" SMALL SCALE ETHANOl PRODUCTION

-DESIGN MANUAL-
1

Kenneth E. Johnson
Environmental and Energy
Center

The University
Of Alabama
In Huntsville

MAST£ ,
September 1981

DISTRIBUTION OF THIS DO·' Ufl'EuT IS

~ " II UNLIMITED
 DISCLAIMER

This report was prepared as an account of work sponsored by an

agency of the United States Government. Neither the United States
Government nor any agency Thereof, nor any of their employees,
makes any warranty, express or implied, or assumes any legal
liability or responsibility for the accuracy, completeness, or
usefulness of any information, apparatus, product, or process
disclosed, or represents that its use would not infringe privately
owned rights. Reference herein to any specific commercial product,
process, or service by trade name, trademark, manufacturer, or
otherwise does not necessarily constitute or imply its endorsement,
recommendation, or favoring by the United States Government or any
agency thereof. The views and opinions of authors expressed herein
do not necessarily state or reflect those of the United States
Government or any agency thereof.
 DISCLAIMER

Portions of this document may be illegible in

electronic image products. Images are produced
from the best available original document.
 UAH RESEARCH REPO
RT NO. 293
...' D O E /R 4/ 10 23 l-
-T 2
DE84 00 04 02
I

• l __ ~------~--~ ·--
SMAL[jSCALE ETHA
NOL PRODUCTION~
0DESIGN MANUA~

Pr ep ar ed fo r
U. S. Department
of Energy

Pr ep ar ed by
Leonard E. Adcoc
k,
· Michael H. El ey I I
B
Kenneth E. Johnsoer na rd J. Sc hr oe r
n En
The U ni ve rs it y ofvi ro nm en ta l & Energy C en te r
Alabam
H un ts vi ll e, Alaba a in H un ts vi ll e
ma 35899

G ra nt Number: DE-FG4480R4 10 23
1. 00 0

'·•
"t·/
. NOTICE
PORTIONS OF THIS RE
It has be PORT. ARE ILUGIBlE
available en reprod
uce.d from the· be
. · . . copy to pe
·- ·
po rmit st
• ssable availability. the b
· roades~
September 1981

;-t0i
0\STRIBUTIOM OF THIS OO
CUMEtiT IS UNUMlTEO
 ABSTRACT

•
The Johnson Environmental and Energy Center with assistance from
the Madison County Farm Bureau Association received a grant from the
U.S. Department of Energy to design, fabricate, and evaluate a small
scale continuous ethanol plant. The scope of the study was to satisfy
four specific objectives. The first objective was to design a small
scale continuous distillation unit capable of producing 10-15 gallons
per hour of 170-190 proof ethanol. A second objective ~as to econo-
mically fabricate the distillation unit.· A third objective was to·
thoroughly evaluate the unit with emphasis on production potentlal,
operation considerations, and energy bala~ce. The fourth objective
was to work with the Farm Bureau in. idcintifying an organization that
would place the unit in a production environment.

The results of the study indicate that the distillation unit

is capable of producing an average of 9-14 gallons per hour (based
on alcohol percent in beer) of 174 proof ethanol. The energy ratio
for distillation is a positive 3:1. Once the unit has reached steady
state very little operator attention is required with the e1<ception
of periodically refluxing. Material cost of the plate column is
approximately $5000. The unit could be built by an individual pro-
vided he is trained in ·welding and has the necessary shop equipment.

This report is a summary of the final report Small Scale Ethanol

.. Production Demonstration, UAH Report No. 291, October 1981. Omitted
from this document are the appendices containing the vendor equtpment
specifications, the detailed data on the distillation test runs and
the boiler efficiency tests and the materials used in the September
19 workshop on the principles of ethanol production using d contin-
uous distillation process.

DISCLAIMER l
This report was prepared as an account of work sponsored by an agency of the United States I
Government. Neither the United States Government nor any agency thereof, nor any of their ,
employees, makes any warranty, express or implied, or assumes any legal liability or responsi-
' bility for the accuracy, completeness, or usefulness of any information, apparatus, product, or i
process disclosed, or represents that its use would not infringe privately owned rights. Refer- I
I ence herein to any specific commercial product, process, or service by trade name, trademark,
.. m'''"'"'""'· " oth'"'"' d= '" '""""rily "''"""" " ;mply ;o omlo~m'"" =m-~
' mendation, or favoring by the United States Government or any agency thereof. The views
: and opinions of authors expressed herein do not necessarily state or reflect those of the
L~~i~~ States Government ur any agem;y thereof. .
 '\.

TABLE OF CONTENTS

INTRODUCTION

DISTILLATION UNIT DESIGN 2

•
Stripping Column 2
Rectifying Column 2
Condenser . . . . ·.2
DISTILLATION UNIT FABRICATION .. 12
TEST PLAN , . 13
TEST CONFIGURATION 15
Distillation Columns 18
Boiler . . . . . Z3
· Mash Cookers .. 28
Heat Exchangers 29
Fermentation Tank 32
St i 11 age Tank . . 34
Product Tank .• 35
Electricity Monitoring .... 36
TEST RESULTS . 37
Production Statistics 37
Energy Consumption 41
Water Consumption •. 43
Heat Exchanger 44
Boiler Efficiency 45
Use of Ethanol in a Spark Ignition Vehicle 46

OBSERVATIONS . . 50
Column Plates 50
Reflux Pump . 50
Bottoms Pump 50
Ball Valves. •. 50
Tank Contamination .. 50
CONCLUSIONS .51

•
 INTRODUCTION

In recent years there has been increased interest in the small

scale on-the-farm production of ethanol. As a result a number of individuals
have built, and are currently operating, small scale ethanol plants .
• Dr. Paul Middaugh from South Dakota was one of the first individuals
who built with the help of his graduate students a distillation unit
capable of producing 15 gallons per hour of 180~190 proof ethanol.

Mr. Gene Schroder a farmer from Colorado is one of the few individuals
who have designed, fabricated, and is operating a small scale plant. His
initial plant in 1979 produced 15-20 gallons per hour. Since then he has
made several modifications and is currently opeYating a much larger
plant producing 50 gallons per hour of 200 proof ethanol. This plant
makes extensive ·use of waste heat recovery techniques to achieve a
.positive energy balance of 2.]8.

In Alabama many individuals have constructed or are constructing

similar small scale plants. Many of these individuals Bre re-)nventing
the wheel and are making the same mistakes and errors. As a r~sult of
this activity the Johnson Environmental and Energy Center with assistance
from the Madison County Farm Bureau Association applied for and received
a grant from the U.S. Department of Energy to design, fabricate, and
evaluate a small scale continuous ethanol plant.

The scope of this study was to satisfy four specific objectives.

The first objective was to design a small scale continuous d(stillation
unit capable of producing 10-15 gallons per hour of 170-190 proof ethanol.
• Additional design parameters were to minimize cost, incorporate features
which would permit a farmer to easily replicate the unit, and have a
positive energy balance. It is the opinion of knowledgeable people in
the field that a 12-inch column may be as small as a farmer would want
on his farm since smaller units would require too much of the farmer's
time. Like much farm equipment, the alcohol plant would probably only
be operated seasonally. For example, the winter months which are tradi-
tionally a slack period on farms would be a good time for fuel production.

