The Experts below are selected from a list of 513 Experts worldwide ranked by ideXlab platform
Vijay Singh - One of the best experts on this subject based on the ideXlab platform.
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Impact of Fractionation Process on the Technical and Economic Viability of Corn Dry Grind Ethanol Process
Processes, 2019Co-Authors: Chinmay Kurambhatti, Deepak Kumar, Vijay SinghAbstract:Use of corn fractionation techniques in Dry Grind Process increases the number of coproducts, enhances their quality and value, generates feedstock for cellulosic ethanol production and potentially increases profitability of the Dry Grind Process. The aim of this study is to develop Process simulation models for eight different wet and Dry corn fractionation techniques recovering germ, pericarp fiber and/or endosperm fiber, and evaluate their techno-economic feasibility at the commercial scale. Ethanol yields for plants Processing 1113.11 MT corn/day were 37.2 to 40 million gal for wet fractionation and 37.3 to 31.3 million gal for Dry fractionation, compared to 40.2 million gal for conventional Dry Grind Process. Capital costs were higher for wet fractionation Processes ($92.85 to $97.38 million) in comparison to conventional ($83.95 million) and Dry fractionation ($83.35 to $84.91 million) Processes. Due to high value of coproducts, ethanol production costs in most fractionation Processes ($1.29 to $1.35/gal) were lower than conventional ($1.36/gal) Process. Internal rate of return for most of the wet (6.88 to 8.58%) and Dry fractionation (6.45 to 7.04%) Processes was higher than the conventional (6.39%) Process. Wet fractionation Process designed for germ and pericarp fiber recovery was most profitable among the Processes.
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Ethanol production from corn fiber separated after liquefaction in the Dry Grind Process
Energies, 2018Co-Authors: Chinmay Kurambhatti, Kent D. Rausch, Mike E Tumbleson, Deepak Kumar, Vijay SinghAbstract:Conversion of corn fiber to ethanol in the Dry Grind Process can increase ethanol yields, improve coproduct quality and contribute to Process sustainability. This work investigates the use of two physio-chemical pretreatments on corn fiber and effect of cellulase enzyme dosage to improve ethanol yields. Fiber separated after liquefaction of corn was pretreated using (I) hot water pretreatment (160 °C for 5, 10 or 20 min) and (II) wet disk milling and converted to ethanol. The conversion efficiencies of hot water pretreated fiber were higher than untreated fiber, with highest increase in conversion (10.4%) achieved for 5 min residence time at 160 °C. Disk milling was not effective in increasing conversion compared to other treatments. Hydrolysis and fermentation of untreated fiber with excess cellulase enzymes resulted in 33.3% higher conversion compared to untreated fiber.
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Increasing ethanol yield through fiber conversion in corn Dry Grind Process
Bioresource Technology, 2018Co-Authors: Chinmay Kurambhatti, Kent D. Rausch, Mike E Tumbleson, Deepak Kumar, Vijay SinghAbstract:Abstract Conversion of corn fiber to ethanol in the Dry Grind Process could increase ethanol yields, reduce downstream Processing costs and improve overall Process profitability. This work investigates the in-situ conversion of corn fiber into ethanol (cellulase addition during simultaneous saccharification and fermentation) during Dry Grind Process. Addition of 30 FPU/g fiber cellulase resulted in 4.6% increase in ethanol yield compared to the conventional Process. Use of excess cellulase (120 FPU/g fiber) resulted in incomplete fermentation and lower ethanol yield compared to the conventional Process. Multiple factors including high concentrations of ethanol and phenolic compounds were responsible for yeast stress and incomplete fermentation in excess cellulase experiments.
