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Instruction Manual
CE 640 Biotechnical Production
of Ethanol
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i
CAD_9
05/2013
AllRightsReservedG.U.N
.T.
GertebauGmbH,
Barsbttel,Germany05/2013
Instruction Manual
Please read and follow the safety regulations before the first installation!
Publication-no.: 918.000 00 D 640 03 (A) CAD_9
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Table of Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Unit description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 General view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Process schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Cooking tank for liquification / saccharification . . . . . . . . . . . . . . . . . 6
2.4 Fermentation tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Distillation unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6 Control cabinet and control technology . . . . . . . . . . . . . . . . . . . . . . 15
2.7 PLC controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.8 Compressed air diaphragm pump (P2 & P3). . . . . . . . . . . . . . . . . . 23
2.9 Diaphragm metering pumps (P1 & P4) with acid supply container (B3)and caustic supply container (B6) . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.10 Installation and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.11 Cleaning the tanks and supply lines with steam . . . . . . . . . . . . . . . 26
2.12 Maintenance / care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.13 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1 Intended Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2 Structure of the Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3 Health hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.4 Hazards for unit and function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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4 Theory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1 Basics of alcohol creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.2 Crushing the raw materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.3 Liquification / saccharification of the raw materials . . . . . . . . . . . . . 38
4.4 Fermenting the mash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.5 Distillation of the mash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.5.1 Basics of distillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.5.2 Construction of a distillation . . . . . . . . . . . . . . . . . . . . . . . . 45
5 Notes on running experiments . . . . . . . . . . . . . . . . . . . . . . . . 47
5.1 Diagram of creating alcohol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.2 Liquification and Saccharification . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.3 Fermentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.4 Distillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6 Data acquisition software . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.1 Software installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.1.1 System requirements:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.1.2 Installation of software . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.2 Software operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.2.1 Menu point:Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.2.2 Menu point:File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.2.3 Menu point:View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.2.4 Menu point:Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.2 Process schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.3 Items supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.4 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
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1 Introduction
Alcohol is an important basematerial for the chem-ical industry. It is mainly obtained from food-stuffs
containing starch such as e.g. potatoes or cereal
products.
The experimental stand CE 640 Biotechnical
Production of Ethanol makes it possible to trace
and research the process of industrial alcohol pro-
duction from the liquification and saccharification
of the original materials to the conversion from
sugar into alcohol on to the distillation of the alco-hol.
The experimental stand uses two stainless steel
agitation vats for this. One is a cooking tank tem-
pered with steam and cold water and one is a fer-
mentation tank tempered with cold and hot water.
Distilling the alcohol is done witha completely inte-
grated distillation system.
Material transport through the system is done by
compressed air-driven conveyor pumps.
For optimal operating conditions, the cooking tank
and the fermentation tank have temperature con-
trols and rpm-regulated stirrers.
Control and monitoring on the system is done
on-site by an integrated PLC. Recording the mea-
surement data and monitoring can also be supple-
mented with a connected PC.
The experimental stand is used only for trainingstudents in the process-, bio- and food-stuffs tech-
nologyandis not intended for industrial purposes.
1 Introduction 1
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Learning Objectives / Experiments
Familiarization with the necessary individualsteps and system components for pro-
duction of ethanol:
gelatinisation by steam injection
liquefaction by use of alpha-amylase
saccharification by use of gluco-amylase
fermentation: conversion of sugar into
ethanol by yeast cultures under an-aerobic conditions
distillation: separation of ethanol fromthe mash
2 1 Introduction
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2 Unit description
2.1 General view
1 Steam pressure regulator valve (V1) 9 Mash pump (P3)
2 Cooking tank for liquification/ saccharification (B1) 10 Cold water control-valve (V2)3 Fermentation tank (B2) 11 Flow meter (F1)
4 Distillation unit (D1) 12 Mash pump (P2)
5 Control cabinet 13 Steam shut-off valve (V23)
6
7
Ethyl alcohol container (B4)
Mash container (B5)
14 Pressure regulator for cold watercontrol valve
8 Diaphragm metering pumps (P1 & P4) 15 Pressure regulator for steam-pressurecontrol valve
2 Unit description 3
CE 640 BIOTECHNICAL PRODUCTION OF ETHANOL
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Fig. 2.1 General view
1 2 3 4 5
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14
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11
12
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2.2 Process schematic
4 2 Unit description
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Fig. 2.2 Process schematic CE 640
CompressedAir
Water
Steam
WarmWater
Water
Water
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Individual components Measuring points
B1 Cooking tank (tank 1) V3 - V7 Solenoid valves
B2 Fermentation tank (tank 2) V8- V27 Ball valves, hand actuated
B3 Acid solution container V26 Steam pressure safety valve
B4 Ethyl alcohol container V28-V32 Ball valves, hand actuated
B5 Mash container T1 Mash temperature B1
B6 Caustic tank T2 Mash temperature B2
D1 Distillation unit T3 Cooling water drain temperature B2
P1 Diaphragm metering pump T4 Distillation unit water bath temperature
P2 Compressed air feed pump B1 - B2 T5 Mash temperature in distillation bubble
P3 Compressed air feed pump B2 - D1 T6 Gas temperature after bubble cap 1
P4 Diaphragm metering pump (caustic) T7 Gas temperature after bubble cap 2
R1 Stirrer geared motor B1 T8 Gas temperature after bubble cap 3
R2 Stirrer geared motor B2 T9 Gas temperature after dephlegmator
R3 Stirrer geared motor D1 Q1 pH value B1
H1 Water bath heater F1 Water flow to B1
V1 Steam control valve PI1 Steam pressure indication
V2 Cooling water control valve
The process diagram shows all components andmeasuring points on the CE 640 as well as all
required pipe connections and supply lines. There
are several ball valves to be opened or closed for
the individual operating states.
More detailed information on setting the individual
ball valves during the individual operating states
can be found in chapter 5 of these instruction.
2 Unit description 5
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2.3 Cooking tank for liquification / saccharification
6 2 Unit description
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Fig. 2.3 Mash tank
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1 Shaft coupling 11 Supports
2 Geared motor 12 Water supply connection
3 Acid supply 13 Sealing plug
4 Cover flap 14 Drain valve
5 Overflow connection 15 Temperature sensor
6 Cover latch 16 Connection to feed-pump
7 Hand-hold for cover 17 Cooling water drain
8 Hinged cover 18 Cooling water feed
9 Inspection glass 19 Steam feed connection
10 pH measuring probe
2 Unit description 7
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Fig. 2.4 Cooker tank / Mash tank
7 8
6
14 15 16 19
4
3
5
17
18
13
10
2
1
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The mash or cooking tank is used for liquefying
and saccharifying the initial materials. This pro-
cess is known as mashing. The container uses an
stirrer for this, consisting of a geared motor and a
pitched blade stirrer on the shaft.
