Technology and economics of ethanol production from fodder beets via solid-phase fermentation

Summary Operating conditions for our semi-continuous, solid-phase fermentation system were optimized for conversion of fodder beets to fuel ethanol and distiller's wet feed (DWF). This information was then used to estimate operating parameters achievable in a commercial plant, and likely baseline production costs of such a plant. Initial acidification of pulp to pH 2.9–3.2 was effective in controlling bacterial contamination. The maximum operating capacity of the fermentor was approximately 92%, with 75% used for commercial application. A fermentation time of 24 h was sufficient to completely ferment the beet pulp to 8–9% (v/v) ethanol. Based on these parameters, a fodder beet cost of $19.25/metric ton ($17.50/ton), other operating and capital costs, and a PF credit of $0.14/L ($0.53/gal), ethanol production costs were estimated to be $0.49/L ($1.87/gal).     

Economic analysis of a modified dry grind ethanol process with recycle of pretreated and enzymatically hydrolyzed distillers' grains

A modification of the conventional dry grind process for producing ethanol from yellow dent corn is considered with respect to its economic value. Process modifications include recycling distillers' grains, after being pretreated and hydrolyzed, with the ground corn and water to go through fermentation again and increase ethanol yields from the corn starch. A dry grind financial model, which has been validated against other financial models in the industry, is utilized to determine the financial impact of the process changes. The hypothesis was that the enhanced process would yield higher revenues through additional ethanol sales, and higher valued dried distillers' grains (DDGS), due to its higher protein content, to mitigate the drop in DDGS yields. A 32% increase in net present value (NPV) for the overall operation is expected when applying the process modifications to a 100million gallon ethanol plant, and an enzyme cost of $0.20 for each additional gallon of ethanol produced. However, there may be no value added to the enhanced dried distillers' grains (eDDGS), even in light of its higher protein levels, as current pricing is expected to be more sensitive to the amino acid profile than the total protein level, and the eDDGS has lower lysine levels, a key amino acid. Thus, there is a decrease in revenue from eDDGS due to the combination of no price change and loss of DDGS yield to ethanol. The financial improvements are a result of the increased revenue from higher ethanol yields outpacing the sum of all added costs, which include higher capital costs, larger loan payments, increased operating costs, and decreased revenues from dried distillers' grains.     

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.     

Survey of US fuel ethanol plants

The ethanol industry is growing in response to increased consumer demands for fuel as well as the renewable fuel standard. Corn ethanol processing creates the following products: 1/3 ethanol, 1/3 distillers grains, and 1/3 carbon dioxide. As the production of ethanol increases so does the generation of its coproducts, and viable uses continually need to be developed. A survey was mailed to operational US ethanol plants to determine current practices. It inquired about processes, equipment used, end products, and desired future directions for coproducts. Results indicated that approximately one-third of plant managers surveyed expressed a willingness to alter current drying time and temperature if it could result in a higher quality coproduct. Other managers indicated hesitation, based on lack of economic incentives, potential cost and return, and capital required. Respondents also reported the desire to use their coproducts in some of the following products: fuels, extrusion, pellets, plastics, and human food applications. These results provide a snapshot of the industry, and indicate that operational changes to the current production of DDGS must be based upon the potential for positive economic returns.     

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.     

Survival of Escherichia coli O157:H7 in ruminal or fecal contents incubated with corn or wheat dried distillers' grains with solubles

Dried distillers' grain with solubles (DDGS) is a by-product of ethanol production, and its use as cattle feed has increased as a result of the expansion of the fuel ethanol industry. However, the inclusion of corn DDGS into feedlot diets may increase the shedding of Escherichia coli O157:H7. This study investigated whether corn or wheat DDGS at 2 concentrations (20% or 40% vs. 100% barley grain) affected the survival of E.?coli O157:H7 in incubations of ruminal digesta and feces. Neither the type nor the level of DDGS had any effect on fermentation or the survival of E. coli O157:H7 in ruminal digesta. However, there was a time by DDGS interaction (p?< 0.05), where the numbers of E.?coli O157:H7 in feces did not differ after 4 or 12?h of incubation but were greater after 24?h in both 40% wheat and 40% corn DDGS as compared with other treatments. Additionally, after 24?h, the numbers of E. coli O157:H7 were greater in fecal incubations with corn DDGS than with wheat DDGS (p?< 0.05). The differences in the numbers of E.?coli O157:H7 were not attributable to changes in pH or in concentrations of volatile fatty acids in the media. These results suggest that the inclusion of high levels of corn or wheat DDGS in feedlot diets of cattle may encourage the survival of E. coli O157:H7 in feces.     

