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Alcohol Education and Processing Effects of Small Grains

Alcohol Education and Processing Effects of Small Grains. Craig Pilgrim Global Marketing Manager EPAC conference Billings, Montana June 26, 2012. Outline . Lallemand (brief overview) Educational Aspects Schools and learning Example of training Small grains Production values

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Alcohol Education and Processing Effects of Small Grains

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  1. Alcohol Education and Processing Effects of Small Grains Craig Pilgrim Global Marketing Manager EPAC conference Billings, Montana June 26, 2012

  2. Outline • Lallemand (brief overview) • Educational Aspects • Schools and learning • Example of training • Small grains • Production values • Composition • Starch and Non Starch Polysaccharides • Enzymes and viscosity • Processing issues • Fermentation issues • Summary

  3. Lallemand in 2012 • Develops, produces and markets yeasts, bacteria and other ingredients derived from those microorganisms for: • bakeries (65% of sales) • wine, beer and alcohol producers (as well as fuel ethanol industry) • animal and human nutrition industries, pharmaceutical industry • other food and agricultural industries • Over 2500 employees (of which 70+ in R&D) in over 35 countries on 5 continents

  4. Our core activity Yeast Bacteria Development, production and marketing of… …and their derivatives

  5. Ethanol Technology Institute Publications Educational Activities

  6. The Alcohol School – Toulouse/Montreal • Now in 31st year of running this class • Organized by Prof Graeme Walker, Ethanol Technology Institute • Non-commercial • Mix of internal and reputable guest speakers • Directed towards: • Senior operational staff • Laboratory staff • Experienced operators/Shift leads • Agenda covers whole process at mid to high level • Some new technology/developmental topics included

  7. The Operators’ School • In fourth year of operation. • Mix of lectures and hands on demonstrations • Organized by the Ethanol Technology Institute • Non-commercial • Directed towards operators and less experienced managers/shift leads • Predominantly in house trainers • Agenda covers complete process including both batch and continuous • Significant aspect of troubleshooting including worked examples/role play

  8. The Alcohol Textbook Ethanol Technology Institute publishes “The Alcohol Textbook” • The most comprehensive book on alcohol production. • Team of internal and external writers. Edited by Dr. Mike Ingledew, Glen Austin and Dave Kelsall. • 5th edition recently published.

  9. Example of educational training • Why training and educational aspect? • Been a part of landscape for more than 30 years • Focus on increasing operations knowledge, better trained personnel • Focus on Montreal is more North America and related grain processing • Corn as main substrate • Focus in Toulouse is more on Rest of World • Small grains is the main topic • The rest of this presentation will discuss aspects of small grain processing and those educational opportunities.

  10. Global Small Grain Production United States Department of Agriculture, Avg. 2008-2010 Crop Years

  11. Raw material usage in US • Corn is KING! • Majority of ethanol producing facilities are using corn. • Some plants, based on locations are using milo, sorghum, barley or wheat. • Inherent issues using small grains • Depending on grain, starch content might be less • Processing could be a bit more difficult • Equipment usage and wear • Viscosity • However, in other parts of the world, small grains are prevalent.

  12. Raw Material Usage for EU • Mostly wheat, sugar beet juice, barley and maize. • Small grains effect production costs. • To minimize costs, blends of products may be used. Source: eBio

  13. Grain Composition Wheat Triticale Rye Barley Corn Sorghum

  14. Small grain challenge Starch granules Protein matrix Outer wall (-Glucan and pentosan) Protein middle lamella Inner cell wall (-Glucan) The small grains contain high concentrations of Non Starchy Polysaccharides (NSPs) which, have high water-binding capacity leading to increased mash viscosity The small grains contain high concentrations of NSPs which, have high water-binding capacity leading to increased mash viscosity Endosperm Cell Structure Source: Novozymes

  15. Grain Composition

  16. Starch Structure Amylose High rigidity High viscosity Amylopectin

  17. Starch breakdown • “Normal” starch breakdown is relatively easy using heat and enzymes. • Long chained polymers known as “dextrins” are broken down with alpha amylase. This reduces viscosity fairly quickly and easily. • Once that happens, another enzyme is added at fermentation known as glucoamylase. • This breaks down the long chains into single glucose units. • Glucose is the primary and preferred source of sugar used by yeast to convert to ethanol.

  18. Non Starch Polysaccharides of Cereal Grains • Arabinoxylan: Especially in wheat, rye and barley. Xylan backbone with L-arabinofuranose (L-arabinose in 5-atom ring form) • Beta-glucan: Linear unbranched beta-D-glucose with one beta-1,3 every 3 or 4 beta-1,4 linkages; in bran of grains

  19. Cereal Grain Non-starch Polysaccharides Need enzymes Need enzymes Source: Novozymes

  20. Viscosity Reducing Enzymes Composition of Grains Needs Xylanase Needs Beta Glucanase Can be converted to fermentable sugars • Beta Glucans and Pentosans are the main cause of high mash viscosities • These “Hemicelluloses” also create problems in thin stillage evaporation and dewatering of fermentation solids Source: Genencor

  21. NSP Comparison in various grains

  22. Non Starch Polysaccharides of Grains-Impact on processing grains to ethanol- • Grains like rye, barley, triticale and wheat contain high levels of hemicelluloses (Beta Glucans, Pentosans) = high viscosity due to high water-binding capacity • Consequences: This reduces the efficiency of • Heat exchange operation • Centrifugal separation of solids • Evaporation • Mass transfer in fermentation • Limited solids concentration in mashing • Negative effect on the energy balance of the process. (lower solids, higher water content, lower ethanol yield, etc.) • Residual Hemicelluloses may contribute to fouling of heat exchangers and distillation equipment Source: Genencor

  23. Composition of Non Starch Polysaccharides of Cereal Grains * Depending on extraction conditions and specific composition

  24. Summary - Processing Small Grains • Milling may be slightly different on equipment wear depending on substrate and variety. • Because of viscosity issues with NSP’s, secondary enzymes will have to be used. (Barley and rye definitely, wheat, depending on variety). • Because of viscosity issues, % solids in fermentation may have to be lower than compared to corn. • Dryhouse may have to be equipped to handle slightly larger volumes and lowers solids syrup. • Seasonal and strain differences in substrate will effect processing more than compared to corn (fairly constant)

  25. Fermentation • Should be fairly comparable to corn or any other starch substrate fermentation. • Things to look for include: • Lower solids fermentations. • Foaming may vary due to substrate and age • Because small grains composition, fermentation yield may decrease because of availability of fermentable sugars.

  26. Fermentation • Time • Nutrients • Antifoam

  27. Fermentation • Time • May take slightly longer due to viscosity issues, mass transfer issues, sugar composition, etc. • May be offset due to lower solids required in some cases. • Nutrients • Antifoam

  28. Fermentation • Time • Nutrients • Usually comparable to corn, but nutrient package may have to be used as well • Antifoam FAN values normalized to 20% DS Thomas and Ingledew, 2006

  29. Fermentation • Time • Nutrients • Antifoam • Due to lower inherent oil levels in these substrates, foaming may be an issue. • Antifoams may have to be used in fermentation. • Corn oil could be used as well. Depending on what DDGS are used for.

  30. Summary • Small grains can be used for ethanol production • Not prevalent in US, but could be used if necessary. • Dependant on areas of US that could grow the crops. • There are some inherent challenges to using small grains. • Mainly viscosity issues and starch content • Small grains are successfully used in other parts of the world for biofuels production.

  31. Summary • Education and Training are key in understanding various processes and substrates. • This is type of presentation you would see in our various schools. • For more information, please see www.ethanoltech.com

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