corn dry grind ethanol biorefinery - abq · 2011-02-19 · dry grind ethanol biorefinery vijay...

Dry Grind Ethanol Biorefinery Vijay Singh

University of Illinois at Urbana-Champaign 1

Biorefinery for Corn Dry Grind Ethanol Production

Vijay SinghAssociate Professor

Department of Agricultural & Biological Engineering

University of Illinois at Urbana-Champaign

Workshop Biorefineries: Recent Advances and New Challenges

Rio de Janeiro, Brazil

November 10-12, 2010

U.S. Motor Gasoline Consumption

8,989,000 barrels/day (2008) 378 million gallons/day 378 million gallons/day

137 billion gallons/yr

US dependence on net Petroleum imports 57%

Source: Energy Information Administration



2022Renewable Fuel Standard (RFS2)

Conventional (Starch) Biofuel

EISA Mandated Biofuel Production Targets15 BGY cap on conventional (starch) biofuel

0 5 10 15 20 25 30 35 40

2012

2015

Production Targets (Billions of Gallons)

Biomass-based diesel

Cellulosic Biofuels

Other Advanced Biofuels

Advanced Biofuels(include cellulosic biofuels other than

starch-based ethanol)

EISA defines Cellulosic Biofuel as “renewable fuel derived from any cellulose, hemicellulose, or lignin that is derived

EISA defines Advanced Biofuel as “renewable fuel, other than ethanol derived from corn starch, that has lifecycle greenhouse gas emissions…that are at least 50 percent less than baseline lifecycle greenhouse gas emissions.” This includes biomass-based diesel, cellulosic biofuels, and other advanced fuels such as sugarcane-based ethanol.

y , , gfrom renewable biomass and that has lifecycle greenhouse gas emissions…that are at least 60 percent less than baseline lifecycle greenhouse gas emissions.” The EPA interprets this to include cellulosic-based diesel fuel.

Different Integrated Biorefineries

• Corn



World Corn Production, 2010

Canada

South Africa2%

Ukraine1%

United States42%

hi

Mexico3%

Argentina2%

India2%

Canada1% Others

14%

China20%

Brazil6%

EU7%

USDA/FAS, January 2010

US Corn Use, 2010

HFCS

Starch2302%

Sweeteners2302%

Cereal/Other1931%

Alcohol1341%

Seed230%

Wet Milling/

Feed/Residual5,55042%Ethanol

4,20032%

HFCS4604%

Wet Milling/ Dry Milling

Dry Grind

Export2,05016% USDA/ERS, January 2010Units = MillionBushels/yr



Composition of Corn Kernel

Pericarp

Endosperm

Germ

Tip Cap

Wet Milling Industry



Corn Wet Milling

Corn Wet Milling Facility

2.5 gal (9.46 L) of Ethanol

1.5 lb (0.68 kg) of Corn Oil

One bushel of Corn(24.5 kg or 56 lb)

3 lb (1.36) of Gluten Meal

12.4 lb (5.62 kg) of Gluten Feed

Ruminant Food

Poultry Food

U.S. Corn Wet-Milling FacilitiesSource: USDA-NASS 2002 Census of Agriculture

Penford

T&LRoquette

T&L

T&LNational

National

ADM

ADM

ADM

ADM

ADM

CPI

CPI

CPICargill

Cargill

Cargill

Cargill

Cargill

CargillCargill

Cargill

GPC

GPCT&L

T&L

T&L

T&LRoquette

Penford

AVRE

Cargill



Size of Corn Storage Facility



Corn Wet Milling Industry

$14.0 billion industry

1000 different products are produced from corn Food

Feed

Fuel

Industrial Products

Corn Dry Grind Facility

Dry Grind Ethanol Process

2.7 gal (10.2 L) of Ethanol

15 lb (6 8 kg) of

One bushel of Corn(25.4 kg or 56 lb)

15 lb (6.8 kg) of DDGS

Ruminant Food



Dry Grind Ethanol Plants

Source: RFA Jan 2010



Conventional Dry Grind Process

Corn

CO2

Liquefaction

Mash

Water

Grinding (Hammermill)

BlendingOverhead product(Recycled back)

Alpha-AmylaseEthanol

Saccharification &Fermentation

GlucoamylaseDehydration column

Stripping/Rectifying column

Yeast &

CentrifugeThinStillage

Wet GrainsSyrup

DDGS

Evaporator

DDGS Utilization in US



150

200

on

)corn DDGS

50

100

Val

ue

($/t

o

http://www.ers.usda.gov/Data/feedgrains/FeedGrainsQueriable.aspx

0

1981 1983 1985 1987 1989 1991 1993 1995 1997 1999 2001 2003 2005 2007 2009

Corn Fractionation Technologies



Wet Fractionation

Soaking corn in water and separating coproducts in aqueous medium

Uses wet grinding mills, hydrocyclones and screens for separation

Example of Wet Fractionation:Enzymatic Dry Grind Corn Process (E-Mill)

2.6 gal

Corn Dry Grind FacilityBushel of Corn(25.4 kg or 56 lb)

Density Density SizeS i (9.84 L)

Ethanol

3.7 lb(1.68 kg) Residual DDGS

3.3 lb (1.49 kg) Germ 4 lb

(1.81 kg) Pericarp

Fiber 4 lb(1.81 kg)

Endosperm

Ruminant Food

ySeparation Separation Separation

Endosperm Fiber

Singh, V., Johnston, D.B., Naidu, K., Rausch, K.D., Belyea, R.L. and Tumbleson, M.E. 2005. Comparison of modified dry grind corn processes for fermentation characteristics and DDGS composition. Cereal Chem. 82:187-190.Wang, P., Singh, V., Xu, L., Johnston, D.B., Rausch, K.D. and Tumbleson, M.E. 2005. Comparison of enzymatic (E-Mill) and conventional dry grind corn processes using a granular starch hydrolyzing enzyme. Cereal Chem. 82:734-738.

