A system and method for producing four animal feeds from grains used by an ethanol production plant

Abstract

The present invention provides a method and system for producing at least four types of animal feed products for different types of animals to maximize the use of all components in whole stillage in an ethanol production plant. The method includes liquefaction, fermentation, distillation, and performing selective particle size separation into three streams, wherein the three streams include a first stream of large particle stream for forming a first animal feed suitable for ruminants, a second stream of crude protein stream for forming a second animal feed suitable for chickens and pigs, and a third stream of fine particle stream for forming a third animal feed suitable for fish and pets. By further concentrating and fortifying the third stream, a syrup containing 35-80% dry solids is obtained.

Description

[0001] Cross-reference to related applications

[0002] This application is a partial continuation of U.S. Patent Application No. 15,187,702, filed June 20, 2016, entitled “A method and system for producing high-value animal feed additives from distillers' grains in an ethanol production process.” This application claims priority over the provisions of U.S. Provisional Patent Application No. 62 / 927,606, filed October 29, 2019, entitled “A system and method for separating four animal feeds from grains used in ethanol production,” which is incorporated herein by reference in its entirety for all purposes. Technical Field

[0003] This invention relates to a method and apparatus for a dry-milled ethanol production system, and more particularly to a method and system for producing at least four types of animal feed from whole distillers grains in a dry-milled ethanol plant. Background Technology

[0004] Figure 1 A typical wet milling process for ethanol production is shown. Figure 2 This demonstrates a typical dry grinding process with a back-end oil recovery system. Figure 3 A typical dry milling process with a back-end oil and protein recovery system is shown. Figure 4 A typical dry grinding process with a front-end grinding and front-end oil recovery system is shown. Figure 5 This demonstrates a typical dry grinding process with back-end grinding and back-end oil recovery.

[0005] Traditional methods for producing various types of ethanol from grains generally follow similar procedures, depending on whether the process is wet milling or dry milling. Wet-milled corn processing plants convert corn kernels into several different byproducts, such as germ (for oil extraction), gluten feed (high-fiber animal feed), gluten meal (high-protein animal feed), and starch-based products, such as ethanol, high-fructose corn syrup, or food and industrial starch. Dry-milled ethanol plants convert corn into two products: ethanol and soluble solids-containing distillers grains (DDGS). If sold as wet animal feed, wet DDGS containing soluble solids is called wet corn ethanol grains (WDGS). If sold as dry animal feed, dry DDGS containing soluble solids is called dry corn ethanol grains (DDGS). In a standard dry-milled ethanol process, in addition to approximately 2.8 gallons of ethanol, one bushel of corn produces approximately 16.5 pounds of dry corn ethanol grains.

[0006] These byproducts provide an important second revenue stream, offsetting a portion of the total cost of ethanol production. Although dried corn ethanol residue contains 10.5% oil and 32% protein, it is still sold as low-value animal feed. Some plants have begun to refine typical processes to separate the valuable oil and protein from dried corn ethanol residue. Currently, approximately 150 plants have back-end oil recovery systems using methods similar to those disclosed in the patented process (US Patent No. 7,601,858, which is incorporated herein by reference in its entirety for all purposes). Five plants are equipped with protein recovery systems employing the process applied for in US Patent No. 8,778,433, entitled "Method and System for Producing High-Protein Corn Flour from Whole Distillers' Grains By-products" (US Patent No. 8,778,433, which is incorporated herein by reference in its entirety for all purposes). Furthermore, over 45 plants operate with pre-grinding mills in the process described in the patents (titled "Dry Milling Ethanol Production Process and System Using Front-End Milling," US Patent Nos. 9,012,291 and 9,689,003, which are incorporated herein by reference in their entirety for all purposes) to increase plant ethanol production and recover valuable oil from the front end.

[0007] Further research has been conducted on back-end grinding to increase oil and protein yields. Some of these are disclosed in, for example, U.S. Patent No. 9,388,475, entitled "System and Method for Separating Oil and Protein from Grains for Ethanol Production". The invention also further develops a concentrated syrup process to produce a high lactic acid concentration in the syrup with 10^9 CFU units of probiotic culture, as disclosed in, for example, U.S. Patent No. 62 / 184,768, entitled "Method and System for Producing High-Value Animal Feed Additives from Whole Distillers' Grains during Ethanol Production". As disclosed in U.S. Patent No. 9,718,006, the invention also develops a multi-section sieving device for separating fiber from protein.

[0008] For all purposes, the above content is incorporated herein by reference in its entirety.

[0009] Regarding wet milling process Figure 1This is a flowchart of a typical wet milling ethanol production process 10. Process 10 begins with a soaking step 11, in which corn is soaked in a solution of water and sulfur dioxide for 24–48 hours to soften the corn kernels for milling, leach soluble components into the soaking water, and loosen the protein matrix along with the endosperm. The corn kernels mainly contain starch, fiber, protein, and oil. The soaked corn (after soaking step 11) with approximately 50% dry solids is then fed to a predetermined milling step (first milling) 12 at the mill, where the corn is milled in a manner that tears the kernels and releases the germ to prepare a high-density (8–9.5 Be) slurry of the milled components—primarily a starch slurry. This is followed by a germ separation step 13 by flotation, where the germ is separated from the remaining slurry using a hydrocyclone. The germ is the oily portion of the corn kernel. The separated germ stream (separated as a germ byproduct) contains some starch, protein, and fiber. It undergoes germ washing to remove the starch and protein, and then enters a dryer to produce approximately 2.5–3 pounds (dry basis) of germ per bushel of corn. The dried germ contains approximately 50% oil on a dry basis.

[0010] The remaining slurry, now free of germ but containing fiber, gluten (i.e., protein), and starch, is then subjected to a refining step (second grinding) 14 in a refining mill, where the endosperm is completely destroyed. In step 14, the endosperm components, including gluten and starch, are released from the fiber. This is followed by fiber separation in step 15, where the slurry is passed through a series of sieves to separate the fiber from the starch and gluten. The fiber in step 15 is washed and is clean, free of gluten and starch. Fiber separation step 15 typically employs a hydrostatic screen or a rotating paddle mounted in a cylindrical screen (paddle screen). Even after washing, the fiber processed by a typical wet mill contains 15%–20% starch. This starch is typically sold along with the fiber as animal feed. The remaining slurry, now free of fiber, is then subjected to a gluten separation step 16, where the starch and gluten are separated by centrifugation. The gluten stream enters a vacuum filter and is then dried in a dryer in step 16A to produce gluten (protein) powder.

[0011] Starch processed in step 16 of starch-gluten separation is typically passed through a jet cooker to begin the process of converting starch into sugar. Jet cooking refers to a cooking process carried out at elevated temperatures and pressures. These elevated temperatures and pressures can vary considerably. Typically, jet cooking occurs at temperatures of approximately 120–150°C (approximately 248–302°F) and pressures of approximately 8.4–10.5 kg / cm³. 2 Under pressure of approximately 120-150 psi, although when using approximately 8.4 kg / cm² 2At a pressure of approximately 120 psi, the temperature can be as low as approximately 104–107°C (approximately 220–225°F). The next steps are liquefaction and loosening (step 17), fermentation (step 18), yeast recovery, and distillation / dehydration (step 19). During liquefaction, the mixture or “mash” is maintained at 90–95°C so that α-amylase hydrolyzes the gelatinized starch into maltodextrin and oligosaccharides (chains of glucose molecules), thus producing liquefied mash or slurry. In saccharification step 17, the liquefied mash is cooled to approximately 50°C, and a commercial enzyme called glucoamylase is added. Glucoamylase hydrolyzes maltodextrin and short-chain oligosaccharides into individual glucose molecules to produce liquefied mash. In fermentation step 18, a common yeast strain (Saccharomyces cerevisiae) is added to metabolize glucose into ethanol and carbon dioxide (CO2).

[0012] After completing the above steps, the fermentation mash (“beer”) contains approximately 17%–18% ethanol (volume / volume basis). Following fermentation step 18 is distillation and dehydration step 19, in which the beer is pumped into a distillation column and boiled to evaporate the ethanol. The ethanol vapor condenses in the distillation column, and the liquid alcohol (in this case, ethanol) exits from the top of the column with approximately 95% purity (190 standard). The 190 standard ethanol is then passed through a molecular sieve dehydration column to remove any remaining residual water, yielding a final product of essentially 100% ethanol (199.5 standard). This anhydrous ethanol can now be used as engine fuel. The solids and some liquid remaining after distillation proceed to evaporation step 20, where yeast can be recovered as a byproduct. The yeast can optionally be recycled back to the fermentation tank in fermentation step 18. In some cases, CO2 is recovered and sold commercially.

[0013] No centrifugation step is required at the end of the wet milling ethanol production process 10 because the germ, fiber, and gluten have already been removed in the preceding separation steps 13, 15, and 16. The "lees" produced after the distillation and dehydration step 19 in the wet milling process 10 are referred to as "syrup".

[0014] The wet milling process 10 can produce high-quality starch products for conversion into ethanol, as well as separated streams of germ, fiber, and protein, which can be sold as byproducts to generate additional revenue streams. However, the wet milling process is complex and costly, requiring significant capital investment and high energy costs for operation.

[0015] Because the capital costs of wet grinding mills can be high, some ethanol plants prefer to use the simpler dry grinding process. Figure 2This is a flowchart of a typical dry-milled ethanol production process 20. As a general reference point, the dry-milled ethanol process 20 can be divided into a front-end process and a back-end process. The portion of process 20 that occurs before distillation 24 (e.g., at the still / distillation apparatus) is considered the "front-end," while the portion of process 20 that occurs after distillation 24 is considered the "back-end." The front-end process of process 20 begins with a grinding step 21, in which dried, whole corn kernels are ground into corn flour or fine powder using a hammer mill. The sieve openings in the hammer mill are typically size 7, or approximately 2.78 mm, resulting in a very broad, bell-shaped particle size distribution, ranging from as small as 45 μm to as large as 2–3 mm. The ground powder is mixed with water to produce a slurry, and a commercial enzyme called α-amylase (not shown) is added. This slurry is then heated to approximately 120°C in a pressurized jet cooking process 12 for approximately 0.5–3 minutes to gel (dissolve) the starch in the ground powder. Note that in some processes, instead of using a jet cooker, a longer holding time is used.

[0016] Following grinding step 21 is liquefaction step 22, in which the ground powder is mixed with cooking water to produce a slurry, and a commercial enzyme called α-amylase (not shown) is typically added. This step adjusts the pH to approximately 5.8–6 and maintains the temperature between 50°C and 105°C to convert insoluble starch in the slurry into soluble starch. The stream following liquefaction step 22 has a dry solids (DS) content of approximately 30%, all components of which are contained within the corn kernels, including sugars, proteins, fiber, starch, germ, coarse corn flour, oil, and salt. There are typically three types of solids in the liquefied stream: fiber, germ, and coarse corn flour, all with approximately the same particle size distribution. Following liquefaction step 22 is simultaneous saccharification and fermentation step 23. This simultaneous step is industrially known as "Simultaneous Scarification and Fermentation" (SSF). In some commercial dry-milled ethanol processes, saccharification and fermentation are performed separately (not shown). Individual saccharification and simultaneous saccharification and fermentation both require approximately 50–60 hours. Fermentation uses a fermenter to convert the sugar into ethanol. Following saccharification and fermentation step 23 is distillation (and dehydration) step 24, which uses a still to recover ethanol.

[0017] Next, at the end of process 20 following distillation 24, there is a fiber separation step 25, which involves separating insoluble solids ("wet filter cake") from the "whole grains" produced by centrifugal distillation step 24. The "wet filter cake" includes fibers (peel, tip, and fine fibers), coarse corn flour, germ particles, and some protein. The liquid exiting the centrifuge contains approximately 6%–8% dry solids, which mainly contains oil, germ, fine fibers, coarse corn flour, protein, soluble solids exiting the fermentation tank, and ash carried by the corn. Some plant-based whole grains with approximately 12–14% dry solids are fed to the first-stage evaporator, where the whole grains are concentrated to 15–25% dry solids before being fed to the fiber separation step 25.

[0018] The diluted lees are split into two streams. Approximately 30-40% of the stream is recycled (“returned”) to be mixed with corn flour in a slurry tank at the start of liquefaction step 22. The remaining stream (approximately 60-70% of the total stream) then enters an evaporator in evaporation step 27 to evaporate the moisture, leaving a concentrated syrup containing the main soluble (dissolved) solids from fermentation (25-40% dry solids). In liquefaction step 22, the returned water is used as part of the cooking water to reduce the consumption of fresh water and save on evaporation energy and equipment costs.

[0019] The concentrated slurry obtained after evaporation step 27 can be subjected to an optional oil recovery step 26, where the slurry can be centrifuged to separate the oil from the syrup (US Patent No. 7,601,858, which is incorporated herein by reference in its entirety for all purposes). The oil can be sold as a separate, high-value product. Corn oil yield is typically around 0.4 lb / bushel, with a high free fatty acid content. This yield recovers only about 1 / 4 of the oil from the corn. After distillation step 24, approximately half of the oil in the corn kernels remains in the germ, which cannot be separated in a typical dry milling process using a centrifuge. The free fatty acid content generated when the oil is kept in the fermenter for approximately 50 hours reduces the value of the oil. (De-oiling) centrifuges can only remove less than 50% of the oil from the syrup because the proteins and oil form an emulsion, failing to achieve the desired level of separation. Adding chemicals such as demulsifiers can improve separation efficiency to some extent, but these chemicals are expensive and can contaminate the dried corn ethanol grains product. Demulsification can also be achieved by heating or increasing the feed temperature of the centrifuge, but this affects the color and quality of the dry corn ethanol grains. Adding a certain amount of ethanol for demulsification (US Patent No. 8,192,627, which is incorporated herein by reference in its entirety for all purposes) can also improve separation and increase oil yield, but it requires explosion-proof equipment and is expensive to operate. All these improvements only increase the oil yield from an average of 0.4 lb / bushel to an average of about 0.6 lb / bushel, while the "free" oil in whole dies is about 1 lb / bushel. The oil / protein emulsion forms throughout the dry milling process and is the main reason for the low oil yield in the downstream oil system.

