Storage,Refining and Milling Storage,Refining and Milling of Cereals before Processing of Cereals before Processing

in Distilleryin Distillery3.European Bioethanol Technology Meeting3.European Bioethanol Technology Meeting

Detmold, Germany, April 24Detmold, Germany, April 24--25,200725,2007

Ing. Josef Ing. Josef ČČapekapek

PROKOP INVEST,a.s. Pardubice, CZECH REPUBLICPROKOP INVEST,a.s. Pardubice, CZECH REPUBLIC

Basic informationBasic information

* * BioethanolBioethanol production in the Czech Republic production in the Czech Republic is based on the E.U. Directive 2003/30 CEis based on the E.U. Directive 2003/30 CE..

* The target is to achieve an addition of 5.75 % of * The target is to achieve an addition of 5.75 % of biofuelbiofuel in consumed petrol and diesel fuel in 2010in consumed petrol and diesel fuel in 2010..

** In 2006, the first line for bioIn 2006, the first line for bio--ethanol production ethanol production from sugar beet was put into operation, designed from sugar beet was put into operation, designed capacity 100,000 mcapacity 100,000 m33/year/year..

** In 2007, three new plants for bioIn 2007, three new plants for bio--ethanol ethanol production from grain will be put into operation, production from grain will be put into operation, designed total capacity 260,000 mdesigned total capacity 260,000 m33/year/year..

PProcessrocess options used in the grain options used in the grain biobio--distilleries in the Czech Republicdistilleries in the Czech Republic

* * The main raw matter is wheat, however, the The main raw matter is wheat, however, the technology also allows corn or technology also allows corn or triticaletriticale processing.processing.

* The plants producing solely the bio* The plants producing solely the bio--ethanol utilise ethanol utilise the grain cleaning and grinding procedure the grain cleaning and grinding procedure described below.described below.

* In combined bio* In combined bio--ethanol and vital gluten ethanol and vital gluten production, the mill technology is applied for production, the mill technology is applied for cleaning, precleaning, pre--milling preparation and milling milling preparation and milling itself.itself.

* The distillery slop processing and utilisation * The distillery slop processing and utilisation method to ensure the energy demand of a biomethod to ensure the energy demand of a bio--distillery is a significant part of the entire solution.distillery is a significant part of the entire solution.

Hustopeče, 100,000 m3/year, 2007

Vrdy, 60,000 m3/year, 2007

Dobrovice, 100,000 m3/year, 2006

Horní Suchá, 100,000 m3/year

Prosenice, 100,000 m3/year

Kolín, 70,000 m3/year, vital gluten 16,000 t/year

Grain

Sugar beet

Basic Basic llayay--out of out of bbioio--ethanol ethanol pplants lants

ETHANOL STORE

WATER TREATMENT

GRAIN: INTAKE

GRAIN: STORE

ETHANOL: FEEDING

CHEMICAL STORE

SLOP PROCESSING

COOLING

OFFICE BUILDING, CONTROL ROOM

WEIGHING AND SAMPLING

FERMENTATION DISTILLATION

GRAIN CLEANING MILLING

Requirements on Requirements on ggrain rain sstortorageage, , refiningrefining, and , and mmillingilling

** To provide a sufficient working reserve of To provide a sufficient working reserve of first class grain for a reasonable price. first class grain for a reasonable price.

* To remove impurities, foreign materials, and * To remove impurities, foreign materials, and microbiological contamination from the microbiological contamination from the grain. grain.

* To provide required size of * To provide required size of groatsgroats or wheat or wheat particles to optimise the bioparticles to optimise the bio--ethanol process ethanol process flow.flow.

Basic flow-sheet diagram for processing of grain before fermentation

FlowFlow-- sheet diagram for sheet diagram for grain grain processing processing includincludee dryingdrying of cornof corn

Grain intake and preGrain intake and pre--refiningrefiningmachinery used in biomachinery used in bio--distilleriesdistilleries

* * Automated grain sampling and sample Automated grain sampling and sample analysis at the plant entranceanalysis at the plant entrance

* Wagon/truck weighing on rail or road * Wagon/truck weighing on rail or road strainstrain--gauge bridges, weighing capacity gauge bridges, weighing capacity 120 t and 80 t120 t and 80 t

* Grain unloading in closed and aspirated * Grain unloading in closed and aspirated premisespremises

* Individual intake lines grain from a * Individual intake lines grain from a wagon/truckwagon/truck

* Grain pre* Grain pre--refining on vibrating refining on vibrating screen including an aspiration screen including an aspiration box and air rebox and air re--circulationcirculation

* Usual grain intake and* Usual grain intake andprepre--refining capacity: 2 x 120t/hrefining capacity: 2 x 120t/h

Grain storage and refiningGrain storage and refining** The grain is stored in circular units with flat The grain is stored in circular units with flat

bottoms, which are mounted from galvanised bottoms, which are mounted from galvanised panels (450g /mpanels (450g /m22))..