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.     

A continuous, farm-scale, solid-phase fermentation process for fuel ethanol and protein feed production from fodder beets

Fuel ethanol (95%) was produced from fodder beets in two farm-scale processes. In the first process, involving conventional submerged fermentation of the fodder beets in a mash, ethanol and a feed (PF) rich in protein, fat, and fiber were produced. Ethanol yields of 70 L/metric ton (7 gal/ton) were obtained; however, resulting beers had low ethanol concentrations [3-5% (v/v)]. The high viscosity of medium and low sugar, beet mashes caused mixing problems which prevented any further increase of beet sugar in the mash. The severely limited the maximum attainable ethanol concentration during fermentation, thereby making the beer costly to distill into fuel ethanol and the process energy inefficient. In order to achieve distillably worthwhile ethanol concentrations of 8-10% (v/v), we developed and tested a solid-phase fermentation process (continuous). In preliminary trials, this system produced fermented pulp with over 8% (v/v) ethanol corresponding to an ethanol yield of 87 L/metric ton (21 gal/ton). Production costs with this novel process are $0.47/L ($1.77/gal) and the energy balance is 2.11. These preliminary cost estimates indicate that fodder beets are potentially competitive with corn as an ethanol feedstock. Additional research, however, is warranted to more precisely refine individual costs, energy balances and the actual value of the PF.     

Assessing protein availability of different bioethanol coproducts in dairy cattle

Bioethanol production has led to the production of considerable quantities of different coproducts. Variation in nutrient profiles as well as nutrient availability among these coproducts may lead to an imbalance in the formulation of diets. The objectives of this study were to fractionate protein and carbohydrates by an in situ approach, to determine ruminal availability of nutrients for microbial protein synthesis and to determine protein availability to dairy cattle for three types of dried distiller's grains with solubles (DDGS; 100% wheat DDGS (WDDGS); DDGS blend1 (BDDGS1, corn to wheat ratio 30 : 70); DDGS blend2 (BDDGS2, corn to wheat ratio 50 : 50)) and for different batches within DDGS type using the 2010 DVE/OEB protein evaluation system. The results indicated that all DDGS types are quantitatively good sources of true protein digested and absorbed in the small intestine (DVE values; 177, 184 and 170 g/kg dry matter (DM) for WDDGS, BDDGS1 and BDDGS2, respectively). Rumen degraded protein balances (OEB) values were 159, 82, 65 g/kg DM in WDDGS, BDDGS1 and BDDGS2, respectively. Despite the differences in ruminal availability of nutrients among the different batches of DDGS, the DVE values only differed between the batches of BDDGS1 (194 v. 176 g/kg DM). In conclusion, when DDGS is included in the rations of dairy cattle, variation in its protein value due to factors such as DDGS batch should be taken into consideration.     

The Economics of Biomass Collection and Transportation and Its Supply to Indiana Cellulosic and Electric Utility Facilities