[0020] An oil and protein recovery process (PCT / US09 / 45163, which is incorporated herein by reference in its entirety for all purposes) was developed using an oil / protein separation step, adding this step to disrupt the oil / protein emulsion in whole grains. Figure 3As shown in process 30, the front-end process is as simple as existing dry milling processes. The process modifies its procedure in the steps following fiber separation 25 in the back-end process. An oil / protein separation step 31 is added between fiber separation step 25 and evaporation step 27. Nozzle centrifuges, other types of disc centrifuges, or disc decanters (WO 2014-082020, incorporated herein by reference in its entirety for all purposes) are commonly used in this application. The diluted lees obtained from fiber separation step 25 are fed to the oil and protein separation step 31, which can be performed using a centrifuge. The oil and protein emulsion is broken up within the centrifuge with a high G-force. Due to the density difference between oil (density 0.9 g / mL) and protein (1.2 g / mL), the oil enters the light phase (overflow) and is discharged, while the protein enters the heavy phase (underflow) and is discharged. The light phase (overflow) is then fed to evaporation step 27 to concentrate to a dry solids content of 25–40% (forming a semi-concentrated syrup). Next, the semi-concentrated syrup is fed to the back-end oil recovery system step 26 to recover the oil in the back end. The light phase stream contains less protein, thus reducing the chance of forming an oil / protein emulsion. The system can achieve an oil yield of up to 0.9 lbs / bushel. The deoiled syrup obtained from the back-end oil recovery step 26 can be further concentrated in an evaporator to a higher syrup concentration (up to 75% dry solids). Low-protein deoiled syrup avoids evaporator scaling. The underflow from the oil and protein separation step 31 enters the protein dehydration step 32 to recover the protein. The separated protein cake with an oil content of less than 3% obtained from the protein dehydration step 32 is fed to the protein dryer step 33 to produce high-value protein powder with a protein content of 50%. The liquid obtained from the protein dehydration step 32 is returned to the front end as reflux liquid, which is used as part of the cooking water in the liquefaction step 22.

[0021] Because the oil remains in the fermenter for more than 50 hours, all oil recovered from the back-end oil recovery system is of poor quality, dark in color, and high in fatty acids (approximately 15-20%). Back-end oil separation is also difficult because oil and protein form an emulsion throughout the dry milling process. Each step in the dry milling process, such as suction and separation, generates some oil and protein emulsion. To obtain high-quality oil and avoid the formation of oil and protein emulsions throughout the dry milling process, front-end oil recovery is a good solution. A three-phase decanter was tested for recovering oil from the liquefied starch stream during the liquefaction step. Due to the high viscosity of the liquefied starch solution and the fact that most of the oil remains in germ form, the oil yield is typically low, around 0.2 lb / bushel. Nevertheless, the oil quality is much better than that obtained from the back end, with a much lighter color and containing approximately 5-9% free fatty acids.

[0022] Develop and improve front-end oil recovery systems (as described in PCT / US12 / 30337, which is incorporated herein by reference in its entirety for all purposes) to increase oil yield and ethanol yield. Figure 4The process (as described in PCT / US12 / 30337, which is incorporated herein by reference in its entirety for all purposes) 40 shows two-stage liquid and solid separation steps 42 and 44 followed by two-stage dewatering and grinding steps 43 and 45, respectively, arranged counter-currently. A portion of the cooking water is added to the storage tank of the storage step 46 (e.g., solid / liquid separation step 49), instead of to the slurry tank of the cooking step 41. In process 40, the cooking water is mixed with the filter cake obtained from the second dewatering and grinding step 45, and then the mixture is fed to the third solid / liquid separation step 49 to recover the liquid, which has a Brix content of about 2 to 3 degrees. Then, the liquid obtained from the third liquid and solid separation step 49 is mixed with the filter cake obtained from the first dewatering and grinding step 43, and then held in the storage tank 46 for about 4 to 6 hours. The contents of the storage tank 46 are then fed to the second solid and liquid separation step 44 to separate the liquid from the solids. The liquid separated in the second liquid and solid separation step 44 has a Brix value of approximately 6–8 and is now used as part of the cooking water to be mixed with the corn flour obtained in the hammer mill grinding step 21, to be sent to the slurry tank of the cooking step 41. Using this countercurrent washing apparatus, the germ particles have approximately twice the retention time in the storage tank step 46, resulting in a much lower Brix value (approximately 6–8 Brix, instead of 25–30 Brix) liquefied starch solution. The germ soaked in a lower Brix environment and having twice the retention time in the liquefaction step allows the germ to soften more easily, enabling it to break off from the shell and release oil in the second dehydration and grinding step 45. This countercurrent washing process 40 also provides medium-sized germ particles obtained from the second stage of dehydration and grinding 45, which are recycled back to the first dehydration and grinding stage to ensure that the germ particles are ground to a predetermined size (e.g., less than 150 micrometers) to release more oil. All coarse corn flour / germ / fiber solid particles have a wide particle size range from less than 45 micrometers to as large as 2-3 mm. Softening the germ particles in a low Brix solution and holding them in a storage tank for a longer time makes the germ softer and easier to break than the fiber. Therefore, the dehydration and milling method can break down more germ particles than the fiber. However, each dehydration and milling step can only reduce the germ particle size to about half of its original size at most. For example, after one dehydration and milling step, germ particles with an average size of 1,000 μm become approximately 600 μm. For germ particles that release oil, the germ particle size is preferably less than 150 μm. Therefore, at least two or three stages of continuous dehydration and milling are typically required to release more oil from the germ particles. The countercurrent washing device allows medium-sized germ to be recycled back to the first dehydration and milling step 42 after the second dehydration and milling step 44 to break down the germ particles again. Select the sieve aperture size for the first and second solid and liquid separation steps 42 and 44 to obtain the desired size level and recycle the germ particles back to the slurry tank.

[0023] After the hammer mill grinding step 21, the mixture is optionally fed to a jet cooker, a second slurry tank, or another storage tank for the cooking step 41. The slurry then enters the first solid-liquid separation step 42, whereby the liquid is separated from the solid.

[0024] In the first solids and liquid separation step 42, the liquid containing oil and small solid particles (germ, protein, and fine fiber) from the liquefied starch solution is sent to the front-end oil recovery step 47. The dehydrated solids (filter cake) stream, primarily containing coarse corn flour / germ / fiber, is sent to the first dehydration and grinding step 43 to break down the solid particles (germ / coarse corn flour / fiber), releasing starch and oil from the coarse corn flour / germ / fiber solid particles. The solids obtained from the first dehydration step 43 are then mixed with the liquid obtained from the third solids and liquid separation step 49 and conveyed to a storage tank for the storage step 46. With less than half the cooking water used in the downstream section, the solids (germ / coarse corn flour / fiber) can remain in the storage tank for more than twice the typical retention time, and with a much lower Brix level. The coarse corn flour / germ / fiber / starch can be quickly and easily softened / broken down along with the starch to liquefy and release oil from the germ particles. After passing through the storage tank in step 46, the slurry is sent to the second solid-liquid separation step 44 for dehydration. The liquid is recycled back to the slurry tank of cooking step 41, with larger germ particles becoming part of the cooking water. The filter cake obtained from the second solid-liquid separation step 44 enters the second dehydration and grinding step 45. Subsequently, the filter cake is mixed with the refluxed water to the third solid-liquid separation step 49. The liquid obtained from the third solid-liquid separation step 49 is sent to the storage tank in step 46. The filter cake obtained from the solid-liquid separation step 49 is sent to the fermenter for fermentation step 23.

[0025] The liquid obtained in the first solid-liquid separation step 42, containing most of the oil at the front end, is sent to the front-end oil recovery system. A three-phase nozzle centrifuge is typically used in oil separation step 47 to separate oil / emulsion / small germ particles from the liquefied starch solution. In oil purification step 48, the light phase, containing most of the oil / emulsion / germ particles and a small amount of liquefied starch solution, is sent to a small three-phase centrifuge (decanter or disc centrifuge) to brighten and purify the oil. The heavy phase and underflow / filter cake phase obtained from three-phase nozzle centrifuge steps 47 and 48 are sent to fermentation step 23, where they are first converted to sugar and then to ethanol. The "beer" from the fermenter, containing approximately 15%–17% ethanol, enters distillation step 24 to recover the ethanol. The whole grains flowing out from the bottom of distillation step 24 can be selectively fed into the first-stage evaporator to pre-concentrate from the normal 12-14% dry solids concentration to 15-25% dry solids concentration, and then passed through a germ cyclone to float any larger germ fragments still in the whole grains (U.S. Provisional Patent Application No. 61 / 638,455, filed April 25, 2012, which is incorporated herein by reference in its entirety for all purposes).

[0026] Depending on the pre-grinding system and the concentration of concentrated whole grains, and the operation step 46A of the germ hydrocyclone, the use of the germ hydrocyclone can increase the oil yield by approximately 0–0.2 lb / bushel. The degermed fiber stream is discharged from the bottom of the germ hydrocyclone, or the whole grains discharged from the bottom of the distillation column is sent to the settling centrifuge in the fiber separation step 25 to recover the fiber as corn fiber (DDG). The overflow from the decanter is divided into two streams: approximately 30%–40% of the stream is used as reflux, while the remaining 60%–70% of the stream is sent to the evaporator step 27 to be concentrated as a syrup byproduct to approximately 35% dry solids.

[0027] Oil recovery in the front-end system produces a lighter color and lower (approximately 5–9%) fatty acid content. Oil yield in the front end is affected by the number of dehydration and milling stages in the front end and the degermination system in the back end. In a single dehydration and milling system, the oil yield is approximately 0.2–0.4 lb / bushel. With two consecutive dehydration and milling stages, the oil yield is approximately 0.3–0.5 lb / bushel. With an additional degermination system in the back end, the oil yield is approximately 0.5–0.6 lb / bushel. Not all oil is obtained in the front-end oil recovery system, as less than half of the oil from the fine germ particles is released in the front-end steps. More oil is released from the germ particles in the back end than in the front end because the ethanol present in the back end acts as a solvent to extract more oil during fermentation step 23 and / or distillation step 24. An additional back-end oil recovery step 26 is required to obtain a higher oil yield.

[0028] Furthermore, if the corn used is old corn or corn dried in a high-temperature environment, the softening process of the germ grains during the storage tank softening process becomes very slow. In this case, more enzymes and larger capacity storage tanks are required (to provide a longer storage time for softening the germ). The aforementioned literature, including patents and patent applications, is incorporated herein by reference in its entirety for all purposes.

[0029] The germ particles in the liquefaction step do not absorb water, and therefore are not easily broken in the dehydration and milling steps 42 and 44. After the dehydration and milling steps, the germ particle size is typically reduced to half its original size. Therefore, more than half of the oil in the corn kernel remains in the germ (oil droplets are protected by protein cell walls) and is not released in the preceding dehydration and milling steps 43 and 45, because the germ particles in the liquefaction step have not yet fully absorbed water and softened enough to be broken up by the mill.

[0030] After fermentation step 23 and distillation step 24, the germ particles have fully absorbed water and are easily crushed by using a grinder. Therefore, the germ particles can be crushed to release more oil by moving one of the front-end dehydration and grinding step 45 and solid-liquid separation step 49 to the rear end (after distillation 24).

[0031] In recent years, corn prices have risen rapidly. Therefore, increasing oil yield in the dry milling industry has become an important issue. For example... Figure 2 The existing back-end oil recovery system described in process 20 has a yield of approximately 0.4 to 0.6 pounds of oil per bushel. Modified back-end oil and, as... Figure 3 Combining the protein recovery method described in process 30, approximately 0.8 lbs / bushel of oil can be produced. A front-end oil recovery system without a back-end oil recovery system can achieve a yield of 0.5 lbs / bushel of oil, while a front-end oil recovery system with a back-end oil recovery system can achieve a yield of 1.1 lbs / bushel. Figure 4 The process described in section 40 is as follows.

[0032] The back-end milling process in U.S. Patent No. 9,388,475 discloses how to improve both front-end and back-end oil recovery, achieving a maximum oil yield of 1.4 lbs / bushel. This process also provides more valuable byproducts, including white fiber (which can be used in secondary alcohol production and the paper industry) and high-value protein powders (gluten meal, spent yeast, and germ protein).

[0033] like Figure 5As shown, as part of a typical front-end dry milling system, corn undergoes a hammer mill grinding step 22, a liquefaction step 23, a fermentation step 23, and a distillation step 24. After distillation step 24, the remaining mash is sent to a liquid-solid separation step 52, where the solid phase contains coarse solids (mainly fiber, germ, and coarse corn flour), and the liquid phase contains fine solids (mainly fine fiber and protein), as well as oil and other liquid substances. The coarse solids fraction is sent to a dehydration grinding step 51 to break down the germ and coarse corn flour, thereby releasing oil and starch. The ground solids are sent to a fiber and protein separation step 53. Return water and fresh cooking water are used as washing liquid to wash all the broken germ and coarse corn flour fibers, which are then returned to the liquefaction step 22 as cooking water to increase the yield of ethanol and oil in the second round. The washed fibers can be used for secondary alcohol production or further purified in a fiber purification step 58 to produce white fibers, which can be used as a raw material in the paper industry or for other processes. The liquid and fine solid fractions obtained from liquid-solid separation step 52 are fed to oil-protein separation step 55. The protein-rich stream from oil-protein separation step 55 is sent to protein dehydration step 32 to produce a protein cake containing 45-50% protein. Protein powder yield can reach up to 6 lbs / bushel. The overflow from protein dehydration step 32 is used as reflux. The oil-rich stream from oil-protein separation step 55 is sent to an evaporator in evaporation step 27 to concentrate it into a syrup with approximately 30-40% dry solids, followed by oil recovery step 57 to recover oil at a yield of up to 1.41 lbs / bushel. This back-end milling system increases ethanol yield to 3%, protein powder (containing 50% protein) yield to 6 lbs / bushel, and oil content to 1.4 lbs / bushel.

[0034] The defatted syrup obtained in evaporation step 27 is sent to syrup fortification step 59. A certain amount of lactic acid-producing probiotic culture is added to the defatted syrup for secondary fermentation, thereby converting the sugar into lactic acid and producing a fortified syrup containing 20% ​​lactic acid (on a dry basis) and 10^ 9 CFU probiotics. Summary of the Invention

[0035] The process disclosed in this application maximizes the utilization of all components in whole distillers' grains to produce animal feed for various types of animals. In some embodiments of this application, an ethanol production process with a back-end grinding system is used to produce four types of animal feed, including:

[0036] 1) First animal feed formulated and prepared for cattle or other ruminants: mainly contains the pericarp and tips of corn. First animal feed mainly contains crude fiber, as well as 10% to 20% protein and less than 4% oil.

