Energetic Optimization of DDGS

Dr. Ludolf Plass

Dr. Peter Pötschacher

Detmold 24.04.2007

The Blue Planet at NightDistribution of Energy Consumption

Fulfilling Mankind's NeedsA Challenge for the Technology

How to fulfill mankind's needs in futureHow to fulfill mankind's needs in future?

How to overcome the imbalance between How to overcome the imbalance between industrialized and developing countries?industrialized and developing countries?

From Natural Resources to Consumers‘ Products

CrudeOil

Bio ResourcesBio Mass

CoalGasCondensates

Natural GasAssociated

Gas

BDO-Anlage

SpecialtiesAbtrennung

n-/iso-butanTrennung

MEK-Synthese

BDO-AnlageFood

SpecialtiesTechnical

Applications

Fuels &Fueladditives

PolymersPlastics

HealthHygienics

Upgrading/Conversion

Purification/ Treatment

„Natural“ Resources

Consumers` Requirements

Energy

Util

izat

ion

CrudeOil

Bio ResourcesBio Mass

CoalGasCondensates

Natural GasAssociated

Gas

BDO-Anlage

SpecialtiesAbtrennung

n-/iso-butanTrennung

MEK-Synthese

BDO-AnlageFood

SpecialtiesTechnical

Applications

Fuels &Fueladditives

PolymersPlastics

HealthHygienics

Upgrading/Conversion

Purification/ Treatment

„Natural“ Resources

Consumers` Requirements

Energy

Util

izat

ion

02468

10121416182022242628

1970 1980 1990 2020 2050

Nuclear energy Coal Petroleum Natural gas Water pow er Other renew able energies

Billion tons of coal equivalent

Source: BP (until 2001), World Energy Council

7.910.4

12.6

14.219.4

27.1

ca. 50%

ca. 50%

• Even in 2050, gas/oil will still cover around 50% of world energy demand

• But coal consumption shows the strongest increase

World Energy Consumption by Energy Source

EU 1st Generation Biofuel Marketwhen meeting the EU Directive

EU 15 States; all notes in 1000 t, Basis Fuel Consumption 1998References: EU-Commision (KOM (2001) 547 fin.)

Feedstock Bioethanol

StarchStarch11stst Generation Generation

SugarSugar11stst GenerationGeneration

CelluloseCellulose22stst GenerationGeneration

wheatwheatbarleybarleycorncornryeryemilomilo

potato, cassava potato, cassava sweet potatosweet potato

ByBy--products fromproducts fromwet millingwet milling

cane molassescane molassesbeet molassesbeet molasses

syrupssyrupsjuicesjuices

ininR & DR & D

Bio-ethanol Process for starch containing feedstock

FeedstockFeedstock

ProductsProducts

Corn oilCorn oil

GlutenGluten

BranBran

StarchStarch

EthanolEthanol

EthanolEthanol

DDGSDDGS

COCO22

...

GlucoseGlucose

HFSHFS

SorbitolSorbitol

Wet MillingWet Milling Dry MillingDry Milling

Feedstock

Milled Grain

Mash

Grain ReceivingCleaning/Storage/

Milling

Fermentation

Stillage Water

Hydrolysis/Liquefaction

StillageSeparation

Thin StillageEvaporation

Back-Set

Wet Cake

Thin StillageStillage

DistillationDehydration

BeerEthanol 99%

STEAM

Dry Milling Process / Upstream

Waste Water

Anaerobic Treat.Methanator/

Filtration

Cooling Tower

Wet Cake

Thin StillageEvaporation

Syrup

Dryer VapourDDGSDrying

DDGS

NaturalGas STEAM

Dry Milling Process / Downstream

Double Column Distillation

MASH

CRUDE ETHANOL

STILLAGE WATER

STILLAGESEPARATION

CO2 / ALDEHYDES

MASH COLUMN (ATM.)

MASH COLUMN (VAC.)

ALDEHYDE COLUMN

PRE - EVAP. STILLAGE

STILLAGE WATERRECTIFIER COLUMN

ETHANOL VAPORDEHYDRATION

FUSEL OILS

WET CAKE

THIN STILLAGETHIN STILLAGE

FUSEL OILSETHANOL > 99%

RAW SPIRIT THIN STILLAGE

STEAM

Bioethanol Case Study 1

ENERGY CONSUMPTIONENERGY CONSUMPTION

1. Electrical Energy1. Electrical Energy2. Life Steam2. Life Steam

300 000 t 300 000 t BioethanolBioethanol per year per year (1 086 000 litre per day)(1 086 000 litre per day)Raw Material: CornRaw Material: CornDry milling processDry milling process

Bioethanol Case Study 2

steam: electricitykg/tA. kWh/tA.

8 bar gMILLING 0 70CONVERSION 503 24FERMENTATION 0 51CHEMICALS/CIP 14 2DISTILLATION/DEHYDRATION 1647 30EVAPORATION 0 26SEPARATION/DRYING 2275 76

sum 4438 278

All values are given per ton of Bioethanol

Bioethanol Case Study 3

Total Energy12278951 kJ/t

9,7 MJ/literLower Heating ValueHu 21 MJ/literRatio 1: 2,2

Bioethanol energy balance

The The BioethanolBioethanol process is often challenged: process is often challenged:

Calorific value of Calorific value of BioethanolBioethanol is 21 MJ/litre.is 21 MJ/litre.Process energy demand of steam and electricity is approx.Process energy demand of steam and electricity is approx.10 MJ/litre (for steam & electric energy )10 MJ/litre (for steam & electric energy )