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Techno-economic feasibility analysis of blue and purple corn Processing for anthocyanin extraction and ethanol production using modified Dry Grind Process
Industrial Crops and Products, 2018Co-Authors: Pavel Somavat, Deepak Kumar, Vijay SinghAbstract:Abstract This study performs the techno-economic analysis of simultaneous ethanol production and anthocyanins extraction from colored corn in a Dry Grind facility. Comprehensive models for the conventional Process using dent corn and modified Process for colored corn including pericarp separation and anthocyanin recovery were developed in the SuperPro designer. Ethanol production for plants Processing 1113.11 MT/day of corn, were estimated 42, 37 and 35.2 million gallon/yr for yellow, blue and purple corn, respectively. Capital investments ranged between $87.9 and $100 million, with a minimum investment for the conventional plant. Irrespective of higher capital investments and gross operating costs, ethanol production cost during purple corn Processing was 42% less than that of yellow corn ($0.75 vs. $1.3/gal ethanol) because of high revenue from anthocyanin extract. Annual anthocyanins extract production from blue corn was only 26.5 MT compared to 879 MT for purple corn, and the Process was not economically viable. The internal rate of return for the plant Processing purple corn was 21.2%, compared to only 8.7% for a conventional plant using yellow dent corn. The use of purple corn in Dry Grind facilities can significantly improve the Process economics and provide anthocyanin extract for use in the food industry.
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germ soak water as nutrient source to improve fermentation of corn grits from modified corn Dry Grind Process
Bioresources and Bioprocessing, 2017Co-Authors: Ankita Juneja, Deepak Kuma, Vijay SinghAbstract:Corn fractionation in modified Dry Grind Processes results in low fermentation efficiency of corn grits because of nutrient deficiency. This study investigated the use of nutrient-rich water from germ soaking to improve grits fermentation in the conventional Dry Grind and granular starch hydrolysis (GSH) Processes. Comparison of germ soak water with the use of protease and external B-vitamin addition in improving grits fermentation was conducted. Use of water from optimum soaking conditions (12 h at 30 °C) resulted in complete fermentation with 29 and 8% higher final ethanol yields compared to that of control in conventional and GSH Process, respectively. Fermentation rate (4–24 h) of corn grits with germ soak water (0.492 v/v-h) was more than double than that of control (0.208 v/v-h) in case of conventional Dry Grind Process. The soaking Process also increased the oil concentration in the germ by about 36%, which would enhance its economic value.
Kent D. Rausch - One of the best experts on this subject based on the ideXlab platform.
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Ethanol production from corn fiber separated after liquefaction in the Dry Grind Process
Energies, 2018Co-Authors: Chinmay Kurambhatti, Kent D. Rausch, Mike E Tumbleson, Deepak Kumar, Vijay SinghAbstract:Conversion of corn fiber to ethanol in the Dry Grind Process can increase ethanol yields, improve coproduct quality and contribute to Process sustainability. This work investigates the use of two physio-chemical pretreatments on corn fiber and effect of cellulase enzyme dosage to improve ethanol yields. Fiber separated after liquefaction of corn was pretreated using (I) hot water pretreatment (160 °C for 5, 10 or 20 min) and (II) wet disk milling and converted to ethanol. The conversion efficiencies of hot water pretreated fiber were higher than untreated fiber, with highest increase in conversion (10.4%) achieved for 5 min residence time at 160 °C. Disk milling was not effective in increasing conversion compared to other treatments. Hydrolysis and fermentation of untreated fiber with excess cellulase enzymes resulted in 33.3% higher conversion compared to untreated fiber.
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Increasing ethanol yield through fiber conversion in corn Dry Grind Process
Bioresource Technology, 2018Co-Authors: Chinmay Kurambhatti, Kent D. Rausch, Mike E Tumbleson, Deepak Kumar, Vijay SinghAbstract:Abstract Conversion of corn fiber to ethanol in the Dry Grind Process could increase ethanol yields, reduce downstream Processing costs and improve overall Process profitability. This work investigates the in-situ conversion of corn fiber into ethanol (cellulase addition during simultaneous saccharification and fermentation) during Dry Grind Process. Addition of 30 FPU/g fiber cellulase resulted in 4.6% increase in ethanol yield compared to the conventional Process. Use of excess cellulase (120 FPU/g fiber) resulted in incomplete fermentation and lower ethanol yield compared to the conventional Process. Multiple factors including high concentrations of ethanol and phenolic compounds were responsible for yeast stress and incomplete fermentation in excess cellulase experiments.
