Optimization and cost estimation of novel wheat biorefining for continuous production of fermentation feedstock

A wheat-based continuous process for the production of a nutrient-complete feedstock for bioethanol production by yeast fermentation has been cost-optimized. This process could substitute for the current wheat dry milling process employed in industry for bioethanol production. Each major wheat component (bran, gluten, starch) is extracted and processed for different end-uses. The separate stages, liquefaction and saccharification, used currently in industry for starch hydrolysis have been integrated into a simplified continuous process by exploiting the complex enzymatic consortium produced by on-site fungal bioconversions. A process producing 120 m3 h-1 nutrient-complete feedstock for bioethanol production containing 250 g L-1 glucose and 0.85 g L-1 free amino nitrogen would result in a production cost of $0.126/kg glucose.