A second objective of this study was to fabricate the distill~tion

unit. Here again cost and ease of fabrication were important factors.
A third objective was to thoroughly evaluate the distillation unit.
Special emphases wer~ on production potential, operational considerations,
and energy balance. Of special interest was to thoroughly evaluate the
energy balance to determine if a net positive energy ratio can be achieved.
A fourth objective of this study was to work with the Madison County
Farm Bureau Association in identifying an organization that would place
the unit into a production environment. In this environment a legal
entity would be established to operate the unit.
 ...'
DISTILLATION UNIT DESIGN

The unit has been designed to operate continuously:and to produce

between 10-15 gallons per hour of 170+ proof ethanol. The engineering
• drawings of the distillation unit are given in Figures 1 through 8 .
Table I contains a complete 1 ist of materials for the unit. The distilla-
tion columns are sieve tray columns which are probably the·most common
type of ve~sel for distillation. The unit consisis of two columns:
a beer or stripping .column and a rectifying column. Both columns are
made of SCH 20 steel, are 16 feet in length, and have a 12-inch inside
diameter.

Stripping Column (See Figures 4 and 5)

The-stripping column consists of 18 stripping plates which are made

of one-fourth inch steel with approximately eight percent of surface area
of each plate drilled out in a pattern of 30 one-half inch di-ameter holes.
Each plate has a downcomer consisting of two inch steel tubing which
extends from one and one-half inches above the plate, through the plate
and down to within one inch of the plate below. At the opposite side
of the plate from the downcomer is a four inch steel tubing cup which
extends one and one-half inches above the plate. The cup of the lower
plate is positioned below the downcomer of the above plate. Liquid will
build up on the plate surface to the height'of the downcomer and then
flow to the plate below. The cup provides a 1 iquid seal to assure vapors
will rise through the holes in the plate a~d not up the downcomers.

The plates are assembled with two seven-sixteenth inch diameter

steel rods which extend the length of the column. The plates are
separated with two one-half inch diameter, steel tubing, each nine and
one-half inches in length. Also several three-sixteenth inch
by three-fourth inch flat steel bars are bent and welded to the. spacer
tubing for additional tray support. The plate spacing is nine and one-
half inches.

Rectifying Column (See Figures 6 and 7)

The rectifying column consists of 27 rectifying plates which are

made of one-fourth inch steel with approximately eight percent of surface
area of each plate drilled oui in a pattern of 966 7/64 inch diameter
holes. Each plate has a one and one-half inch steel tubing downcomer
and a three and one-half inch steel tubing cup similar to the stripping
column. The plate assembly is identical to the stripping column.

Condenser

The condenser consists of 200 feet of three-fourth inch Type M

copper tubing. The tubino is bent in a circular f.::~shion und placed in
an 18 inch diameter by five foot steel tank.

2
 I
G,
,
( ; ··)
\ '
1..

3 II
I
·W 3ft,"
~ f3o\.•s
130LTS
bEQu"'~~'f

~i. '
SI'J>.~E'C
',!#' ®1'2..EGI.VII>I.L"'/ r~AC.e'D
("T'fP) ,,14- (rtf>)'
•
s \
L ~ G~S~~r

I
~-
_J.__, ~ ~

~
I ToP

I I"
PL"T~
A"'?I<O)<-
I

I -==-,,. ...~......_....,.. ~'"'=' "' io~

PLP>'T-. .
ou~- I
...
C.LE"'-t-.l
~

I:::;Y-1
"'"" , "j) I -, . . !
I I
tl ?'-"''"'='>

·--' ~ ' j II 2.1 (

~·
s'/1 .. Y")., 1q~ •

:3~
I /I.. I
REt=

L~
- - - \1..NOMINICII.. ?1?,..

~~
. (Stt-11.0) -

·:.:=:;:::.. . .-- l
ol

II
1-1 1 J -1 c~~.-)J: I I ·I
Oo,TIOM
,_--- ~ Plf'\"t.,:

-0-J
~--
(R~r-)

13' !>l.f'~.,~:
' 1/ ,, ) _,,.

65~
\.'I t,. ~~ , 1 1~ '2.

rr~';"I~ ,,..)
' ' .
e B
., 1 ~"p, r·s·
- -r -.~ ~ PriO:THtt'"~ ==JJ!;4~
11J"\
E--·/. ~€)o
""""ll
7~
'
1 {j~ J
1
I
?Ut'li> \
)
1'4

-·- - -- ---·-
Y' ·.1
4AVf'l<lX~
_. - ~ - _
- -- • ,

1
+
-"">=~
_
~
_I
~
~G"'s~t:r
\b,."OIARINv

~------~_ __I.---"- Y,--.,- I'L~

I
i
I I
1
(! \ ~
.I IB><:_IB
@ X 'l.
3n;lioL ''

Vt i)OLTS j
Q
V
0 s'"F-8' FR""'\"'1..:
(31
C30L>S
l'l.Eav"'LLi
SPr-.ceo
sPr>.~.oc
4 E"Q
li
I'
'· i
~~ 10 SC.I"\~c I'

Figure 1. Front View of Distillation Unit

J\JtJE: ''Vol
3
•

j ;.....,.. •• _ 3 I

I'_I . 4 p,,... .

.!
>\() 'i~

L --
I'
.
~· i>t?o&. n 1ne'"'p
\ S I<;.HT ~~V(;.~$
:If.( • ?IPE;' 1'\.AC~ tt-l
'"L~I"l . T14HI :liN :t.P.
C c.C:P,I< \41.)S'C0 PL,. c<..t>

Figure 2. Right Side View of Distillation Unit

4
 ,.
~ --- , I

.;-j
I

I .-~~r ~@ ,.~
,,.,;= -··- \

• r~
I \
i
31, ~---~ !

U
~
4
,.t-IPT
P•~"'" I

~· ,. 1,. c:-:-~ I~
/ TH R>.r.'\:>

.., ~· \ !

\ J ·<" Pt?E

PIT"'~~~
jlllf
2.1 I
t::',.. ~
r--- --· l i " 1\l'l'I?OY,
~~;J i
...· I I
I_ .".
A- .~

rr.-
PoRT~
'"" ~'·: r~. ~L I':; <LC~ ·.tl ·Qt } 'i l ..J
l -
_ _. .J
-·· -
'
------, . ._.-• .. - -~
• I I
I
\{) '$TILLI"\C.E
I
I
Q Tl'>.t--11:::

J
~
':-CV

at
~ ~ -c: : ~~
: : _-------~M~m~
1-\E"'\ -
... ·~. ..
T
"" " "'"
t-t!:21

-
J_:1:
,_
L
l_l~)'·- '-~ · ·
/
•.
'
·,. ,,..,s

" (.,
.
" ,"J\
'""
_
""· - -------
1
u\ \___')
I IS. I

. --- )
t-~I"T"'
t." P•l-'" 2.
•
P17~ I I. Il.·~ y / ,

\___/_~ _k_ ~ .... !,,.,.= ~ ... ----

/ \fiR(,_\> "-..... \

•
- ( PuMP

..I - :';\
_.-R..:..;;·
:.tJT:
\UJ\G·E.
- · ·1
2.
I4Q~c ''

NOT 'TO .S<I'\1.\7

Figure 3. Left Side View of Distillation Unit

,.JUI\!6 l'l~l

5
 ...
I

7/.
/I (Jr.
/
/

I
i
'I
! i
\
I
VL " He><. G s. I
SE:t.: 51<'GI<H I' i'JI<,!.
L <Ht\\"11.'~- )

