Post on 15-Dec-2015
Dr. Gary MahoneyDr. Petros Katsioloudis
Berea CollegeBerea, Kentucky
ITEA's 70th Annual ConferenceSalt Lake City, UtahFebruary 21-23, 2008
GoalsThis presentation will discuss the lessons
learned in producing and testing ethanol fuel in internal combustion engines. Engine redesign and modification will be discussed.
to provide experiences and activities related to the Designed World; specifically Agriculture and Related Biotechnologies, Energy and Power Technologies, and Transportation Technologies.
Goals cont.to gain experience and insight into
Technology and Society; to provide hands-on experiences in the effects of Technology on the Environment, the role of society in the development and use of technology and the influence of technology on history.
to provide experiences in the production of renewable alternative fuels, testing of the fuels, and modification of engine design to better utilize the alternative fuels.
The process of obtaining a Federal license to own and operate a distillation device
Form TTB F 5110.74http://www.ttb.gov/forms/f511074.pdf
Instruction Sheet for form TTB F 5110.74
Page #1 of TTB F 5110.74
Page #2 of TTB F 5110.74
Page #3 of TTB F 5110.74
History
HistoryThe first evidence of distillation comes from
Babylonia and dates from the 2nd millennium BC.
Specially shaped clay pots were used to extract small amounts of distilled alcohol through natural cooling for use in perfumes.
http://en.wikipedia.org/wiki/Distilled_beverage
HistoryBy the 3rd century AD, alchemists in
Alexandria, Egypt, may have used an early form of distillation to produce alcohol for sublimation or for coloring metal
http://en.wikipedia.org/wiki/Distilled_beverage
HistoryAlcohol was fully purified for the first time by
Muslim chemists in the 8th and 9th centuries. http://en.wikipedia.org/wiki/Distilled_beverage
HistoryFreeze distillation, the "Mongolian still", are
known to have been in use in Central Asia sometime in the early Middle Ages.
http://en.wikipedia.org/wiki/Distilled_beverage
HistoryDistilled alcohol beverages first appeared in
Europe in the mid-12th century among alchemists, who were more interested in medical "elixirs" than making gold from lead.
http://en.wikipedia.org/wiki/Distilled_beverage
History: London 1651
http://www.moonshine-still.com/page5.htm
History: Corty’s Still
History: Adam’s Still
http://www.moonshine-still.com/page6.htm
History: Irish Still
http://www.moonshine-still.com/page5.htm
History: Appalachian Still (caught)
http://www.moonshine-still.com/page5.htm
History: Modern Distillation Plant
Process of producing fuel grade ethanolThe still used in this project was a
Column Reflux Still.The plans are available at
http://www.moonshine-still.com/
http://www.moonshine-still.com/page22.htm
ProcessesMashing: converting starches to sugars.Fermentation: converting sugars to alcohol
and carbon dioxide.Distillation: separating the alcohol from the
beer.
Equipment:
34-40L pot with lidA large stirring spoonA floating thermometerHydrometerImmersion chillerScale
Ingredients:
Corn mash:23L of soft tap water8L (4Kg or 8.8 lbs) cornmeal1 ½ L (3/4 Kg or 1.65 lbs) crushed 2-
row pale barley malt
MashingGrain is ground into smaller components to
facilitate the chemical reaction.At least 10% of the grain bill should be
sprouted (malted) grain to provide the enzymes necessary to convert starches to sugar.
Alpha and Beta amylase enzymes are used.
Mashing: shelling grain
Mashing: grinding grain
Mashing: malted barley
Mashing: cooking the mash.
Thin mash:23L of water3.6Kg of table sugar 2 packets of Champaign yeast
Process:
Heat the water to 73C (163F)Turn off the heat and stir in the cornmealThe temperature should rest at about 66C
(151F) and the mash will thickenMake sure the temp is under 71F (160F)Stir in 100ml of crushed barley maltCover the pot and leave for 20 minutes (stir
every few minutes)
Mashing
Turn the heat back on high and stir continually until the mash comes to a boil.
Turn the heat off and continue to stir for five minutes.
Cover the pot and allow it to cool (or use an immersion chiller) to 66.5C (152F)
Mashing: rest
Stir in the remainder of the crushed barley malt
The temp should rest at about 65C (149F)Cover and let rest for 90 minutes (stir every
15 minutes)(At this point it would be cooled with an
immersion chiller to under 100F, oxygenated and the yeast would be pitched)
Our process will be “thin-mashing”. In order to gain more alcohol we will add water and table sugar.
