Hybrid Separation for Barley Fermentation Yield
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Solution Overview
Problem
Current processes for producing fermentation products from grains, such as dry grind and wet mill processes, face challenges in efficiently converting non-corn grains due to their abrasive nature, varying carbohydrate concentrations, and high viscosity, leading to significant modifications and increased costs, necessitating a more cost-efficient method for grain conversion and component separation without compromising product quality.
Innovation Solution
A process involving the use of a single feedstock of barley or a combination of grains, which includes dehulling, grinding, liquefying with enzymes, and fermenting to produce fermentation products, along with a hybrid separation process that uses mechanical separation devices to improve oil recovery and yield, and the addition of enzymes like beta-glucanase to enhance starch conversion efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wet mill process is used to separate grain components, then more high-valued products are produced, but capital costs and operating costs increase substantially
Solution Approach 1:
The wet mill process is divided into separate functional units: a separator that divides ground grain into starch-containing liquid and insoluble solids, followed by distinct processing lines for each stream. This segmentation allows selective recovery of valuable components while maintaining operational simplicity.
Solution Approach 2:
The grain is ground and separated before fermentation occurs. By performing mechanical separation preliminarily, the process enables targeted processing of starch and protein streams, maximizing product value before the fermentation stage.
2Device complexity
If dry grind process is used, then capital costs and operating costs are lower, but only limited products are produced
Solution Approach 1:
A separator acts as an intermediary device between grinding and fermentation, enabling the dry grind process to produce multiple products. The separator divides the ground grain stream into starch-containing liquid (for alcohol production) and insoluble solids (for gluten meal/feed production), adding product diversity without requiring complete wet mill complexity.
3Adaptability or versatility
If existing facilities are used to process non-corn grains, then production can continue, but significant modifications are required due to abrasive nature and varying properties
Solution Approach 1:
The process parameters (grinding conditions, separation settings, enzyme additions) are optimized for specific non-corn feedstocks like barley, rye, and wheat. By adjusting these parameters rather than modifying facility structure, the system adapts to different grain types with varying abrasive properties, carbohydrate concentrations, and viscosities.
Solution Approach 2:
The separator and fermentation system are designed to handle multiple grain types universally. The same core equipment processes corn, barley, rye, wheat, and other grains by adjusting operational parameters, eliminating the need for facility modifications when switching feedstocks.
4Productivity
If mechanical separation devices are used to filter large particles from slurry, then oil recovery and yield are improved, but process complexity increases
Solution Approach 1:
The separation process is segmented into stages: initial mechanical filtration of large particles, followed by enzymatic treatment of the filtrate. This staged approach recovers oil efficiently while keeping each individual step simple and manageable.
Solution Approach 2:
Enzymes act as intermediaries that facilitate oil recovery from the liquid stream after mechanical separation. The enzymes break down complex molecules, enabling easier extraction and purification of oil without requiring complex mechanical separation systems.
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 reduces the need for significant modifications to existing facilities, lowers costs, and increases the yield of fermentation products by efficiently separating and recovering components, while maintaining product quality and improving oil recovery.
Implementation Method 1
liquefying the barley berries with an alpha-amylase and water to create a slurry
Implementation Method 2
saccharifying the slurry by adding a glucoamylase to a mash
Implementation Method 3
fermenting the mash with a microorganism to produce the fermentation product
Implementation Method 4
filtering a large-particles stream from a slurry containing small particles and dissolved materials based on a series of mechanical separation devices
Implementation Method 5
heating the lower-solids stream in a tank
Data Source
AI summary
This disclosure describes techniques for using a single feedstock of barley to produce a fermented product and a method for filtering a large-particles stream from a liquid stream containing small particles of a process stream using a series of mechanical separation devices to increase yield.