[0037] 2) Secondary animal feed formulated and prepared for chickens and / or pigs. This secondary animal feed mainly contains fine fiber, zein from corn, and deoiled germ protein containing some fine fiber. It contains 40%–45% protein and less than 4% oil.

[0038] 3) A third type of animal feed formulated and prepared for fish and pets. This third type of animal feed mainly contains spent yeast protein, germ protein, and corn gliadin from corn. It contains 45% to 50% protein and less than 4% oil.

[0039] 4) A fourth type of animal feed, formulated and prepared, containing a fortified syrup intended as part of an infant animal's milk diet or as an animal nutritional supplement. This fourth type of animal feed is formulated to be rich in minerals (from inside corn), nutrients (from inside yeast cells), and up to 20% lactic acid (on a dry basis) and 10^ 9 CFU (e.g., 100 million CFU) of probiotic units.

[0040] This instruction manual provides the most efficient method for producing the above four animal feeds using whole distillers' grains. For example, Figure 6 One exemplary embodiment for producing animal feed is shown.

[0041] exist Figure 6 In this process, the upstream processes (from corn milling step 21 to distillation step 24) can use the same or similar processes / equipment as those used in typical commercial dry milling processes. (See also...) Figure 6 The whole distiller's grains are sent to the selective particle separation step 61, which generates three streams:

[0042] a) A first stream containing a large amount of solids, wherein the first stream mainly contains pericarps, tips, germ, and coarse cornmeal. The first stream should be as dry as possible.

[0043] b) A second stream containing fine fibers and a much higher concentration of zein (zein is inside the corn).

[0044] c) A third stream containing waste yeast, fine germ, and the purest form of protein. This can be achieved using multiple screens (with various screen sizes and types of open troughs), one or more paddle screens, one or more pressure screens, one or more vibrating screens in a continuously arranged multi-stage configuration, or combinations thereof.

[0045] The following provides a more detailed description of the three material flows mentioned above.

[0046] The primary animal feed for feeding cattle or other ruminants

[0047] In some embodiments of this application, the first animal feed is used to feed cattle or other ruminants. The first animal feed can be prepared using the first feed stream described above. The first feed stream obtained after the selective particle size separation step 61 (e.g., having larger solids: fiber, germ, and coarse corn flour) is sent to a selective grinding step 51 for dehydration and grinding. In the selective grinding step 51, the germ and coarse corn flour particles are broken down to release starch, protein, and oil.

[0048] Fiber washing step 68 receives the product obtained from selective milling step 51. Fiber washing step 68 washes the fibers and removes broken coarse cornmeal and germ particles by using reflux and a certain amount of fresh cooking water as the washing liquid. The washing liquid releases starch, protein, oil, germ, and / or combinations thereof, wherein the washing liquid is returned to liquefaction step 22 to produce more ethanol (increasing the ethanol yield to 3%), increasing the oil yield to 1.4 lb / bushel, and increasing the protein yield to 7 lb / bushel. Fiber washed in fiber washing step 68 has less than 20% protein and less than 4-5% oil, making it ideal for cattle feeding.

[0049] The second type of animal feed for chickens and pigs

[0050] The second feed stream (e.g., a medium-sized particle stream) primarily contains fine fibers and zein from corn. This second stream is the slurry exiting the selective particle size separation step 61, which is then fed to the protein dehydration step 62 to produce a protein filter cake. The protein powder contains 40%–50% protein. The protein yield is 2.5–4.5 pounds per bushel and can be used as a secondary animal feed for chickens and pigs.

[0051] The third type of animal feed for fish and family pets

[0052] The overflow obtained in protein dehydration step 62 contains some yeast and fine germ proteins, which are combined with the fine protein stream obtained in selective particle size separation step 61 as a combination step 62A.

[0053] The third stream, including the overflow obtained in step 62A (e.g., a fine protein stream), mainly contains yeast protein, fine germ protein, and oil. The third stream is sent to the oil and protein separation step 65 to produce an oil-rich stream (overflow) and a protein-rich stream (underflow).

[0054] In the oil and protein separation step 65, the underflow (the protein-rich feed stream) is sent to the protein dehydration step 63 to produce high-quality protein powder containing 45-50% protein and a good amino acid distribution of up to 3 pounds per bushel, which is formulated and prepared as feed for fish and domestic pets.

[0055] The fourth type of animal feed contains concentrated syrup that is used as part of the milk diet for infant animals or as a nutritional supplement for animals.

[0056] The oil-rich stream obtained from the selective particle size separation step 61 (via the oil and protein separation step 65) is fed to the evaporator of the evaporation step 27 to produce a syrup with 30-40% dry solids. The syrup obtained from the evaporation step 27 is sent to the oil recovery step 57 to produce up to 1.4 pounds per bushel of oil.

[0057] In oil recovery step 57, the deoiled syrup contains the deoiled syrup sent to syrup fortification step 59 via evaporation step 27. In syrup fortification step 59, a probiotic culture producing lactic acid is added to the deoiled syrup for secondary fermentation, thereby converting residual sugar into lactic acid and containing up to 10^ 9 Fortified probiotic products containing CFU units of probiotics. For all purposes, the entire contents of the relevant U.S. Provisional Patent Application No. 62 / 184,768 are incorporated herein by reference in their entirety.

[0058] In syrup fortification step 59, the fortified syrup contains all the minerals found in corn, vitamins from yeast cells, all soluble proteins, up to 20% lactic acid (on a dry basis), and 10^ 9 CFU probiotic units. In some embodiments of this application, the concentrated syrup can be further concentrated to 85% dry solids by using a low-temperature vacuum evaporator in the low-temperature evaporation step 64. In the low-temperature evaporation step 64, a waste heat recovery system (see...) Figure 15The high-temperature waste heat stream treated by a dryer is used as a heat source, saving energy. The concentrated syrup in the low-temperature evaporation step 64 can be applied and sprayed onto any other dry animal feed to produce an animal feed product with a moisture content higher than 10%, which can be stored at room temperature for a long time without spoiling due to the salt, sugar, and lactic acid content in the concentrated syrup. This concentrated syrup can be used to prepare infant animal food formulas and as a binder in the pelleting / bucketing step of all pelleted / bucket animal feeds. The concentrated syrup can also be used to make drinking water formulas for all animals. This syrup, rich in low pH and high glycerol content (keeping plant leaves moist), can also be used as an organic and natural plant insect repellent to keep insects away from seedlings. Because of its high K+ and P+ content, the concentrated syrup can also be used as an organic fertilizer for plants. In addition, the low pH concentrated syrup with high lactic acid and glycerol content can be used as a soil conditioner to keep soil moist and promote better plant growth. This 85% DS (dry solids) concentrated syrup can also be used as a natural organic wet animal feed preservative. Data shows that mixing 85% dry solids concentrated syrup with wet protein filter cake (25% dry solids) in a 1:1 ratio creates a high-nutritional-value wet animal feed containing only 55% dry solids. This moist feed can be stored at 40°C (104°F) for four months without spoilage. Therefore, this concentrated syrup can be added as part of a feed additive to the dry feed in a typical dry feed system, as the concentrated syrup has a high nutritional value of up to 10^ 9 CFU units of probiotic culture and lactic acid.

[0059] The specific techniques employed in this invention will be further explained through the following embodiments and accompanying drawings. Attached Figure Description

[0060] Embodiments will now be described by way of example with reference to the accompanying drawings, which are exemplary and not limiting. Throughout all the drawings mentioned in this application, elements with the same number refer to the same element.

[0061] Figure 1 Typical wet milling processes and systems for producing ethanol and soluble grains are shown.

[0062] Figure 2 A typical dry milling process and system for producing ethanol is shown, in which oil is recovered using a downstream process.

[0063] Figure 3 A typical dry milling process and system for producing ethanol is shown, which uses back-end processes to recover oil and protein.

[0064] Figure 4 This demonstrates a typical dry grinding process that uses pre-grinding and pre-oil recovery processes to increase the yield of ethanol and oil.

[0065] Figure 5 Typical systems and methods for separating high-value byproducts from grains are described, in which the grains are used to produce ethanol via a back-end selective milling process to increase the yields of oil, alcohol, and protein.

[0066] Figure 6 Systems and methods for producing four types of animal feed according to some embodiments are shown.

[0067] Figure 7 Systems and methods for producing four types of animal feed for various animals are shown according to some embodiments.

[0068] Figure 8 A separation system for separating various particle sizes is shown according to some embodiments.

[0069] Figure 9 Another system and method for particle size separation according to some embodiments is shown.

[0070] Figure 10 Another system and method for particle size separation according to some embodiments is shown.

[0071] Figure 11 A paddle screen with a three-section screen and high-speed washing capability is shown according to some embodiments.

[0072] Figure 12A The diagram illustrates a screen tube design with slit openings perpendicular (intersecting) to the direction of liquid flow, according to some embodiments.

[0073] Figure 12B The diagram shows a screen design with slit openings parallel to the direction of liquid flow, according to some embodiments.

[0074] Figure 13 This describes, according to some embodiments, a fortified probiotic syrup used as a preservative to form probiotic wet feed for animals.

[0075] Figure 14 The illustration shows a fortified probiotic syrup used as a binder to form fortified probiotic dry feed pellets for animals, according to some embodiments.

[0076] Figure 15 A process for producing high-concentration fortified probiotic syrup according to some embodiments is shown. Detailed Implementation

[0077] The embodiments of this application will be described in further detail below with reference to the accompanying drawings. While the invention has been described in conjunction with the following embodiments, it should be understood that these embodiments are not intended to limit the invention to these examples. Rather, the invention is intended to cover substitutions, modifications, and equivalents that may be included within the spirit and scope of the invention as defined by the appended claims. Furthermore, in the following detailed description of the invention, numerous specific details are set forth in order to more fully illustrate the invention. However, it will be apparent to those skilled in the art who will benefit from the invention that the invention can be practiced without these specific details. In other instances, well-known methods and processes, components, and treatments have not been described in detail so as not to unnecessarily obscure aspects of the invention. Of course, it will be understood that in the development of any such practical implementation, many implementation-specific decisions must be made to achieve the specific goals of the developers, such as compliance with application- and business-related constraints, and these specific goals vary from implementation to implementation and from developer to developer. Furthermore, it should be understood that such development efforts may be complex and time-consuming, but this remains a routine engineering task for those skilled in the art who will benefit from the invention.

[0078] A typical dry-milled ethanol plant produces only one ethanol byproduct called dried corn ethanol grains (DDGS). DDGS typically contains approximately 29%–31% protein, 11%–13% oil, and 4%–6% starch. Furthermore, the yield of DDGS is approximately 15–16 pounds per bushel, containing approximately 4.6 pounds per bushel of protein, 1.9 pounds per bushel of oil, and 0.8 pounds per bushel of starch. Despite the high protein and oil content, DDGS commands a low selling price.

[0079] The reasons include its high fiber content, making dried corn ethanol residues suitable only for ruminants such as cattle. In other words, dried corn ethanol residues are not suitable for monogastric animals such as chickens or fish. This invention provides a method for separating the components / ingredients of dried corn ethanol residues, resulting in a higher purity of the separated components. This method, as a byproduct of ethanol production processes, yields components with higher purity, thus increasing the value of the byproduct. The byproduct can be used in various applications and industries, including in the paper industry to prepare water-resistant pulp and secondary alcohol feedstocks containing white fiber (less than 10% protein, less than 3% oil, and less than 2% starch). Furthermore, the byproduct can be used to prepare nutritious animal feeds containing crude protein powder (more than 40% protein, less than 4% oil, and less than 2% starch), fine protein powder (more than 45% protein, less than 3% oil, and less than 1% starch), corn oil, and concentrated syrup. Dried corn ethanol residues contain five main parts / components, as follows:

[0080] The first part consists of larger solid particles (greater than 400 micrometers in size), which is a combination of fibers (e.g., pericarps and tips) bound with some protein and starch, coarse corn flour (e.g., fine fibers bound with protein and starch), and germ particles with oil droplets protected by protein cell walls within the germ. The yield of the first part is approximately 6 pounds per bushel, and its composition is 28% protein, 8% oil, and 4% starch.

[0081] Part Two: The crude protein fraction mainly contains zein and some fine fibers bound to starch. Part Two also contains insoluble solids with a density of 1.1. Particle size ranges from 50 to 500 μm. The yield is approximately 4 lbs / bushel, and its composition is 45% protein, 5% oil, and 2% starch.

[0082] Part Three: A very fine germ paste and spent yeast fraction. Part Three has a density of approximately 1 and a particle size range from submicron to 50 μm. The yield of Part Three is approximately 2.5 lbs / bushel, and its composition is 45% protein, 30% oil, and 2% starch.

[0083] Part 4: Corn contains soluble solids of inorganic salts, sugars, and fermentation byproducts, including lactic acid, glycerol, and acetic acid. The yield is approximately 4 pounds per bushel, consisting of 10% protein, 7% oil, and 5% starch.

[0084] Part 5: "Free" oil. The oil can be recovered using one or more centrifuges. The yield is approximately 1 pound per bushel.

[0085] Nevertheless, typical dried corn ethanol residues (DDGS) are not a valuable byproduct because all the compounds are cross-contaminated. Therefore, methods, processes, and equipment are used to separate, purify, and / or isolate valuable components for the production of animal feed.

[0086] In some embodiments of this application, a method for better decomposing component mixtures is disclosed, which can lead to finer / better separation and produce purer products. Therefore, the products can become more valuable byproducts, such as those with purer compositions. Examples include purer corn oil, purer crude protein concentrate (protein content greater than 45%, oil content less than 3%, starch content less than 2%), purer fine protein concentrate (protein content greater than 45%, oil content less than 3%, starch content less than 1%), purer white fiber (protein content less than 15% and oil content less than 3%), and nutrient-rich syrups. This invention provides a method for producing four types of animal feed suitable for various animal types and providing purer, more valuable byproducts.

[0087] In some embodiments of this application, six additional features, steps, processes, and / or apparatus are used in conjunction with typical dry milling processes / equipment. According to some embodiments, the invention provides a more thorough separation between fiber, protein, and oil, which in turn produces purer and more valuable byproducts (e.g., low-protein fiber feed, crude protein gluten meal, protein with a particularly high ratio of spent yeast and germ, and concentrated syrups for various animal feeds). (See below and...) Figure 6 The above six additional features were disclosed in the document:

[0088] (1) Selective particle separation (step 61): The whole lees is sent to selective particle separation step 61 to separate the insoluble solids into three parts: a) coarse fiber (e.g., pericarp and apex), germ and coarse corn flour; b) fine fiber and coarse corn gliadin; and c) fine protein (e.g., waste yeast and germ protein).

