Process simulation of modified dry grind ethanol plant with recycle of pretreated and enzymatically hydrolyzed distillers' grains

Distillers' grains (DG), a co-product of a dry grind ethanol process, is an excellent source of supplemental proteins in livestock feed. Studies have shown that, due to its high polymeric sugar contents and ease of hydrolysis, the distillers' grains have potential as an additional source of fermentable sugars for ethanol fermentation. The benefit of processing the distillers' grains to extract fermentable sugars lies in an increased ethanol yield without significant modification in the current dry grind technology. Three different potential configurations of process alternatives in which pretreated and hydrolyzed distillers' grains are recycled for an enhanced overall ethanol yield are proposed and discussed in this paper based on the liquid hot water (LHW) pretreatment of distillers' grains. Possible limitations of each proposed process are also discussed. This paper presents a compositional analysis of distillers' grains, as well as a simulation of the modified dry grind processes with recycle of distillers' grains. Simulated material balances for the modified dry grind processes are established based on the base case assumptions. These balances are compared to the conventional dry grind process in terms of ethanol yield, compositions of its co-products, and accumulation of fermentation inhibitors. Results show that 14% higher ethanol yield is achievable by processing and hydrolyzing the distillers' grains for additional fermentable sugars, as compared to the conventional dry grind process. Accumulation of fermentation by-products and inhibitory components in the proposed process is predicted to be 2-5 times higher than in the conventional dry grind process. The impact of fermentation inhibitors is reviewed and discussed. The final eDDGS (enhanced dried distillers' grains) from the modified processes has 30-40% greater protein content per mass than DDGS, and its potential as a value-added process is also analyzed. While the case studies used to illustrate the process simulation are based on LHW pretreated DG, the process simulation itself provides a framework for evaluation of the impact of other pretreatments.     

Composition of corn dry-grind ethanol by-products: DDGS, wet cake, and thin stillage

DDGS and wet distillers' grains are the major co-products of the dry grind ethanol facilities. As they are mainly used as animal feed, a typical compositional analysis of the DDGS and wet distillers' grains mainly focuses on defining the feedstock's nutritional characteristics. With an increasing demand for fuel ethanol, the DDGS and wet distillers' grains are viewed as a potential bridge feedstock for ethanol production from other cellulosic biomass. The introduction of DDGS or wet distillers' grains as an additional feed to the existing dry grind plants for increased ethanol yield requires a different approach to the compositional analysis of the material. Rather than focusing on its nutritional value, this new approach aims at determining more detailed chemical composition, especially on polymeric sugars such as cellulose, starch and xylan, which release fermentable sugars upon enzymatic hydrolysis. In this paper we present a detailed and complete compositional analysis procedure suggested for DDGS and wet distillers' grains, as well as the resulting compositions completed by three different research groups. Polymeric sugars, crude protein, crude oil and ash contents of DDGS and wet distillers' grains were accurately and reproducibly determined by the compositional analysis procedure described in this paper.     

Biotechnological processes for conversion of corn into ethanol

Ethanol has been utilized as a fuel source in the United States since the turn of the century. However, it has repeatedly faced significant commercial viability obstacles relative to petroleum. Renewed interest exists in ethanol as a fuel source today owing to its positive impact on rural America, the environment and United States energy security. Today, most fuel ethanol is produced by either the dry grind or the wet mill process. Current technologies allow for 2.5 gallons (wet mill process) to 2.8 gallons (dry grind process) of ethanol (1 gallon = 3.785 l) per bushel of corn. Valuable co-products, distillers dried grains with solubles (dry grind) and corn gluten meal and feed (wet mill), are also generated in the production of ethanol. While current supplies are generated from both processes, the majority of the growth in the industry is from dry grind plant construction in rural communities across the corn belt. While fuel ethanol production is an energy-efficient process today, additional research is occurring to improve its long-term economic viability. Three of the most significant areas of research are in the production of hybrids with a higher starch content or a higher extractable starch content, in the conversion of the corn kernel fiber fraction to ethanol, and in the identification and development of new and higher-value co-products.     

