New Technologies In the Dry Grind Corn Ethanol Industry Hunter Flodman, PhD Department of Chemical Engineering University of Nebraska - Lincoln

Transcription

1 New Technologies In the Dry Grind Corn Ethanol Industry Hunter Flodman, PhD Department of Chemical Engineering University of Nebraska - Lincoln NDEQ Ethanol Workshop, Grand Island, NE 11/18/2015

2 Presentation Outline Traditional Practices Recently Adopted Technology Less Common Technologies being Tested 2

3 Distillation Thin Stillage Backset Cook Tube Traditional Practice NH 3 Yeast Liq Liq Flash Drum α-amylase ph = 5.7 Slurry 1 bu Milled Corn γ-amylase ph = 5.2 H 2 SO 4 α-amylase Off-gas to Scrubber Receiver 2.8 gal Ethanol Cook Water Fermenter Fermenter Fermenter Beer Well Centrifuge 16.5 lb DGS Dryer Evaporators 0.5 lb Corn Oil Centrifuge Syrup 3

4 Low ph α-amylase Example Novozymes Liquozyme LpH Process Change / Capital Investment Minimal Advantages Viscosity reduction at Low ph Reduce or eliminate ammonia usage for ph adjustment Reduce sulfuric acid use Potential to reduce viscosity and increase throughput 4

5 Distillation Thin Stillage Backset Cook Tube Low ph α-amylase NH 3 Yeast Liq Liq Flash Drum α-amylase ph = 5.7 Slurry 1 bu Milled Corn γ-amylase Aqueous Urea ph = 5.2 H 2 SO 4 Reduced α-amylase Off-gas to Scrubber Receiver 2.8 gal Ethanol ph ~ 5.2 Cook Water Fermenter Fermenter Fermenter Beer Well Centrifuge 16.5 lb DGS Dryer Evaporators 0.5 lb Corn Oil Centrifuge Syrup 5

6 No Cook Process Example POET BPX Process Change / Capital Investment Substantial Advantages Simultaneous saccharification and fermentation while eliminating cooking. Lower energy and GHG emissions. Higher quality distillers grain feed products. Low free fatty acid corn oil. 6

7 No Cook Production Cook Tube Distillation Thin Stillage Backset Yeast Liq Liq Flash Drum Slurry 1 bu Milled Corn α-amylase γ-amylase Off-gas to Scrubber Receiver Lower Energy Consumption 2.8 gal Ethanol Cook Water Fermenter Fermenter Fermenter Beer Well Centrifuge Higher Quality Coproducts 16.5 lb DGS Dryer Evaporators 0.5 lb Corn Oil Centrifuge Syrup 7

8 GMO Corn Containing α-amylase Example Syngenta Enogen Process Change / Capital Investment Minimal Advantages Eliminate α-amylase addition Viscosity Reduction at Low ph Reduce or eliminate ammonia usage for ph adjustment Reduce sulfuric acid use Potential to reduce viscosity and increase throughput Potential to reduce energy requirements 8

9 Distillation Thin Stillage Backset Cook Tube GMO Corn Containing α-amylase Yeast Liq Liq Flash Drum Reduced NH 3 α-amylase Slurry 0.1 bu Enogen 0.9 bu Corn γ-amylase Receiver Aqueous Urea H 2 SO 4 Reduced α-amylase Off-gas to Scrubber 2.8 gal Ethanol Cook Water Fermenter Fermenter Fermenter Beer Well Centrifuge 16.5 lb DGS Dryer Evaporators 0.5 lb Corn Oil Centrifuge Syrup 9

10 GMO Yeast Expressing ϒ-amylase Example TransFerm Yield Plus Process Change / Capital Investment Minimal Advantages Reduce ϒ-amylase addition Reduce substrate inhibition during fermentation resulting in increased ethanol production and decreased glycerol production. 10

