Method of producing ethanol

Abstract

There is provided a process of producing ethanol. The process includes processing a starch derivative-comprising slurry via a reactive process, including fermentation, with effect that at least a fermentation product, that includes ethanol, and a gaseous by-product material, that includes gaseous carbon dioxide, is produced, and processing the gaseous by-product material via a reactive process, with effect that a liquid material product, including ethanol, is produced. The concentration of ethanol, within the produced fermentation product, has a value that is at least 40% of the end of batch concentration of ethanol within the fermentation product, and no more than 95% of the end of batch concentration of ethanol within the fermentation product.

Description

METHOD OF PRODUCING ETHANOLFIELD

[0001] The present disclosure relates to the field of ethanol production.BACKGROUND

[0002] The production of ethanol worldwide by fermentation consumes huge amounts of sugar (often in the form of corn) and generates huge amounts of carbon dioxide. This ethanol is often concentrated by distillation. The distillation process is energy intensive and as such, distillation plants are often highly specialized in function: any variation in feedstock can impact operation deleteriously. As a result, the adoption of new technologies in the ethanol production industry can be relatively slow.SUMMARY

[0003] In one aspect there is provided a process of producing ethanol, comprising: processing a starch derivative-comprising slurry via a reactive process, including fermentation, with effect that at least a fermentation product, that includes ethanol, and a gaseous by-product material, that includes gaseous carbon dioxide, is produced; and processing the gaseous by-product material via a reactive process, with effect that a liquid material product, including ethanol, is produced; wherein: the concentration of ethanol, within the produced fermentation product, has a value that is at least 40% of the end of batch concentration of ethanol within the fermentation product, and no more than 95% of the end of batch concentration of ethanol within the fermentation product.

[0004] In another aspect there is provided a process of producing ethanol, comprising: processing a starch derivative-comprising slurry via a reactive process, including fermentation, with effect that at least a fermentation product, that includes ethanol, and a gaseous by-product material, that includes gaseous carbon dioxide, is produced; terminating the fermentation in response to a determination that the concentration of ethanol, withinthe produced fermentation product, has a value that is at least 40% of the end of batch concentration of ethanol within the fermentation product, and no more than 95% of the end of batch concentration of ethanol within the fermentation product; and processing the gaseous by-product material via a reactive process, with effect that a liquid material product, including ethanol, is produced.

[0005] In another aspect there is provided a process of producing ethanol, comprising: processing a starch derivative-comprising slurry via a reactive process, including fermentation, with effect that at least a fermentation product, that includes ethanol, and a gaseous by-product material, that includes gaseous carbon dioxide, is produced; and processing the gaseous by-product material via a reactive process, with effect that a liquid material product, including ethanol, is produced; wherein: the concentration of ethanol, within the produced fermentation product, has a value that is at least 40% of the endpoint titer of ethanol within the fermentation product, and no more than 95% of the endpoint titer of ethanol within the fermentation product.

[0006] In another aspect there is provided a process of producing ethanol, comprising: processing a starch derivative-comprising slurry via a reactive process, including fermentation, with effect that at least a fermentation product, that includes ethanol, and a gaseous by-product material, that includes gaseous carbon dioxide, is produced; terminating the fermentation in response to a determination that the concentration of ethanol, within the produced fermentation product, has a value that is at least 40%, of the endpoint titer of ethanol within the fermentation product, and no more than 95% of the endpoint titer of ethanol within the fermentation product; and processing the gaseous by-product material via a reactive process, with effect that a liquid material product, including ethanol, is produced.

[0007] In another aspect there is provided a process of producing ethanol, comprising: processing a starch derivative-comprising slurry via a reactive process, including fermentation, with effect that at least a fermentation product, that includes ethanol, and a gaseous by-product material, that includes gaseous carbon dioxide, is produced; terminating the fermentation in response to a determination that the gaseous carbon dioxide has been produced, over a continuous time interval of at least 60 minutes, at a mass rate that is belowa maximum value, wherein the mass rate is computed as a rolling average over a period of time that is within a range, and the range is from ten (10) to 15 minutes, and the maximum value is no more than 50% of the batch peak for a mass rate of production of gaseous carbon dioxide by the fermentation; and processing the gaseous by-product material via a reactive process, with effect that a liquid material product, including ethanol, is produced.

