The document discusses the process of ethanol production from corn. It explains that corn is first ground into flour and mixed with water and enzymes to break it down into sugars. Yeast ferments the sugars to produce ethanol, which is then distilled. The byproducts of distillation like dried grains and carbon dioxide are also discussed. The document also covers using ethanol in cars, including types of ethanol blends and modifications needed to vehicles to enable their use.

1. -how ethanol is made
-using ethanol in your car
-better gas mileage
-the effects of ethanol on your engine

2. Ethanol is another name for ethyl
alcohol, or “grain alcohol”
Made from corn starch it is 200
proof ethanol.

3. First of all there are two types of processes.
 Wet milling: this is probably only 20% of the
plants in the US.
 Dry milling: is about 80% of the plants in the US.
 The difference is how the starch (typically corn
starch) is processed in the beginning. Steeped or
not steeped.

4.  Starch
Starch belongs to a group of chemical
compounds called carbohydrates which are
energy storage units in plants such as corn.
They are called this because they contain only
carbon, hydrogen, and oxygen or sugar (i.e.
glucose) molecules.
These glucose molecules are connected
together and can be broken down by enzymes
then used as “food” for yeast cells.

5. • Endosperm – This is the part
where the starch comes from.
Part of the gluten also comes
from here. 65-75% of the
kernel is comprised of this.
• Germ – this is the part of the
corn that oil is made from.
About 5% of the kernel is
comprised of germ.
• Pericarp – This is the outer
layer of the kernel. It
comprises 5% of the kernel.
• Tip Cap – where the kernel
obtains nutrients to grow.
• Other components – Moisture
comprises about 15% and ash
and other solubles are about
6%.

6. Starch is a series of sugar molecules linked together in corn and it
has two main parts: amylose and amylopectin.
Amylose is a straight or linear chain of sugar molecules linked
together.
Amylopectin is a branched chain of sugars called dextrins.

10. Yeast convert sugar into alcohol – the same fermentation process that has
been used for thousands of years, although on a much larger scale. A
typical dry mill production facility produces 50 to 100 million gallons of
ethanol a year!!!

11. Corn and/or Milo is delivered to
the silos.
Then ground into a flour by the
hammer mills.

12.  The hammer mill hoppers have screens to
measure the particle sizes going into the plant to
keep larger particles out. Such as cobs and/or
rocks.
 The flour is sent by vacuum and conveyor belt to
the Mingler to mix and then sent to the Slurry
Tank.

13. Cooking
 Liquefaction
 Saccharification
 Fermentation
 Distillation
 Biproducts

14.  The addition of water, heat and enzymes break
the ground corn into fine slurry.

15.  The slurry is heated for sterilization and is pumped
to a Liquefaction tank where other enzymes and
heat are added to convert the starches into
glucose sugars.

17.  Next the corn slurry (mash) is pumped into
fermentors where yeast is added to begin the
forty-eight to fifty hour batch fermentation process.
 After the fermentation process the “beer” is sent to
the beer well.

19.  After fermentation, the resulting "beer" is
transferred to distillation columns where the
ethanol is separated from the remaining "stillage."
 The ethanol is concentrated to 190 proof using
conventional distillation and then is dehydrated to
approximately 200 proof in a molecular sieve
system.

20.  The solubles are then concentrated and used as
Condensed Distillers Solubles (CDS) or "syrup.“
 The coarse grain and the syrup are then dried
together to produce dried distillers grains with solubles
(DDGS), a high quality, nutritious livestock feed.
 The CO2 released during fermentation is captured and
sold for use in carbonating soft drinks and beverages
and the manufacture of dry ice.

22. WET FEED or DRY FEED
mixed with SYRUP!!
Makes Happy Cows!!

23. Carbon Dioxide Captured!!!!
Carbon Dioxide puts fizz in
your drink!!

24.  Ethanol from the ethanol plant has denaturant in it, so don’t
drink it!
 E10 is 10% ethanol and 90% gasoline and denaturant, it can
be used in ANY car.
 E85 is 15% ethanol and 85% gasoline and denaturant.
 Different types of denaturant are added due to the climate in
different areas. Ethanol does not spark as good as gasoline.

25. Using ethanol will clean out your engine sludge that
is why you need good filters if converting.
Reducing knocking and pinging.
Ethanol (E85) doesn’t have as much energy as
gasoline. But it has lower emissions and better for
your engine.
Using Ethanol is less expensive and does improve
your mileage because it is higher in octane than
gas.

26.  Government tests have proven that using E85 help to
reduce hydrocarbon, benzene, and carbon dioxide
emissions!!! These are major contributors to global
warming and pollution.
 CO2 is released during ethanol production BUT it is
recaptured and used in the soda pop you are drinking!!
 Using Ethanol helps to decrease carbons in the carbon
cycle unlike fossil fuel combustion.
 Ethanol also degrades quickly in water which is less of a
risk during a spill than gasoline. It is biodegradable!!

27.  Vin number: the 2nd
and 3rd
number of the vin tells
the manufacture of the car.
 The 4th
through the 8th
tells the car’s brand, engine
size, and type.
 So, the 2nd
, 3rd
, and 8th
numbers in the vin identify
flex fuel vehicles.
 Easier yet, look at your gas cap or buy a FFV
(flex fuel vehicle, can use either gas or E85)
www.e85fuel.com

29.  The largest difference between an E85 powered
vehicle and a gasoline powered vehicle is that
their computer modules are meant to read
different amounts of oxygen within the fuel.
E85 contains a higher amount of oxygen. Your
"check engine light" will come on.

30.  Other modifications have to be made to be
compatible with using ethanol. The fuel tank, fuel
lines, fuel injectors, computer system, and anti-
siphon devices.
 Only one way has government approval. The
easy way….

31.  FlexTek is simply a computer component that
changes the pulse width of your injectors. You
simply remove your injector plugs on your fuel
injectors and insert them into the FlexTek.
 FlexTek works by opening the injectors open
longer and sending more fuel through to the
combustion chamber.
 The FlexTek has a switch reading "A" or "G“.
Running Alcohol (E85) or Gasoline.

33.  Use high quality synthetic oil! E10 and E85 can
be corrosive, especially if converting an older car.
Have the oil changed on schedule.
 Use High Flow Air Filter. These will catch any
particles that may flake off from the engine.
 Use Fuel Efficient spark plugs with cold start
warranty.
 Lastly, change the fuel filter if having trouble early
on.

35. Enzymes:
http://www.genencor.com/cms/connect/genencor
www.enzymedevelopment.com
Compatible cars:
http://gmdynamic.com/gmfuelcalc/
http://e85-ifc.comhttp://www.e85fuel.com/pdf/vin.pdf
Fuel calculator:
http://gmdynamic.com/gmfuelcalc/
Link for other gas powered engines:
http://www.ethanolrfa.org/resource/warranty/

36.  Video
ethanolhttp://www.drivingethanol.org/ethanol_facts
/ethanol_flash_demo.htm
 Where to buy E85
http://www.eere.energy.gov/afdc/fuels/ethanol_loc
ations.html or
http://www.e85refueling.com/locations.php?
state=ksKansas
 Cara’s email: iucarabou@yahoo.com