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Evaporator Fouling Tendencies of Thin Stillage and Concentrates From the Dry Grind Process
Heat Transfer Engineering, 2016Co-Authors: Ravi Challa, David B Johnston, Mike E Tumbleson, Vijay Singh, Yizhe B. Zhang, Nicki J. Engeseth, Kent D. RauschAbstract:ABSTRACTIn the United States, more than 200 maize Processing plants use multiple-effect evaporators to remove water from thin stillage and steepwater during Dry Grind and wet milling Processes, respectively. During the Dry Grind Process, unfermentables are centrifuged and the liquid fraction, thin stillage, is concentrated in multiple effect evaporators. Evaporator fouling occurs during thin stillage concentration and may be from deposition of proteins, fat, fiber, and/or carbohydrates on evaporator surfaces. Studies on evaporator fouling from maize Processing streams are limited and fundamental causes are not well understood. Therefore, the overall objective was to investigate effects of compositional variation on evaporator fouling during thin stillage concentration. Effects of total solids during evaporator concentration, removal of post fermentation oil, corn oil and glycerol addition, and overall plant operation were studied. Thin stillage had lower fouling rates compared to evaporator concentrates. ...
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Comparison of Protein Concentrate, Protein Isolate and Wet Sieving Processes for Enriching DDGS Protein
Journal of the American Oil Chemists' Society, 2014Co-Authors: Song Li, Kent D. Rausch, Mike E Tumbleson, Wei Liu, Vijay SinghAbstract:Distillers dried grains with solubles (DDGS) is a coproduct of the Dry Grind ethanol Process. Due to its high fiber content, use of DDGS is limited as an ingredient in ruminant animal diets. Reducing fiber and increasing protein content will increase the value of DDGS. Further increase in protein content and decrease in fiber content can be achieved by removing oligosaccharides and other soluble carbohydrates from DDGS. Two DDGS samples were produced: one using the conventional Dry Grind Process (conventional DDGS) and another using a modified Dry Grind Process (E-Mill DDGS). Three protein enrichment Processes were used on E-Mill and conventional DDGS. These enrichment Processes were protein concentrate and isolate Processes, adapted from soybean industry, and a wet sieving Process. For E-Mill DDGS, protein contents of protein concentrate, protein isolate and sieved coproducts were 48, 52 and 51 % (db), respectively, compared to 42 % (db) for E-Mill DDGS. For conventional DDGS, protein contents of protein concentrate, protein isolate and sieved coproducts were 33, 37 and 40 % (db), respectively compared to 34 % (db) for conventional DDGS. Among the three Processes, the wet-sieving Process resulted in the highest protein content for conventional and E-Mill DDGS samples.
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Microfiltration of thin stillage: Process simulation and economic analyses.
Biomass and Bioenergy, 2011Co-Authors: Amit Arora, Mike E Tumbleson, Vijay Singh, Bruce S. Dien, Ronald L. Belyea, Anupam Seth, Kent D. RauschAbstract:Abstract In plant scale operations, multistage membrane systems have been adopted for cost minimization. We considered design optimization and operation of a continuous microfiltration (MF) system for the corn Dry Grind Process. The objectives were to develop a model to simulate a multistage MF system, optimize area requirements and stages required for a multistage system and perform economic analysis of a multistage MF system for a 40 million gal/yr ethanol plant. Total area requirement decreased with number of stages but there was tradeoff between higher capital costs involved at higher number of stages. To achieve thin stillage total solids concentration from 7 to 35%, a 5 stage membrane system was found to be optimum with area requirement of 655 m 2 for minimum cost. Increase in the input stream flow rate from 1.54 × 10 6 to 2.89 × 10 6 L/day significantly increased the total capital cost of the system by 47%. Compared to a single stage system, an optimal system had a 50% reduction in operating costs. Optimal system also showed potential to Process more than twice the amount of thin stillage compared to a 4 effect evaporator system for given conditions.
