Progress on developing value-added uses for distillers grains: current and evolving opportunities

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1 Agricultural and Biosystems Engineering Conference Proceedings and Presentations Agricultural and Biosystems Engineering Progress on developing value-added uses for distillers grains: current and evolving opportunities Kurt A. Rosentrater Iowa State University, Follow this and additional works at: Part of the Agriculture Commons, Bioresource and Agricultural Engineering Commons, and the Oil, Gas, and Energy Commons The complete bibliographic information for this item can be found at abe_eng_conf/346. For information on how to cite this item, please visit howtocite.html. This Presentation is brought to you for free and open access by the Agricultural and Biosystems Engineering at Iowa State University Digital Repository. It has been accepted for inclusion in Agricultural and Biosystems Engineering Conference Proceedings and Presentations by an authorized administrator of Iowa State University Digital Repository. For more information, please contact

2 Progress on developing value-added uses for distillers grains: current and evolving opportunities Abstract This presentation is on on recent developments with distillers grains (DG) which are a valuable co-product in the ethanol process. Disciplines Agriculture Bioresource and Agricultural Engineering Oil, Gas, and Energy This presentation is available at Iowa State University Digital Repository:

3 Progress on Developing Value- Added Uses for Distillers Grains: Current and Evolving Opportunities Kurt A. Rosentrater, Ph.D. Department of Agricultural and Biosystems Engineering Iowa State University (515)

4 OVERVIEW 1. Ethyl alcohol 2. Coproducts 3. Ongoing research 4. New opportunities 5. Concluding thoughts 2

5 ETHYL ALCOHOL 3

6 Ethyl Alcohol The Fuel of the Future 1860 Nicholas Otto (b. 1832, d. 1891), a German inventor, used ethanol to fuel an internal combustion engine 1896 Henry Ford s (b. 1863, d. 1947) first automobile, the quadricycle, used corn-based ethanol as fuel 1908 Hart-Parr Company (Charles City, IA) manufactured tractors that could use ethanol as a fuel Henry Ford s (b. 1863, d. 1947) Model T used corn-based ethanol, gasoline, or a combinations as fuel 1918 World War I caused increased need for fuel, including ethanol; demand for ethanol reached nearly 60 million gal/year 1940 The U.S. Army constructed and operated a fuel ethanol plant in Omaha, NE Ethanol was extensively used as a motor fuel additive prior to the end of World War II (ca. 1933) 4

7 Ethyl Alcohol The Fuel of the Future The first distillation column for the production of fuel ethanol was invented by Dennis and Dave Vander Griend at South Dakota State University in 1978/1979 5

8 DDGS Historically Many people have asked what the fuel ethanol industry is going to do about the growing piles of non-fermented leftovers Grain distillers have developed equipment and an attractive market for their recovered grains (Boruff, 1947) Distillers are recovering, drying, and marketing their destarched grain stillage as distillers dried grains and dried solubles (Boruff, 1952) This question has been around for quite some time, and it also appears that a viable solution had already been developed as far back as the 1940s 6

9 DDGS Historically In the 1940s / 1950s 17 lb (7.7 kg) of distillers feed was produced for every 1 bu (56 lb; 25.4 kg) of grain that was processed into ethanol Similar to today But over 700 gal (2650 L) of water was required to produce this feed (Boruff, 1947; Boruff, 1952; Boruff et al., 1943) vs. < 4 gal. of water today 7

10 GRAIN ALCOHOL DISTILLERY (ca. 1947) 8

11 MODERN DRY GRIND PROCESS 9

12 U.S. ETHANOL GROWTH Fuel Ethanol (gal) x Ethanol Production RFS Mandated Production Coproduct Generation Feb. 2011: 204 plants, 13,771 Mg/y RFS: 15,000 Mg/y of biofuel by Coproducts (t) x Year Growth of U.S. fuel ethanol industry 10

13 U.S. ETHANOL GROWTH 1.2E+17 Consumption - Fossil Total U.S. Energy (Btu) 1E+17 8E+16 6E+16 4E+16 Production - Fossil Nuclear Renewable Total Consumption 2E Year US EIA,

14 U.S. ETHANOL GROWTH Crude Oil 37% Renewable 8% Nuclear 9% Solar, 1% Geothermal, 5% Waste, 6% Wind, 9% Biofuels, 20% Coal 21% Wood, 24% Hydroelectric, 35% Natural Gas 25% Since 1950s, generally 5 to 9 % of total U.S. US EIA, 2011 energy supply has been renewable 12

15 COPRODUCTS 13

16 ETHANOL COPRODUCTS Distillers Dried Grains with Solubles Condensed Distillers Solubles Distillers Wet Grains 14

17 Jan-80 Jan-81 Jan-82 Jan-83 Jan-84 Jan-85 Jan-86 Jan-87 Jan-88 Jan-89 Jan-90 Jan-91 Jan-92 Jan-93 Jan-94 Jan-95 Jan-96 Jan-97 Jan-98 Jan-99 Jan-00 Jan-01 Jan-02 Jan-03 Jan-04 Jan-05 Jan-06 Jan-07 Jan-08 Jan-09 Jan-10 Jan-11 Jan-12 DDGS Price ($/t) COPRODUCT PRICES Date 15

