Energy Saving in Ethanol Production During the Mashing Process
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1 Energy Saving in Ethanol Production During the Mashing Process 3. European Bioethanol Technology Meeting Association of Cereal Research, Detmold (Germany) April 2007 PD Dr. Thomas Senn
2 Energy Saving in Mashing Process High gravity mashing DS% up to 35% Less water to heat up STARGEN-Process Maximum temperature of 59 C in mashing No additional thermal energy during mashing if hot water or stillage backset is used
3 High Gravity Mashing Mashing Conditions Stillage backset 25%; ph 5,0-5,2; 50 C; 30 min Enzymes» Liquozyme + Viscozyme Wheat Liquifaction at 85 C; 60 min» Start of saccharification and fermentation at C Enzymes» Spirizyme Fuel + Alcalase Isostab 30 ml / m³ of mash Urea 400g / m³, Phosphoric Acid 100g/m³
4 Use of thermostable Xylanase Gammaxylanase HTL Mash viscosity without Xylanase
5 Einsatz thermostabiler Xylanase Gammaxylanase HTL Mash viscosity using Xylanase
6 Dependency of EtOH Concentration on DS % in Mash y = 0,32x + 1,9557 R 2 = 0,9857 %vol A DS %
7 Dependency of Ethanol Yield LA/100 kg Wheat on DS % in Mash 47 LA/100 kg Wheat y = -0,4564x + 53,446 R 2 = 0, DS %
8 High Gravity Mashing 350 kg Wheat or Triticale / 1000 L of mash Add thermostable Xylanases with liquifaction enzymes After Liquifaction rest ph is lowered to 4,0 Dilute mash to ~ 1,6 m³ Simultaneous saccharification and fermentation
9 High Gravity Mashing - Conclusion Fermentation efficiency drops, if the ethanol content in the fermented mashes exceeds 10%vol EtOH Benefits can be used if mashes are diluted before fermentation cooling!! Fermentation to 10%vol EtOH can be finished within h The process has to be tailored to each plant Low viscosities lead to benefits in fermentation, cooling, pumping, stirring, destillation...
10 Mash Preparation Genencor Standard Stillage backset 25%; ph 5,7; C; 30 min Enzymes Spezyme Ethyl + Optimash BG Liquifaction at 85 C; 60 min Start of saccharification and fermentation at C Enzymes Fermenzyme L Protease GC 106 Isostab 30 ml / m³ of mash
11 Mash Preparation Hohenheim Stillage backset 25%; ph 5,7 Liquifaction at 85 C; 60 min Enzymes Liquozyme + Gammazyme HTL Start of saccharification and fermentation at C Enzymes Gammaclast 2 OP + SAN Super 360 L (20%) Isostab 30 ml/m³ of mash
12 Mash Preparation STARGEN Stillage backset 25%; ph 3,8-4,2; C; 2h Enzymes GC Optimash BG Start of saccharification and fermentation at C; ph at start 3,5-3,6 Enzymes STARGEN GC 106 Isostab 30 ml/m³ of mash
13 Duration of Fermentations %vol EtOH Genencor Standard STARGEN 0 0,00 10,00 20,00 30,00 40,00 50,00 60,00 70,00 80,00 Time h
14 STARGEN Fermentation time: 3h
15 STARGEN Fermentation time: 3h
16 STARGEN Fermentation time: 21h
17 STARGEN Fermentation time: 21h
18 STARGEN Fermentation time: 69h
19 30 Contents of Extract and Ethanol During Fermentation Hohenheim Process Extract (%mas) Ethanol (%mas) Time (h) Extrakt Alkohol
20 Content g/l STARGEN Process: "Extract Contents" from different mashes Glycerol Lactic acid DP3 DP2 DP Time h
21 Ethanol Yield from Triticale Using Different Enzyme Systems LA / 100 kg Grain Genencor Hohenheim Stargen Enzymes
22 STARGEN Process Maximum temperature 59 C Simultaneous starch degradation from native granules, saccharification and fermentation It should be possible to finish fermentation within 60 h ( max 10%vol EtOH ) Fermentation was free from infections without problems although we used a traditional yeast mash Low temperature and viscosities lead to energy savings in cooling (water), pumping, stirring...
23 Thank You Very Much for Your Attention
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