From slow labor-intensive composition analysis to digitalized monitoring.
Connect ZYMON to your process to digitalize your bioethanol plant for 24/7 automated process control and optimization
EARLY WARNING DETECTION SYSTEM
Above threshold organic acids? Poor sugar hydrolysis? Slow ethanol productivities? All signs your batch is heading in the wrong direction. A slow fermentation not only decreases your plant efficiency, but also increases the risk of contamination, potentially causing drops in ethanol of up to several percent (i.e., %, v/v). Controlling infection prevents competition for sugars, reduces yeast stress, and enables maximum alcohol yields to be achieved, while the knock-on downstream effects such as sugar residue fouling and organic acid build-up in thin stillage are also prevented.
AUTOMATE LACTIC AND ACETIC ACID MEASUREMENTS WITH ZYMON AND TAKE EARLY ACTIONS BASED ON THE WARNINGS!
Regular HPLC analysis may indicate an infection or issue is occurring several hours after sampling and may require additional laboratory support for confirmation – eating into the time in which you can effectively respond. ZYMON systematically records actionable live data, and provides an early warning alarm system about organic acid build-up.
Maximize your batch-to-batch performance with robust 24/7 process monitoring
Slow fermentation rates can result in lower ethanol titers caused by poor yeast health, inadequate process management, or sub-optimal sugar production. With round the clock monitoring of critical parameters, plant managers have the information to assess deviations from the ‘golden batch’ and take immediate action to guarantee target metrics are achieved!
ZYMON’S OUTPUTS PROVIDE A BENCH-MARKING TOOL TO ASSESS BATCH-TO-BATCH PERFORMANCE BY MONITORING SUGAR CONSUMPTION AND ETHANOL PRODUCTION RATES IN REAL-TIME
Take advantage of live process monitoring to perform timely interventions and batch-to-batch improvements, such as:
Fine-tune of enzyme dosage rate to prevent osmotic stress while maintaining high fermentation rates.
Tuning of fermentation temperature profile to maximize both enzyme and yeast potential.
Making a more critical assessments of changes to key inputs such as yeast strain, nutrient dosage, and enzyme cocktail.
INLINE CAUSTIC CIP MONITORING
Improper sanitation can result in poor fermentation performance, reduced efficiency, increase operational costs and diminish profit margins. Commonly used caustic-based chemicals for the CIP process can be quickly neutralized if the concentrations and volumes are not carefully managed, resulting in ineffective cleaning and possibly spreading potential contaminants throughout the plant.
ZYMON ENSURES PROPER PLANT SANITATION BY INLINE CAUSTIC CIP MONITORING
ZYMON monitors the chemical composition and strength of caustic based cleaning agents in-line, helping operators adjust chemical dosing and CIP process optimization to ensure proper sanitation and optimal process performance.
AVOID UNNECESSARY SAMPLING
The time demands on a bioethanol plant laboratory can be significant with constant trade-offs being made between routine quality control analyses and possibly critical samples requiring rapid turnarounds to aid process interventions. Instrumentation and operator error, sample preservation and data entry can also lead to significant issues and time delays in fermentation management.
ZYMON ALLOWS COMPLETE 24/7 MONITORING OF FERMENTATION PROCESSES, RETURNING ACTIONABLE RESULTS DIRECTLY COMPARABLE WITH STANDARDIZED HPLC ANALYSIS EVERY 5 MINUTES
This frees up routine laboratory capacity and operator time to provide improved services on other critical parameters such as raw material analysis, yeast propagation monitoring (cell counts and viability), and detailed product composition analysis (distillation & feed analyses).
YEAST & ENZYME OPTIMIZATION
Enzymes and yeast contribute significantly to the cost of bioethanol processes. Enzymes dosed at too high a rate could lead to a net over-production of glucose and osmotic stress to the yeast. Vice-versa, underdosing of enzymes and/or yeast leads to loses in productivity and yield. Attaining the optimal dosing strategy is impossible without reliable data.
THE REAL-TIME ACTIONABLE DATA PROVIDED BY ZYMON ALLOWS YOU TO CONFIDENTLY IMPROVE ENZYME AND YEAST USAGE – BOOSTING FERMENTATION ACTIVITY DIRECTLY IN THE PROCESS
ZYMON allows you to get straight answers by quantifying the true enzyme and yeast performance directly in the process, by monitoring sugar profiles, ethanol productivities, and glucoamylase activity rates in real-time. Detailed batch-to-batch data can be used to make iterative improvements in operation parameters, and yeast and enzyme usage, that ultimately result in meaningful improvements in process metrics and input savings.
REDUCE FERMENTATION TIME
Substrate and product concentrations, and yeast and glucoamylase activities are crucial to the fermentation process duration, but currently it is difficult to determine when a batch has truly finished with conventional off-line sampling.
GO DIGITAL WITH ZYMON AND IMPROVE YOUR PRODUCTION CAPACITY
ZYMON can indicate when a batch has reached a steady state, a threshold titer, or when the rate of fermentation has dropped below a given level. This will overall aid in optimization of batch duration and result in higher throughputs should a plant have flexibility up- and down-stream.