Modeling the process and costs of fuel ethanol production by the corn dry-grind process

The corn dry-grind process is the most widely used method in the U.S. for generating fuel ethanol by fermentation of grain. Increasing demand for domestically produced fuel and changes in the regulations on fuel oxygenates have led to increased production of ethanol mainly by the dry-grind process. Fuel ethanol plants are being commissioned and constructed at an unprecedented rate based on this demand, though a need for a more efficient and cost-effective plant still exists.A process and cost model for a conventional corn dry-grind processing facility producing 119 million kg/year (40 million gal/year) of ethanol was developed as a research tool for use in evaluating new processing technologies and products from starch-based commodities. The models were developed using SuperPro Designer® software and they handle the composition of raw materials and products, sizing of unit operations, utility consumptions, estimation of capital and operating costs, and the revenues from products and coproducts. The model is based on data gathered from ethanol producers, technology suppliers, equipment manufacturers, and engineers working in the industry. Intended applications of this model include: evaluating existing and new grain conversion technologies, determining the impact of alternate feedstocks, and sensitivity analysis of key economic factors. In one sensitivity analysis, the cost of producing ethanol increased from US$ 0.235 l−1 to US$ 0.365 l−1 (US$ 0.89 gal−1 to US$ 1.38 gal−1) as the price of corn increased from US$ 0.071 kg−1 to US$ 0.125 kg−1 (US$ 1.80 bu−1 to US$ 3.20 bu−1). Another example gave a reduction from 151 to 140 million l/year as the amount of starch in the feed was lowered from 59.5% to 55% (w/w).This model is available on request from the authors for non-commercial research and educational uses to show the impact on ethanol production costs of changes in the process and coproducts of the ethanol from starch process.