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Overview of Fuel Ethanol Production and Distillers Grains Kurt A Iowa State University From the SelectedWorks of Kurt A. Rosentrater 2012 Overview of Fuel Ethanol Production and Distillers Grains Kurt A. Rosentrater, United States Department of Agriculture Available at: https://works.bepress.com/kurt_rosentrater/218/ 2 Overview of Fuel Ethanol Production and Distillers Grains Kurt A. Rosentrater CONTENTS 2.1 Introduction ................................. :............................................................................................. 7 2.2 The Fuel Ethanol Industry--Current and Past.. ........................................................................ 8 2.3 The Fuel Ethanol Industry-Questions and Controversies ..................................................... 10 2.4 Ethanol Manufacturing ........................................................................................................... 18 2.5 Importance of Coproducts from Ethanol Production .............................................................. 19 2.6 Coproduct Constraints and Challenges ................................................................................... 23 2. 7 Improvement of Ethanol Production, Coproduct Quality, and End Uses ............................... 27 2.8 Conclusions ............................................................................................................................. 30 References ........................................................................................................................................ 30 2.1 INTRODUCTION Modern societies face many challenges, including growing populations, increased demands for food, clothing, housing, consumer goods, and the concomitant raw materials required to produce all of these. Additionally, there is a growing need for energy, which is most easily met by use of fossil fuels (e.g., coal, natural gas, and petroleum). In 2008, the overall U.S. demand for energy was 99.3 x 1015 Btu (1.05 x 1014 MJ); 84% of this was supplied by fossil sources (U.S. EIA, 2009). Transportation fuels accounted for 28% of all energy consumed during this time, and nearly 97% of this came from fossil sources. Domestic production of crude oil was 4.96 million barrels per day, whereas imports were 9.76 million barrels per day (nearly two-thirds of the total U.S. demand) (U.S. EIA, 2009). Many argue that this scenario is not sustainable in the long term, for a variety of reasons (such as the need for energy independence and global warming), and other alternatives are needed. Biofuels, which are renewable sources of energy, can help meet some of these increasing needs. They can be produced from a variety of materials, including cereal grains (such as corn, barley, and wheat), oilseeds (such as soybean, canota, and flax), sugary crops (such as sugar canes), legumes (such as alfalfa), perennial grasses (such as switchgrass, miscanthus, prairie cord grass, and others), agricultural residues (such as com stover and wheat stems), algae, food processing wastes, and other biological materials. Indeed, the lignocellulosic ethanol industry is poised to consume large quanti­ ties of biomass. At this point in time, however, the most heavily used feedstock for biofuel produc­ tion in the United States is corn grain, because industrial-scale alcohol production from com starch is readily accomplished, and at a lower cost, compared to other available biomass substrates. The most commonly used process for the production of fuel ethanol from corn is the dry grind process (Figure 2.1), the primary coproduct of which is distillers dried grains with solubles (DDGS). The goals of this chapter are twofold: (1) to briefly describe the current fuel ethanol industry, how the industry has evolved to its current state, and controversies surrounding this industry; and (2) to 7 8 Distillers Grains: Production, Properties, and Utilization Raw corn Thin stillage Dewatering Distillers wet grains Condensed distillers solubles DDGS '-----,----' Water & nonfermentable solids Ethanol FIGURE 2.1 Simplified flow chart of dry grind fuel ethanol production. briefly discuss ethanol and coproduct manufacturing practices, explain the importance of coprod­ ucts, and describe how coproduct quality and potential uses are expanding as the industry continues to evolve. 