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Ethanol Production Process

Ethanol Production Process

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Published by J'Carlo Carpio

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Published by: J'Carlo Carpio on Oct 01, 2010
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11/14/2010

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Description of Dry Mill Process

Dry milling is the least intensive method for producing ethanol.ƒ Dry Milling is the most common ethanol production method in the United States. dried distiller s grains are sold to cattle farmers for feed. Dried distiller s grains with solubles (DDGS) are one of the byproducts from dry milling. Though this process requires less energy. .it also creates fewer byproducts.

it cannot be stored for as long as dried distiller s grains. However.ƒ Wet stillage. another form of livestock feed. Carbon dioxide (CO2) is the last byproduct from dry milling. . is another byproduct from the dry milling process. Soda companies often buy this byproduct to use for carbonation in their beverages.

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.ƒ The majority of corn arrives at the site via rail car delivered by Wisconsin and Southern Railroad approximately three times per week. Nearby corn arrives by truck. Automated unloading systems can be self-operated by the truck driver and the rail cars are typically unloaded during low truck traffic times.

. the corn is transferred to a "day bin" and metered to the hammermill by a computer-controlled weigh belt feeder.000bushel storage bins.ƒ A fifteen thousand bushel per hour grain system screens the corn for rocks and cobs before being sent to one of two 225. then ground and pneumatically conveyed to the slurry tank for enzymatic processing. To begin processing.

heat and enzymes break the ground corn into fine slurry. The slurry is heated for sterilization and is pumped to a Liquefaction tank where other enzymes are added to convert the starches into glucose sugars.ƒ The addition of water. Next the corn slurry is pumped into one of three fermenters where yeast is added to begin the forty-eight to fifty hour batch fermentation process. .

ƒ ICM's process utilizes a vacuum distillation system to divide the alcohol from the corn mash. Both streams are routed to the dehydration equipment. 145 proof alcohol exiting the distillation stripper then exits the rectifier at 190 proof and is dried to 200 proof in an ICM designed molecular sieve. .

"thin stillage" is pumped to a steam driven evaporator to produce a thick syrup. "wet cake" are conveyed to the DDG dryer. The solids stream exiting the centrifuge.ƒ Mash streams from the distillation stripper are pumped to one of several decanter type centrifuges for dewatering. The water. .

This unit removes moisture and produces the golden dried distillers grains with solubles (DDGS).ƒ Syrup from the evaporator and wet cake from the centrifuge are conveyed to the DDGS natural gas fired rotary dryer. Multiple passes produces a ten percent moisture product (DDGS) and one pass drying produces a fifty percent moisture product (DWG). . BSE will have the capability to produce either product on a daily basis.

.ƒ The ten percent DDGS is pneumatically conveyed to flat storage to cool and readied for shipment via jumbo rail car or hopper bottom trucks. Fifty percent moisture DWG is shipped locally via "moving floor" trucks.

ƒ There are two. There are truck and railcar load-out facilities. The tanks were built to code and utilize the covered top floating roof design which incorporates the appropriate relief valves. Additional smaller tanks were erected for denaturant storage and temporary storage. . seven hundred fifty thousand gallon denatured ethanol storage tanks on site.

At this time BSE plans to look at CO2 recovery as a future venture. . Additional transfer fans will need to be added pending the specifications of the future CO2 vendor.ƒ The fermenter produces carbon dioxide gas that can be processed into salable product. ICM's design will collect the gases and remove impurities with a packed water scrubber.

.ƒ The principal products produced at our ethanol plant are ethanol and distiller grains.

 An oxygenated fuel additive that can reduce carbon monoxide vehicle emissions. and  A non-petroleum-based gasoline extender. a fuel component made primarily from corn and various other grains. and can be used as:  An octane enhancer in fuels.ƒ Ethanol is ethyl alcohol. . Most ethanol is used in its primary form for blending with unleaded gasoline and other fuel products.

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