Level #1: Biomilling Process

The Biomilling™ Process is a front-end process that maximizes ethanol yields while increasing the number of value-added co-products in ethanol production. Through a more efficient first or gross fractionation of the corn kernel into its component parts, the Biomilling Process replaces the front-end “dry-grind” process currently being used in most ethanol facilities today, providing a significant improvement in profitability for the ethanol industry. An ethanol producer utilizing the Biomilling front-end would provide essentially a starch-only feedstock to the fermentor for conversion to ethanol, resulting in more efficient starch to ethanol conversion, elimination of most VOC’s (volatile organic compounds), and an increased number and value of marketable co-products.

The Biomilling Process takes place in a stand-alone, front-end facility located next to an ethanol plant. Incoming corn is first fractioned at the Biomilling facility into its three major components, endosperm, germ, and pericarp, are fed to the fermentation process. The elimination of most of the non/unfermentables allows for optimization of the starch load sent to the fermentor. This not only provides for more efficient fermentation, but also results in significant reduction in VOC’s.

In separate paths following fractionation, the two remaining components (pericarp, and germ) are further processed into three co-products: crude corn oil, corn germ meal and corn bran. The final co-product is a high protein DDG-recovered post fermentation from the conversion of starch to ethanol.

Benefits to an Ethanol Facility

• Increased Profits from Additional Co-Products
• Extended Ethanol Capacity
• Reduced Overall Energy Consumption
• Reduced VOC’s

Increased Profits from Additional Co-Products
The Biomilling Process can increase profits by enhancing the marketability of residual materials as value-added co-products. The separation of the corn germ and pericarp from the endosperm prior to fermentation allows for the production of commodity co-products including crude corn oil, corn germ and corn bran. In addition, high protein DDGs are obtained from the conversion of starch to ethanol. Whereas traditional dry-grind co-products include only dried distiller's grains selling for approximately $0.04/lb, the Biomilling Process produces six co-products at an overall average selling price of $0.08/lb, with some reaching as high as $0.41/lb (numbers based on five-year average pricing).

The Biomilling Process provides a very clean fiber stream, which in one scenario, can be further processed through Biorefining, Inc.’s Bio-Extraction Process. This results in a very efficient fractionation into even more rare and valuable components such as specialty sugars, gums, pectins and both soluable and insoluable fibers. In addition, amino acids, free fatty acids, glucose derivatives, and glycerin can also be derived from other co-product streams using the Bio-Extraction Process. The Biomilling Process is the first step to a “biorefining” approach that includes Bio-Extraction to maximize the market value of co-products derived from corn and other grains.
(back to top)

Extended Ethanol Capacity
The Biomilling Process reduces fermentation inhibitors (unfermentables) prior to the fermentation process, allowing for more efficient ethanol production. In traditional dry-grind ethanol production, these components are typically fed along with the starch to the fermentor. The Biomilling Process may reduce the amount of unfermentables from 35% down to as low as 7%. Increased ethanol yields are attained through enhanced conversion of starch to ethanol. First, more effective starch extraction improves fermentation, thus generating maximum ethanol yields per bushel of corn (up to a 3% increase depending on site specific conditions). In addition, removal of most of the unfermentables (oil, protein and fiber) increases the raw volume of starch that can be placed into the fermentation tanks.
(back to top)

Reduced Overall Energy Consumption
By providing a more efficient fermentation of starch to ethanol, the Biomilling Process can significantly reduce overall energy consumption. Overall BTU usage is conserved through the reduction of unfermentables loaded into the fermentor and through lowered drying costs associated with the higher solids content of the Biomilling co-products.
(back to top)

Reduced VOC’s
By minimizing the introduction of the germ and fiber into the fermentor, not only are residence times lowered, but the creation of unwanted byproducts (which when dried, result in volatile organic compounds or VOC’s) are also reduced to the point that thermal oxidizers may not be required.
(back to top)

 

close