<; \'<>'!" WEI..'P I

'
I
I i I
I I I
II I' I I
,,
I D~
:~
' I
I CJ Yt..
I

I I
iI
I
I
I
I
i
i
!
i
I
i
I I
I
I _- ~
II 0::)
TlJBI~JG

;~)
I I I l

I i !
I
I
-·' I
I
I
"fj~' Dl"-
I
I

L-~W
I I I

I I I I / I II
I
II
I I I
I
v' I
I
I I
·- _j_
-- ~_j :
I
: I
.I I I
I
I
I :I II I
I
I I I
• I I I 1
I
I
! I
I
____..{d I
I
i
!
I
I

Yt • ,~ot:> ~

Figure 4. Stripping Column (Typical-)

JUNC 1'\~\

6
 ./··
,.
cj)
/ ~
//
-Br ·
'·

/
( .' .~ I
_;
' .:

/
I (
~:J,,. ..•,
i .
. / -. ~\
\
I I
\
I 3~ --
I I
4 '--'"""
1\
I
II II
_.., .
.'31:' I

t_ _:_;
\ .Jt · I
\
\
I
I\ I "\ \I
I ----- ~ -· - -~ i +
I .,
\. I\
! 2.
I
,,
/
I
/
/

\..._ __. .. .
. u .
I \\
~

\ ._ )
__ ./
I
;
/

\\ ...
\ /

t. ··-.. \
' '
....
/

\. \ .t

"·
--~
-~ ..... ...~

-. -------- -.- -·----..

I
I
/
lt. ,,
··- -.

Dl~ (
I~" Pll"'
t.
FOi~ S?M~'(:;)
. --~ ------- ----
,,
' y2.. D\f\

30 ~l.,lC5 Lot,..~\:)
1>-.S S 1-\oWt-1

Figure 5. Stripping Plate Hole Configuration

7
 - - -- - - - - - - - - - -- --·---·--·- -·--···- - - - -- - -- -
-,.
<T
=
----
\ - ~
u
·-Cl..
>-
t-
c
E
-
u

;:)
0
01
c
>-
4-
·-
.;.J
u co
Q)
0::::
\..0
Q)
L
- Ir. .'.-.·. .---------~ _:
;:)
\
01
u...
'=-=-'5d
_ - ~
'-'
i ~"'t
:- ~ -----1
 -·

//
,/
,
/_
0
a
()
0

-----
-- - -~ -
0 0
~ () - 0 \
/ / o a o . / _.-- I ~> ,, n
- / n o o _ 1
..... ,' C' ('I ·,
/ o o a o o o'-.. . ._
/
/
/
_.-
a
aa _o
a 0 (1
I
1 '\
\' 0
ooa"
0 0 () vr
•:I
/ 0 O 0 a a O0? a ,r - - - - - ~ ·--T---·· -----~ a a a O a O; a 0 c
J
:I:
/ o o a a o ' a a_a o a
o ao a o a aaa a oa . I ~-~ - -~ -r-----· -- ------ - au a a o o o 0 a o a o
c
0 a a 0 0 0 a _ I C:'l . o o o 0 a a .t .:::::r 0
a o a ·a o a
a , -~ . I o a o o a o a
:~lrc
o o aa a o a a · ~ •I ;' _ o o o o a a a a.
a a a b a a a \ 1 -~ r.i\"?- , .: o o o
a . a a a \
a a a a a a a a -,~ .. I') 0 0 0 0 0 0 0 0
·o o o o o o o o a o o o'o,o o o o o \
\
aooaaoaaa 1 i aaoaCoooo \ 0 ° C I ~
0 a 0 0 0 a a a a 0 ··- ·- - 1 0 a a 0 a a 0 0 0 0I ' l __ fe <;) o o
i \
~,1 ~: t :~ ~
a 0 a 0 0 a a a . o a a ~ 1 ~ 0 a a a a a a 0 ~ 0 c
r
J
r
I
· o o a o o o a a a o · a a a <!:::> a o · o a a a a o o o 0 d t) \
&
a 0 0 a 0 0 a a a 0 0 0 0 a . c 0 I) 0 a a a 0 0 0 u ,) () 0 i,
I Q Q
a o o
Q a a 0 a a _a a 0 I () a a ( I f I ~) 0 a 0 0 () 0 0 (', a 0 V a
o o o a·"" a o o a o a I _c a o_~ a o _9 o a ~a~ :) o o - \ I =~~
0 cb
c I 0
0 \ :r::
·a o o o a a a a o o o a J~J' o -v· - ~o a o a'~" a I --1 a o o 0 . 0 0
1 0 o .- ~a a o a a Q a 0 a r:- o ru o_}o o o a a --t---. o 0
--i-'o ~ o ;-~:-~ L:_t"-/oo a o oo o o o ~a a~~ oo. 6oo
o.a a o ~bo.-a o a o a o a a o ·- !~~ c)
- ~ : :-~ o a a~ a..
I 1o () o 1 / a a o o o a a a a C) 1 a o a a .a o a· 0 0 · ,0 , c) o _ en
c
1 ~o o o a a a a a a a a o o I q o o o a a a a a a '-' 0 - o ·
I o C) o o u o o o o o a o a a o ,o a ·.:: o o o o o a o 0 u 0 o 'Cl <! ~
>-
I a . 0 0 a 0 0 a a 0 a 0 a 0 0 (J (\ 0 0 0 a a a a 0 0 0 0 0 I .. 0. ....,
, c) 0 0 o o a o a o a o a o o ~ o o o o o o a o a o o o <) 1 · . . . . . . __ ... u
0 0 0 0 0 0 0 0 0 a 0 0 a 0 0 0 0 a a a a a 0 0 a 0 0 ,i ~'"' Q)
o o o a o o o a a a 0 0 0 p 0 0 0 a a a a a o a 0 a a1
I
0:::
\, () a () a a a 0 a a a a 0 a , 0 a 0 0 a a a a a 0 a 0 a ;
\_ _Q 0 0 0 0 o o o o o o o _o ? o o o o - o o o o \) o - 0 o Q.- q.
a 0 0 0 0 a a 0 a 0 0 ~ a· a 0 a 0 a 0 0 a a 0 0 a 0 0
;;i .
"';s
\ 0 a 0 0 0 0 0 a a 0 0 a a 0 1a 0 0 0 a 0 a a 0 0 a 0 () ~
0 a 0 a a 0 a a 0 a a 0 a 01 a 0 0 a 0 a a a a 0 l) ~
0 a 0 a 0 a 0 a 0 0 0 ~ ~ a 0 0 0 0 a 0 0 0 0 u 0 - .· ~
0 a a a a a 0 0 0 0 1 j a 0 a a a a 0 0 () U , <f J
a a a a a o a o o o ___ , ..._, a o a o a a :> r·. o I . ,..,"'
·a a a o o a a .. a ~ ./·,o--~ j ~:,.. o o a o a a a o o. .- 1-
o a a a a a a 0 ,,-, I") a 0 a 0 a a a 0 ..- 1 l J
a a o a o a a a ----~1 a a a o a o 0 0 ' _/ ~"' ~
0 0 0 a a a 0 0 .0 0 0 a 0 0 / _,- -
000000 ' oaao.ao --
0 :) o o o a I , ·· a o a o a a
o· o a a a o ',, , .~ o a c a o o .-
-. . .o. o c a a o --------.;..-- ·- o o o a a o _.,.
----. '·, 0 0 0 0 1. o· a 0 0 0 ' ,/
'• ,
, o 0 0 0 a a a 0 /
- - ,, 0 a c ') 0 a 0 0 -··
'r
 "
~ DIA "'OI.£S
, I'"O\~ '/z"I3DLIS \0 F"n,.,..t-'\i:.