Heating the original materials is done with a direct
hot steam line into the cooking tank through a jet.
This enables an increase in liquid by around 15%.
To prevent the mash from running back into the
steam feed line, it is built into a non-return valve.
This valve can be removed from the interior of thecontainer with the jet as a complete unit.
The container is equipped with a double-jacket,
through which water can be pumped for cooling
the mash if required. Temperature monitoring is
done by a temperature sensor built into its floor.
The tank also has a pH value measuring probe for
regulating the pH value.
For the required lowering of the pH value during
the process, the tank has an acid inlet with a dia-
phragm metering pump. For the required lowering
of the pHvalue during the process, the tank has an
acid supply with a diaphragm metering pump.This
measuring probe is only installed when the system
is to be operated.
The cooking tank is designed as an open con-
tainer. That means that steam will escape through
the openings in the cover while cooking. To fill the
containerwith rawmaterialsuch as grain,potatoes
or enzymes, the cover is made in two parts and
can be opened. It is secured by means of a
latch-pin.
The container, cover and all attachment parts are
made of stainless steel.
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2.4 Fermentation tank
2 Unit description 9
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Fig. 2.5 Fermentation tank
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1 Sealing plug 10 Fill opening
2 Clean-out opening 11 Supports
3 Coupling 12 Cooling water outlet
4 Geared motor 13 Cooling water control valve
5 Cover 14 Drain valve
6 Mash feed 15 Connection to feed-pump
7 Temperature sensor for mash 16 Temperature sensor for cooling water drain
8 Inspection glass 17 Cooling water inlet
9 Fermentation lock 18 Double jacket container
19 Shut-off valve for cooling water
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Fig. 2.6 Fermentation tank (Tank 2)
3 4 9 10 11 12
13 14 15 18 19
2
1
17
19
6
7
8
5
16
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The fermentation tank converts the sugar con-
tained in the mash into alcohol. This tank can be
sealedair tight and temperedwithcold and hot wa-
ter using a water jacket. The cold or hot hot water
flows through a double jacket on the outside of the
tank. The fermentation tank is equipped with an
stirrer for optimal mash mixing. It consists of a
speed regulated geared motor and an stirrer with
two pitched blade stirrers. The temperature of the
mash is monitored with a temperature sensor.
To regulate the temperature more efficiently, an-other temperature sensor is located on the cooling
water drain.
The cover of the container is equipped with a
latched clean-out opening and a fill opening. The
stirrer shaft is run into the container through a fer-
mentation lock (see Fig. 2.7).
1 Geared motor
2 Coupling
3 O-ring
4 Divider
5 Stirrer shaft
6 Sealing liquid area
7 Cover
8 Sealing liquid
9 Spacer post for geared motor
10 O-ring
Thesealing liquid(normally water) in thefermenta-tion lock completely closes the interior of the con-
tainer off from the atmosphere. The CO2 gener-
ated in the fermentation process pearls up as gas
bubbles through the sealing liquid and escapes
into the atmosphere without the air from outside
being able to enter the container.
In order to improve monitoring, the fermentation
lock is made of transparent plastic.
2 Unit description 11
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Fig. 2.7 Fermentation lock, cut-out view
1
2
3
4
5
6
7
8
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All other components of the fermentation tank are
made of stainless steel, as is the cooking tank.
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2.5 Distillation unit
2 Unit description 13
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Fig. 2.8 Distillation unit
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The distillation unit is a modified boiler heater with
water bath (6). It contains bubble cap (1) tray col-
umn, dephlegmator (2) and condenser (4). T1 -
T10 indicate the positionsof the individual temper-
ature sensors in the system. For a detailed de-
scription of the individual components and mea-
surement connections, please read the attached
operating instructions of the manufacturer.
14 2 Unit description
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Fig. 2.9 Distillation unit, overview
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2.6 Control cabinet and control technology
1 pH transducer
2 PLC controller (touch-screen)
3 Schematic diagram
4 EMERGENCY STOP button
5 Master switch
6 PC connection, USB
The control cabinet contains all required control
and regulating elements of the CE 640.
Control and regulation are carried out by the PLC
controller (PLC = programmable logic controller)
built into the side of the control cabinet. The con-
troller is menu guided. All entries and control in-
structions are entered via the touch screen. The
actual control of individual components such as
regulating valves, stirrer, pumps and heating con-
2 Unit description 15
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Fig. 2.10 Control cabinet, overview
1
2
3
4
5
6
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trol is handled with the PLC installed in the control
cabinet.
All of the temperatures that are recorded in the ex-
perimental stand are shown on the touch screen.
The pH values and the temperature from the pH
measuring probe are shown on a separate mea-
suring device.
The entire system can be switched on or off with
the main switch.
Actuating the EMERGENCY STOP button switches
the electrical power off for the entire system.
The measurement data can be recorded and
saved through an interface on the side of the con-
trol cabinet using the respective data acquisition
software.
The measurement data can be recorded and
saved via a USB interface to the bottomright of the
side of the control cabinet using the associated
data acquisition software.
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2.7 PLC controller
The PLC controller is started automatically whenthe experimental stand is switched on and shows
the start menu (Fig. 2.11).
On the Start menu, you will find an operating hour
meter and some touch fields.
The sub-menus are reached by touching the indi-
vidual touch fields on the screen.
The screen offers choices between the parameter
settings for temperature control circuits in:
Mash (Cooking) tank (tank 1) with tem-perature- und pH-value control
Fermentation tank (tank 2) and
Distillation with temperature control
The parameters for the control circuit must match
the respective installation location and the respec-
tive environmental conditions. For details in this
regard, please refer to current technical literature
on control technology.
To change the user language go to sub-menuPa-
rameter (Fig. 2.12)
From here, the display language for the PLC con-troller can be changed.
The system time, date and the brightness of the
screen can also be set.
If an error has occurred on the PLC, a list of the er-
rors that have occurred will be displayed.
Return brings you back to the previous start
menu.
2 Unit description 17
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Fig. 2.11 Start menu
Fig. 2.12 Parameter
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From the start menu (Fig.2.11), the Mash tank
B1 can betouched tochangeto the menurespon-
sible for the cooking tank.