[0008] In another aspect there is provided a process of producing ethanol, comprising: processing a starch derivative-comprising slurry via a reactive process, including fermentation, with effect that at least a fermentation product, that includes ethanol, and a gaseous by-product material, that includes gaseous carbon dioxide, is produced; terminating the fermentation prior to completion of a baseline cycle that is characteristic of the fermentation, such that the fermentation has a time duration that is less than a time duration of the baseline cycle wherein: the time duration, of the fermentation within the fermentation reaction zone 12, has a value that is at least 35% of a value of the time duration of the baseline cycle, and no more than 95% of a value of the time duration of the baseline cycle; and processing the gaseous by-product material via a reactive process, with effect that a liquid material product, including ethanol, is produced.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 is a schematic illustration showing a process according to an example embodiment of the invention.DETAILED DESCRIPTION

[0010] Referring to Figure 1, there is provided a process for producing ethanol from a starchderivative comprising material 62. In some embodiments, for example, a starch-comprising material 60 is subjected to liquefaction within a liquefaction zone 60, with effect that a starch derivative-comprising slurry 10 is produced. In some embodiments, for example, the starch derivative-comprising material 62 includes ground corn.

[0011] In some embodiments, for example, the starch derivative-comprising slurry 10 includes water, a starch derivative, and one or more enzymes. The starch derivative-comprising slurry 10 is processed via a reactive process within a reaction zone configuration to produce a fermentation product. In some embodiments, for example, the starch derivative-comprising slurry is supplied to the reaction zone configuration, and the fermentation product is recovered from the reaction zone configuration.

[0012] In some embodiments, for example, the reactive process includes a fermentation. In some of these embodiments, for example, the reactive process includes a saccharification, followed by the fermentation. In this respect, in some embodiments, for example, the reaction zone configuration includes a saccharification reaction zone 11 and a fermentation reaction zone 12. In some embodiments, for example, a material feed, including the starch derivative-comprising slurry, is supplied to the saccharification reaction zone 11 with effect that the starch derivative-comprising slurry is converted, via saccharification (which, in some embodiments, includes enzymatic hydrolysis), to a fermentable sugar-rich slurry (which is derived from the starch derivative-comprising slurry 10). The fermentable sugar rich slurry is processed, via fermentation within the fermentation reaction zone 12, to produce a fermentation product 14 and a gaseous by-product material 16 that includes gaseous carbon dioxide. The fermentable sugar-rich slurry is inoculated with yeast within the fermentation reaction zone 12, and the fermentation is effectuated in response to the inoculation. The fermentation product includes ethanol. The produced ethanol is then recovered as an ethanol product 20 from the fermentation product, such as, for example, via distillation within a distillation zone within a distillation column 18, with effect that a residual slurry (whole stillage 22) is produced. In some embodiments, for example, the whole stillage is subjected to centrifugation within a centrifuge 24 to obtain thin stillage 26, and the thin stillage 26 is recycled such that the material feed to the reaction zone configuration includes the thin stillage. In some embodiments, for example, the thin stillage 26 is combined with at least the starch derivative-comprising slurry 10 and supplied to the reaction zone configuration such that the recycling is to the reaction zone configuration.

[0013] In some embodiments, for example, the fermentation is a batch process, and the fermentation, within the fermentation reaction zone 12, is terminated prior to end of batch, upon determination of an end of batch condition, as identified below, such that an ethanol production-enhanced cycle is defined. Upon the termination, the concentration of ethanol, within the fermentation product, is less than the end of batch ethanol concentration (determinable by experiment). After the termination of the fermentation within the fermentation reaction zone 12, the fermentation product is recovered from the fermentation reaction zone 12, and the fermentation reaction zone 12 is refilled with a fresh sugar-rich slurry for processing by fermentation. In some embodiments, for example, because of the early termination, the thin stillage contains relatively more fermentable sugars in comparison to a thin stillage derived from a fermentation product produced by a fermentation whose cycle is completed (fermentation is terminated at end of batch). By terminating the fermentation, within the fermentation reaction zone 12, prior to the end of batch, and replacing the fermentation product with a fresh fermentable sugar-rich slurry within the fermentation reaction zone, a higher rate of production of ethanol is achievable. In some embodiments, for example, after the termination, the ethanol production-enhanced cycle is repeated at least once, such as, for example, at least twice, such as, for example, at least three times.

