Ethanol From Corn Process Dry Mill Ethanol Process
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Ethanol From Corn Process Dry Mill Ethanol Process Proprietary and Confidential © Copyright 2007 Pavilion Technologies Lina M Rueda
© Copyright 2007 Pavilion Technologies 2
The Distillery Flow Diagram: From Corn to Ethanol Plus Co-products 1 bushel of corn (56 lbs) Ethanol (17. 6 lbs) Milling + DDGS (17 lbs) Starch (32 lbs) + Heat (7450 BTU) Liquefaction Saccharification Fermentable sugar (36 lbs) Fermentation Recovery Dryhouse © Copyright 2007 Pavilion Technologies 3 + CO 2 (18. 4 lbs)
Fermentation Fundamentals • Key Ingredients - Starch (sugar source) - Enzymes (breakdown of starches) - Yeast (conversion of sugar to ethanol) • Key Process Components - Enzyme addition - Yeast propagation - Fermentation cycle - Cooling system © Copyright 2007 Pavilion Technologies 4
Process Description • Milling • Cooking and mixing • - Milled corn and cook water - a-Amylase to break down long polymer chains (starch), reduce solids - Solubilization of sugars - Release of bound sugars: starch is bound to protein and fiber which is released during cooking - Gelatinization: absorb water so enzymes can react with molecules Liquefaction - • Using a-Amylase to break down starches to shorter chain molecules Saccharification and Fermentation - Batch processs (~ 50 -60 hours) - Exothermic - Glucoamylase is used to break down short chained molecules to glucose - Yeast is added to convert glucose to ethanol © Copyright 2007 Pavilion Technologies 5
Water Balance Milling 8 8 Process Water Beer Feed Slurry Tank Liquefaction Methanator © Copyright 2007 Pavilion Technologies Backset 6
Fermentation 8 Yeast Propagation Fermenter Beer Feed Enzymes Slurry Tank Liquefaction Backset © Copyright 2007 Pavilion Technologies 7
Process Description • Distillation - Separate Ethanol from non-fermentable components • Dehydration - Azeotropic Distillation - Molecular Sieves • Non-Fermentables - Centrifugation - Evaporation - Drying © Copyright 2007 Pavilion Technologies 8
Distillation Vaporizer Temperature Rectifier Reflux Sieve Feed Sieve Back Pressure Beer Feed Evap. Steam Flow © Copyright 2007 Pavilion Technologies 9
Dryer, Evaporator and TO Wet Cake Pad Whole Stillage Centrifuge Feed Dryers Thin Stillage Syrup Tank Steam Flow Evaporators © Copyright 2007 Pavilion Technologies 10
Control Strategy $ costs Energy, feedstock, Product Values Ethanol Plant-Wide Optimizer Slurry/Waterbalance APC Fermentation APC Dryer Evap TOAPC & Distill/Sieve APC Plant and constraint Measurements (CV) Mv setpoints © Copyright 2007 Pavilion Technologies 11
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