Beruflich Dokumente
Kultur Dokumente
Starch case
Production Processes
Feedstock Preparation
Fermentation
Distillation
Sugar case
Collection
Milling and
filtering
Fermentation
C6
Distillation
Fermentation
C6
Distillation
Starch case
Feedstock
cleaning
Milling
Liquefaction
Cooking
Saccharification
Conditioning
Milling
Termochemical
hydrolysis
Separation L/S
Fermentation
C5
Distillation
2nd Enzymatic
Hydrolysis
Fermentation
C6
Starch
Starch is a carbohydrate consisting of a large number of glucose units joined
by glycosidic bonds.
Starch is a storage polysaccharide of plants, consists entirely of glucose
monomers. Plants store surplus starch as granules within chloroplasts and
other plastids.
Starch
Starch consists of a mixture of two types of polymers: amylose and
amylopectin.
The classic test for the presence of starch is reaction with iodine.
If starch molecules are present in a substance, the addition of iodine yields a
deep blue color.
Characteristics of starch
Starch is generally insoluble in water at room temperature. Because of this, starch in nature
is stored in cells as small granules which can be seen under a microscope.
Starch granules are quite resistant to penetration by both water and hydrolytic enzymes due
to the formation of hydrogen bonds within the same molecule and with other neighboring
molecules. However, these inter- and intra-hydrogen bonds can become weak as the
temperature of the suspension is raised.
When an aqueous suspension of starch is heated, the hydrogen bonds weaken, water is
absorbed, and the starch granules swell.
This process is commonly called gelatinization because the solution formed has a
gelatinous, highly viscous consistency. The same process has long been employed to thicken
broth in food preparation.
Where is it found?
Roots/Tubers
Potato
Cassava
Tapioca
Cereal
Corn
Waxy corn
Wheat
Rice
Waxy rice
Amaranth starch
(Bar: 1 m)
Arrowroot starch
(Bar: 20 m)
Buckwheat starch
(Bar: 5 m)
Cassava starch
(Bar: 10 m)
Corn starch
(Bar: 10 m)
Oat starch
(Bar: 5 m)
Potato starch
(Bar: 50 m)
Rice starch
(Bar: 2 m)
Starch Composition
Amylose. Linear a-1,4 glucose chain. DP: 180-320, MW~106. Branch
approximately every 200 glucose units
Amylopectin. Linear a-1,4 chain with an a-1,6 branch approximately every 20
glucose units. MW~108
Amylose: amylopectin ~ 1:3
Starch Composition
Starch
Tapioca
Potato
Wheat
Corn
Waxy corn
Hi amylose
Rice
% amylose % amylopectin
17%
83%
~20%
~80%
25-26%
~75%
24-28%
~75
~0%
~100%
~ 75%
~ 25%
22%
78%
Amylose
Amylose-linear polysaccharide-linked by -(14) glycosidic linkage between glucose
residues.
Molecular weight: less than 0.5 million
Water soluble
Can form coils which will trap iodine and turn blue
Amylopectin
Amylopectin is branched linked by (16) linkage b/w glucose residues and also by (14).
Water insoluble.
Molecular weight: 50-500 million
Limited coiling causes purplish-red color when iodine added
Starch Granule
Made in the cytoplasm of plant cells
Amylopectin forms in concentric circles with amylose dispersed in between
Held together by hydrogen bonds
The granule swells when heated in water
Starch Granule
Amylopectin in Granules
Granule Structure
To obtain sugar from the starch of many different plants, rather than just
sugar beets or sugar cane.
Gelatinization
When starch is heated in water
Hydrogen bonds break, allowing water to enter the granule and the granule
swells
Amylose migrates out of the granule
H-bonding between water and amylopectin increases
Reduced free water changes the viscosity of the starch mixture, thickening it
Effect of pH on gelatinization
Visco/Amylo/Graph
ViscoAmyloGraph
Viscosity
heating
constant temperature
65oC
30oC
90oC
Time
Advantages:
Simple
Time saving
Disadvantages:
More by-product, DE value only 90
Requiring fine starch
Need corrosion resistant materials
Need more energy for heating
The higher the DE, the more sugars and less dextrins are present.