[0014] In some embodiments, for example, the fermentation, within the fermentation reaction zone 12, is terminated such that the concentration of ethanol, within the produced fermentation product, is less than the end of batch ethanol concentration (determinable by experiment). In some embodiments, for example, the fermentation, within the fermentation reaction zone 12, is terminated in response to a determination that the concentration of ethanol within the fermentation product 14, within the fermentation reaction zone 12, has a value that is at least 40% of the value of the end of batch concentration of ethanol within the fermentation product 14, and no more that 95% (such as, for example, no more than 90%, such as, for example, no more than 85%, such as, for example, no more than 90%, such as,for example, no more than 75%) of the value of the end of batch concentration of ethanol within the fermentation product 14. In some embodiments, for example, the fermentation, within the fermentation reaction zone 12, is terminated in response to a determination that the concentration of ethanol within the fermentation product 14, within the fermentation reaction zone 12, has a value that is at least 50% of the value of the end of batch concentration of ethanol within the fermentation product 14, and no more that 95% (such as, for example, no more than 90%, such as, for example, no more than 85%, such as, for example, no more than 90%, such as, for example, no more than 75%) of the value of the end of batch concentration of ethanol within the fermentation product 14. In some embodiments, for example, the fermentation, within the fermentation reaction zone 12, is terminated in response to a determination that the concentration of ethanol within the fermentation product 14, within the fermentation reaction zone 12, has a value that is at least 60% of the value of the end of batch concentration of ethanol within the fermentation product 14, and no more that 95% (such as, for example, no more than 90%, such as, for example, no more than 85%, such as, for example, no more than 90%, such as, for example, no more than 75%) of the value of the end of batch concentration of ethanol within the fermentation product 14. In some embodiments, for example, the fermentation, within the fermentation reaction zone 12, is terminated in response to a determination that the concentration of ethanol within the fermentation product 14, within the fermentation reaction zone 12, has a value that is at least 70% of the value of the end of batch concentration of ethanol within the fermentation product 14, and no more that 95% (such as, for example, no more than 90%, such as, for example, no more than 85%, such as, for example, no more than 90%, such as, for example, no more than 75%) of the value of the end of batch concentration of ethanol within the fermentation product 14. In some embodiments, for example, the fermentation, within the fermentation reaction zone 12, is terminated in response to a determination that the concentration of ethanol within the fermentation product 14, within the fermentation reaction zone 12, has a value that is at least 80% of the value of the end of batch concentration of ethanol within the fermentation product 14, and no more that 95% (such as, for example, no more than 90%, such as, forexample, no more than 85%) of the value of the end of batch concentration of ethanol within the fermentation product 14.

[0015] In some embodiments, for example, the fermentation, within the fermentation reaction zone, is terminated such that the concentration of ethanol, within the produced fermentation product 14, is less than the endpoint titer (determinable by experiment). In some embodiments, for example, the fermentation, within the fermentation reaction zone, is terminated in response to a determination that the concentration of ethanol within the fermentation product 14, within the fermentation reaction zone, has a value that is at least 40% of the value of the endpoint titer, and no more that 95% (such as, for example, no more than 90%, such as, for example, no more than 85%, such as, for example, no more than 80%, such as, for example, no more than 75%) of the endpoint titer. In some embodiments, for example, the fermentation, within the fermentation reaction zone, is terminated in response to a determination that the concentration of ethanol within the fermentation product 14, within the fermentation reaction zone, has a value that is at least 50% of the value of the endpoint titer, and no more than 95% (such as, for example, no more than 90%, such as, for example, no more than 85%, such as, for example, no more than 80%, such as, for example, no more than 75%) of the endpoint titer. In some embodiments, for example, the fermentation, within the fermentation reaction zone, is terminated in response to a determination that the concentration of ethanol within the fermentation product 14, within the fermentation reaction zone, has a value that is at least 60% of the value of the endpoint titer, and no more than 95% (such as, for example, no more than 90%, such as, for example, no more than 85%, such as, for example, no more than 80%, such as, for example, no more than 75%) of the endpoint titer. In some embodiments, for example, the fermentation, within the fermentation reaction zone, is terminated in response to a determination that the concentration of ethanol within the fermentation product 14, within the fermentation reaction zone, has a value that is at least 70% of the value of the endpoint titer, and no more than 95% (such as, for example, no more than 90%, such as, for example, no more than 85%, such as, for example, no more than 80%, such as, for example, no more than 75%) of theendpoint titer. In some embodiments, for example, the fermentation, within the fermentation reaction zone, is terminated in response to a determination that the concentration of ethanol within the fermentation product 14, within the fermentation reaction zone, has a value that is at least 80% of the value of the endpoint titer, and no more than 95% (such as, for example, no more than 90%, such as, for example, no more than 85%) of the endpoint titer.