This menu can be used to regulate the tempera-
ture T1 and to set the pH value in the container
(Fig. 2.13). In this instance (controlled operation)
the actual value is shown (1) and the set value of
the controller is displayed (2).
The pH value in the cooking tank is regulated by
adding acid and caustic using the diaphragm me-tering pumps.
To activate thesecontrollers, thebutton" Manual"
(3) is to be switched to " Auto".
On the display(4), the control valve set value can
beread for the temperature control for T1. If the set
value of the valves should be controlled manually,
the button (3) for temperature T1 must first be setto Manual. This activates field (5) and the set
value can bedefined between -100% and +100%.
-100% = Cooling water valve fully open
+100% = Heating steam valve fully open
The button"R1" can beusedtoswitchthe stirrer on
or off.
The following is standard for switch fields
Switch field is green : Element is switched on
Switch field is red : Element is switched off
18 2 Unit description
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Fig. 2.13 Mash tank
1 3 2
4 5
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On button(7), the rpm of the stirrer can beset.The
rpm/speed can also be changed with the stirrer
running.
Using the buttons "V6", (8) und (9) , tank 1 can be
fed a defined volume of fresh water. Button (8) is
used for defining the volume in this case. Button
"V6" is used for activating a solenoid valve, which
opens the fresh water supply. A flow meter is used
to determine the quantity of water flowing and this
is displayed with display (9). After achieving the
present volume, the solenoid valve closes auto-matically.
Button "Pump P2 " is used for actuating a com-
pressed air-driven diaphragm pump, which feeds
the container contents from tank 1 to tank 2.
Return brings you back to the previous menu.
The "Next" button (Fig.2.15) can be used for set-
ting the control parameters Kp, Tn and Tv for the
heating steam and cooling water control valve.
The button " Graph " can be used to show the
progress of the temperature and the pH value over
time.
The control valves for the temperature control of
tank 1 is a consistent pneumatic control valve,
which is regulated with an analogue signal.
2 Unit description 19
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Fig. 2.14 Mash tank parameter
Fig. 2.15 Mash tank
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The control menu of tank 2 is constructed the
same as the one for tank 1 (Fig. 2.13).
The difference is that tank 2 only has a tempera-
ture control for cooling.
The stirrer can berun either in temporal intervals or
continuously.
Following settings are possible:
stirrer speed in rpm
on-time in min off-time in min
With Buttons "Pump P2" and "Pump P2" both of
the compressed air-driven diaphragm pumps are
operated.
Pump 2 feeds the container content fromtank 1 to tank 2.
Pump 3 feeds the container content fromtank 2 into the distillation unit.
The settings for control parameters Kp, Tn and Tv
for tank 2 is made the same as for tank 1
(Fig.2.14).
Tank 2 has a solenoid valve as actuator. There-
fore, a minimum switch-on duration can be set forthe solenoid valve in the menu with parameter
minimum on period. The precision of the
controller can be set with the period parameter.
The greater the value of period in relation to
minimum on period, the more precise the
controller can work.
The actuator solenoid valve is activated by binary
switching signals.
20 2 Unit description
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Fig. 2.16 Fermentation
Fig. 2.17 Fermentation parameter
Fig. 2.18 Fermentation
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Return brings you back to the previous menu.
In the menu for distillation, the temperatureT9 is
regulated as a command variable for the distillation
(Fig. 2.19). The function of the individual buttons
and displays are the same as for tanks 1 and 2.
An stirrer in the distillation bubble can be operated
from this page of the menu. The rpm of this stirrer
is not variable.
Pump 3 can be operated from here to fill the distil-
lationbubblewith thecontainercontent of tank 2.
On a diagram with the positions of the various sen-
sors all measured temperatures of the distillation
unit are shown.
Return brings you back to the previous menu.
The settings for control parameters Kp, Tn and Tv
for distillation are made the same as for tank 1
(Fig.2.14).
The distillation has a heater as an actuator. There-
fore, a minimum switch-on duration can be set for
the heater in the menu with parameter minimum
on period. The precision of the controller can be
set with the period parameter. The greater the
value of period in relation to minimum on pe-riod, the more precise the controller can work.
The actuator heater is activated by binary switch-
ing signals.
The parameter deviation for change over
describes the relationship between command
variable control and disturbance variable control.
Normally this parameter is set to 0
Return brings you back to the previous menu.
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Fig. 2.19 Distillation Parameter
Fig. 2.20 Distillation, over temperature
Fig. 2.21 Distillation
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From the start menu (Fig. 2.11), the Measure-ment button can be actuated to bring up an over-
view ofallmeasurement data from theentireunit.
An numerical input field (Fig. 2.23) appears forentering command variables or for changing
parameters or speeds (rpm).
Numbers are entered here without any delimiters
or separating characters of any kind and must be
confirmed with RET.
Example:
To enter a temperature of 40.5C, the numbers
405 must be entered and then the entry must be
confirmed with RET. The separation character is
inserted automatically and the value is accepted
as a new command variable.
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Fig. 2.22 Example for numerical input
Fig. 2.23 Measurement
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2.8 Compressed air diaphragm pump (P2 & P3)
To feed the container content from the cookingtank (B1) into the fermentation tank (B2) and then
on to the distillation unit (D1), the CE640 system is
equipped with two compressed air operated -
double diaphragm pumps. These pumps require a
compressed air supply to function. The maximum
air-pressure is set on a pressure regulator (1) on
the respective pump. The supply volume of the
pumpisset witha control valve (2). Air lines can be
removed from the threaded connections (3).
The compressed air diaphragm pumps are
designed for transferring liquids up to a viscosity of
10,000 mPas. Solid material particles having a
diameter of up to
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2.9 Diaphragm metering pumps (P1 & P4) with acid supply container (B3)
and caustic supply container (B6)
The mash must be acidified to optimise the
saccharification process. Acid is added using the
diaphragm metering pump (P1), while caustic is
added using the diaphragm metering pump (P2).
Both pumps (Fig. 2.27 & Fig. 2.28) are operated
using the PLC controller. The acid solution from
the supply container (B3) and the caustic solution
from the supply container (B6) are conveyed into
the cooking tank through a hose connection.The feed quantity can be set on the front of the
pump:
Adjusting the pump stroke and
Adjusting the stroke frequency
The pump stroke is set with a rotary knob be-tween 0 and 100%
The stroke frequency is set with the small ro-tary knob between 0 and 100%.
The pump cannot be started by hand (manually),
only by an external signal from the PLC.