The DE value of starch is zero and that of dextrose is 100.
Starch Hydrolysis
Fungi
Bacillus amyloliquefacians
B. caldolyticus
B. coagulans
B. cereus
B. lichenformii
B. subtilis
B. stearothermophilus
Escherichia spp..
Lactobacillus spp..
Micrococcus spp.
Pseudomonas spp.
Proteus spp.
Serratia spp.
Aspergillus
Candida
Cephalosporium
Mucor
Neurospora
Penicillium
-Amylase (Alpha-Amylase)
Produced by bacteria and fungi, Industrially it is obtained from Bacillus
amyloliquefaciens.
Ca-metalloenzyme
By acting at random location along the starch chain , amylase breaks down
long chain carbohydrate ultimately yielding maltotriose and maltose or
glucose and limit dextrin from amylopectin.
Because it can act anywhere on the substrate amylase tends to be faster
than amylases.
It is called an endoglucanase because it normally attacks internal 1,4
bonds.
-Amylase
Found primarily in plants, but is infrequently made by bacteria.
Removes maltose molecules from the non reducing ends of starch.
-amylase catalyzes the hydrolysis of the second -1,4 glycosidic bond,
cleaving off two glucose units (maltose) at a time.
So it removes molecules from the external end, it is called an exoglucanase.
works from the non reducing end.
Fruit ripening starch converted to maltose by -amylase which gives sweet
flavor.
Found mainly in plants but is infrequently made by bacteria.
Pullulanase or Isoamylase
A special kind of glucanase, an amylolytic enzyme that degrades pullulan.
Pullulan is a polysaccharide polymer consisting of maltotriose units.
Three glucose in maltotriose connected by (1-4) glycosidic bond whereas
consecutive maltotriose units are connected to each other by (1-6) glycosidic
bonds.
Pullulan is produced from starch by fungus Auerobasidium pullulans.
Endoenzymes
Exoenzymes(non-reducing end)
Liquefaction
Higher temperature hydrolysis of starch involve a starch gelatinization
process, dissolution of the nanogram sized starch granules (swells and
bursts) to form a viscous suspension.
During liquefaction, long-chained starch molecules are partial hydrolysis into
smaller branched and linear chains of glucose units (dextrins), with
concomitant loss in viscosity.
Enzyme: amylase
End-point : DE value 20-30
iodide brown
Saccharification
Involving the production of glucose and a little maltose by further hydrolysis.
Enzyme: glucoamylase
End-point : DE is the highest
HFS process
Advantages
Higher quality
Save energy
Protect environment
Disadvantages
Complex operation
Time consuming
Acid-enzyme hydrolysis
Acid
Glucoamylase
---------
liquefaction
saccharification
Some products
Inhibition Effect
For high conversion, inhibition effect increases the size of reactor more
than 5 times !!!
Cassava Case
What is Cassava
The scientific name Manihot Esculenta Crantz.
The cassava plant is the only species in its genus group that serves
as a food crop.
It stands to be the fourth largest staple in the world after, wheat,
rice and maize.
About 500 million people around the world depend cassava as a
staple food.
It is the third largest source of carbohydrates in plants used for
food in the world.
Cassava plant
Cassava root
The cassava root is toxic because it contains the chemical cyanogenic glucoside
which becomes cyanide. So processing of the root is so important
Sriroth et al,. 2010. The promise of a technology revolution in cassava bioethanol From Thai
practice to the world practice , Fuel.
