Biofuels Journal - January/February 2008 - (Page 46)

Sequential Extraction Ethanol Process Could Provide Many High-Value Co-Products dry mill now, also affecting the cost of constructing a plant. He estimates the sequential extraction process could double the cost of building a plant, but wants to re-engineer the process to reduce that upfront investment. Even though the initial investment would be high, Johnson said, the resulting co-products would more than pay for the initial investment, bringing in as much as twice the number of dollars per bushel of corn. How the Process Works Dr. Lawrence Johnson of Iowa State University is seeking funding to study a process that could make ethanol plants more profitable. A radical approach to producing ethanol involving fractionation and “borrowing” ethanol is the focus of a new study by Lawrence Johnson, director for the Center for Crops Utilization Research at Iowa State University, Ames, IA. Johnson (515-294-0160) plans to apply to the Iowa Power fund in December for a grant to support the study that will update the economic models associated with the process for current-sized dry mill ethanol plants. This would be Johnson’s second study into the sequential ethanol extraction process. Johnson’s original study, funded by the Governor’s Great Lakes Council and completed in 1994, determined that the sequential extraction process could be profitable for a 20 million-gallon-peryear (MMGY) wet mill ethanol plant. “Back then, a 20 MMGY plant was big,” Johnson said. “Now that would be considered small.” The sequential extraction process could create several high-value co-products such as oil and protein, could save a step in the process, and potentially produce more ethanol. In addition, most ethanol plants are Johnson’s process involves simultaneous ethanol drying and oil extraction and extraction of zein while producing a food-grade protein concentrate. “In one step, we’re extracting the oil and zein and drying the ethanol,” Johnson said. “We borrow the alcohol in the process, we are not consuming it,” Johnson continued. Normally, ethanol producers use molecular sieves to distill ethanol from 95% to 100% by removing the last remnants of moisture. “In a conventional process, molecular sieves are the dehydration step,” Johnson said. “In our process, by borrowing the alcohol, we accomplish dehydration and get the oil and zein at the same time.” He said in theory, this should save ethanol producers money because of a reduced step in the ethanol process. Co-Products able. We envision that being used for food purposes for human consumption.” In addition, the sequential extraction process could be modified to also separate some cellulose that could then be fermented with modern cellulosic ethanol techniques, producing even more ethanol per bushel of corn, he said. The other co-products, such as the oil, which is red in color, could be used as a feedstock for biodiesel, Johnson said. He said it could also have pharmaceutical value. Zein has been utilized as a coating for confectionery nuts to prevent oxidative rancidity and even in paper cups, soda bottle cap linings, clothing fabric, buttons, adhesives, coatings and binders. Seeking Funding Now The process “sat on a shelf” for several years because at the time, ethanol plants were not large enough to make this economically feasible, Johnson noted. But this fall, he decided to take a fresh look at it and is seeking funding to update the economic models. “What I’m looking to do with the grant is a reassessment of the economics,” Johnson said. “Let’s update the information and re-run the model to see where we’re at today.” He said if this turns out to be as economically attractive as he thinks it will, he will investigate engineering techniques to make it even more economical. Myke Feinman, editor In this process, ethanol is one of many high-value co-products. “You have to think like a protein company,” Johnson said. “Ethanol becomes a co-product. Zein is more valuable on a per pound basis. Oil is more valuable on a per pound basis. The other food-grade protein fraction is more valu- “In our process, by borrowing the alcohol, we accomplish dehydration and get the oil and zein at the same time.” - Lawrence Johnson, Iowa State University 46 BFJ | JAN/FEB 08

Table of Contents Feed for the Digital Edition of Biofuels Journal - January/February 2008

Biofuels Journal - January/February 2008 Contents Biofuels Safety Lockout/Tagout Managing Safety Ethanol Incidents Hot Work Safety Arresting Falls Firefighting Foam Confined Spaces Natural Fiber Clothing LifeLine Foods - St. Joseph, MO Sen. Richard Lugar, R-Indiana A New Energy Era POET - Portland, IN Company Profile, OPW State Ethanol Promotion State Report: Nebraska Anti-Lignin Beetles Sequential Extraction Developing Energy Crops Stover Logistics Cellulosic Ground Covers DDGS to Feed Fish Miscanthus: Energy Crop Webinar Series Launched New Fractionation Process Tropical Maize Ethanol Synthetic Fuel High Starch Corn Testing Abengoa's Cellulosic Ethanol Plans Credits and Incentives POET Cob Harvest High Oil Corn SunOpta Steam Explosion Process Enough Water? Ethanol Water Use Seth Snyder, Argonne National Laboratory Continuous Fermentation ACE Blend Study Wood Waste Ethanol Fodder Beet Ethanol Monthly Ethanol Production Ethanol Terminal Wood Feedstock Carbon Credits Bio Motor Oil Ethanol Bacteria Ethanol Pipeline Ethanol Plant Construction - Canada Cellulosic Ethanol Plants Under Consideration Cellulosic Ethanol Plants Construction Map In the Pipeline Ethanol Blending History Ethanol World Calendar Profile: Zabler, Pine Lake Corn Processors Industry News Western Dubuque Biodiesel - Farley, IA Profile: Winkel, Central Iowa Energy Biodiesel Construction List Biodiesel Plants Under Construction Map Wet vs. Dry Biomass Storage Book Review Green Earth Fuels - Houston, TX Biodiesel News Alternative Feedstocks Glycerol as Feed EPA Requires Standards Mustard Biodiesel Sun Grant Initiatives Biodiesel Jet Glycerol Alternatives Platts Advanced Biofuels Seminar Cellulosic Heating Oil Glycerine Used for Ethanol Blackmer Fremont Industries Biomass Association DOE Grants $7.7 Million for Biofuels Aecometric Corp. Civacon Viking Pump, Inc. SimplexGrinnell ICM Inc. Applied Milling Systems Ad Index

Biofuels Journal - January/February 2008

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