Technology and economics of fermentation alcohol — An update

Fermentation alcohol is being widely studied as an alternative fuel, and production is increasing, especially in Brazil, where the goal is more than 10 billion litres per year by 1985.Fuel markets are hundreds of times greater than the traditional ethanol markets which the existing industry supplies. To make a material contribution to fuel supply, fermentation ethanol must be treated as a major chemical and produced in large-volume, highly efficient plants. Such plants must be assured of a continuous supply of low-cost raw materials for which suitable processes have been developed and commercially proven. Sugar cane in the tropics and grains in some temperate countries meet these requirements; cellulosics do not qualify at present, nor will they in the foreseeable future, without major breakthroughs.Using techniques borrowed from the starch sweetener industry, starchy materials may be economically hydrolysed to fermentable sugars; rapid acid hydrolysis may prove superior to enzymatic processes. Major projects are under way to replace traditional batch or cascade fermentations with rapid, single-vessel continuous units, but these have not yet been fully proven. Where suitable, yeast recycle is being used as a means of increasing alcohol yields, and energy-efficient distillation methods of the petrochemical industry are being adopted. The consequent large reduction in steam consumption greatly reduces the appeal of other methods which have been proposed to remove water.Opportunities for process improvements abound, especially in developing (1) the means to provide cellulosic raw materials in large quantities at acceptable costs, (2) economically effective methods of pretreating and hydrolysing cellulosics, (3) practical organisms for converting five-carbon sugars to ethanol and (4) higher fermentation yields and efficiencies using bacteria or immobilized yeast.