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BY RPPLIED IMRGE, INC.

Design and Construction of a 7,.500 liter Immobilized Cell Reactor.Separator for Ethanol Production from Whey

M. ClarkDale, Sr. Research Engineer Divisionof Biochemical and Food Process Engineering, Ag. Eng. Dept. Purdue University, WestLafayette, IN 4790%1146

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Written for presentationat the 1992Annual Meeting of the American Institute of ChemicalEngineers,Miami, Nov. 2-6

Updatedfor publication in"Chapter One" 2/2/93, mcd

Abstract A 7_00 liter reactor/separator hasbeenconstructed theproduction for ofethanolrom f concenwated wheypermeate. This unit is sited in Hopkinton IA, across the street from a whey generating cheese plant. A two phase construction project consisting of 1) building and testing a reactor/separator with a solvent absorberin a single unified housing, and 2) building and testing an exwactive distillation/product stripper for the recovery of anhydrous ethanol is under way. The design capacity of this unit is250,000 gal/yr of anhydrous produc, . Design and construction details of the reactor/absorber separator are t given, and design parameters for the extractive distillation system are described. DISCLAIMER
This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes anywarranty, express,or implied, or assumes any legal liability or responsibility for the accuracy, completeness, _r usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does notnecessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.

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Introduction
A novel continuous fermenter-separator for the production of ethanol fromwaste sugars has been under development at Purdue University and was patented in 1985. Conversion of waste sugars from whey or starch wastes streams can reduce BeD of the wastes by up to 90% while producing a valuable commodity chemical, ethanol. The Immobilized Cell Ro_ctor-Separator (ICRS) is a continuous system utilizing immobilized cells and simultaneous separation of the ethanol. This systemshould allow on-site production of ethanol by food processors having a trouble-some waste stream. .. Ethanol production from the available food processing wastes may represent the most viable method for the u'ttlization of large volumes of waste carbohydrates. Current ethanol production in the USA is at about 5 billion pounds/year with an available market of 78 billion pounds/year if all motor fuelwere a 10% ethanol blend. Readily fermentable available annual waste streams of whey permeate (3.4 billion pounds solids), corn and potato food processing wastes (6.3 billion pounds solids), molasses (5.4 billion pounds solids) could possibly produce up to 6 billion pounds of ethanol per year, with an energy equivalent of 6 x 10t3Btu/year. Further energy savings is gained by eliminating wastetreatment energy, which is typically about 1 KW per pound of BeD (up to 12 billion KW/yearnationwide,about x 1Ot3Btu/year). or 12 ConceptDescription The ICRS concept ses u wholelive microbial adsorbed oan absorbent cells t packing malzix convertugars ethanolndcarbon to s to a dioxide.he ethanolsmoved fromthe T i liquid phase as it is formed into an inert stripping gas phase circulated through the...