ARS "Baseline" DDGS plant 38,717 BTU/gal 3,242

2022 "Vanilla" DDGS plant projection 28,660 BTU/gal 2,251

2022 Projections, DDGS

"Vanilla" Plant 28,660 BTU/gal 2,251

With CHP 30,898 BTU/gal 512

With CHP and Fractionation 25,854 BTU/gal 1,512

With CHP, Fractionation and Membrane Seperation 21,354 BTU/gal 1,682

With CHP, Fraction, Membrane Seperation, and Raw Starch Hydrolysis 16,568 BTU/gal 1,682

2022 Projections, Wet DGS

"Vanilla" Plant 17,081 BTU/gal 2,251

With CHP 19,320 BTU/gal 512

With CHP and Fractionation 17,285 BTU/gal 1,512

With CHP, Fractionation and Membrane Seperation 12,785 BTU/gal 1,682

With CHP, Fraction, Membrane Seperation, and Raw Starch Hydrolysis 9,932 BTU/gal 1,682

Assumptions

40.4% of thermal energy is used for drying DGS, 59.6% used for ehtanol production

Corn fractionation reduces thermal energy usage by 17.6% of total for DDGS (Updated Mueller Paper)

Corn fractionation reduces thermal energy usage by 7.1% when producing wet DGS (since drying benefits of fractionation are i

Corn Fractionation increases electrical energy use by 1000 BTU/gal (Mueller Paper, increases to 1kWh per gal)

Membrane separation reduces thermal energy usage by 4500 BTU/gal *Conversations with Vaperma/EPA(Vane)

Membrane separation increases electricity usage by 0.05 kWh per gal *Conversations with Vaperma/EPA(Vane)

Membrane separation reduces thermal energy by 15.7% and increases Electrical by 7.6% from 2022 base

Raw Starch Hydrolysis reduces base thermal energy by 16.7%

Plants with fractionation produce 0.163kg corn oil/gal ethanol

Natural Gas

Thermal Electricity

Natural Gas

Thermal Electricity

Natural Gas

Thermal Electricity
BTU/gal 43,447 BTU/gal 3,125 BTU/gal

BTU/gal 35,824 BTU/gal 2,694 BTU/gal

BTU/gal 35,824 BTU/gal 2,694 BTU/gal

BTU/gal 39,407 BTU/gal 205 BTU/gal

BTU/gal 33,102 BTU/gal 986 BTU/gal Natural Gas Boiler

BTU/gal 27,477 BTU/gal 1,191 BTU/gal Natural Gas CHP

BTU/gal 21,495 BTU/gal 1,191 BTU/gal Coal Boiler

Coal CHP

Biomass Boiler

Boimass CHP

BTU/gal 21,351 BTU/gal 2,694 BTU/gal Integ. Biogas Energy System

BTU/gal 24,934 BTU/gal 205 BTU/gal

BTU/gal 22,390 BTU/gal 986 BTU/gal

BTU/gal 16,766 BTU/gal 1,191 BTU/gal

BTU/gal 13,200 BTU/gal 1,191 BTU/gal

Corn Oil Extraction

Raw Starch Hydrolysis

Corn Fractionation

Membrane Seperation

 benefits of fractionation are irrelevent)

1kWh per gal) Dry Thremal Avg. (w/improvements)

rma/EPA(Vane) Dry Electrical Avg. (w/improvements)

ma/EPA(Vane)

Wet Thremal Avg. (w/improvements)*

Wet Electrical Avg. (w/improvements)

Assuming 37% DGS sold wet

2022 Thermal Average

2022 Electrical Averate

Natural Gas Fueled

Coal Fueled

Biomass Fueld

Biogas Fueld

2022 Natural Gas plant with Corn Oil Extraction

Dry DDG

Wet DDG

Weighted Avg (37% wet)

Biomass

Electricity Thermal Electricity

Biomass

Electricity Thermal Electricity

Biomass

Electricity Thermal Electricity
Number of Plants Thermal Energy Electrical Energy Thermal Weighted

2020 2025 2022 2020 2025 2022 2022 (kWh)2022 (BTU)

54.0% 42.0% 49.2% 29156 27915 28660 0.66 2251 14101

11.0% 13.0% 11.8% 31433 30096 30898 0.15 512 3646

0.0% 0.0% 0.0% 36444 34894 35824 0.79 2694 0

4.0% 4.0% 4.0% 40089 38383 39407 0.06 205 1576

10.0% 12.0% 10.8% 36444 34894 35824 0.79 2694 3869

9.0% 12.0% 10.2% 40089 38383 39407 0.06 205 4019

12.0% 16.0% 13.6% 13211 12649 12986 0.06 205 1766

Total 28977

Reduction Weighted Reduction Weigthed Reduction Weighted Reduction

70.0% 5.4% 3.78% -9.9% -6.93% 0.0% 0.0% -9.9%

22.0% 16.7% 3.67% 0.0% 0.00% 16.7% 3.67% 0.0%

20.0% 17.6% 3.52% -29.0% -5.80% 7.1% 1.42% -29.0%

5.0% 15.7% 0.79% -7.6% -0.38% 15.7% 0.79% -7.6%

Total 11.76% Total -13.11% Total 5.88% Total

25570

1714

16255

1714

22123 BTU/gal

1714 BTU/gal

61.0%

4.0%

21.0%

14.0%

h Corn Oil Extraction Thermal Electrical

27111.98 2473.409

17,081 2473.409

23400.56 2473.409

Wet DDGS

Thermal Energy Electrical Energy

2022 Penertaion

Thermal Energy

Dry DDGS

Electrical Energy
Electrical Weighted

1107

60

0

8

291

21

28

1515

Weighted

-6.93%

0.00%

-5.80%

-0.38%

-13.11%

Electrical Energy