"
11 y7.. Dlf\

D I r:>- 1-\t)l..t:: ~
~Q s?~c.-<:'D
(. f"o~ 3j8 " \SOLi" S To 1"\..~T E.)

·,

"QIA \·loLE:.s ~:;.~ SPr'\( ...0\::l

(!o~ Jjg' 01 fJOL \ ;_; )

-.

•
g PIP..

VIEW C-C..

Figure 8. Miscellaneous Plate Hole Patterns

10
 TABLE I. LIST OF MATERIALS

ITEM QUANTITY DESCRIPTION COST

1 32 ft. 12 in. dia. sch. 20 steel pipe $ 783

2 45 12 in. dia. ~ steel plate (for trays) 405
3 30 ft. 4 in. dia. sch. 20 steel pipe 139
4 6 8 in. dia. rings J. 54
6 ·2 0-30 lb. steam gauge 6
7 2 15 lb. pop off valve 25
8 16 ft. 2 in. dia. steel tubing extra thin wall 80
9 3 ft. 4 in. dia. steel tubing sch. 40 29
10 15 ft. H in. dia. steel·tubing sch. 20 75
' 11 4 ft. 3t 1n. dia. steel ·tubing selL 20 30
12 5 4 in. 90° weld elbow (sch. 20) 73
-13 2 Weld caps 12 11 to 4 11 20
14 6 16 in. d i a. rings 108
15 2 18 x 18 x i i n . steel plate 32
16 12 ft. 3/4 in. steel pipe 86
17 18 4 in. steel cap sch. 20 183
18 1 Steel plat.form 350
19 1 Steel platform 150
20 32 ft. 3/4 in. steel pipe 23
21 1 3/4 in. tee 1
22 64 ft. 1/2 in. d i a. steel rod 37
23 64 ft. i in. steel sch. 40 pipe 48
26 2 ft. 1 ~ in. steel pipe 3
27 2 1 ~ in. steel elbow 4
28 4 3/4 in. steel elbow 2
29 2 3/4 in. to 1/2 in. copper elbow reducer 3
30 4 ft. 2 in. s tee 1 pipe 9
31 1 B.ottoin pump 470
Teel 1 P898 rotary screw 9 gpm pump
Dayton i hp. 5 x 994 adj~stable drive
4 x 179 coupling body
1 x 4o8 spider
1 P 675 mounting base
32 Reflux pump
Jabsco 12510-0001
Neoprene. impeller
33 1 Feed pump (same as item 31) .470
34 2 Temperature gauges 250
J~ G Temperature gauges 186
36 3 3/4 in. gate valves 29
100 1 Stee 1 tank 18 in. x 5 ft. p 1a in s tee 1 150
101 1 Steel collection drum 125
102 200 3/4 in. copper tubing {Type M} 94

Misc. i terns $ 200

$4906

11
 DISTILLATION UNIT FABRICATION

After evaluating a number of options, it was decided to have the

.. unit fabricated by an industrial firm. Bid packages were prepared and
sent to four firms in Alabama. Only one firm, Industrial Innovators, Inc.
(Ill) of Ashford, Alabama, submitted a bid. This firm was already manu-
facturing and marketing small scale distillation units, and therefore
could easily fabricate the unit.

The material costs of the distillation unit were re-estimated in

September 1981. These costs are. included in Table I. lri summary, these
costs are:

Materials . 3356
Pumps ~nd temperature gauges 1550
TOTAL 4906
The total labor costs were not estim~ted.; however, the-major l~bor cost
item was the fabrication of the column plates.

'

12
 TEST PLAN

The test plan consisted of the fo ll owing runs:

Run 1 : Prepare 300 gallons of 9 percent water/alcohol beer and

distill

Run 2: Prepare 500 gallons of 9 percent water/alcohol beer and

distill

Run 3: Prepare 800 gallons of 9 percent water/alcohol beer and

distill

Run 4: Prepare 800 gaJlons of 10 percent water/~lcohol beer and

distill

Run 5: Prepar~ 800 gallons of 10 percent water/alcohol beer and

distill ;

Run 6: Prepare 700 gallons of 7 percent water/alcohol be~r and

distill

Run 7: Prepare 1000 gallons of 11 percent water/alcohol beer and

distill
I

Run 8: Prepare 1000 gallons of 12·percent water/alcohol beer and

distill
i
Run 9: Prepare 500 gallons of mash using 2a bushels of wheat
(56 lbs/bu) following instructions in Table I and distill.

By using a mash consisting of alcohol and water it was possible

to more accurately control the percent alcohol in the beer. The
percent alcohol was varied between 7 and 12 percent to test the
still performance over a range of input. The alcohol/water mixture
also permitted the more rapid testing of the unit rather than preparing
mash and waiting three days for fermentation~ ·

13
'

TABLE I I. COOKING AND FERMENTATION INSTRUCTIONS

1. Prepare a 25% (w/w) grain mash by adding 17 gals. of water

to 56 lbs. (one bushel) of milled grain (12 to 16 mesh).
The final volume will be approximately 23.7 gals. since
56 lbs. of grain displaces its own weight in water (6.7 gal.).
If starch is used, rather than grain, the mash. should be
adjusted with water to approximately 25 to 35% ·(w/w) solids.

2. Adjust the grain mash to pH 6.0 to 6.5 with a 10% 1 ime slurry.
As an option hold for one hour at 60°C (140°F).

3. Add TAKA-THERM at 0.15% base~ on the dry starch content (DSB)

of the milled grain. For corn this is 0.05 lb. (22.7 g)
TAKA-THERM per 56 lbs. grain.

4. With contin~ous agitation, begin heating the mash. When the

temperature of the mash reaches 66°C (150°F), ·the grain starch
will begin ~o gelatinize and rapidly thicken. Continue heating
-at a rate such that the mash remains fluid and efficient agi-
tation can be maintained. In the event that the mash is heated
too rapidly, high viscosity will prevent efficient agitation.
When this occurs, heating should be stopped until the viscosity
is reduced.

5. Continue heating the mash to 90°C to l00°C (194°F to 212°F)

and hold until 1 iquefaction is complete.· This should require
a hold period of approximately 30 to 90 minutes. ·complete
1 iquefaction can be judged by determing the reducing sugar
content of the mash by an appropriate method. An acceptable
method is Dextrose Equivalents (DE). When complete 1 iquefaction
is achieved, the mash will be 10 to 14 DE. An alternative test
is to use an iodine solution to test filtered mash. A light
yellow to 1 ight red color indicates complete liquefaction.

6. When liquefaction is compiete, adjust the mash to 18% (w/w)

sol ids with approximately 8 gals. of water and/or stillage.
The final grain concentration should be 56 lbs. of grain in 32
gals. final volume.
0
7. Cool mash to 90 F as fast as possible.

8. Add .4 oz/bushel GASOLASE (fine brown powder). Mix well.

9. Add .8 oz/bushel DISTILLER'S YEAST, (granulated brown powder).

Mix well.

10. Ferment 2-3 days at 80°F to 90°F with occasional gentle agitation.

11. Mash now ready for distillation.

12. With experience, the above rates may be reduced by as much as

50%-60% without loss of yield.

14
 TEST CONFIGURATION

A schematic of the test configuration for the distillation unit

i.s given in Figure 9. Figures 10 and 11 are photographs of the test
configuration.

Water Out
· ........