Improvement in fermentation characteristics of degermed ground corn by lipid supplementation

With rapid growth of fuel ethanol industry, and concomitant increase in distillers dried grains with solubles (DDGS), new corn fractionation technologies that reduce DDGS volume and produce higher value coproducts in dry grind ethanol process have been developed. One of the technologies, a dry degerm, defiber (3D) process (similar to conventional corn dry milling) was used to separate germ and pericarp fiber prior to the endosperm fraction fermentation. Recovery of germ and pericarp fiber in the 3D process results in removal of lipids from the fermentation medium. Biosynthesis of lipids, which is important for cell growth and viability, cannot proceed in strictly anaerobic fermentations. The effects of ten different lipid supplements on improving fermentation rates and ethanol yields were studied and compared to the conventional dry grind process. Endosperm fraction (from the 3D process) was mixed with water and liquefied by enzymatic hydrolysis and was fermented using simultaneous saccharification and fermentation. The highest ethanol concentration (13.7% v/v) was achieved with conventional dry grind process. Control treatment (endosperm fraction from 3D process without lipid supplementation) produced the lowest ethanol concentration (11.2% v/v). Three lipid treatments (fatty acid ester, alkylphenol, and ethoxylated sorbitan ester 1836) were most effective in improving final ethanol concentrations. Fatty acid ester treatment produced the highest final ethanol concentration (12.3% v/v) among all lipid supplementation treatments. Mean final ethanol concentrations of alkylphenol and ethoxylated sorbitan ester 1836 supplemented samples were 12.3 and 12.0% v/v, respectively.Mention of brand or firm names does not constitute an endorsement by University of Illinois or USDA above others of similar nature not mentioned     

Cellulose conversion in dry grind ethanol plants

The expansion of the dry grind ethanol industry provides a unique opportunity to introduce cellulose conversion technology to existing grain to ethanol plants, while enhancing ethanol yields by up to 14%, and decreasing the volume while increasing protein content of distiller's grains. The technologies required are cellulose pretreatment, enzyme hydrolysis, fermentation, and drying. Laboratory data combined with compositional analysis and process simulations are used to present a comparative analysis of a dry grind process to a process with pretreatment and hydrolysis of cellulose in distiller's grains. The additional processing steps are projected to give a 32% increase in net present value if process modifications are made to a 100 million gallon/year plant.     

Enzyme hydrolysis and ethanol fermentation of liquid hot water and AFEX pretreated distillers' grains at high-solids loadings

The dry milling ethanol industry produces distiller's grains as major co-products, which are composed of unhydrolyzed and unfermented polymeric sugars. Utilization of the distiller's grains as an additional source of fermentable sugars has the potential to increase overall ethanol yields in current dry grind processes. In this study, controlled pH liquid hot water pretreatment (LHW) and ammonia fiber expansion (AFEX) treatment have been applied to enhance enzymatic digestibility of the distiller's grains. Both pretreatment methods significantly increased the hydrolysis rate of distiller's dried grains with solubles (DDGS) over unpretreated material, resulting in 90% cellulose conversion to glucose within 24h of hydrolysis at an enzyme loading of 15FPU cellulase and 40 IU beta-glucosidase per gram of glucan and a solids loading of 5% DDGS. Hydrolysis of the pretreated wet distiller's grains at 13-15% (wt of dry distiller's grains per wt of total mixture) solids loading at the same enzyme reduced cellulose conversion to 70% and increased conversion time to 72h for both LHW and AFEX pretreatments. However, when the cellulase was supplemented with xylanase and feruloyl esterase, the pretreated wet distiller's grains at 15% or 20% solids (w/w) gave 80% glucose and 50% xylose yields. The rationale for supplementation of cellulases with non-cellulolytic enzymes is given by Dien et al., later in this journal volume. Fermentation of the hydrolyzed wet distiller's grains by glucose fermenting Saccharomyces cerevisiae ATCC 4124 strain resulted in 100% theoretical ethanol yields for both LHW and AFEX pretreated wet distiller's grains. The solids remaining after fermentation had significantly higher protein content and are representative of a protein-enhanced wet DG that would result in enhanced DDGS. Enhanced DDGS refers to the solid product of a modified dry grind process in which the distiller's grains are recycled and processed further to extract the unutilized polymeric sugars. Compositional changes of the laboratory generated enhanced DDGS are also presented and discussed.     

