The Alcohol Textbook

448 Pages·2003·4.48 MB·English

by  K.A. Jacques

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Edited by KAJacques, TPLyons and DR Kelsall
Foreword iii
The Alcohol Textbook
4th Edition
A reference for the beverage, fuel and industrial alcohol industries
K.A. Jacques, PhD
T.P. Lyons, PhD
D.R. Kelsall
iv T.P. Lyons
Nottingham University Press
Manor Farm, Main Street, Thrumpton
Nottingham, NG11 0AX, United Kingdom
NOTTINGHAM
Published by Nottingham University Press (2nd Edition) 1995
Third edition published 1999
Fourth edition published 2003
© Alltech Inc 2003
All rights reserved. No part of this publication
may be reproduced in any material form
(including photocopying or storing in any
medium by electronic means and whether or not
transiently or incidentally to some other use of
this publication) without the written permission
of the copyright holder except in accordance with
the provisions of the Copyright, Designs and
Patents Act 1988. Applications for the copyright
holder’s written permission to reproduce any part
of this publication should be addressed to the publishers.
ISBN 1-897676-13-1
Page layout and design by Nottingham University Press, Nottingham
Printed and bound by Bath Press, Bath, England
Foreword v
Contents
Foreword ix
T. Pearse Lyons
Presient, Alltech Inc., Nicholasville, Kentucky, USA
Ethanol industry today
1 Ethanol around the world: rapid growth in policies, technology and production 1
T. Pearse Lyons
Alltech Inc., Nicholasville, Kentucky, USA
Raw material handling and processing
2 Grain dry milling and cooking procedures: extracting sugars in preparation for
fermentation 9
Dave R. Kelsall and T. Pearse Lyons
Alltech Inc., Nicholasville, Kentucky, USA
3 Enzymatic conversion of starch to fermentable sugars 23
Ronan F. Power
North American Biosciences Center, Alltech Inc., Nicholasville, Kentucky, USA
4 Grain handling: a critical aspect of distillery operation 33
David J. Radzanowski
Alltech Inc., Nicholasville, Kentucky, USA
Substrates for ethanol production
5 Lignocellulosics to ethanol: meeting ethanol demand in the future 41
Charles A. Abbas
Archer Daniels Midland, Decatur, Illinois, USA
6 Ethanol production from cassava 59
Nguyen T.T. Vinh
The Research Institute of Brewing, Hanoi, Vietnam
7 Whey alcohol - a viable outlet for whey? 65
Jack O’Shea
Alltech Inc., Dunboyne, County Meath, Ireland
8 Treatment and fermentation of molasses when making rum-type spirits 75
Robert Piggot
Alltech Inc., Nicholasville, Kentucky, USA
vi T.P. Lyons
Yeast and management of fermentation
9 Understanding yeast fundamentals 85
Inge Russell
International Centre for Brewing and Distilling, School of Life Sciences,
Heriot-Watt University, Edinburgh, UK
10 Practical management of yeast: conversion of sugars to ethanol 121
Dave R. Kelsall and T. Pearse Lyons
Alltech Inc., Nicholasville, Kentucky, USA
11 Continuous fermentation in the fuel alcohol industry:
How does the technology affect yeast? 135
W. M. Ingledew
University of Saskatchewan, Saskatoon, Saskatchewan, Canada
12 Understanding near infrared spectroscopy and its applications in the distillery 145
Don Livermore1, Qian Wang2and Richard S. Jackson2
1Hiram Walker & Sons Ltd., Walkerville, Ontario, Canada
2Bruker Optics Inc., Billerica, Massachusetts, USA
13 Emerging biorefineries and biotechnological applications of nonconventional
yeast: now and in the future 171
Charles A. Abbas
Archer Daniels Midland, Decatur, Illinois, USA
Beverage alcohol production
14 Production of Scotch and Irish whiskies: their history and evolution 193
T. Pearse Lyons
Alltech Inc., Nicholasville, Kentucky, USA
15 Tequila production from agave: historical influences and contemporary processes 223
Miguel Cedeño Cruz
Tequila Herradura, S.A. de C.V. Ex-Hda San Jose del Refugio Amatitán, Jalisco, México
16 Production of heavy and light rums: fermentation and maturation 247
Robert Piggot
Alltech Inc., Nicholasville, Kentucky, USA
17 From pot stills to continuous stills: flavor modification by distillation 255
Robert Piggot
Alltech Inc., Nicholasville, Kentucky, USA
18 From liqueurs to ‘malternatives’: the art of flavoring and compounding alcohol 265
Andy Head and Becky Timmons
North American Biosciences Center, Alltech Inc., Nicholasville, Kentucky, USA