But calorific value of DDGS is not considered (FODDER)But calorific value of DDGS is not considered (FODDER)

Alternatives in Stillage Processing

When DDGS should be used as source of energy following alternatiWhen DDGS should be used as source of energy following alternatives in ves in down stream could be considered:down stream could be considered:

•• StillageStillage as animal feed (traditional)as animal feed (traditional)•• Chemical/Biologic conversion of lignocelluloses to ethanol Chemical/Biologic conversion of lignocelluloses to ethanol •• BiogasBiogas•• Incineration and coIncineration and co--generation of electricity and steam generation of electricity and steam •• Incineration for steam generationIncineration for steam generation•• Gasification Gasification SynSyn--gas gas --> > Gasmotor Gasmotor or synthesis to Methanol or synthesis to Methanol

and/or and/or SynSyn--fuelfuel

LiquidLiquid

Wet solidWet solid

durable 1durable 1--2 days2 days0.4 0.4 -- 0.7 l 0.7 l alcalc. prod. / animal / day. prod. / animal / day

Dry solidDry solid (DDGS)(DDGS)

durable 6durable 6--10 days10 days3 3 -- 5 l 5 l alcalc. prod. / animal / day. prod. / animal / day

durable longdurable long--termterm4 4 -- 6 l 6 l alcalc. prod. / animal / day. prod. / animal / day

Alternatives: Stillage as feed

Stillage as feed

potable alc fuel alccapacity 20.000 lW/d 1.000.000 lW/d

cattle 28.571 50.000 1.428.571 2.500.000 Liquid4.000 6.667 200.000 333.333 Wet solid3.333 5.000 166.667 250.000 Dry solid

Bioethanol Plant Alternative Biogas

Feedstock

Milled Grain

Mash

Grain ReceivingCleaning/Storage/

Milling

Fermentation

Stillage WaterHydrolysis/

Liquefaction

StillageSeparation

BiogasFermentation

Back-Set

Wet Cake

Thin StillageStillage

DistillationDehydration

Beer Ethanol 99%

STEAM

Bioethanol Plant Alternative Biogas

Fertiliz

Biogas purification(desulphur.,

condensation)

Conditioning ofdigested sludge

Biogas combustion

Off gas

Off gas turbine

Ammoniastripping

Digest water

Digest sludgewet cake

Digest sludgeevaporation

Digest sludgeseparation

Digest sludge water

Cond. digest water

Dryer steam

Biogasfermentation

Biogas

Digest sludgedrying

Condensates to process water recycling

STEAM

Electricity

Bioethanol Plant - Basis Rye Alternative Biogas

Ethanol (99.6 %) 300 kgTechn. alcohol 8 kgFusel oil 5 kg

DDGS ~ 400 kg

Bioethanol PlantRye Basis

CO2

280 kg

Rye1,000 kg

Starch 60 %Protein 10 – 12 %Moisture 12 % Protein 25 – 32 %

Moisture 14 %

el. Power 0,26 MW

Fertilizer ~ 190 kg

150.000 tpa Ethanol from Corn

Panda Hereford

Bioethanol Plant - Basis Corn Alternative: Power/Steam Production from cow manure

Bioethanol Plant - Basis Corn Alternative: Power/Steam Production from DDGS

DDGS

Anaerobic Treat.Methanator/

Filtration INCINERATIONof DDGS

Cooling Tower

Waste Water

Wet Cake

Syrup

Thin StillageEvaporation

DDGSDrying Dryer Vapour

NaturalGas

STEAM

Electricity

To GridTo Plant

STEAM

Bioethanol Plant - Basis Corn Alternative: DDGS incineration

300.000 tpa Ethanol

PreparationFermentationDistillation

Centr. Sep. Evaporation.

Steam cons.84 t/h

10 bar

Steam cons.

68 t/h

10 bar

Steam cons.152 t/h

10 bar

Electricity37 MW

Steamturbine

IncinerationDrying

CakeWet 77,40 t/hTS 32% %TS 24,70 t/h

SyrupWet 51,80 t/hTS 35% %TS 18,10 t/h

DDGS dryedWet 61,14 t/hTS 70% %TS 42,80 t/h

Combined Biofuel Plants for the Future

Bio syncurde

MtSynfuel-Production

160 kt/a Diesel

40 kt/a Gasoline

Gasification210 t/h

Biomass30 t/h

6 t/hsteam

21 t/hWaste

Methanol

Biodiesel-Production

100 kt/a Biodiesel

32 t/h Saat

ca. 70 kha

14 t/hWaste

Bioethanol-Production

100 kt/a Bioethanol

35 t/hsteam

41 t/hGrain

40 t/hBiomass

ca. 70 kha

130 t/h Biomass

approx. 5 decentralLR-Pyrolysis-Plants

1. Plant 2. Plant 3. Plant

Summery

Breakthrough of Breakthrough of Bioethanol Bioethanol was enabled due to the fact that the was enabled due to the fact that the stillagestillage problem was solved also for big plant capacities. problem was solved also for big plant capacities.

DDGS is a valuable Byproduct used as fodderDDGS is a valuable Byproduct used as fodder

Should the DDGS price drop there are technological solutions Should the DDGS price drop there are technological solutions available.available.

Straight forward approach: Combustion and Cogeneration Straight forward approach: Combustion and Cogeneration –– Energy Energy consumption of the plant can be covered +consumption of the plant can be covered +surplus of electricity can be supplied to the grid.surplus of electricity can be supplied to the grid.

The Sun and Plants Deliver Enough Renewable Energy and Raw Materials for Mankind`s Needs

ThankThankYou!You!

!!!!

!!Questions?Questions?