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

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Presentation transcript:

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

© Copyright 2007 Pavilion Technologies 2

3 The Distillery Flow Diagram: From Corn to Ethanol Plus Co-products 1 bushel of corn (56 lbs) Starch (32 lbs) Milling Fermentable sugar (36 lbs) Liquefaction Saccharification Ethanol (17.6 lbs) + DDGS (17 lbs) + Heat (7450 BTU) + CO2 (18.4 lbs) Fermentation Recovery Dryhouse

© Copyright 2007 Pavilion Technologies 4 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 5 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 (~ 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 6 Water Balance 8 8 Methanator Slurry Tank Process Water Liquefaction Backset Beer Feed Milling

© Copyright 2007 Pavilion Technologies 7 Fermentation 8 Slurry Tank Liquefaction Backset Beer Feed Fermenter Yeast Propagation Enzymes

© Copyright 2007 Pavilion Technologies 8 Distillation - Separate Ethanol from non-fermentable components Dehydration - Azeotropic Distillation - Molecular Sieves Non-Fermentables - Centrifugation - Evaporation - Drying Process Description

© Copyright 2007 Pavilion Technologies 9 Distillation Beer Feed Evap. Steam Steam Flow Sieve Back Pressure Rectifier Reflux Sieve Feed Vaporizer Temperature

© Copyright 2007 Pavilion Technologies 10 Dryer, Evaporator and TO Steam Flow Centrifuge Feed Whole Stillage Thin Stillage Syrup Tank Wet Cake Pad Evaporators Dryers

© Copyright 2007 Pavilion Technologies 11 Control Strategy Ethanol Plant-Wide Optimizer Dryer Evap TOAPC & Distill/Sieve APC Fermentation APC Slurry/Waterbalance APC Mv setpoints Plant and constraint Measurements (CV) Energy, feedstock, Product Values $ costs