[0089] (2) Dehydration and milling (step 51): There are more than 2 pounds / bushel of unbroken germ and about 1 pound / bushel of coarse cornmeal (e.g., starch bound with fine fibers and proteins) in the whole grains. These dehydrated particles are sent to dehydration and milling in step 51 to be broken down, thereby releasing the oil, starch and protein from the germ and coarse cornmeal.

[0090] (3) Fiber Washing (Step 68): The solids obtained from the dehydration and milling step 51 are fed to the fiber washing step 68. Recycled and fresh cooking water are used as washing liquid to wash the fibers and remove broken germ and coarse corn flour, and the recycled water is returned to the liquefaction step 22 as cooking water. The ethanol yield is increased to 3%, and the oil yield is increased to 1.4 lb / bushel. The washed fibers are in a more fibrous form (less than 15% protein, less than 4% oil, and less than 2% starch). The washed fibers can be used as dairy cow feed or as a secondary alcohol feedstock or for cellulose processing.

[0091] (4) Crude zein protein powder (step 62): The crude zein protein with fine fibers obtained from the selective particle separation step 61 is sent to the protein dehydration step 62 to produce gluten powder with up to 5 pounds / bushel containing about 45% protein, less than 3% oil and less than 2% starch, which is ideal for chicken and pig feed.

[0092] (5) Crushing the oil and protein emulsion and specially cleaned thin distillers' grains (step 65): Crude protein is removed prior to the oil and protein separation step 65, reducing the solids load in this step by more than 50%. The oil-rich stream (thin distillers' grains) contains less than 2.0% by volume of solids, while the solids volume content is 7%. Therefore, this extra-clean oil-rich stream is concentrated to 85% dry solids in the evaporator instead of the normal 35%. This higher concentration of syrup saves energy, reduces the load on the dry corn distillers' grains dryer, and may even allow bypassing / not using the dryer. The protein-rich stream from the oil and protein separation step 65 is sent to the protein dehydration step 63 to produce a high-protein powder (50% protein, 3% oil, and less than 2% starch), ideal for pet and fish food diets.

[0093] (6) Low-temperature evaporation and concentration of syrup (step 59): The deoiled syrup obtained in oil recovery step 57 is sent to syrup concentration step 59, where a certain amount of lactic acid probiotic culture, such as Lactobacillus plantarum ZJ316, Lactobacillus amyloliquefaciens, Lactobacillus fermentum, and Lactobacillus mucosa, is added to convert the residual sugar into lactic acid. This constitutes a secondary fermentation, which produces up to 20% (on a dry basis) of lactic acid and 10^ 9 CFU (Cost-Free Units) of probiotics. By using a low-temperature vacuum evaporator to avoid high temperatures, this concentration system can concentrate dry solids syrups to up to 85%, as high temperatures destroy valuable nutrients in the syrup. In some embodiments of this application, this highly concentrated syrup can bypass the dryer and be added to dried feed after the drying step to create a “wetter” (more than 10% moisture), “non-spoilage” (can maintain “higher nutritional value” for an extended period at room temperature) “probiotic” animal feed product. This syrup, rich in 85% dry solids, can also be used as an animal food supplement as part of infant formula and / or animal drinking water formulations.

[0094] Figure 13 and 14 The application of the produced syrup is shown.

[0095] Figure 13 A system 1300 is shown that uses concentrated syrup as a preservative to form probiotic wet feed for animals.

[0096] like Figure 13As shown, concentrated syrup can be used as a concentrated probiotic wet feed system. Data shows that mixing 85% dry solids syrup 1302 with 25% dry solids wet filter cake 1304 processed by a protein decanter in a 1:1 ratio to form a 55% dry solids wet feed for piglets can be stored at room temperature (40°C) for four months without spoilage. The ratios mentioned above are listed as examples. Any other ratio can be used to mix 85% dry solids concentrated syrup or 35% dry solids concentrated syrup with any other components from the methods disclosed in this invention. For example, 85% dry solids syrup 1302 can be mixed with 25% dry solids wet filter cake 1304 processed by a protein decanter in ratios of 1:2, 1:5, 1:10, 10:1, 4:1, and 0.5:1.

[0097] like Figure 13 As shown, whole distillers' grains 1308 can be used to produce syrup 1310, corn fiber wet filter cake 1304, corn protein wet filter cake 1316, and yeast / germ protein wet filter cake 1322.

[0098] In some embodiments of this application, syrup 1310 undergoes secondary fermentation with added probiotic culture to produce fortified probiotic syrup 1312 with 35% dry solids, which has a dry solids content as high as 10^ 9 This probiotic-rich syrup contains CFU units of active probiotic culture and 20% (on a dry basis) lactic acid. It can be further concentrated to become a highly concentrated probiotic-rich syrup 1314 with 85% dry solids, containing up to 10^ 7 CFU units of probiotics. Therefore, this 85% dry solids syrup is primarily used as a preservative in wet animal feed systems. A combination of 35% high-probiotic CFU unit concentrated syrup and 85% high-concentration solids concentrated syrup can be used to prevent spoilage in wet animal feed systems.

[0099] In this application, probiotic syrups 1312 and 1314, which are rich in 35% dry solids, can be combined with other substances obtained by dry milling to form probiotic-rich wet feed preservatives (to prevent spoilage). For example, the 35% dry solids syrup can be mixed with corn gluten wet filter cake 1316 to prepare probiotic-rich wet corn gluten feed 1318 for chickens and ducks. Similarly, the 85% dry solids highly concentrated fortified syrup 1314 can be mixed with corn fiber wet filter cake 1304 to prepare fortified corn fiber probiotic wet feed 1318 for dairy cows. In some embodiments of this application, the 85% dry solids highly concentrated fortified syrup 1302 can be mixed with yeast / germ protein wet filter cake 1322 to prepare fortified probiotic wet yeast / germ feed 1320 for domestic pets and fish.

[0100] Figure 14A system 1400 is shown that uses fortified probiotic syrup as a binder to form fortified probiotic dry feed pellets for animals.

[0101] like Figure 14 As shown, both concentrated syrups (35% dry solids and 85% dry solids) can be used as binders to prepare animal feed pellets / tubes, in which the concentrated syrup is added. These pellets / tubes have a high lactic acid content and high probiotic units, and can be used as part of a feed supplement.

[0102] like Figure 14 As shown, whole grains 1402 can be used to produce syrup 1406, dried corn fiber 1408, dried corn protein 1410, and dried yeast / germ protein 1412.

[0103] In some embodiments of this application, syrup 1406 may be concentrated into probiotic syrup 1414 rich in 35% dry solids, which may be further concentrated into highly concentrated syrup 1416 rich in 85% dry solids.

[0104] In this application, a probiotic syrup 1414 rich in 35% dry solids can be mixed with dried corn protein 1410 to prepare probiotic-rich dried protein feed pellets 1420 for chickens and ducks. Similarly, a fortified syrup 1416 highly concentrated with 85% dry solids can be mixed with desiccated corn fiber 1408 to prepare fortified corn fiber probiotic pellets 1418 for cattle and pigs. In some embodiments of this application, the fortified syrup 1416 highly concentrated with 85% dry solids can be mixed with dried yeast / germ protein 1412 to prepare fortified probiotic dried yeast / germ feed pellets 1422 for domestic pets and fish.

[0105] like Figure 13 and 14 The concentrated syrup can be concentrated to a dry solids percentage of 35% to 85%. Fortified syrups of a predetermined percentage (any percentage from 35% to 85% dry solids; such as 35%, 40%, 43%, 60%, 78%, and 85%) can be used to blend with other components from the ethanol production process described herein to produce animal feed or for granulation, including… Figure 13 The corn fiber wet filter cake 1304, corn protein wet filter cake 1316, and yeast / germ protein wet filter cake 1322, as well as the corn fiber 1408 dried in a dryer. Figure 14 Corn protein 1410 dried by a dryer and yeast / germ protein 1412 dried by a dryer.

[0106] Figure 15 A waste heat recovery system 1500 for evaporating and concentrating syrup is shown according to some embodiments.

[0107] like Figure 15 As shown, a waste heat recovery system 1500 can be added to recover the waste heat treated by the dryer 1502, thereby evaporating and concentrating the syrup from 35% to 85% dry solids at the vacuum evaporator 1504 without using other heat sources. The syrup mentioned above can be obtained through a syrup fortification process 1506, which can be... Figure 6 Syrup fortification step 59.

[0108] The aforementioned improved stages, steps, or methods may be used, in whole or in part, with or added to typical dry grinding equipment as needed to produce high-quality and valuable byproducts.

[0109] Further details of the present invention are as follows:

[0110] Corn kernels contain approximately 3 pounds / bushel of gluten protein and 1 pound / bushel of germ protein. Fermentation also produces approximately 0.4 pounds / bushel of yeast protein. Therefore, the total protein content in the whole grains is approximately 4.5 pounds / bushel of total protein. This invention develops a protein recovery process (similar to patent 8,778,433, which is incorporated herein by reference in its entirety for all purposes) that adds an oil / protein separation step 31, a protein dehydration step 32, and a protein drying step 32 to produce protein powder with 50% protein purity. Figure 3 As shown in Process 30, the remainder of the process is the same as or substantially similar to a typical dry milling process. Using Process 30 yields only about 3.0 lb / bushel of protein powder, containing 50% protein, thus recovering only 33% of the protein in the whole grains. Approximately 1.9 lb / bushel of oil is present in the corn kernels, and current back-end oil recovery systems give an average yield of about 0.8 lb / bushel, recovering only about 43% of the oil.

[0111] Using front-end grinding processes (such as...) Figure 4 Protein yield increased to 3.5 lbs / bushel, and oil yield increased to approximately 0.9 lbs / bushel. Post-grinding ( Figure 5 This method further increases the yield of ethanol, oil, and protein by breaking down the germ and coarse corn flour in corn fiber and separating / recovering oil and protein from the fiber (which is bound to protein and oil) in dried corn alcohol residue. Simultaneously, the separation / recovery of protein and oil improves fiber purity, resulting in the production of more valuable white fiber instead of corn fiber.

[0112] In a typical dry milling process, more than half of the corn germ remains in its germ form within the whole distillers' grains. The oil within the germ is protected by the protein cell walls and cannot pass through... Figure 2The oil recovery system in a typical dry mill with a back-end oil recovery system, as described in process 20, separates and recovers the oil.

[0113] Improved back-end grinding process, such as Figure 5 As shown. Process 50 includes a liquid and solid separation step 52, a dehydration and grinding step 51, a germ and fiber separation step 53, and a fiber purification step for recovering the germ. The dehydration and grinding step 51 grinds the germ and breaks down the protein cell walls to release oil and produce white fiber.

[0114] In process 50, corn is fed to hammer milling step 21, liquefaction step 22, fermentation step 23, and distillation step 24, similar to a typical dry milling process. The bottom layer of the distillate in distillation step 24 (e.g., whole grains) contains fiber, germ particles, corn protein, yeast, and byproducts from the fermentation tank and ash from the corn. Whole grains with 12%–14% dry solids can be fed to a first evaporator (pre-concentration step 28) to concentrate to 15%–25% dry solids. Whole grains or concentrated whole grains are fed to liquid and solids separation step 52 to separate the solids (primarily fiber, germ, and coarse corn flour) from the liquid (primarily protein, fine germ, starch particles, oil, fine fiber, and soluble solids). The solid phase is fed to dehydration milling step 51 to break down the germ and coarse corn flour particles, thereby releasing oil and starch. Next, after dehydration milling step 51, the milled solids are fed to fiber / protein separation step 53. In this step, reflux and fresh cooking water are used as washing water to wash away broken germ and coarse corn flour from the fibers. The light phase obtained from germ and fiber separation step 53 mainly consists of germ particles and liquid, with the filtrate being returned to the upstream end (e.g., liquefaction step 22) as part of the cooking water. The retained solids from germ and fiber separation step 53 continue through fiber purification step 58 to produce white fibers for secondary alcohol production or water-resistant pulp.

[0115] The liquid phase obtained from the solid-liquid separation step 52 is sent to the oil and protein separation step 55, where the product is separated into two streams: an oil-rich stream and a protein-rich stream. The protein-rich stream is sent to the protein dehydration step 32 to produce a protein filter cake. The oil-rich stream is sent to the evaporation step 27 to concentrate it to a content of 30-40% dry solids. The concentrated syrup is sent to the oil recovery step 57 to recover the oil in the light phase. The deoiled syrup in the heavy phase is sent to the syrup fortification step 59 to convert the sugar into lactic acid by adding a lactate culture, thereby producing up to 20% lactic acid (on a dry basis) with a content of 10^ 9 CFU (Central Fuel Unit) of probiotics.

[0116] In the liquid-solid separation step 52, a two-stage paddle sieve with sieve openings in the range of 100–300 μm, as described in U.S. Patent No. 9,718,006, is used. Other types of sieve separation devices, such as pressure sieves, conical sieves, and vibrating sieves, can also be used. The sieve opening determines the quality and quantity of protein produced. Smaller sieve openings provide higher protein purity (up to 55%) but lower protein yield (down to 2 lbs / bushel). In contrast, larger sieve openings provide lower protein purity (down to 40%) and higher protein powder yield (up to 6 lbs / bushel). A high-speed disc mill is typically used in the dehydration and milling step 51. However, in some embodiments of this application, any other type of particle size reduction device, such as a roller mill, supraton, or pin mill, is used. In the fiber and protein separation step 53, a paddle sieve with a high-speed washing design is used, but in some embodiments of this application, other types of solid washing devices, such as conical sieves, are used. The sieve aperture size ranges from 300 to 500 μm, which determines the quality and quantity of fiber purity and yield. For example, using a 300 μm sieve aperture, the fiber yield is approximately 5 lb / bushel and 15% protein. Using a 2000 μm sieve aperture, the fiber yield is approximately 2 lb / bushel and 10% protein. A nozzle centrifuge or a disc sedimentation centrifuge is typically used in the oil and protein separation step 55. A sedimentation centrifuge and a three-phase decanter are typically used in the oil recovery step 57.

