Energy Saving in Ethanol Production During the Mashing Process · Energy Saving in Ethanol...
Transcript of 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
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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
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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
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Hohenheim University, Section of Fermentation Technology, Research Distillery
Use of thermostable Xylanase Gammaxylanase HTL
Mash viscosity without Xylanase
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Hohenheim University, Section of Fermentation Technology, Research Distillery
Einsatz thermostabiler XylanaseGammaxylanase HTL
Mash viscosity using Xylanase
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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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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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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
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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...
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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
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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
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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
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Hohenheim University, Section of Fermentation Technology, Research Distillery
Duration of Fermentations
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STARGEN
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Hohenheim University, Section of Fermentation Technology, Research Distillery
STARGEN Fermentation time: 3h
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Hohenheim University, Section of Fermentation Technology, Research Distillery
STARGEN Fermentation time: 3h
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Hohenheim University, Section of Fermentation Technology, Research Distillery
STARGEN Fermentation time: 21h
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Hohenheim University, Section of Fermentation Technology, Research Distillery
STARGEN Fermentation time: 21h
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Hohenheim University, Section of Fermentation Technology, Research Distillery
STARGEN Fermentation time: 69h
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Hohenheim University, Section of Fermentation Technology, Research Distillery
Contents of Extract and Ethanol During Fermentation Hohenheim Process
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Hohenheim University, Section of Fermentation Technology, Research Distillery
STARGEN Process: "Extract Contents" from different mashes
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Hohenheim University, Section of Fermentation Technology, Research Distillery
Ethanol Yield from Triticale Using Different Enzyme Systems
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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.....
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Hohenheim University, Section of Fermentation Technology, Research Distillery
Thank You Very Muchfor
Your Attention