With cellulosic energy production from biomass becoming popular in renewable energy research, agricultural producers may be called upon to plant and collect corn stover or harvest switchgrass to supply feedstocks to nearby facilities. Determining the production and transportation cost to the producer of corn stover or switchgrass and the amount available within a given distance from the plant will result in a per metric ton cost the plant will need to pay producers in order to receive sufficient quantities of biomass. This research computes up-to-date biomass production costs using recent prices for all important cost components including seed, fertilizer, herbicide, mowing/shredding, raking, baling, storage, handling, and transportation. The cost estimates also include nutrient replacement for corn stover. The total per metric ton cost is a combination of these cost components depending on whether equipment is owned or custom hired, what baling options are used, the size of the farm, and the transport distance. Total costs per dry metric ton for biomass with a transportation distance of 60 km ranges between $63 and $75 for corn stover and $80 and $96 for switchgrass. Using the county quantity data and this cost information, we then estimate biomass supply curves for three Indiana coal-fired electric utilities. This supply framework can be applied to plants of any size, location, and type, such as future cellulosic ethanol plants. Finally, greenhouse gas emissions reductions are estimated from using biomass instead of coal for part of the utility energy and also the carbon tax required to make the biomass and coal costs equivalent. Depending on the assumed CO₂ price, the use of biomass instead of coal is found to decrease overall costs in most cases.     

Low temperature pre-treatment of new cultivar of corn for ethanol production and nutrient value of its distiller’s dried grains with soluble

The objective of this work was to evaluate the production of bioethanol from a new Korean variety of corn (Gangdaok) and to assess low temperature pre-treatment of corn mashes before simultaneous saccharification and fermentation. Corn mashes containing 178 g/L of total sugar were fermented with Saccharomyces cerevisiae CHY 1011(KCTC 11250BP) at 35°C. Fermentation of mash supplemented with solid glucoamylase was completed within 48 h, and the ethanol produced was 474.0 and 473.1 L/ton as dry base with low temperature pre-treatment and pressure pretreatment, respectively. Furthermore, the DDGS of Gangdaok cultivar contained more essential amino acids (21.1 mg/g) than did Ambrosia cultivar (USA corn), which is a widely used feedstock. In addition, there were no significant differences in ethanol yield or amino acid concentration in DDGS between low temperature pre-treatment and pressure pretreatment. The results show that Gangdaok holds potential economic advantages if applied to the bioethanol and feed industries.     

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     

Fermentation of Barley by Using Saccharomyces cerevisiae: Examination of Barley as a Feedstock for Bioethanol Production and Value-Added Products