[0117] The above method recovers the oil at the back end (after the fermentation step), which produces oil that is not of optimal quality (e.g., dark color and about 13% FFA). Figure 4 Process 40 in the process recovers oil at the front end (e.g., before the fermentation step), which provides better oil quality (lighter color and about 7% FFA). However, the front-end oil recovery system has an oil yield of only 0.5 lbs / bushel at most.

[0118] Figure 6 An improved high-yield back-end oil recovery system 60 according to some embodiments is shown.

[0119] The process 60 includes a back-end oil recovery system that provides an oil yield of up to 1.4 lb / bushel. Embodiments of the invention release more than half of the oil still bound inside the germ particles during liquefaction step 22. Using system 60, even more oil is released from the germ during fermentation step 23 and distillation step 24 because the ethanol present in the fermenter of fermentation step 23 serves as a solvent for extracting oil from the germ particles. Furthermore, the high temperatures used in distillation step 24 also “cook” the germ to release the bound oil. The oil produced by the aforementioned system 60 is 1.8 times the oil yield of a typical front-end oil recovery process. Therefore, the method and system of the present invention produce unforeseen and unpredictable results, generating additional oil in unexpectedly high quantities.

[0120] Based on the functional principles disclosed above, the present invention provides a method and system for increasing oil yield by releasing more bound / unreleased oil, wherein the bound / unreleased oil is released, unbound and / or released in fermentation step 23 and distillation step 24.

[0121] In some embodiments of this application, the methods and systems disclosed in this invention include the following processes / steps:

[0122] a) A step of sending the oily stream from the back-end steps / processes to the front-end process and recovering the oil by using a front-end oil recovery system (e.g., sending out the oily stream / part of any step (e.g., fiber washing step 68) after fermentation step 23 and recovering the oil in liquefaction step 22).

[0123] b) Recovering the germ in a back-end process step, sending the germ back to a front-end step, re-grinding the germ (e.g., the germ sent back to the front end) to release oil, and recovering the oil in a front-end oil recovery system step; and

[0124] c) Add a back-end dehydration and milling step 51 to release oil from the germ, then send the product back to the front end containing the oil and protein emulsion, and recover the oil by using a step in the front-end oil recovery system.

[0125] Generally, germ particles in front-end oil production systems cannot fully absorb water, and when crushed using a grinder, the germ particles become even harder.

[0126] In contrast, this invention provides an improved method and system. Following fermentation step 23 and distillation step 24, the germ particles fully absorb water and become softer, making them easier to break down in a mill, where the distillation step cooks the germ at the bottom of the still. Furthermore, fiber and protein separation step 53 and / or fiber washing step 68 are used to wash away attached protein, oil, and starch particles from the fibers, where the solution or liquid is returned to the upstream process as cooking water. The disclosed process provides a method and system for recovering more oil and producing more ethanol in a second round.

[0127] By reducing the percentage of starch in dry corn ethanol residue to below 2%, the back-end milling process increases ethanol yield to 3%. By reducing the percentage of oil in dry corn ethanol residue from 10% to 4%, the back-end milling technology also increases oil yield to 1.4 lbs / bushel.

[0128] Using a back-end milling process offers several advantages, including the production of pure fiber (as low as 10% protein and 3% oil). Protein yield also increases from 3.5 lb / bushel to 6 lb / bushel, but protein purity may decrease from 50% to below 45%. In some embodiments of this application, only one type of protein powder (e.g., ...) is produced in this simple back-end system. Figure 5 High-value waste yeast and germ protein are mixed with zein and fine fiber in this protein powder. Based on market demand for high-quality protein powder for pet and fish food, this invention provides a process and system for separating the above protein mixture into two proteins: one for home pet and fish feed made from waste yeast and germ protein with a protein content of 45%; and the other for chicken and pig feed made from zein and fine fiber containing approximately 45% protein.

[0129] Some embodiments of this application also disclose more advantageous features in other embodiments. For example, according to some embodiments, four types of animal feed are made from whole distillers' grains and lees. This invention provides a most efficient and economical method for producing animal feed using dry milling equipment. The whole distillers' grains and lees have 7-9 lb / bushel of solid particles with a size greater than 500 μm. The solid particles consist primarily of pericarp and apex, and contain a certain amount of germ and coarse cornmeal particles. The solid particles also contain 25%-27% protein and 7%-9% oil.

[0130] Still referencing Figure 6After the back-end milling step 51, the solids have a yield of 10%–20% protein and 3%–5% oil. Using the back-end milling system, the protein yield in whole distillers' grains increases from 4 lb / bushel to 6 lb / bushel, containing zein, fine fiber, germ protein, and spent yeast. Spent yeast and germ are more valuable than zein and fine fiber. Spent yeast and germ protein can be used in pet and fish feed, while zein and fine fiber are better suited for chicken and pig feed. Separating the different components helps meet market demands.

[0131] Reference Figure 6 This invention discloses more detailed embodiments. Typically, after the solid fibers and proteins are removed, the liquid is called diluted lees. Diluted lees contain all the minerals from corn and nutrients (such as vitamins) from dead yeast cells, which are valuable ingredients suitable for making infant animal feed.

[0132] In some embodiments of this application, high-temperature drying is intentionally avoided to prevent high temperatures from damaging temperature-sensitive components. In some embodiments of this application, a high-speed nozzle centrifuge or a disc decanter is used to produce particularly clean dilute lees (containing less than 2% by volume of solids by rotational testing) and can be evaporated to contain 85% dry solids.

[0133] As described above, this high-solids syrup bypasses (e.g., does not pass through or avoids using) the dryer and is added directly to the dry solids after the drying step, forming a "not wet" (can be maintained at room temperature for a long time) under "wet" conditions (more than 10% moisture). This high-nutrient animal feed product containing concentrated syrup bypasses the high-temperature dryer to avoid the high-value nutrients (called "unknown growth factors") in the concentrated syrup being decomposed by the high temperatures in the dryer. Diluted lees are typically evaporated into a syrup with 30%–40% dry solids. The syrup is then sent to a deoiling step to recover valuable oils that can be used to produce biodiesel. Then, through a syrup fortification step 59, residual sugars are converted to lactic acid by adding lactic acid, thereby producing a probiotic culture. Furthermore, a secondary fermentation step produces up to 20% (on a dry basis) lactic acid and 10^ 9 CFU (Cost-Free Units) of probiotics. This concentrated syrup can be sent to a low-temperature vacuum evaporator to concentrate it to 85% dry solids. Next, the concentrated syrup can be added to the dried feed product from the dryer to form a final feed product containing the concentrated syrup, avoiding the need for a high-temperature dryer.

[0134] Still referencing Figure 6 In process 60, after the hammer milling step 21, liquefaction step 22, fermentation step 23 and distillation step 24, the whole mash undergoes a selective particle size separation step 61.

[0135] Following step 61, the whole distiller's grains are separated into three different solid particle sizes: a) particles larger than 300 μm (e.g., primarily composed of pericarp, tips, germ, and coarse corn flour); b) particles 50–300 μm, primarily containing fine fibers and zein; and c) particles smaller than 50 μm, primarily containing spent yeast, germ, and protein. The choice of screen size can depend on the upstream process used (e.g., hammer mill screen opening size), the required product purity, and the quality to meet market demands. The invention also discloses a paddle screen with three screen sections capable of separating these three streams. Any other type of shielding device can be used. In some embodiments of this application, three screening devices / three screens are used consecutively to achieve this separation of the three streams based on different particle sizes:

[0136] A) Large-diameter feed stream (mainly pericarps, tips, germ, and coarse cornmeal): The whole grains are fed to the selective particle size separation step 61. The product from the selective particle size separation step 61 is sent to the selective grinding step 51 for grinding and milling to break down the germ and coarse cornmeal particles. In the fiber washing step 68, the broken germ and coarse cornmeal particles are washed off the fibers using a reflux liquid and fresh cooking water 601 as the washing liquid. The washing liquid in the fiber washing step 68 carries all the broken germ and coarse cornmeal particles back to the liquefaction step 22 for further recovery of more oil and protein. The washed fibers obtained from the fiber washing step 68 now contain 10%–15% protein and 3% oil, which is ideal for manufacturing dairy cow feed. These fibers can be digested by dairy cows and used as an energy source.

[0137] B) The medium-sized particle stream primarily contains fine fibers and zein. The medium-sized particle stream obtained from selective particle size separation 61 is fed to a protein dehydration step 62 to produce a protein filter cake. The protein shell is used as feed for chickens and pigs. A sedimentation centrifuge is typically used in the dehydration step 62. In some other embodiments, a vacuum drum filter is used. In the dehydration step 62, the overflow from the decanter containing fine proteins (primarily spent yeast and germ proteins) is mixed with the fine particle stream obtained from selective particle size separation 61 and then fed to an oil and protein separation step 65.

[0138] C) The fine-particle stream mainly contains spent yeast, germ protein, oil, and protein emulsion. The fine-particle stream is sent to the oil and protein separation step 65. This step typically uses a high-speed nozzle centrifuge or a newer disc settling centrifuge. A high-G-force centrifuge is used to break up the oil and protein emulsion. The protein-rich stream is sent to the protein dehydration step 63 to produce a high-quality protein filter cake for home pet and fish diets. This step typically uses a settling centrifuge. The overflow from the protein dehydration step 63 is used as reflux 602.

[0139] In oil and protein separation step 65, the oil-rich stream is fed to the evaporator of evaporation step 27 to concentrate the solution to a dry solids content of 30%–40% (e.g., 35% dry solids syrup). The result is fed to oil recovery step 57 to recover corn oil, which is used as a biodiesel feedstock. The deoiled syrup is fed to syrup fortification step 59 to convert residual sugars in the syrup into lactic acid, which is accomplished by adding a certain amount of lactic acid-producing probiotic culture, where secondary fermentation occurs. After syrup concentration step 59, in low-temperature evaporation step 64, the concentrated syrup is further concentrated to a syrup content of 85% using a low-temperature vacuum evaporator. A waste heat recovery system (not shown) can be used to save energy by using waste heat recovered from the dryer and used as a heat source for the low-temperature vacuum evaporator. This 85% concentrated syrup contains 20% lactic acid (on a dry basis) and 10^ 7 CFU probiotics can be used as a milk substitute for infants or as part of animal drinking water. It can also be used as a binder in all feed pelleting processes. Furthermore, the 85% concentrated syrup bypasses / avoids the dryer, meaning it can be added to any dried feed product that has undergone dryer treatment to form the final feed product.

[0140] In the selective particle size separation step 61, the method and equipment specifications for separating the whole distiller's grains into three or more streams can be determined by factors such as predetermined particle size, particle shape, particle density, or combinations thereof. For example, a paddle screen with three screen sizes in one device (e.g., three screen openings of 50, 300, and 300 / 500 μm) can be used. Solids passing through the first section of the screen with a 50 μm opening are solids smaller than 50 μm, including spent yeast and germ protein. Solids passing through the second section of the screen with a 300 μm opening are particles between 50 and 300 μm in size, including fine fibers and zein. Before proceeding to the dewatering and milling step 51, all solids larger than 300 μm are dewatered in the final section of the screen with a 300 μm opening.

[0141] The basic mechanical function of the three-section paddle screen is similar to that of the two-section paddle screen, which is described in great detail in U.S. Patent No. 9,718,006. This new three-section paddle screen design incorporates one or more additional screen sections on top of an existing two-section paddle screen, as described in U.S. Patent No. 9,718,006, forming this new three-section paddle screen design. Therefore, the machine can separate three types of solids in a single device, instead of using two consecutively arranged screening devices to perform the task.

[0142] As part of this invention, the three-section paddle screen is further improved. There are three different types of solids in the whole grains. The solids vary in size and shape. Therefore, simply using the difference in the screen opening size in the three sections of the screen cannot achieve better sharpness separation.

[0143] In some embodiments of this application, different types of sieve apertures (e.g., round or slotted apertures) are used. The whole distillers' grains contain three types of solids: a) coarse fibers (peel and apex) with thin, plate-like solids and some germ and coarse corn flour solids with the same three-dimensional blocky solids; b) zein with fine fibers having a smaller diameter (less than 50 μm, with long fibers greater than 0.5 mm); and c) spent yeast and fine germ protein with a size less than 50 μm and the same three-dimensional shape. To provide better and clearer separation of these three types of solids, this invention discloses a three-section paddle sieve (see...). Figure 11 This three-section screen will have different screen opening sizes and different types of screen opening designs.

[0144] Figure 12A The opening of the groove 1202 in the vertical (e.g., cross) liquid flow 1204 is shown. Figure 12B The screen shows a narrow slot opening parallel to the liquid flow. This three-section paddle screen produces a more thorough separation of solids of different sizes / types in the feed.

[0145] For example, a 50-micron wedge-shaped wire mesh screen with slit openings perpendicular (intersecting) to the liquid flow is used on the first section of the screen, so waste yeast and fine germ particles smaller than 50 μm pass through the first section of the screen and are collected in the first filtrate chamber, such as... Figure 11 As shown. Zeatin and fine (diameter less than 50 μm) long (length greater than 500 μm) fibers will not pass through because the slit opening is perpendicular (intersecting) to the liquid flow (for fibrous solids longer than 500 μm, even if the diameter is less than 50 μm), because when the length of long fibers is always in the same direction as the liquid flow, a length greater than 500 μm cannot pass through a slit opening of only 50 μm.

[0146] In the second sieve section, a wedge-shaped metal wire sieve with openings of 75–300 μm is used. This sieve has slit openings parallel to the liquid flow. Even zein with fine fibers longer than 500 μm can / will pass through the sieve and be collected in the second segmented filtrate chamber because the slit openings are parallel to the liquid flow. Because it is a long-fiber solid, its length is always in the same direction as the liquid flow.

[0147] In the third sieve, the opening can be a round hole or any other slit sieve with a mesh size greater than 500 μm to retain any solids larger than 500 μm and to dehydrate them to the greatest extent possible before feeding them into the selective grinding step 51.

[0148] In some embodiments of this application, three different types of sieve openings are used on the whole grains. Figure 11 The apparatus shown herein illustrates the separation test results for three types of solids. Based on the expected mass and quantity of the three types of solids in the final product, three screens with different sizes and types of slits can be modified and adjusted. The advantages of this three-stage paddle screen design disclosed herein will be apparent in 70, 80, and 90% of samples. Figure 7 , 8 The process of (9) is discussed in more detail, and the method has various screening devices for the separation of three solids from the whole distillers' grains stream.