Mike E Tumbleson - One of the best experts on this subject based on the ideXlab platform.
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Ethanol production from corn fiber separated after liquefaction in the Dry Grind Process
Energies, 2018Co-Authors: Chinmay Kurambhatti, Kent D. Rausch, Mike E Tumbleson, Deepak Kumar, Vijay SinghAbstract:Conversion of corn fiber to ethanol in the Dry Grind Process can increase ethanol yields, improve coproduct quality and contribute to Process sustainability. This work investigates the use of two physio-chemical pretreatments on corn fiber and effect of cellulase enzyme dosage to improve ethanol yields. Fiber separated after liquefaction of corn was pretreated using (I) hot water pretreatment (160 °C for 5, 10 or 20 min) and (II) wet disk milling and converted to ethanol. The conversion efficiencies of hot water pretreated fiber were higher than untreated fiber, with highest increase in conversion (10.4%) achieved for 5 min residence time at 160 °C. Disk milling was not effective in increasing conversion compared to other treatments. Hydrolysis and fermentation of untreated fiber with excess cellulase enzymes resulted in 33.3% higher conversion compared to untreated fiber.
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Increasing ethanol yield through fiber conversion in corn Dry Grind Process
Bioresource Technology, 2018Co-Authors: Chinmay Kurambhatti, Kent D. Rausch, Mike E Tumbleson, Deepak Kumar, Vijay SinghAbstract:Abstract Conversion of corn fiber to ethanol in the Dry Grind Process could increase ethanol yields, reduce downstream Processing costs and improve overall Process profitability. This work investigates the in-situ conversion of corn fiber into ethanol (cellulase addition during simultaneous saccharification and fermentation) during Dry Grind Process. Addition of 30 FPU/g fiber cellulase resulted in 4.6% increase in ethanol yield compared to the conventional Process. Use of excess cellulase (120 FPU/g fiber) resulted in incomplete fermentation and lower ethanol yield compared to the conventional Process. Multiple factors including high concentrations of ethanol and phenolic compounds were responsible for yeast stress and incomplete fermentation in excess cellulase experiments.
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Evaporator Fouling Tendencies of Thin Stillage and Concentrates From the Dry Grind Process
Heat Transfer Engineering, 2016Co-Authors: Ravi Challa, David B Johnston, Mike E Tumbleson, Vijay Singh, Yizhe B. Zhang, Nicki J. Engeseth, Kent D. RauschAbstract:ABSTRACTIn the United States, more than 200 maize Processing plants use multiple-effect evaporators to remove water from thin stillage and steepwater during Dry Grind and wet milling Processes, respectively. During the Dry Grind Process, unfermentables are centrifuged and the liquid fraction, thin stillage, is concentrated in multiple effect evaporators. Evaporator fouling occurs during thin stillage concentration and may be from deposition of proteins, fat, fiber, and/or carbohydrates on evaporator surfaces. Studies on evaporator fouling from maize Processing streams are limited and fundamental causes are not well understood. Therefore, the overall objective was to investigate effects of compositional variation on evaporator fouling during thin stillage concentration. Effects of total solids during evaporator concentration, removal of post fermentation oil, corn oil and glycerol addition, and overall plant operation were studied. Thin stillage had lower fouling rates compared to evaporator concentrates. ...