2.2 THE FUEL ETHANOL INDUSTRY-CURRENT AND PAST Ethanol is a combustible material that can readily be used as a liquid fuel. It has, in fact, been used for this purpose for more than 150 years (see Chapter 3), although up until recent times the industry has been quite small. The modern corn-based fuel ethanol industry, however, has reached a scale that can augment the nation's supply of transportation fuels. In 2008, for example, ethanol displaced more than 321 million barrels of oil (Urbanchuk, 2009), which accounted for nearly 5% of all oil imports. To help meet the increasing demand for transportation fuels, the number of ethanol plants has been rapidly increasing in recent years, as has the quantity of fuel ethanol produced (Figure 2.2). At the beginning of 2011, however, that number had risen to 204 plants with a production capac­ ity of nearly 51.1 billion L/y (13.5 billion gaily) (www.ethanolrfa.org). And, over the next several years, the Renewable Fuel Standard (RFS) mandates the use of 15 billion gal/y (56.8 billion Lly) of renewable biofuels (i.e., primarily corn-based ethanol). Because the industry is dynamic and still growing, the current production numbers will likely be outdated by the time this book is pub­ lished. As production volume increases, the processing residues (known collectively as "distillers grains"-Figure 2.3) will increase in tandem (as shown in Figure 2.2). It is anticipated that over 40 million metric tonnes (t) of distillers grains (wet and dry) will eventually be produced by the U.S. fuel ethanol industry. Over the last decade, while many new fuel ethanol plants have been built, considerable innova­ tions have occurred in the industry, not only in production processes used and final products pro­ duced, but also in terms of optimizing raw materials, water, and energy consumed. Some of these innovations have arisen with the advent of dry grind processing. Due to many advantages, including erties, and Utilization Overview of Fuel Ethanol Production and Distillers Grains 9 16000 45 --tr-Ethanol production 40 14000 -- RFS mandated. production -B- DDGS generation 12000 35 "'0...... X 30 "' 10000 ......0 ~ X ~ 25 0 8000 3 t:: 20 Vl es -5QJ 0 6000 "0 ] . 15 4000 10 2000 5 Year FIGURE 2.2 Trends in fuel ethanol production over time, and estimated DDGS generation; RFS denotes levels mandated by the RFS. (Adapted from RFA, 2009b. Industry Resources: Co-products. Renewable Fuels Association: Washington, DC. Available online: www.ethanolrfa.org/pages/industry-resources/coproducts/; RFA, 2009c. Growing Innovation. 2009 Ethanol Industry Outlook. Renewable Fuels Association. Washington, DC. Available at: www.ethanolrfa.org/pages/annual-industry-outlook/.) mportance of coprod­ :he industry continues . It has, in fact, been until recent times the however, has reached for example, ethanol ounted for nearly 5% of ethanol plants has roduced (Figure 2.2). 1 a production capac­ over the next several tl/y (56.8 billion Lly) 1stry is dynamic and ime this book is pub­ FIGURE 2.3 An example of distillers dried grains with solubles (DDGS), as it is currently available from ectively as "distillers most fuel ethanol plants (author's photograph). ticipated that over 40 lower capital and operating costs (including energy inputs), most new ethanol plants are dry grind produced by the U.S. facilities (Figure 2.4) as opposed to the older style wet mills. In 2002, 50% of U.S. ethanol plants were dry grind; in 2004 that number had risen to 67%; in 2006 dry grind plants constituted 79% of considerable innova­ all facilities; and in 2009 the fraction had grown to over 80% (RFA, 2009c). id final products pro­ Most ethanol plants are centered in the Midwest and north-central portions of the United umed. Some of these States-which happens to coincide with the primary production region for corn (i.e., fermentation tdvantages, including substrate)-the Corn Belt. But, in recent years, ethanol plants have been built in other states as well. 10 Distillers Grains: Production, Properties, and Utilization FIGURE 2.4 A typical dry grind corn-to-ethanol manufacturing plant. This plant has a nominal production capacity of approximately 120 million gaily (450 million Lly) (author's photograph). For example, in 2002, there were ethanol plants in 20 states; in 2009, however, there were plants in 26 states (Figure 2.5). Some of these plants are so-called destination plants, which are located near concentrated ethanol markets, and the raw corn is shipped to the plant. This scenario is the inverse of those plants that are located in the Corn Belt. It is true that as the industry has grown, the concomitant consumption of corn has grown as well (Figure 2.6). In 2008, for example, over 30% of the U.S. corn crop was used to produce ethanol. When examining these numbers, however, it is important to be aware of several key points: exports have been relatively constant over time, there has been a slight decline in the corn used for ani­ mal feed, and the overall quantity of corn that is produced by U.S. farmers has been substantially increasing over time. Thus, it appears that the corn that is used to produce ethanol is actually arising mostly from the growing corn supply; it is also slightly displacing use for livestock feed. It is also
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