Tropical/Sub-tropical crop
19000,000 hectares
233,000 Tonnes
Starch in cassava
Protein
matrix
Protein
middle
lamella
Starch
granules
Outer wall
(-Glucan and
pentosan)
Inner cell wall
(-Glucan)
Starch
Fried-Chips
Goren-Krupuk
Bio-ethanol production
Ethanol factory in Thai Nguan near Khon Kaen (Thailand)
Viscozyme Cassava R
Viscozyme cassava C
2. Alpha-Amylase
3. Gluco-Amylase
Spirizyme Fuel
Spirizyme Ultra
Spirizyme Excel
Cooking
Fermentation
Type of
enzyme
added
Alpha-Amylase
Gluco-Amylase
Enzyme
name
1. Viscozyme cassava R
2. Viscozyme cassava C
1. Liquozyme SC
2. Liquozyme SCDS
1. Spirizyme fuel
2. Spirizyme ultra
3. Spirizyme Excel
Main
Purpose
To convert dextrin to
glucose
Other
Benefits
1. Enable mash to be
pumped
2. Avoids gel formation
3. Lower heating and cooling
cost
Enables yeast to
consume the glucose
and generate ethanol
Working
Temp
50-55C
84-86C
32-35C
Roots
Chips
Starch
% Starch
25
65
85
180
468
612
167
435
569
100% theoretical
Ethanol, litres
93% efficiency
Ethanol, litres
Alpha-amylase
DP6
DP4
DP3
DP2
Pre-fermentation saccharification
Pre-fermentation saccharification in separate tank for a few hours at
optimal conditions
Simultaneous saccharification and fermentation
Sugars are generated with the yeast present
Occurs at typical fermentation conditions
Simple
sugars
Long chain sugars
(Dextrins)
- Moisture 15 %
- Starch content 65% (wet basis)
362.17 T/D
85.00% TS
Milling
1,248.50 T/D
Water
Mixing
1,794.43 T/D
17.16% TS
Steam
Liquefaction
120 T/D
1,914.43 T/D
16.08% TS
SSF
Fermentation
CO2
114.98 T/D
1,799.45 T/D
7.42%(w/w) Alcohol
Spent wash recycle
177.53 T/D
124.58 T/D
95% Alcohol
Spent wash recycle
6.23 T/D
Fusel oil
0.50 T/D
Thick Slop
1,496.84 T/D
6.5% TS
Distillation
Molecular Sieve
Dehydration
Fuel Ethanol
118.35 T/D or
150,000 L/D
Less amylose =
more ethanol
Total ethanol
(mL/Kg of starch)
250
Total ethanol
(ml ethanol /
kg starch)
200
150
100
50
With enzyme
0
CM 523-7
Without enzyme
Rayong 60
NEP
Clone
WAXY
4 1/3 days
Normal Starch
Normal Starch
Starch-less mutation
Source:
L. Carvalho
EMBRAPA
Brazil
Boiler
Ethanol
Maize or Cassava
Distillation &
dehydration
Liquefaction
& saccharification
Starch
degradation
Sugarcane juices
Fermentation
Sugarcane
Thermo-stable
Alpha-amylase
(Liquefacction)
Sorce of
satrch
Yeasts
Storage
tank
Glucoamylase
(Saccharification)
Distillation &
dehydration
Secondary
Liquefaction
(95 C 90)
Fermentation
Slurry tank
Grinding
Saccharification
60 C (8-10 horas)
Jet cooker
>100 C
(5-8)
Solids
Thermo-stable
Alpha-amylase
(Liquefacction)
Sorce of
satrch
Yeasts
Storage
tank
Distillation &
dehydration
Secondary
Liquefaction
(95 C 90)
Fermentation
Slurry tank
Grinding
Saccharification
60 C (8-10 horas)
Jet cooker
>100 C
(5-8)
New enzymes
LiquefactionGlucoamylase
+ saccharification
(Saccharification)
Solids
Sorce of
satrch
Yeasts
Storage
tank
Liquefaction
Liquefaction
+ saccharification
+ saccharification
+ fermentation
Distillation &
dehydration
Fermentation
New enzymes
+ yeasts
New enzymes
Saccharification
60 C (8-10 horas)
Slurry tank
Grinding
Solids
100
~80%
80
60
40
20
~30%
0
0
10
20
30
Time (minutes)
40
50
60
60
40
~60%
~30%
20
0
0
10
20
30
Time (minutes)
40
50
60
Cassava traits
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Nombre comn
Tipo
Arpn
Brasilera 1
Brasilera 2
Carai
Ceiba
Indio
Lupuna
Pibicho 005
Arawana
Barandilla
Canero
Catala
Cuya
Lombriz
Manicuera
Morada
Pjaro ahumao
Pan
Pata de paloma
Pibicho
Piririca
Vega
Yema de huevo
Brava
Brava
Brava
Brava
Brava
Brava
Brava
Brava
Dulce
Dulce
Dulce
Dulce
Dulce
Dulce
Dulce
Dulce
Dulce
Dulce
Dulce
Dulce
Dulce
Dulce
Dulce
a)
b)
Figura. 5-3 a) Tanque de lavado de yuca de 25 L y pre-filtro de fondo b) Lechada de yuca despus de lavado.
