Corn residues (35% Glucose, 18% Xylose) 10 tons x 4 per day

1. Removed toxics and acids Corn residues (35% Glucose, 18% Xylose) 10 tons x 4 per day water water water steam Precipitated acid, toxics and charcoals Adding CaOH2 (2.42 tons) to pH 10 then adding H3PO4 to pH 5 and 2.4% Charcoal (2.40 tons),  to remove toxics Waste Charcoal recycle steam Step 1 Disk mills (dry)1 T(C): 25 C Processing time: 1 hour Step 7 Toxics removal and charcoal recycle Solid-liquid separator Rotary drum filter (same as step 3) Step 6 Neutralization and detoxification T(C): 100 and later 37 C pH: 5.0 Processing time: 1 hour Size: 100 m3 water Ground Biomass Other nutrients Adding 30 m3 of 10% (wt %) H2SO4 solution Sugars storage tank Size: 150 m3 T(C): 37 C pH: 5.0 Seed culture Genetic engineering yeast containing addition of xylose utilizing pathway Step 2 Acid Hydrolysis (1) T(C): 100 C Processing time: 3 hours Size: 150 m3 Acid recycle Sugars + nutrients (6.48 tons Xylose and 12.60 tons Glucose) Hydrolyzed hemicellulose: 1.62 tons Hydrolyzed cellulose: 3.15 tons + acids + toxics Recycle dry cell as yeast extract steam Step 3 Solid-liquid separator2 Rotary drum filter pH: < 1.0 Processing time: 1 hour Size: 30 m2 Step 8 Batch Fermentation3 of yeast T(C): 37 C pH: 5.0 Processing time: 24 hours (1 day) Size: 100 m3 Step 10 Distillation4 20 trays single column (0.5 x 2 m) T(C): 80 C Processing time: 1 hour steam Sugars + acid (Liquid phase) Cellulose (Solid phase) steam Adding 30 m3 of 30% (wt %) H2SO4 solution Step 9 Solid-liquid separator Centrifuge T(C): --- C pH: --- (same as step 3) dryer Step 4 Acid hydrolysis (2) T(C): 100 C Processing time: 3 hours Size: 150 m3 (80% ethanol) Cell (Solid phase) Step 11 PV Membrane5 T(C): 25C Processing time: 1 hour Liquid phase 8.57 tons ethanol (5.7% wt%) Steam, electricity water (99.8% ethanol) Step 12 Burner Step 5 Solid-liquid separator Rotary drum filter (same as step 3) 8.57 tons ethanol Yield = 0.21 tons ethanol/tons Biomass Lignin: 18.8 tons