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New Green Process Technology For Energy Efficient
Ethanol Production and Decreased Fermentation
Time Via Enzymatic Water Removal From Distillers
Grains
Bia Henriques, David Johnston and Muthanna
Al-Dahhan
Results/Analysis
Discussion/Conclusion
Background
Schematic diagram of the dry grind process.
Enzyme addition is represented by dashed line
into fermentor.

• Multifect GC showed highest dewatering capability
• Suggested dosage of 0.67kg per metric ton dry
  corn
• Mash with 30 solids loading
• Observed 16-20/w increase in dewatering
• GC106 gave highest reduction in fermentation time
• Suggested Dosage of 0.67kg per metric ton dry
  corn
• Mash with 30 solids loading
• Significant reduction in fermentation time
• Reduction in viscosity of mash with enzymes
• Potential oil separation with Multifect GC

• GC220, Multifect GC and GC 106 are commercially
  available, enzyme cocktails

Control No Treatment

• Dewatering increased with increasing GC220 load
• Dewatering effect tapers off at around 0.015 mL
  of enzyme/100 mL of mash
• 95 of maximum dewatering achieved with 0.015 mL
  of enzyme
• Small increase in dewatering with increasing
  protease load

• Benefits to drier
• Emissions reduction
• Residence time reduction
• Operating temperature reduction
• Energy input reduction
• Benefits to fermentation
• Fermentation time reduction
• Productivity increase
• Benefits to centrifuge
• Viscosity reduction
• Evaporator able to handle extra water
• Possible improvement in water recycle
• Possible savings of 0.8 to 1.2 million for
  40mmgpy plant

• Bonds between water molecules and polyssacharides
• Different bonding types and strengths
• Maximum water binding capacity
• One hydrogen bond between water and
  polyssacharide
• Molecule is highly hydrophilic

• Duplicate data
• Differences in dry solid pellet weight were not
  significant for the most part
• Some material may be solubilizing but the amount
  is too small to be quantified

• Attempt to disrupt network of hydrogen bonding
• Free water
• Cell wall degrading enzymes hydrolyze and cleave
  cellulose and hemicellulose
• Possible use of enzymes to disrupt bonding
• Cell wall degrading and proteolytic enzymes
• Increase
• Water removal during centrifugation
• Productivity
• Decrease
• Drier temperature, residence time and emissions
• Fermentation time

• Decrease in dewatering with increase in protease
  load
• Specially as MGC load is increased, dewatering
  effect decreases with increasing protease load
• MGC and GC106 could have inhibiting effect when
  added together to mash
• Highest dewatering seen when no protease is
  present

Future Work

• Addition of enzymes to fermentation
• Maximize activity time
• Look at commercially available enzyme
  combinations
• Maintain industrial parameters
• Temperature
• pH
• Residence times
• Centrifugal force

• Ferm Gen Experiment
• Reduce fermentation time
• Centrifuge Modeling
• Compare theoretical to experimental data
• Plant Trial
• Center Ethanol Sauget, IL
• Scheduled
• October 2008

• Duplicate data
• Definite downwards trend in the dry solid pellet
  weights
• Statistically only weights at 0.02 mL of GC220
  and above are different from rest
• Some solubilization could be occurring but not
  possible to quantify

Methodology
Acknowledgements
Saccharification, Fermentation and Enzymatic
Hydrolysis
Corn Grind
Liquefaction

• Thank you Genencor and Novozymes for all of the
  enzymes
• Thank you Dr. Vijay Singh for providing the corn
  from UofI Urbana/Champagne
• I would like to thank the following people for
  all their support
• Dr. Muthanna Al-Dahhan (Advisor)
• Dr. David Johnston (Advisor USDA)
• Dr. Kevin Hicks (Research Leader USDA)
• Dr. Andy McAloon (Modeling and Economics USDA)
• Financial support from
• USDA
• WashU-SIUE/NASEO Grant 65356
• CREL sponsors

• Graph shows weight loss of fermentation flasks
  over time
• Enzyme treated mash has significant increase in
  weight loss rate compared to control
• At 32 hours enzyme treated mash is at 95
  completion whereas control is at 79 completion
• Fermentation time can be decreased, increasing
  ethanol production

Evaporation
Centrifugation
Analysis
Filtration