Dr. Gary Mahoney Dr. Petros Katsioloudis Berea College Berea, Kentucky ITEA's 70th Annual Conference Salt Lake City, Utah February 21-23, 2008.

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 [email protected] Katsioloudis [email protected]