The objective of this study was to examine the ethanol yield potential of three barley varieties (Xena, Bold, and Fibar) in comparison to two benchmarks, corn and wheat. Very high gravity (VHG; 30% solids) fermentations using both conventional and Stargen 001 enzymes for starch hydrolysis were carried out as simultaneous saccharification and fermentation. The grains and their corresponding dried distiller''s grain with solubles (DDGS) were also analyzed for nutritional and value-added characteristics. A VHG traditional fermentation approach utilizing jet-cooking fermentation revealed that both dehulled Bold and Xena barley produced ethanol concentrations higher than that produced by wheat (12.3, 12.2, and 11.9%, respectively) but lower than that produced by corn (13.8%). VHG-modified Stargen-based fermentation of dehulled Bold barley demonstrated comparable performance (14.3% ethanol) relative to that of corn (14.5%) and wheat (13.3%). Several important components were found to survive fermentation and were concentrated in DDGS. The highest yield of phenolics was detected in the DDGS (modified Stargen 001, 20% solids) of Xena (14.6 mg of gallic acid/g) and Bold (15.0 mg of gallic acid/g) when the hull was not removed before fermentation. The highest concentration of sterols in DDGS from barley was found in Xena (3.9 mg/g) when the hull was included. The DDGS recovered from corn had the highest concentration of fatty acids (72.6 and 77.5 mg/g). The DDGS recovered from VHG jet-cooking fermentations of Fibar, dehulled Bold, and corn demonstrated similar levels of tocopherols and tocotrienols. Corn DDGS was highest in crude fat but was lowest in crude protein and in vitro energy digestibility. Wheat DDGS was highest in crude protein content, similar to previous studies. The barley DDGS was the highest in in vitro energy digestibility.The growing need for energy independence and proposed renewable fuels has led recently to a major expansion of fuel ethanol production. In North America, this activity primarily uses corn as a feedstock. The need to find other cost-effective and efficient grains for ethanol production has increased in significance. Cereal grains are high in starch and are currently being utilized for ethanol production (26, 41). To ensure long-term viability of the industry, fermentation strategies that focus on holistic utilization of the feedstock that maximize value addition will increase in importance. The focus of industry is slowly moving from biorefineries that anticipate subsidy and government policy to integrated biorefineries that produce multiple products. Multiple product streams and integrated by-product management are thought to ensure better financial stability and opportunities for diversified income streams.Barley is a potential candidate for industrial ethanol production (10) since its ethanol yield is comparable to that of wheat but below that of American corn, which is currently the preferred industrial feedstock. Barley contains on average 63 to 65% starch, 8 to 13% protein, 2 to 3% fat, 1 to 1.5% soluble gums, 8 to 10% hemicellulose, ca. 2.9% lignin, and 2 to 2.5% ash (15, 27). Barley also contains a hull that could be fermented using cellulolytic enzymes, providing opportunities for integrated biorefineries that utilize more feedstocks than corn. Potential coproducts of ethanol production from barley include protein, fiber, fatty acids, tocopherols, and tocotrienols (40). The nutritional value of barley, based on amino acid content, is greater than that for corn and is not significantly affected by the fermentation process (40). A range of nutraceutical and functional food products, as well as amylase, amylase inhibitors, β-amylase, and oxalate oxidase, are found in barley grains and may have potential for extraction and commercial applications (6, 22, 33). Hull-less barley lines, high in both protein (particularly lysine) and starch, and low in fiber, have recently been developed (11, 14, 32). Since starch recovery and thus ethanol yields are lower for barley than corn, coproduct recovery becomes even more essential for profitability (43).Enzymes used for the pretreatment of grains prior to fermentation have traditionally been α-amylases and glucoamylases. The α-amylase decreases the viscosity of the mash (25) and performs the liquefaction of the pretreatment process. The liquefaction step is typically done at high temperatures of 100 to 120°C (38) with direct steam injection (jet-cooking). The α-amylase action serves to break starch at α-(1,4)-glucosidic bonds, producing smaller dextrin chains. During the saccharification step of the pretreatment, the dextrins produced by α-amylase are then acted on by glucoamylase. This conventional method has a considerable economic drawback, because the mash must undergo a cooking step prior to fermentation. Many industrial ethanol producers use jet-cooking to raise the mash temperature to 100 to 120°C. Because of this temperature requirement, the conventional process uses a large amount of energy to produce ethanol.Recently, a new line of cold starch hydrolyzing enzymes was developed. An example of these enzymes is Stargen 001, which is referred to as a raw starch hydrolyzing enzyme because starch is hydrolyzed to fermentable sugars while the temperature remains at or below a temperature of 48°C (38). Stargen 001 replaces the liquefaction and saccharification steps performed by conventional digestion enzymes (i.e., α-amylase and glucoamylase) and releases free glucose and other fermentable sugars for use by yeast cells. Stargen 001 is a cocktail of modified α-amylase and glucoamylase enzymes that work together to convert starch into dextrins, followed by the hydrolysis of dextrins to fermentable sugars (37, 38). With the absence of a cooking stage in the cold hydrolysis method, the potential exists that the dried distiller''s grain plus solubles (DDGS) produced by fermentation would have less damage so that the proteins contained in the DDGS could be of more value (18).The objectives of the present study were to examine the ethanol yield potentials of three barley varieties (Xena, Bold, and Fibar) and two benchmark grains (Pioneer Hi-Bred corn and CPS wheat) using conventional (jet-cooking) and cold starch hydrolysis with Stargen 001. In addition, dehulling was tested for the potential to increase ethanol yields, because hull does not contain fermentable starch; both hulled and dehulled mashes were studied where possible. The grains and their corresponding DDGS were analyzed for nutritional value and the presence of potential value-added products such as fatty acids, tocopherols, tocotrienols, sterols, and polyphenols.     

