EXPERIENCES ON BIOETHANOL FROM CORN ... ON BIOETHANOL FROM CORN Detmold, Germany 25.04.2006 Domokos Sipos, HUNGRANA Content: - technical aspects (3, 4, 5,6) - raw material (7, 8,9)

EXPERIENCES ON BIOETHANOL FROM CORNDetmold, Germany 25.04.2006

Domokos Sipos, HUNGRANA

Content:

- technical aspects (3, 4, 5,6)

- raw material (7, 8,9)

- efficiency, cost (10,11)

- legal aspects (12)

Dry line Wet lineMaize 100 T

Dry grind

Suspendation

Jet-cooker

Liquefaction

Saccharification

Fermentation

Distillation

DDGS 28.5 T

Fine alcohol 370 ahl CGF 3T

Millhouse

Starchmilk

Jet, liquefaciton

Saccharification

Filtration

Permeate

Sweetenersproduction

Alcohol production on the base of cornAlcohol production on the base of corn

Retentate

CGF 14,5 T

Gluten 4,5 T

Germ 6,5 T

Steep liq.

Complete processComplete processRECEIVED CORN

CLEANED CORN

STARCHMILK

NATIVE STARCH

MODIFIED STARCH

SWEETENERSGLUCOSE SYRUPS

ISOSWEET 111 (F42)LIQUID-DEXTROSE ETHANOL

DEXTROSE-MONOHYDRAT ISOSWEET 041 (F55) ANHYDROUS ALCOHOL

GERM

GLUTEN

CGF

BROKEN CORN

STEEP LIQUOR

Ethanol productionEthanol production1500 ahl1500 ahl//dayday

WATER

MIXING TANKMIXING TANK

OLD FERMENTORSOLD FERMENTORSYEAST

NEW FERMENTORSNEW FERMENTORS

NEW BEER COLUMNNEW BEER COLUMNSTILLAGE 51 TDS/D

FOOD FINE ALCOHOLFOOD FINE ALCOHOL

OLD RECT. COLUMNOLD RECT. COLUMN

OLD HEADS COLUMNOLD HEADS COLUMN

OLD ZEOLITE BEDOLD ZEOLITE BED

ANHYDROUS ALCOHOLANHYDROUS ALCOHOL

TECHNICAL ALCOHOL

FUSEL OIL

CGF

RETENTATE 296 TDS/D

Max.300 ahl/day

Max.600 ahl/day

1500 ahl/day

NEW RECT. COLUMNNEW RECT. COLUMNFUSEL OIL

NEW ZEOLITE BEDNEW ZEOLITE BED

BIOETHANOLBIOETHANOL

Max.1200 ahl/day


Property Unit Standard Value (max.)

Appearance - - clear and colourless

Density @20°C g/cm3 EN ISO 12185 0.79Sulphur wt ppm EN ISO 20846 1Water wt ppm EN ISO 12937 1000Aldehid content wt ppm ASTM D 2119 500Iron content wt ppm ICP method 0.1Chlorine content wt ppm EN 14077 1Acidity as acetit acid wt ppm ASTM D 1613 10

Basicity as NH 3 wt ppm ASTM D 1614 1Permanganate time minutes ASTM D 1363 min. 60Methanol content wt% ASTM D 5501 0.5Cation content wt ppm ICP method 3

Ethanol content wt% ASTM D 5501 SP 107 min. 99.3

Other heavier alcohol wt% ASTM D 5501 0.5

Ester content wt ppm SP 107 500Dry residue wt ppm ASTM D 1353 50

BIOETHANOL SPECIFICATION

11,0011,5012,0012,5013,0013,5014,00

1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005


3,703,803,904,004,104,204,304,404,50

1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005

8,608,809,009,209,409,609,80

10,00

1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005

70,0070,5071,0071,5072,0072,5073,00

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

2005

MOISTURE

OIL (GERM)

PROTEIN

STARCH

QUALITY TREND OF MAIZE SINCE 1994

%

15,00

17,00

19,00

21,00

23,00

25,00

27,00

199419951996199719981999200020012002200320042005

3,40

3,603,80

4,00

4,204,40

4,60

199419951996199719981999200020012002200320042005

8,008,208,408,608,809,009,209,409,609,80199419951996199719981999200020012002200320042005

68,0068,5069,0069,5070,0070,5071,0071,5072,0072,5073,00

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

2005

DRY WET


Quality parameter Requirement Caused problems if maize is out of specification

GMO non-GMO product GMO contaminated

Mould mould free toxin contamination - T2

DON-toxin max. 0.3 mg/kg co-products contaminated by 4-5 times level of DON

Germination min. 40 % separation problems - starch/protein changing quality of co-products

Special requirements over standard on maize as raw material


3

4

5

6

7

8

1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005

t/ha

4000

5000

6000

7000

8000

9000

10000

mill

ion

tons

Average yieldMaize production

HUNGARIAN MAIZE PRODUCTION 1994-2005


Yields-starch:- gluten meal:- germ:- gluten feed:

69-70 %7.5 %4.5 %

18-19 %

Starch recovery: 96-98 %

Ethanol yield: 270 kg maize for 1 ahl ethanol

SPECIFIC FIGURES OF PRODUCTIVITY

Utilities consumption: -steam 180 kg/hl - total energy 340 kWh/hl


dry** wet**Production cost (1 $ = 1 €/hl) 50 25 35 45 40

Raw material 60% 80% 50% 56% 45%

Energy/environment 18% 0 17% 31% 37%

Others (labour, capital, maintenance etc.) 22% 20% 30% 13% 18%

Hungary - maizeEU* Brasil* USA*

PRODUCTION COST COMPARISON

* Ref: UEPA – February 2006

** Based on 3000 hl/day capacity


EU HungaryType of subsidy Direct EU NationalArea limit (ha) 1.5 million 16,000Farmers limit EUR no limit 3000 EUR/3 yearsSubsidy EUR/ha 45 27

Subsidised period (years) till end of 2006 continuous

only the current year if issued

Bioethanol plant - deposit EUR/ha 60 60

Bioethanol producer not subsidised by National Budget

Bioethanol plant - same obligation based on EU legislation- special contract conditions with farmers- administrative obligations

COMPARISON OF BIOETHNAOL „PRODUCERS” BETWEEN EU AND HUNGARY

Documents

EXPERIENCES ON BIOETHANOL FROM CORN ... ON BIOETHANOL FROM CORN Detmold, Germany 25.04.2006 Domokos Sipos, HUNGRANA Content: - technical aspects (3, 4, 5,6) - raw material (7, 8,9)