Diaphragm metering pump
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Fig. 2.26 Diaphragm metering pump (P1)
Fig. 2.27 Diaphragm metering pump (P4)
Fig. 2.28 Tank (B3 & B6)
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2.10 Installation and commissioning
The installation and commissioning of the devicedemands a few prerequisites from the installation
location and the supply equipment:
Setting up the test stand. The front and theleft and right hand sides of the test stand
must be readily accessible. The room in
which the test stand is set up must be ade-
quately ventilated.
Connect the water supply to (4) cold waterand (5) hot water (Fig. 2.29)
Attach drain lines to (1).
Attach steam supply to (2), technical special-ist only.
Attach steam pressure-relief line to (3), tech-nical specialist only. The steam pressure-re-
lief line must end in a secure space or in theopen, outside.
Connect the compressed air supply for thesystem (6) (connection in the bottom right of
the left side).
Attach the power supply (ensure that the cor-rect voltage supply is used!).
Check the fuse in the control cabinet before
switching the unit on. Screw the pH measuring probe into tank 1
and make electrical connections.
Switch on the unit at the master switch.
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Fig. 2.29 Supply connections
1 2 3 4 5 6
Fig. 2.30 Supply connections
1 3 2 4 5 6
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2.13 Shutdown
When the system is to be shut down or anylength of time, all supply lines are to be dis-
connected and all liquids are to be drained
from the hoses and system components.
The pH measuring probe is to be removed,packaged and storage according to section
2.12.
All parts of the system and hoses are to be
cleaned thoroughly and any encrustationand solids are to be removed.
Completely emptyandrinse the container forthe acid solution.
Rinse out the diaphragmmetering pump withlotsofwater to removeany residualacid from
the pump and the hose connections.
Disconnect the system from the electrical
power supply.
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3 Safety
Before putting the device into operation, the
experiment instructions are to be read thor-
oughly and especially the safety notes
Prior to starting the experiments, all partici-
pants are to be briefed on the safety aspects
and the correct handling of the unit!
3.1 Intended Use
The unit is tobeusedonly for teachingpurposes.
3.2 Structure of the Safety Instructions
The signal words DANGER, WARNING or CAU-
TION indicate the probability andpotential severity
of injury.
An additional symbol indicates the nature of the
hazard or a required action.
Signal word Explanation
DANGER Indicates a situation which, if not avoided, will result in
death or serious injury.
WARNING Indicates a situation which, if not avoided, may result in
death or serious injury.
CAUTION Indicates a situation which, if not avoided, may result inminor or moderately serious injury.
NOTICE Indicates a situation which may result in damage to
equipment, or provides instructions on operation of
the equipment.
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Symbol Explanation
Hazardous Electrical voltage
Risk of burnshot surface
Toxic materials
Corrosive materials
Risk of entanglementrotating parts
Hand injuries
Notice
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3.3 Health hazards
WARNING
Electrical connections are exposed when the
control unit is open.
Risk of electric shock.
Disconnect from the mains supply beforeopening.
Work should only be performed by qualifiedelectricians.
Protect the control cabinet against water andmoisture.
WARNING
Hazardous electrical voltage
Risk of electric shock. Never operate the unit without a correctly in-
stalled earth wire.
Non-compliance with this requirementmeans that the operator and the unit are no
longer adequately protected.
Incaseofdanger, isolate the systemfromthemains by using the EMERGENCY STOP
button or unplugging.
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WARNING
The alcohol that is produced with this systemis raw alcohol and is not suitable for consump-
tion.
DANGER of poisoning!
Consumingrawalcohol, even in smalldoses,can lead to irreversible damage to health!
While operating the distillation, make surethat there is proper ventilation to prevent an
accumulationofalcohol ingredients in theair.
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WARNING
Steam lines and partsof the distillation unit getvery hot. Hot steam can escapeat the pressure
relief line.
DANGER of burning / scalding!
Tank 1 becomes very hot during the heatingoperation. Do not touch the jacket surface of
the tank during operation .
Neveroperate the steamheating for tank1with-
out a closed steam pressure-relief line.
Never operate the steam heating of tank 1without the water supply in tank 1.
While operating the distillation unit, much ofthe equipment will get very hot. Do not touch
the surface of the water bath, the distillation
bubble and the column.
Observe all safety notes for the distillation unit in
the attached operating instructions of the manu-
facturer. Non-adherence can lead to extensive
danger to health.
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WARNING
Handling acid and caustic carries a risk ofchemical burns.
DANGER of damage to health!
The hazards and safety information de-scribed in the safetydata sheets must be fol-
lowed closely when handling the acid and
buffer solutions used in the experiments.
WARNING
Rotating parts.
RISK of injury!!
Do not reach into the rotating coupling of thestirrer in tank 1.
Do not reach into the rotating coupling of thestirrer in tank 2.
Do not reach into the rotating stirrer of thedistillation bubble.
WARNING
Risk of crushing at hinged lid.DANGER of injuries !
When opening tank 1, always secure thecover with the latch-pin.
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3.4 Hazards for unit and function
NOTICE!
After completion of individual sections of theexperiment, always clean and rinse any sys-
tem parts and hoses/lines that have been
used, thoroughly.
NOTICE!
The pHmeasuring probe isnever tobeput intostorage dry. After using the measuring probe,
remove it, clean it and put in wet storage.
In addition, followthe instructionsof themea-
suring probe manufacturer.
NOTICE!
After the experiment, do not leave any acidicsolution in the acid container and acid supply
container. After using acid, remove all acid
from the acid container, diaphragm metering
pump and hose connections and rinse out
with water.
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4 Theory
4.1 Basics of alcohol creation
The foundation of alcohol creation is the alcoholic
fermentation through which glucose with the addi-
tion of yeast causes ethanol and carbon dioxide.
This happens according to the following formula:
C6H1206 -> 2 C2H5OH + 2 CO2
glucose + yeast -> ethanol + carbon dioxide
The yeast is used as a biological aid in creating al-
cohol, which starts the initial conversion of the glu-
cose into ethanol. Information on the precise prog-
ress during alcohol fermentation can be found in
popular literature on the subject.
To distil alcohol from high-starch content raw ma-
terials that normally have very low glucose or
sugar contents, the raw material must go through
various process steps in order to obtaina sufficientamount of alcohol.
The process of alcohol creation is divided into five
steps:
Crushing the raw materials
Condensation
Saccharification
Fermentation
Distillation
Each of these steps requires different process
conditions to achieve optimal yields of alcohol.
