DESC:COMPLETE SPECIFICATION
Title of Invention-
Automated Bioethanol Processor.
FIELD OF THE INVENTION
The present invention relates to a fully automated batch model machine for the conversion of multiple feedstock into bioethanol.
BACKGROUND OF THE INVENTION
Continued growth of the global economy has increased both energy consumption and concern regarding the accumulation of atmospheric greenhouse gases, and their effects on climate change. In response, many countries are developing renewable energy, including biofuel production. Biofuels are any fuels produced from biomass, such as organic waste materials, and such fuels can have a significantly reduced ecological footprint compared to traditional fossil fuels. Production of biofuels from renewable feedstocks has captured considerable scientific attention since they could be used to supply energy and alternative fuels. Bioethanol is one of the most interesting biofuels due to its positive impact on the environment. Bioethanol is considered a potential substitute for the conventional gasoline and can be used directly in vehicles or blended with the gasoline, thereby reducing greenhouse gas emissions and consumption of gasoline. Currently, it is mostly produced from sugar- and starch-containing raw materials. However, various available types of lignocellulosic biomass such as agricultural and forestry residues, and herbaceous energy
crops could serve as feedstocks for the production of bioethanol, energy, heat and value-added chemicals. Lignocellulose is a complex mixture of carbohydrates that needs an efficient pre-treatment to make accessible pathways to enzymes for the production of
fermentable sugars, which after hydrolysis are fermented into ethanol. Despite technical and economic difficulties, renewable lignocellulosic raw materials represent low-cost feedstocks that do not compete with the food and feed chain, thereby stimulating the sustainability. Different bioprocess operational modes were developed for bioethanol production from renewable raw materials. Furthermore, alternative bioethanol separation and purification processes have also been intensively developed.
Different types of biomass have a potential as raw materials for bioethanol production. Because of their chemical composition, i.e. carbohydrate sources, they mostly form three groups: (i) sugar-containing raw materials: sugar beet, sugarcane, molasses, whey, sweet sorghum, (ii) starch-containing feedstocks: grains such as corn, wheat, root crops such as cassava, and (iii) lignocellulosic biomass: straw, agricultural waste, crop and wood residues (26). However, these sugar and starch-containing feedstocks (first generation) compete with their use as food or feed, thus influencing their supply. Therefore, lignocellulosic biomass (second generation) represents an alternative feedstock for bioethanol production due to its low cost, availability, wide distribution and it is not competitive with food and feed crops. One of the major problems faced by the bioethanol
industry is that the centralized production strategy, raw material availability and advanced technology. However, most of the referred prior arts are different from the present invention because they don’t address the small scale production of bioethanol in a fully automated machine with multiple feedstocks. Further, they don’t address the separation and purification
of the crude bioethanol in an automated mode. At present, there is no standard equipment for catalysed bioethanol production in India. In view of this, the present invention address the shortcomings in the existing production equipment for small scale bioethanol production and unlike the systems and methods known in the art, the present invention is well-suited for the purified bioethanol production with multiple feedstocks.
OBJECT OF THE INVENTION
1. The primary object of the present invention is to provide a fully automated machine for the conversion of multiple feedstocks (Sugar, Starch, Lignocellulosic and algal-based raw materials) into purified bioethanol.
2. Other object of this invention is the unique setup of the machine, in one form, consists of a pre-treatment and hydrolysis tank that is configured to convert multiple feedstocks into fermentable sugars.
3. The invention consists of main reactor, a fully automated efficient fermentation tank, which can convert the fermentable sugars into ethanol.
3. Other object of this invention is the unique setup of the machine, in one form, consists of a distillation tank, where vacuum based distillation will be done and ethanol distilled out.
4. Other object of this invention is the unique setup of the machine, in one form, consists of filtration unit and a collection tank, where purified bioethanol will be collected after filtration process.
5. The Filtration unit is connected before the collection tank, where filtration processes will be completed with the support of the motor pump.
6. All these functionalities and processes are coordinated with the support of the object, a processor with Programmable Logic Controller support system and innovatively designed for both automatic and manual, hybrid mode.
STATEMENT OF THE INVENTION
The invention relates to a fully automated machine for the production of bioethanol from multiple feedstocks. This may be accomplished by fermentation process. Conventional bioethanol production is done in big scale plant whereas this invention will provide an equipment for small scale production of bioethanol through innovative steps.
Figures Explained
Fig 1: BIO-ETHANOL PROCESSING MACHINE with Milling/Shredder Unit
1. Milling Container/Shredder unit - That mills/shreds the raw materials under multiple feedstocks categories
2. Solenoid valve - To regulate the fluid
3. Pump- To move fluids from one place to another
4. Pretreatment tank - Where recalcitrant structures of cellulosic biomasses will be disrupted primarily.
5. Hydrolysis tank - Where hydrolysis steps will be done that convert carbohydrate polymers to fermentable sugars
6. Main Reactor tank - Where the sugars will be converted into ethanol with the support of microflora
7. Filtration unit - The innovative filtration steps will be completed in the unit
8. Distillation tank- Where a partially purified fermented products will be transported
9. Vacuum pump- To initiate the vacuum conditions as part of distillation process
10. Filtration unit- The innovative filtration steps for premium grade highly purified bioethanol will be completed in the unit
11.Bioethanol Storage tank - Where the final purified bioethanol will be stored
12.Byproducts Storage tank- Where the by-products will be stored
13.Controlling unit- Controls the entire system using a Programmable Logic Controller system.