1000
Gal
'ressure Re.ctifying
Cooker Column
(ficurc (Pllo{ure 10)
z•J

Jransfer
,rPump l'iater
Supply

SteaJII

Figure 9. System Schematic of Test Configuration

15
-- -1-1
c
:::>
c
0
0
Figure 11. Test Configuration
Distilla t ion Columns

The di st i llation columns are installed as shown in Figures 9- 11.

The incomi ng mash is pumped from the fermentation tank through the shell
and tube heat exchanger to the top of the stripping column by a variable
speed rotar y screw pump (See Figure 12). The specifications of the pump
are given i n Appendix B. Steam enters at the bottom of the stripping
column.

The sti llage falls to the bottom of the stripping column and is
removed by a centrifugal pump (See Figure 13). A small 10 gallon sump
tank was installed in the stillage line to keep a prime on the stillage
pump (See Fi gure 13).

The bottoms collected in the rectifying column are removed andre-

turned to t he top of the stripping column by a variable speed rotary
screw pump (See Figure 14). The specifications of the pumps are given
in Appendi x B. A gate valve is also installed in the 1 ine to further
control the bottoms flow.

Fi gure 12. Variable Speed Rotary Screw Feed Pump

18
 Figure 13. Stillage Pump and 10 Gallon Sump

Figure 14. Variable Speed Rotary Screw Bottoms Pump

li
 Figure 15. Column Temperature Gauges

The stripping and rectifying columns are each instrumented with

six dial temperature gauges evenly spaced to monitor the temperature
in the columns (See Figure 15). The steam input is adjusted by a hand
gate valve to maintain the temperature at the bottom of the stripping
co 1umn above 212 0 F. A temperature below 212 0 F will result •1n a 1ass
of product in the stillage. Likewise a temperature in excess of 212 °F
requires additional energy.

20
 The temperature at the top of the rectifying column is monitored
by a dial temperature gauge (See Figure 16}. A neoprene imp~ller reflux
pump (See Figure 17) is used to transfer product back to the top of the
rectifying column. A strainer is installed in-1 ine to minimize the
foreign particles entering the pump. Specifications of the pump are
given in Appendix B.

As the temperature rises on the rectifying column, the operator

turns on the reflux pump for several seconds. This sequence is con-
tinued throughout the run to control the column temperature.

Figure 16. Temperature Gauges for Top of Columns

21
 0..
E
::J
a..
><
::J
4-
Q)
ex::
!"-- N
N
Q)
L..
::J
O'l
lA..
Boiler

A 30 bhp industrial tubeless boiler was purchased from Industrial

Boiler Company, Thomasville, Georgia. The detailed specifications of
the boiler are given .in Appendix C. The boiler is fired with No. 2
oil (140,0og BTU's/gal) .and has the capacity of producing 1035 lbs of
steam (212 F) per hour which is equivalent to 1,005,000 BTU's/hr.

A photograph of the boiler installation is given in Figure 18.

A 280 gallon fuel tank was installed underground approximately eight
feet from the boiler. A stack thermometer was installed to measure
exhaust temperature (See Figure 19). Figure 20 contains a photograph
of the steam distribution system from the boiler to the cooker and
column.

Figure 18 . 30 Hp Boiler

23
Fiaure 19. Stack Thermorneler and Water Meter Installation

Figure 20. Steam Distribution

24
 A chemical feeder system was installed to treat the boiler water.
A BT-20 feeder system and B-42 boiler chemicals were purchased from
Cu 11 i gan. In addition two 7 inch portab 1e exchanger softener tanks
from Culligan were also installed for heating the boiler feed water.
Detailed specifications of the water treatment are given in Appendix D.
A photograph of the chemical feed system is given in Figure 21.

Figure 21. Chemical Feed System

25
 All boiler feed water is first fed through the water softener
(See Figure 22). If the system is distilling ethanol the treated water
is routed through the ethanol condenser and preheated before being fed
into the boiler. A feed water overflow connected to a drain is used
for the excess boiler feed water.

Figure 22. Water Softener Installation

26
 Figure 23. Water Meter Installation

Two water meters are lnstall~d to measure water usaoP.. One 5/8
inch water meter is installed on the outlet side of the water softeners
(See Figure 23). A second 5/8 inch water meter is installed on the
boiler feed water 1 ine to measure the boiler water usage (See Figure 19).

27
Mash Cookers

A 1000 gallon pressure cooker (See Figure 24) from Industrial

Innovators Inc., Ashford, Alabama, was used for all mash preparation.
The cooker uses live steam for cooking and can operate at pressures
up to 70 psig. Steam enters the boiler from the top and is distri-
buted through a three inch pipe approximately two feet from the bottom
of the cooker. The steam input is controlled using a two inch gate valve.

Figure 24. 1000 Gallon Pressure Cooker

28
Heat Exchangers

A 60 foot shell and tube heat exchanger was fabricated for both
cooling the mash during cooking and -preheating the mash prior to dis-
tillation. The drawing and parts list of the heat exchanger are given
in Figure 25 and Table I I I. Figure 26 Is a photograph of the heat exchanger.

Three clamp-on dial thermometers are used to monitor inlet and

outlet temperatures of the heat exchangers (See Figure 27).

TABLE I I I. LIST OF MATERIALS

ITEM QUANTITY DESCRIPTION

1 60 ft. 4 n. dia. steel pipe (Sch. 20)

2 62 ft. 3 n. dia. copper tubing (Type M)
3 2 3 n. to 2 in. copper reducer
4 8 8 n. dia. i. steel ring
5 2 6 n. dia. t; steel ring
6 2 4 n. dia. i; steel ring
7 2 ft. 2 n. dia. steel pipe (Sch 20)
8 6 gasket
9 2 3 in. 90° elbows
10 2 2 in. female copper adapter

29
( 4-\ ,
J.8 biP.

' i ~0'-.:..:;
..S?P."-:.\)
€0
~0 R.
CoPPt.:.""R
1
RED\H..~'' .3/3' ' l:lol..l S

30 I

Figure 25. Heat Exchanger

30
 Figure 26. Heat Exchanger

Figure 27. Heat Exchanger Temperature Gauges

31
Fermentation Tank
A 1250 gallon steel fermentation tank was purchased from Industrial
Innovators Inc. Figure 28 is a photograph of the tank. An i~-line
strainer was installed during Runs 1-7 to protect the in-1 ine flow meter
(See Figure 29). The strainer and flow meter were removed during Run 8
which used wheat.

Figure 28. 1250 Gallon Fermentation Tank

32
Figure 29. Feed Flow Meter and Strainer Installation

33
Stillage Tank

A 1250 gallon polyolifin tank was used for the spent st,illage.
The tank is a one piece polyolifin molding and is 84 inches in di-
ameter, 60 inches in height, and has 1/4 inch walls. The tank was
purchased from H&W distributors in Mooresville, Alabama. Detailed
specifications of the tank are given in Appendix E. A photograph
of the tank is given in Figure 30.

Figure 30. 1250 Gallon Stillage Tc:HJk

Product Tank

A 200 gallon polyol ifin tank is used for product storage (See
Figure 31). Specifications on the tank are given in Appendix. E.
Electricity Monitoring

A number of KWH meters (See Figure 32) were installed to measure

electric consumption of each of the pump motors. The consumption was
measured on the following meters:

1. Mash feed pump motor

2. Bottoms pump motor
3. Reflux pump motor
4. Stillage pump motor

Two KWH meters were also installed to monitor the boiler fuel
pump motor, boiler motor and chemical feeder motor (See Figure 33).

Each KWH meter was calibrated by the Huntsville Utilities and

had an error of less than 2 percent.

