ECOS 2008 - Poland

PROCESS INTEGRATION OF YEAST

FERMENTATION PLANT
Rašković P.1, Anastasovski A.2, Markovska Lj.2,Meško V.2
1
Faculty of Technology, University of Nis, Serbia, buki@bankerinter.net
2
Faculty of Technology and Metallurgy, Ss Cyril and Methodius University, Skopje,
Republic of Macedonia

ABSTRACT: Process integration (PI) is a system oriented approach to process

design of new or retrofitting of existing industrial plants, which applications are
focused on resource conservation, pollution prevention and waste management.
Some of research institutions reported that: “PI is probably the best approach that
can be used to obtain significant energy and water savings as well as pollution
reductions for different kind of industries”. The potential of PI exceeded the results
obtained by traditional audits, and approaches based on separate optimization of
individual process units. This paper provides a part of process integration study in
the plant for yeast and alcohol production, situated in the town Bitola, Republic of
Macedonia. Research roadmap is divided in four phases and the final solutions,
based on three starting scenarios, are obtained by Pinch analysis. Evaluation of
results revealed the parameters of Heat Exchanger Network with significance
energy saving potential and short pay-back potential.

Keywords: process integration, yeast fermentation plant, pinch technology.

NOMENCLATURE T -temperature (0C), (K)

