Now that we know some reasons that ethanol is used, lets take a look at how it is made. To make ethanol, a lot of corn is needed. Corn is about 70% starch, 6% germ, 14% water, and 10% fiber. To expose the starch for processing, the kernels are dumped into a grinder and ground into corn "flour". Liquid is then added to the flour to create a mash. This mash is heated in order to further break down the starch into sugar. After cooling, the new mash is transported to a fermentation tank. Yeast is added to begin the fermentation process where the sugar is made into alcohol. After fermentation is complete, the alcohol has to be purified by removing the solid mash and water. This process is called distillation, this process is repeated until the alcohol is 95% pure. This almost pure alcohol goes through a molecular sleeve where the bigger alcohol molecules are separated from the water molecules. When finished, the final product is 200 proof, or 100% alcohol. This is shipped to a refinery for other processes to allow it to be added to gasoline. The leftover syrup is added to the leftover mash and dehydrated to be sold to farms for use as cattle feed. This mash, now called distiller grains has a nutritional value equal to or even better than whole corn.




