How Ethanol is Made

The production of ethanol or ethyl alcohol from starch or sugar-based feedstocks is among man's
earliest ventures into value-added processing. While the basic steps remain the same, the process
has been considerably refined in recent years, leading to a very efficient process. There are two
production processes: wet milling and dry milling. The main difference between the two is in the
initial treatment of the grain.
Importantly, companies today are involved in technological innovations such as fractionation,
low heat fermentation, methane capture from landfills and biomass gasification that reduce the
amount of fossil energy needed to produce ethanol and distillers grains. The use of pre-treated or
"gray water" and other efficiencies are reducing the need for fresh water in ethanol production.
A host of new technologies allow ethanol producers to capture additional value by adding corn
oil, recoverable carbon dioxide, corn syrup, bio-based chemcials, and other co-products to their
traditional output of feed and fuel.
Take a virtual tour of an ethanol plant and learn about the production process. (Courtesy of
Patriot Renewable Fuels, LLC)

The Ethanol Production Process Dry Milling

Enlarge this image.

In dry milling, the entire corn kernel or other starchy grain is first ground into flour, which is
referred to in the industry as "meal" and processed without separating out the various component
parts of the grain. The meal is slurried with water to form a "mash." Enzymes are added to the
mash to convert the starch to dextrose, a simple sugar. Ammonia is added for pH control and as a
nutrient to the yeast.
The mash is processed in a high-temperature cooker to reduce bacteria levels ahead of
fermentation. The mash is cooled and transferred to fermenters where yeast is added and the
conversion of sugar to ethanol and carbon dioxide (CO2) begins.
The fermentation process generally takes about 40 to 50 hours. During this part of the process,
the mash is agitated and kept cool to facilitate the activity of the yeast. After fermentation, the
resulting "beer" is transferred to distillation columns where the ethanol is separated from the
remaining "stillage." The ethanol is concentrated to 190 proof using conventional distillation and
then is dehydrated to approximately 200 proof in a molecular sieve system.
The anhydrous ethanol is then blended with about 5% denaturant (such as natural gasoline) to
render it undrinkable and thus not subject to beverage alcohol tax. It is then ready for shipment to
gasoline terminals or retailers.
The stillage is sent through a centrifuge that separates the coarse grain from the solubles. The
solubles are then concentrated to about 30% solids by evaporation, resulting in Condensed
Distillers Solubles (CDS) or "syrup." The coarse grain and the syrup are then dried together to
produce dried distillers grains with solubles (DDGS), a high quality, nutritious livestock feed.
The CO2 released during fermentation is captured and sold for use in carbonating soft drinks and
beverages and the manufacture of dry ice.

The Ethanol Production Process - Wet Milling

In wet milling, the grain is soaked or "steeped" in water and dilute sulfurous acid for 24 to 48
hours. This steeping facilitates the separation of the grain into its many component parts.
After steeping, the corn slurry is processed through a series of grinders to separate the corn germ.
The corn oil from the germ is either extracted on-site or sold to crushers who extract the corn oil.
The remaining fiber, gluten and starch components are further segregated using centrifugal,
screen and hydroclonic separators.
The steeping liquor is concentrated in an evaporator. This concentrated product, heavy steep
water, is co-dried with the fiber component and is then sold as corn gluten feed to the livestock
industry. Heavy steep water is also sold by itself as a feed ingredient and is used as a component
in Ice Ban, an environmentally friendly alternative to salt for removing ice from roads.
The gluten component (protein) is filtered and dried to produce the corn gluten meal co-product.
This product is highly sought after as a feed ingredient in poultry broiler operations.
The starch and any remaining water from the mash can then be processed in one of three ways:
fermented into ethanol, dried and sold as dried or modified corn starch, or processed into corn
syrup. The fermentation process for ethanol is very similar to the dry mill process described
above.

Feed Co-products from Ethanol Production

Ethanol production requires ony the starch portion of a corn kernel. The remaining protein, fat,
fiber and other nutrients are returned to the global livestock and poultry feed markets. Every
bushel of corn processed by an ethanol plant produces approximately 17 pounds of animal feed.
For more information on current co-product production, visit our co-products page.

The Production of Ethanol from Cellulosic Biomass

This process flow diagram shows the basic steps in production of ethanol from cellulosic
biomass. Note that there are a variety of options for pretreatment and other steps in the process
and that several technologies combine two or all three of the hydrolysis and fermentation steps
within the shaded box. Chart courtesy of the National Renewable Energ
- See more at: http://www.ethanolrfa.org/pages/how-ethanol-is-made#sthash.LnhJOkBZ.dpuf

Question: How Does Ethanol Performance Compare to Gasoline?

Ethanol is widely available and reasonably inexpensive, but what kind of performance can
drivers expect from a car running on ethanol or an ethanol/gasoline blend?
Answer:
One gallon of pure ethanol contains about 66 percent as much energy as a gallon of gasoline. A
gallon of E85, a common blend of 85 percent ethanol and 15 percent gasoline, contains about 71
Drivers who use E85 can expect about 15 percent less fuel economy than they would get with
gasoline. Other performance factors such as power, acceleration, and cruising speed are
essentially equivalent in vehicles burning E85 and conventional fuels.

Question: What is Ethanol?

Answer: Ethanol (which is also called ethyl alcohol or grain alcohol, and abbreviated as EtOH)
is an alcohol-based alternative fuel that is blended with gasoline to produce a fuel with a higher
octane rating and fewer harmful emissions than unblended gasoline.
Ethanol is made from grains or other plants
Another form of ethanol, called bioethanol, can be made from many types of trees and grasses,
although the process is more difficult.
The chemical formula for ethanol is CH3CH2OH. Essentially, ethanol is ethane with a hydrogen
molecule replaced by a hydroxyl radical, -OH, which is bonded to a carbon atom.
Blending ethanol with gasoline
Blends of at least 85 percent ethanol are considered alternative fuels under the Energy Policy Act
of 1992. E85, a blend of 85 percent ethanol and 15 percent gasoline, is used in flexible fuel
vehicles, which are offered by most major auto manufacturers. Flexible fuel vehcles can run on
gasoline, E85, or any combination of the two.