Figure 32. KWH Meter Installation

Figure 33. KWH Meters for Monitoring Boiler

36
 TEST RESULTS

Production Statistics

Table IV summarizes the production statistics for the test runs.

A total of over 5000 gallons of mash was distilled during the test
runs .. The production ranged between 8-1] gallons per hour. The proof
correc~ed for temperature ranged between 150-176.

The production for Runs 4, 6, and 8 are given in Figures 34, 35,
and 36. The test .results indicate that product is produced approximately
one hour after mash is fed into the system. Furthermore, the system
reaches equilibrium approximately three hours after the start of the run.
Once equilibrium is reached product can be collected at a constant rate
depending on the mash feed rate and the percent alcohol in the mash.

A number of mash feed rates were tested ranging from a low of 68

gallons per hour to a high of 147 gallons per hour. The higher feed
rates resulted in flooding of the rectifying column and consequently,
the sys'tem becoming unstable. The·;results of the tE;;st run!f indicated an
optimum feed rate of 140 gallons per hour.

The stillage was collected for Runs 4, 6, 7, and 8. The amount

of ethanol remaining in the siillage ranged between 0.25 percent and
2.4 percent. Ideally this percentage should be between 0.1-0.2 percent.
'" Based on the amount of mash fed through the system the amount of
product should have been greater than actually recorded. For example
in Run 4, 81.9 gallons of 200 proof ethanol should have been produced.
However by adding the product yields and .ethanol remaining in the
stillage only gives 67 + 5.9 or 72.9 gallons. For Run 6 an estimated
8.2 gallons and for Run 8 an estimated 32.6 gallons are lost. No good
explanation can be given for this apparent loss. One explanation is
an accumulation of errors resulting from the hydrometers, gas chromato-
.graph and flow meters.

TABLE IV, PRODUCTION STATISTICS

I IIASH STILLAGE PRODUCT

Tl"" Tl""' Tl""'
Take
Before
! Theoret i ca 1 Time Before

Run
%
Beer
I Vol Feed
(gal}
Feed Time
Feed
Rate
(gph)
Alcohol
200 Proof
(gal)
Vol
(gal)
Proof
Alcohol
100 Proof
{gal)
Vol Rate Proof
(gal) (gph) (corrected)
200 Proof
(gal)
Rate
200 Proof
(gal)
'
Product
Over
Product
Over
Take
Product
(hr-mln) (hr·min)
Off
Product

9.0 297 ):00-6:)0 85 26.7 ~I 102 21 ):30 1-0

8.9 - 511 9:30-5:00 68 ~5.5 65 171 56-7.1 - 35 6.~ 10:00 1-0 2-45 tt :45-5:15

9.0 Btl 8:)5-6:00 86 7J;2 ~-2 56 170 ~8 6.9 9:)0 1-10 2-40 11:00-6:00

9.8 840 8:35-):45. 117 82.) 950 1.25 5-9 78 16.7 172 67 1~.) 8:~0 1-)5 )-25 11:)0-4:10

6.6 674 10: 15-):05 140 ~4.4 875 o.s 2.2 )9 9.8 176 )~ 8.5 10:)0 1-5 . 2·20 11 :45-):45

11.0 IDOl 9:40-4 :)0 147 110.0 1050 J.O 15.8 150 10:00 1-)0

12.1 1025 10:15-5:15 146 124.0 1100 4.8 26.4 75 15.6 173 65 1).5 10:00 o-45 Z-45 1Z: )0-5 :20

IU.) aS SO r 1 :4u·5: IS IUU s,.a u.::. :t::t: ~~~ 43 a.6 12 :UU Z-50 3-5 IZ: 15-S: IS
68 76

37
 20 Beer ceed : 117 gph
% Alcohol in Beer : 9.75%
,•·
18

..c
a. .
Ol
16
...
II)

"'
a:

"'>0 14
E
II)
a:
...u
::>
"0
0
1..
0..
12

10

12:30 1 :30 2:30 3:30 4:30

Time

Vol (gal) 15 15 15 .15 18

Proof 181 183 181 179 148

Figure 34 .. Ethanol Production for Run 4

':2
a.
~

...
II)
.Beer Feed : 140 gph
"'
a:
% Alcohol in Beer : 6.6%
"'0>
E
II)
a:
...u
...
"0
0
1..
~
0..

11 :45 12:45 1 :45 2:45 3:45

Time

Vol (gal) 10 10 5 14
Proof 177 179 182 172

Figure J5. Ethanol Production for Run 6

38
 '

.,

26

24 Beer Feed : 146 gph

% Alcohol in Beer: 12.1%

:ca.
"' 18
....Q)
Ill
a:
Ill
> 16
0
E
Q)
a:
....
u
::J
.. ~·
"'0
... 14
0
Q..

12

•·
10

l
I
I
12.30 I. 30 2.30 3.30 4.30 . 5.30
Time
Vol (gal) 6 15 15 15 25
Proof (corrected) 180 177 178 177 162

Figure· 36. Ethanol Production for Run 8

39
 The ethanol production for Run 9 (wheat) is given in Figure 37. It
should be noted that it began to rain at 2:20 p.m. At that time the
temperature was lowered in the column and product stopped. An hour later
the sy~tem had reached equilibrium again, and product was withdrawn from
the system. However, by 5:15p.m., all the mash had been pumped into
the system. Therefore, the ethanol collected in the columns was collected
and measured, which resulted in 68 gallons of 76 proof (adjusted for
temperature)

Beer Feed : 100 gph (approx)

D
..c
a. %Alcohol in Beer: 10.5%
Ol

..,
Q)

ro
0::
;.r-
ro ....--.;;::_
>
0
E
Q)
0::
..,...,
10
.. ::J
"0
0
....
a..

6 1-

n l
II :00
•• 12: 15 I: 15 2:15 3:15 4:15 5:15

D.
2:20 Rain Began

Time

Vol (ga 1) 7 10 5 68
Proof 155 156 153 76

Figure 37 Ethanol Production for Run 9

4o
Energy Consumption

Table V summarizes the energy consumption during distillation

for the test runs. Fuel usage for the boiler ranged from 2.1 to 2.75
gallons of #2 oil per hour. The fuel consumption for Runs 4, 6, :and
8 ranged from 2.2 to 2.4 gallons per hour (or 308,000 to 336~000 BTU's
per hour).

The electrical consumption was only available for Run 8

and average only 2474 BTU's per hour.

The product production ranged from 6.4 to 14.3 gallons of 200

proof ethanol per hour. The production for Runs 4, 6, ~nd 8 ranged
from 8.5 to 14.3 gallons of 200 proof ethanol per hour ·(or 717,400 to
1,206,920 BTU's per hour). It should be noted that the product pro-
duction is based on only the time elapsed after product began to be
removed from the system. This is a valid assumption since the still
is designed to operat~ continuously. Consequently the time for the
system to reach equilibrium should be relatively short as compared
to the theoretical time the system would operate during continuous
d is t i 11 at ion. ~·

Given the above assumption the following energy balance equation

can be stated:

Energy balance =BTU's produced/hr

BTU's used/hr

Gallons 200 proof/hr x 84,400 BTU's/gal

=
Gallons #2 fuel/hr x 140,000 BTU's/gal + KW/hr x 3414 BTU's/KW

Using this equation a positive energy balarice during.distillation

was achieved for all test runs. The energy balance ranged between
1.54 and 3.67. For example, 1.54 BTU's were produced for every 1 BTU's
used.

The energy balance for Runs 4, 6, and 8 ranged from 2.33 to 3.67.
The average of th~se three runs was 3.~. That is,· 3.2 BTU's were pro-
duced for every 1 BTU used.

