Capacity of Ethanol Plant 30 MMgpy (million gal per year) 113.

52 MMLpy (million liter per year)

Corn feed 2.82E+05 tpy (ton per year)

Water Usage 4.54E+06 ton per year

Wastewater Produced 1.48E+06 ton per year
Steam Energy 1.21E+09 MJ per year
Electricity 4.80E+08 MJ per year
Processing water 4.31E+07 MJ per year
Total Energy 1.73E+09 MJ per year
DDGS 9.31E+04 ton per year
CO2 8.66E+04 ton per year

Energy

Corn Ethanol
Corn to Ethanol Dry
Mill Process
Water Solids

CO2 Wastewater
A Milling
Inlet Outlet
Corn powder,
Corn, Ai 1.00 kg Ao 1.00 kg
Corn Feed
B Mashing Water Usage
Inlet Outlet Total Mass In
Corn powder,
Bi1 1.00 kg Mash, Bo 2.60 kg
Water, Bi2 1.60 kg Ethanol Out

Inlet total, Bi 2.60 kg Outlet total, Bo 2.60 kg CO2 Out

DDGS Out
C Cooking/ Liquefaction Wastewater Out
Inlet Outlet Total Mass Out
Liquefied
Mash, Ci1 2.60 kg Mash, Co1 2.67 kg
Wastewater,
Steam, Ci2 0.30 kg Co2 0.23 kg

Inlet total, Ci 2.90 kg Outlet total, Co 2.90 kg

D Fermentation
Inlet Outlet
Liquefied Fermented
Mash, Di1 2.67 kg Mash, Do1 2.97 kg
Fermenter
Water, Di2 0.61 kg CO2, Do2 0.31 kg

Inlet total, Di 3.28 kg Outlet total, Do 3.28 kg

K Scrubber
Inlet Outlet
Fermenter CO2 Emitted,
CO2, Ki1 0.31 kg Ko1 0.31 kg
Wastewater,
Water, Ki2 0.17 kg Ko2 0.17 kg

Inlet total, Ki 0.48 kg Outlet total, Ko 0.48 kg

F Distillation
Inlet Outlet
Fermented
Mash, Fi 2.97 kg Ethanol, Fo1 0.32 kg
Solids, Fo2 2.44 kg
Wastewater,
Fo3 0.21 kg

Inlet total, Fi 2.97 kg Outlet total, Fo 2.97 kg

G Solids Seperation
Inlet Outlet
This Stillage,
Solids, Gi 2.44 kg Go1 1.85 kg
 Wet Cake,
Go2 0.59 kg
Outlet total,
Inlet total, Gi 2.44 kg Go 2.44 kg

H Evaporator
Inlet Outlet
This Stillage,
Hi 1.85 kg Syrup, Ho1 0.36 kg
Wastewater,
Ho2 1.48 kg

Inlet total, Hi 1.85 kg Outlet total, Ho 1.85 kg

J Dryer
Inlet Outlet
Syrup, Ji1 0.36 kg DDGS, Jo1 0.33 kg
Wastewater,
Wet Cake, Ji2 0.59 kg Jo2 0.62 kg

Inlet total, Hi 0.95 kg Outlet total, Jo 0.95 kg

 Input
Derived from Fan Mei, MS Thesis, 2006

Corn Feed 1.00 kg

Water Usage 2.68 kg
Total Mass In 3.68 kg

Ethanol Out 0.32 kg

0.31 kg
DDGS Out 0.33 kg
Wastewater Out 2.72 kg
Total Mass Out 3.68 kg
Et - Thermal Energy Ee - Electricity Energy
Total Energy Demand

Literature Ethanol Conversion Process (Btu/gal)

Pimental and Patzek (2005) 54684
Pimental (2001) 75118
Lorenz and Morris (1995) 53956
Wang et al. (1999) 40850
Shapouri et al. (2002) 51779
Mei et al. (2006) 46114
Average 53750

Thermal Energy (MJ/L)

14.00

Energy Flow Thermal Energy (MJ/L)

A - Milling 0.21
C- Cooking/Liquefaction 2.81
D - Fermentation
F - Distillation 4.76
J - Drying 6.22
Ethanol Conversion Process (MJ/L)
15.26
20.97
15.06
11.40
14.45
12.87
15.00

Electricity Energy (MJ/L)

1.00 (Mei, 2006)

Electricity Energy (MJ/L)

0.10
0.06
0.06
0.37
0.41
CO2 emission is estimated from weight basis reaction stoichiometry

Starch + 0.1111 Water -> 1.1111 Glucose Reaction 1 (Mei, MS Thesis, 2006)

Glucose -> 0.4589 Ethanol + 0.4641 CO2 + 0.05 other Reaction 2 (Mei, MS Thesis, 2006)

Starch 0.595 kg/kg Corn (From corn composition)

Glucose 0.661 kg/kg Corn (From Reaction 1)
CO2 0.307 kg/kg Corn 0.763 kg/L EthOH (From Reaction 2)
(Mei, MS Thesis, 2006)

(Mei, MS Thesis, 2006)

Corn to Ethanol Conversion Rate 2.50 - 2.85 gal ethanol/bushel corn This model 2.70 gal ethanol/bushel corn
Corn to Ethanol Conversion Rate 0.402 L EthOH/kg corn 2.49 kg corn/L EthOH 1 bushel = 56 lb = 25.4 kg
Water Usage 15 L water/kg corn 40 L water/L EthOH (Pimentel and Patzek 2005) 1 L EthOH = 0.789 kg
Wastewater Produced 13 L water/L EthOH 13 L water/L EthOH (Pimentel and Patzek 2005) 1 Btu = 1055 J
Steam Energy 2546 kcal/L EthOH 10.65 MJ/L EthOH (Pimentel and Patzek 2005)
Electricity 1011 kcal/L EthOH 4.23 MJ/L EthOH (Pimentel and Patzek 2005)
Processing water 0.09 kcal/L water 0.38 MJ/L EthOH (Pimentel and Patzek 2005)
Total Energy 15.26 MJ/L EthOH 54684.55
DDGS 0.33 kg DDGS/kg corn 0.82 kg DDGS/L EthOH (Pimentel and Patzek 2005)
CO2 0.307 kg CO2/kg corn 0.76 kg CO2/L EthOH (Mei, MS Thesis, 2006)

Energy (15.3 MJ/L)

Corn (2.49 kg/L) Ethanol (1 L or 0.789 kg)

Corn to Ethanol Dry
Mill Process
Water Solids (0.82 kg DDGS/L)

CO2 Wastewater
(0.76 kg/L)
= 56 lb = 25.4 kg
H = 0.789 kg
Corn Composition
Component Mass Content %
Water 15.0%
Starch 59.5%
Protein 7.7%
Oil 3.4%
Other 14.5%
Total 100%