a)
b)
c)
d)
Figura. 5-4 a) almidn final obtenido despus de secado, b) fondos recogidos despus del proceso de decantacin, c)
proceso de secado en bandejas del almidn despus de decantacin d) mancha recogido en el prefiltro (L2)
Cassava characterization
Nombre comn
Armenia (HMC-1)
Arpon
Brasilera1
Brasilera2
Carai
Ceiba
Indio
Lupuna
Pibicho005
Arawana
Barandilla
Canero
Catalan 022
Cuya
Lombriz
Manicuera
Morada
Pjaro ahumao
Pan
Pata de Palomo
Pibicho
Piririca
Vega
Yema de Huevo
% cenizas (p/p)
0.0029
0.0050
0.0042
0.0015 B
0.0025
0.0041
0.0039
0.0078
0.0067
0.0088
0.0087
0.0083
0.0067
0.0074
0.0093
0.0055
0.0068
0.0127 A
0.0029
0.0066
0.0072
0.0068
0.0084
0.0071
Almidn Total
p/p (bs)
0.9039
0.9444M
0.9208
0.9382
0.9438
0.9414
0.9503 M
0.9420
0.9429
0.9046
0.9578 M
0.9366
0.9457
0.9548 M
0.9453
0.9443
0.9108 B
0.9469
0.9309
0.9311
0.9495
0.9151 B
0.9407
0.9539 M
almidn libre
(p/p)
0.175
0.152
0.157
0.153
0.175 M
0.117
0.140
0.103
0.087
0.218 M
0.142
0.113
0.125
0.085
0.125
0.132
0.180 M
0.117
0.139
0.103
0.127
0.161 M
0.137
0.123
IAA*
(p/p)
9.00
5.94
30.44A
6.72
11.45 A
5.67
6.01
3.75 B
6.46
6.12
6.28
5.28
5.18
7.41
5.99
6.08
8.86
5.5
26.18 A
5.12
6.61
4.85
7.43
4.21
ISA**
(ml)
9.30
9.11
26.59 A
5.74
12.62
5.92
6.53
3.71 B
15.28 A
3.78 B
13.89 A
7.38
5.89
4.65
5.22
14.26 A
7.18
4.27
26.57 A
5.32
16.39 A
5.84
6.78
5.93
PH***
(p/p)
9.97
6.42
34.55 A
7.06
13.37 A
6.18
6.63
3.92 B
7.21
6.47
7.16
5.86
5.65
8.00
6.50
6.96
9.52
5.89
29.30 A
5.34
7.68
5.08
7.90
4.55
Variedad
almidn libre
(p/p)
Protena
(% p/p)
Amilosa
(p/p)
Ponderacin de datos
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
BlancoArm
Arawana
Arpon
Barandilla
Brasilera1
Brasilera2
Canero
Carai
Catalan022
Ceiba
Cuya
Indio
Lombriz
Lupuna
Manicuera
Morada
Pjaro ahumao
Pan
0.175
0.218A
0.152
0.142
0.157
0.153
0.113
0.175
0.125
0.117
0.085 B
0.140
0.125
0.103
0.132
0.180
0.117
0.139
233.717 B
691.818
867.762
564.486
467.795
614.293
728.358
445.919
516.322
568.133
1,020.397 A
649.731
423.328
556.012
390.933
683.460
238.884 B
655.127
0.318
0.142
0.137 B
0.192
0.206
0.421
0.245
0.200
0.348
0.248
0.451
0.444
0.405
0.273
0.123 B
0.602
0.689
0.803 A
0.027
0.060 A
0.031
0.044
0.024
0.013 B
0.024
0.030
0.013 B
0.042
0.044
0.046