Run 9 (wheat) used an average of 2.1 gallons of #2 oil per hour

and produced an average of 8.6 gallons per hour 6f 200 proof ethanol.
The energy balance was 2.47 which was less than Runs 4 and 8.

41
·.·

TABLE V. ENERGY BALANCE DURING DISTILLATION

/

Fuel Fuel Elect Ethane 1 Product

Fuel
Time Used Used Used KWH Used Time 200 Proof · 200 Proof 200 Proof BTU Prod/
Run (hrs) (ga 1) (gph) (BTU' s/hr) Used (BTO's/hr) Hr (gal) (gph) .. (Bfu• s/hr) BTU Used

4.0 11 2.75 385,000 21

2 8.25 21 2.5 350,000 5.5 35 6.4 540,160 1.54
3 9.~ 24.5 2.6 364,uuu 7 48 6.9 582,360 1.60
4 8.0 19 2.4 336,000 4.7 67 ' 14.3 1,206,920 3.59
5 2.5
6 6.25 14 2.2 308,000 4 34 8.5 717,400 2.33
7 8.5
8 8.0 17.6 2.2 308,000 5.8 2474 4.8 65 -13.5 1,139. 400 3.67
9 8.0 1.7 2.1 294,000 5 43 8.6 725,840 2.47

42
 ,.

Water Consumption

Table VI summarizes the water consumption during distillation for

the test runs. Si.nce live steam was injected into the column, the boiler
required 100 percent make-up in water. Consequently ihe boiler water
make-up rang&d from 22 to 33 gallons per hour. For Runs 4, 6, and 8
the water make-up averaged 30 gallons per hour.

The u§ag~ in water for the cond~nser. ranged fr9m 2~3 to 4j2 gal~
lons per hour. The water consumpti6n decreased du~ing each run. The
consumption should have remained constant; however it appears that pos-
sibly the portable water softeners lines began to clog with usage and
reduce the water flow.

:···

TABLE VI. WATER USAGE

..
43
Heat Exchanger
The shell and tube heat exchanger was used during Runs 7 arid 8.
The various temperatures are given in Table VI I. Computing the average
temperatures results in an average mash in temperature of 92°F and mash
out temperature of l42°F and an average stillage in temperature of l88°F
and stillage out temperature of l30°F. N.o noticeable reduction in fuel
consumption was noticed by using the heat exchanger. However Run 8 did
have the best erergy balance of 3.67 .

.... ··
.

TABLE VI I. TEMPERATURE IN SHELL AND TUBE HEAT EXCHANGER

Mash Stillage·o
Temperature oF Temperature F
Time In Out In Out

Run 7 10:00 91 138 204 138

10:30 91 155 200 134
11 :00 91 152 196 132
11 :30 91 152 200 138
1,2:00 91 152 198 138
12:30 91 138 189 110
1 :00 91 105 194 140

Run 8 95 125 149 120

11 :30 92 140 174 126
92 147 172 126
2:25 92 .154 ,

44
 Boiler Efficiency

The boiler efficiency was checked twice during the test program:
July 7, after Run 2 and August 5, after Run 8. The summary of the
tests is given in Table VI I I. The two tests indicated ihe boiler
performing very efficiently between 83 and 86 percent.

TABLE VI I I. BOILER EFFICIENCY TESTS

Eff i c i~ncy Test

,.
July 7 Auqust 5

C0 10% 11%
2
02 6% 10.5%

Stack temperature 450 OF 400 °F

Efficiency 83.5% 85.6%

·.•

45
 ..

Use of Ethanol in a Spark Ignition Vehicle

A 100% ethanol .fueled car, a Comodoro, was used to test various

ethanol pro6fs in a spark ignition engine. Thls car is being produced
by General Motors of Brazil and being distributed in Brazil.

Alcohol Cars for America Inc. in Cullman, Alabama, has established

a distributorship in the United States. The vehicle used in the evalu-
ation was purchased by the Alabama Department of Energy ·from this
Alabama distributorship.

The specifications on the Comodoro are:

0 In 1 ine 2500 cc, 89 hp 4 cylinder engine

0 Single venturi carburetor
0 10.5:1 compression ratio
0 4 speed manual transmission
0 3. 54: 1 final drive ratio
0 14 inch wheels ... _. ~-
0 Bias ply tires
0 65 1 iter fuel tank
0 No pollution controls

Figure 38 is a photograph of the Comodoro in its test configuration

in the Johnson Center's laboratory. A Clayton single series chassis dyna-
,.
mometer was used to measure fuel economy.' This dynamometer provides a
steady load to the rear wheels which increases linearly with velocity.
While the car runs on the dynamometer, the ethanol that is being consumed
is measured through a graduated cylinder. The simulated distance driven
is measured by the vehicle's odometer.

The results of the dynamometer tests are given in Table IX. The
car was tested at 35 and 45 mph using 170, 180, and 190 proof ethanol.
Each run consisted of using one quart of fuel. Each test was replicated
four times.

Tt:~ble IX. Fu~::l Economy using the Dynamometer (mpg)

Velocity Fue 1. Proof

mpg 170 180 190

30 18.7 18.5 18.1

45 12.3 12.5 15.2

,>'

The vehicle was also evaluated on-the-road usin~ the route out-.
1 ined in Figure 39. The results are given _in Table X. Six trips were
run each on Route #1 and Route #2. A trip of 185 miles was also made
from Huntsville to Montgomery.
46
FigJre 38. The General Motors of Brazil Ethanol Car
 ,.
! .
>-

....
...
!' ;-- 1
L~! 1!AKJ:.OC
110 I
I

zl
I
-
rn
1 I
II
II
I
1
I
I
4

Figure 39. Routes

48
 '.

Table X. Fue 1 Economy on the Road·

Route Distance Miles

Route (miles) Driven

l 10.6 63.6

2 12.3 73.8

137.4
Fuel used (gallons of 170 proof) 13.3

Fuel economy (mpg) 10.3

Trip to Montgomery 185

Fuel used (gallons of 180 proof) 10. 1
~ ·: .":";.
4·.
~
Fuel economy (mpg) 18.3

Very little difference was noticed in the fuel economy using

the lower proof ethanol. The distillation unit produced an average
of 170+ proof. Therefore it was encouraging that a low proof ethanol
(170+) did not reduc~ vehic~e performance and did not increase the
fuel consumption.

The fuel economy was significantly greater on the long distance

trip of 185 miles to Montgomery as cbmpar~d to the dynamometer runs.
One explanation is the engine was relatively cold during the dyna-
mometer runs. Once the engine is warm, fuel economy increased signi-
ficantly.
 OBSERVATIONS

Column Plates

The column plates were made of 1/4 inch steel. The 1/2 inch
holes were punched in the stripping plates. The 7/64 inch holes
were manually drilled in the rectifying plates. The thickness of
the rectifying plates could possibly be reduced to ·118 inch and
thus would reduce the labor.

Reflux Pump

The centrifugal pump initially purchased began to cavitate

when hot ethanol was refluxed. This pump was replaced with a flexible
impeller pump.

Bottoms Pump

The centrif~gal pump initially purchased to return the bottoms

in the rectifying column to the s~ripping column began to cavitate
when the hot liquid was returned. This pump was replaced with a
variable speed rotary screw pump. This pump permitted better flow
control especially when flooding occurred in the rectifying column.

Ball Valves

The ball valves developed leaks and were replaced with oversized
·gate valves to allow better control of the flow rates.

