Panda Ethanol
Ethanol and Co-products
Ethanol, also known as ethyl alcohol, is a high-proof form of grain alcohol. It is produced by removing starch from a carbohydrate-based feedstockFeedstock: A raw material used for industrial processing., such as corn, converting the starch into sugar and fermenting it with yeast.
A blend of ethanol and turpentine fueled the first American internal combustion engine in 1826. In addition, Henry Ford designed the Model T automobile to run on ethanol calling it "the fuel of the future." It can be used as an effective octane-boosting fuel additive or as a stand-alone fuel.
Step 1: The entire corn kernel is ground into flour, also called meal, and the starch is extracted.
Step 2: The meal is processed with enzymesEnzymes: A protein used to break down starches (carbohydrates) into complex sugars (dextrins) or simple sugars (glucose). and the starch is converted into sugar.
Step 3: The meal is placed in a high-temperature cooker to reduce bacteria levels before fermentation.
Step 4: The meal is transferred to fermentorsFermentor: A mechanical device that creates optimal growing conditions for the production of large numbers of microorganisms. Fermentors usually have a heater or cooler to maintain a constant temperature and an agitator for aeration.. Yeast is added and the conversion of sugar to ethanol begins. Fermentation takes about 40-50 hours.
Step 5: Fermentation produces a liquid, which is sent to distillationDistillation: The process of separating and purifying a liquid by successively boiling it and then condensing its vapors. columns. Here, the ethanol is separated from the remaining "stillage."
Step 6: The anhydrous ethanol is blended with approximately 4.75 percent denaturant, such as gasoline. This makes the ethanol — a 200 proof alcohol —undrinkable. Because it is now undrinkable, it is not subject to beverage alcohol tax.
Step 7: In steps 1-6, starch is the only element of the corn used, but there are other parts of the kernel to take advantage of. The leftover fiber, protein and fatty oils are blended with solublesSolubles: a corn syrup-like byproduct created after ethanol has been extracted from the corn mash during the distillation process. to create distillers grains with solubles (DGS)—a nutrient-rich animal feed. This livestock feed is then sold to cattle feeders. Other important co-products of the production process include CO2Carbon dioxide (CO2): a gas co-product of ethanol production used for beverage carbonation, refrigeration of food products (dry ice), and food preservation. It is also used as a shielding gas for welding and can be injected into difficult or aging oilfields for enhanced oil recovery., which is produced during fermentation, and ashAsh: A co-product of biomass-fueled ethanol production. Ash can be used as a soil additive for farming, a bed lining for cattle pens, a paving filler for road beds and a strengthening agent in building materials such as cement and cinder blocks., in the case of Panda's bio-fueled facilities, which is produced during the manure gasification process.
