Economic and Technical Analysis of Ethanol Dry Milling: Model Description

Ethanol, the common name for ethyl alcohol, is fuel grade alcohol that is predominately produced through the fermentation of simple carbohydrates by yeasts. In the United States, the carbohydrate feedstock most commonly used in the commercial production of ethanol is yellow dent corn (YDC). The use of ethanol in combustion engines emits less greenhouse gasses than its petroleum equivalent, and it is widely hoped that the increased substitution of petroleum by ethanol will reduce US dependence on imported oil and decrease greenhouse gas emissions. Production of ethanol within the United States is expected to double, from 3.4 billion gallons in 2004, to about seven billion gallons in the next five years. Two processes currently being utilized to produce ethanol from YDC are dry milling and wet milling. The wet mill process is more versatile than the dry mill process in that it produces a greater variety of products; starch, corn syrup, ethanol, Splenda, etc., which allows for the wet mill to better react to market conditions. However, the costs of construction and operation of a wet mill are much greater than those of a dry mill. If ethanol is the target product, then it can be produced at a lower cost and more efficiently in a dry mill plant than in a wet mill plant, under current economic conditions. Of the more than 70 US ethanol plants currently in production, only a few are of the wet mill variety. A descriptive engineering spreadsheet model (DM model) was developed to model the dry mill ethanol production process. This model was created to better understand the economics of the ethanol dry mill production process and how the profitability of dry mill plants is affected under different conditions. It was also developed to determine the economic and environmental costs and benefits of utilizing new and different technologies in the dry mill process. Specifically, this model was constructed to conduct an economic analysis for novel processes of obtaining greater alcohol yields in the dry mill process by conducting a secondary fermentation of sugars converted from lignocellulosics found in the dry mill co-product, distiller’s grains. This research is being conducted at Purdue University, Michigan State, Iowa State, USDA, and NCAUR under a grant from the US Department of Energy. The DM model is more technically precise, and more transparent, than other models of the dry mill process that have been constructed for similar purposes. The Tiffany and Eidman model (TE model) uses broad generalities of the dry mill process, based on the current state of