v -velocity (m/s)
A -area (m2) I={i} -streams
cp specific heat (J/kgK)
CC -capital cost ($/year) Greek symbols
CO -operating cost ($/year) α -heat transffer coefficient (W/m2K)
CT -total annual cost ($/year) λ -conductivity (W/mK)
CU -utility cost ($/year) η -boiler efficiency
d -diameter (m) μ -viscosity (Pa s)
Fl -fuel (heavy oil) ρ -density (kg/m3)
G -mass flow rate (kg/s)
h -specific enthalpy (J/kg) Subscripts
HEN(S)-heat exchanger network (synthesis) a - water inlet in boiler
HRAT-min. temperature difference (0C) C - cold
Hd -lower heating value (kJ/kg) g - gaseous
m -mass flow rate (kg/s) f - liquid
Nu -Nusselt dimensionless number(-) H - hot
Pr -Prandt dimensionless number(-) min- minimum
Re -Reynolds dimensionless number(-) S - steam outlet from boiler
Q -heat flow rate (W)
1. INTRODUCTION
In this paper a part Process Integration
(PI) study of yeast fermentation plant is
presented. The primal goal of the study is to
validate the improvements made by energy
audits, and to identify and estimate new
opportunities to reduce the energy and raw
materials consumption in the plant.
Figure 1: The simplified roadmap of
research
Generally, yeast manufacture can be
classified as semi-continuous processes,
remarking that during some operating period
the processes have continuous character. In
order to create the feasible and practical
solution with short-payback period, PI task
is addressed to continuous operations,
during that period. Another assumption is
based on the fact that PI task involved only
the material and energy flows between the
main production subsystems.
Research roadmap is divided in four
phases. In the first phase, the physical model
of yeast fermentation plant is described and
defined as the network of inter-connected
subsystems. Mathematical model of the
plant was based on mass end energy balance
equations of subsystems. In the next phase,
numerical model of plant is implemented in
the spreadsheet software tool named BtY [2]
developed on Microsoft Excel programming
platform. Thermodynamic properties of
some streams are calculated by the use of
water/steam properties simulator. For the
phase of PI (Pinch analysis) three scenario
are defined. Data extraction task is
improved with spreadsheet software which
enabled the calculation of thermodynamic
and economic parameters for HENS
purpose. Pinch analysis is realized by
NiPinch[3] software, and limited on the
results of targeting task. The simplified
roadmap is presented in Fig. 1.
2. YEAST AND ALC. PRODUCTION
The word "yeast" comes from the
Sanskrit 'yas' meaning "to seethe or boil".
Today the name yeast is applied specifically
to a certain group of microscopic fungi and
to commercial products consisting of masses
of dried yeast cells or of yeast with a starchy
material and pressed into yeast cakes. Louis
Pasteur, in the 1850's, first discovered and
described the fermentation process, which
led to the development and cultivation of the
yeast we use today.
Yeast belong to the group of unicellular
fungi, a few species of which are commonly
used to leaven bread and ferment alcoholic
beverages. The most number of yeasts
belong to the division Ascomycota, but the
well-known and commercially significant
yeasts are Saccharomyces cerevisiae. These
organisms is commonly used as baker's
yeast and for some types of fermentation.
Yeast is often taken as a vitamin supplement
because it content proteins, B vitamins,
niacin, and folic acid.
The process of fermentation in yeast
production can be classified according to the
presence of air either on Aerobic (with air)
or Anaerobic (without air). Aerobic
fermentation represents yeast biomass
growth using energy from biochemical
oxidation of glucose via energetic
component as ATP (Adenosine Tri
Phosphate). Final product of Aerobic
fermentation commonly exist in two forms:
compressed cakes (also called fresh yeast)
and dehydrated granules (dry yeast). Fresh
yeast (contain about 70% moisture is ivory
coloured with a yellowish hue, soft, moist
and easily crumbled. Dry yeast is fresh
compressed yeast that has been dried until
the moisture content of about 8%. The
granules of dry yeast become active again
only by mixing with a warm liquid. The
main advantage of dry yeast longer shelf life
and easy storage.
The process of anaerobic fermentation
(known as Alcoholic fermentation) has
slower activity, focused on converting sugar
to alcohol rather that increasing the number
of yeast cells. Alcoholic fermentation make
transformation of glucose to ethyl alcohol
with byproducts obtained by yeast cells
metabolism. Biochemical oxido-reduction
reaction of this process is known as
Embden-Meyerhof-Parnas pathway, or
Glycolisys. Final product of anaerobic
fermentation is Ethyl alcohol, also known as
Ethanol, a flammable, colorless chemical
compound that is used for beverage or
industrial purposes. It is usually distributed
in the form of pure ethyl alcohol, completely
denatured or specifically denatured ethanol.
3. PLANT DESCRIPTION
The reference plant for process
integration research in this paper, is one of
the Balkan’s oldest and biggest factory for
yeast and alcohol production named AD” F-
ka za Kvasec i Alkohol–Bitola”. The factory
is placed in the city of Bitola, southwest
region of Republic of Macedonia, close to
Macedonian – Greece border. The main
product of the manufacture are:
• refined and denaturized ethyl alcohol,
• dry and fresh baker`s yeast,
• wine and selenium yeast,
• baker`s additives, bee food,....
The average annual production of these
product are: 1200 t of dry yeast, 6000 t of
fresh yeast and approx. 5x106 m3 of ethyl
alcohol (as refined ethanol-potable alcohol).
The physical model of the plant (Fig. 1)
can be presented as the network of inter-
connected subsystems according to the
technology operations of manufacture
roadmap. Production processes are framed
inside two main routes:
• First baker`s yeast route, which
comprises:
o Preparation of feeding material
(subsystem A),
o Aerobic fermentation (subsystem B),
o Centrifugal separation (subsystem E),
o Filtration (subsystem F),
o Drying (subsystem G), and
o Final yeast storage and packaging
stage.
• The second alcohol route comprises:
o Preparation of feeding material
(subsystem A),
o Anaerobic fermentation (subsist. H),
o Separation of alcoholic wort and yeast
cream (subsystem C),
o Distillation of alcoholic wort
(subsystem D) and
o Final, alcohol storage stage.
Production process (for both products)
start in the subsystem A, where raw
molasses (RML) (stored in the raw molasses
tank) is treated in order to obtained the
prepared molasses (PML). RML contain 45–
50% of sucrose and other components like:
glucose, fructose and some vitamins(such as
biotin). RML are first mixed with hot
water(HW1), in order to create the molasses
solution (MS). Next, MS is leading in the
first centrifugation stage, where solids and
voluminous sediments (discharged streams
CSD) are removed. One part of solids
coagulates due to sulphuric acid presence.
After centrifugation, clarified MS are
sterilized by law pressure steam (LP1) and
then lead to the second separation stage -
phase separator. Phase separation enabled
the remove of volatile organic acids (lactic
acid, butyric acid, sulphuric dioxide etc.
which inhibit the process of yeast
fermentation) from MS stream. Final
product from this stage, PML is first cooled
in plate heat exchanger (by cold water ,CW1)
and stored in Prepared molasses tank.
In the next stage of manufacture –
Fermentation stage (subsystem B),
production process is divided on two
separate routes: yeast production route and
alcohol route.
In the case of yeast production, PML are
transferred in the aerobic fermentation unit.
Fermentation process is improved by the use
of hot water (HW2). Another input in
subsystem are:
• feeding salts (FS),
• cold water (CW2) stream-needful for
vessels surface cleaning,
• water from regional system (RWS)-used
for control of fermentation temperature
• air stream (AS)-used as source of oxigen
for yeast biomass growth.
Final product of fermentation process is
yeast wort (YW).
In the next phase YW is purified crossing
the three stage centrifuge in subsystem E.
After separating process, yeast cream (YC)
is washed by cold water (CW3) and then
stored in Yeast cream storage tank.
Impurities obtained as the result of treatment
are sending into drainage systems (ImS).
Hot water stream (HW3) is used for washing
of centrifugation system.
The first form of final product -Fresh
yeast (yeast with content of 30 – 34% dry
matter) is produced in subsystem F, through
the filtration process and by the use of
rotation vacuum filter. A part of fresh yeast
(FY), obtained in this stage, is transferred in
the storage stage, while the rest is sent to
subsystems G, in additional treatment.
Filtrate (FL), obtained by water washing
treatment, is discharged.
Subsystem G (fluid bed dryer process
unit) is supplied with LP steam (LP2), hot
water (HW5) and dry air (DA). Final product
from this subsystem, Dry yeast (DY), with
content of 95 – 97% matter, is transported to
the storage and packaging stage. Outgoing
stream (HA), from subsystem E, represent
the hot humid air.
In the case of alcohol production route
PML is first dosed in anaerobic fermentation
unit. The process of anaerobic fermentation
is improved by the presence of hot (HW6)
and cold water (CW6). Alcohol yeast cream
(AYC), as starter culture for that feed batch
fermentation, is added from Alcohol yeast
cream tank. One of the products of
fermentation are exhaust gases (EG),
mixture of carbon dioxide, vapour and
ethanol. The product of anaerobic
fermentation process, is alcoholic fermented
media (AFM), with content of approx. 8-10
%Vol. of ethanol.
In the next stage, subsystem C, AFM is
separated into two substreams: alcoholic
wort (AF) and alcoholic yeast cream (AYC),
stream. Alcoholic wort (AF) is then feeding
in steam distillation unit, subsystem D. The
results of distillation are: 96% Vol. ethyl
alcohol (EA) and technical alcohol (TA)
stored in STE and STA tanks. Technical
alcohol present a mixture of ethanol,
aldehydes (represented with acetaldehyde)
and some other less volatile components
than ethanol. The distillation waste streams
are:
• molasses residues (MR),
• organic acids water solution known as
Luter (LT), and
• cooling water from shall and tube heat
exchangers (WHE).
Figure 2: Physical model of yeast and alcohol production plant
4. PROCESSES INTEGRATION TASK
The PI task is accomplished by the use of
thermodynamic method – Pinch analysis[4].
The result of research presented in this
paper are limited on targeting task and
realized on three different scenarios. In all
scenarios only the streams with considerable
heat capacity are involved (Table I).
Scenario 1 and Scenario 2 comprised only
the liquid streams, as Scenario 3 had one
more cold stream-air stream (DA) utilized in
drying subsystem. In the case of Scenario 2
and Scenario 3 the supply temperatures of
hot streams (CWS and WHS) are obtained
after preheating in HW and Water Heating
systems. In the case of Scenario 1 supply
temperatures of this streams are the
temperatures before entering these units.

