Overview of the Ethanol Industry and Co-Products Matthew L. Gibson, Ph.D. Mark Giesemann, Ph.D. Kip Karges, Ph.D. Reciprocal Meat Conference Brookings, SD June 20, 2007
Overview Birds-eye View 1. Fuel Ethanol Industry Very brief Production 2. Feed Products Current Products New / Future
Introduction Fuel Ethanol Industry
Nomenclature Distillers Dried Grains w/ Solubles D D G / S
Dry Grind, Fuel Process 2006 Dakota Gold Marketing
Modern, Dry-grind, Fuel Ethanol Plant 2006 Dakota Gold Marketing
Industry Organizations (A Selected Few ) Renewable Fuels Association www.ethanolrfa.org American Coalition for Ethanol www.ethanol.org National Ethanol Vehicle Coalition www.e85fuel.com
Fuel Ethanol Plants MidWest 84 542 Operating 132 Construction 86 532 230 155 656 1,702 85 3 212 102 831 155 Sites: DTN, May 18, 07 Current Production: RFA, 07 2006 Broin and Associates, Inc. 67
Ethanol Production USA 1980-2016 18 16 Billion Gallons 14 12 RFS 10 8 6 4 4.5 2 0 '79-'80 '84-'85 '89-'90 '94-'95 '99-'00 '04-'05 '09-'10 '14-'15 Growth: Dry Grind * Adapted from PRX Digest, page 42, May 12, 2007
Uses of Fuel Ethanol Brief Overview Renewable Fuel E-85 Octane Booster ~ 113 Oxygenate Replaces MTBE Small Engine E-10 Marine E-10 Automotive E-10 & E-85 Aviation AGE-85
USA Protein Availability '04 - '05 '05 - '06 45 40 DDG/S Surpasses Cotton and Canola 35.62 36.60 Million Metric Tons 35 30 25 20 15 10 6.86 9.20 7.62 7.38 7.00 7.66 5 0 DDGS Cotton Canola SBM
DDG/S Production USA 1996 2016 50 45 40 35 30 25 20 15 10 5 0 Million Tons Growth: Dry Grind Actual Projected '95-'96 '96-'97 '97-'98 '98-'99 '99-'00 '00-'01 '01-'02 '02-'03 '03-'04 '04-'05 '05-'06 '06-'07 '07-'08 '08-'09 '09-'10 '10-'11 '11-'12 '12-'13 '13-'14 '14-'15 '15-'16 * Adapted from PRX Digest, page 42, May 12, 2007
WHAT IS IN A BUSHEL OF CORN 1 = 1 / 3 1 / 3 1 / 3
DDG/S Rule O Thumb Nutrient Balance: Corn x 3
Quality & Nutrition
General Definitions New / Golden Old / Brown Reduced Maillard Browning Increasing non-ruminant usage Extensive Maillard Browning Little non-ruminant usage Grain: From: Corn Fuel Grains: Corn & Mixed From: Fuel & Potable
Define Product Nutrients / Quality How do we measure?
DDG/S Variability Selected Nutrients Source Nutrient* Industry-wide Source DG CP 30.1 (2.6) 30.7 (1.2) Fat 11.5 (3.5) 11.9 (0.7) ADICP 28.9 (11.7) 8.2 (2.3) NE L 1.93 (0.14) 2.19 (0.04) P 0.88(0.14) 0.70 (0.10) * Mean (Std Dev) Robinson, 2004
* Dakota Gold Brand Only Not Industry-wide values Dakota Gold* Nutrient Database Over 1,700 Analyses > 600 New Crop 06 07 Values Listed Proximate Analysis Energy Values Fiber Fractions Amino Acids Minerals Trace Minerals www.poetenergy.com/nutrition
# 2 Yellow Corn
Mycotoxins Concentrated 3X from Corn Are not destroyed during process Fermentation Drying Yearly & Geographical Variation Of Note Aflatoxins, Fumonisins, DON, Zearalenone
Mycotoxin Testing Procedures Corn S-ELISA 2 Suppliers HPLC DDG/S AOAC Lab HPLC S-ELISA?
Energy Nutrition 1 ME-S Values, kcal/kg 2 Exp. 1 Exp. 2 Mean Grower 4,707 2,983 3,845 Finisher 4,191 3,428 3,810 Mean 4,449 3,206 3,828 NRC 3,032 1 Spiehs, et al., U MN 2 DMB
Energy Nutrition 1 ME-S Values, kcal/lb 2 Ingredient NRC DGRA Corn 3,842 3,864 DDGS 3,032 3,940 1 Allee, 2005 2 DMB
Corn Protein New Crop 03 04
Amino Acid Nutrition Dakota Gold LYS* Crop Yr x s n 03 04 0.96 0.20 > 500 04 05 0.94 0.12 > 200 05 06 0.95 0.10 > 400 06 07 0.91 0.06 > 200 *AFB
Lysine Digestibility Swine Digestibility Trials Source LYS TOT DC LYS DIG NRC 0.62 47 0.29 Old 1 0.68 0 0.00 MNSD 1 0.83 53 0.44 SD Low 2 0.68 44 0.30 SD High 2 0.85 63 0.54 1 Whitney et al, 1999 2 Stein et al, 2006
Chick AA Digestibility Ergul, et al 1 (cont.) 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 Digestible LYS 0.38 L* = 41.8 b* = 32.9 0.65 L* = 53.8 b* = 42.8 1 PSA, 2003
Variability in Color Batal & Dale 1 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 Digestible LYS 0.18 L* = 50.4 b* = 7.41 0.66 L* = 60.3 b* = 25.9 1 PSA, 2006
Phosphorus Bioavailability Gold Standard * Methods Swine Slope Ratio Assay Comparison: MSP (NaH 2 PO 4 ) Fibula: Ash & Breaking Bioavailability Native: 85 % Phytase: 100 % * Allee and Fent, 2005
Fat Analysis Corn 1 DDG/S 2 C16:0 11 13 C18:1 cis 24 29 C18:2 cis 59 51 Ω 3 0.7 2 Ω 6 58 52 Unsat:Sat 6.5 4.6 I Value 125 110 FFA 0? 10 1 NRC 2 DGRA
New Processes & New Technology
2005 Broin and Associates, Inc.
Conventional vs BPX Conventional L* 52 a* 11 b* 39 L* 51 a* 15 b* 44
Advantages Physical Characteristics Improved Handling Flowability, Transport, Storage Enhanced Pelleting Increased Density Chemical Characteristics Heat Damage Improved Nutrition
Bio-refinery Concept
Dakota Gold HP DDG
Process Flow: Ingredient Origin* Whole Corn Dry Milling FF Germ Bran Endosperm Fermentation Dry Corn Germ Dehydrated Hi-Pro DDG Syrup Blend Dakota Bran (Bran & Syrup) * Feed Products in Red
Dakota Gold HP Crude Protein 43.0 Crude Fat 4.3 LYS 1.4 MET 1.2 CYS 1.6 Phos 0.5
Corn Germ Dehydrated Crude Protein 17.5 Crude Fat 20.0 LYS 0.8 MET 0.3 CYS 0.5 Phos 1.7
Energy Nutrition 1 ME-S Values, kcal/kg 2 Ingredient NRC DGRA Corn 3,842 3,864 DDG/S 3,032 3,940 Dakota Gold HP - 4,049 Corn Germ Dehy - 4,504 1 Allee, 2005 2 DMB
Summary Ethanol Industry Explosive Growth New Technologies Distillers Grains Source of Nutrients Quality Issues New Products
Any Questions?