Clay Adsorption for Toxin Removal in Ethanol Production

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Solution Overview

Problem

The ethanol production process generates toxins, particularly aflatoxins, in distillers dried grains with solubles (DDGS), which are undesirable in animal feeds, and existing methods do not effectively address toxin concentration and bioavailability.

Innovation Solution

Adding clay, such as bentonite/montmorillonite or attapulgite/palygorskite clay, to the corn, slurry tank, enzymes, mash cooking, and fermentation steps during ethanol production to increase ethanol production rates, reduce toxin presence, and enhance enzyme activity by binding and removing toxins.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional ethanol production methods are used, then ethanol can be produced from corn, but toxins such as aflatoxin are concentrated in the residue corn solids (DDGS), making them undesirable for animal feeds

Engineering Contradiction:

Improveethanol production rateVSAvoidtoxin concentration in DDGS

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

Clay is introduced as an intermediary substance that binds to toxins (aflatoxin) in the corn mixture. The clay acts as a mediator between the toxin and the final DDGS product, absorbing the toxin through adsorption and preventing its concentration in the animal feed output, while allowing ethanol production to proceed normally

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent converts the harmful effect of toxin presence into a beneficial outcome by using clay to bind and remove toxins. The toxin-binding capability of clay transforms the problem of toxin concentration into a solution, producing cleaner DDGS suitable for animal feeds while maintaining ethanol production efficiency

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Productivity

If clay is added to increase ethanol production rate, then enzyme activity increases, but the process complexity increases

Engineering Contradiction:

Improveethanol production rateVSAvoidprocess complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The clay serves multiple functions simultaneously: it binds toxins, enhances enzyme activity, and improves ethanol production rate. By using a single additive (clay) that performs multiple roles, the patent avoids adding complex processing steps or multiple separate substances, thereby maintaining process simplicity while achieving multiple improvements

Inventive Principle:

Principle #25Self-service

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

The use of clay significantly decreases aflatoxin levels in DDGS, reduces toxin bioavailability, and increases ethanol production rates and enzyme activity, making the ethanol production process more efficient and safer for animal feeds.

Implementation Method 1

the clay binds to the toxin and by removing the clay, the toxin may also be removed

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

Clay may also increase enzyme activity

Methodology Applied

Scientific EffectEnzyme catalysis: Enzyme

Implementation Method 3

fermentation (enzymes, water and yeast are added to the mash, which is continually agitated and cooled until the ethanol concentration has been maximized)

Methodology Applied

Scientific EffectFermentation: Fermentation

Data Source

PatentUS9458475B2Clay in ethanol production

Publication Date: 2016.10.04 OIL DRI OF AMERICA

AI summary

The present methods involves methods of improving ethanol production which may comprise the addition of clay during ethanol production.