D3MAX - D3MAX Process Technology
The D3MAX process enhances the efficiency of existing ethanol plants by utilizing a technologically advanced, lower-cost pretreatment system. Unlike traditional methods, the wet cake from the ethanol plant is pre-treated, allowing the D3MAX process to operate under milder temperature, pressure, and pH conditions. This innovation reduces both equipment and operational costs significantly. Furthermore, the process converts the cellulose and hemicellulose in the wet cake into monomeric sugars, which are then fermented into ethanol. Additionally, any residual starch in the wet cake is also converted and fermented, streamlining the overall ethanol production process. The resultant byproducts are treated similarly to traditional ethanol plants, creating a high-protein, low-fiber DDGS, which is ideal for monogastric animals and cattle feed. The process can be seamlessly integrated into around 190 dry mill ethanol plants across the US, making it an essential advancement for the ethanol industry.
An important advantage of the D3MAX process is that the wet cake has been “cooked” or pre-pretreated in the ethanol plant. This means that the D3MAX pretreatment can be run at much lower temperature and pressure, and milder pH conditions. The net result is that the cost of the pretreatment equipment is significantly reduced and operating costs are also reduced.
In a presentation at the 2015 Fuel Ethanol Workshop in Minneapolis, Novozymes, a leading cellulase enzyme producer, described corn fiber as a “captive feedstock for cellulosic ethanol with a production potential of 1.3 billion gallons of cellulosic ethanol per year.” Novozymes confirmed BBI’s experience that “corn fiber requires mild pretreatment and has less inhibitors” and further stated “Corn fiber is easily digestible with low enzyme dose.” Novozymes presented experimental results showing that equal conversion of corn fiber is achieved with one-third the enzyme dose compared to corn stover.
The D3MAX process converts the cellulose and hemicellulose in wet cake to monomeric sugars which are then fermented to ethanol. Residual starch in the wet cake is converted to sugar and fermented to ethanol. After fermentation, the “beer” is distilled and dehydrated in the same manner as ethanol produced from corn starch. Water containing protein, lignin, and other non-fermentables is removed from the bottom of the beer column and processed in the same manner as whole stillage in a dry mill ethanol plant to produce a low fiber, high protein DDGS.
Converting the fiber and residual starch in the wet cake to ethanol reduces the volume of DDGS by about 20%. The protein concentration is increased to about 40%. This low fiber, high protein DDGS is suitable for feed for monogastric animals including swine and poultry, in addition to use as a feed for cattle and dairy cows.
The D3MAX process is a “bolt-on” technology suitable for implementation at approximately 190 dry mill ethanol plants in the US.
The benefits of our technology and our competitive advantages are significant and will drive market demand for the D3MAX process. D3MAX is positioned to outperform our competitors for the following reasons:
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D3MAX produces higher yields from corn fiber at lower costs.
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D3MAX is a true “bolt-on” technology for all dry mill ethanol plants. The D3MAX process can be installed without significant downtime or interruption of ethanol production.
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Overall ethanol yield with D3MAX is increased from 2.8 anhydrous gallons per bushel to 3.11 gal/bu.
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Dryer energy use is reduced by 20% with D3MAX.
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DDGS protein is increased from 30% to over 38% with D3MAX.
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The high protein DDGS produced by the D3MAX process is more suitable than traditional DDGS for use with monogastric animals such as swine and poultry.
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Our yeast ferments the glucose, xylose, and arabinose in the corn fiber increasing the yield of cellulosic ethanol.
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Our yeast has GRAS status (Generally Recognized As Safe) and is safe for use in animal feed.
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The D3MAX process produces cellulosic ethanol and increases an ethanol plant’s output by approximately 10% with no increase in corn grind.
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The D3MAX produces cellulosic ethanol from corn fiber and residual starch generating D3 RINs, the highest value RINs under the RFS.
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The projected payback to an ethanol plant that installs the D3MAX process is less than one year.
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Corn oil available for recovery is increased from 1.0 lb/bu to 1.5 lb/bu.
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D3MAX processes the corn fiber in wet cake which has been “cooked” or “pre-pretreated” in the ethanol plant, allowing for much milder pretreatment and lower enzyme dosage resulting in lower capital and operating costs than our competitors.
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D3MAX processes the wet cake allowing for much higher solids loading resulting in lower capital and operating costs than our competitors.
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The distillers grain dryer in an ethanol plant is de-bottlenecked allowing the ethanol plant to increase its grind by up to 28% (mole sieves and other plant subsystems may have to be modified).
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By increasing the corn grind by 28% and using D3MAX to convert wet cake fiber to cellulosic ethanol, overall ethanol production can be increase by 40%