Corn to Ethanol Dry Mill Processing

Corn to Ethanol
Dry Mill Processing
Dry Mill Production Process Ethanol production technologies have advanced significantly over the past 20 years. New technology applications include computer-controlled processes, high-tolerance yeasts, enzyme improvements, steam and electricity cogeneration, and molecular sieve driers. Dry mill processing, which simplifies ethanol production by processing the whole corn kernel into fuel and livestock feed, has reduced the capital cost to produce fuel compared to wet mill facilities that generate a number for food products in addition to ethanol.
1. Milling
Corn is ne-milled to expose its starch. Corn Milling Alpha-Amylase Liq Tank

2. Cooking and Liquefaction

Steam

Milled corn, water, and an enzyme, alpha-amylase, are mixed and heated to 230F to liquefy the starch, forming a mash. Gluco-Amylase CO2

3. Fermentation

Fermentation

Yeast

4. Distillation
The beer is distilled and separated into a 95 percent alcohol stream and a residual stillage stream containing solids.

The mash is cooled and a second enzyme, gluco-amylase, is added to convert the starch to sugars. Yeast is added to the mash to ferment the sugars, producing a beer containing 10 percent ethanol, solids, and carbon dioxide. Carbon dioxide may be sold as a by-product.

Steam

7. Distillers Dried Grains and Solubles (DDGS) DDGS

Recovered Liquids

Centrifuge and Drying

5. Dehydration
Stillage Any water remaining in the 95 percent alcohol stream is dried by a molecular sieve system forming anhydrous ethanol (no water, or 200 proof alcohol).

Molecular Sieves Denaturant Fuel Alcohol 200 Proof Alcohol

Fuel

Corn to Ethanol Mike McCurdy 303.299.5217

The stillage is processed through a centrifuge and heated dryer to remove the bulk of the liquids. The remaining solid material, DDGS, is a co-product of the ethanol production process and is sold as animal feed. Facilities with local animal feed operations can sell a partially dried form, wet distillers' grains with solubles (WGS), or wet cake, to reduce energy costs.

6. Denaturing

Ethanol to be used as a fuel is blended with a denaturant making it unt for human consumption. Natural gasoline, an oileld co-product, is often used as the denaturant due to its low cost.

Rule of Thumb Cost Benchmarking Operating Costs Ethanol facility operating costs are often benchmarked by tracking the unit cost per gallon of ethanol produced. The table below shows typical unit operating costs for facilities producing between 30 million and 120 million gallons of ethanol annually. The data does not include corn costs or credit for making co-products.

Rules of Thumb: Dry mill ethanol facilities produce 2.65 to 2.8 gallons of ethanol per bushel of corn (depending upon the starch content of the corn and the process efficiency). Between three and four gallons of water are used to produce one gallon of ethanol. Facilities use 30,000 to 35,000 BTUs (British thermal units) of fuel per gallon of ethanol produced. Approximately two-thirds of the fuel is used to generate steam and one-third used for drying. Dry mill facilities produce approximately 18 pounds of DDGS. Facilities that can sell wet cake can reduce fuel consumption to approximately 20,000 BTUs per gallon of ethanol produced. Facilities use 0.6 to 0.9 kilowatt hour of electricity per gallon of ethanol produced. Dry mill facilities produce approximately 18 pounds of DDGS per bushel of corn (56 pounds of corn per bushel). Dry mill facilities typically employ between 40 to 45 people. Most facilities in the U.S. report construction costs between $1.50 and $2.00 per annual gallon of capacity, exclusive of owners and financing costs.

Some large ethanol production facilities have their own cogeneration facilities that produce both electrical power and steam. This capital investment lowers the dependence on outside sources for steam and power and reduces energy operating costs. Naturally, fluctuations in natural gas prices and differences in process efficiency can have a significant impact on energy costs. Chemicals and Denaturant Chemical and denaturant costs represent a large portion of total unit operating costs and range from $0.11 to $0.22 per gallon of ethanol produced. Usually, larger facilities are able to procure chemicals at more attractive prices. Chemical consumption includes yeast, yeast nutrients, denaturant, alpha-amylase (for liquefying starch), gluco-amylase (for converting starch to sugar), and a variety of antibiotics, disinfectants, water treating chemicals, pH adjustors, and other chemicals. Operating and Maintenance (O&M) O&M costs represents a sizeable portion of total unit operating costs and can range from $0.20 to $0.25 per gallon of ethanol produced, depending on the facility size and type. Summary Range Since 1987, ethanol production Energy $0.16 - $0.37 Chemicals $0.06 - $0.08 facility operating costs have Denaturant $0.05 - $0.14 fallen more than 30 percent Operations and Management $0.20 - $0.25 due to improvements in energy General and Administrative $0.04 - $0.06 efficiency, economies of scale Water and Sewage $0.01 - $0.02 realized from building larger Total Operating Costs $0.52 - $0.92 facilities, and labor reductions Typical Unit Operating Costs, US$ per Gallon of Ethanol Produced, 2008 from automation and control implementation. Operating costs are expected to continue falling as additional energy economization techniques and yield enhancements are implemented in the near future.
For more information, contact Mike McCurdy, Process Consultant
1801 California Street, Suite 2800 | Denver, CO 80202 tel: 303.299.5217 | francis.m.mccurdy@saic.com

Carol Babb, Renewable Generation Services Director

1801 California Street, Suite 2800 | Denver, CO 80202 tel: 303.299.5273 | email: carol.l.babb@saic.com

Bill Crump, Senior Director

1801 California Street, Suite 2800 | Denver, CO 80202 tel: 303.299.5216 | email: william.r.crump@saic.com Visit us online at: www.saic.com Energy | Environment | National Security | Health | Critical Infrastructure
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