[0016] In some embodiments, for example, the fermentation, within the fermentation reaction zone 12, is terminated prior to completion of a baseline cycle that is characteristic of the fermentation, such that the fermentation has a time duration that is less than a time duration of the baseline cycle. In some embodiments, for example, the time duration, of the fermentation within the fermentation reaction zone 12, has a value that is at least 35% (such as, for example, at least 40%, such as, for example, at least 45%, such as, for example, at least 50%, such as, for example, at least 55%, such as, for example, at least 60%, such as, for example, at least 65%, such as, for example, at least 70%, such as, for example, at least 75%, such as, for example, at least 80%, such as, for example, at least 85%) of a value of the time duration of the baseline cycle, and no more than 95% of a value of the time duration of the baseline cycle. In some embodiments, for example, the time duration, of the fermentation within the fermentation reaction zone 12, has a value that is at least 35% (such as, for example, at least 40%, such as, for example, at least 45%, such as, for example, at least 50%, such as, for example, at least 55%, such as, for example, at least 60%, such as, for example, at least 65%, such as, for example, at least 70%, such as, for example, at least 75%, such as, for example, at least 80%) of a value of the time duration of the baseline cycle, and no more than 85% of a value of the time duration of the baseline cycle. In some embodiments, for example, the time duration, of the fermentation within the fermentation reaction zone 12, has a value that is at least 35% (such as, for example, at least 40%, such as, for example, at least 45%, such as, for example, at least 50%, such as, for example, at least 55%, such as, for example, at least 60%, such as, for example, at least 65%, such as, for example, at least 70%, such as, for example, at least 75%) of a value of the time duration of the baseline cycle, andno more than 80% of a value of the time duration of the baseline cycle. In some embodiments, for example, the time duration, of the fermentation within the fermentation reaction zone 12, has a value that is at least 35% (such as, for example, at least 40%, such as, for example, at least 45%, such as, for example, at least 50%, such as, for example, at least 55%, such as, for example, at least 60%, such as, for example, at least 65%, such as, for example, at least 70%) of a value of the time duration of the baseline cycle, and no more than 75% of a value of the time duration of the baseline cycle.

[0017] In some embodiments, for example, the fermentation, within the fermentation reaction zone 12, is terminated in response to a determination that the gaseous carbon dioxide has been produced, over a continuous time interval of at least 60 minutes, at a mass rate that is below a maximum value, wherein the mass rate is computed as a rolling average over a period of time that is within a range, and the range is from ten (10) to 15 minutes. In some embodiments, for example, the maximum value is no more than 50% of the batch peak for a mass rate of production of gaseous carbon dioxide (such as, for example, no more than 45% of the batch peak, such as, for example, no more than 40% of the batch peak) by the fermentation. The batch peak is determinable by experiment.

[0018] In some embodiments, for example, a convertible gaseous material 32, including the gaseous material by-product 16 obtained from the fermentation reaction zone 12, is fractionated within a fractionation zone 28 such that a carbon dioxide-rich gaseous material 30 is produced. In some embodiments, for example, the fractionating zone 28 is distributed across first and second unit operations in series. In some embodiments, for example, the gaseous material by-product 16 is cooled in a first unit operation to condense at least water and ethanol such that a conditioned gaseous material by-product is obtained and processed via a second unit operation. In some embodiments, for example, the second unit operation is an amine scrubber which absorbs carbon dioxide in aqueous amine solution, and is then regenerated to release and yield the carbon dioxide-rich gaseous material 30 (which, for example, includes at least 99 weight% carbon dioxide, based on the total weight of thecarbon dioxide-rich gaseous material 30). In some embodiments, for example, the second unit operation is a pressure swing absorber which, via cyclic adsorption / desorption, yields the carbon dioxide-rich gaseous material (which, for example, includes 90 to 95 weight% carbon dioxide, based on the total weight of the carbon dioxide-rich gaseous material 30). In some embodiments, for example, the unit operation is a membrane separation process. The carbon dioxide-rich material 30 is compressed by a compressor 34 and admixed with gaseous diatomic hydrogen 38 within a mixing zone 36 to produce a gaseous admixture 40 disposed at a pressure that is within a range, and the range is from 10 bar (absolute) to 50 bar (absolute). In some embodiments, within the gaseous admixture 40, the ratio of mass of gaseous carbon dioxide to mass of gaseous diatomic hydrogen, is within a range, and the range is from 7.3:1 to 3.7:1, such as, for example, 6.9:1 to 5.1:1. The gaseous admixture 40 is supplied to a catalyst-stimulated reaction zone 42, with effect that a reactive process is effected such that a reaction product 44 is produced, and the reactive process includes catalytic reduction of carbon dioxide, as follows:Catalyst2CO2+ 6H2- ► C2H6O + 3H2OSolvent