Figure:2 –BIOETHANOL REACTOR
a) Harvesting Pipe - Where Bioethanol drains to the storage/harvesting system
b) Aerator- Used for aeration/mixing air in reactor
c) Thermal jacket- Helps to retain/ maintain the optimum temperature of the reactor.
d) Baffle- Helps to maintain the homogenous mixing of the raw materials and enzymes
e) Reactor tank- Where entire reaction processes takes place, which encompasses the aerator (b), Thermal Jacket (c), Baffle (d), Sensor Probes (k,l,m), impeller (n) . The raw materials and inoculum are dropped to this Reactor tank separately and mixed for reaction as further detailed in the Description of the Complete Specification.
f) Antifoam Controller- Which controls the air or foam produced during the reaction steps
g) Inoculation Pipe- Used to transfer the inoculum (fermentation) to the reactor tank(e )
h) Stirring system- That stirs to maintain the homogeneity of solutions in the reactor tank.
i) Pressure valve- A safety valve used to control or limit the pressure in the reactor
j) Raw material Feeding pipe- Helps to feed the raw materials to the reactor
k) Oxygen sensor- That senses oxygen presence in the reactor
l) pH probe- That senses the pH conditions in the reactor
m) Temperature probe- That senses the temperature in the reactor and maintains the temperature to an preset optimum condition.
n) Impeller- A rotating device designed to alter the flow of materials in the reactor to blend the ingredients to a perfect mixture.
DESCRIPTION OF THE INVENTION
As shown in FIG.1, Miller container/Shredder unit (FIG.1.1) that mills/shreds the raw materials under multiple feedstocks categories (sugar/cellulose/lignocellulosic/algal based), which will then transferred to a pre-treatment tank (FIG.1.4) and hydrolysis tank (FIG.1.5) with the support of solenoid valves (FIG.1.2) and pumps (FIG.1.3). The milling or shredding (mechanical treatment) of the feedstocks will be completed in this Miller container/Shredder unit. The milled/shredded the polymeric cellulose/sugar/lignocellulosic/algal based feed stocks in the pre-treatment and hydrolysis tanks designed in such a way that it will be chemically or enzymatically converted into fermentable sugars. The sugars will be transferred to main reactor tank (FIG.1.6), where the sugars will be converted into ethanol with the support of microflora, especially yeast (Saccharomyces cerevisiae). In addition to the yeast, other specific microflora or innovative inoculum will be used as part of fermentation process. The optimum conditions will be maintained in the main reactor tank (Fig.2) which is made of stainless steel with different specifications. An aerator (Fig.2b) and antifoam controller (Fig.2f) will be placed to control the microbial growth; a thermal jacket (Fig.2c) to maintain the temperature, which will be probed by temperature sensor (Fig.2m); a stirring system (Fig.2h) with impellers and baffles (Fig.2d),placed for evenly mixing the medium with the microflora; the microflora and raw materials will be added to the reactor tank (Fig.2e) with the support of inoculation pipe (Fig.2g) and raw material feeding pipe (Fig.2j) respectively; the pH and oxygen level, which are critical
for the fermentation steps will be monitored and probed with the support of pH probe Fig.2 (k) and oxygen sensor (Fig.2l) and after the completion of 24hr fermentation process, the whole extracts will be transferred to a filtration tank through a harvesting pipe (a). For safety purpose, a pressure valve (Fig.2i) will be placed on the top of the reactor, which is essentially required for fermentation process. The innovative filtration steps will be completed in the filtration tank (FIG.1.7), which contains a filter having curated size of 2500-5000 micro meters integrated with active carbon filter, enabling the machine to remove the stains of slurry, which is a combination of the ingredients, where a partially purified fermented products will be transported to a distillation tank (FIG.1.8), where under vaccum conditions (FIG.1.9) and high temperature (above 80oC), the ethanol will be distilled out and transferred to a filtration unit (FIG.1.10) which employees unique filter filters having a curated size 50-100 micro metres, enabling fine flow of purified bioethanol . After filtration, the final purified bioethanol will be stored in a bioethanol storage tank (FIG.1.11) and the by-products will be stored in a storage tank (FIG.1.12) for further use. As the entire system is automated, it is being configured and assembled using a Programmable Logic Controller system (FIG.1.13) and, it is being programmed for batch wise bioethanol production steps. To detect the leakage of ethanol, a highly inflammable material used in the reaction mixtures, will be detected by the ethanol sensors configured in the machine, and will be controlled and alerted with the support
of PLC system. Manual operating procedures are also assembled in the system (FIG.1.13), which can be effectively used for hybrid mode operating procedures, if there is any programmable failures. A user interface is provided which contain switches, indicators, a standard input mechanism and an electronic display. A frame assembly is provided comprising a base frame with anchor legs and a mount frame to which the housing for the machine, will be mounted.