Composition of corn and distillers dried grains with solubles from dry grind ethanol processing

Increase in the demand for ethanol has resulted in growth in the dry grind (DG) ethanol industry. In DG processing, the whole corn kernel is fermented, resulting in two main coproducts, ethanol and distillers dried grains with solubles (DDGS). Marketing of DDGS is critical to the economic stability of DG plants. The composition of DDGS can vary considerably; this reduces market value. Factors that cause variation in composition need to be evaluated. The objective was to determine the relationship between composition of corn and composition of DDGS. Samples of corn and DDGS were obtained from a DG ethanol plant and analyzed for protein, fat, starch and other nutrients. Concentrations of protein, fiber and starch were similar to published data for corn but were higher for DDGS. Coefficients of variation for protein fat and fiber concentrations were similar for corn and DDGS. There were no significant correlations between concentrations of components in corn and those in DDGS. Variation in the composition of DDGS was not related to variation in corn composition and probably was due to variation in processing streams or processing techniques. This implies that reducing the variation in composition of DDG will require modification of processing strategies.     

Improving the corn-ethanol industry: studying protein separation techniques to obtain higher value-added product options for distillers grains

Currently in America the biofuel ethanol is primarily being produced by the dry grind technique to obtain the starch contained in the corn grains and subsequently subjected to fermentation. This so-called 1st generation technology has two setbacks; first the lingering debate whether its life cycle contributes to a reduction of fossil fuels and the animal feed sectors future supply/demand imbalance caused by the co-product dry distillers grains (DDGS). Additional utilization of the cellulosic components and separation of the proteins for use as chemical precursors have the potential to alleviate both setbacks. Several different corn feedstock layouts were treated with 2nd generation ammonia fiber expansion (AFEX) pre-treatment technology and tested for protein separation options (protease solubilization). The resulting system has the potential to greatly improve ethanol yields with lower bioprocessing energy costs and satisfy a significant portion of the organic chemical industry.     

An engineering and economic evaluation of wet and dry pre-fractionation processes for dry-grind ethanol facilities

An engineering-economic model was developed to compare the profitability of the wet fractionation process, a generic dry fractionation process, and the conventional dry grind process. Under market conditions as of January 2011, only fractionation processes generated a positive cash flow. Reduced unit manufacturing costs and increased ethanol production capacity were two major contributions. Corn and ethanol price sensitivity analysis showed that the wet fractionation process always outperformed a generic dry fractionation process at any scenario considered in this research. A generic dry fractionation process would provide better economic performance than the conventional dry grind process if corn price was low and ethanol price was high. All three processes would perform more resiliently if the DDGS price was determined by its composition.     

Pilot scale fiber separation from distillers dried grains with solubles (DDGS) using sieving and air classification

Distillers dried grains with solubles (DDGS), the coproduct of fuel ethanol production from cereal grains like corn, is mainly used as cattle feed and is used at low inclusion levels in poultry and swine diets because of high fiber content. Elusieve process, the combination of sieving and air classification (elutriation), was developed in laboratory scale to separate fiber from DDGS to result in a low fiber product which would be more suitable for poultry and swine. In this pilot scale study, DDGS was sieved at a rate of 0.25 kg/s (1 ton/h) into four sieve fractions using a sifter and the three largest sieve fractions were air classified using aspirators to separate fiber on a continuous basis. Results were similar to laboratory scale. Nearly 12.4% by weight of DDGS was separated as Fiber product and resulted in two high protein products that had low fiber contents. Payback period for the Elusieve process in an existing dry grind plant processing corn at the rate of 2030 metric tonnes/day (80,000 bushels/day) would be 1.1 yr.     