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4.2 Crushing the raw materials
The target of crushing is pulping the starch con-
tained in the raw materials. During this process,
ensure that the starch is not destroyed during the
crushing. Pulping is normally done with ham-
mer-mills or monopumps.
Crushing the raw materials is not a component of
the CE 640 experiment stand. Information on the
topic of crushing can be read in popular literature
on the subject.
4.3 Liquification / saccharification of the raw materials
The liquification / saccharification of the raw mate-
rials, so-called mashing, has the purpose of con-
verting the starch contained in the raw materials
into glucose.
For the liquification and saccharification, special
enzymes must be added to the raw mash that are
essential for the conversion from starch into glu-
cose. The advantage of enzymes, in comparison
to other catalysers, is their chemo-selectivity.
Therefore, perfectly suitable enzymes for the re-
spectivepairingof substrate/productareavailable.
The liquification is done while adding an enzyme (
in this case, alpha-amylase) at a temperature of
90- 95C.
Liquefying the raw mash is necessary since the
heating causes the enclosed starch to cluster into
long chains of molecules. This can make stirring
and feeding the mash mechanically impossible.
The enzyme alpha-amylase breaks the long
chains of starch molecules into short molecule
chains. This leads to a clear reduction in the vis-
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cosity of the mash and therefore to a higher flow
capability and better feeding capabilities.To achieve optimal enzyme activity, the ambient
conditions must be adapted to the respective type
of enzyme. For alpha-amylase, that means an am-
bient temperature of 90- 95C and a pH value of
> 6.5.
After the mash has been liquefied and the starch is
in short molecule chains, the starch must be con-
verted into glucose. This procedure is the saccha-rification. This requires adding another enzyme to
the mash. Prior to this however, the ambient condi-
tions mustbe changed again toachieve anoptimal
enzyme activity andtherefore a high percentage of
glucose in the mash. For the enzyme gluco-amy-
lase, the mashmust becooled to 55-60Cand the
pH value must be lowered to 4.5 - 5.5.
Theentireprocedure of liquification andsaccharifi-
cation of the mash takes about 2 to 3 hours includ-
ing the half hour resting time after liquification and
after saccharification.
After the completion of the saccharification, the
mash must be cooled before the next step in the
process.
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4.4 Fermenting the mash
Thefermentation converts theglucose in themash
into alcohol. Yeast must be added to the mash for
this. The yeast coverts the glucose into ethanol
and carbon dioxide.
Yeast is a livingmicro-organismthat belongs to the
fungus group. Unlike enzymes from the previous
process steps, yeast has the ability to reproduce.
The scope of reproduction depends on the appli-
cable ambient conditions. Yeast is very sensitive
to temperature, as are all organisms.
Temperature range 28 ... 32C :
Optimal, the conversion from glucose
into alcohol achieves a maximum.
Temperatures below 12C :
Yeast initiates activity.
Temperatures above 40C :
Yeast dies.Besides alcohol andcarbondioxide, heat is gener-
ated duringthefermentation process,whichslowly
heats the mash. Therefore, the temperature must
be monitored and the fermentation tank must be
cooled in some cases.
To achieve a good mixture between the mash and
the yeast during the fermentation process, an stir-
rer slowly mixes the mash. This mixing can carry
on continuously at low rpm or at high rpm inintervals.
The fermentation of the mash must be done in a
closed container that does not allow any contact
with the atmosphere. Otherwise, there is a danger
of a bacteria contamination that could result in
turning the alcohol fermentation into a vinegar
fermentation.
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During the fermentation process, carbondioxide is
produced, which escapes into the atmospherethrough a fermentation lock. This can be recog-
nized by the gas bubbles escaping in the sealing
liquid of the fermentation lock.
The duration of the fermentation depends on dif-
ferent factors:
Temperature
Type of yeast
Intensity of the mixingNormally, a fermentation experiment takes be-
tween approx. 68 - 72h. That makes regular moni-
toring of the processes necessary.
The following must be checked regularly:
Fermentation lock
Fermentation temperature:
Foam build-up and fill level in the fer-
mentation tank
During the fermentation, carbon dioxide foam
builds up on the surface of the mash. This is not
permitted to escapethrough thefermentation lock.
The height of the foam layer must be checked reg-
ularly through the inspection-glass therefore. The
build-up of this foam layer is a sign of active fer-
mentation in the mash.
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4.5 Distillation of the mash
After completed fermentation, the distillation is the
last step in creating alcohol. Thedistillationof alco-
hol from the mash is done with the help of a water
bath distillery. This system works in the same way
as large industrial systems.
4.5.1 Basics of distillation
Distillation and rectification are two important ther-mal separationprocedures. Thiscan obtainone or
more of the volatile components from a volatile
mixture with several volatile components with a
high degree of purity. This separation process
functions by means of the basic operations of
evaporation and condensation. The difference be-
tween distillation / rectification and the separation
process of evaporation is that in evaporation only
one of the components is volatile. In distillation /rectification the vapour phase has a different com-
position to the liquid phase. This fact is the basis
for distillation and rectification.
The difference between rectification and distilla-
tion is that in rectification the vapours emanating
from the recovered condensate are partially re-
turned to the column and made to perform materi-
als transfer with the risingvapours onor at suitable
column fitments.In distillation the rising vapours are immediately
condensed in a condenser and drawn off without a
return line.
Theconcentrations in thevapourphase(y)andthe
liquidphase (x) can becalculated for the ideal case
using RAOULTs Law and DALTONs Law, if the
vapour pressure curves of the respective compo-
nents are known. Normally however the molecular
proportions of the two phases at equilibrium are
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determined experimentally. The calculation of the
molecular proportions should for instance result inan ideal two partmixture benzene (A) / toluene (B).
An ideal two part mixture has been achieved when
the partial vapour pressure curves are linear and
the molecules of the components behave exactly
as the pure components on their own.
From RAOULTs law:
pA = P0A xA and pB = p0B xB
( in this case xA + xB = 1 and pA + pB = p )
and with DALTONs law :
pA
= yA
p and pB
= yBp
( in this case yA + yB = 1 and pA + pB = p )
the pressure diagram shown in figure 4.1 can becreated.The pressurediagram shows that the two
part mixture of benzene / toluene behaves ideally
based on the two straight line partial pressure
curves ( 1 + 2 ). Curve 3 shows the total vapour
pressure by molecular proportion xA.
Diagram 4.2 shows the typical courseof the boiling
and condensation lines in the boiling diagram for
benzene / toluene at a pressure of p = 1.01 x105
Pa. From the boiling diagram,as shown in the dia-
gram, an equilibrium diagram can be created.