0.026
0.060 A
0.039
0.056
0.053
0.052
0.163
0.565
0.417
0.383
0.369
0.342
0.318
0.406
0.285
0.331
0.260
0.376
0.296
0.337
0.347
0.461
0.290
0.363
19
20
21
22
23
Patadepaloma
Pibicho
Pibicho005
Piririca
Vega
0.103
660.238
0.350
0.054
0.127
0.087 B
0.161
0.137
720.488
521.576
2,713.573 A
607.513
0.405
0.454
0.619
0.410
0.055
0.038
0.014 B
0.038
0.328
0.376
0.253
0.573
0.273
Enzymes employed
70000
60000
50000
40000
30000
20000
10000
0
0
10
15
20
25
30
Tiempo (horas)
Figura. 6-10 Seleccin del tiempo de reaccin de las enzimas GC626 (E1); GZYMER480 (E2) y STARGENTM 001 (E3) obtenida de las dextrinas producidas a travs
del tiempo.
1.2e+5
1.0e+5
8.0e+4
6.0e+4
4.0e+4
2.0e+4
0.0
10
15
20
25
30
Tiempo (horas)
Figura. 6-14 Cintica del par enzimtico GC6262 y GZYMER480 adicionadas simultneamente a tres
diferentes concentraciones de sustrato para la variedad de almidn de yuca Arpon (Y1). Tratamiento
Y1S1 (concentracin de sustrato al 12% w/v); Y1S2 (concentracin de sustrato al 28% w/v); Y1S3
(concentracin de sustrato al 32% w/v)
70000
60000
50000
40000
30000
20000
10000
0
0
10
15
20
25
30
Tiempo (horas)
Figura. 6-15 Cintica del par enzimtico GC6262 y GZYMER480 adicionado simultneamente a tres
diferentes concentraciones de sustrato para el almidn de la variedad de yuca Arawana (Y2). Tratamiento
Y1S1 (concentracin de sustrato al 12% w/v); Y1S2 (concentracin de sustrato al 28% w/v); Y1S3
(concentracin de sustrato al 32% w/v)
1.2e+5
1.0e+5
8.0e+4
6.0e+4
4.0e+4
2.0e+4
0.0
0
10
15
20
25
30
Tiempo (horas)
Figura. 6-16 Cintica del par enzimtico GC6262 y GZYMER480 adicionadas simultneamente a tres
diferentes concentraciones de sustrato para la variedad de almidn de yuca Piririca (Y3). Tratamiento Y1S1
(concentracin de sustrato al 12% w/v); Y1S2 (concentracin de sustrato al 28% w/v); Y1S3
(concentracin de sustrato al 32% w/v)
Rendimiento de la hidrolisis
Variedad
Arpon
Arpon
Arpon
Arawana
Arawana
Arawana
Piririca
Piririca
Piririca
Concentraci
Concentracin final
n de
de dextrina (ppm)
sustrato w/v
12%
43822.56
28%
73118.42
32%
81803.35
12%
32977.95
28%
43352.42
32%
56595.24
12%
38081.44
28%
69482.66
32%
68128.48
Rendimiento
(g Azcar/g Almidn)
36.52%
26.11%
25.56%
27.48%
15.48%
17.69%
31.73%
12.41%
21.29%