18 Sales Price ($/t) COPRODUCT PRICES Corn SBM DDGS 0 Jan-11 Feb-11 Apr-11 Jun-11 Jul-11 Sep-11 Nov-11 Date 16

19 DDGS Price Relative to (%) COPRODUCT PRICES Corn SBM 0 Jan-11 Feb-11 Apr-11 Jun-11 Jul-11 Sep-11 Nov-11 Date 17

20 Price / Unit Protein ($/ t/% protein) COPRODUCT VALUES SBM DDGS Corn Jan-11 Feb-11 Apr-11 Jun-11 Jul-11 Sep-11 Nov-11 Date 18

21 Value ($/bu corn) DDGS Value (% of total revenue) COPRODUCT VALUES Value of Ethanol ($/bu corn) Value of DDGS ($/bu corn) DDGS Value (% total) Oct-09 Jan-10 May-10 Aug-10 Nov-10 Feb-11 Jun-11 Sep-11 Dec-11 Date 19

22 COPRODUCT RESEARCH As ethanol industry grows, supply of coproducts will grow Balance = key to sustainability Livestock producers Ethanol manufacturers 20

23 ONGOING RESEARCH 21

24 ONGOING RESEARCH Fuel vs. Food vs. Feed vs. Plastics vs. Chemicals vs. Other uses Goals: Augment current uses Develop new market opportunities Develop/optimize processes and products Improve sustainability Context: Application of physics and chemistry to biological systems Manufacturing with biological polymers: proteins, fibers, lipids 22

25 ONGOING RESEARCH Material handling Pelleting/densification Aquaculture Human foods Plastic composites 23

26 MATERIAL HANDLING 24

27 MATERIAL HANDLING Sieve Opening Size (mm) Scale bar = 3.91 mm Scale bar = 2.50 mm Scale bar = 2.34 mm Scale bar = mm Scale bar = mm Scale bar = 0.52 mm Scale bar = 0.36 mm Scale bar = 0.26 mm 25

28 MATERIAL HANDLING Carbohydrate Protein Batch 1 Batch Particle Diameter (mm) Plant

29 MATERIAL HANDLING z= a + bx + cy HR (-) AoR ( o ) Mass Flow Rate (g/min) x= AoR ( ) y = HR (-) z= MFR (g/min) R 2 = 0.99 Error= 2.42 MFR < 100 = Poor Flow 100 < MFR < 120 = Fair Flow MFR > 120 = Good Flow Good flow Fair flow Poor flow 27

30 MATERIAL HANDLING AoR ( o ) HR (-) Moisture Content (% db) z= a + b/x + cy x= AoR ( ) y = HR (-) z= Moisture content (%, db) R 2 = 0.71 Error= 4.50 Moisture < 9.9 (Good Flow) 9.9 < Moisture < 17.5 (Fair Flow) 17.5 > Moisture (Poor Flow) Good flow Fair flow Poor flow 28

31 MATERIAL HANDLING CC/Dispersibility * d/f (-) Plant 2 y = x R 2 = Plant 5 y = 2E-11e x R 2 = Plant Plant 4 Plant PBD/ABD (-) 29

32 PELLETING/DENSIFICATION 30

33 PELLETING/DENSIFICATION Mag. x 10 DDGS A Mfg B

34 PELLETING/DENSIFICATION a $50/ton DDGS Sales Price, s $100/ton DDGS Sales Price, s $150/ton DDGS Sales Price, s $200/ton DDGS Sales Price, s 15 $/ton pelleting cost, Cop Total Slack Cost per Car, SCcar ($/car) $/ton pelleting cost, Cop 5 $/ton pelleting cost, Cop Pelleting Cost per Car, Pcar ($/car) Percentage of DDGS Pelleted, p (%) Resulting slack costs and costs of pelleting for each rail car due to differing DDGS sales prices and annualized pelleting cost a) breakeven occurs at points of intersection 32

35 PELLETING/DENSIFICATION 1500 $50/ton DDGS Sales Price, s $100/ton DDGS Sales Price, s $150/ton DDGS Sales Price, s $200/ton DDGS Sales Price, s 10 $/ton pelleting cost, Cop 15 $/ton pelleting cost, Cop 5 $/ton pelleting cost, Cop b 1500 Total Slack Cost per Car, SC car ($/car) Pelleting Cost per Car, Pcar ($/car) Percentage of DDGS Pelleted, p (%) Resulting slack costs and costs of pelleting for each rail car due to differing DDGS sales prices and annualized pelleting cost b) magnification of the intersections clearly shows the proportion of DDGS which needs to be pelleted to achieve breakeven 33

36 PELLETING/DENSIFICATION p (%) s ($/ton) Cop ($/ton) p (%) Percent of DDGS pelleted, p (%), required to achieve breakeven increases as both DDGS Sales Price, s ($/ton), and Pelleting Cost, Cop ($/ton), increase 34

37 35

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