Although the demand for fuel ethanol has risen dramatically over the last decade, ethanol plants face vigorous competition and razor-thin margins. As a result, ethanol plant operators must remain focused on managing costs, increasing ethanol yield and maximizing gross margins.
The Solenis fermentation efficiency program was developed specifically to help ethanol producers address these needs. It combines our decades-long experience in fermentation and ethanol production with our world-class products and services to provide a comprehensive, end-to-end solution for ethanol producers worldwide, regardless of the type of feedstock (sugar cane, sugar beet, corn, wheat) or the preferred fermentation process (continuous versus batch), with or without yeast cell recycling.
Ethanol plants using the Solenis fermentation efficiency program record many benefits, including:
- Enhanced stability of the fermentation process
- Improved thermal- and acid-tolerance of yeast cells
- Improved microbiological control
- Increased productivity, with greater ethanol yield
- Improved ethanol product quality
- Reduced water and steam consumption
- Reduced pollutant emissions
- Decreased total operating costs
How It Works
The Solenis fermentation efficiency program links together all of the chemistries required for fermentation to create synergies that lead to more efficient, more robust ethanol production without installing additional capacity. The program is backed by the insights and expertise of Solenis’ team of sales professionals and applications experts, who work side-by-side with plant technical staff to develop a fully customized solution based on the plant’s unique operating needs.
The Solenis fermentation efficiency program typically includes the following products:
- Antifoams and Defoamers — A side effect of more robust fermentation is the generation of more carbon dioxide, leading to increased foaming. Solenis offers a complete family of high-performance antifoams and defoamers that effectively control the foam produced in a wide range of fermentation process applications.
- Biocides and Antimicrobials — Bacteria can also carry out fermentation, which means they can compete with yeast cells for available sugars and nutrients. Before introducing cell nutrition additives, Solenis recommends the use of biocides and antimicrobials to keep bacterial levels as low as possible.
- Nutrients — Maintaining the best possible cell yeast physiology is vital to efficient ethanol production, so the program provides a spectrum of macro- and micronutrients to maintain the thermal- and acid-tolerance of yeast cells.
- Scale Inhibitors — Increased scaling in distillation columns is typical as more salts are separated during high-efficiency centrifugation, making scale inhibitors a necessity. Solenis offers a complete portfolio of scale inhibitors and antiscalants for controlling the formation of virtually any type of scale.
- Viscosity Modifiers — The chemical control of typical fuel ethanol feedstocks can generate high viscosity levels that can throttle back the fermentation process. As a result, the Solenis fermentation efficiency program includes viscosity modifiers to improve system rheology, increase the efficiency of yeast cell centrifugation and maintain a more stable fermentation.
In addition to these chemistries, the Solenis fermentation efficiency program may also be bundled with any of our proprietary sensors, analyzers and controllers. Our team of professionals will consult with plant operators to determine the most appropriate monitoring and control solution.
Recorded Results
The Solenis fermentation efficiency program can help boost yields and quality. A Brazilian fuel ethanol plant producing a million liters of ethanol a day recently reported the following results after starting the fermentation efficiency program:
- Increased alcohol yield by 11.0%
- Reduced water consumption by 44%
- Decreased operational costs by 33%
- Reduced system downtime
More Information
If you have a question about the Solenis fermentation efficiency program or would like free technical advice on a technical challenge, ask a Solenis expert today.
