Ethanol Production from Corn Contaminated with Fumonisins: A Preliminary Economic Analysis Including Novel Processing Alternatives

Abstract

In this work, technical and economical feasibility of bioethanol production from corn with high concentrations of fumonisins is analyzed. Based on data obtained from a limited number of experiments, the cost data of ethanol facilities and conceptual design methods maximum prices for corn contaminated with fumonisins are estimated. The scope of the analysis includes average ethanol concentrations in the fermentor in a range of 6 wt % and 3 wt % for noncontaminated corn and strongly contaminated corn (1400 ppm), respectively. The maximum price for contaminated corn varies from 66% to 33% of the fumonisins-free feedstock cost, according to the level of contamination. The performance of the continuously operated process was also analyzed considering the coupling of the fermentor with a pervaporation unit for continuous ethanol separation. Estimations were made for a volumetric productivity of alcohol of 7.8 kg/(m 3 h) and membrane flux (0.9 kg/(m 2 h)) and selectivity (S = 5) corresponding to a commercial PDMS membrane for a level of 6 wt % ethanol in the stirred-tank fermentor. Results show that an increase of 100% in the membrane flux with a constant value for the selectivity is required to make the continuous alternative attractive.

Fumonisins in Conventional and Transgenic, Insect-Resistant Maize Intended for Fuel Ethanol Production: Implications for Fermentation Efficiency and DDGS Co-Product Quality

“…Within this range, there were no consistent relationships between ethanol yield and insect injury, infection, or ground grain fumonisin contamination. Sosa et al did find fumonisin contamination impacted ethanol yield, however the levels of contamination at which this occurred were unrealistic for naturally contaminated maize in the U.S. (100–1400 mg/kg) [ 20 ]. ANOVA analysis performed on mean ethanol production for the hybrid × insect infestation combinations in the six experiments revealed only a few significant differences in ethanol yield among the different treatment combinations, and these differences were always <1.5% of total ethanol yield.…”

“…Strains of Saccharomyces cerevisiae (which are common brewing yeasts) have shown sensitivity to fumonisin B 1 , manifesting in inhibition of culture growth rates [ 18 ]. Additionally, fumonisin contamination <3 mg/kg was not found to have a significant effect on ethanol production [ 19 ] but contamination in the range of 100–1400 mg/kg resulted in a decrease in final ethanol yield with increasing fumonisin concentration [ 20 ]. At the extremes, final ethanol yield was reduced from 6% by weight (for uncontaminated maize) to 3% by weight (in 1400 mg/kg contaminated maize) in the fermentation broth [ 20 ].…”

“…Additionally, fumonisin contamination <3 mg/kg was not found to have a significant effect on ethanol production [ 19 ] but contamination in the range of 100–1400 mg/kg resulted in a decrease in final ethanol yield with increasing fumonisin concentration [ 20 ]. At the extremes, final ethanol yield was reduced from 6% by weight (for uncontaminated maize) to 3% by weight (in 1400 mg/kg contaminated maize) in the fermentation broth [ 20 ]. Contamination at 1400 mg/kg fumonisin exceeds levels reported for naturally-contaminated maize and was achieved in this study through fungal inoculation of kernels; there currently are no results available for ethanol production from maize naturally contaminated with fumonisins in a regionally-relevant range of concentrations.…”

Mycotoxin Contamination in the EU Feed Supply Chain: A Focus on Cereal Byproducts

“…In this context, cereal lots for industrial use should comply with the quality parameter applicable to food and feed. To improve the economic sustainability of the biofuel industry, the surveillance of mycotoxin contamination in grains, kernel cleaning, improved knowledge of mycotoxin repartitioning and fractionation during the ethanol processing, evaluation of alternative bioethanol production process, and monitoring methods represent effective tools to reduce the risk of mycotoxins in DDGS and for a better acceptance of ethanol co-products as feed ingredients [ 119 , 120 ].…”

Mycotoxin Biotransformation by Native and Commercial Enzymes: Present and Future Perspectives

“…Sosa et al [ 156 ] performed a preliminary economic analysis evaluating the feasibility of using fumonisin highly contaminated corns as feedstock for ethanol production. The authors calculated that the advantages deriving from the lower price of contaminated raw materials is balanced by the increase of the operating costs and the decrease of the final ethanol production by the fermenter.…”