Progress 09/15/09 to 04/30/10
Outputs
Progress Report Objectives (from AD-416) The objective of this research project is to develop new, cost effective, alternative methods and engineering processes for corn processing and fractionation using enzymes, immobilized enzymes and othere environmentally sustainable processes that maximize the yields of products and co-p[roducts (starch, protein, ethanol, oil, and fiber) and increase co-product marketr diversity and value while eliminating hazardous processing aids, such as sulfites. Approach (from AD-416) This project was conceived and developed from the concept of taking a new approach to existing processes with the connecting element being enzymatic application. Many of the milling processes currently in use have been done in a similar fashion for over 100 years. By carefully reexamining what we know and don't know, and what works and what still has room for improvement we can use this to guide research towards beneficial modifications of existing processes and invent completely new design concepts. The experimentation for this project is constructed to cover fundamental research through design and economic assessment. Scale- up studies are incorporated into the plan where appropriate demonstration efforts and material are required. Process modeling and cost analysis are critical elements that are incorporated throughout the project design and are intended to aid in the overall process evaluation and to help identify potential problems early in experimentation. This is the final report for the project 1935-41000-081-00D. Over the course of the 5 year project, significant accomplishments were made. The first publically available process and cost models for Fuel ethanol production using the Corn Dry Grind process, Corn Wet Milling using the conventional sulfite process, and Enzymatic Corn Wet Milling using a new enzyme based process were developed, validated and published under this project. These models have been requested and shared with 1000�s of research scientists in academia, industry and government throughout the world. The wet milling process model has been requested and used as a teaching tool in engineering classes in the US and abroad. An enzymatic corn wet milling process was developed that replaced the use of sulfites in the conventional process. After extensive testing and multiple publications, two separate full scale plant trials of the Enzymatic Corn Wet Milling process were conducted. These trials generated significant data used in the development of economic and process models. A unique process for improving the energy and water use in fuel ethanol production was developed under this project. The process utilizes enzymes added during fermentation for decreasing the water binding of the insoluble fiber so it can be more easily separated. This allows more efficient drying and reduced energy utilization in the processing facilities. During the course of the project, a full scale plant trial was done at a 54 MGY processing facility of the enzymatic dewatering process. The trial clearly demonstrated a significant decrease in the total natural gas usage for the ethanol facilities and this data was used to develop process and cost models. Several strains of the yeast Phaffia rhodozyma were developed for production of astaxanthin, which is a high-value added co-product that can be produced from by-product streams in a corn ethanol plant such as thin stillage and corn fiber residues. These strains were capable of utilizing all the major carbon substrates (glycerol, glucose, xylose, and arabinose) from the aforementioned corn ethanol by-product streams. The developed strains demonstrated capability of utilizing the fermentable sugars in an actual hydrolysate made from corn fiber pretreated with aqueous ammonia and converting them to astaxanthin at similar efficiencies observed with clean synthetic sugar solutions. Corn fiber gum (CFG), an arabinoxylan, is an alkaline extract of "corn fiber" an abundant low-value by-product of corn wet/dry milling. CFG fractions from were isolated, characterized and their emulsifying properties studied and found to be superior when compared to the well known gold standard emulsifier gum arabic. Our results suggest that CFG has significant potential to replace some or all of the multimillion $ market of imported gum arabic. Corn Fiber Gum was also found to contain functional structural components that may have nutraceutical value, further enhancing its useful properties. This research generated significant data that has been used in a number of publications and has been met with strong interest by food companies and a CRADA is in progress.
Impacts
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Publications
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