The quantitative determination of the equilibrium
condition is determined as follows:
y x
xA
A
A
1 1( )
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Fig. 4.1 Pressure diagrambenzene / toluene
Fig. 4.2 Boiling diagram / equilibriumdiagram benzene / toluene
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For this, is defined as relative volatility. This is
the relation between the molecular proportions atequilibrium of the vapour phase and of the liquid
phase.
y x
y x
A A
B B
For an ideal two part mixture by using RAOULTs
Law and DALTON Law it produces:
pp
A
B
0
0
The greater the amount of , the further the equi-
librium trend is from the diagonals and the easier
the distilling separation.
In diagram 4.3 for instance boiling diagrams and
equilibrium diagrams for non-ideal two part mix-
tures are shown.
Further information on these mixtures and thequantitative determination of equilibrium condi-
tions can be found in technical literature.
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Fig. 4.3 Boiling diagram / equilibriumdiagram for real mixtures
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4.5.2 Construction of a distillation
Each distillationdevice is basicallyconstructedac-
cording to Fig. 4.4 .
The batch evaporates in the distillation bubble (2).
In this instance, a sufficiently large evaporation
chamber must exist. The constant heating of the
batch mixture can be achieved by e.g. an stirrer in
the distillation bubble. The heating (3) of the batch
mixture can be done directly or indirectly through a
water bath with sensitive batch materials.
The isolation column (1) separates the parts of the
gas mixture with a low boiling point from those with
a highboiling point bycondensationof those witha
high boiling point on the isolation column fixtures.
Columns with filling materials or with bottoms can
be used as isolatingcolumns.Another possibility is
the dephlegmator. This is constructed as a water
container, throughwhich thegasis routedin tubes.
The water temperature of this container must be
slightly higher than the initial temperature of the
cooling water from the condenser.
The isolating columnof the CE640 is a bubble cap
tray column with 3 layers in combination with a
water-filled dephlegmator.
The last components of a distillation apparatus is
the condenser(4), in which the gas parts that have
a low boiling point are condensed and escape the
condenserandthedistillationprocess as liquid.
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Fig. 4.4 Distillation apparatus
4
1
2
3
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5 Notes on running experiments
5.1 Diagram of creating alcohol
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Condensation
Cooling
Saccharific
ation
Cooling
Fermentation
Evaporation
Cooling
Condensa
tion
Distillation
R
awalcohol
Distilleryyeastculture
Alp
haamylase
An
tifoamingagent
Wa
ter>5dH
Po
tatoes
Glucoamylase
Su
lphuricacid
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The diagram shows the principle of the process
with the respective conditions that must be at-tained for the respective process steps. This dia-
gram applies for the procedure used in creating
raw alcohol from potatoes.
The steps liquification > cooling > saccharification
> cooling are performed in tank 1.
The fermentation is performed in the fermentation
tank.
Evaporating > cooling > condensing is all done in
the distillation unit.
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5.2 Liquification and Saccharification
The liquification of potatoes begins outside of the
experimental stand. The potatoes must be
crushed into a mash. The amount of potatoes de-
pends on the desired fill level of the system. A ref-
erence value for the CE 640 is ~10...15 kg.
The hand valves are to be positioned according to
the following table for the liquif icat ion /
saccharification. The designations of the valves
can be seen in process image (see 2.2 or 7.2).
ValveSetting/function
ValveSetting/function
ValveSetting/function
V1 Control valve V11 omitted V21 Closed
V2 Control valve V12 Closed V22 Closed
V3 Closed V13 Closed V23 Open
V4 Closed V14 Closed V24 Closed
V5 Closed V15 Position 1 V25 Closed
V6 Solenoid valve V16 Position 1 V26 Safety valve
V7 Solenoid valve V17 Closed V28 Closed
V8 Open V18 Closed V31 Closed
V9 Open V19 Closed V32 Closed
V10 Closed V20 Closed
NOTICE! Before the experiment, the overflow
hoses must be connected to all overflow points of
the system.
The liquification process is as follows:
Set valves according to the previous table.
Close valve V23.
Fill theacid supplycontainerwith sulphuricacid solutionof concentration 0.5mole/litre .
Switch on system.
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Install the pH measuring probe and connect the supply
line.
Call up the control menu for tank 1.
Make steam supply.
Enter the water supply quantity (~ 5...10 litre) on thePLC controller and fill in tank 1.
Enter the set temperature 90...95C on the PLC control-ler.Steam will berouted through the water supplynow.
Switch on the stirrer for tank 1.
Slowly open valve V23.
After reaching the set temperature in tank 1 , add ~10%of the amount of crushed potatoes.
Add the enzyme alpha-amylase according to manufac-turers specifications.
Now, slowly add small portions of the potato mass untilthe fill level of tank 1 reaches the pH sensor.
After the potato mass and the enzymes have been com-pletely added, the temperature must be held at a con-
stant temperature higher than 90C for a minimum of
30 minutes.
Than cool the mash to a temperature of ~55...58C (Setthe temperature on the PLC controller). Cooling water
flows through the outer jacket of tank 1.
pH value drop to 4.5...5.5 ( Enter the pH value on the
PLC controller). The pump now feeds in the acid solu-tion to tank 1.
Add the enzyme gluco-amylase and the anti-foamingagent according to manufacturers specifications.
After this addition, the temperature must be held for aminimum of30minutes withina range from55...58C.
Cool the mash to a temperature of ~28...30C.
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5.3 Fermentation
After pumping from the cooking tank into the fermentation
tank, the fermentation portion of the experiment is begun.
The portion takes up the most time. The durationof this phase
normally takes several days. First, all required supplies must
be made ready for this long period. The hand valves are to be
set according to the following table for the fermentation
process.
ValveSetting/
functionValve
Setting/
functionValve
Setting/
function
V1 Closed V11 omitted V21 Closed
V2 Closed V12 Open V22 Closed
V3 Closed V13 Closed V23 Closed
V4 Solenoid valve V14 Closed V24 Open
V5 Closed V15 Position 2 V25 Closed
V6 Closed V16 Position 1 V26 Safety valve
V7 Closed V17 Closed V28 Closed
V8 Open V18 Closed V31 Closed
V9 Closed V19 Closed V32 Closed
V10 Closed V20 Closed
After pumping over, the distilling yeast must be added tothe mash. The metering is to be done according to man-
ufacturers specifications.
Seal the fermentation tank hermetically against the at-
mosphere.
