Alcohol Education and Processing Effects of Small Grains

Craig Pilgrim

Global Marketing Manager

EPAC conference

Billings, Montana

June 26, 2012

Outline

• Lallemand (brief overview)• Educational Aspects

Schools and learning

• Example of training• Small grains

Production values Composition Starch and Non Starch Polysaccharides Enzymes and viscosity Processing issues Fermentation issues

• Summary

Lallemand in 2012

• Develops, produces and markets yeasts, bacteria and other ingredients derived from those microorganisms for: bakeries (65% of sales) wine, beer and alcohol producers (as well as fuel

ethanol industry) animal and human nutrition industries,

pharmaceutical industry other food and agricultural industries

• Over 2500 employees (of which 70+ in R&D) in over 35 countries on 5 continents

Our core activity

Development, production and marketing of…

…and their derivatives

Yeast Bacteria

Ethanol Technology Institute

Publications Educational Activities

The Alcohol School – Toulouse/Montreal

• Now in 31st year of running this class • Organized by Prof Graeme Walker,

Ethanol Technology Institute• Non-commercial • Mix of internal and reputable guest

speakers• Directed towards:

Senior operational staff Laboratory staff Experienced operators/Shift leads

• Agenda covers whole process at mid to high level

• Some new technology/developmental topics included

The Operators’ School

• In fourth year of operation. • Mix of lectures and hands on demonstrations• Organized by the Ethanol Technology Institute• Non-commercial• Directed towards operators and less experienced

managers/shift leads• Predominantly in house trainers• Agenda covers complete process including both batch and

continuous• Significant aspect of troubleshooting including worked

examples/role play

The Alcohol Textbook

Ethanol Technology Institute publishes “The Alcohol Textbook”• The most comprehensive book

on alcohol production.• Team of internal and external

writers. Edited by Dr. Mike Ingledew, Glen Austin and Dave Kelsall.

• 5th edition recently published.

Example of educational training

• Why training and educational aspect? Been a part of landscape for more than 30 years Focus on increasing operations knowledge, better trained

personnel

• Focus on Montreal is more North America and related grain processing Corn as main substrate

• Focus in Toulouse is more on Rest of World Small grains is the main topic

• The rest of this presentation will discuss aspects of small grain processing and those educational opportunities.

Global Small Grain Production

United States Department of Agriculture, Avg. 2008-2010 Crop Years

Raw material usage in US

• Corn is KING!• Majority of ethanol producing facilities are

using corn.• Some plants, based on locations are

using milo, sorghum, barley or wheat.• Inherent issues using small grains

Depending on grain, starch content might be less

Processing could be a bit more difficultEquipment usage and wearViscosity

• However, in other parts of the world, small grains are prevalent.

Raw Material Usage for EU

• Mostly wheat, sugar beet juice, barley and maize.

• Small grains effect production costs.

• To minimize costs, blends of products may be used.

Source: eBio

Grain Composition

Wheat Triticale Rye Barley Corn Sorghum

Small grain challenge

The small grains contain high concentrations of NSPs which, have high water-binding capacity leading to increased mash viscosity

Protein middle lamella

Outer wall(-Glucan and pentosan)

Inner cell wall (-Glucan)

Starch granules

Protein matrix

Endosperm Cell Structure

The small grains contain high concentrations of Non Starchy Polysaccharides (NSPs) which, have high water-binding capacity leading to increased mash viscosity

Source: Novozymes

Grain Composition

Component% content of dry matter

Corn Wheat Barley Rye Sorghum Millet

Protein 9-12 12–14 10-11 10-15 11-12 15.4

Fat 4.5 3.0 2.5-3.0 2.0-3.0 3.6 3.9

Starch 65-72 67-70 52-64 55-65 72-75 70.8

Ash 1.5 2.0 2.3 2.0 1.7 1.2

Total cell wall material 9.6 11.4 14.0 14.6 n/a n/a

Water extractable non-starchy polysaccharides:

Arabinoxylans 0.03 0.6 0.3 1.4 nil nil

Beta-glucans 0.05 0.14 2.4 0.8 nil nil

Starch Structure

Amylose

Amylopectin

High viscosity

High rigidity

Starch breakdown

• “Normal” starch breakdown is relatively easy using heat and enzymes.

• Long chained polymers known as “dextrins” are broken down with alpha amylase. This reduces viscosity fairly quickly and easily.

• Once that happens, another enzyme is added at fermentation known as glucoamylase.