[0019] In this respect, the reaction product 44 includes ethanol.

[0020] In some embodiments, the reaction product 44 is passed through a condenser 46 such that a conditioned reaction product 48 is produced. In some embodiments, for example, the condenser effectuates condensation of condensables, such as water and ethanol, from the product 48. The conditioned reaction product 48 is fractionated within a fractionation zone 54, of a knock-out drum, into a liquid material 50, that includes ethanol, and a gaseous material 52, that includes, predominantly, unreacted gaseous carbon dioxide and gaseous diatomic hydrogen. The liquid material is processed for recovery of ethanol, such as, for example, via distillation (such as via distillation within the distillation zone of the distillation column). The gaseous material is recycled to the fractionation zone, such that the convertible gaseous material includes the gaseous material.

[0021] The subject matter will now be descried in further details in the following non-limiting prophetic examples.Example 1

[0022] Consider a hypothetical ethanol batch production plant. This plant has a vat that is adapted to receive 1000 kg of corn and ferment that corn over a 46-hour period at about 32-34°C [see A. McAloon, F. Taylor, and W. Yee, "Determining the Cost of Producing Ethanol from Corn Starch and Lignocellulosic Feedstocks," p. 44, 2000, October 2000, NREL / TP-580-28893] to produce 330 kg of ethanol [see Environ. Sci. Technol. 2023, 57, 5391-5403 (https: / / doi.org / 10.1021 / acs.est.2c04784)] and 320 kg of carbon dioxide.

[0023] Fermentation is assumed to have 93.2% conversion efficiency, while liquefaction and saccharification conversion efficiency and ethanol recovery is 99%. Corn is assumed to be composed of 40.52% carbon. The density of ethanol is 0.79 kg / L. The reaction equations are as follows:i. Liquefaction of starch to maltoseii. Saccharification of maltose to glucoseiii. Fermentation of glucose to ethanolC6H12O6yeaSt2CM)+2C02

[0024] From the above equations, 1 kg of starch produces 1.06 kg of maltose, and 1 kg of maltose produces 1.05 kg of glucose. 1 kg of glucose produces 0.51 kg of ethanol and 0.49 kg of CO2.

[0025] Every 24 hours, this plant produces 172 kg of ethanol. For each kilogram of ethanol produced, 0.97 kg of carbon dioxide is produced, and 3.03 kg of corn is consumed.Example 2

[0026] Consider this same plant with additional catalytic carbon dioxide utilization.

[0027] In this plant, fermentation of 1000 kg of corn is again conducted at 32-34°C and is terminated at 46 hours. At the end of this period, 330 kg of ethanol and 320 kg of carbon dioxide have been produced.

[0028] This 320 kg of carbon dioxide is introduced to dihydrogen and catalytically reduced to ethanol, in accordance with the following reaction:Catalyst2CO2+ 6H2- ► C2H6O + 3H2OSolvent

[0029] At an 89% yield [See An, B., Li, Z., Song, Y. et al. “Cooperative copper centres in a metal-organic framework for selective conversion ofCO2 to ethanol." Nature Catalysis 2019, 2, 709-717 (https: / / doi.org / 10.1038 / s41929-019-03Q8-5) ], this produces 134 kg ethanol and 35.2 kg carbon dioxide. This plant now produces - with no modification to the fermentation vats - 40% more ethanol. [330 kg plus 134 = 464 kg in 46 hours].

[0030] Every 24 hours, this plant produces 242 kg of ethanol. For each kilogram of ethanol produced, 0.035 kg of carbon dioxide is produced, and 2.15 kg of corn is consumed.Example 3

[0031] Now, consider this same plant, modified according to an embodiment of the invention.