Add 30L of waterCheck the specific gravity
Mashing: thin mash
Add table sugar until the SG reads between 1.060 and 1.070. (about 3.6 Kg)
This will lower the temperature and oxygenate the mash
Two packets of dry Champaign yeast will be added and the fermentation vessel will be capped
Mashing: measuring the specific gravity
Alternative MethodsSour Mashing is a method that eliminated the
cooking step.Initially, it is very inefficient, however the
same grains are used over and over until a complete conversion is obtained.
Sour Mash RecipeFor a 5 gallon mash: 5 gallons soft, filtered water. 7 lbs cracked corn. 6-8 pieces/kernel is the
proper crack. 7 lbs of granulated sugar. 1 tbsp yeast (distillers yeast if available.) January 2,
2008:http://homedistiller.org/wiki/index.php/Uncle_Jesse's_Simple_Sour_Mash_Method
Theory
The conversion of starches to sugars is a natural process, accelerated by cooking. An uncooked mash will convert starches to sugars but much more slowly and less efficiently. The added sugar will ferment easily and will provide most of the alcohol in the beer.
January 2, 2008:http://homedistiller.org/wiki/index.php/Uncle_Jesse's_Simple_Sour_Mash_Method
The first distillation run will be a "sweet" run since there will not be any backset to use for sour mashing. It is recommend that the spirits collected in the first run be used as feints for the next run.
January 2, 2008:http://homedistiller.org/wiki/index.php/Uncle_Jesse's_Simple_Sour_Mash_Method
First Fermentation
Put ingredients into the fermenter in the order listed
Fermentation should start in 6 to 12 hours.It should take 3 or 4 days for the ebullition to
end.Siphon your beer out of the fermenter with a
racking cane and charge your still. January 2, 2008:http://homedistiller.org/wiki/index.php/Uncle_Jesse's_Simple_Sour_Mash_Method
Start with 25% backset (liquid left in the boiler after distillation).
This means that for a 5 gallon mash you will use 1-1/4 gallons of backset and 3-3/4 gallons of water.
January 2, 2008:http://homedistiller.org/wiki/index.php/Uncle_Jesse's_Simple_Sour_Mash_Method
Put 3-3/4 gallons of water back into the fermenter so the yeast won't die.
Scoop off the spend corn and replace with an equal volume of new corn.
Add 1-1/4 gallons of backset and 7 more pounds of granulated sugar.
January 2, 2008:http://homedistiller.org/wiki/index.php/Uncle_Jesse's_Simple_Sour_Mash_Method
Fermentation
Krauskopf,K.(2003).The Physical Universe,11th edition.McGraw-Hill: Boston.
2526126 22 COOHHCOHC
Yeast is used to convert sugar to alcohol. The byproduct is carbon dioxide.
Fermentation
Fermentation: check specific gravity
Fermentation: pitching the yeast
Fermentation
Distillation
DistillationTo calculate the amount of energy used:
TmcQ
Distillation
http://www.moonshine-still.com/page23.htm
Distillation
http://www.moonshine-still.com/page23.htm
Distillation: straining the Beer
Distillation
Distillation
Distillation Plant
Horsepower testing and engine modification
Modified Cylinder Head
Modified Cylinder Head
Dynamometer
Dynamometer
Ethanol SourcesSwitch grass 1150 gal/acre
Sweet Potato 1069 gal/acre
Poplar Wood 1000 gal/acre
Sugar Cane 662 gal/acre
Corn 370 gal/acre
Wheat 277 gal/acre
References:
http://www.ttb.gov/forms/f511074.pdfhttp://en.wikipedia.org/wiki/Distilled_beveragehttp://www.moonshine-still.com/page5.htmhttp://www.moonshine-still.com/page6.htmhttp://www.moonshine-still.com/page22.htmJanuary 2, 2008:http://homedistiller.org/wiki/index.php/Uncle_Jesse's_Simple_Sour_Mash_MethodKrauskopf,K.(2003).The Physical Universe,11th edition.McGraw-Hill: Boston.http://www.moonshine-still.com/page23.htm
Contact info:
Gary Mahoney mahoneyg@berea.eduPetros Katsioloudis katsioloudisp@berea.edu