Singh – Dry Grind Ethanol ProcessIst US-Brazil Fulbright Course on Biofuels, Sao Paulo, Brazil

University of Illinois at Urbana-Champaign

Dry Grind Ethanol Process Overview

Vijay Singh

Associate ProfessorDepartment of Agricultural & Biological Engineering

University of Illinois at Urbana-Champaign, Urbana, IL

1st Brazil-U.S. Biofuels Short Course

São Paulo, Brazil

July 27 - August 7, 2009

Ethanol Produced from a Bushel of Corn

Corn Dry Grind Facility

2.7 gal (10.2 L) of Ethanol

Corn Dry Grind Facility

One bushel of Corn(25 kg or 56 lb)

15 lb (6.8 kg) of DDGS

Ruminant Food

Singh – Dry Grind Ethanol ProcessIst US-Brazil Fulbright Course on Biofuels, Sao Paulo, Brazil

University of Illinois at Urbana-Champaign

Ethanol Production Process Steps

• Grain Receiving & Cleaning

• Grinding & Mixing• Grinding & Mixing

• Cooking & Liquefaction

• Saccharification & Fermentation

• Distillation & Dehydration

• Coproduct Recovery

Corn

Jet Cooker

HeatExchanger

Liquefaction

AlphaAmylase

Milling Glucoamylase

Water

SteamFlash

Ethanol Production Process

Thin Stillage

Slurry

BeerDryer

190°Proof

Ethanol

200°Proof

EthanolMole SievesEthanol

Storage

y& Yeast

Saccharification &Fermentation

Steam

Mash

Steam

Thin StillageRecycle

WholeStillage

CentrifugeEvaporator

Syrup

ThinStillage

WetGrains

Distillation System

DDGS

Dryer Recycle

Cooling

Singh – Dry Grind Ethanol ProcessIst US-Brazil Fulbright Course on Biofuels, Sao Paulo, Brazil

University of Illinois at Urbana-Champaign

Corn Receiving

Corn

Jet Cooker

HeatExchanger

Liquefaction

AlphaAmylase

Milling Glucoamylase

Water

SteamFlash

Thin Stillage

Slurry

BeerDryer

190°Proof

Ethanol

200°Proof

EthanolMole SievesEthanol

Storage

y& Yeast

Saccharification &Fermentation

Steam

Mash

Steam

Thin StillageRecycle

WholeStillage

CentrifugeEvaporator

Syrup

ThinStillage

WetGrains

Distillation System

DDGS

Dryer Recycle

Cooling

Corn Receiving

Singh – Dry Grind Ethanol ProcessIst US-Brazil Fulbright Course on Biofuels, Sao Paulo, Brazil

University of Illinois at Urbana-Champaign

Corn Receiving

Corn Receiving

Singh – Dry Grind Ethanol ProcessIst US-Brazil Fulbright Course on Biofuels, Sao Paulo, Brazil

University of Illinois at Urbana-Champaign

Corn Receiving

Corn Quality Testing

• Corn delivered at plant is measured for– Moisture content– Moisture content

– Fungus Contamination

– BCFM (broken corn and foreign material)

– Test Weight

– Grade

Singh – Dry Grind Ethanol ProcessIst US-Brazil Fulbright Course on Biofuels, Sao Paulo, Brazil

University of Illinois at Urbana-Champaign

Corn Receiving & Storage

Corn Storage and Milling

Singh – Dry Grind Ethanol ProcessIst US-Brazil Fulbright Course on Biofuels, Sao Paulo, Brazil

University of Illinois at Urbana-Champaign

Corn Milling: Hammer Mills

Corn Slurry Preparation and Cooking

Corn

Jet Cooker

HeatExchanger

Liquefaction

AlphaAmylase

Milling Glucoamylase

Water

SteamFlash

Thin Stillage

Slurry

BeerDryer

190°Proof

Ethanol

200°Proof

EthanolMole SievesEthanol

Storage

y& Yeast

Saccharification &Fermentation

Steam

Mash

Steam

Thin StillageRecycle

WholeStillage

CentrifugeEvaporator

Syrup

ThinStillage

WetGrains

Distillation System

DDGS

Dryer Recycle

Cooling

Singh – Dry Grind Ethanol ProcessIst US-Brazil Fulbright Course on Biofuels, Sao Paulo, Brazil

