energy saving in ethanol production during the mashing process · energy saving in ethanol...
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Hohenheim University, Section of Fermentation Technology, Research Distillery
Energy Saving in Ethanol Production During the Mashing Process
3. European Bioethanol Technology Meeting
Association of Cereal Research, Detmold (Germany)
24. – 25. April 2007
PD Dr. Thomas Senn
Hohenheim University, Section of Fermentation Technology, Research Distillery
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
Hohenheim University, Section of Fermentation Technology, Research Distillery
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 fermentationat 32-34°C
– Enzymes» Spirizyme Fuel + Alcalase
• Isostab 30 ml / m³ of mash• Urea 400g / m³, Phosphoric Acid 100g/m³
Hohenheim University, Section of Fermentation Technology, Research Distillery
Use of thermostable Xylanase Gammaxylanase HTL
Mash viscosity without Xylanase
Hohenheim University, Section of Fermentation Technology, Research Distillery
Einsatz thermostabiler XylanaseGammaxylanase HTL
Mash viscosity using Xylanase
Hohenheim University, Section of Fermentation Technology, Research Distillery
Dependency of EtOH Concentration on DS % in Mash
y = 0,32x + 1,9557R2 = 0,9857
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15 20 25 30 35 40
DS %
%vo
l A
Hohenheim University, Section of Fermentation Technology, Research Distillery
Dependency of Ethanol Yield LA/100 kg Wheat on DS % in Mash
y = -0,4564x + 53,446R2 = 0,8617
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39
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15 20 25 30 35DS %
LA/1
00 k
g W
heat
Hohenheim University, Section of Fermentation Technology, Research Distillery
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
Hohenheim University, Section of Fermentation Technology, Research Distillery
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 48 - 52 h
• The process has to be tailored to each plant• Low viscosities lead to benefits in fermentation,
cooling, pumping, stirring, destillation...
Hohenheim University, Section of Fermentation Technology, Research Distillery
Mash Preparation „Genencor Standard“
• Stillage backset 25%; pH 5,7; 57-58°C; 30 min• Enzymes
– Spezyme Ethyl + Optimash BG• Liquifaction at 85°C; 60 min• Start of saccharification and fermentation at
32-34°C• Enzymes
– Fermenzyme L 400 + Protease GC 106• Isostab 30 ml / m³ of mash
Hohenheim University, Section of Fermentation Technology, Research Distillery
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 32-34°C
• Enzymes– Gammaclast 2 OP + SAN Super 360 L (20%)
• Isostab 30 ml/m³ of mash
Hohenheim University, Section of Fermentation Technology, Research Distillery
Mash Preparation „STARGEN“
• Stillage backset 25%; pH 3,8-4,2; 56-57°C; 2h• Enzymes
– GC 626 + Optimash BG
• Start of saccharification and fermentation at 31-32°C; pH at start 3,5-3,6
• Enzymes– STARGEN 001 + GC 106
• Isostab 30 ml/m³ of mash
Hohenheim University, Section of Fermentation Technology, Research Distillery
Duration of Fermentations
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12
0,00 10,00 20,00 30,00 40,00 50,00 60,00 70,00 80,00
Time h
%vo
l EtO
H
Genencor Standard
STARGEN
Hohenheim University, Section of Fermentation Technology, Research Distillery
STARGEN Fermentation time: 3h
Hohenheim University, Section of Fermentation Technology, Research Distillery
STARGEN Fermentation time: 3h
Hohenheim University, Section of Fermentation Technology, Research Distillery
STARGEN Fermentation time: 21h
Hohenheim University, Section of Fermentation Technology, Research Distillery
STARGEN Fermentation time: 21h
Hohenheim University, Section of Fermentation Technology, Research Distillery
STARGEN Fermentation time: 69h
Hohenheim University, Section of Fermentation Technology, Research Distillery
Contents of Extract and Ethanol During Fermentation Hohenheim Process
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5
10
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25
30
0 20 40 60 80 100Time (h)
Extra
ct (%
mas
)
0
2
4
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10
12
Etha
nol (
%m
as)
Extrakt Alkohol
Hohenheim University, Section of Fermentation Technology, Research Distillery
STARGEN Process: "Extract Contents" from different mashes
0
2
4
6
8
10
12
3 21 21 24 27 68 69
Time h
Con
tent
g/L
GlycerolLactic acidDP3DP2DP1
Hohenheim University, Section of Fermentation Technology, Research Distillery
Ethanol Yield from Triticale Using Different Enzyme Systems
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Genencor Hohenheim StargenEnzymes
LA /
100
kg G
rain
Hohenheim University, Section of Fermentation Technology, Research Distillery
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.....
Hohenheim University, Section of Fermentation Technology, Research Distillery
Thank You Very Muchfor
Your Attention