Innova&ve water reclama&on pilot plant with animal feed produc&on from ethanol wastes

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1 Innova&ve water reclama&on pilot plant with animal feed produc&on from ethanol wastes J. (Hans) van Leeuwen Chris Koza, Dan Erickson, Mary Rasmussen, Debjani Mitra, Duygu Ozsoy, Mike Persia, Nick Gabler Iowa State University and MycoInnovaLons

2 Typical corn dry-grind ethanol plant Distillation Fermentor Ethanol Water Enzymes CO 2 Milling Cooking Corn DDGS Distillers dried grains with solubles Syrup Vapor Evaporator DDG Dryer Thin stillage Thick stillage Whole stillage Dewatering

3 Corn to ethanol plant limitations Ethanol 1/3 CO 2 1/3 Water Stillage DDG(S) 1/3 The solution? $$$$$ 2c/gal

4 Thin stillage characteristics Total Solids (TS), % 6.1 Total Chemical Oxygen Demand (TCOD), mg/l 100,000 ph 4 and 100 COD:5N:1P Total Nitrogen, mg/l as N 5,700 Total Phosphorus, mg/l as P 1,300 ph Glycerol Lactic Acetic acid g/l 3 4 g/l 1 2 g/l

5 Rhizopus microsporus var. oligosporus Phylogeny Kingdom Fungi Order Mucorales Family Mucoraceae Genus Rhizopus Species microsporus var. oligosporus Tempeh eaten by humans for centuries AnLmicrobials produced can lead to increased GI health GRAS Status from the FDA

6 The MycoMeal process Dewatering

7 Design approach to fungal thin stillage treatment reactor Objective Water reclamation Rapid fungal growth Fungal pellet formation Requirement Approach Implementation High-rate Aerobic Rhizopus organic fungal microsporus removal process High aeration Fine porous Deep tank rate High Renumber diffusers High agitation shear Draft tube recirculation

8 Design approach to fungal harvesting, dewatering and drying Objective Requirement Approach Implementa tion Fungal harvesting Rapid separation Size-based selection Course screen ease Dewatering Low energy Cloth Vacuum ease Product preservation input Drying below 12% filtration filtration Evaporation Microwave drying

9 Flow diagram of pilot plant

10 Fungal cultivation Shake flask cultures 50 L Preculture 1600 L reactor Heat exchanger

11 Porous diffusers for aeration

12 Pilot plant team showing quality improvement Team members Chris Koza and Dan Erickson graduate students

13 Screen harvesting

14 Spin filter developed Biomass in bags are spun in a washing machine to remove excess water

15 Microwave drying Cellencor microwave dryer used to prepare animal feed with 12% moisture content

16 Microwave drying

17 Alternative technologies tested - drying and dewatering Filter press Centrifuge Drum dryer These technologies were not found suitable for fungal biomass

18 Vacuum filtration

19 Change in thin stillage quality Parameter Typical change COD 30-60% Suspended solids 80-90% Acetic acid 80-98% Lactic acid 80-90% Glycerol 50-80% ph Up by 0.5

20 Analysis of amino acids in fungal biomass Amino acid % Aspar&c Acid 2.07 Threonine 0.95 Serine 0.88 Glutamic Acid 2.90 Proline 1.41 Glycine 1.00 Alanine 1.98 Valine 1.36 Amino acid % Isoleucine 1.09 Leucine 2.34 Tyrosine 0.83 Phenylalanine 1.31 Lysine 1.36 His&dine 0.71 Arginine 0.96 Total Amino Acids 21.2

21 Analysis of oil extracted from fungal biomass Fatty acid Name of fatty acid % in oil C 16 Hexadecanoic acid 15.8 C 16:1 Palmitoleic acid 0.28 C 17:0 Heptadecanoic acid 0.70 C 18:0 Stearic acid 3.0 C 18:1 Oleic acid 27.0 C 18:2 Linoleic acid 49.8 C 18:3 Gamma linolenic acid 1.55 C 18:3 Alpha linolenic acid 1.40

22 Animal feed testing Feeding tests with chickens and pigs proved that the fungal biomass Mycomeal is an excellent feed ingredient for monogastrics

23 Gross nutritional indicators (proximate analysis and metabolizable energy) Feed ingredient Fungal biomass Corn 2 Soybean meal (48%) 2 DDGS 3 Crude protein (%) Methionine Cystine Total sulfur amino acids Lysine Threonine Arginine Ether extract (%) Total fat Crude fiber (%) Total ash (%) Phosphorus Starch (%) TME n (kcal/kg) * 5,382 3,470 2,485 2,845 *Total metabolizable energy as determined in poultry trials including excreta analysis 2 NRC, 1994; 3 Waldroup et al., 2007

24 Feeding trials Other than poultry and pigs, the fungal biomass is acraclve to pets and humans. We expect to develop a nutrilonal supplement from fungi to help alleviate malnutrilon in developing countries

25 Recognition of research , 2008, 2009,

26 MycoInnovations Scale- up &me has arrived Small adjustments needed

27 Acknowledgements q Drs. Hui Wang and Larry Johnson, Center for Crops ULlizaLon Research, Iowa State University q Ranae Jorgenson, AURI, Minneapolis q Norm Olson, Biomass Conversion Facility, Nevada, Iowa q Iowa Energy Center for funding q Lincolnway Energy for raw materials and advice

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