Fate of virginiamycin through the fuel ethanol production process

Antibiotics are frequently used to prevent and treat bacterial contamination of commercial fuel ethanol fermentations, but there is concern that antibiotic residues may persist in the distillers grains coproducts. A study to evaluate the fate of virginiamycin during the ethanol production process was conducted in the pilot plant facilities at the National Corn to Ethanol Research Center, Edwardsville, IL. Three 15,000-liter fermentor runs were performed: one with no antibiotic (F1), one dosed with 2 parts per million (ppm) of a commercial virginiamycin product (F2), and one dosed at 20 ppm of virginiamycin product (F3). Fermentor samples, distillers dried grains with solubles (DDGS), and process intermediates (whole stillage, thin stillage, syrup, and wet cake) were collected from each run and analyzed for virginiamycin M and virginiamycin S using a liquid chromatography-mass spectrometry method. Virginiamycin M was detected in all process intermediates of the F3 run. On a dry-weight basis, virginiamycin M concentrations decreased approximately 97 %, from 41 μg/g in the fermentor to 1.4 μg/g in the DDGS. Using a disc plate bioassay, antibiotic activity was detected in DDGS from both the F2 and F3 runs, with values of 0.69 μg virginiamycin equivalent/g sample and 8.9 μg/g, respectively. No antibiotic activity (<0.6 μg/g) was detected in any of the F1 samples or in the fermentor and process intermediate samples from the F2 run. These results demonstrate that low concentrations of biologically active antibiotic may persist in distillers grains coproducts produced from fermentations treated with virginiamycin.     

Production of carotenoids byPhaffia rhodozyma grown on media composed of corn wet-milling co-products

Summary Natural isolates of the carotenoid-producing yeastPhaffia rhodozyma were analyzed for their ability to grow and to produce carotenoids in culture media composed exclusively of co-products of corn wet-milling for fuel ethanol production. FiveP. rhodozyma strains were tested for biomass produced (dry weight) and carotenoid yield. Six co-products were examined, ranging in cost from approximately $0.02 per kg to $0.11 per kg, all less expensive than conventional or agricultural growth substrates previously tested. The three co-products allowing the greatest accumulation of biomass and carotenoids byP. rhodozyma were thin stillage (TS), corn condensed distiller's solubles (CCDS) and corn gluten feed (CGF). Of the medium compositions tested, 10–15% CGF, 70% TS and 6–8% CCDS generally allowed maximum carotenoid production. Cultures grown in these three media produced up to 65%. 148% and 104% of the carotenoid yield per ml of yeast extract/malt extract (YM) cultures, respectively. Under the conditions tested, this was at an approximate medium cost of $0.67 per g carotenoids for CCDS and $0.73 per g for CGF as compared to $385.00 per g for YM. These results indicate that certain co-products of corn wet-milling can serve, at the appropriate concentration, as efficient, economical substrates for growth and carotenoid production byPhaffia rhodozyma.The mention of firm names or trade products does not imply that they are endorsed or recommended by the US Department of Agriculture over other firms or similar products not mentioned.     

Thermodynamics of the Corn-Ethanol Biofuel Cycle

This article defines sustainability and sustainable cyclic processes, and quantifies the degree of non-renewability of a major biofuel: ethanol produced from industrially grown corn. It demonstrates that more fossil energy is used to produce ethanol from corn than the ethanol's calorific value. Analysis of the carbon cycle shows that all leftovers from ethanol production must be returned back to the fields to limit the irreversible mining of soil humus. Thus, production of ethanol from whole plants is unsustainable. In 2004, ethanol production from corn will generate 8 million tons of incremental CO₂, over and above the amount of CO₂ generated by burning gasoline with 115% of the calorific value of this ethanol. It next calculates the cumulative exergy (available free energy) consumed in corn farming and ethanol production, and estimates the minimum amount of work necessary to restore the key non-renewable resources consumed by the industrial corn-ethanol cycle. This amount of work is compared with the maximum useful work obtained from the industrial corn-ethanol cycle. It appears that if the corn-ethanol exergy is used to power a car engine, the minimum restoration work is about 6 times the maximum useful work from the cycle. This ratio drops down to 2 if an ideal fuel cell is used to process the ethanol. The article estimates the U.S. taxpayer subsidies of the industrial corn-ethanol cycle at $3.8 billion in 2004. The parallel subsidies by the environment are estimated at $1.8 billion in 2004. The latter estimate will increase manifold when the restoration costs of aquifers, streams, and rivers, and the Gulf of Mexico are also included. Finally, the article estimates that (per year and unit area) the inefficient solar cells produce ～ 100 times more electricity than corn ethanol. There is a need for more reliance on sunlight, the only source of renewable energy on the earth.     