The innovative machine facilitates usage of multiple feedstocks as raw material, without making any alteration to the machine. To enable this functionality the machine is preprogrammed with specific pretreatment and hydrolysis steps. This is made possible by the functionality of Programmable Logic Controller (Fig 1.13). The said program can be preset according to the available feed stock
Dated this the 27th day of November 2024

,CLAIMS:CLAIMS
We Claim:-
1. An innovative machine which automates the production of purified bioethanol from multiple feedstocks.
a) As claimed in claim 1, this innovative machine contains a REACTOR (Fig 2, Fig1.6) which contains :-
A Reactor tank (fig2-e) Where entire reaction processes takes place, which encompasses the aerator (fig2. b) which facilitates aeration/mixing air in reactor, Thermal Jacket (fig2. c), which Helps to retain/ maintain the optimum temperature of the reactor., Baffle (fig2. d) which helps to maintain the homogenous mixing of the raw materials and enzymes, Sensor Probes (fig2. - k,l and m) an Oxygen sensor- That senses oxygen presence in the reactor, pH probe- That senses the pH conditions in the reactor and Temperature probe- That senses the temperature in the reactor and maintains the temperature to an preset optimum condition, respectively; impeller (fig2. n) which is a rotating device designed to alter the flow of materials in the reactor to blend the ingredients to a perfect mixture. The raw materials and inoculum are dropped to this Reactor tank separately and mixed for reaction as further detailed in the Description of the Complete Specification. The said reactor tank is fitted with a Harvesting piper (Fig2.a) Where Bioethanol drains to the storage/harvesting system; Antifoam Controller (fig2.f) Which controls the air or foam produced during the reaction steps; Inoculation Pipe (fig 2-g) Used to transfer the inoculum (fermentation) to the reactor tank; Stirring system(fig 2-h) That stirs to maintain the homogeneity of solutions in the reactor tank; Pressure valve(fig 2-i) A safety valve used to control or limit the pressure in the reactor; Raw material Feeding pipe (fig.2.j) which helps to feed the raw materials to the reactor.As claimed in claim 1, this innovative machine contains a pre-treatment (Fig1.4) and hydrolysis tank (Fig 1.5) that is configured to convert multiple feedstocks into fermentable sugars.
b) As claimed in claim 1, the innovative machine contains a distillation tank (Fig1.8), where vacuum-based distillation will be done and ethanol distilled out.
c) As claimed in claim 1, the innovative machine contains a unique setup of the machine, in one form, consists of filtration unit (fig 1. 10) where filtration processes will be completed with the support of the motor pump and a collection/storage tank (Fig 1.11) , where purified bioethanol will be collected after filtration process.
d) As claimed in claim 1, there is a Programmable Logic Controller (fig1.13) support system attached to the innovative machine to control the functionalities and processes of the system, both automatically, manually and hybrid mode as per the requirement of the situation.
e) As claimed in claim 1, the innovation contains a Vacuum pump (fig 1. 9)- To initiate the vacuum conditions as part of distillation process
f) As claimed in claim 1, the innovation contains a Byproducts Storage tank (fig 1. 12) Where the by-products will be stored.
g) As claimed in claim 1, the innovative machine is fitted with a Milling Container/Shredder unit (fig 1.1) which is used to mill/shred the raw materials under multiple feedstocks categories
h) As claimed in claim 1, the innovative machine is fitted with a Solenoid valve (fig 1.2) ,To regulate the fluid flow.
i) As claimed in claim 1, the innovative machine is fitted with a motor Pump (fig 1.3) which push the fluids to the desired locations.
j) As claimed in claim 1, the innovative machine is fitted with a Filtration tank (Fig 1.7) which contains a mesh having curated size of 2500-5000 micro meters integrated with active carbon mesh, enabling the machine to remove the stains of slurry, which is a combination of the ingredients.

2. The innovative machine employees an innovative process of filtration using the filtration unit (Fig 1.10), which employees unique filters having size 50-100 micro meters, enabling fine flow of purified bioethanol to the storage tank (FIG.1.11)
3. The innovative machine is fitted with a Filtration tank (Fig 1.7) which contains a filters having curated size of 2500-5000 micro meters integrated with active carbon filter, enabling the machine to remove the stains of slurry, which is a combination of the ingredients.
4. The innovative machine facilitates usage of multiple feedstocks as raw material, without making any alteration to the machine. To enable this functionality the machine is preprogrammed with specific pretreatment and hydrolysis steps. This is made possible by the functionality of Programmable Logic Controller (Fig 1.13)