Effects of Modified Processes in Dry-Grind Ethanol Production on Phosphorus Distribution in Coproducts

Modeling National Embedded Phosphorus Flows of Corn Ethanol Distillers' Grains to Elucidate Nutrient Reduction Opportunities

Freshwater quality and ecosystem impairment associated with excess phosphorus (P) loadings have led to federally mandated P reduction for certain organic waste streams. Phosphorus reduction from livestock and poultry feeds such as corn ethanol distillers' grains (DGs) presents a centralized strategy for reducing P loss from animal manurein agriculturally intensive states, but little is known about the actual distribution and geospatial P contributions of DGs as animal feed. Here, a county-level flow network for corn ethanol DGs was simulated in the United States to elucidate opportunities for P reduction and the potential for nutrient trading between centralized sources. Overall, the estimated P in DGs that was transferred to US animal feeding operations was nearly twice that present in all human waste prior to treatment. Simulation results suggest that Midwestern states account for an estimated 63% of domestic DG usage, with 72% utilized within the state of production. County-level data were also used to highlight the potential of using nutrient trading markets to incentivize P recovery from DGs at biorefineries within an agriculturally intensive watershed region in Iowa. In summary, corn ethanol biorefineries represent a key leverage point for sustainable P management at the national and local scales.

Volumetric Scale-Up of a Packed-Bed Ion-Exchange System to Extract Phytate from Thin Stillage

Phytate is the main form of phosphorus in corn ethanol coproducts and poses digestion issues in monogastric-animal feed. Extracting phytate as a commodity chemical will bring extra revenue to the corn ethanol industry and reduces potential phosphorus pollution from livestock waste management. We assessed a simplified scale-up approach of an ion-exchange separation system applied to extract phytate from thin stillage using volumetric parameters and simplifications of the van Deemter model. Thin stillage is one of the main byproducts generated on dry-grind corn-to-ethanol plants and accounts for the liquid portion of the bottom product generated in the ethanol distillation process. Thin stillage is rich in dissolved phytate, which served as the basis for an ion-exchange extraction system developed with a scalability factor of 50. Under the evaluated conditions, similar breakthrough profiles were obtained when similar Péclet and Stanton numbers were maintained for the scales studied, demonstrating that a simple and straightforward scale-up can be attained if special attention is given to maintaining both parameters as the basis of calculations of the plate numbers of ion-exchange columns.

Comparison of digestible and metabolizable energy and digestible phosphorus and amino acid content of corn ethanol coproducts from Brazil and the United States produced using fiber separation technology for swine

Three experiments (exp.) were conducted to determine and compare the digestibility of nutrients and energy of corn distillers dried grains with solubles (DDGS) from the United States (USDDGS), a dried mixture of corn bran with solubles (CBS) from Brazil (BRCBS), and high protein corn distillers dried grains (HP-DDG) from the United States (USHPDG) and Brazil (BRHPDG) in growing pigs. The feed ingredients were evaluated for apparent total tract digestibility (ATTD) of gross energy (GE), dry matter (DM), crude protein (CP), ether extract, neutral and acid detergent fiber (NDF and ADF, respectively), and digestible and metabolizable energy (DE and ME, respectively) using the total collection and index methods in exp. 1; ATTD and standardized total tract digestibility (STTD) of phosphorus (P) in exp. 2; and apparent (AID) and standardized (SID) ileal digestibilities of CP and amino acids (AA) in exp. 3. Fifty crossbred barrows (32.4 ± 6.9, 38.3 ± 5.2, and 46.2 ± 5.3 kg body weight [BW], in exp. 1, 2, and 3, respectively) were fed a corn basal diet in exp. 1, a P-free diet in exp. 2, and an N-free diet in exp. 3 or diets with 40% inclusion of test ingredients to provide 10 replications per treatment. Pigs were housed individually in metabolism cages (exp. 1) or in pens (exp. 2 and 3) and fed at 2.8 times the maintenance DE requirement (110 kcal/kg BW0.75) based on their BW at the beginning of each experiment. Except for ATTD of NDF, which tended (P = 0.058) to be greater by the index method compared with the total collection method, no difference between the total collection and index methods was observed for ATTD of remaining nutrients and DE. The ATTD of DM, GE, NDF, and DE content of BRHPDG were greater (P < 0.001) than USHPDG, BRCBS, and USDDGS. The AID of CP, Arg, His, Ile, Leu, Lys, Thr, and Val and the SID of His, Leu, Lys, and Val of BRHPDG were 8% to 36% greater (P < 0.05) than those from USHPDG. Except for Trp, all AID and SID AA values were greater (P < 0.05) in BRHPDG than in USHPDG. The ATTD of DM, GE, NDF, and ADF; DE and ME content; AID of CP, Arg, Ile, Leu, Phe, Thr, and Trp; and SID of CP, Arg, Phe, and Thr of USDDGS were 9% to 45% greater (P < 0.05) than those in BRCBS. The ATTD and the STTD of P in USHPDG and USDDGS were 26% to 42% greater (P < 0.05) compared with BRHPDG and BRCBS. In conclusion, BRHPDG had a greater digestibility of energy and most of the AA than USHPDG, while the BRCBS evaluated had lower nutritional value than the USDDGS source.