Intrinsic Characteristics of Modified DDGS and Effective Handling Strategies NC -213 Meeting, February th Kansas city,

Investigators K-State Kaliramesh Siliveru Graduate Research Assistant Kingsly Ambrose Assistant Professor Rumela Bhadra Postdoctoral Research Associate USDA-ARS Mark Casada Research Agricultural Engineer NDSU Kristin Whitney Research Specialist Senay Simsek Associate Professor 2

Introduction Objectives Materials and Methods Results Future Work Outline 3

4 Distillers Dried Grains with Solubles (DDGS) 28-35% protein, 30-32% fiber & 8-12% fat (comes from CDS*/syrup), vital amino acids, phosphorous Dry grinding process Corn Ground Cooked Liquefaction Alpha amylase Fermentation Yeast & Glucoamylase CO 2 Distillation Separated Distiller’s Grains (DDG) Ethanol Thin stillage Condensed Solubles (CDS) DDG + S (DDGS)

5 DDGS and Ethanol Production 35.5 million MT (2013) 9.7 million MT exported 210 Bioethanol Plants Operating Capacities of 14,877.5 MG/year ethanol Source: Colorado Geological Survey website, updated March 2011

6 Modified DDGS (M-DDGS) Low oil ( 4- 5% fat) DDGS Increased profits in oil extraction Around 105 dry grind ethanol plant extracted oil (USGC, 2012) (50% of plants) Price of crude oil is $0.45/lb Oil extraction investment ~ $3 million, recovery period – 3 to 4 months Ref: Shurson, J. and B. Kerr. Reduced oil DDGS – It’s not the fat, It’s the fiber. Nutriquest DDGS Symposium. Des Moines, IA, March 21, ​

7 Thin stillage Crude Corn Oil Extraction Method 1 Whole stillage Extraction Method 2 CDS Corn Oil Feed Back- end Extraction Flow Diagram About 30% corn oil is removed from Method 1 and 60% oil is removed from Method 2 Ref: Shurson, J. and B. Kerr. Reduced oil DDGS – It’s not the fat, It’s the fiber. Nutriquest DDGS Symposium. Des Moines, IA, March 21, ​ Modified DDGS (M-DDGS)

8 Flowability Problems in M-DDGS Caking of DDGS in rail cars; segregation during discharge Economic loss: Cost to break the ‘cakes’ and unload cars Safety Issues App. $9000 in repairs (semi-annually) Avoiding loading hot DDGS can delay onset of caking (Kingsly and Ileleji, 2011)

9 Develop heat transfer model for cooling of M- DDGS pile Validate the developed model experimentally in a lab scale Objectives

Materials and Methods 10

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SIMULATION Solved by: Finite volume method in ANSYS FLUENT Simulations were carried out for summer (24.77 °C) and winter (6 °C). 12

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VALIDATION 14

Results Predicted and actual temperature profiles of low oil DDGS pile when cooled to K (24.77 °C). 15

Predicted and actual temperature profiles of low oil DDGS pile when cooled to K (6 °C). 16

Predicted Temperature Profiles for a larger pile (A) when cooled to (24.77 °C) (B) when cooled to K (6 °C). 17

Standard error of prediction (K) for the developed model 18

Conclusions A 3-dimensional heat transfer model based on finite volume method was developed to predict cooling pattern of M-DDGS pile. The developed model predicted temperatures with acceptable accuracy. 19

The model will be validated with the field data which will be collected in an industry in summer and winter seasons. Hopper flow analysis of M-DDGS is currently being carried out. Future Work 20

Acknowledgements The Andersons Research Grant Program POET Nutrition Dr. Josephine Boac- Grain Science and Industry, K-State Thank You! 21