Blends with more ethanol, such as E95, are also premium alternative fuels. Blends with lower
concentrations of ethanol, such as E10 (10 percent ethanol and 90 percent gasoline), are
sometimes used to increase octane and improve emissions quality, but are not considered
alternative fuels.
Ethanol is good for the economy
And because ethanol is produced domestically, from domestically grown crops, it reduces U.S.
dependence on foreign oil and increases the nations energy

Question: How is Ethanol Made?

Answer: Ethanol can be made from any crop or plant that contains a large amount of sugar or
components that can be converted into sugar, such as starch or cellulose.
As their names imply, sugar beets and sugar cane contain natural sugar. Crops such as corn,
wheat and barley contain starch that can be easily converted to sugar. Most trees and grasses are
made of cellulose, which can also be converted into sugar, although not as easily as starch.
Most ethanol is produced using a four-step process:
1. The ethanol feedstock (crops or plants) are ground up for easier processing;
2. Sugar is dissolved from the ground material, or the starch or cellulose is converted into
sugar;
3. Microbes feed on the sugar, producing ethanol and carbon dioxide as byproducts; and
4. The ethanol is purified to achieve the correct concentration.
It is also possible to produce ethanol through a wet-milling process, which is used by many large
ethanol producers. This process also yields byproducts such as high-fructose corn syrup, which is
used as a sweetener in many prepared foods.

Question: How Much Does it Cost to Use Ethanol?

Ethanol is a widely available alternative fuel that can be used in many vehicles that are already
on the road, but is it cost-effective to use ethanol or an ethanol/gasoline blend in place of
unblended gasoline?

Answer: A gallon of E85, a blend of 85 percent ethanol and 15 percent gasoline, usually costs
about the same as a gallon of regular gasoline, although prices may vary somewhat depending on
location.
Comparable cost per gallon, but less fuel economy
A gallon of ethanol contains less energy than a gallon of gasoline, however, so you may get
lower mileage with ethanol and be required to fill your tank more often, which may could to your
fuel costs.
For more current information about the cost of ethanol and other alternative fuels, download the
most recent Alternative Fuel Price Report from the U.S. Department of Energy.
Vehicles that use ethanol cost no more than others
Vehicles that can use E85 are widely available in many modelssedans, minivans, SUVs,
pickups and light trucksand usually cost about the same as vehicles that run exclusively on
gasoline. The U.S. Department of Energy provides an online Flexible Fuel Vehicle Cost
Calculator that makes it easy to determine the costs and benefits of using E85 in a flexible fuel
vehicle where you live.

Question: What are the Benefits of Using Ethanol?

Ethanol is a relatively low-cost alternative fuel, but what are the benefits of using ethanol or an
ethanol blend in place of unblended gasoline?
Answer: Using ethanol as an alternative to gasoline provides several key benefits.
Ethanol is good for the environment
Overall, ethanol is considered to be better for the environment than gasoline. Ethanol-fueled
vehicles produce lower carbon monoxide and carbon dioxide emissions, and the same or lower
levels of hydrocarbon and oxides of nitrogen emissions.
E85, a blend of 85 percent ethanol and 15 percent gasoline, also has fewer volatile components
than gasoline, which means fewer emissions from evaporation.
Adding ethanol to gasoline in lower percentages, such as 10 percent ethanol and 90 percent
gasoline (E10), reduces carbon monoxide emissions from the gasoline and improves fuel octane.
Ethanol is widely available and easy to use
Flexible fuel vehicles that can use E85 are widely available and come in many different styles
from most major auto manufacturers. E85 is also widely available at a growing number of
stations throughout the United States.

Flexible fuel vehicles have the advantage of being able to use E85, gasoline, or a combination of
the two, giving drivers the flexibility to choose the fuel that is most readily available and best
suited to their needs.

Ethanol is good for the economy

Ethanol production supports farmers and creates domestic jobs. And because ethanol is produced
domestically, from domestically grown crops, it reduces U.S.
dependence on foreign oil and increases the nations energy independence.

What are the Drawbacks of Using Ethanol?

Ethanol and other biofuels are often promoted as clean and relatively low-cost alternatives to
gasoline, but what are the challenges inherent in the widespread adoption of ethanol and other
biofuels?
Answer: The two biggest criticisms of ethanol and other biofuels are:
1. Creating plant-based biofuels requires too much farmland to be practical or sustainable
Producing ethanol and other biofuels takes more energy than the fuel can generate.
The challenge of growing enough crops to meet the demands of ethanol and/or biodiesel
production is significant and, some say, insurmountable. According to some authorities,
producing enough biofuels to enable their widespread adoption could mean converting most of
the worlds remaining forests and open spaces to farmlanda sacrifice few people would be
willing to make.
Replacing only five percent of the nations diesel consumption with biodiesel would require
diverting approximately 60 percent of todays soy crops to biodiesel production, says Matthew
Brown, an energy consultant and former energy program director at the National Conference of
State Legislatures. Thats bad news for tofu lovers.
In a 2005 study, Cornell University researcher David Pimental factored in the energy needed to
grow crops and convert them to biofuels and concluded that producing ethanol from corn
required 29 percent more energy than ethanol is capable of generating.
Pimental found similar problems with making biodiesel from soybeans.
There is just no energy benefit to using plant biomass for liquid fuel, Pimentel says.