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Comparison of Protein Concentrate, Protein Isolate and Wet Sieving Processes for Enriching DDGS Protein
Journal of the American Oil Chemists' Society, 2014Co-Authors: Song Li, Kent D. Rausch, Mike E Tumbleson, Wei Liu, Vijay SinghAbstract:Distillers dried grains with solubles (DDGS) is a coproduct of the Dry Grind ethanol Process. Due to its high fiber content, use of DDGS is limited as an ingredient in ruminant animal diets. Reducing fiber and increasing protein content will increase the value of DDGS. Further increase in protein content and decrease in fiber content can be achieved by removing oligosaccharides and other soluble carbohydrates from DDGS. Two DDGS samples were produced: one using the conventional Dry Grind Process (conventional DDGS) and another using a modified Dry Grind Process (E-Mill DDGS). Three protein enrichment Processes were used on E-Mill and conventional DDGS. These enrichment Processes were protein concentrate and isolate Processes, adapted from soybean industry, and a wet sieving Process. For E-Mill DDGS, protein contents of protein concentrate, protein isolate and sieved coproducts were 48, 52 and 51 % (db), respectively, compared to 42 % (db) for E-Mill DDGS. For conventional DDGS, protein contents of protein concentrate, protein isolate and sieved coproducts were 33, 37 and 40 % (db), respectively compared to 34 % (db) for conventional DDGS. Among the three Processes, the wet-sieving Process resulted in the highest protein content for conventional and E-Mill DDGS samples.
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Microfiltration of thin stillage: Process simulation and economic analyses.
Biomass and Bioenergy, 2011Co-Authors: Amit Arora, Mike E Tumbleson, Vijay Singh, Bruce S. Dien, Ronald L. Belyea, Anupam Seth, Kent D. RauschAbstract:Abstract In plant scale operations, multistage membrane systems have been adopted for cost minimization. We considered design optimization and operation of a continuous microfiltration (MF) system for the corn Dry Grind Process. The objectives were to develop a model to simulate a multistage MF system, optimize area requirements and stages required for a multistage system and perform economic analysis of a multistage MF system for a 40 million gal/yr ethanol plant. Total area requirement decreased with number of stages but there was tradeoff between higher capital costs involved at higher number of stages. To achieve thin stillage total solids concentration from 7 to 35%, a 5 stage membrane system was found to be optimum with area requirement of 655 m 2 for minimum cost. Increase in the input stream flow rate from 1.54 × 10 6 to 2.89 × 10 6 L/day significantly increased the total capital cost of the system by 47%. Compared to a single stage system, an optimal system had a 50% reduction in operating costs. Optimal system also showed potential to Process more than twice the amount of thin stillage compared to a 4 effect evaporator system for given conditions.
S R Eckhoff - One of the best experts on this subject based on the ideXlab platform.
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FUEL ETHANOL FERMENTATION OF DEGERMED AND DEHULLED CORN
2015Co-Authors: Taylor F. L, J. C. Craig, A. Mcaloon J. L, P. Yang, J. Wahjudi, S R EckhoffAbstract:In the U.S., fuel ethanol is made either from cornstarch, or from ground whole corn. The wet milling Process yields edible oil, and a high-protein animal feed, in addition to pure cornstarch, for which making fuel ethanol is just one of many valuable applications. The Dry-Grind Process is less capital-intensive, but distillers ' dried grains (DDGS), a widely used animal feed, is the only co-product. Neither Process is ideally suited to making low cost fuel ethanol. New corn milling technology developed at the University of Illinois at Urbana/Champaign (UIUC) recovers the valuable oil (Quick-Germ Process) and a purified fiber co-product (Quick-Fiber Process). The potential exists to integrate these Processes into the existing Dry-Grind Process, but the fermentability of the crude starch remaining after Quick-Germ has not been tested. Therefore, a series of carefully controlled and monitored pilot scale (50 L) fermentations was undertaken. The results showed that enough oil remained in the Quick-Germ mash to prevent foaming during fermentation. It was found that when Quick-Germ, Quick-Fiber and whole corn mashes were made up to the same initial concentration of fermentables in the liquid phase, the time from inoculation to finish the fermentation was the same for all 3 treatments. Computer modeling and comparative cost analysis indicate savings of 2 to 4 cents per gallon of ethanol with Quick-Germ. The savings are sensitive to the price of corn oil
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an engineering and economic evaluation of wet and Dry pre fractionation Processes for Dry Grind ethanol facilities
Bioresource Technology, 2011Co-Authors: Tao Lin, Luis F Rodriguez, S R EckhoffAbstract:An engineering–economic model was developed to compare the profitability of the wet fractionation Process, a generic Dry fractionation Process, and the conventional Dry Grind Process. Under market conditions as of January 2011, only fractionation Processes generated a positive cash flow. Reduced unit manufacturing costs and increased ethanol production capacity were two major contributions. Corn and ethanol price sensitivity analysis showed that the wet fractionation Process always outperformed a generic Dry fractionation Process at any scenario considered in this research. A generic Dry fractionation Process would provide better economic performance than the conventional Dry Grind Process if corn price was low and ethanol price was high. All three Processes would perform more resiliently if the DDGS price was determined by its composition.
