E-Modules: Ethanol Plant Unit Operations
Plant Operation E-Modules — one E-Module for each unit operation of a dry-grind ethanol plant, from grain receiving to product loadout.
- 01Grain Receiving & StorageTruck and rail unloading, sampling, aeration
- 02Grain Cleaning & MillingScalping, hammer mills, particle size distribution
- 03Slurry PreparationMixing, solids loading, backset ratio, pH control
- 04Cooking & LiquefactionJet cooking, alpha-amylase, viscosity, DE
- 05SaccharificationGlucoamylase dosing, SSF, residual starch
- 06Yeast PropagationPropagator design, aeration, nutrients, pitching rate
- 07FermentationBatch, fed-batch, continuous; kinetics, yield, cooling
- 08Contamination ControlBacterial load, antimicrobials, sanitation, monitoring
- 09Beer Well & CO₂ RecoveryBeer storage, scrubber recovery, CO₂ capture
- 10DistillationBeer column, rectifier, side stripper, energy balance
- 11DehydrationMolecular sieves, regeneration, water spec
- 12Stillage SeparationDecanter centrifuges, wet cake, thin stillage split
- 13Evaporation & SyrupMultiple-effect evaporators, fouling, syrup solids
- 14Corn Oil ExtractionSyrup oil recovery, demulsifiers, oil yield
- 15Drying & DDGSRotary dryers, WDGS/DDGS quality, thermal oxidizer
- 16Tank Farm & LoadoutDenaturing, storage, ASTM D4806, loadout
- 17UtilitiesSteam, cooling towers, process water, CIP
- 18Process Control & LaboratoryDCS, HPLC analytics, mass balance, QA/QC
E-Modules: FermAxiom Electronic Tools
Electronic Tools E-Modules — step-by-step guidance for each FermAxiom calculator and model: inputs, method basis, and results.
- 01Cell Counter Calculator BasicHemocytometer counts, dilution factors, viability, and cell concentration
- 02Advanced Yeast Cell CounterImage-based counting, staining, budding index, and count statistics
- 03Yeast Pitching & Inoculum CalculatorPitching rate, inoculum volume, and propagation sizing
- 04Ethanol Suite: Inoculum & Seed TrainStage-by-stage scale-up, transfer criteria, and seed-train design
- 05Ethanol Suite: Medium FormulationCarbon, nitrogen, mineral, and vitamin requirements by stage
- 06Ethanol Suite: Fermentation SimulatorKinetic model structure, inhibition terms, and scenario runs
- 07Ethanol Suite: Yield CalculatorTheoretical and actual yield, carbon balance, and losses
- 08Fermentation Heat CalculatorHeat of fermentation, cooling duty, and heat exchanger capacity
- 09Ethanol Industrial Plant ModelInteractive 3D dry-grind plant, unit operations, and stream flows
- 10HDYC Yeast Plant ModelInteractive 3D fed-batch yeast plant, P&ID, and equipment layout
- 11Linking Tools into a WorkflowCarrying results from cell count to pitching, medium, and simulation
- 12Interpreting Tool ResultsUnits, assumptions, validity ranges, and comparison with plant data
E-Modules: Analytical Methods
Analytical Methods E-Modules — methods used to monitor ethanol fermentation, from sampling through coproduct and product quality.
- 01Sampling & Sample PreparationRepresentative sampling, quenching, filtration, and sample storage
- 02HPLC Analysis of Fermentation BrothSugars, ethanol, glycerol, and organic acids
- 03Yeast Biomass QuantificationYeast cell counting & viability: hemocytometry and vital stainingBuyAvailable
- 04Microbial Contamination TestingPlate counts, lactic acid bacteria detection, and molecular methods
- 05Starch & Residual SugarsEnzymatic starch assay, dextrins, and residual starch in stillage
- 06Solids, Moisture & DensityTotal and dissolved solids, refractometry, and density
- 07Ethanol DeterminationGas chromatography, density meters, and rapid in-plant methods
- 08Nitrogen & Nutrient AnalysisFree amino nitrogen, urea, ammonia, phosphate, and minerals
- 09Enzyme Activity AssaysAlpha-amylase, glucoamylase, and protease activity units
- 10DDGS & Coproduct AnalysisProtein, fat, fiber, moisture, and mycotoxins
- 11Fuel Ethanol QualityASTM D4806 parameters, water content, and denaturant
- 12Method Validation & QA/QCCalibration, linearity, LOD/LOQ, and control charts
E-Modules: Process Simulation, Modeling & Data Analysis
Quantitative Analysis E-Modules — building, fitting, and applying bioprocess models, and analyzing laboratory and plant data.
- 01Mass & Energy BalancesStream tables, component balances, and closure checks
- 02Stoichiometry & Yield ModelsTheoretical yield, biomass and byproduct carbon partitioning
- 03Microbial Growth KineticsMonod kinetics, substrate and ethanol inhibition
- 04ODE Fermentation ModelsBatch, fed-batch, and continuous model formulation and solution
- 05Parameter EstimationNonlinear regression, confidence intervals, and identifiability
- 06Fed-Batch Feeding StrategiesExponential feeds, oxygen- and RQ-based feed control
- 07Heat & Oxygen TransferkLa, oxygen uptake, cooling capacity, and transfer limits
- 08Scale-Up & Scale-DownPower per volume, mixing time, and similarity criteria
- 09Whole-Plant SimulationUnit-operation models linked into a plant flowsheet
- 10Techno-Economic AnalysisCapital and operating cost, cash flow, and sensitivity analysis
- 11Experimental Design & StatisticsDoE, ANOVA, regression, and response surface methods
- 12Plant Data AnalysisHistorian data, trending, statistical process control, and KPIs