[0032] In this plant, fermentation of 1000 kg of corn is again conducted at 32-34°C but is terminated at 36 hours [See IJCRT International Conference Proceeding ICGTETM, Dec 2017, ISSN: 2320-2882 (doi: http: / / doi.one / 10.1727 / IJCRT.17171)]. At the end of this period, 275 kg of ethanol and 267 kg of carbon dioxide have been produced. The next batch is then started.

[0033] Thus, at a steady state, this plant in a 46-hour periodConsumes 46 / 36 x 1000 kg = 1278 kg of cornProduces 46 / 36 x 275 kg = 351 kg ethanolProduces 46 / 36 x 267 kg = 341 kg carbon dioxide

[0034] This 341 kg of carbon dioxide is introduced to dihydrogen and catalytically reduced to ethanol, in accordance with the reaction described above.

[0035] At an 89% yield (see An, B., Li, Z., Song, Y. et al. "Cooperative copper centres in a metal-organic framework for selective conversion ofCO2 to ethanol." Nature Catalysis 2019, 2, 709-717 (https: / / doi.org / 10.1038 / s41929-019-03Q8-5), this produces 143 kg ethanol and 37.5 kg carbon dioxide.

[0036] This plant now produces - with no modification to the fermentation vats - 50% more ethanol. [351 kg plus 143 kg = 494 kg in 46 hours]

[0037] Every 24 hours, this plant produces 257.7 kg of ethanol.

[0038] For each kilogram of ethanol produced, 0.029 kg of carbon dioxide is produced, and 2.59 kg of corn is consumed.Example 4

[0039] In addition to the process modified in Example 3, the backset or thin stillage obtained from centrifugation is recycled in the usual yeast fermentation method and accounts for 15%of the fermentation product volume. For the corn-to-ethanol process, an additional 6-10 hours is required for liquefaction and saccharification processes. After liquefaction, backset (recycled thin stillage from the centrifuge) is added, amounting to 15% by volume of the final mash. The process described herein reduces the time, resulting in a higher amount of residual maltose. However, this excess maltose will be recycled as a higher amount of backset, which will result in no loss of maltose obtained from corn starch after dry milling. This thin stillage will contain a higher amount of fermentable sugar because of the early termination of the fermentation. This modified process will have an incremental effect on ethanol production from fermentation and carbon dioxide conversion by reintroducing the higher sugar content thin stillage.

[0040] In Example 3, the fermentation is terminated at 36 hours. This results in the thin stillage containing fermentable sugars equivalent to 55 kg ethanol, which is produced during an uninterrupted 46 hours offermentation. Thus, at a steady state, when recycled, this thin stillage in 10 hours• produces 10 / 46x55 kg = 12 kg ethanol• produces 10 / 46x53 kg = 11.5 kg carbon dioxide

[0041] This 11.5 kg of carbon dioxide is introduced to dihydrogen and catalytically reduced to ethanol, in accordance with the reaction described above. At an 89% yield [see An, B., Li, Z., Song, Y. et al. "Cooperative copper centres in a metal-organic framework for selective conversion of CO 2 to ethanol." Nature Catalysis 2019, 2, 709-717 (https: / / doi.org / 10.1038 / s41929-019-0308-5)], this produces 4.8 kg ethanol and 1.2 kg carbon dioxide.

[0042] This plant, according to this embodiment of the invention, now produces - with no modification to the fermentation vats - 55% more ethanol. [494 kg plus 12 kg plus 4.8 kg = 510.8 kg in 46 hours]

[0043] Every 24 hours, this plant produces 266.5 kg of ethanol.For each kilogram of ethanol produced, 0.030 kg of carbon dioxide is produced, and 2.5 kg of corn is consumed.

[0044] The following sets out a summary of the above :

[0045] The preceding discussion provides many example embodiments. Although each embodiment represents a single combination of inventive elements, other examples may include all suitable combinations of the disclosed elements. Thus if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, other remaining combinations of A, B, C, or D, may also be used.

[0046] Although the embodiments have been described in detail, it should be understood that various changes, substitutions and alterations could be made herein.

[0047] Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, and composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed, that perform substantially the same function or achieve substantially the sameresult as the corresponding embodiments described herein may be utilized. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.

[0048] As can be understood, the examples described above and illustrated are intended to be examples only. The invention is defined by the appended claims.