Tank Contamination

The development of rust inside the steel fermentation tank caused

minor problems in pump operations and clogged 1 ines. As a result
strainers were installed before the feed and reflux pumps. Also con-
tamination in the fermentation tanks caused problems. in mash preparation.

50
 CONCLUSIONS

The conclusions resulting from this study are:

o The distillation unit is capable of continuously producing an

average of 9-14 gallons per hour· (based on alcohol percent in
beer) of 174 proof ethanol. This equates to 12 gallons per hour
of 200 proof ethanol.

o The unit requires approximately three hours to reach steady state

before product can be withdrawn.

o Once the unit has reached steady state very 1 ittle operator atten-
tion is required with the exception of periodically refluxing for
3-5 seconds some of the product back into the rectifying column.
to control the te~perature. This step tould be readily automated.

o The energy ratio for distillation averaged a positive 3:1. That

is, one BTU in fuel was required .. to produce three~BTU's Qf ethanol.

o Water consumptio~ averaged 300 gallons per hour through the condenser.
Of this amount 30 gallons per hour were used as make-up water to the
boiler. ·

o The boiler operated at an average efficiency of 85%.

o The unit is very sensitive to parameter changes such as feed rate,

steam, and column temperature .. The result is a flooding of the
rectifying column.

o High quality pumps designed for transferring sol ids such as mash
::and stillage and ethanol at an el~vated temperature are essential
to minimize operational problems.

o The distillation unit could be built by an individual provided he

is trained in welding and has the necessary machine· shop equipment.

o Tank contamination especially rusi in the fermentation tank and

foreign bacteria caused problems in fermentation. This suggests
a fairly clean operating environment and the use of lined or stain-
'· less steel tanks.

o A General Motors of Brazil ethanol car was tested with 170, 180 and
190 proof ethanol. Very 1 ittle difference in fuel economy was
noticed using the lower proofs.
T

51
 •
Table XI contains the required fermentation capacity and corn
requirement as a function of alcohol production. Tabke XI I contains
the additional acres of corn needed to support a cattle feeding
r facility and the additional fertilizer potential as a function of
plant size. ·

v For example. if the decision was to produce 13 gallons/hour, 24

hours/day, the annual production would be 100,000 gallons. To produce
this amount would require 9360 gallons of fermentation capacity and
124 bushels of corn per day or 60,000 bu~hels per year. Also 653
cattle would be needed to consume the 20% DGWS stillage. These cattle
would need an additional 60,882 bushels of corn per year to complete
the ration. Forty-nine tons of manure would be produced by these
animals.

52
 •
•

r
TABLE XI. SIZING ETIIJINOl ri.AIIT

Annual Alcohol Oai Jy Alcohol Hourly Alcohol Mash Usage/ Tot:~ I Fenaentat ion Bu of CoTn Bu of Com Acres Corn Acres Corn Acres Com
rroJuct ion Production Product ion • Day 1 Capnci ty 2 Required/ Required Needed at Needed at Needed at
(~al/yr) 320 day/yr 10 hrs/day 24 hrs/day .• (gal) (gal) Day 3 pr/yr 100 Bu/Acre 150 Bu/Acre 180 Bu/Acre
(gal ) (gal ) . (gal )

15,000 47 4. 7 470 . 1410 19 6,000 60 40 33

30,000 94 9.4 940 2820 38 12,000 120 80 67
50,000 156 15.6 1560 4680 62 20,000 200 133 Ill
100,000 312 31.2 ll 3120 9360 124 40,000 400 266 222
150,000 469 46.P 19 4690 14070 188 60,000 bOO 400 JJ3
300,000 938 39 9380 28140 375 120,000 I, 200 800 666
500,000 1563 65 15630 46890 625 200,000 2,000 1,333 l,lll
1,000,000 3125 130 31250 !iiJ'lSU 1250 400,000 4,000 2,666 2,222

1. Assume 10\ alcohol yield

Assume 25 gallons of water added 'per bushel

2. Assume 3 days fermentation time and

therefore 3 fermentation tanks

3. Assume 2.5 gallons alcohol/bushel corn

'

TABLE xn. ADDITIONAL ACRES Of CORN M£[0[0 TO SUPPORT CATTLE fEEDING fACILil'i' AND HRTilllER POTENTIAl

Humber of Add' I Bu of Additional Acres of Corn Needed

corn needed pr to Sueport Feed in2 Faclll t:t: Tons of /1anure Acres Nltroqen
~~~· c=~~~
C•t tIe Needed Acres K 0
Dally Gallons yr to complete lao Bu f!l I5o Bu ~ ISO Bu Produced 2
Alcohol Pliint to Consume @ will cover at will cover
Size of Product ion Stlllaqe ration Per Acre Per Acre Per Acre Per Year 1501 per acre at 601 acre at 120.1 acre

15,000 '7
20i OGwS ~8 ~.Ill ~I 61 51 lo 65 ]8
2]
..
t.oG oc,.,s ~~ ),lt17 ]I I~ 20 ll I~
15 10 8 ll I]
60t OCwS
~0 .000
20~ OCwS ~· ·~6
l7 1,51'
18,268 18]
68
122
16
101 IS 8• ,,,"65 71
]8
t.O\ ot.ws
60t DCwS
50,000 156
~8
65
6,8]5
],0]8 ]0 20
lB
17
1
5 "27
" 26
16~

""8
201 OCwS ]27 )O,t.lt1 lD' 20] 1]5 218 128
11,)8~ 6]
ltOt OCwS
60\ DCwS
IUU.UUU )1.1.
16]
10~ 5.066 '"
51
76
)' 28
267
'5 ··~72
6'
'I
20\ OCwS 65] 60,882 60~ ••6 ))8 ~~ 270 .)5 256
ltO't DCwS
60\ DCwS
150.000 16~
]27
217
22,771
10,1)1
228
101
152
68
126
56 "
16
1)5
~·
218
145
128
85

2Cit OCwS ~80 ~1,)11 ~I) 608 507 1) lloS 65) )8.
)1,17] 228 l! 20)
190
~~· )27 192
flO\ OCwS )41
60\ OCwS )26 15,192 151 101 85. 25 1)5 218 128
)00,000 9!8
20l DCwS 1,960 182,682 1,826 1,218 I,Oit. 116 810 1,)06 768
'-Dt. oews 980 68,)16 682 156 )80 72 106 651 ]81
M* or.... o;. 652 )O,)BI )02 202 170 ;u i]U •;6 256
500,000 1,56)
20't OCwS ),266 )01,108 ),Oitli 2,029 1,691 24] 1,)50 2,117 1,280
I!Ot OCwS 1,6)) 11],887 1,1)8 759 6]2 122 2,675 1,088 610
60l OCwS 1,087 50,657 506 )]8 281 81 •so 725 126
1 l'ti II ion ),125
20, OCwS 6,5]2 608,816 6,088 l,o58 ),]82 186 2,700 1,]5, 2,560
l!Ot OCwS ),266 227,77li 2,276 1,518 1,161t 211 1,)50 2,176 1,280
60\ OCwS 2,171t 101,)11! 1,012 676 562 162 900 l,lt50 852
Auumptions
"( One Bu;~el o: ~~~~h~ 1 2 p~ 0~~!!~~~ ~~7~~6o=~~ds of OCwS {stillage).
~~~hc:nl:t coruumes 17.87 pounds of CCIIIIPieto ration per d•Y·
0

62 pounds of Nitrogen.
110 pounds P o •
2 5
117 pound1 ·K D.
2

53