H2SO4 c b sung ti u ra ca thng h ha nhm gim pH xung thch hp cho qu trnh nhn men. Dng dch hm long cng c th b sung vo v tr ny gim pH, iu ny s lm gim lng H2SO4 tiu th nhng s lm tng thnh phn cht rn trong dch.

Trong thi gian di dng nh my, thng ha trn, thng h ha v cc ng ng lin quan s c v sinh lm sch bng h thng CIP.
5. S dng ca khu vc nhn men ging v ln men

Thuyt minh:

H thng ln men gm 6 thng, trong thng u tin l thng nhn ging, 4 thng ln men cng kch thc v thng cha gim chn. Nh my s dng qu trnh ln men theo m chuyn ha ng c kh nng ln men thnh Ethanol v CO2 da trn hot ng ca men.

Qu trnh nhn men ging din ra thng nhn men TK-3102. Thng nhn men c trang b cnh khuy v c lm lnh bn ngoi bng bm tun hon v thit b lm lnh. Cc dng np vo thng nhn ging vi cc mc ch nh sau:

Men ging: c hot ha t men kh ng bnh thng ha trn men TK3101 Dch bt: cung cp ngun thc n cho men Nc cng ngh: gim % thnh phn rn
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Enzyme Gluco-amylaza: chuyn ha dextrin v ng a thnh ng gluc lm ngun thc n cho men ging Ur: l cht dinh dng cho men H2SO4: iu chnh pH thch hp cho qu trnh nhn men Khng kh (kh nn): cung cp Oxy men pht trin Du chng to bt (nu cn).

Qu trnh nhn men theo m v ton b m nhn men s c cp cho thng ln men khi hot ng ca men t c im ti u, bnh thng thi gian lu dch trong thng nhn men l 12h/m. Sau mi m, thng nhn men, thit b lm lnh v cc ng ng lin quan c v sinh lm sch bng h thng CIP ngn nga nhim khun.

Qu trnh ln men theo m vi hiu sut 94% v thi gian lu 48h/m. Qu trnh ln men sinh nhit nn phi tun hon dch ang ln men qua thit b lm mt bn ngoi duy tr nhit thng ln men khong 32oC.

Sau khi t thi gian ln men, gim chn c bm n thng cha gim chn. Th tch thng cha gim chn bng 1,3 ln th tch thng ln men. Ti y gim chn s c cung cp lin tc cho khu vc chng ct. thu hi nng lng, gim chn trc khi n khu vc chng cp s c gia nhit s b 1 trong 2 thit b trao i nhit m tc nhn gia nhit l dch sau nu.

Kh CO2 th s c ra s b bng nc tch lng cn b cun theo, sau CO2 c a n phn xng thu hi v ha lng CO2. Kh CO2 sinh ra c th to bt trong thng ln men, do mi thng ln men c trang b cc u phun cht chng to bt khi cn.

Cc thng ln men v ng ng ln quan, cc thit b trao i nhit u c kt ni vi h thng CIP lm sch v tit trng. H thng ln men c trang b vi ng ng v iu khin cho php lm v sinh hay bo tr bt k thng ln men no cng khng nh hng n vic cung cp gim chn lin tc.
6. S dng ca khu vc chng ct Trang 20

Chng ct l qu trnh lm bay hi ethanol c trong gim chn v nng nng ethanol ln xp x 95 %vol.

Ethnaol trong gim chn c tch ra khi dch hm s dng h thng vi 3 thp chng ct.

H thng chng ct gm ba thp, bao gm hai thp chng ct th v mt thp chng ct tinh. Thp chng ct th #1 vn hnh p sut kh quyn. Thp chng ct th #2 vn hnh p sut chn khng v thp tinh vn hnh p sut xp x l 3.4 bar(a).

Gim chn c a n nh ca mi thp chng ct th vi t l nh nhau. Sau khi gia nhit, gim chn i vo thp th #1 c nhit sp x l 88oC (190oF), v i vo thp th #2 vi nhit sp x l 77oC (170oF). Sn phm y ca thp th, hay gi l dch hm, c a i x l. Hi ethanol t nh ca cc thp th c ngng t v bm n thp tinh. Ti y n c nng nng ln 95%v. Ethanol ra khi thp tinh c a sang h thng tch nc. Dng ra khi y thp tinh ch yu l nc cng vi lng nh ethanol v cc cht hu c d bay hi c quay li qu trnh cng ngh.

H thng chng ct c tnh ton hiu sut s dng nng lng l ln nht. Phn ct ca nh thp tinh c s dng cung cp nhit cho cc thp th. Hi ngng t c tun hon li thp tinh lm dng hi lu nh. axit ca sn phm c iu khin bng cch loi b cc kh khng tan trong ethanol vi mt qu trnh ring.
7. S dng ca khu vc tch nc

Vic loi b nc, lm khan cn sn xut cn nhin liu c thc hin trong h thng tch nc ry phn t. Ry phn t lm vic c bn l hp ph chn lc pha hi. Trong trng hp ny, nc c hp ph trong cc mao qun trong khi ethanol thot ra ngoi. Nc b hp ph s c loi b sut trong giai on ti sinh v c a tr li h thng chng ct thu hi ethanol.

