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Fractionation for Ethanol / Biobutanol

          Corn Fractionation

    • As corn-based ethanol production has nearly peaked at the 15,000,000,000 gallons per year cap, producers are looking to dry corn fractionation to make their existing production capacity more efficient and profitable.

           Wheat Fractionation / Barley Fractionation

    • Tremendous opportunities currently exist with wheat and barley feedstocks. When fractionated, the biofuels complex may be labeled as 'Advanced Biofuels', due to the extremely low carbon footprint which can be created by using the biomass generated from the wheat and barley fractionation process. Many Advanced Biofuels plants will qualify for government loan guarantees.

What is Fractionation?
The fractionation of cereal grains, as applied to ethanol / biobutanol production, is the mechanical separation of the grain's physical components of pericarp (bran or hull), endosperm, and usually, germ. AMS has various fractionation technologies which may be applied to multiple ethanol / biobutanol feedstocks including maize (corn) ( see Corn Fractionation Brochure ), sorghum (milo), wheat, barley, rice, and other grains ( see Small Grains Brochure ). Yucca (cassava or mandioca), although not a cereal grain, may also be enhanced as an ethanol / biobutanol feedstock using AMS and partnering technologies
( see Cassava Brochure ).

Why Fractionation?
There is a reason why 'Fractionation' is a buzzword throughout the ethanol / biobutanol industry. No matter the feedstock, fractionation offers multiple advantages to the ethanol / biobutanol producer to make their business more profitable. Some of the significant advantages are the following:

  • More Efficient Utilization of Fermentation Vessels
    AMS fractionation eliminates up to 18% by weight, or approximately 35% by volume, of relatively non-fermentable, high fiber co-products. This creates approximately 35% more space in the fermentation vessels for the production of ethanol / biobutanol.
  • More Efficient Saccarification
    Starch linkages become more accessible to enzymatic activity due to increased starch loading and the absence of non-fermentables. This results in a more rapid conversion and/or decreased enzyme usage. This, in conjunction with more efficient utilization of fermentation vessels, allows for an increase in plant ethanol / biobutanol output of approximately 18%.
  • Significant Reductions in Natural Gas Consumption
    Natural gas costs are typically a production facility's largest operating cost, other than the feedstock. Drying of DDGS can account for the majority of the natural gas consumption. Isolation of bran and germ on the front end of the plant eliminates the bulk of the solids being handled throughout the fermentation process. These products no longer need to be dried from extremely high moistures on the back end of the plant. A typical plant can save millions of dollars per year on natural gas costs. Moreover, utilizing the bran co-product as a solid fuel via combustion or gasification ( see Drying and Co-Product Utilization ) can replace the majority of the energy consumed by the production facility.
  • Isolation of High Oil Content Germ
    The extraction of germ can be accomplished effectively in nearly all grains. However, it is typically most profitable to apply degermination to corn due to the large size of the germ. While about a third of the oil in a corn kernel is locked up in the starch-protein matrix of the endosperm, the germ contains nearly all of the remaining oil. AMS corn degermination systems produce a pure whole germ stream capable of providing greater than one pound per bushel of valuable oil.

  • Isolation of High Total Dietary Fiber Bran
    Whether the feedstock is corn, barley, wheat, rice, or other cereal grains, the bran coat provides excellent supplementation for human consumption. The bran also makes an excellent animal feed with or without the syrup from the ethanol plant mixed with it. In many cases, the best value for the bran comes as a solid fuel to reduce dependence on the volatile natural gas markets ( see Drying and Co-Product Utilization ).
  • Optional Production of Food Grade Prime Products
    AMS plants are food grade and can co-produce prime food products and fermentation stock from all grains. Flaking grit, brewer's grits, prime meals, semolinas and flours all have the capability to help a plant squeeze more value out of a bushel of grain ( see LifeLine Foods Brochure ).
  • Platform for Emerging Technologies
    Fractionation is the key to unlocking the potential for several emerging technologies. Biobutanol and other fermentation technologies such as cellulosic conversion of the grain's fiber, starch isolation from endosperm, and 'no cook' all may have a large impact on the biofuels industry. Fractionation is essential for any of these technologies to perform efficiently.
  • High Resultant DDGS Protein
    Isolating the fibrous non-fermentables on the front end of the plant prevents them from passing through the ethanol plant and being present in the DDGS. Therefore, the remaining solids are concentrated with proteins which were present in the endosperm's starch-protein matrix and yeast protein.