Fill the fermentation lock with water.
Close the latches in the cover.
Check whether valve V21 is closed.
Set valve V15 so that the fermentation tank isenclosed from the atmosphere.
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Then switch on the stirrer of the fermentation tank to
achieve a good mixture.
NOTICE! The stirrer is not to be operated continually
during fermentation since the foam build-up would be
too great.
During fermentation, carbon dioxide builds up in the in-
terior of the fermentation tank. This escapes through
the fermentation lock on the head of the fermentationtank (canbe recognizedby gas bubbles in the fermenta-
tion lock). The development of gas bubbles only begins
after a fewhoursof thefermentation process,however.
During the fermentation process, perform the followingchecks regularly:
Temperature in the fermentation tank
Fill level in the fermentation tank
Fill level in the fermentation lock - refill if nec-essary
The temperature can be set and monitored on the PLC
controller.
Thetemperature in thefermentation tank is regulated by
feeding cold and hot water into the double jacket around
the fermentation tank.
NOTICE! During fermentation, the temperature in-creases slightly and then drops continuously after
~12 h.
After a mixing timeof~5h the stirrer shouldonlybeoper-ated in intervals. Interval operation supports the escape
of carbondioxide frommash. The durations for the inter-
vals can only be determined from trying it yourself.
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If the fill level in the fermentation tank is too highand fluid
is forced out the fermentation lock, some mash will haveto be drained out through valve V13.
During the fermentation process, mash samples canbe taken
andtested foralcohol andresidualsugarcontent. This is done
by separating the liquid from the floating particles and deter-
mining the alcohol content with an alcohol meter and the re-
sidual sugar content with a saccharimeter.
The fermentation process is completed after a period of~68...72 h. No more gas bubbles should be escapingthrough the fermentation lock then.
The mash must then be fed into the distillation unit. Thisis done by opening valves V21 and V17 and setting the
three-way valve V16 so that the feed is to the distilla-
tion unit. Open the filling opening in the cover of the fer-
mentation tank.
Afterwards, pump P3 can be switched on from the PLC
controller and the mash can be pumped into the distilla-
tion unit.
After pumping is complete, close valve V17.
The fermentation tank must be cleaned as soon as possible
after pumping the mash out to prevent any biological degrad-
ing of the residual mash.
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5.4 Distillation
The last process step is the distillation of the alcohol
fromthe mash. The valvesmust be set as follows for the
distillation process.
ValveSetting/function
ValveSetting/function
ValveSetting/function
V1 Closed V11 omitted V21 Open
V2 Closed V12 Closed V22 Closed
V3 Closed V13 Closed V23 ClosedV4 Closed V14 Closed V24 Closed
V5 Closed V15 Position 1 V25 Closed
V6 Closed V16 Position 1 V26 Safety valve
V7 Closed V17 Open / Closed V28 Closed
V8 Open V18 Closed V31 Closed
V9 Closed V19 Closed V32 Closed
V10 Closed V20 Open
Read the instructions by the manufacturer for an
exact description of the distillation unit.
WARNING
The alcohol that is produced with this system
is raw alcohol and is not suitable for consump-
tion.
DANGER of poisoning!
Consumingrawalcohol, even in smalldoses,can lead to irreversible damage to health!
While operating the distillation, make surethat there is proper ventilation to prevent an
accumulationofalcohol ingredients in theair.
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WARNING
Steam lines and partsof the distillation unit getvery hot. Hot steam can escapeat the pressure
relief line.
DANGER of burning / scalding!
Tank 1 becomes very hot during the heatingoperation. Do not touch the jacket surface of
the tank during operation .
Neveroperate the steamheating for tank1with-
out a closed steam pressure-relief line.
Never operate the steam heating of tank 1without the water supply in tank 1.
While operating the distillation unit, much ofthe equipment will get very hot. Do not touch
the surface of the water bath, the distillation
bubble and the column.
Trouble-free functionality of the cooling water system is
absolutely necessary for proper distillation operation.
The distillation occurs as follows:
Close valve V17.
Fill the water bath to the mark with water.
Fill the condenser and the dephlegmator with wa-ter.
Set the thermostat for the cooling water flow ac-cording to the manufacturers instructions.
Set the gas temperature T9 for control to78...79C.
Switch on the stirrer for the distillation unit.
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While heating, monitor the temperature and the
water pressure in the water bath continuously. Af-ter achieving the temperature set for T9, the heat-
ing is controlled by switching the heater. The con-
densing alcohol flows into the alcohol supply and
then into the ethanol container (B4) from there.
During the distillation procedure, slowly increasethe value for temperature T9 to 90...95C and set
the cooling water thermostat to a higher tempera-
ture at the same time.
After separating all alcohol, switch the distillationunit off according to the manufacturers instruc-
tions.
After the distillation unit has cooled to ~30...40C ,the residual mash can be drained through valve
V19 and can be disposed of. Clean the distillation
unit according to the instructions of the manufac-
turer. All liquids are to be drained and the system
dried.
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6 Data acquisition software
6.1 Software installation
6.1.1 System requirements:
PC with Pentium IV, 1 GHz
Minimum 1024 MB RAM
Minimum 11GB of availablehard disk space
1 CD-ROM drive
USB-port Graphics resolution min. 1024 x 768 Pixel,
True Color
Operating system:Windows XP / Windows Vista/ Windows 7
6.1.2 Installation of software
The following are needed for the installation: A fully operational PCwithUSB port (formini-
mum requirements see chapter 6.1.1).
G.U.N.T. CD-ROMAll components necessary to install and run
the program are contained on the CD-ROM
supplied by G.U.N.T.
Hardware driver installationWithout Internet
Set up USB connection to PC
Call up the Device Manager
Manually install the driver for "USB FAST
SERIAL ADAPTER"
Right-click on "USB FAST SERIALADAPTER"
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Update the driver software
Search the computer for driver soft-ware
Insert the CD-ROM in the drive (e.g.drive D)
Install the driver from D:\USB-COM-M
Restart the PC
Installation with Internet connection (Windows 7)
BWhen prompted to install new device driversoftware, download the driver from the
Internet. (The"Automatically install Windows
update" option may need to be activated.))
Install the driver from the Internet.
Restart the PC
Installing the CE 640 software
Insert the CD-ROMinthe drive (e.g. drive D)
Open EXPLORER under WINDOWS andselect the CD-ROM.
Open the subdirectory \installer\.
Run Setup.exe in D:\installer\setup.exe. (As-suming D is the CD-ROM drive.)
