The Profitability Impact of a Qualified and

Trained Analytical Lab Staff

Sabrina Trupia, Ph.D. and Jessica M. Sido

NCERC

Three functions of Ethanol Plant Laboratory Staff

Performance

Understanding Communication

Laboratory Performance

Time spent on each test decreases

Fewer samples to re-run

Reliable analyses and reliable data

Hopper

Hammer Mill

Slurry Tank Jet

Cooker Fermentation

Ethanol Storage

Molecular Sieve

Distillation System

Evaporator(Syrup)Drum Dryer

Liquefaction

9

9

Centrifuge

DDGS

The Corn to Ethanol Process (Dry Grind)

(200 Proof )

(190 Proof )

WholeStillage

(Recycled Water)

(Cooling)

( Wet Cake)

(ThinStillage)

(Heating)

TM

Centrifuge

DETS %pH

DEpH pH

HPLC

H2O %

Prox.Anal.

TS%Prox. Anal.

Amino AcidsTotal P

Ashetc.

Risk

HPLC

Particle Size Grain Qual

Mycotoxins

Understanding Processes

Curves for Glucose and Ethanol Over Time

02468

101214

1 2 3 4 5 6 7 8 9 10

Fermentation Time

Per

cen

t w

/v

Ethanol

Glucose

Ability to recognize a problem

Ability to assess the problem

Ability to troubleshoot and to see where the problem originates (plant or lab)

Communication with Plant

Conveying the appropriate information to the operators

Quick response to changes in plant conditions

Providing more information that just data values

Is data integrity and quality (i.e. “good” data) only important to R&D labs?

RFA Guidelines

“First, the [QA/QC] program should continually monitor the reliability (accuracy and precision) of the results being reported. It should answer the question “How good (accurate and precise) are the results obtained?” This function is the determination of quality. “

“The second function is the control of quality to meet the program requirements for reliability. “

http://www.ethanolrfa.org/industry/resources/qaqc/

Is “good” data only important to R&D labs?

“Providing the highest quality products that meet customer expectations is of the highest priority for ethanol production facilities”

“The success of an ethanol production facility depends on the Quality Control lab”

--Kristy Moore, Renewable Fuels Association

“Hard to justify [financially] only until you see the results”

“When lab data is used as a problem-solving tool, it does save money for the ethanol plant”

-- Andrew Kim, Center Ethanol

Laboratory Practices =

Problem-solving Tools

Fermentation Management Maximize ethanol production

Minimize fermentation problems

Mass Balance Helps update the mass balance of production

Recognize trends leading to problems

Risk Management Contaminants (S, antibiotics...) in ethanol and/or co-

products

Cost Impact Example: Fermentation Management

A single contamination event resulting in one stuck fermentor (3-4% residual sugars) costs approximately $20,000

Chronic contamination resulting in a loss of 0.25%wv ethanol per fermentor = approx. $1,740,000 per year (@ $1.74 per gallon ethanol)

In a 50 MGPY Ethanol Plant (750,000 gal fermentor)

Lallemand Ethanol Technology (2008); ethanol price: NYMEX Jun 8, 2009

Effective Training

Training is best accomplished in three stages

Initial : exposure to lab procedures

Intermediate : active demonstration

Final : Hands-on training

Throughout, lab practices are tied to plant processes

Thanks to…Lab Staff @ NCERC John CaupertBrian WrennYan ZhangJack BallingerAndrew KimKristy Moore

…Questions?