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

Ethanol From Corn Process Dry Mill Ethanol Process Proprietary and Confidential © Copyright 2007 Pavilion Technologies Lina M Rueda

© Copyright 2007 Pavilion Technologies 2

© Copyright 2007 Pavilion Technologies 2

The Distillery Flow Diagram: From Corn to Ethanol Plus Co-products 1 bushel of corn

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)

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

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 ©

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

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

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

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

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

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