Follow the instructions in the dialog box.
The computer must be restarted after completing
the installation.
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6.2 Software operation
After starting the program for the first time, the lan-
guage must be selected once.
The program has three tasks:
Clear representation of the current mea-sured values in the system diagram
Plotting of measured values (x,t)
Graphical display of values
Program structure
The menu items are context-specific, i.e. not all
menu items are always enabled. The menu bar
contains 5 options with the following sub-items:
Start
File
View
Language
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Fig. 6.1 Measurement value recordingsettings
11
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System diagram
This view shows the current measured values in aclear process diagram. The measurement values
are temperature and pH value in tank 1
About GUNT
Shows information about GUNT.
EXIT
Exits the program.
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Fig. 6.3 About GUNT
Fig. 6.4 System Diagram
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6.2.2 Menu point:File
New
(Charts only)
Creates a new data set.
Open
(Charts only)
Opens a saved data set and allows the data to be
viewed in a Measurement diagram or measured
values to be added.
Print
(Charts only)
Prints out the time lapse graphs on the default
printer.
Print window
(with Charts) Prints out a hardcopy on the stan-
dard printer.
(with System diagram) Prints out the system dia-gram currently displayed on the standard printer.
6.2.3 Menu point:View
Clear graph
(Charts only)
Clears the graph on the screen.
Play / pause
(Charts only)
Starts / stops the advance of the display.
6.2.4 Menu point:Language
German
English
French
Spanish
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7 Appendix
7.1 Technical data
Apparatus Complete L x W x H: 3400 x 1200 x 2000 mm
Weight: approx. 500 kg
Electrical supply: 3 x 400 V/ 50 Hz
alternative 3 x 220 V/ 60 Hz
Compressed air requirements: 1,5 ... 6 bar
Steam requirements: Q 15 kg/h
pmin 3 bar
Cooling water requirements: min. 400 litre/h
via fresh water connection
Mash tank Capacity: 60 litre
x h 341 x 675 mm
Material: Stainless steel
Inspection glass: DN 50, DIN 28120
Temperature measurement probe PT 100
Fermentation tank Capacity: 48 litre
x h 341 x 675 mm
Material: Stainless steel
Inspection glass: DN 50, DIN 28120
Temperature measurement probe PT 100
7 Appendix 65
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Diaphragm feed pump L x W x H: 190 x 140 x 200 mm
Max. head 72 m
Max. capacity 27 litre/min
Max. suction lift wet 7 m
Max. particle size 4 mm
Max. air consumption: 12 m/h
Connections: Intake side 3/8
Delivery Side 3/8
Air intake 1/8
Material: Diaphragm: EPDM
Sphere: EPDM
Housing: PP
Diaphragm metering pump L x W x H: 262 x 102 x 186 mm
Max. operating pressure: 16 bar
Max. capacity 2.1 litre/h
Max. suction lift wet 6 m
Connection: 6 x 4 mm
Connection voltage: 100...230 VAC
Connection frequency: 50...60 Hz
Materials Metering head: PP
Valves: PP
Seals: EPDM
Balls: ceramic
Control valve steam Nominal size: DN 15
Pressure stage: PN 40
Kvs value: 0.4
Characteristic curve: linear
Material: Stainless steel
Max. supply air pressure: 4 bar
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Control valve cooling water Nominal size: DN 20
Pressure stage: PN 16
Kvs value: 4.0
Characteristic curve: linear
Material: Cast iron
Nominal signal range 0,4...2,0 bar
Solenoid valve Nominal size: DN 4
Pressure Range: 0...6 bar
Kv value 0.5
Connection: G3/8
Connection voltage: 24 VDC
Ethyl alcohol container Capacity: 10 litre
Material: PE
Mash container L x W x H: 600 x 400 x 165 mm
Capacity: 30 litre
Material: HDPE
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7.2 Process schematic
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7.3 Items supplied
1 System complete in steel trolley on castors
1 pH-measuring probe
1 Ethyl alcohol container
1 Mash container, portable
1 Set of water hoses with sleeve material
1 Steam hose, stainless steel mesh-wound
1 Alpha amylase, 0,5 litre1 Gluco amylase, 1 litre
1 Antifoaming agent, 1 litre
1 Distilling yeast, 500 gr
1 Software on CD
1 Data transmission cable
1 Instruction manual
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7.4 Index
AAlpha- Amylase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38, 50
B
Boiler heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Bubble cap tray column . . . . . . . . . . . . . . . . . . . . . . . 14, 45Buffer solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
C
Carbon dioxide . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 40 - 41Chemo- Selectivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Compressed air diaphragm pump . . . . . . . . . . . . . . . . . . 23
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 45, 56Control cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cooking tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Crushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
D
Damage to health . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Data acquisition software. . . . . . . . . . . . . . . . . . . . . . . . . 16Dephlegmator . . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 45, 56Diaphragm metering pump . . . . . . . . . . . . . . . . . 24, 28, 35
Diaphragm pump . . . . . . . . . . . . . . . . . . . . . . . . . 19, 23, 36Distillation . . . . . . . . . . . . . . . . . . . . . 17, 21, 32, 42, 45, 55Distillation unit . . . . . . . . . . . . . . . . . . . . . 13, 20, 36, 48, 54
E
Enzymes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 38Ethanol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
F
Fermentation . . . . . . . . . . . . . . . . . . . . . . . . 37, 40 - 41, 48Fermentation lock . . . . . . . . . . . . . . . . . . . . . . . . 11, 41, 53Fermentation tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9, 11
Flow meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Fresh water supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19G
Gluco- Amylase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Gluco-Amylase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Glucose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 - 38
I
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Installation of software. . . . . . . . . . . . . . . . . . . . . . . . . . . 59
L
Liquification. . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 38 - 39, 49
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M
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Maintenance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Mash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Mash tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Mashing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 38
P
PLC controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17, 53Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Pitched blade agitator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Pitched blade agitators . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Poisoning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32, 55
Process diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5R
Raw alcohol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32, 55S
Saccharification . . . . . . . . . . . . . . . . . . . . . . . 1, 38 - 39, 49Saccharimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Safety notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Sealing liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Software operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Starch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Stirrer . . . . . . . . . . . . . . . . 8, 11, 18, 20 - 21, 40, 50, 53, 56System diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63System time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
T
Temperature control . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 19W
Water bath distillery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Y
Yeast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 40
PpH measuring probe . . . . . . . . . . . . . . . . 16, 25, 28, 35, 50pH reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50pH value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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