Distribution of phosphorus compounds in corn processing

Distillers dried grains with solubles (DDGS) and corn gluten feed (CGF) are major coproducts of ethanol production from corn dry grind and wet milling facilities, respectively. These coproducts contain important nutrients, nevertheless, high levels of phosphorus (P). About 50-80% of the P in these products is in an organically bound form known as phytate. The phytate P in these products cannot be digested by nonruminant animals. Consequently, large quantities of phytate are deposited into the soil with the animal wastes which potentially could cause P pollution in soil and underground water resources. As regulations on the concentration of P material in ethanol production coproducts become more restrictive, measures need to be taken for effective extraction of phytate P from the coproducts to make these processes more environmentally compatible. Proper marketing of coproducts is critical to the overall economy of ethanol production facilities. In this study, distribution of P compounds in different streams of dry grind and wet milling operations was determined. In the dry grind process, the highest P concentration was found to be in the condensed distillers solubles (CDS) at about 1.34 wt.% (db). About 59% of P in this stream was in phosphates form. The highest concentration of P in the wet milling process was found in the light steep water at about 3.4 wt.% (db). In this stream, about 22% of P was attributed to phosphates.     

Enzyme characterization for hydrolysis of AFEX and liquid hot-water pretreated distillers' grains and their conversion to ethanol

Dried distillers' grains with solubles (DDGS), a co-product of corn ethanol production, was investigated as a feedstock for additional ethanol production. DDGS was pretreated with liquid hot-water (LHW) and ammonia fiber explosion (AFEX) processes. Cellulose was readily converted to glucose from both LHW and AFEX treated DDGS using a mixture of commercial cellulase and beta-glucosidase; however, these enzymes were ineffective at saccharifying the xylan present in the pretreated DDGS. Several commercial enzyme preparations were evaluated in combination with cellulase to saccharify pretreated DDGS xylan and it was found that adding commercial grade (e.g. impure) pectinase and feruloyl esterase (FAE) preparations were effective at releasing arabinose and xylose. The response of sugar yields for pretreated AFEX and LHW DDGS (6wt%/solids) were determined for different enzyme loadings of FAE and pectinase and modeled as a response surfaces. Arabinose and xylose yields rose with increasing FAE and pectinase enzyme dosages for both pretreated materials. When hydrolyzed at 20wt%/solids with the same blend of commercial enzymes, the yields were 278 and 261g sugars (i.e. total of arabinose, xylose, and glucose) per kg of DDGS (dry basis, db) for AFEX and LHW pretreated DDGS, respectively. The pretreated DDGS's were also evaluated for fermentation using Saccharomyces cerevisiae at 15wt%/solids. Pretreated DDGS were readily fermented and were converted to ethanol at 89-90% efficiency based upon total glucans; S. cerevisiae does not ferment arabinose or xylose.     

Modeling the effects of pelleting on the logistics of distillers grains shipping

The energy security needs of energy importing nations continue to escalate. It is clear that biofuels can help meet some of the increasing need for energy. Theoretically, these can be produced from a variety of biological materials, including agricultural residues (such as corn stover and wheat straw), perennial grasses, legumes, algae, and other biological materials. Currently, however, the most heavily utilized material is corn starch. Industrial fuel ethanol production in the US primarily uses corn, because it is readily converted into fuel at a relatively low cost compared to other biomass sources. The production of corn-based ethanol in the US is dramatically increasing. As the industry continues to grow, the amount of byproducts and coproducts also increases. At the moment, the nonfermentable residues (which are dried and sold as distillers dried grains with solubles – DDGS) are utilized only as livestock feed. The sale of coproducts provides ethanol processors with a substantial revenue source and significantly increases the profitability of the production process. Even though these materials are used to feed animals in local markets, as the size and scope of the industry continues to grow, the need to ship large quantities of coproducts grows as well. This includes both domestic as well as international transportation. Value-added processing options offer the potential to increase the sustainability of each ethanol plant, and thus the industry overall. However, implementation of new technologies will be dependent upon how their costs interact with current processing costs and the logistics of coproduct deliveries. The objective of this study was to examine some of these issues by developing a computer model to determine potential cost ramifications of using various alternative technologies during ethanol processing. This paper focuses specifically on adding a densification unit operation (i.e., pelleting) to produce value-added DDGS at a fuel ethanol manufacturing plant. We have examined the economic implications of pelleting DDGS for varying DDGS production rates (100–1000 tons/d) and pelleting rates (0–100%), for a series of DDGS sales prices ($50–$200/ton). As the proportion of pelleting increases, the cost of transporting DDGS to distant markets drastically declines, because the rail cars can be filled to capacity. For example, at a DDGS sales price of $50/ton, 100% pelleting will reduce shipping costs (both direct and indirect) by 89% compared to shipping the DDGS in bulk form (i.e., no pelleting), whereas at a DDGS sales price of $200/ton, it will reduce costs by over 96%. It is clear that the sustainability of the ethanol industry can be improved by implementing pelleting technology for the coproducts, especially at those plants that ship their DDGS via rail.     

