Electrochemically Activated Anolyte for Starch Extraction
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Solution Overview
Problem
The industrial starch separation and extraction industry faces challenges with microbial contamination and the use of harmful biocides like sulfur dioxide, which can lead to adverse effects on product quality and safety, and the need for costly oxidizing agents like peroxide for neutralization.
Innovation Solution
The use of electrochemically activated aqueous anolyte solutions with specific pH and oxidation-reduction potential ranges is introduced for steeping and processing starch-based products, providing a non-toxic and effective antimicrobial treatment that replaces sulfur dioxide and enhances starch modification, while reducing the reliance on hazardous chemicals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sulfur dioxide is used for microbial decontamination during steeping, then microbial contamination is controlled, but harmful chemical residues remain in the starch product
Solution Approach 1:
The patent changes the chemical parameters of the steeping water by using electrochemically activated solutions with controlled pH (3-6) and high oxidation-reduction potential (+650 mV to +1200 mV). This creates a harsh oxidative environment that kills microorganisms without requiring sulfur dioxide, thus eliminating harmful chemical residues while maintaining effective decontamination
Solution Approach 2:
The patent replaces the chemical mechanism (sulfur dioxide) with an electrochemical mechanism (electrochemically activated water). The electrochemical activation process generates reactive oxygen species and other antimicrobial agents in situ, substituting the need for harmful chemical additives while achieving the same microbial control function
2Reliability
If peroxide is added to neutralize sulfur dioxide, then chemical balance is achieved, but processing costs increase
Solution Approach 1:
The patent extracts or removes the need for sulfur dioxide from the steeping process entirely. By using electrochemically activated water as the primary steeping medium, the process eliminates the requirement for subsequent neutralization steps with peroxide, thereby removing the associated costs while maintaining chemical balance through the controlled oxidation environment
Solution Approach 2:
The patent uses inexpensive, readily available materials (water and electricity for electrochemical activation) instead of expensive chemical additives like sulfur dioxide and peroxide. The electrochemically activated water acts as a disposable, single-use treatment that neutralizes itself after use, eliminating the need for additional neutralizing agents and reducing overall material costs
3Reliability
If electrochemically activated aqueous anolyte solutions are used for steeping, then microbial contamination is reduced and starch quality is improved, but processing complexity increases
Solution Approach 1:
The patent implements a self-service system where the electrochemical activation unit is integrated directly into the steeping water supply system. The system automatically generates electrochemically activated water on-demand by passing electricity through ordinary water, eliminating the need for manual preparation or handling of complex chemical solutions. The process self-regulates through controlled electrochemical reactions that continuously generate antimicrobial agents throughout the steeping period
Solution Approach 2:
The patent introduces an electrochemical activation unit as an intermediary device between the water supply and the steeping vessels. This intermediary converts ordinary water into electrochemically activated water with antimicrobial properties, serving as a bridge that simplifies the overall process by replacing complex chemical handling with a straightforward electrochemical conversion step
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces microbial contamination, improves starch quality, and increases the production of pharmaceutical-grade starch, ensuring safer and more efficient processing with reduced chemical usage and costs.
Implementation Method 1
The use of electrochemically activated aqueous anolyte solutions with specific pH and oxidation-reduction potential ranges is introduced for steeping and processing starch-based products
Implementation Method 2
aqueous anolyte product having a pH in the range of from about 4.5 to about 7.5 and a positive oxidation-reduction potential of at least +650 mV
Data Source
AI summary
A method of starch extraction, starch modification, and/or malting comprising (a) steeping a starch source in the presence of an aqueous anolyte product, (b) adding an aqueous anolyte product to an intermediate product extraction slurry comprising starch and gluten, (c) adding an aqueous anolyte product to a starch product slurry produced by separating the starch and gluten, (d) contacting an extracted starch product with a type and amount of an aqueous anolyte product effective for modifying the starch product and/or (e) steeping the starch source in the presence of an aqueous catholyte product.