Transcript The Profitability Impact of a Qualified and Trained

The Profitability Impact of
a Qualified and Trained
Analytical Lab Staff
Sabrina Trupia, Ph.D. and Jessica M. Sido
NCERC
Three functions of Ethanol
Plant Laboratory Staff
Performance
Understanding
Communication
Laboratory Performance

Time spent on each test
decreases

Fewer samples to re-run

Reliable analyses and
reliable data
The Corn to Ethanol Process (Dry Grind)
Mycotoxins
Grain
Qual
DE
pH
Particle Size
pH
HPLC
Hammer Mill
Liquefaction
Slurry
Tank
Prox.
Anal.
(Cooling)
Jet
Cooker
DE
TS %
pH
Fermentation
(Heating)
(190 Proof )
H2O %
Ethanol
Storage
Risk
Prox. Anal.
DDGS
9
Amino Acids
Total P
Ash
etc.
Drum Dryer
Distillation
System
Molecular
Sieve
9
(200 Proof )
(Recycled Water)
HPLC
Centrifuge
TS%
Evaporator
(Syrup)
Whole
Stillage
Centrifuge
(Thin
Stillage)
( Wet Cake)
TM
Understanding Processes
Percent w/v
Curves for Glucose and Ethanol Over
Time
14
12
10
8
6
4
2
0

Ability to recognize a problem

Ability to assess the problem

Ability to troubleshoot and to
see where the problem
originates (plant or lab)
Ethanol
Glucose
1
2
3
4
5
6
7
8
Fermentation Time
9 10
Communication with Plant

Conveying the appropriate
information to the operators

Quick response to changes in
plant conditions

Providing more information
that just data values
Is data integrity and quality
(i.e. “good” data) only important
to R&D labs?
RFA Guidelines
“First, the [QA/QC] program should
continually monitor the reliability
(accuracy and precision) of the results
being reported. It should answer the
question “How good (accurate and
precise) are the results obtained?” This
function is the determination of quality.
“
“The second function is the control of quality
to meet the program requirements for
reliability. “
http://www.ethanolrfa.org/industry/resources/qaqc/
Is “good” data only important to R&D labs?
“Providing the highest quality products that meet
customer expectations is of the highest priority for
ethanol production facilities”
“The success of an ethanol production facility depends on
the Quality Control lab”
--Kristy Moore, Renewable Fuels Association
“Hard to justify [financially] only until you see the results”
“When lab data is used as a problem-solving tool, it does
save money for the ethanol plant”
-- Andrew Kim, Center Ethanol
Laboratory Practices
=
Problem-solving Tools



Fermentation Management

Maximize ethanol production

Minimize fermentation problems
Mass Balance

Helps update the mass balance of production

Recognize trends leading to problems
Risk Management

Contaminants (S, antibiotics...) in ethanol and/or coproducts
Cost Impact Example:
Fermentation Management
In a 50 MGPY Ethanol Plant (750,000
gal fermentor)

A single contamination event resulting in one
stuck fermentor (3-4% residual sugars) costs
approximately $20,000

Chronic contamination resulting in a loss of
0.25%wv ethanol per fermentor = approx.
$1,740,000 per year (@ $1.74 per gallon ethanol)
Lallemand Ethanol Technology (2008); ethanol price: NYMEX Jun 8, 2009
Effective Training
Training is best accomplished in three stages

Initial : exposure to lab procedures

Intermediate : active demonstration

Final : Hands-on training
Throughout, lab practices are tied to plant
processes
Thanks to…
Lab Staff @ NCERC
John Caupert
Brian Wrenn
Yan Zhang
Jack Ballinger
Andrew Kim
Kristy Moore
…Questions?