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an engineering and economic evaluation of quick germ quick fiber Process for Dry Grind ethanol facilities model description and documentation
Bioresource Technology, 2010Co-Authors: Luis F Rodriguez, Tao Lin, Madhu Khanna, Aslihan D Spaulding, S R EckhoffAbstract:An engineering economic model, which is mass balanced and compositionally driven, was developed to compare the conventional corn Dry-Grind Process and the pre-fractionation Process called "Quick germ/Quick fiber". For the purposes of this model, the distillers dried grains with solubles price was correlated to its protein and fiber composition and the long-term average relationship with the corn price. This paper has been prepared to describe the development of the model and provide documentation for its use. This model can be used to provide decision support for ethanol producers considering the new emerging technologies that may provide sustainability to the business of ethanol production from corn.
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an engineering and economic evaluation of quick germ quick fiber Process for Dry Grind ethanol facilities analysis
Bioresource Technology, 2010Co-Authors: Luis F Rodriguez, Tao Lin, Madhu Khanna, Aslihan D Spaulding, S R EckhoffAbstract:Abstract An engineering economic model, which is mass balanced and compositionally driven, was developed to compare the conventional corn Dry-Grind Process and the pre-fractionation Process called quick germ–quick fiber (QQ). In this model, documented in a companion article, the distillers dried grains with solubles (DDGS) price was linked with its protein and fiber content as well as with the long-term average relationship with the corn price. The detailed economic analysis showed that the QQ plant retrofitted from conventional Dry-Grind ethanol plant reduces the manufacturing cost of ethanol by 13.5 ¢/gallon and has net present value of nearly $4 million greater than the conventional Dry-Grind plant at an interest rate of 4% in 15 years. Ethanol and feedstock price sensitivity analysis showed that the QQ plant gains more profits when ethanol price increases than conventional Dry-Grind ethanol plant. An optimistic analysis of the QQ Process suggests that the greater value of the modified DDGS would provide greater resistance to fluctuations in corn price for QQ facilities. This model can be used to provide decision support for ethanol producers.
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a review of economic energy analysis of the conventional and the modified Dry Grind ethanol Process
American Society of Agricultural and Biological Engineers Annual International Meeting 2009, 2009Co-Authors: Tao Lin, Luis F Rodriguez, S R EckhoffAbstract:Biofuels are one of many renewable energy technologies offering an opportunity to put our civilization on more sustainable ground. Ethanol currently constitutes 99% of all biofuels in the United States. To meet this demand, the current ethanol plant expansion in the industry is mainly based on the Dry Grind Process. Over the past several years, this industry is suffering great pressure with currently fluctuating feedstock prices. Several modified Dry Grind Processes have been developed aiming at increasing the profitability of the ethanol plant, and significant improvements have been observed on the Process efficiency and the value of coproducts. Previous economic analyses suggest that corn, ethanol and energy prices and ethanol yield are the four major factors that will affect the profitability of the conventional Dry Grind plants. However, for the modified Dry Grind Process, the composition of coproducts is another key factor. Thermal energy and electric power are two major forms of energy consumption in the ethanol plant. The amount of total energy consumption varies widely in previously published works, and those papers often lack detail on energy use at the unit Process scale. For these reasons, computer simulation will be an alternative to better understand the energy flow and the composition of various Processing streams in Dry Grind ethanol production, modified and otherwise. To evaluate the modified Dry Grind ethanol Process, an engineering economic model should consist of two parts: a chemical Process model illustrating the energy consumption and cost of the baseline plant and a user-friendly economic model, that chemical Process model should be directly linked to the economic model. Thus, both models should be mass balanced and compositionally driven enabling economic analyses sensitive to the quality, quantity, and variability of available feedstocks.
