INTRODUCTION

Ethanol as Biofuel

Ethanol (C2H5OH) is an intoxicating, energy-

yielding molecule produced by alcoholic fermentation

from plants with high carbohydrate content such as barley,

wheat, corn, and grapes and other raw material containing

high level of starch (Science Direct, n.d.). The Energy

Information Agency (2005) describes the history of

ethanol. Ethanol’s first use was to power an engine in

1826, and in 1876, Nicolaus Otto, the inventor of the

modern four-cycle internal combustion engine, used ethanol to power an early engine. Ethanol

also was used as a lighting fuel in the 1850s, but its use curtailed when it was taxed as liquor to

help pay for the Civil War. Ethanol use as a fuel continued after the tax was repealed, and fueled

Henry Ford’s Model T in 1908. The first ethanol blended with gasoline for use as an octane booster

occurred in the 1920s and 1930s, and was in high demand during World War II because of fuel

shortages (North Dakota State University, 2010).

Ethanol is a renewable fuel made from corn and other plant materials. The use of ethanol

is widespread, and more than 98% of gasoline in the U.S. contains some ethanol. The most

common blend of ethanol is E10 (10% ethanol, 90% gasoline). Ethanol is also available as E85 (or

flex fuel)—a high-level ethanol blend containing 51% to 83% ethanol, depending on geography

and season—for use in flexible fuel vehicles. E15 is defined by the Environmental Protection

Agency as a blend of 10.5% to 15% ethanol with gasoline. E15 is an approved ethanol blend for
use in model year 2001 and newer light-duty conventional gas vehicles. A gallon of ethanol

contains less energy than a gallon of gasoline, resulting in lower fuel economy when operating

your vehicle. The impact to fuel economy varies depending on the energy difference in the blend

used. For example, E85, which contains 83% ethanol content, has about 27% less energy per gallon

than gasoline (the impact to fuel economy lessens as ethanol content decreases). Engines in

gasoline vehicles, including flexible-fuel vehicles (FFVs), are optimized for gasoline. If they were

optimized to run on higher ethanol blends, fuel economy would likely increase as a result of

increased engine efficiency.

Ethanol also has a higher octane number than gasoline, which provides increased power and

performance. For example, Indianapolis 500 drivers often fuel their race cars with E98 because of

its high octane. There are currently projects underway, including the Co-Optimization of Fuels and

Engines initiative, to understand the potential for improving engine efficiency through the use of

ethanol blends and other high-octane biofuels. (Biofuel Association Australia, 2016).
MANUFACTURABILITY

Dry mill process is a simpler process compared to wet mill process thus producing fewer

products. Ethanol from corn involves multistep procedure that can be breakdown into five steps

namely; 1) grinding, 2) cooking and liquefaction, 3) saccharification, 4) fermentation, and 5)

distillation.This process of producing ethanol from corn as the main raw material is being widely

utilized in the USA and South America.

Yield:

Dry mill process of ethanol production from corn produces generate 2.8 gal of ethanol from

every bushel which is approximately 8 gal of corn. Corn on a dry basis consist of 73% starch and

27% is protein, fiber, and oil. (Penn State University, 2018).

By-product:

The process involves the production of by-product such as dried distillers grains

(DDGs) and carbon dioxide (CO2) amounting to 17 lbs each per bushel of corn used to produce

ethanol.

Process Usage:

Dry mill process to produce ethanol from corn has not been widely used in the Philippines

but rather the utilization of sugarcane as the predominant raw material since the Philippines is a

sugar-producing country. The process is being adopted primarily by the USA and South America.
SAFETY:

The table below show the operating temperature and pressure of the equipment involved

in the production of ethanol from corn via dry milling process. The overall process includes 2

equipment that operates under elevated pressure and 3 equipment that works within elevated

temperature.

