Ethanol Production from Corn Dry Milling
Ethanol Production Costs Report | Issue C | Q3 2024
| Report Details |
| 300 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 300 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This study presents the economics of hydrous Ethanol production from corn in the United States using a typical dry milling process. Initially, corn is ground, slurried with water and then submitted to enzymatic hydrolysis, which convert starch to glucose. Next, the glucose is fermented to Ethanol by yeasts, yielding Hydrous Ethanol.
The report provides a comprehensive study of Ethanol production and related Ethanol production cost, covering three key aspects: a complete description of the Ethanol production process examined; an in-depth analysis of the related Ethanol plant capital cost (Capex); and an evaluation of the respective Ethanol plant operating costs (Opex).
The Ethanol production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Ethanol plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Ethanol plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises three major sections: (1) Liquefaction & Saccharification; (2) Fermentation; and (3) Products Separation.
Liquefaction & Saccharification. Initially, the corn is ground in order to increase its surface area, exposing starch and allowing more efficient hydrolysis to occur. Then, in liquefaction and saccharification steps, the startch content of the corn is broken down into smaller glucose units. Such liquefaction and saccharification involves enzymatic hydrolyses of the startch under controlled temperature and pH, where alpha-amylase and gluco-amylase hydrolyze starch into fermentable sugars.
Fermentation. Next, the glucose solution from saccharification is fed to the fermentation vessel, where Ethanol is produced from glucose by yeast fermentation. The fermentation is carried out in batch mode and under anaerobic process conditions. The pH control of the fermentation is made by addition of lime. The temperature is controlled by recirculation through external heat exchangers.
Products Separation. Each fermentation batch produces a mixture called beer, containing yeast, bran, gluten, and about 9 wt% (12% by volume) of Ethanol. Subsequently, the beer passes through concentration and distillation steps, yielding Hydrous Ethanol. The non-fermented material recovered is passed through centrifugation, evaporation and drying steps to produce Distiller's Dried Grain with Solubles (DDGS) as by-product.
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Production Process Information
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Production Costs Datasheet
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Operating Cost Details
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Ethanol production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Ethanol process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Ethanol production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Ethanol plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
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