Foreword vii
19 Production of American whiskies: bourbon, corn, rye and Tennessee 275
Ron Ralph
Ron Ralph & Associates Inc., Louisville, Kentucky, USA
Contamination and hygiene
20 Bacterial contamination and control in ethanol production 287
N.V. Narendranath
North American Biosciences Center, Alltech Inc., Nicholasville, Kentucky, USA
21 Managing the four Ts of cleaning and sanitizing: time, temperature, titration and
turbulence 299
Jim Larson and Joe Power
North American Biosciences Center, Alltech Inc., Nicholasville, Kentucky, USA
Recovery
22 Ethanol distillation: the fundamentals 319
P. W. Madson
KATZEN International, Inc., Cincinnati, Ohio, USA
23 Development and operation of the molecular sieve: an industry standard 337
R. L. Bibb Swain
Delta-T Corporation, Williamsburg, Virginia, USA
Engineering ethanol fermentations
24 Water reuse in fuel alcohol plants: effect on fermentation
Is a ‘zero discharge’ concept attainable? 343
W. M. Ingledew
University of Saskatchewan, Saskatoon, Saskatchewan, Canada
25 Understanding energy use and energy users in contemporary ethanol plants 355
John Meredith
Ro-Tech, Inc., Louisville, Kentucky, USA
The dryhouse, co-products and the future
26 Dryhouse design: focusing on reliability and return on investment 363
John Meredith
Ro-Tech, Inc., Louisville, Kentucky, USA
27 Ethanol production and the modern livestock feed industry: a relationship
continuing to grow 377
Kate A. Jacques
North American Biosciences Center, Alltech Inc., Nicholasville, Kentucky, USA
viii T.P. Lyons
28 Biorefineries: the versatile fermentation plants of the future 387
Karl A. Dawson
North American Biosciences Center, Alltech Inc., Nicholasville, Kentucky, USA
The Alcohol Alphabet 399
A glossary of terms used in the ethanol-producing industries
Index 441
Foreword ix
Foreword
Alcohol production: a traditional process changing rapidly
T. PEARSE LYONS
President, Alltech Inc., Nicholasville, Kentucky, USA
In its simplest form, alcohol production is the liters/tonne. In fact, we predict yields of 3.2
process of preparing starch- or sugar-containing gallons in the near future. For molasses, the
raw materials for fermentation by yeast, which advent of detranases can ensure maximum
is currently the only microorganism used for yields. Every aspect of cooking and fermentation
converting sugar into alcohol. The ethanol is must be controlled, however.
then concentrated and recovered in a process
called distillation. Though essentially a simple
process, making it happen with maximum The cooking process
efficiency on a very large scale is a remarkable
combination of microbiology and engineering. Much debate exists at the moment regarding the
Over the past 25 years progress has been made cooking process. It is a sad reflection perhaps
in virtually all aspects of the process, but what on our industry that since the pioneering PhD
are the challenges facing alcohol in the future? work by Dr. John Murtagh in 1972 no further
Beginning with raw material processing, here scientific thesis has been published on cooking.
are the areas that we feel need to be addressed: Should grain be finely ground? Should cooking
involve high temperature α-amylase or should
an entirely different type of enzyme be used?
Raw material reception and processing Often the enzyme selected is one developed
based on experience in the corn wet milling
Despite many declarations to the contrary, it is sector, which may be far from ideal for dry mill
virtually impossible for a distillery to accurately alcohol production.
calculate true yields. A sampling of grains is Our industry needs a new enzyme, one tailored
either done in very cursory fashion or not at all. to our specific needs: converting grain to
The distiller must see himself first as a processor fermentable sugar. Raw materials contain not
of grain rather than a producer of alcohol. He only starch, but also hemicellulose (a polymer
must know accurately how much starch is of 5-carbon sugars) and cellulose. The cooking
present in his raw material and he must be able process must be designed to loosen these
to measure that immediately. NIR spectroscopy materials such that they release bound starch and
has much to offer in terms of raw material also become available in turn for fermentation.