* The grain in the units may b* The grain in the units may bee actively aerated actively aerated in accordance with grainin accordance with grain temperaturetemperature..

* Storage silo capacity and number upon * Storage silo capacity and number upon customer demandcustomer demand..

* Capacity of grain transported into/out of the * Capacity of grain transported into/out of the silos makes 120t/h, or 75t/hsilos makes 120t/h, or 75t/h..

* Vibrating screens* Vibrating screens with aspiration boxes,and with aspiration boxes,and doubledouble--screen stoner are installed. screen stoner are installed.

* The whole machinery set is equipped with * The whole machinery set is equipped with efficient aspiration, and dust separation by efficient aspiration, and dust separation by filters with automated refiningfilters with automated refining..

Storaging silos under constructionStoraging silos under construction

Grain milling in standard bioGrain milling in standard bio--distilleriedistilleriess* * To grind the whole grain, a vertical impact To grind the whole grain, a vertical impact

mill is mostly used.mill is mostly used.* In frame of this widely used technology, * In frame of this widely used technology,

starch stored in the endosperm of the starch stored in the endosperm of the cereal grain ascereal grain as well as grain surface layer well as grain surface layer with with fiberfiber and cereal germ enter the and cereal germ enter the fermentation process.fermentation process.

* Relatively wide fractioning range of * Relatively wide fractioning range of breaks, and higher power demand factor of breaks, and higher power demand factor of the process is a negative of an impact the process is a negative of an impact grinder. grinder.

* This may be improved by a roller grinder * This may be improved by a roller grinder combined with a grading screen and combined with a grading screen and another grinder or reanother grinder or re--circulation of larger circulation of larger breaks particles, but the entire machinery breaks particles, but the entire machinery set will have a large demand on space. set will have a large demand on space.

New grain grinding machineryNew grain grinding machinery* * The basic part contains The basic part contains SJKSJK roller grinder including three pairs roller grinder including three pairs

of rolls and integrated double product screening.of rolls and integrated double product screening.* The second part of the machinery designated * The second part of the machinery designated ASJASJ contains a contains a

small selfsmall self--suction impact grinder, and a cyclone with a filter suction impact grinder, and a cyclone with a filter and fan.and fan.

* The output of the machine as well as resulting fraction of th* The output of the machine as well as resulting fraction of the e product may be modified by selecting of roll grooving and product may be modified by selecting of roll grooving and adjusting sizes of screen holes. Under operation, it may be adjusting sizes of screen holes. Under operation, it may be further modified by grain further modified by grain feeedingfeeeding, which is controlled , which is controlled automatically, and adjusting of roller gap.automatically, and adjusting of roller gap.

* * The roller grinder is fitted with six The roller grinder is fitted with six rollsrolls of various grooving of various grooving with the diameter of 300 mm, and length of 500, 800 with the diameter of 300 mm, and length of 500, 800 or 1,000 mm. or 1,000 mm.

* * A massive and practically designed fabrication of the A massive and practically designed fabrication of the SJK SJK machine allows easy machinery maintenance and sanitation.machine allows easy machinery maintenance and sanitation.

SJK&ASJ SJK&ASJ New grain New grain grinding machinery grinding machinery

SJK&ASJ SJK&ASJ GGrindingrinding machinery functionsmachinery functions

* * The SJK The SJK rollerroller grinder has a modular design, and consists of three grinder has a modular design, and consists of three roller mill boxes, two vibration screen boxes, and single electrroller mill boxes, two vibration screen boxes, and single electric ic motor for drive of each pair of rollsmotor for drive of each pair of rolls

* * Grain is supplied to the first roller grinder (2) by roller feedGrain is supplied to the first roller grinder (2) by roller feeder (1), er (1), which is controlled electronicallywhich is controlled electronically

* The coarse break is screened on the first vibrating screen (* The coarse break is screened on the first vibrating screen (3). 3). * The finer fraction is after* The finer fraction is after--ground by the second roll grinder (4).ground by the second roll grinder (4).* The more coarse fraction is supplied to the third roller gri* The more coarse fraction is supplied to the third roller grinder (5), nder (5),

and the and the final final product is screened by the secondproduct is screened by the second screen (6)screen (6)..* The * The spilloverspillover from the screen (6) is suckedfrom the screen (6) is sucked by a small impact by a small impact

grinder (8), and the finegrinder (8), and the fine particleparticles are returned over the cyclone (10) s are returned over the cyclone (10) with a filter (9) into a collection worm of the final product (1with a filter (9) into a collection worm of the final product (13)3)..