INTENSIVE EQUIPMENT:

Table: Equipment for Dry Milling Process with operating pressure and temperature

Equipment Number Pressure Temperature

Storage Tank ST-001 101.325 kPa 20ºC

Hammer Mill HM-001 101.325 kPa 30ºC

Slurry Tank SLT-001 101.325 kPa 30ºC

Pressure Cooker PC-001 310.264 kPa 147.37ºC

Water Tank WT-001 101.325 kPa 15.55ºC

Cooler CO-001 101.325 kPa 15.55ºC

Mixing Tank MT-001 101.325 kPa 62.78 ºC

Cooler CO-002 101.325 kPa 25ºC

Storage Tank ST-002 101.325 kPa 30.56ºC

Fermentor FE-001 101.325 kPa 30.56ºC

Fermentor FE-002 101.325 kPa 30.56ºC

Fermentor FE-003 101.325 kPa 30.56ºC

Condenser CR-001 101.325 kPa 144.59ºC

Distilling Column DC-001 411. 617 kPa 144.59ºC

Accumulator AC-001 101.325 kPa 25ºC

Heat Exchanger HE-002 411. 617 kPa 36.67ºC

Storage Tank ST-003 101.325 kPa 35 ºC

Purifying Column PC-002 101.325 kPa 25ºC

Heat Exchanger HE-003 411. 617 kPa 25ºC

Heat Exchanger HE-004 411. 617 kPa 91ºC

Reboiler RB-001 101.325kPa 91ºC

Storage Tank ST-004 101.325 kPa 37.78ºC

Rectifying Column RC-001 101.325 kPa 25ºC

Heat Exchanger HE-005 411. 617 kPa 25ºC

Reboiler RB-002 101.325 kPa 91ºC

Heat Exchanger HE-006 101.325 kPa 32.22ºC

Storage Tank ST-005 101.325 kPa 32.22ºC

Heat Exchanger HE-007 101.325 kPa 15.56 ºC

Storage tank ST-006 101.325 kPa 25ºC

Corn serves as the predominant raw material in the production of ethanol via dry milling

process. Corn is considered to be non-hazardous by OSHA because it is a form of land crop in

agriculture with nutritional basis and value. A common yeast to use is saccharomyces cerevisiae,

which is a unicellular fungus in order to permit fermentation to take place. It is not also considered

hazardous by the OSHA.

Handling saccharomyces cerevisiae does not exhibit acute and over exposure harm in case

of eye and skin contact as well as inhalation and digestion. However, in case of eye contact.

Immediately flush eyes with water. When skin was exposed and in contact with saccharomyces

cerevisiae, wash the affected area with water and remove contaminated clothing or shoes and get

medical attention if irritation occurs. In case of inhalation or digestion, expose the victim in fresh

air and keep at rest in a relax position until a medical aid and personnel is present.

Raw materials should be stored and regulated in a secured place with local regulations. Use

appropriate containment to avoid environmental contamination. It is always advised to wear

protective attire and apparatus in the manufacturing or process field to prevent and reduce accident

brought by the chemicals and equipment present in the operation.

Production of ethanol and other biofuels is typically a more complicated process and leaves

a larger footprint in terms of land use than does production of many fossil-fuel sources of energy.

At the ethanol processing plant or biorefinery, greater amounts of energy are typically required

than were used in the growing and transporting of the corn to the plant. Production of corn ethanol

and the ensuing increased demand for corn can pose environmental challenges if care is not

exercised in bringing additional (T. Douglas, 2009)

REFERENCE:

Penn State University. (n.d.). How Corn is Processed to Make Ethanol. Retrieved November 20,

2018, from https://www.e-education.psu.edu/egee439/node/673

Affymetrix. (n.d.). SAFETY DATA SHEET. Retrieved November 21, 2018, from

http://www.affymetrix.com/support/technical/usb/msds/23546A.pdf

Douglas, T. (2009). Economic and Environmental Impacts of U.S. Corn Ethanol Production and

Use. Retrieved November 24, 2018, from

http://research.stlouisfed.org/publications/red/2009/01/Tiffany.pdf

Biofuel Association Australia. (2016). How is ethanol made? Retrieved November 24, 2018, from

http://biofuelsassociation.com.au/biofuels/ethanol/how-is-ethanol-made/

North Dakota State University. (2010). History of Ethanol Production and Policy. Retrieved

November 22, 2018, from https://www.ag.ndsu.edu/energy/biofuels/energy-briefs/history-of-

ethanol-production-and-policy.
Science Direct. (n.d.). Ethanol. Retrieved November 22, 2018, from

https://www.sciencedirect.com/topics/pharmacology-toxicology-and-pharmaceutical-

science/ethanol