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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
Dry Grind Ethanol Biorefinery Vijay Singh
University of Illinois at Urbana-Champaign 2
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
Dry Grind Ethanol Biorefinery Vijay Singh
University of Illinois at Urbana-Champaign 3
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
Dry Grind Ethanol Biorefinery Vijay Singh
University of Illinois at Urbana-Champaign 4
Composition of Corn Kernel
Pericarp
Endosperm
Germ
Tip Cap
Wet Milling Industry
Dry Grind Ethanol Biorefinery Vijay Singh
University of Illinois at Urbana-Champaign 5
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
Dry Grind Ethanol Biorefinery Vijay Singh
University of Illinois at Urbana-Champaign 6
Size of Corn Storage Facility
Dry Grind Ethanol Biorefinery Vijay Singh
University of Illinois at Urbana-Champaign 7
Corn Wet Milling Industry
$14.0 billion industry
1000 different products are produced from corn Food
Feed
Fuel
Industrial Products
Corn Dry Grind Facility
Dry Grind Ethanol Process
2.7 gal (10.2 L) of Ethanol
15 lb (6 8 kg) of
One bushel of Corn(25.4 kg or 56 lb)
15 lb (6.8 kg) of DDGS
Ruminant Food
Dry Grind Ethanol Biorefinery Vijay Singh
University of Illinois at Urbana-Champaign 8
Dry Grind Ethanol Plants
Source: RFA Jan 2010
Dry Grind Ethanol Biorefinery Vijay Singh
University of Illinois at Urbana-Champaign 9
Conventional Dry Grind Process
Corn
CO2
Liquefaction
Mash
Water
Grinding (Hammermill)
BlendingOverhead product(Recycled back)
Alpha-AmylaseEthanol
Saccharification &Fermentation
GlucoamylaseDehydration column
Stripping/Rectifying column
Yeast &
CentrifugeThinStillage
Wet GrainsSyrup
DDGS
Evaporator
DDGS Utilization in US
Dry Grind Ethanol Biorefinery Vijay Singh
University of Illinois at Urbana-Champaign 10
150
200
on
)corn DDGS
50
100
Val
ue
($/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
Dry Grind Ethanol Biorefinery Vijay Singh
University of Illinois at Urbana-Champaign 11
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
Dry Grind Ethanol Biorefinery Vijay Singh
University of Illinois at Urbana-Champaign 12
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)
Dry Grind Ethanol Biorefinery Vijay Singh
University of Illinois at Urbana-Champaign 13
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 (%)
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.
Grain Dry Fractionation
Tempering corn with steam or hot water and dry separation of coproducts
Uses dry degerminators, gravity tables and sifters for separation
Dry Grind Ethanol Biorefinery Vijay Singh
University of Illinois at Urbana-Champaign 14
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
CentrifugeThinStillage
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.
Dry Grind Ethanol Biorefinery Vijay Singh
University of Illinois at Urbana-Champaign 15
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
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.
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
Dry Grind Ethanol Biorefinery Vijay Singh
University of Illinois at Urbana-Champaign 16
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
CentrifugeThinStillage
Wet GrainsSyrup
DDGS
Evaporator
Oil
Fiber Zein
Th k !Thanks!