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Ethanol Distillation Process (Dry Milling)
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Milling: The corn (or barley or wheat) first passes through hammer mills, which grind it into a fine powder called meal.


Liquefaction: The meal is then mixed with water and alpha-amylase, and passes through cookers where the starch is
liquefied. Heat is applied to enable liquefaction. Cookers with high temperature stages (120-150 degrees Celsius) and
a lower temperature holding period (95 degrees Celsius) are used. These high temperatures reduce bacteria levels in
the mash.


Saccharification: The mash from the cookers is cooled and the secondary enzyme (gluco-amylase) is added to convert
the liquefied starch to fermentable sugars (dextrose), a process called saccharification.


Fermentation: Yeast is then added to the mash to ferment the sugars to ethanol and carbon dioxide. Using a continuous
process, the fermenting mash is allowed to flow, or cascade, through several fermenters until the mash is fully
fermented and leaves the final tank. In a batch fermentation process, the mash stays in one fermenter for about
48 hours before the distillation process is started.


Distillation: The fermented mash, now called "beer," contains about 10 percent alcohol, as well as all the non-fermentable
solids from the corn and the yeast cells. The mash is pumped to the continuous flow, multi-column distillation system
where the alcohol is removed from the solids and the water. The alcohol leaves the top of the final column at about 96
percent strength, and the residue mash, called stillage, is transferred from the base of the column to the co-product
processing area.


Dehydration: The alcohol from the top of the column passes through a dehydration system where the remaining water is
removed. Most ethanol plants use a molecular sieve to capture the last bit of water in the ethanol. The alcohol product
at this stage is called anhydrous (pure, or without water) ethanol and is approximately 200 proof.


Denaturing: Ethanol that will be used for fuel is then denatured with a small amount (2 to 5 percent) of some product,
like gasoline, to make it unfit for human consumption.


Co-Products: Two main co-products are created in the production of ethanol: carbon dioxide and distillers grain.
Carbon dioxide is given off in great quantities during fermentation and many ethanol plants collect it, clean it of
any residual alcohol, compress it and sell it for use to carbonate beverages or in the flash freezing of meat.
Distillers grains, wet and dried, are high in protein and other nutrients and are a highly valued livestock feed
ingredient. Some ethanol plants also create a "syrup" containing some of the solids that can be a separate production
sold in addition to the distillers grain, or combined with it. Ethanol production is a no-waste process that adds
value to the corn by converting it into other products.






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