Fate of Fumonisin B(1) in Naturally Contaminated Corn during Ethanol Fermentation

Two lots of corn naturally contaminated with fumonisin B(1) (15 and 36 ppm) and a control lot (no fumonisin B(1) detected) were used as substrates for ethanol production in replicate 8.5-liter yeast fermentations. Ethanol yields were 8.8% for both the control and low-fumonisin corn, while the high-fumonisin corn contained less starch and produced 7.2% ethanol. Little degradation of fumonisin occurred during fermentation, and most was recovered in the distillers' grains, thin stillage, and distillers' solubles fractions. No toxin was detected in the distilled alcohol or centrifuge solids. Ethanol fermentation of fumonisin-contaminated corn coupled with effective detoxification of distillers' grains and aqueous stillage is suggested as a practical process strategy for salvaging contaminated corn.     

Fate of Fumonisin B1 in Naturally Contaminated Corn during Ethanol Fermentation

Two lots of corn naturally contaminated with fumonisin B₁ (15 and 36 ppm) and a control lot (no fumonisin B₁ detected) were used as substrates for ethanol production in replicate 8.5-liter yeast fermentations. Ethanol yields were 8.8% for both the control and low-fumonisin corn, while the high-fumonisin corn contained less starch and produced 7.2% ethanol. Little degradation of fumonisin occurred during fermentation, and most was recovered in the distillers' grains, thin stillage, and distillers' solubles fractions. No toxin was detected in the distilled alcohol or centrifuge solids. Ethanol fermentation of fumonisin-contaminated corn coupled with effective detoxification of distillers' grains and aqueous stillage is suggested as a practical process strategy for salvaging contaminated corn.     

Determination of energy and amino acid digestibility in growing pigs fed corn distillers' dried grains with solubles containing different lipid levels

Two experiments were conducted to estimate the digestibility of energy, nitrogen and amino acids (AA) in growing pigs fed diets containing one of five corn distillers' dried grains with solubles (DDGS), including three normal oil DDGS (NO-DDGS) and two low oil DDGS (LO-DDGS) samples. Exp. 1 was conducted to determine the digestible energy (DE) and metabolisable energy (ME) content. Six growing barrows (initial body weight [BW]: 35.1 +/- 2.2 kg) were allotted to a 6 x 6 Latin square design, with six periods and six diets. One diet was a corn soybean meal basal diet and the other five diets were based on corn, soybean meal and 28.8% DDGS. The average DE and ME values for the three NO-DDGS samples were 16.0 and 14.9 MJ/kg dry matter (DM). These values were 9 and 13% greater than the LO-DDGS values of 14.7 and 13.2 MJ/kg DM respectively. Exp. 2 was conducted to determine and compare apparent (AID) and standardised (SID) ileal digestibility for crude protein and AA in the five DDGS samples. Six growing barrows (initial BW, 32.2 +/- 1.9 kg) fitted with a simple T-cannula were allotted to a 6 x 6 Latin square design with six periods and six diets. Five of the diets were based on the five DDGS samples, and the remaining one diet was nitrogen-free diet based on cornstarch and sucrose. Titanium dioxide (0.1%) was used as inert marker. The results of the experiment showed the largest variation among the different samples in AID and SID for lysine (from 41.8 to 65.8% and 53.8 to 73.9% respectively) and threonine (from 54.3 to 73.8% and 65.2 to 79.5% respectively). Also, among the indispensable AA, the SID values for arginine, histidine, threonine and tryptophan observed in LO-DDGS were not different from the values derived from NO-DDGS. In conclusion, LO-DDGS may have decreased energy compared with NO-DDGS because of its lower fat content. However, oil removal during the production of DDGS may not affect amino acid digestibility.     