• This breaks down the long chains into single glucose units.

• Glucose is the primary and preferred source of sugar used by yeast to convert to ethanol.

Non Starch Polysaccharides of Cereal Grains

• Arabinoxylan:

Especially in wheat, rye and barley. Xylan backbone with L-arabinofuranose (L-arabinose in 5-atom ring form)

• Beta-glucan:

Linear unbranched beta-D-glucose with one beta-1,3 every 3 or 4 beta-1,4 linkages; in bran of grains

Cereal Grain Non-starch Polysaccharides

Need enzymes Need enzymes

Source: Novozymes

Viscosity Reducing Enzymes Composition of Grains

Needs Beta Glucanase

Needs Xylanase

Can be convertedto fermentablesugars

• Beta Glucans and Pentosans are the main cause of high mash viscosities• These “Hemicelluloses” also create problems in thin stillage evaporation

and dewatering of fermentation solids

Source: Genencor

NSP Comparison in various grains

Wheat Barley Rye Corn0

0.5

1

1.5

2

2.5

3

Beta-glucaner

Arabinoxylaner

% W

ate

r-e

xtr

ac

tab

le N

SP

Non Starch Polysaccharides of Grains-Impact on processing grains to ethanol-

• Grains like rye, barley, triticale and wheat contain high levels of hemicelluloses (Beta Glucans, Pentosans) = high viscosity due to high water-binding capacity

• Consequences: This reduces the efficiency of Heat exchange operation Centrifugal separation of solids Evaporation Mass transfer in fermentation

• Limited solids concentration in mashing

• Negative effect on the energy balance of the process. (lower solids, higher water content, lower ethanol yield, etc.)

• Residual Hemicelluloses may contribute to fouling of heat

exchangers and distillation equipment

Source: Genencor

Composition of Non Starch Polysaccharides of Cereal Grains

Common Name

Water soluble

Specific viscosity

Primary monomer Linkage Monomer

fermentable

Beta Glucan Yes* High Glucoseβ 1,4 +

β 1,3Yes

Cellulose No Low Glucose β 1,4 Yes

Arabinoxylan Yes* High Xylose, Arabinose

β 1,4

β 1,3 + β 1,2No

Fructan Yes Low Fructose β 2,6 + β 2,1 Yes

* Depending on extraction conditions and specific composition

Summary - Processing Small Grains

• Milling may be slightly different on equipment wear depending on substrate and variety.

• Because of viscosity issues with NSP’s, secondary enzymes will have to be used. (Barley and rye definitely, wheat, depending on variety).

• Because of viscosity issues, % solids in fermentation may have to be lower than compared to corn.

• Dryhouse may have to be equipped to handle slightly larger volumes and lowers solids syrup.

• Seasonal and strain differences in substrate will effect processing more than compared to corn (fairly constant)

Fermentation

• Should be fairly comparable to corn or any other starch substrate fermentation.

• Things to look for include: Lower solids fermentations. Foaming may vary due to substrate and age Because small grains composition, fermentation yield may

decrease because of availability of fermentable sugars.

Fermentation

• Time• Nutrients• Antifoam

Fermentation

• Time May take slightly longer due to viscosity

issues, mass transfer issues, sugar composition, etc.

May be offset due to lower solids required in some cases.

• Nutrients• Antifoam

Fermentation

Thomas and Ingledew, 2006

FAN (mg/L Mash)Total Usable

Wheat 82 64

Barley 84 62

Hulless Barley 124 100

Oats 193 159

Hulless Oats 184 130

Rye 103 83

Corn 70 58

Starch Slurry ~ 0 ~ 0

FAN values normalized to 20% DS

• Time• Nutrients

Usually comparable to corn, but nutrient package may have to be used as well

• Antifoam

Fermentation

• Time• Nutrients• Antifoam

Due to lower inherent oil levels in these substrates, foaming may be an issue.

Antifoams may have to be used in fermentation.Corn oil could be used as well. Depending on

what DDGS are used for.

Summary

• Small grains can be used for ethanol production

• Not prevalent in US, but could be used if necessary. Dependant on areas of US that could grow the crops.

• There are some inherent challenges to using small grains. Mainly viscosity issues and starch content

• Small grains are successfully used in other parts of the world for biofuels production.

Summary

• Education and Training are key in understanding various processes and substrates.

• This is type of presentation you would see in our various schools.

• For more information, please see www.ethanoltech.com