Separation of glucose and pentose sugars by selective enzyme hydrolysis of AFEX-treated corn fiber.

A process was developed to fractionate corn fiber into glucose- and pentose-rich fractions. Corn fiber was ammonia fiber explosion treated at 90 degrees C, using 1 g anhydrous ammonia pergram of drybiomass, 60% moisture, and 30-min residence time. Twenty four hour hydrolysis of ammonia fiber explosion-treated corn fiber with cellulase converted 83% of available glucanto-glucose. In this hydrolysis the hemicellulose was partially broken down with 81% of the xylan and 68% of the arabinan being contained in the hydrolysate after filtration to remove lignin and other insoluble material. Addition of ethanol was used to precipitate and recover the solubilized hemicellulose from the hydrolysate, followed by hydrolysis with 2% (v/v) sulfuric acid to convert the recovered xylan and arabinan to monomeric sugars. Using this method, 57% of xylose and 54% of arabinose available in corn fiber were recovered in a pentose-rich stream. The carbohydrate composition of the pentose-enriched stream was 5% glucose, 57% xylose, 27% arabinose, and 11% galactose. The carbohydrate composition of the glucose-enriched stream was 87% glucose, 5% xylose, 6% arabinose, and 1% galactose, and contained 83% of glucose available from the corn fiber.

Enhancing profitability of dry mill ethanol plants: process modeling and economics of conversion of degermed defibered corn to ethanol.

An Aspen Plus modeling platform was developed to evaluate the performance of the conversion process of degermed defibered corn (DDC) to ethanol in 15- and 40-million gallons per year (MGPY) dry mill ethanol plants. Upstream corn milling equipment in conventional dry mill ethanol plants was replaced with germ and fiber separation equipment. DDC with higher starch content was fed to the existing saccharification and fermentation units, resulting in higher ethanol productivity than with regular corn. The results of the DDC models were compared with those of conventional dry mill ethanol process models. A simple financial analysis that included capital and operating costs, revenues, earnings, and return on investment was created to evaluate each model comparatively. Case studies were performed on 15- and 40-MGPY base case models with two DDC process designs and DDC with a mechanical oil extraction process.

Effect of germ and fiber removal on production of ethanol from corn.

Ethanol fermentations were conducted using both whole corn, and corn with 100% of the germ, and a portion (approximately 74%) of the fiber removed. Ethanol production increased 11% in the germ and fiber-removed corn vs the whole corn. The protein content of distiller's dried grains and solubles increased from 30 to 36%, and phosphate levels were 60% lower in corn with germ and fiber removed vs whole corn. Removal of germ and fiber prior to fermentation allows higher starch loading and results in increased ethanol production. The integration of germ and fiber removal in the dry-grind ethanol industry could increase capacity and add valuable coproducts, resulting in increased productivity and profits.