Commodity Production Costs Report

Ethanol Production from Corn Dry Milling

Ethanol Operating Costs & Plant Construction Costs

300 kta United States-based plant | 107 Pages | Issue C | Q3 2024
Starting at $799 USD | See Report Editions Prices

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.

Key reference(s): ?

Ethanol Production Cost Report 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
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
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 80 Pages | 22 Tables | 9 Images

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Table of Contents


Features
  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
  • Plant Capital Cost Details
  • Operating Cost Details
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 90 Pages | 28 Tables | 13 Images

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Updated with Q3 2024 Data

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Table of Contents


Features
  • 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
  • Costs in Different Countries Add-on
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  • 107 Pages | 34 Tables | 22 Images
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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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