[0149] The three-stage screen design disclosed herein is a further improvement upon the first two-stage screen design described in U.S. Patent 9,718,006. The three-stage screen design disclosed herein increases the solids washing capacity of the previous two-stage screen design, which has a limited wash water capacity and a small wash-dewatering area. A larger screen ID (e.g., the inner diameter of the screen), a larger wash water inlet pipe size, and a larger washing area can meet the high-rate washing capacity useful in this downstream grinding process.

[0150] Figure 7 A process 70 for producing animal feed according to some embodiments is shown. The same reference numerals denote the same process steps, and the details described in the figures are not repeated. After the hammer milling step 21, liquefaction step 21, fermentation step 23, and distillation step 24, a liquid-solid separation step 71 is performed.

[0151] In the liquid-solid separation step 71, the whole grains are fed to a two- or three-stage screening device, such as a paddle screen with a first 300 μm screen and a second 300 / 500 μm screen. Particles passing through the first section with the 300 μm screen include particles smaller than 300 μm, including spent yeast, germ protein, fine fibers, and zein. The combined protein stream is then fed to another separation device, such as a decanter, to remove larger and heavier solids. The larger solids, including fine fibers and zein, can be used to make protein filter cake as feed for chickens and pigs.

[0152] The decanter overflow carrying all the lighter and smaller particles (e.g., spent yeast and germ protein) is separated from the larger and heavier solids described above. Using the above process, solids are separated by first filtering with one or more screens, and then using one or more sedimentation separation methods (e.g., using a combination of particle size and density as separation principles).

[0153] Figure 8 A process 80 for producing animal feed according to some embodiments is shown. Figure 7 The same reference figures for the same process steps and details described herein are incorporated by reference and will not be repeated. After the hammer milling step 21, liquefaction step 21, fermentation step 23 and distillation step 24, the crude solids separation step 81 is performed.

[0154] In the coarse solids separation step 81, the whole distiller's grains are separated into coarse solids (fiber, germ, and coarse corn flour) and proteins (waste yeast, germ protein, and corn protein). A paddle screen with two segmented screens can be used in this step.

[0155] In the coarse solids separation step 81, the coarse solids stream (including fiber, germ, and coarse cornmeal particles) is fed to the selective grinding step 51 to break down the germ and coarse cornmeal. Next, a fiber washing step 68 is performed to recover a second round of protein and oil. In the fiber washing step 68, the washed fiber has a low protein content (e.g., less than 15%) and a low oil content (e.g., less than 3%), which can be used as cattle feed 801.

[0156] In the coarse solids separation step 81, the liquid and all protein particles are fed to the fine solids separation step 82 to separate the fine solids (waste yeast and fine germ protein) from the medium-sized solids (corn protein and fine fiber). In the fine solids separation step 82, a pressure screen or other type of screen, such as a conical screen, can be used. The corn protein and fine fiber retained in the fine solids separation step 82 are then fed to the protein dehydration step 62 to produce corn (corn gliadin) protein for chicken and pig production.

[0157] The overflow containing some fine proteins (waste yeast and fine germ protein) obtained from protein dehydration step 62 is mixed with the filtrate obtained from fine solids separation step 82 and sent to oil protein separation step 65. Fine solids separation step 82 in process 80 provides a more precise separation between fine proteins (waste yeast and fine germ protein) and corn protein (corn gliadin).

[0158] As described above, the liquid and all protein components (waste yeast, germ protein, fine fibers, and zein) obtained from the coarse solids separation step 81 are sent to the fine solids separation step 82 to separate two protein streams. The first protein stream contains waste yeast and fine germ protein. The second protein stream contains fine fibers with zein. The second protein stream (e.g., containing fine fibers and zein) is sent to the protein dehydration step 62 to produce coarse protein powder with a protein content of 40%–45% and less than 3% oil, wherein the coarse protein powder is used to prepare feed for chickens and pigs. The oil-containing fine protein stream is sent to the oil and protein separation step 65. Next, a protein dehydration step 63 is performed to produce high-quality protein from the waste yeast and germ protein, which can be used as feed for domestic pets and fish.

[0159] In the oil and protein separation step 65, the oil stream is fed to the evaporation step 27, oil recovery step 57, syrup fortification step 59, and low-temperature evaporation step 64 to produce a fortified syrup with 85% dry solids, which is consistent with... Figure 6 process 60 and Figure 7 The process is similar to that described in process 70.

[0160] In some embodiments of this application, a paddle sieve with an aperture size between 200 and 500 micrometers is used in the oil and protein separation step 65. In other embodiments, another type of sieve device is used, such as a conical sieve or a vibrating sieve. The sieve aperture size determines the quality and quantity of the produced fiber feed and protein powder.

[0161] For example, using a fine sieve results in a higher fiber yield, which in turn produces a higher protein and oil content in the fiber side / section. According to some embodiments, pressure sieves, conical sieves, continuous brush filters, and any other screening devices can be used in the fine solids separation step 82. The sieve size used determines the quality and quantity of protein produced. Smaller sieve openings provide high-quality, fine protein used as feed for fish and pets, but at a lower yield.

[0162] In some embodiments of this application, the screen is a sheet with round holes, slotted openings, or wedge-shaped wire screens. In some embodiments of this application, two types of wedge-shaped wire screens are used. One type has cross / counterflow slotted openings. The other type has openings parallel to the flow. Slotted openings that cross the flow prevent fine fibers from passing through. In contrast, openings parallel to the flow allow fine fibers to pass more easily through slotted openings. Wedge-shaped wires with slots parallel to the flow are used for protein and fiber separation at step 81, and wedge-shaped wire slots that cross the flow are used for the separation of both types of proteins at step 82.

[0163] Figure 9Another system and method for animal feed production, according to some embodiments, are shown. In process 90, three solids separation steps 91 are used, which combine... Figure 8 The function and / or structure of the coarse solids separation step 81 and the fine separation step 82 in process 80. The three solids separation steps 91 use a three-section paddle screen with three sections of screen inside. Each section screen has a different size of screen aperture and a different type of screen design to achieve a predetermined degree of solids separation of whole distillers' grains into three animal feed products for three animals.

[0164] For example, the first stage of a three-stage paddle screen has a screen aperture of 50~200μm and has a round hole screen or a wedge wire screen. The round hole screen or wedge wire screen has a groove through which the material flow passes, so that the fine solids (mainly yeast protein and germ protein) in the whole mash will pass through and be separated.

[0165] The second stage of the three-stage paddle sieve has a sieve aperture of 100~400μm. The sieve aperture is a wedge-shaped wire mesh. The gaps of the wedge-shaped wire mesh are parallel to the water flow, allowing fine fibers and zein to pass through the sieve and be separated from the whole grains.

[0166] The third-stage sieve has 300-500 μm sieve openings and features either round-hole or wedge-shaped wire sieves to separate coarse solids (fiber, coarse corn flour, and germ particles). This third-stage sieve also has a structure / function for dehydration. The fiber, germ, and coarse corn flour are then fed to a selective grinding step 51. The sieve size openings and sieve type are variable and adjustable depending on the desired purity and yield of the three animal feeds.

[0167] exist Figure 9 In process 90, all three types of different solids are separated after fermentation step 23. However, coarse solids (fibrous portions) can be removed before fermentation step 23 to improve fermentation efficiency. Figure 10 This is further illustrated in the text.

[0168] Figure 10 A dry milling ethanol production process 1000 according to some embodiments is shown, which removes fiber and produces three kinds of animal feed before the fermentation step.

[0169] exist Figure 10 In the process, corn undergoes a hammer milling step 21 to form corn flour, which is then mixed in a slurry tank with a low-Burley's liquefied starch solution. The slurry tank has an optional jet cooker to liquefy the starch in a jet cooker processing step 41, thereby forming a high-Burley's liquefied starch (>20) in the slurry tank.

[0170] In the jet cooker processing step 41, the slurry, a mixture of solid particles (peel, tips, coarse corn flour, and germ) and liquid (mainly liquefied starch solution (greater than 20 Brix)), is sent to the solids sorting and washing step 100. In the solids sorting and washing step 100, the filtrate from the first screen (such as protein, fine germ particles, etc.) mainly contains fine solids from the high Brix liquefied starch solution, which is then sent to the fermentation tank in the fermentation step 23.

[0171] In the solids sorting and washing step 100, the second and third sieves are used to wash the solids (peel, tip, germ, and coarse corn flour). The filtrate (low Brix) obtained in the solid / liquid separation step 46 is used as a washing liquid to wash the coarse solids (peel, tip, coarse corn flour, and germ). In the solids sorting and washing step 100, the washing liquid obtained from the second and third sieves is recycled back to the slurry tank as cooking water in step 41.

[0172] In the solids sorting and washing step 100, the washed solids (peel, tip, coarse corn flour, and germ) have a much lower Brix content after soaking / cooking and have a much longer time in the liquefaction tank step 43 to become softer and easier to break down. The soaked / cooked solids are then sent to the solid / liquid separation step 46 for dehydration. The filtrate obtained in the solid / liquid separation step 46 is used as the washing liquid in the solids sorting and washing step 100. In the solid / liquid separation step 46, the dehydrated solids are sent to the particle size reduction device step 51 to break down the coarse corn flour and germ particles.

[0173] In step 51 of the particle size reduction device, the solid is sent to the solid sorting and washing step 101.

[0174] In solid / liquid separation step 46, the liquid obtained from the first sieve, containing broken coarse corn flour and germ particles, is sent to liquefaction step 43. Wash solids (mainly pericarps and tips) can be removed before fermentation step 23. Removing fibers before fermentation improves fermentation capacity and efficiency. However, the disadvantage is that the fibers contain more germ and coarse corn flour particles, which can affect fermentation efficiency. Figure 9 Compared to process 90 (which does not remove fiber from the whole mash before fermentation), this may result in lower yields of ethanol, oil, and protein.

[0175] exist Figure 10 In process 100, the entire front end (before fermentation step 23) is designed to have solid particles (fiber, coarse corn flour and germ) and liquid (cooking water) flowing in countercurrent to provide maximum soaking / cooking time in a much lower Brix sugar solution, resulting in purer fiber (less coarse corn flour and germ) in the front end.

[0176] For solids sorting and washing steps 100, 101, and 102, in some embodiments of this application, any existing screening device, such as a vibrating screen, conical screen, sieve bowl decanter, and pressure screen, is used. Furthermore, Figure 10 Process 1000 also provides continuously set additional stage screens for separating different types of solids, washing, and dewatering in a single step. This invention also designs / develops a novel three-stage paddle screen with high-speed washing capabilities. Any other particle size reduction device, such as a supraton, mill, pin mill, and roller mill, can be used in particle size reduction step 51. Roller mills use less horsepower and employ shear force to reduce particle thickness, which can be used in the front-end liquefaction step 43. Mills use more horsepower and incorporate shear force with some cutting action to reduce particle size, which can be used in both front-end and back-end particle size reduction steps (e.g., step 51). Pin mills use less horsepower and no cutting action, functioning by reducing particle size through impact force, and can be used in place of mills for both the front and back ends of particle size reduction step 51. Supratons use extremely high shear force to break particles into extremely fine particles, making them ideal for breaking coarse corn flour and germ particles in both front-end and back-end steps. However, the power homogenizer (Supraton) can cause fiber breakage, which can lead to dehydration problems downstream.

[0177] exist Figure 10 At the end of process 1000 (after fermentation step 23), the whole mash is sent to solid-liquid separation step 82 after distillation 24. In solid-liquid separation step 82, the solids (mainly germ and coarse corn flour particles) are sent to a particle size reducer in solid size reduction step 51 for further crushing to release starch and oil. In solid size reduction step 51, the crushed coarse corn flour and germ particles are sent to solid sorting and washing step 102 to separate broken germ / coarse corn flour particles from fine fibers. Fresh cooking water and reflux are used as washing water in solid sorting and washing step 102. The filtrate from solid separation and washing step 102 is used as washing water in the solid separation and washing step 101.

[0178] In the solid-liquid separation step 82, the filtrate contains proteins (yeast protein, fine germ protein and corn protein), which is sent to the protein decanter 62 to separate / dehydrate the corn protein for use in the preparation of chicken / pig feed 1002.

[0179] The overflow from protein decanter 62, containing yeast protein and fine germ protein, is sent to dilute lees clarification step 65 to separate the oil from the protein. In dilute lees clarification step 65, the underflow (rich in protein) is sent to another protein decanter 63 to produce a high-grade yeast / germ protein filter cake 1004 for use in household pets and fish.

[0180] In the dilute lees clarification step 65, the overflow (rich in oil) is sent to an evaporator for evaporation step 27 to produce a 30-35% dry solids syrup. The syrup is then sent to the downstream oil recovery step 26 to recover corn oil for use as a feedstock in biodiesel production.

[0181] Figure 15 A method for producing high-concentration fortified probiotic syrup according to some embodiments is described. For example... Figure 15 As shown in the process, the deoiled syrup is sent to the secondary fermentation step (such as...). Figure 10 Step 59). Add the mixture of probiotic cultures that produce lactic acid to the second fermenter (e.g., Figure 10 Step 59) converts the residual sugar into lactic acid, producing a lactic acid-rich syrup containing up to 20% lactic acid (on a dry basis) and 6 x 10^9 CFU of probiotic units. This probiotic syrup, rich in 30-35% dry solids, can be further evaporated in a low-temperature vacuum evaporator 1502 to up to 85% dry solids to form a highly concentrated dry solids-rich syrup that can be used as a food supplement in all animal feeds. A waste heat recovery system (e.g., from dryer 1502) can be added to the low-temperature vacuum evaporator 1504 to use waste heat from dryer 1502 as a heat source.

[0182] Figure 13 Both fortified syrups (35% dry solids and up to 85% dry solids) are shown to contain very high-value nutrients, such as vitamins from yeast cell extracts, and up to 20% lactic acid plus up to 10^ 9 Each probiotic unit can be used as a food preservative to keep wet feed fresh and prevent it from spoiling in wet feed systems in animal farms.

[0183] Figure 14 The concentrated syrup (35%–90% dry solids) is shown to contain very high-value nutrients, such as vitamins from yeast cell extract and up to 20% lactic acid plus up to 10^ 9 Each probiotic unit can be used as a food supplement in all (wet / dry) feed systems in animal farms. Alternatively, it can be used as a binder in the form of fortified probiotic pellets or feed buckets for feeding cageless animals as antibiotic-free animal feed.