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Qu trnh hp ph thc hin p sut d trong khi qu trnh ti sinh thc hin p sut chn khng.

H thng gim axit c thit k loi b CO2 v axit cacbonic lm cho nng axit cao. Phn ln dng cn khan sau khi ra khi thp tch nc c ngng t v a vo thp kh axit. Mt phn nh hi ethanol khan c a vo y thp kh axit tch kh CO2 cn lu li. Dng lng (sn phm cui cng) thu c y ca thp kh axit c lm mt v chuyn n b cha.
8. S dng ca phn xng thu hi CO2

Thuyt minh: Dng kh CO2 thot ra t khu vc ln men (sau khi c ra s b) c dn n dy chuyn thu hi CO2. Ti y kh CO2 th c x l qua cc cng on sau: 3.8.1. Tch bt F- 8601: Trc tin, kh CO2 th c ra bng nc trong thng tch bt tch ht bt c trong dng kh t cc thng ln men. Lng bt trong thng tch bt s t ng chy trn ra ngoi. 3.8.2. Nn kh CR-8601 A/B (hoc ballon):

Sau khi ra khi thit b tch bt, kh CO2 th c nn trc khi qua thp ra nc. Ngoi ra, c th dng ballon (thit b tn cha) m bo dng kh c cung cp lin tc cho cc cng on sau v m bo p sut u vo cho my nn. 3.8.3. Ra nc VS-8601:

Sau khi c nn, kh CO2 s i qua thit b ra bng nc tch trit cc tp cht ho tan trong nc. tit kim nc th lng nc sau khi ra s c dng lm nc ra thng tch bt. 3.8.4. Nn kh CO2 CR-8602A/B:

My nn piston hoc my nn vt ti c s dng nn kh CO2 ln 17-18 bar. 3.8.5. Lm mt E-8601, E-8602:

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Sau khi ra khi my nn, nhit kh CO2 s tng ln, khi s c lm mt 2 cp bng nc lm mt v mi cht lnh NH3 gim nhit ca dng kh CO2 nhm tng hiu qu ca qu trnh tinh ch, ng thi cng lm ngng t hi nc ln trong kh CO2. 3.8.6. Ra KMnO4 VS-8602:

Kh CO2 c nn s i qua thit b ra KMnO4 tch cc hp cht d b oxy ha. Dung dch KMnO4 ra s c tun hon s dng n khi nng dung dch gim n mt mc quy nh th thay mi. 3.8.7. Lc Cacbon hot tnh F-8602:

Dng kh CO2 tip tc i qua thp lc Cacbon hot tnh tch ru, cc hydrocacbon v cc hp cht d chy. 3.8.8. Tch nc F-8603:

Sau khi ra khi thp lc cacbon hot tnh, kh CO2 tip tc c tch nc ti thit b tch nc bng ry phn t F-8603. Ti y, hi nc ln theo kh CO2 s c gi li. Kh CO2 kh s qua h thng ngng t. 3.8.9. Lm lnh v ngng t CO2:

Kh CO2 kh s c ha lng nhit -27oC trong h thng ngng t kh. H thng ny bao gm: my nn lnh (dng NH3), thit b trao i nhit E-8603, thp chng VS8603. 3.8.10. Thit b tch NO2:

Thit b tch NO2 (nu cn) s c lp t loi b bt k vt NO2 no trong CO2 t yu cu CO2 thc phm. 3.8.11. Thng cha VS-8605:
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Sau khi ha lng, CO2 c cha trong thng cha VS-8605 c sc cha 245 tn CO2. Thng cha c thit k kn, c lp chn khng cng nh lp bo n cha CO2 lng p sut 17-18 bar, nhit -27oC. 3.8.12. Xut sn phm:

Sn phm t thng cha c xut ra xe bn bng h thng cn xut sn phm. H thng xut sn phm y (Bottom loading) c s dng, bao gm ng tun hon hi khp kn cn bng p.
9. S khi ca cm ly tm dch hm - sy b - Biogas

XLNT

Thuyt minh:

Dch hm t thng cha (whole stillage tank) c a n my ly tm (decanter). Ti decanter, phn ln (khong 75% khi lng) cc thnh phn rn c trong dch hm s c phn tch to thnh b m (wet cake). Dng dch i ra khi decanter gi l dng dch hm long (thinslop), mt phn c hi lu li quy trnh cng ngh v phn cn li a n khu vc thu hi mtan v x l nc thi.

B m c m khong 65-70% khi lng c a n my sy to thnh b kh c m khong 10% khi lng, b kh c cha trong sil c sc cha 7 ngy v c bn cho cc nh thu mua dng lm cht n hay thc n cho gia sc. Hi nc sinh ra trong qu trnh sy c ngng t v gp vi dng dch hm long a n khu vc x l. Trong trng hp my sy b h hng th b m s c a n sil cha, sil cha b m c sc cha 1 ngy.

Dng dch hm long c a i x l k kh thu hi biogas, biogas sinh ra dng lm nhin liu t l hi. Lng nc thi sau khi qua bc x l k kh v cc dng nc thi khc nh: nc thi sinh hot, nc v sinh nh xng, nc x y thp, nc x y l hi, c x l hiu kh, tuyn ni, lng lc v kh trng nc thi t tiu chun x thi ra.
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