Table I: Process integration task

Temp (0C) mcp ΔQ α CU (utility cost)
Stream Scenario
Tsup Ttar (kW/0C) (kW) (kW/m2K) ($/GJ)
Cold streams
Scenario 1 5.0 90.0 5.815 494.3 1.505 19.36
CWS Scenario 2 40.0 90.0 5.815 290.8 1.505 19.36
Scenario 3 40.0 90.0 5.815 290.8 1.505 19.36
Scenario 1 20 60 9.304 372.2 1.505 19.36
WHS Scenario 2 40 60 9.304 186.1 1.505 19.36
Scenario 3 40 60 9.304 186.1 1.505 19.36
DA Scenario 3 40.0 90.0 3.154 157.7 0.0101 19.36
Hot streams
Scenario 1 106.0 25.0 2.874 232.8 1.507 3.89
MR Scenario 2 106.0 40 2.874 189.7 1.507 3.89
Scenario 3 106.0 40 2.874 189.7 1.507 3.89
Scenario 1 105.0 40 0.887 57.63 1.447 3.89
LT Scenario 2 105.0 40 0.8866 57.63 1.447 3.89
Scenario 3 105.0 40 0.8866 57.63 1.447 3.89
Scenario 1 70.0 43.3 13.93 371.9 1.843 3.89
WHE Scenario 2 70.0 43.3 13.93 371.9 1.843 3.89
Scenario 3 70.0 43.3 13.96 371.9 1.843 3.89
Utility
CW Cold 5 10 1.505 3.89
LP Hot 174 173 3.522 19.36

Heat transfer coefficient (α) and Utility cost operating cost and capital cost of HEN
(CU) are obtained from spreadsheet solution (in this case ΔTmin=20 (oC) and
software. Mathematical expressions of these operating period is 4000 (h/year) for all
calculation are presented in Appendix. scenarios).

