Methods and systems for producing ethanol using raw starch and fractionation

Abstract

The present invention relates to methods for producing high levels of alcohol during fermentation of plant material, and to the high alcohol beer produced. The method can include fractionating the plant material. The present invention also relates to methods for producing high protein distiller's dried grain from fermentation of plant material, and to the high protein distiller's dried grain produced. The method can include drying a co-product by ring drying, flash drying, or fluid bed drying. The present invention further relates to reduced stack emissions from drying distillation products from the production of ethanol.

We claim: 
     
         1 . A fractionated corn material comprising an endosperm component, wherein the endosperm component is cavitated or disrupted. 
     
     
         2 . The fractionated corn material of  claim 1 , wherein the corn comprises a germ component, a fiber component, and the endosperm component, and further wherein at least a portion of the germ component and at least a portion of the fiber component have been separated from the endosperm component. 
     
     
         3 . The fractionated corn material of  claim 1 , wherein the surface area of the endosperm component is increased. 
     
     
         4 . The fractionated corn material of  claim 1 , wherein the endosperm component is cavitated or disrupted by a method selected from the group consisting of vibrating the corn material, treating the corn material with emulsion technology, treating the corn material with rotary pulsation, treating the corn material with magnetostriction, treating the corn material with ferromagnetic materials, and sonicating the corn material. 
     
     
         5 . The fractionated corn material of  claim 1 , wherein the endosperm component is ground so that 50% or more of the fractionated corn material can fit through a sieve with a 0.5 mm screen. 
     
     
         6 . An aqueous composition comprising the fractionated corn material of  claim 1 . 
     
     
         7 . The aqueous composition of  claim 6 , further comprising an acid stable fungal alpha amylase, a yeast and a glucoamylase.