[0184] In this invention, the descriptions of process steps, products, properties of products (e.g., particle size), and actions to be performed are interchangeable and optional in all the accompanying drawings.

[0185] Those skilled in the art will understand that the processes and steps described in any of the accompanying drawings and description sections can be used in any other accompanying drawings and description sections. All the described processes and steps can be performed in the appropriate equipment or structure. For example, distillation steps can be carried out in a still, fermentation steps in a fermenter, and separation steps can be carried out using any filtration and / or separation device such as a centrifuge, decanter, or sieve.

[0186] In this invention, fermentation step 23 serves to divide the process and / or system into two ends, including a front-end process and a back-end process. The front-end step is a step performed before fermentation step 23. The back-end step comprises steps performed after fermentation step 23. In different embodiments, fermentation step 23 can be considered part of the front-end or part of the back-end.

[0187] In the following text, Figure 11 A three-section paddle screen is shown according to some embodiments.

[0188] Early efforts focused on providing improved equipment and methods for separating materials, such as fibers, from slurries or other liquid media in a more efficient manner, leading to the multi-zone screening device in U.S. Patent No. 9,718,006. The multi-zone screening device in U.S. Patent No. 9,718,006 is a dual-chamber paddle screener with a screen zone diameter of 400 mm. Having only two chambers significantly limits the amount of product that can be produced by this machine. The machine's throughput is approximately 1000 gallons per minute. Wash water is limited to a maximum of 90 GPM per unit, and the small amount of wash water allows for less purification of large-diameter particles and poorer recovery of corresponding small-diameter particles passing through the screen. Furthermore, a typical device can separate more than one type of small particle. For example, in dry milling processes, whole grains contain coarse corn flour, germ, zein, yeast, fine fibers, and coarse fibers. If the solids are to be separated into a purer form, many existing devices are required to make it work. Therefore, this disclosure provides three segmented paddle screens with a screen diameter of 600 mm, which can maximize the washing water to 600 gpm.

[0189] exist Figure 11 The image shows a cross-sectional view of a three-part paddle screen.

[0190] refer to Figure 11 The device 1100 includes a single, independent unit configured for pre-cleaning and separation (e.g., filtering materials, such as fibers, from a liquid medium, followed by further cleaning / dehydration of the material).

[0191] Regarding wet milling processes, for example, equipment 1100 can perform initial filtration of the slurry and pre-washing of the fibers to clean the fibers and remove starch / gluten associated with / attached to the fibers, as well as washing / dehydration of the fibers.

[0192] Regarding the dry milling process, the equipment 1100 can also perform initial filtration and pre-washing of the fibers to clean the fibers and remove the thin lees associated with / attached to the fibers, as well as washing / dehydrating the fibers.

[0193] like Figure 11 As shown, device 1100 includes a fixed cylindrical screen 1102 with a plurality of openings 1104 formed thereon to allow a liquid medium to pass through the screen 1102 while preventing coarser fibers from passing through. The liquid medium includes, for example, any washing water and any starch and / or gluten and / or fine suspended particles (including yeast produced during fermentation) washed off the fibers. The screen 1102 is disposed inside a housing 1106, including a first end wall 1108 and a second end wall 1110. The screen 1102 is located around the central axis 1114 of device 1100 and extends substantially along its length (L).

[0194] Although the present invention can use single or integral screens, Figure 11 The screen 1102 shown has separate first, second, and third screen segments 1102A, 1102B, and 1102C, which generally correspond to the lengths of the first, second, and third segments 1116A, 1116B, and 1116C of the housing 1106, respectively. The first screen segment 1102A is located near a tangential feed inlet 1118, which is located at one end of the device 1100 adjacent to the first region 1116A, to receive incoming material and liquid media, and the first screen segment 1102A extends partially along the length (L) of the device 1100 to about one-third of its length. The second screen segment 1102B is located near the first screen segment 1102A, and the third screen segment 1102C is located near the second screen segment 1102B, extending partially along the remainder of the length (L) of the device 1100 to near the fiber discharge chute 1120, which is located at the opposite end of the adjacent third region 1116C of the device 1100. Note that the lengths of the first, second, and third screen segments 102A, 102B, and 102C can be adjusted. Furthermore, although only three screen segments 102A, 102B, and 102C are shown in this invention, it should be understood that more than three screen segments can be used. Additionally, although the diameter of the screen 1102 is shown as substantially constant along its length, the screen diameter can vary along at least one or more of its portions.

[0195] Screen 1102 may include a wedge-shaped wire type with slit openings perpendicular or parallel to the direction of liquid flow or at any angle to the direction of liquid flow, or a round-hole, thin-plate screen. In other embodiments, the screen may be a rod-shaped screen, a thin metal screen (e.g., a mesh screen), or a filter cloth with a metal reinforcement design. Those skilled in the art will recognize other types of screens that may be used according to the embodiments. The openings 1104 in screen 1102 may vary depending on the specific application and the type of material being filtered. For example, for fiber filtration, the size of the openings 1104 in the first, second, and third screen segments 1102A, 1102B, 1102C is expected to be approximately 10 μm to 1 mm. In another example, the openings 1104 may be approximately 30 μm to 500 μm. The openings 1104 in the first screen segment 1102A may have the same size as the openings in the second screen segment 1102B, be larger than the openings in the second screen segment 1102B, or be smaller than the openings in the second screen segment. Those skilled in the art will recognize how to determine the size of the opening 1104 to achieve the desired material filtration. A suitable screen type, screen opening size, and the option to select screen slots perpendicular or parallel to the water flow or circular holes can be chosen to meet the needs of any process.

[0196] As described above, the housing 1106 generally surrounds the screen 1102 and is adapted to collect media passing through the opening 1104 in the screen 1102. The housing 1106 includes at least one sidewall 1122 connecting the first, second, and third end walls 1108, 1110, 1112 to define the interior. The housing 1106 also includes at least one internal panel 1124 that divides the housing 1106 into first, second, and third sections 1116A, 1116B, 1116C, the first, second, and third sections 1116A, 1116B, 1116C respectively including a first, second, or third funnel 1126A, 1126B, and 1126C, the funnel 1126A, 1126B, and 1126C having a corresponding outlet for removing filtered liquid media and guiding the filtered liquid media to a desired location. The first region 1116A typically defines an initial pre-washing and separation zone, the second region 1116B typically defines a solid particle separation zone, and the third region 1116C typically defines a washing / dewatering zone. The end of the third region 1116C includes a discharge chute 1120 where the separated and washed / dewatered fibrous material can be collected for further processing. Although three regions 1116A, 1116B, and 1116C are shown herein, those skilled in the art will understand that the number of separation zones 1116A, the number of liquid / solid particle separation zones 1116B, and the number of washing / dewatering zones 1116C can be application-specific. The housing 1106 can have any suitable shape.

[0197] Referring further to tangential feed inlet 1118, feed inlet 1118 is located at one end of the device adjacent to the first region 1116A and is in fluid communication with the interior of the first screen section 1102A. Feed inlet 1118 supplies media and materials (e.g., fibers) to device 1100 and can introduce media and materials in a vortex manner (tangentially along the outer wall) to initiate fiber filtration upon entry into device 1100. The feed inlet opening area can be adjusted according to the feed rate and feed pressure to ensure that the feed tangential velocity is as close as possible to the blade entanglement velocity, thereby achieving maximum optimization results.

[0198] The conveyor 1130 includes a rotatable shaft 1132 extending along the length (L) of the device 1100 and positioned about a central axis 1114. The shaft 1132 defines a first segment 1134A, which generally corresponds to a first region 1116A, and includes a plurality of spaced-apart blades 1136 extending generally horizontally along the length of the first region 1116A. The spaced-apart blades 1136 also extend in a direction away from the shaft 1132, such that the outer surface of each blade is spaced apart from the first screen segment 1102A. The space between adjacent blades 1136 defines an open cavity and provides a fluid flow path for liquid media (e.g., slurry and / or wash water) during the filtration of materials (e.g., fibers), and their size can be adapted to the design throughput of the device. The number of blades 1136 can range from about 2 to about 10. In another example, the number of blades 1136 ranges from about 4 to 8. In yet another example, the number of blades 1136 is 6. The thickness of blade 1136 can range from about 1 / 4 to about 2 inches. In another example, the thickness of blade 1136 can range from about 1 / 4 to 1 / 2 inch. The shape and orientation of blade 1136 can be changed as needed to regulate the flow of liquid materials and media, as well as the filtration characteristics of device 1100. In one example, blade 1136 can be oriented helically around the length of the first portion 1134A of shaft 1132. In another example, the pitch or angle of blade 1136 relative to the shaft and the spacing between blades 136 can be adjusted, and this spacing from one blade 136 to the next blade 136 can be constant or variable.

[0199] At least one strip scraper 1140 is helically wound and secured to the outer surface of blade 1136, occupying the area between the outer surface of blade 1136 and the first screen segment 1102A. The strip scraper 1140, which may be continuous or discontinuous, is substantially helically wound around and along the length of blade 1136, which together define a helical conveyor 1142 for moving material and liquid media toward and towards the screen 1102, thereby aiding in cleaning the material and separating it from the medium. The glass strip scraper 1140 includes an outer edge configured to be located near the inner surface of the first screen segment 1102A. For example, a small gap (approximately 0.3 mm to 2.0 mm) may exist between the outer edge of the strip scraper 1140 and the first screen segment 1102A to accommodate, for example, relative movement between them, while still effectively keeping the filtration area at the first screen segment 1102A clean. The thickness of the scraper 1140 can be approximately 1 mm to 30 mm, but can be varied as needed. In another example, the thickness of the scraper 1140 can be approximately 3 mm to 10 mm.

[0200] In one embodiment, the helical conveyor 1142 may have a multi-threaded configuration (e.g., having multiple helical threads extending along at least a portion of its length), which can enhance the filtration of material from liquid media while preventing clogging of the screen 1102. Those skilled in the art will recognize other configurations that facilitate material movement through the device 1100 to meet the requirements of a particular application, and the invention is not limited to these. Figure 11 The specific configuration shown. Another design variable that allows the screw conveyor 1142 to be configured for a particular application is the pitch of the scraper 1140 along the length of the blade 1136. For example, in one embodiment, the pitch may vary along the length.

[0201] The shaft 1132 of the conveyor 1130 also defines a second section 1134B adjacent to the first section 1134A, which generally corresponds to the second region 1116B. The second section 1134B includes a plurality of paddles 1146 that extend parallel to and adjacent to the second screen section 1102B, generally along its length. Each paddle screen 1146 is connected to the shaft 1132 by a plurality of spaced-apart support arms 1148. The length of each paddle screen 1146 can be adjusted as needed. The paddle screens 1146 facilitate the movement of material and media toward the second screen section 1102B and the discharge port 1120 for further separation and drying of the material. The spacing between the paddle screens 1146 from one paddle screen 1146 to the next paddle can be constant or variable. Each paddle screen 1146 may optionally include one or more rakes 1150. In one example, the number of rakes 1150 may range from approximately 4 to 8. For example, the number of rakes 1150 and paddle screens 1146 can be varied depending on the amount of solids in the feed. The gap between screens 1102 and paddle screens 1146 can range from approximately 0.25 to 0.65 inches. Smaller gaps result in drier filter cakes with greater capacity and purer fibers. Larger gaps produce wetter filter cakes with lower capacity and a purer protein stream in the slurry passing through the screen openings.

[0202] Motor 1152 is operatively connected to conveyor 1130 for rotating shaft 1132 about central axis 1114. A controller may be operatively connected to motor 1152 for controlling the rotational speed of conveyor 1130, which may be constant or variable. Rotation of shaft 1132 can be achieved by a suitable motor 1152 or other prime mover, as understood in the field of this invention. For example, one end of shaft 1132 may be operatively connected to an electric motor, such as via a suitable belt or by direct drive, to rotate shaft 1132 about central axis 1114. In one embodiment, the controller may be a computer that controls the rotational speed of shaft 1132. Such controllers are generally known to those skilled in the art. The rotational speed of shaft 1132 can be selectively varied depending on the specific application. In one embodiment, shaft 1132 may rotate at speeds (revolutions per minute) in the range of about 100 rpm to 2000 RPM. In another example, the speed may be in the range of about 400 to 1000 RPM. In another example, the speed can be in the range of approximately 500 to 900 RPM. Higher speeds offer higher capacity but consume more power. Those skilled in the art will recognize that these values ​​are exemplary and that speeds can be selected and optimized to meet the needs of specific applications.

[0203] The shaft 1132 of the conveyor 1130 also includes a liquid inlet 1156, which is located at the center within the shaft 1132 and extends substantially along the length of the shaft 1132. The liquid inlet 1156 is adapted to receive wash water from a desired water source. The shaft 1132 also has a plurality of liquid outlets 1158 associated with the liquid inlet 1156, which are spaced substantially along the length of the shaft 1132 within first, second, and third zones 1116A, 1116B, and 1116C, for introducing wash water therein. One or more outlets 1158 can be controlled or completely eliminated to prevent or reduce the amount of wash water entering any of the zones 1116A, 1116B, and 1116C. Additionally, counter-current washing technology can be employed to conserve wash water.

[0204] The conveyor system allows for pre-washing and filtration, as well as gentle (low turbulence) dehydration in the first zone 1116A, which is ideal for avoiding emulsions and forcing excessively large particles through the screen 1102.

[0205] In the third region 1116C, the paddle 1146 performs the predetermined work of producing drier fibers to maximize the recovery of the liquid medium from the fiber material. It is anticipated that the fiber material discharged from the equipment through the discharge chute 1120 may contain approximately 55% to 80% water. This water concentration range represents a significant improvement over conventional systems (e.g., pressure and paddle screen devices), which typically provide fiber material with approximately 80% to 92% water.

[0206] The device 1100 also includes a baffle 1160, which is circumferentially disposed around and fixed to the shaft 1132 around the junction between the first and second regions 116A, 116B. Specifically, the baffle 1160 is located near the end of the screw conveyor 1142 and the beginning of the blade 1146. The baffle 1160 extends in a direction away from the shaft 1132, generally perpendicular to the screen 1102, and includes an outer surface spaced therefrom. The gap between the baffle 1160 and the screen 1102 can be adjusted as needed. In one example, the gap can be in the range of about 1 / 8 to 1 inch. The baffle 1160 helps control the amount of compacted liquid medium in the first region 1116A and the amount that can move from the first region to the second regions 1116A, 1116B, regardless of the size of the opening 1104 in the screen 1102.