University of Illinois at Urbana-Champaign

Cooking: Jet Cooker

Liquefaction

Corn

Jet Cooker

HeatExchanger

Liquefaction

AlphaAmylase

Milling Glucoamylase

Water

SteamFlash

Thin Stillage

Slurry

BeerDryer

190°Proof

Ethanol

200°Proof

EthanolMole SievesEthanol

Storage

y& Yeast

Saccharification &Fermentation

Steam

Mash

Steam

Thin StillageRecycle

WholeStillage

CentrifugeEvaporator

Syrup

ThinStillage

WetGrains

Distillation System

DDGS

Dryer Recycle

Cooling

Singh – Dry Grind Ethanol ProcessIst US-Brazil Fulbright Course on Biofuels, Sao Paulo, Brazil

University of Illinois at Urbana-Champaign

Liquefaction Tanks

Saccharification and Fermentation

Corn

Jet Cooker

HeatExchanger

Liquefaction

AlphaAmylase

Milling Glucoamylase

Water

SteamFlash

Thin Stillage

Slurry

BeerDryer

190°Proof

Ethanol

200°Proof

EthanolMole SievesEthanol

Storage

y& Yeast

Saccharification &Fermentation

Steam

Mash

Steam

Thin StillageRecycle

WholeStillage

CentrifugeEvaporator

Syrup

ThinStillage

WetGrains

Distillation System

DDGS

Dryer Recycle

Cooling

Singh – Dry Grind Ethanol ProcessIst US-Brazil Fulbright Course on Biofuels, Sao Paulo, Brazil

University of Illinois at Urbana-Champaign

Yeast Propagation Tank

Different Phases of Yeast Growth Cycle

LAG

LOG

STATIONARY

DEATHGrowth

LAG

Time

Singh – Dry Grind Ethanol ProcessIst US-Brazil Fulbright Course on Biofuels, Sao Paulo, Brazil

University of Illinois at Urbana-Champaign

Saccharification and Fermentation

Beer Well

Singh – Dry Grind Ethanol ProcessIst US-Brazil Fulbright Course on Biofuels, Sao Paulo, Brazil

University of Illinois at Urbana-Champaign

Distillation

Corn

Jet Cooker

HeatExchanger

Liquefaction

AlphaAmylase

Milling Glucoamylase

Water

SteamFlash

Thin Stillage

Slurry

BeerDryer

190°Proof

Ethanol

200°Proof

EthanolMole SievesEthanol

Storage

y& Yeast

Saccharification &Fermentation

Steam

Mash

Steam

Thin StillageRecycle

WholeStillage

CentrifugeEvaporator

Syrup

ThinStillage

WetGrains

Distillation System

DDGS

Dryer Recycle

Cooling

Distillation

Singh – Dry Grind Ethanol ProcessIst US-Brazil Fulbright Course on Biofuels, Sao Paulo, Brazil

University of Illinois at Urbana-Champaign

Mole Sieves

Corn

Jet Cooker

HeatExchanger

Liquefaction

AlphaAmylase

Milling Glucoamylase

Water

SteamFlash

Thin Stillage

Slurry

BeerDryer

190°Proof

Ethanol

200°Proof

EthanolMole SievesEthanol

Storage

y& Yeast

Saccharification &Fermentation

Steam

Mash

Steam

Thin StillageRecycle

WholeStillage

CentrifugeEvaporator

Syrup

ThinStillage

WetGrains

Distillation System

DDGS

Dryer Recycle

Cooling

Mole Sieves

Singh – Dry Grind Ethanol ProcessIst US-Brazil Fulbright Course on Biofuels, Sao Paulo, Brazil