New grain grinding machinery New grain grinding machinery aspirationaspiration and pneumatic transport diagraand pneumatic transport diagramm

Grinding line dimensionGrinding line dimensionss

KolínKolín BioBio--ethanol and Vital Gluten ethanol and Vital Gluten Production Plant ProjectProduction Plant Project

* * To ensure production of bioTo ensure production of bio--ethanol for mixing with ethanol for mixing with fuel amounting to 68,000 mfuel amounting to 68,000 m33 per year;per year;

* To ensure production of vital gluten for food industry * To ensure production of vital gluten for food industry amounting to 16,000 t per year; andamounting to 16,000 t per year; and

* To process the by* To process the by--products, i.e. bran and distillery products, i.e. bran and distillery slops in frame of power production by slops in frame of power production by environmentally friendly and costenvironmentally friendly and cost--effective methods.effective methods.

KolínKolín BioBio--distillery works conceptdistillery works concept

Kolín Bio-ethanol Plant block diagram

Grain intake, preGrain intake, pre--refinery, and storage refinery, and storage

Grain refining in vital gluten productionGrain refining in vital gluten production

* * The grain refinery is included in the mill building. The grain refinery is included in the mill building. More effective More effective grain refinery and, especially, first rate grain preparation prigrain refinery and, especially, first rate grain preparation prior to or to the milling in orderthe milling in order toto fractionation offractionation of bran layers of the grain, bran layers of the grain, and achieving a high yield of endosperm is and achieving a high yield of endosperm is requirrequireded

* The refinery machinery contains particularly the following pa* The refinery machinery contains particularly the following parts: rts: sieves,sieves, drydry stoners, stoners, scouringscouring machines, water dispensers, mixers, machines, water dispensers, mixers, mass feeders, and maturing silos for moistened grain.mass feeders, and maturing silos for moistened grain.

KolínKolín BioBio--ethanol Plant grain refineryethanol Plant grain refinery

Grain milling in vital gluten productionGrain milling in vital gluten production** Only two wheat sorts, and bran is produced. Approximately 75 % Only two wheat sorts, and bran is produced. Approximately 75 %

of wheat with low ash contents for gluten production, and 10 % oof wheat with low ash contents for gluten production, and 10 % of f wheat enter the fermentation process.wheat enter the fermentation process.

* * Approximately 15 % of bran is added to separated slops, and thenApproximately 15 % of bran is added to separated slops, and thenprocessed for use of power production in the bioprocessed for use of power production in the bio--distillery.distillery.

* Basically, the machinery includes a milling stand* Basically, the machinery includes a milling standss with eight and with eight and four four rollsrolls, pin, pin--type mills, type mills, plansiftersplansifters, , vibrational vibrational bran finishers bran finishers and and sifting devicessifting devices

PQV plansifters** The sifting schemes allow for parallel lining in two groups, The sifting schemes allow for parallel lining in two groups,

and technological subdivision of the sifting part in two and technological subdivision of the sifting part in two separate parts. separate parts.

* The sorted product is supplied both by sieve frame channels * The sorted product is supplied both by sieve frame channels and channels of stainless box and light laminated door. The and channels of stainless box and light laminated door. The remnantremnant--free evacuation of the sifter is ensured by an outlet free evacuation of the sifter is ensured by an outlet shape.shape.

DEBRANNING PROCES PTMTDEBRANNING PROCES PTMT

* Is a new technological process consisting in * Is a new technological process consisting in step by step removal of bran layers from the step by step removal of bran layers from the wheat kernelwheat kernel

* It has the same primary goal as the * It has the same primary goal as the conventional milling proces but it does it in conventional milling proces but it does it in a new and more effective way as it a new and more effective way as it recognized and makes use of physical and recognized and makes use of physical and chemical properties of different bran layerschemical properties of different bran layers

DebranningDebranning Technological ProcessTechnological Process

Friction machine Friction machine Abrasion machineAbrasion machinePTLPTL PTBPTB

Friction machineFriction machine PTLPTL

Abrasion machineAbrasion machine PTBPTB

Thank you for your attentionThank you for your attentionPROKOP INVEST a.s.PROKOP INVEST a.s.Dělnická 35Dělnická 35533 01 Pardubice533 01 PardubiceCzech RepublicCzech RepublicEE-- mail: . mail: . prokop@prokop.czprokop@prokop.czTel:+420 466 655 300Tel:+420 466 655 300www:prokop.czwww:prokop.cz