[0207] Additionally, one or more removable inlet panels 1162 may be provided on the top side of the sidewall 1122 of the housing 1106 for access to the interior of the device 1100. Furthermore, an external valve 1164 may be located on the lower side of the sidewall 1122 of the housing 1106, allowing for the acquisition and analysis / testing, for example, of filtered liquid media, such as starch and protein concentrations, from the first region 1116A, the second region 1116B, and the third region 1116C.

[0208] Device 1100 may have an aspect ratio (L / D) greater than 2. In one embodiment, device 1100 may have an L / D ratio between approximately 2 and 10, and more preferably between 4 and 6. These values ​​are exemplary, and those skilled in the art will recognize other ratios suitable for a particular application.

[0209] In application, the methods and processes disclosed in this invention can be used to prepare animal feed using a variety of raw materials. For example, while corn is used as an example, all other types of grains can be used, including but not limited to wheat, barley, sorghum, rye, rice, oats, etc. Products produced using the systems and methods disclosed in this invention include white fiber for the paper industry, raw materials for secondary alcohol production, and clean sugar solutions for secondary alcohols, lysine, and plastics. Furthermore, the processes described in this invention can be combined with the use of sugar solutions from other biotechnological manufacturing methods, such as sugarcane and pentose sugars from other cellulosic raw materials.

[0210] During the process, particles of different sizes are selectively separated after fermentation. Each portion of the different components (e.g., proteins and nutrients) is separated into various animal feeds for different types of animals.

[0211] The invention has been described with reference to specific embodiments in conjunction with details in order to facilitate understanding of the principles of its construction and operation. Such reference to specific embodiments and their details in this application is not intended to limit the scope of the appended claims. It will be apparent to those skilled in the art that various other modifications may be made to the embodiments chosen for illustration without departing from the spirit and scope of the invention as defined by the claims.

Claims

1. A method for producing animal feed using whole distillers' grains in a dry grinding process, characterized in that, Includes the following steps: a) Liquefy the ground feed and ferment the liquefied ground feed; b) The fermented ground feed produces whole grains, which are then sent to an evaporator for distillation; c) After distillation, the whole lees is separated into at least three parts in one step by selective particle separation using a paddle screen with different screen sizes and different screen types. These parts are a solid part, a slurry part, and a liquid part. In the selective particle separation step, the at least three parts can be separated in one step in the paddle screen. The solid portion mainly contains germ and coarse corn flour particles, wherein the germ contains oil and the coarse corn flour particles contain starch-bound fine fibers and protein. The slurry portion contains fiber and zein, and the liquid portion contains protein, oil and soluble solids; d) Selective dehydration and milling to break up at least a portion of the germ and the coarse corn flour particles, forming selectively milled inclusions in the solid portion; Selective grinding is employed to release starch and protein together from the coarse corn flour particles and to release oil from the germ; e) The solid obtained from the selective dehydration and milling is subjected to fiber washing to remove the germ and the coarse corn flour particles, forming washed fibers, and broken coarse corn flour and germ particles are removed by using reflux and fresh cooking water as washing liquid; and f) Producing a first animal feed by using the selectively dehydrated and milled contents as raw material, the first animal feed having a fiber content of more than 50% and a protein content of 10%-20% and an oil content of less than 4% suitable for ruminants.

2. The method for producing animal feed using whole distillers' grains in a dry grinding process according to claim 1, characterized in that, The selectively ground components after fiber washing contain less than 20% protein, less than 6% oil, and less than 3% starch.

3. The method for producing animal feed using whole distillers' grains in a dry grinding process according to claim 1, characterized in that, The process includes the following steps after the fiber washing: The germ and coarse corn flour particles, which are ground to form fine germ and coarse corn flour, are recycled to the process steps prior to fermentation to further recover oil and produce ethanol for a second round of front-end processes.

4. The method for producing animal feed using whole distillers' grains in a dry grinding process according to claim 1, characterized in that, The method further includes separating the whole grains into the solid portion and the liquid portion after distillation in step c), and then performing a first protein dehydration on the liquid portion using a sedimentation centrifuge or a vacuum drum filter. The liquid portion contains fine fibers and zein.

5. The method for producing animal feed using whole distillers' grains in a dry grinding process according to claim 4, characterized in that, This further includes using the product of the first protein dehydration to produce protein powder for chickens and pigs.

6. The method for producing animal feed using whole distillers' grains in a dry grinding process according to claim 4, characterized in that, This further includes separating oil and protein from the fine particulate stream after distillation in step c) to separate the whole grains into the solid portion and the liquid portion.

7. The method for producing animal feed using whole distillers' grains in a dry grinding process according to claim 6, characterized in that, This further includes a second protein dehydration process using a sedimentation centrifuge on the protein-rich stream of the separated oil and protein to produce protein powder suitable for family pets and fish.

8. The method for producing animal feed using whole distillers' grains in a dry grinding process according to claim 6, characterized in that, This further includes evaporating the separated oil and the oil-rich fraction of the protein separation to produce a syrup with a dry solids content of 30% to 40%.

9. The method for producing animal feed using whole distillers' grains in a dry grinding process according to claim 8, characterized in that, This further includes removing oil from the evaporated product using a low-temperature vacuum evaporator and subjecting it to secondary fermentation to convert the residual sugar into no more than 20% lactic acid and 10^9 CFU / g probiotics to form a concentrated syrup.

10. The method for producing animal feed using whole distillers' grains in a dry grinding process according to claim 8, characterized in that, This further includes using a low-temperature vacuum evaporator with a temperature below 140 degrees Fahrenheit to concentrate the syrup to a concentrated syrup with a dry solids content of 85%.

11. The method for producing animal feed using whole distillers' grains in a dry milling process according to claim 10, characterized in that, This further includes forming concentrated syrup animal feed with a moisture content of more than 10% without passing it through a high-temperature dryer at a temperature exceeding 1000 degrees Fahrenheit.

12. The method for producing animal feed using whole distillers' grains in a dry grinding process according to claim 1, characterized in that, This further includes removing the pericarp and the tip of the fruit before fermentation to improve fermentation efficiency.

13. The method for producing animal feed using whole distillers' grains in a dry grinding process according to claim 1, characterized in that, The selective grinding mentioned above includes the use of multi-segment screens with different sieve aperture sizes.

14. The method for producing animal feed using whole distillers' grains in a dry grinding process according to claim 13, characterized in that, The multi-segment screen comprises wedge-shaped metal wires with slot openings parallel to the material flow.

15. The method for producing animal feed using whole distillers' grains in a dry milling process according to claim 13, characterized in that, The multi-segment screen comprises wedge-shaped metal wires with slot openings perpendicular to the material flow.

16. A method for producing animal feed using whole distillers' grains in a dry milling process, characterized in that, Includes the following steps: a) Liquefy the ground feed and ferment the liquefied ground feed; b) The fermented ground feed produces whole grains, which are then sent to an evaporator for distillation; c) After distillation, selective particle separation is performed using a paddle sieve with different screen sizes and types based on particle size, separating the whole grains into at least three streams in one step. The three streams include a first stream of large particles, a second stream of coarse protein, and a third stream of fine particles. In the selective particle separation step, the at least three parts can be separated in one step using the paddle sieve. d) Using the content of the first feed stream as raw material, a first animal feed suitable for ruminants is formed by the following steps: a fiber content >50%, a protein content of 10%-20%, and an oil content of less than 4%. a. Perform selective dehydration milling to break down at least a portion of the germ and coarse corn flour particles, forming selectively milled inclusions in the solid portion to release starch and protein together from the coarse corn flour particles and oil from the germ; b. Perform fiber washing to remove the germ and the coarse corn flour particles, forming washed fibers, and remove broken coarse corn flour and germ particles by using reflux and fresh cooking water as washing liquid; and c. Perform a first fiber dehydration on the washing fibers; e) Using the content material of the second stream as raw material, the second stream is subjected to protein dehydration using a sedimentation centrifuge or a vacuum drum filter to form a second animal feed suitable for chickens and pigs with 40%-45% protein and less than 4% oil. The second stream is a slurry that flows out after the selective particle separation, which undergoes protein dehydration to produce a protein filter cake. f) Using the content of the third feed stream as raw material, a third animal feed suitable for fish and domestic pets is formed by the following steps, comprising yeast protein, fine germ protein and oil: a. The third stream is combined with the overflow from the first fiber dewatering and then oil and protein are separated to produce an oil-rich stream and a protein-rich stream; as well as b. The protein-rich stream obtained from the separation of the oil and the protein is subjected to a second protein dehydration using a sedimentation centrifuge to produce protein powder containing 45-50% protein. as well as g) Form a fourth animal feed containing no more than 20% lactic acid and 10^9 CFU of probiotics through the following steps: a. The oil-rich feed stream obtained from the oil evaporation and protein separation steps; b. After evaporation, the syrup is fortified to form a syrup with a dry solids content of more than 30%-40%; as well as c. Use a low-temperature vacuum evaporator to perform low-temperature evaporation at a temperature not exceeding 140 degrees Fahrenheit to concentrate the syrup to a dry solids content of more than 80%.

17. The method for producing animal feed using whole distillers' grains in a dry milling process according to claim 16, characterized in that, Further oil recovery is carried out after evaporation.

18. The method for producing animal feed using whole distillers' grains in a dry milling process according to claim 16, characterized in that, This further includes using the liquid stream obtained from the second protein dehydration step to supply the reflux liquid from the pre-fermentation step.

19. A method for producing animal feed using whole distillers' grains in a dry grinding process, characterized in that, Includes the following steps: a) Liquefy the ground feed and ferment the liquefied ground feed; b) The fermented ground feed produces whole grains, which are then sent to an evaporator for distillation; c) After distillation, the whole grains are separated into at least a first stream and a second stream in one step by using a paddle screen with different screen sizes and different screen types. In the selective particle separation step, at least two streams can be separated at one time in the paddle screen. This includes a three-stage separation device with a first screen filter and a second screen filter in the first and second stages, and a decanter in the third stage; d) By using the content material of the first feed stream, a first animal feed for ruminants is formed, comprising a fiber content greater than 50%, a protein content of 10%-20%, and an oil content of less than 4%; and e) By using the content material of the second feed stream, a second animal feed for chickens and pigs with a protein content of 40-45% and an oil content of less than 4% is formed.

20. The method for producing animal feed using whole distillers' grains in a dry milling process according to claim 19, characterized in that, This further includes using a third stream of feed as a raw material generated from the separation process to produce a third animal feed for fish and pets.

21. The method for producing animal feed using whole distillers' grains in a dry milling process according to claim 20, characterized in that, The separation process wherein the whole grains are separated into a large-particle stream as the first stream, a protein dehydrated stream as the second stream, and a fine-particle stream as the third stream.

22. The method for producing animal feed using whole distillers' grains in a dry milling process according to claim 19, characterized in that, The separation process includes using a crude solids separation process to separate the whole grains obtained from the distillation step into a crude protein fraction and a protein fraction.

23. The method for producing animal feed using whole distillers' grains in a dry grinding process according to claim 19, characterized in that, The separation process includes separating the whole grains obtained from the distillation step into fiber and germ fractions, fine protein fractions, and fiber and corn protein fractions.

24. A method for producing animal feed using whole distillers' grains in a dry grinding process, characterized in that, Includes the following steps: a) The feed is hammer-milled to form corn flour, which is then mixed in a slurry tank with a low-Burley liquefied starch solution, the slurry tank having a jet cooker to liquefy the starch. b) In the jet cooker processing step, the slurry containing a mixture of solid particles and liquid is subjected to solid separation washing; c) In the solid sorting and washing step, the filtrate from the first screen contains fine solids from the liquefied starch and is sent to a fermentation tank for fermentation. d) The fermented lees are then distilled. e) Liquefy the feed after the solids have been sorted and washed; f) In the solid sorting and washing step, the second and third screens are used to wash the solids, and the washing liquid obtained from the second and third screens is recycled back to the slurry tank as cooking water in the jet cooker treatment step. g) The cooked solids are subjected to solid-liquid separation for dehydration, and the resulting filtrate is used as the washing liquid in the solids sorting and washing step. The dehydrated solids are then subjected to particle size reduction using a particle size reducer to break down coarse corn flour and germ particles; and h) After the particle size reduction step, the solid is subjected to a second solid sorting and washing.

25. The method for producing animal feed using whole distillers' grains in a dry milling process according to claim 24, characterized in that, The liquefied starch formed in the slurry tank has a Brix degree greater than 20.

26. The method for producing animal feed using whole distillers' grains in a dry milling process according to claim 24, characterized in that, The solid particles are fruit peel, pointed tip, coarse corn flour and germ, and the liquid is a solution of the liquefied starch with a Brix degree greater than 20.

27. The method for producing animal feed using whole distillers' grains in a dry milling process according to claim 24, characterized in that, In the solid-liquid separation step, the liquid obtained from the first section of the sieve, which contains broken coarse corn flour and germ particles, is liquefied.

28. The method for producing animal feed using whole distillers' grains in a dry milling process according to claim 24, characterized in that, In the solid-liquid separation step, the solid particles are sent to a particle size reducer to reduce their size, thereby further breaking them down to release starch and oil.

29. The method for producing animal feed using whole distillers' grains in a dry milling process according to claim 24, characterized in that, Following the particle size reduction step, the crushed coarse corn flour and germ particles undergo a third solids sorting and washing process to separate the coarse corn flour and germ particles from the fine fibers.

30. The method for producing animal feed using whole distillers' grains in a dry milling process according to claim 29, characterized in that, The filtrate from the third solids separation and washing step is used as washing water in the second solids separation and washing step.

31. The method for producing animal feed using whole distillers' grains in a dry milling process according to claim 24, characterized in that, In the solid-liquid separation step, the filtrate contains protein, and the filtrate is sent to a protein decanter to separate and dehydrate corn protein for use in the preparation of chicken / pig feed.

32. The method for producing animal feed using whole distillers' grains in a dry grinding process according to claim 31, characterized in that, The overflow from the protein decanter contains yeast protein and fine germ protein and is sent to dilute lees for clarification to separate the oil from the protein.

33. The method for producing animal feed using whole distillers' grains in a dry grinding process according to claim 32, characterized in that, Following the clarification step of the distillers' grains, the protein-rich underflow is sent to another protein decanter to produce yeast and germ protein filter cake for use in household pets and fish.

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