Corn Cob Combustion for Ethanol Process Heat
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Solution Overview
Problem
The conventional ethanol manufacturing process from corn consumes large quantities of energy, primarily due to the combustion of natural gas and petroleum-based fuels during harvesting, shelling, and transportation, with limited efficiency and increased costs, and the use of stover as fuel is costly and inefficient.
Innovation Solution
Implementing an ear corn harvester to separate corn cobs from kernels, which are then used as a renewable fuel source for heat in the ethanol manufacturing process, while using a central shelling station to consolidate shelling operations and reduce energy consumption and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional combines are used for harvesting and shelling corn, then corn kernels can be separated from cobs in the field, but large quantities of natural gas and petroleum-based fuels are consumed during the process
Solution Approach 1:
The invention extracts the shelling operation from the combine and separates it into a distinct function performed by corn cobs at the ethanol plant. Instead of using the combine's mechanical shelling mechanism that consumes fuel, the corn kernels are separated from cobs by using the cobs themselves as fuel, thereby eliminating the need for fuel-consuming shelling operations.
Solution Approach 2:
The corn cobs serve a dual purpose: they are both the waste material to be discarded and the fuel source for the ethanol manufacturing process. The cobs 'serve themselves' by providing the energy needed for the process that converts corn kernels into ethanol, eliminating the need for external fuel sources.
2Reliability
If natural gas is used for heat in the ethanol manufacturing process, then reliable heat supply is ensured, but operating costs increase and energy efficiency decreases
Solution Approach 1:
The ethanol plant uses its own waste product (corn cobs) as the fuel source for generating heat. This self-service approach converts what would be discarded material into a valuable energy resource, eliminating the need to purchase external natural gas and improving overall energy efficiency of the manufacturing process.
Solution Approach 2:
Instead of discarding corn cobs as waste material, the invention recovers their energy value by using them as fuel. This transforms a waste stream into a useful resource that provides heat for the ethanol manufacturing process, thereby reducing energy losses and improving efficiency.
3Use of energy by moving object
If stover is used as fuel for the ethanol manufacturing process, then some energy needs are met, but the cost is high and efficiency is reduced
Solution Approach 1:
The invention uses corn cobs, which are essentially disposable waste material from the harvesting process, as the fuel source. These cobs have negligible value as a resource but provide excellent fuel properties, offering a cheap and efficient energy source that eliminates the need to pay for more expensive fuel options like stover.
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 conserves energy and reduces operating costs by utilizing corn cobs as a free fuel source, minimizing the need for natural gas and petroleum-based fuels, and optimizing the harvesting and shelling process with ear corn harvesters and central shelling stations, resulting in significant cost savings and environmental benefits.
Implementation Method 1
the combustion of fuel, typically natural gas
Data Source
AI summary
Ear corn is picked from corn fields by ear corn harvesters and transported to a central shelling station associated with an ethanol manufacturing facility. Shelled corn from the central shelling station is processed into ethanol at the ethanol manufacturing facility, and corn cobs from the central shelling station are burned to provide process heat for the ethanol manufacturing process. Energy is conserved and costs are reduced during the picking and shelling of the ear corn and by the burning of cobs for process heat.