Continuous Starch Liquefaction Process for High Dry Substance Slurries
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current starch liquefaction processes are inefficient and costly due to the need for high enzyme amounts and energy consumption, particularly when dealing with starch slurries above 40 weight/weight % dry substance, which leads to equipment blockages and require additional energy-intensive evaporation steps to achieve desired dry substance levels.
Innovation Solution
A continuous process for starch liquefaction that utilizes a pre-liquefaction step with enzymatic treatment to create a starch slurry with degraded starch, allowing for higher dry substance levels up to 80 weight/weight % without equipment issues, using indirect heating and continuous enzyme addition to maintain optimal conditions, reducing energy consumption and enzyme usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If starch slurry with high dry substance (above 40 w/w %) is used, then process efficiency and microbial stability are improved, but equipment blockages occur and processing becomes difficult
Solution Approach 1:
The patent applies preliminary action by performing a pre-liquefaction step before the main liquefaction process. This pre-treatment modifies the starch structure in advance, reducing its viscosity and preventing blockages in equipment during subsequent high-concentration processing, thus enabling efficient processing of starch slurries with dry substance above 40 w/w %
2Quantity of substance
If additional concentration step by evaporation is added, then desired dry substance level is achieved, but energy consumption increases significantly
Solution Approach 1:
The patent applies parameter changes by modifying the starch slurry through pre-liquefaction and continuous liquefaction processes that alter the starch molecular structure. This changes the physical and chemical parameters of the starch, enabling direct production of syrups with desired dry substance levels (60-85 w/w %) without requiring energy-intensive evaporation steps, thus significantly reducing energy consumption
3Reliability
If very high amounts of enzymes are used, then starch hydrolysis is achieved, but process cost and inefficiency increase
Solution Approach 1:
The patent applies continuity of useful action by implementing a continuous liquefaction process where enzymes are added continuously rather than in large batch amounts. This continuous addition maintains optimal enzyme activity throughout the process, achieving complete starch hydrolysis more efficiently and reducing overall enzyme consumption and process costs
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 process achieves efficient starch liquefaction at higher dry substance levels, reducing energy consumption and enzyme requirements, resulting in a more cost-effective and environmentally friendly production of high dextrose or maltose containing liquors with fewer evaporation steps needed.
Implementation Method 1
a starch slurry having a DE of from 0.05 to 9 and comprising degraded starch
Implementation Method 2
Starch hydrolysis process can yield glucose syrups, high maltose syrups, very high maltose syrups and the like
Implementation Method 3
Taking into account heating via steam injection for the liquefaction
Implementation Method 4
At these temperatures, the starch gelatinizes and viscosity increases
Implementation Method 5
subsequent flashing for the saccharification
Implementation Method 6
this concentration step usually requires a high energy input and is therefore not cost efficient
Data Source
AI summary
The present invention relates to a process for the liquefaction of starch present in a starch slurry comprising degraded starch and having a DE of from 0.05 to 9. Preferably, the invention relates to a process for the liquefaction of starch present in a starch slurry comprising degraded starch, said starch slurry having a high dry substance. Further preferably, the invention relates to a continuous process for liquefaction of starch present in a starch slurry comprising degraded starch and having a high dry substance.