applications; and this topic is detailed in this
volume. However, if we control the process and
use the appropriate enzymes from solid state Yeast and fermentation
fermentation, such as Rhizozyme™ and
Allzyme™ SSF, which are capable of releasing Despite all we know about it, yeast remains
not just bound starch but also hemicellulose and underrated and misunderstood. It is the
cellulose, we can and indeed some plants do, workhorse of the distillery, yet ‘economies’ on
get 2.9+ gallons per bushel (116 gallons or 420 quality and quantity of yeast are made; and we
x T.P. Lyons
Corn Rye
STARCH
Wheat Potatoes
LIQUIFACTION
Barley Milo (sorghum)
Enzymes
DEXTRINS Cellulose
Molasses Agave
Sugarcane SUGAR Sugarbeets
Whey
CO-PRODUCTS
Yeast CO2
DDGS BIOREFINERY
Wet cake
Value-added
PRIMARY ALCOHOL Solubles
co-products
POT STILL CONTINUOUS STILL
Irish Rum Grain Grain Fuel
Whiskey Whisky Alcohol Alcohol
Malt Tequila
Whisky
Bourbon Gin Vodka
Blended Whisky
Scotch Whisky
WHITE SPIRITS
MATURATION SPIRITS
often force it to grow and operate under uncontrolled, will prevent the yeast from
unsuitable conditions. As Professor Mike performing. Operating a fermentation at 23%
Ingledew has pointed out many times, the ethanol is totally different than operating a
fermentor is not a garbage can! We must make distillery at 8% ethanol. Any minor change,
sure that conditions in fermentation are optimum whether in mycotoxin level, salt level or nutrient
for yeast. level can have a major impact on performance.
Like our need for appropriate enzymes, ethanol
production also requires yeast with higher
ethanol and temperature tolerance if we are to Microbial contamination
keep progressing to higher levels of alcohol in
the fermentor. Today, 17-20% abv is becoming A distillery is never going to be a sterile
standard in our industry as we move to high fermentation and even those of us who have had
temperature ThermosaccTM-like yeast. When the good fortune to operate in sterile fermentation
used in combination with enzymes capable of conditions know how easily infection can take
extracting increasing amounts of sugar, such as hold. Since the yeast is a relatively slow-growing
those produced by surface culture fermentation, microorganism compared to most of the
yeast can bring us to a whole new level. infectious microorganisms (Lactobacillus, etc.),
While 23% ethanol by volume in the fermentor it is critical that we have an arsenal of
without loss of performance is possible given antimicrobial agents and effective cleaning
the right yeast and enzyme combination, it can products and programs ready to protect the
only be done by careful management of the so- fermentor environment.
called stress factors. Factors which, if left
Foreword xi
Recovery and utilization of co-products with PhD and masters degrees, our industry has
very few. Unlike the brewing industry, which
As we review our overall process, it is obviously has no less than five brewing schools around
critical that we maximize utilization of co- the world, the annual Alltech Alcohol School
products. Assuming the feedstock is corn, the remains the only venue for industry-wide
major cost factors are the raw material, energy, training.
enzymes, processing chemical cost (water The Alltech Institute of Brewing and Distilling,
treatment, etc.) and labor. Much of these costs established in 2000, set out to address this
can be offset with 17 lbs of distillers grains shortfall by working in conjunction with the
coming from each bushel of corn; but we must Heriot-Watt University in Scotland. Perhaps our
maximize the return on this essential product. industry should use the brewing industry as a
Distillers grains with solubles (DDGS) are model. Scholarships should be funded and
currently (July 2003) selling for around $80/ton perhaps a bioscience center concept established.
and corn for $2.20 per bushel. At $0.04 per lb Bioscience centers bridge the gap between
($80/ton), 17 lbs of DDGS gives us a credit of university and industry by creating an
$0.68. This is set against the $2.20 bushel of environment where students are encouraged to
corn or the $0.03-0.04 for enzymes. If on the complete higher degrees while doing industry-
other hand, new or novel products could be focused research.
made from distillers grains, (i.e. improved by-
pass proteins for cattle, pre-hydrolyzed DDGS
for human foods), the financial impact could be Conclusions
substantial. The future will see many new
products built around DDGS. This is the subject The alcohol industry, therefore, is alive and well,
of a separate chapter in this volume. and we have been given an opportunity to
As dry mills shift toward biorefining, instead achieve something that many of us thought
of simply grinding, corn, yield of ethanol would have been achieved by the mid-1980s.
becomes only one part of the economic We have a superb oxygenate that will help
equation. Perhaps in the future, further reduce global warming and at the same time
processing of distillers grains will create products enable us to add value to our grains. The world
that make spent grains the single most important is not short of starch and sugar, the world is short
raw material from a distillery. After all, they are of protein. The fuel alcohol industry and
rich and valuable protein sources, a commodity beverage alcohol industries therefore are in fact
in very short supply across the world. generators of protein; it only remains for us to
make sure the proteins we generate are the most
advantageous possible to man and beast.
Education The chapters in this book we hope will help
the reader realize the complexity and at the same
Perhaps the biggest surprise, as one surveys the time the simplicity of the process of converting
progress that has been made in the last 20 years sugars to ethanol. If we make your search for
is how little progress has been made in the area information just a little easier, we will have
of education. Unlike the brewing industry, which achieved our objective. If we can encourage
seems to have an abundance of professionals more research, then we will be well-rewarded.