Table II: Sensitivity analysis parameters

5. RESULT AND FUTURE WORK
Input parametars Range
Evaluation of targeting results are HRAT (ΔTmin) 12÷28(oC)
presented in the form of sensitivity analysis Operating period /year 2000÷4000 (hour)
Short review of parameters and research Output parametars
ranges are presented in Table II. Qmin (kW)
The first evaluation criteria was the Amin (m2)
potential for HEN solution wich need short- Nmin (-)
CC ($/year)
payback period. This kind of potential is CO ($/year)
presented as ratio between annual saving of CT ($/year)
 Graphical presentation of this potential
is expressed by slope angle of scenario
curve in Fig 3. It is obvious that solutions
obtained by Scenario 1 and Scenario 2, are
more appropriate than solution obtained by
Scenario 3, according to the duration of pay-
back period.
1 and Scenario 2 that contribution is
considerably less than in Scenario 3; logical
conclusion: these scenarios are more
suitable for previously defined goal: quick-
win solution.

Figure 3: Pay-back potential

Figure 4: Percentage contribution of HEN

capital cost in Total annual cost

Explanation of such results can be found

in sensitivity analysis of HEN cost inside
ΔTmin operating range (operating period is
4000 (h/year)). Analysis expressed the
percentage contribution of HEN capital cost
Figure 5: Total cost analysis in relation
in Total annual cost. In the case of Scenario
with operating period during the year
Sensitivity analysis inside ΔTmin operating
range exposed intersection point (ΔTmin≈
16 (oC)) between Scenario 1 an Scenario 2
curve. This exposure was the initial for total
cost analysis, but this time in relation with
operating period during the year. Analysis
(presented in Fig. 5) involved only Scenario
1 and Scenario 2, and the results are
obtained for 3 values of HRAT (ΔTmin=12,
16 and 28 (oC)). Graphical presentations
demonstrate percent increase of total annual
cost in relation with working time period of
HEN.
Total cost analysis indicate the existence
of two regions:
• First – region which covered the
percentage increase of CT inside the
HRAT range 12-16(oC),
• Second – region which covered the
percentage increase of CT inside the
HRAT range 16-28(oC),
According to the position and slope of
the curves, one general conclusion can be
made: inside the first region HEN solution
of Scenario 2 is preferred than solution of
Scenario 1. The conclusion inside second
region is quite opposite. The reason for that
is threshold problem position of composite
curve in the case of Scenario 1 in range
ΔTmin=12÷-20 (oC). By rising the value of
HRAT, operating cost increase but capital
cost do not decrease till the presence of
threshold position. So despite the
preferences presented in diagram of Fig.1,
final conclusion is the privilege of Scenario
2 in the case of lower value of HRAT.
However, Scenario 1 confirm the better pay-
back potential in the case of higher HRAT
values.
As the conclusion we can say that this
part of PI study clarified the potentials for
energy savings inside the yeast and alcohol
manufacture plant and establish the correct
direction of future research. Results
obtained in targeting phase will be the
starting position for HEN design and
optimization in the following papers.
REFERENCES
[1] Rašković, P., Step-by-Step Process
Integration Method for the
Improvements and Optimization of
Sodium Tripolyphosphate Process
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Meshko, Heat integration of ethanol
and yeast manufacture, Macedonian
Journal of Chemistry and Chemical
Engineering, 26(2) ; (2007):135-146
[3] Rašković, P., Ni Pinch-software tool for
heat exchanger network synthesis, In
Proceedings of the Computational
engineering in fluid dynamic and
energy technology, I professional
seminar, Niš, Serbia, 2004 p.99-708..
[4] Smith R. Chemical Process Design,
New York: McGraw-Hill, 1995.
APPENDIX
Heat transfer coefficient-α:
α = f (Nu = 0.023 ⋅ Re 0.8 ⋅ Pr 0.33 ,
i i
λ ,c , ρ , μ , v , d ),i ∈ ( CW ,CWS ,WHS , DA )
i p,i i i i
α i = f (Nui = 0.026 ⋅ Re0.6 ⋅ Pr 0.3 ,
λi , c p,i , ρi , μi , vi , d ), i ∈ ( MR , LT ,WHE )
αi = f ⎨
[ ( f g
) ]
⎧ Nu = 0.021 ⋅ Re 0.8 ⋅ Pr 0.43 1 + ρ /ρ 0.5 / 2 ,⎫
⎪ i ⎪
⎬,
⎪⎩λi , c p,i , ρ i , μ i , vi , d ⎪⎭
i ∈ ( LP )
Utility cost-CU:
CU H = C Fl ⋅
(
1 ⋅ hS − ha )
⋅ 10 6 [$ / GJ ],
η ⋅ Hd
CU C − obtained from literature [4]