Claims

CLAIMS:

1. A process of producing ethanol, comprising:processing a starch derivative-comprising slurry via a reactive process, including fermentation, with effect that at least a fermentation product, that includes ethanol, and a gaseous byproduct material, that includes gaseous carbon dioxide, is produced; andprocessing the gaseous by-product material via a reactive process, with effect that a liquid material product, including ethanol, is produced;wherein:the concentration of ethanol, within the produced fermentation product, has a value that is at least 40% of the end of batch concentration of ethanol within the fermentation product, and no more than 95% of the end of batch concentration of ethanol within the fermentation product.

2. A process of producing ethanol, comprising:processing a starch derivative-comprising slurry via a reactive process, including fermentation, with effect that at least a fermentation product, that includes ethanol, and a gaseous byproduct material, that includes gaseous carbon dioxide, is produced;terminating the fermentation in response to a determination that the concentration of ethanol, within the produced fermentation product, has a value that is at least 40% of the end of batch concentration of ethanol within the fermentation product, and no more than 95% of the end of batch concentration of ethanol within the fermentation product; andprocessing the gaseous by-product material via a reactive process, with effect that a liquid material product, including ethanol, is produced.

3. A process of producing ethanol, comprising:processing a starch derivative-comprising slurry via a reactive process, including fermentation, with effect that at least a fermentation product, that includes ethanol, and a gaseous byproduct material, that includes gaseous carbon dioxide, is produced; andprocessing the gaseous by-product material via a reactive process, with effect that a liquid material product, including ethanol, is produced;wherein:the concentration of ethanol, within the produced fermentation product, has a value that is at least 40% of the endpoint titer of ethanol within the fermentation product, and no more than 95% of the endpoint titer of ethanol within the fermentation product.

4. A process of producing ethanol, comprising:processing a starch derivative-comprising slurry via a reactive process, including fermentation, with effect that at least a fermentation product, that includes ethanol, and a gaseous byproduct material, that includes gaseous carbon dioxide, is produced;terminating the fermentation in response to a determination that the concentration of ethanol, within the produced fermentation product, has a value that is at least 40%, of the endpoint titer of ethanol within the fermentation product, and no more than 95% of the endpoint titer of ethanol within the fermentation product; andprocessing the gaseous by-product material via a reactive process, with effect that a liquid material product, including ethanol, is produced.

5. A process of producing ethanol, comprising:processing a starch derivative-comprising slurry via a reactive process, including fermentation, with effect that at least a fermentation product, that includes ethanol, and a gaseous byproduct material, that includes gaseous carbon dioxide, is produced;terminating the fermentation in response to a determination that the gaseous carbon dioxide has been produced, over a continuous time interval of at least 60 minutes, at a mass rate that is below a maximum value, wherein the mass rate is computed as a rolling average over a period of time that is within a range, and the range is from ten (10) to 15 minutes, and the maximum value is no more than 50% of the batch peak for a mass rate of production of gaseous carbon dioxide by the fermentation; andprocessing the gaseous by-product material via a reactive process, with effect that a liquid material product, including ethanol, is produced.

6. A process of producing ethanol, comprising:processing a starch derivative-comprising slurry via a reactive process, including fermentation, with effect that at least a fermentation product, that includes ethanol, and a gaseous byproduct material, that includes gaseous carbon dioxide, is produced;terminating the fermentation prior to completion of a baseline cycle that is characteristic of the fermentation, such that the fermentation has a time duration that is less than a time duration of the baseline cycle.wherein:the time duration, of the fermentation within the fermentation reaction zone 12, has a value that is at least 35% of a value of the time duration of the baseline cycle, and no more than 95% of a value of the time duration of the baseline cycle;andprocessing the gaseous by-product material via a reactive process, with effect that a liquid material product, including ethanol, is produced.

7. The process as claimed in any one of claim 1 to 6;wherein:the fermentation product includes whole stillage;and the process further comprises:processing the whole stillage with effect that thin stillage is produced; andrecycling the thin stillage to the fermentation zone.

8. The process as claimed in any one of claims 1 to 7;further comprising:recovering ethanol from the fermentation product via distillation;recovering ethanol from the liquid material product via distillation.

9. The process as claimed in any one of claims 1 to 8;wherein:the reactive process, via which the gaseous by-product material is processed to produce the liquid material product, is stimulated by a catalyst.

10. The process as claimed in any one of claims 1 to 9;wherein:the starch includes ground corn.

11. An ethanol production-enhanced cycle including the process as claimed in any one of claims 1 to 10;wherein:the cycle is repeated at least once.

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