David B Johnston - One of the best experts on this subject based on the ideXlab platform.
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Evaporator Fouling Tendencies of Thin Stillage and Concentrates From the Dry Grind Process
Heat Transfer Engineering, 2016Co-Authors: Ravi Challa, David B Johnston, Mike E Tumbleson, Vijay Singh, Yizhe B. Zhang, Nicki J. Engeseth, Kent D. RauschAbstract:ABSTRACTIn the United States, more than 200 maize Processing plants use multiple-effect evaporators to remove water from thin stillage and steepwater during Dry Grind and wet milling Processes, respectively. During the Dry Grind Process, unfermentables are centrifuged and the liquid fraction, thin stillage, is concentrated in multiple effect evaporators. Evaporator fouling occurs during thin stillage concentration and may be from deposition of proteins, fat, fiber, and/or carbohydrates on evaporator surfaces. Studies on evaporator fouling from maize Processing streams are limited and fundamental causes are not well understood. Therefore, the overall objective was to investigate effects of compositional variation on evaporator fouling during thin stillage concentration. Effects of total solids during evaporator concentration, removal of post fermentation oil, corn oil and glycerol addition, and overall plant operation were studied. Thin stillage had lower fouling rates compared to evaporator concentrates. ...
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Effects of Protease and Urea on a Granular Starch Hydrolyzing Process for Corn Ethanol Production
Cereal Chemistry Journal, 2009Co-Authors: Ping Wang, David B Johnston, Kent D. Rausch, Mike E Tumbleson, Shelly J. Schmidt, Vijay SinghAbstract:ABSTRACT The Dry Grind Process using granular starch hydrolyzing enzymes (GSHE) saves energy. The amount of GSHE used is an important factor affecting Dry Grind Process economics. Proteases can weaken protein matrix to aid starch release and may reduce GSHE doses. Two specific proteases, an exoprotease and an endoprotease, were evaluated in the Dry Grind Process using GSHE (GSH Process). The effect of protease and urea addition on GSH Process was also evaluated. Addition of these proteases resulted in higher ethanol concentrations (mean increase of 0.3–1.8 v/v) and lower distillers' dried grains with solubles (DDGS) yields (mean decrease of 1.3–8.0% db) compared with the control (no protease addition). As protease levels and GSHE increased, ethanol concentrations increased and DDGS yields decreased. Protease addition reduced the required GSHE dose. Final mean ethanol concentrations without urea (15.2% v/v) were higher than with urea (15.0% v/v) in GSH Process across all protease treatments.
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Improvement in fermentation characteristics of degermed ground corn by lipid supplementation
Journal of Industrial Microbiology and Biotechnology, 2006Co-Authors: Ganti S. Murthy, David B Johnston, Kent D. Rausch, Vijay Singh, Mike E TumblesonAbstract:With rapid growth of fuel ethanol industry, and concomitant increase in distillers dried grains with solubles (DDGS), new corn fractionation technologies that reduce DDGS volume and produce higher value coproducts in Dry Grind ethanol Process have been developed. One of the technologies, a Dry degerm, defiber (3D) Process (similar to conventional corn Dry milling) was used to separate germ and pericarp fiber prior to the endosperm fraction fermentation. Recovery of germ and pericarp fiber in the 3D Process results in removal of lipids from the fermentation medium. Biosynthesis of lipids, which is important for cell growth and viability, cannot proceed in strictly anaerobic fermentations. The effects of ten different lipid supplements on improving fermentation rates and ethanol yields were studied and compared to the conventional Dry Grind Process. Endosperm fraction (from the 3D Process) was mixed with water and liquefied by enzymatic hydrolysis and was fermented using simultaneous saccharification and fermentation. The highest ethanol concentration (13.7% v/v) was achieved with conventional Dry Grind Process. Control treatment (endosperm fraction from 3D Process without lipid supplementation) produced the lowest ethanol concentration (11.2% v/v). Three lipid treatments (fatty acid ester, alkylphenol, and ethoxylated sorbitan ester 1836) were most effective in improving final ethanol concentrations. Fatty acid ester treatment produced the highest final ethanol concentration (12.3% v/v) among all lipid supplementation treatments. Mean final ethanol concentrations of alkylphenol and ethoxylated sorbitan ester 1836 supplemented samples were 12.3 and 12.0% v/v, respectively.