Why the Sudden Interest in Fractionation?
Milling installations have been efficiently dry fractionating grain for decades, although with a different emphasis on products (typically food products). But, by and large, the process of dry fractionation has only recently been accepted by the dry-grind ethanol industry. One must wonder...if dry fractionation has been possible for decades and the benefits are so apparent, why is fractionation just now being applied to the production of ethanol? Consideration of fractionation before fermentation for ethanol was considered at least as early as 1997, but for many reasons the technology has recently increased in popularity. Some of the reasons include:

  • Increased Demand for Biofuels
    The recent increased demand for ethanol has producers looking to expand production capacities. Fractionation is one relatively quick way to increase capacity and be prepared for biobutanol production in the near future.

  • Volatile Natural Gas Prices
    Volatile natural gas prices have producers looking for ways to decrease drying costs and for alternative sources of fuel. Fractionation can provide relief in both of these areas.

  • Phasing Out of Trans-Fatty Acids in Foods
    Corn oil, which is free of trans-fats, is a very attractive alternative to soy oil, which contains trans-fatty acids. Fractionation isolates the high oil germ and prepares it for oil expelling.

  • Increased Demand for Biodiesel
    Although there is a premium for corn oil sold to the human consumption industry, biodiesel plants are a perfect outlet for valuable corn oil.

  • 'Crossover' In Knowledge and Technology between the Cereal Milling Industry and the Biofuels Industry
    Until recently, the synergies between the cereal milling industry and the ethanol / biobutanol industry were not fully recognized. Now there is more exchange of technology and communication between those who understand fermentation and those who understand cereal milling.

  • Adverse Market Conditions
    During times of unfavorable market conditions for the biofuels producer, fractionation provides the producer a way to remain more profitable. When grain prices rise and biofuel prices fall, AMS fractionation provides a way to improve plant efficiency to help survive the 'crunch'.

  • Saturated DDGS Markets
    The typical ethanol plant can generate nearly one million pounds of DDGS per day. With all of the new ethanol plants on-line the DDGS markets continue to saturate, which will significantly bring down the price that ethanol plants can get for their DDGS. Ethanol plants that fractionate and diversify their co-products will produce less DDGS, although at a premium price, while other valuable co-products are generated as well.

Why Applied Milling Systems?
Applied Milling Systems' values, along with diverse experience in the cereal milling and biofuel processes, provide a foundation that ensures your process will operate more efficiently and that your working relationship with Applied Milling Systems will be an enjoyable and profitable one.

The Process - Fractionation for Fermentation

Fractionation for cereal grains is neither new, nor unproven. It is not magic, and it's benefits are not based upon 'smoke and mirrors'. All of the aforementioned benefits are real enough and applying traditional cereal milling techniques to ethanol production is an idea whose time has come.

Proudly offering the following equipment for your corn fractionation, as well as small grains applications:

    
 
Pre-Cleaning Separator SPR
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Vibro-Separator (Vibro-Block)
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Multi-Cleaner MCS20
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Closed-Circuit Aspirator SCC
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Air Separator SAP
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Conical Air Separator TC
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Gravity Selector SGS
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Auto. Damping system HIGROS-TEC III
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Automatic Damping System
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Intensive Dampener BI-MIX
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Degerminator DG6000
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Corn Degerminator MD/37
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Vertical Dry Degerminator SBR-SV27/65
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Dehuller/Debranner DSB
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Densimetric Table STD
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Ponderal Flow Measurer RFP
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Production Electronic Controller
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Purifier (Semolina)
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Superimposed Rollermill (Synthesis)
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Rollermill (Synthesis)
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Plansifter (Modulo)
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Horizontal Vibrating Sifter GVSO
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Turbo-Sifter TRF
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Monosifter SPM
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Twin-Sifter SPM 2
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Fluidized Bed Dryer
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Double Cyclonic Husk Furnace
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Copyright 2006