11 Distillation Thin Stillage Backset Cook Tube GMO Yeast ϒ-amylase NH 3 Reduced γ-amylase Yeast ph = 5.2 H 2 SO 4 Liq Liq α-amylase Off-gas to Scrubber Flash Drum Receiver 2.8 gal Ethanol α-amylase Slurry ph = 5.7 Cook Water 1 bu Milled Corn Fermenter Fermenter Fermenter Beer Well Centrifuge 16.5 lb DGS Dryer Evaporators 0.5 lb Corn Oil Centrifuge Syrup 11

12 α-amylase Enzyme Cocktails Example Avantec Amp by Novozymes Process Change / Capital Investment Minimal Advantages Eliminate the need to add stand-alone proteases. Reduce urea and ammonia use by 70%. Reduce surfactant use and increase corn oil recovery. Effective at a wide ph range giving process flexibility. 12

13 Distillation Thin Stillage Backset Cook Tube α-amylase Cocktails NH 3 Yeast Liq Liq Flash Drum α-amylase ph = 5.7 Slurry 1 bu Milled Corn γ-amylase Reduced Aqueous Urea ph = 5.2 H 2 SO 4 Reduced α-amylase Off-gas to Scrubber Receiver 2.8 gal Ethanol ph ~ 5.2 Cook Water Fermenter Fermenter Fermenter Beer Well Centrifuge 16.5 lb DGS Dryer Evaporators 0.5 lb Corn Oil Centrifuge Reduced Surfactant Use Syrup 13

14 Whole Stillage Fermentation Example Cellerate TM Syngenta Process Change / Capital Investment Significant Advantages Residual starch converted to ethanol. C6 cellulosic sugars converted to ethanol. D3 RINs to increase profitability. Increased oil yield. Increased protein content of DDGS. 14

15 Whole Stillage Fermentation 15

16 Fiber Separation Technology Example ICM Fiber Separation Process Change / Capital Investment Significant Advantages Increase plant throughput while decreasing energy use and GHG emissions. Increase oil recovery. Create a high protein, low fiber coproduct. Create a high fiber, low protein coproduct. 16

17 Fiber Separation Thin Stillage Backset Starch, Protein, and Germ to conventional processing Fiber Screening Additional Grinding / Milling Slurry Milled Corn To Fiber Dewatering and Drying Cook Water ICMs selective milling technology used for wet grinding slurry. 17

18 Biobutanol Conversion Example Gevo Biobutanol Process Change / Capital Investment Significant Advantages Isobutanol is chemically similar to gasoline. Isobutanol can be used to produce petrochemicals as a petroleum substitute. Fuel Properties Gasoline Ethanol Isobutanol Octane Blending RVP (psi) % Energy of Gasoline Oxygent (wt%)

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20 Zein Extraction Example Prairie Gold Inc. Front End Zein Extraction Process Change / Capital Investment Significant Advantages Produces a byproduct which can be used for pharmaceuticals, films and packaging, and biopolymers. Higher quality zein than wet milling extraction by avoiding the steeping process. Increase in fermenter capacity. Increase in protein quality of DDGS. 20

21 Front End Zein Extraction Starch, fiber, germ, and residual protein to slurry tank Membrane Separation Zein Extraction Milled Corn Ethanol Returned to Distillation Zein Processing Ethanol Zein Product Prairie Gold Inc. Class 1 Div. 1 Pilot Plant 21

22 Renewable Diesel Example UOP Process Change / Capital Investment New Plant Advantages Produces ASTM premium grade diesel fuel from vegetable oils and animals fats using classic oil refining technology (hydrotreating). Chemically equivalent to petroleum derived diesel. 22

23 Renewable Diesel Production from Corn Oil 23

24 Acetaldehyde Emissions Any process change which affects fermentation which includes changes in enzymes, enzyme dosage, yeast, fermentation temperature, etc may influence acetaldehyde emissions. 24

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26 Questions and Discussion Hunter Flodman, PhD Department of Chemical and Biomolecular Engineering (402)