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modeling the Process and costs of fuel ethanol production by the corn Dry Grind Process
Industrial Crops and Products, 2006Co-Authors: Jason R Kwiatkowski, Andrew J Mcaloon, Frank Taylor, David B JohnstonAbstract:The corn Dry-Grind Process is the most widely used method in the U.S. for generating fuel ethanol by fermentation of grain. Increasing demand for domestically produced fuel and changes in the regulations on fuel oxygenates have led to increased production of ethanol mainly by the Dry-Grind Process. Fuel ethanol plants are being commissioned and constructed at an unprecedented rate based on this demand, though a need for a more efficient and cost-effective plant still exists. A Process and cost model for a conventional corn Dry-Grind Processing facility producing 119 million kg/year (40 million gal/year) of ethanol was developed as a research tool for use in evaluating new Processing technologies and products from starch-based commodities. The models were developed using SuperPro Designer ® software and they handle the composition of raw materials and products, sizing of unit operations, utility consumptions, estimation of capital and operating costs, and the revenues from products and coproducts. The model is based on data gathered from ethanol producers, technology suppliers, equipment manufacturers, and engineers working in the industry. Intended applications of this model include: evaluating existing and new grain conversion technologies, determining the impact of alternate feedstocks, and sensitivity analysis of key economic factors. In one sensitivity analysis, the cost of producing ethanol increased from US$ 0.235 l −1 to US$ 0.365 l −1 (US$ 0.89 gal −1 to US$ 1.38 gal −1 ) as the price of corn increased from US$ 0.071 kg −1 to US$ 0.125 kg −1 (US$ 1.80 bu −1 to US$ 3.20 bu −1 ). Another example gave a reduction
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Effect of B vitamin and Lipid Supplementation to Improve Fermentation Characteristics of the Modified Dry Grind Process
2006 Portland Oregon July 9-12 2006, 2006Co-Authors: Ganti S. Murthy, David B Johnston, Kent D. Rausch, Vijay P. Singh, Mike E TumblesonAbstract:Fractionation technologies that produce higher value coproducts from Dry Grind corn Processing have been developed. In one of the fractionation technologies, Dry degerm defiber (3D) Process, separation of germ and pericarp fiber is performed prior to fermentation of the endosperm fraction. Fermentation characteristics of endosperm fraction from the 3D Process are inferior to ground whole corn because of a deficiency in lipids essential for yeast growth. Lipid supplementation and B vitamins separately improved glucose utilization and increased ethanol concentration. In this study, combinations of B vitamins and lipids were used to evaluate synergistic effect of two micronutrients added during the fermentation of endosperm fraction from 3D Process. Combinations of B vitamins and lipids enhanced ethanol production by improving glucose utilization (due to B vitamins) and higher ethanol tolerance (due to lipid supplements). All lipid and B vitamins treatments had higher final ethanol concentrations compared to control with no added supplements. One of the six lipid supplements tested showed higher ethanol concentrations compared to other lipid supplements. Higher fermenter productivity and higher final ethanol concentrations can be achieved by lipid and B vitamin supplementation of endosperm fraction from 3D Process.