University of Illinois at Urbana-Champaign

Mole Sieve Beads

Whole Stillage Processing

Corn

Jet Cooker

HeatExchanger

Liquefaction

AlphaAmylase

Milling Glucoamylase

Water

SteamFlash

Thin Stillage

Slurry

BeerDryer

190°Proof

Ethanol

200°Proof

EthanolMole SievesEthanol

Storage

y& Yeast

Saccharification &Fermentation

Steam

Mash

Steam

Thin StillageRecycle

WholeStillage

CentrifugeEvaporator

Syrup

ThinStillage

WetGrains

Distillation System

DDGS

Dryer Recycle

Cooling

Singh – Dry Grind Ethanol ProcessIst US-Brazil Fulbright Course on Biofuels, Sao Paulo, Brazil

University of Illinois at Urbana-Champaign

Whole Stillage Centrifuge

Whole Stillage Centrifuge

Singh – Dry Grind Ethanol ProcessIst US-Brazil Fulbright Course on Biofuels, Sao Paulo, Brazil

University of Illinois at Urbana-Champaign

Wet Distiller Grains (Wet Cake)

Wet Distiller Grains (Wet Cake)

Singh – Dry Grind Ethanol ProcessIst US-Brazil Fulbright Course on Biofuels, Sao Paulo, Brazil

University of Illinois at Urbana-Champaign

Thin Stillage Evaporation and DDGS Drying

Corn

Jet Cooker

HeatExchanger

Liquefaction

AlphaAmylase

Milling Glucoamylase

Water

SteamFlash

Thin Stillage

Slurry

BeerDryer

190°Proof

Ethanol

200°Proof

EthanolMole SievesEthanol

Storage

y& Yeast

Saccharification &Fermentation

Steam

Mash

Steam

Thin StillageRecycle

WholeStillage

CentrifugeEvaporator

Syrup

ThinStillage

WetGrains

Distillation System

DDGS

Dryer Recycle

Cooling

Thin Stillage Evaporation

Singh – Dry Grind Ethanol ProcessIst US-Brazil Fulbright Course on Biofuels, Sao Paulo, Brazil

University of Illinois at Urbana-Champaign

Thin Stillage Evaporation

Ethanol Loadout

Singh – Dry Grind Ethanol ProcessIst US-Brazil Fulbright Course on Biofuels, Sao Paulo, Brazil

University of Illinois at Urbana-Champaign

Ethanol Loadout

Feed Dryer

Singh – Dry Grind Ethanol ProcessIst US-Brazil Fulbright Course on Biofuels, Sao Paulo, Brazil

University of Illinois at Urbana-Champaign

Feed Dryer

DDGS Storage and Loadout

Corn

Jet Cooker

HeatExchanger

Liquefaction

AlphaAmylase

Milling Glucoamylase

Water

SteamFlash

Thin Stillage

Slurry

BeerDryer

190°Proof

Ethanol

200°Proof

EthanolMole SievesEthanol

Storage

y& Yeast

Saccharification &Fermentation

Steam

Mash

Steam

Thin StillageRecycle

WholeStillage

CentrifugeEvaporator

Syrup

ThinStillage

WetGrains

Distillation System

DDGS

Dryer Recycle

Cooling

Singh – Dry Grind Ethanol ProcessIst US-Brazil Fulbright Course on Biofuels, Sao Paulo, Brazil

University of Illinois at Urbana-Champaign

DDGS Storage and Loadout

DDGS Loadout

Singh – Dry Grind Ethanol ProcessIst US-Brazil Fulbright Course on Biofuels, Sao Paulo, Brazil

University of Illinois at Urbana-Champaign

CO2 Recovery

CO2 Facility

Singh – Dry Grind Ethanol ProcessIst US-Brazil Fulbright Course on Biofuels, Sao Paulo, Brazil

University of Illinois at Urbana-Champaign

CO2 Storage

Regenerative Thermal Oxidizer