Nonruminant Food



Soaking

Corn

IncubationEnzymes

(GSH + Protease)

Enzymatic Dry Grind Corn Process (E-Mill)

Grinding (Degermination mill)

Germ clones

Germ & FiberGerm & Fiber Dryer

Aspirator

PericarpFiber

GermAir

Fine Grinding(Degermination mill)

CO2Overhead(Recycled)

L f

Stripping/Rectifyingcolumn

Screens

Endosperm FiberSaccharification& Fermentation

EthanolDehydration columnYeast & Enzymes

Liquefaction

E-Mill DDGSWang, P., Singh, V., Xu, L., Johnston, D.B., Rausch, K.D. and Tumbleson, M.E. 2005. Comparison of enzymatic (E-Mill) and conventional dry grind corn processes using a granular starch hydrolyzing enzyme. Cereal Chem. 82:734-738.

Fermentation Profiles: Conventional and E-Mill Processes

12

14

v/v 100%

2

4

6

8

10

Eth

anol

Con

cen

trat

ion

%v

Conventional

E-Mill

Conventional Rate

E-Mill Rate

64%

Singh, V., Johnston, D.B., Naidu, K., Rausch, K.D., Belyea, R.L. and Tumbleson, M.E. 2005. Comparison ofmodified dry grind corn processes for fermentation characteristics and DDGS composition. Cereal Chem. 82:187-190.

0

0 20 40 60 80

Fermentation Time (hr)



DDGS Composition: Wet Fractionation (E-Mill Process)

Conv. E-Mill SBM CGM

Crude 28.50 58.50 53.90 66.70Protein (%)

Crude Fat 12.70 4.53 1.11 2.77(%)

Ash (%) 3.61 3.24 ---- ----

Acid Det. 10.8 2.03 5.95 6.88Fiber (%)


Grain Dry Fractionation

Tempering corn with steam or hot water and dry separation of coproducts

Uses dry degerminators, gravity tables and sifters for separation



Example of Corn Dry Fractionation:Dry Degerm Defiber Process (3D Process)

Bushel of Corn(25.4 kg or 56 lb)

Dry Grind Facility

2.5 gal (9.46 L) Ethanol

7.0 lb(3.17 kg) Residual DDGS

Size andDensity Separation

4 lb(1.81 kg)

Germ

+

Ruminant Food4 lb(1.81 kg) Pericarp

Fiber

Nonruminant FoodMurthy, G.S., Singh, V., Johnston, D.B., Rausch, K.D. and Tumbleson, M.E. 2006. Evaluation and strategies toimprove fermentation characteristics of modified dry grind corn processes. Cereal Chem. 83:455-459.

Corn Steam

Th h

Tails (Grits)Beall Degerminator

Germ

Sifter

PericarpFiber

Example of Dry Fractionation: 3D Process

Saccharification& Fermentation

CO2MashOverhead product(Recycled back)

Dehydration column

Throughs(Germ + Pericarp Fiber)

Hammer Mill

EndospermFraction

Water

Roller Mill

Ethanol

Stripping/Rectifyingcolumn

Yeast & EnzymesLiquefaction


Wet Grains Syrup

3D DDGS

Evaporator

Murthy, G.S., Singh, V., Johnston, D.B., Rausch, K.D. and Tumbleson, M.E. 2006. Evaluation and strategies toimprove fermentation characteristics of modified dry grind corn processes. Cereal Chem. 83:455-459.



Other Benefits of Fractionation Processes: Other Benefits of Fractionation Processes: Recovery of Valuable CoproductsRecovery of Valuable Coproducts

Recovery of germ, pericarp and endosperm fiber as valuable coproductsp p Germ

Corn Germ Oil

Pericarp and Endosperm Fiber Corn Fiber Oil

Corn Fiber Gum

Ethanol

R f Z i f E Mill DDGS

Fiber Oil

Recovery of Zein from E-Mill DDGS Fiber Gum


Dien, B.S., Johnston, D.B., Hicks, K.B., Cotta, M.A. and Singh, V. 2005. Hydrolysis and fermentation of pericarpand endosperm fiber recovered from enzymatic corn dry grind process. Cereal Chem. 82:616-620.

Corn Fractionation PlantsCorn Fractionation Plants

Dry Fractionation Plants• Poet Research Center

S tl d SDScotland, SD• Poet Biorefining Glennville East

Albert Lea, MN• Renew Energy

Jefferson, WI• Poet Biorefining

Coon Rapids, IA• Lifeline Foods

St. Joseph, MO

Wet Fractionation Plant• Badger State Ethanol

Monroe, WI



Other Fractionation TechnologiesCorn

Grinding (Hammermill)

Glucoamylase

CO2

Liquefaction

Mash

Water

BlendingOverhead product(Recycled back)

Dehydration column

Alpha-Amylase

Yeast &Ethanol

ThinSaccharification &Fermentation

Glucoamylase

Stripping/Rectifying column


Wet GrainsSyrup

DDGS

Evaporator

Oil

Fiber Zein

Th k !Thanks!

corn dry grind ethanol biorefinery - abq · 2011-02-19 · dry grind ethanol biorefinery vijay...

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