Changes in mineral concentrations and phosphorus profile during dry-grind processing of corn into ethanol

For determining variation in mineral composition and phosphorus (P) profile among streams of dry-grind ethanol production, samples of ground corn, intermediate streams, and distillers dried grains with solubles (DDGS) were obtained from three commercial plants. Most attributes (dry matter concentrations) increased significantly from corn to cooked slurry but fermentation caused most significant increase in all attributes. During centrifugation, more minerals went into thin stillage than wet grains, making minerals most concentrated in the former. Mineral increase in DDGS over corn was about 3 fold, except for Na, S, Ca, and Fe. The first three had much higher fold of increase, presumably due to exogenous addition. During fermentation, phytate P and inorganic P had 2.54 and 10.37 fold of increase over corn, respectively, while relative to total P, % phytate P decreased and % inorganic P increased significantly. These observations suggest that phytate underwent some degradation, presumably due to activity of yeast phytase.     

Effects of wheat dried distillers' grains with solubles and cinnamaldehyde on in vitro fermentation and protein degradation using the Rusitec technique

This study was conducted to evaluate the effect of wheat dried distillers' grains with solubles (DDGS) and cinnamaldehyde (CIN) on in vitro fermentation and microbial profiles using the rumen simulation technique. The control substrate (10% barley silage, 85% barley grain and 5% supplement, on dry matter basis) and the wheat DDGS substrate (30% wheat DDGS replaced an equal portion of barley grain) were combined with 0 and 300 mg CIN/l of culture fluid. The inclusion of DDGS increased (p < 0.05) the concentration of volatile fatty acids (VFA) and the molar proportion of acetate and propionate. Dry matter disappearance (p = 0.03) and production of bacterial protein (p < 0.01) were greater, whereas the disappearances of crude protein (CP) and neutral detergent fibre were less (p < 0.01) for the DDGS than for the control substrate. With addition of CIN, concentration of total VFA decreased and fermentation pattern changed to greater acetate and less propionate proportions (p < 0.01). The CIN reduced (p < 0.01) methane production and CP degradability. The copy numbers of Fibrobacter, Prevotella and Archaea were not affected by DDGS but were reduced (p < 0.05) by CIN. The results indicate that replacing barley grain by DDGS increased nutrient fermentability and potentially increase protein flows to the intestine. Supplementation of high-grain substrates with CIN reduced methane production and potentially increased the true protein reaching the small intestine; however, overall reduction of feed fermentation may lower the feeding value of a high-grain diet.     

Integrating alkaline extraction of proteins with enzymatic hydrolysis of cellulose from wet distiller’s grains and solubles

Fractionation of distiller’s grains into value added products may serve to improve the economic viability of dry grind corn ethanol facilities in the wake of variable corn and ethanol prices. This research is aimed at creating a high protein, high lysine product from the grain using alkaline protein extractions in conjunction with hydrolysis of the remaining fiber to sugars which are then fermented to ethanol. Alkaline extractions improved the lysine content in protein products, although protein solubility did not exceed 45% of the total protein. In addition, oligomeric carbohydrates, starch, and other water solubles were also extracted, leading to a low purity protein product. Resulting sugar yields following ammonia fiber expansion (AFEX) pretreatment were also lower for extracted distiller’s grains. From these experiments, it does not appear likely that alkaline extraction is a useful tool for fractionation of distiller’s grains. However, pretreatment and hydrolysis can be an effective tool for further fractionation of protein.     

Evaluation of dried distillers' grains with solubles (DDGS) as a protein source for broilers

Male broiler chicks (n=120) were fed diets containing 0, 5, 10 or 15% dried distillers' grains with solubles (DDGS) from the 12th day up to the end of fattening (day 35). During this period feed intake, weight gain and excreta quality (pH, DM) were tested. A digestibility trial was carried out on four birds from each group on the last five days of the experiment to determine the digestibility of organic matter and CP of the different diets. The protein digestibility was evaluated using three different methods; uric acid correction, alpha-amino-N and amino acid-N. There were no significant effects of increased DDGS levels on feed intake, weight gain, excreta quality or digestibility of CP and organic matter. However, feed conversion showed a tendency to decline at the highest DDGS level (15%). Digestibility of DDGS protein was estimated to be 77%. There was no significant difference between uric acid and alpha-amino-N method, but both methods had a significantly lower CP digestibility than amino acid-N. The present results indicate that DDGS can be used as a protein source in diets for fattening broilers up to 10-15%.