Cofermentation of sweet sorghum juice and grain for production of fuel ethanol and distillers' wet grain

In an attempt to reduce the costs associated with fuel ethanol production from grain, the authors used sweet sorghum juice as a partial or complete replacement for tap-water in mash preparation and fermentation. This juice, which was an unutilized by-product of sweet sorghum silage preservation by the Ag-Bag method, contained 6·5–7·6% (wt/wt) reducing sugar and produced up to 3·51% (v/v) ethanol beers after fermentation. Varying amounts of this juice were mixed with water and corn or wheat, either before or after liquefaction (front-end or back-end loading, respectively). When over 60% juice replacement was used in front-end loading trials, salt buildup, due to required pH adjustments during cooking, inhibited yeast metabolism and thereby reduced yields. This inhibition was not observed during back-end loading trials since acid and base usage during cooking were reduced. However, in all trials we noted yeast inhibition by some factor(s) present in juice from sweet sorghum variety NK 8368. This inhibition was not observed with variety NK 405. If sweet sorghum juice is used to replace 40% of the water and either 12·5% of the corn or 12% of the wheat in mash preparation, production costs can be reduced by $0.032/liter ($0.12/US gallon) for corn and $0.040/liter ($0.15/US gallon) for wheat.     

Ethanolic fermentation of hydrolysates from ammonia fiber expansion (AFEX) treated corn stover and distillers grain without detoxification and external nutrient supplementation

External nutrient supplementation and detoxification of hydrolysate significantly increase the production cost of cellulosic ethanol. In this study, we investigated the feasibility of fermenting cellulosic hydrolysates without washing, detoxification or external nutrient supplementation using ethanologens Escherichia coli KO11 and the adapted strain ML01 at low initial cell density (16 mg dry weight/L). The cellulosic hydrolysates were derived from enzymatically digested ammonia fiber expansion (AFEX)-treated corn stover and dry distiller's grain and solubles (DDGS) at high solids loading (18% by weight). The adaptation was achieved through selective evolution of KO11 on hydrolysate from AFEX-treated corn stover. All cellulosic hydrolysates tested (36-52 g/L glucose) were fermentable. Regardless of strains, metabolic ethanol yields were near the theoretical limit (0.51 g ethanol/g consumed sugar). Volumetric ethanol productivity of 1.2 g/h/L was achieved in fermentation on DDGS hydrolysate and DDGS improved the fermentability of hydrolysate from corn stover. However, enzymatic hydrolysis and xylose utilization during fermentation were the bottlenecks for ethanol production from corn stover at these experimental conditions. In conclusion, fermentation under the baseline conditions was feasible. Utilization of nutrient-rich feedstocks such as DDGS in fermentation can replace expensive media supplementation.     

Evaluation of value-added components of dried distiller's grain with solubles from triticale and wheat

This study focused on the detection of value-added co-products in dried distiller’s grain plus soluble (DDGS), a possibility that could open new avenues for further processing and marketing of DDGS and improving economic sustainability of ethanol industry. Varieties of triticale, wheat and two benchmarks, CPS wheat and Pioneer Hi-Bred corn, were fermented using two very high gravity (VHG) fermentation approaches: jet-cooking and raw starch processing (STARGEN fermentation). DDGS from STARGEN fermentation could be promising sources of value-added co-products. Pronghorn triticale DDGS (STARGEN fermentation) had the highest concentration of sterols (3.7 mg/g), phenolic compounds (13.61 mg GAE/g), and β-glucan (2.07%). CDC Ptarmigan DDGS (STARGEN fermentation) had the highest concentration of tocopherols and tocotrienols (107.0 μg/g), 1.93% of β-glucan, and 53.0 mg/g of fatty acids. AC Reed DDGS (STARGEN method) showed 1.97% of β-glucan. This study shows that proper choice of fermentation approach and feedstock for ethanol production could improve commercial quality of DDGS.     

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.