Corn Grain Ethanol Processing Reducing Separation Complexity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional corn grain processing methods for ethanol production require multiple separation processes, increasing complexity and costs due to the mixing of germ and residual bran with grits, and the presence of pericarp complicates separation, necessitating multiple gravity separators.
Innovation Solution
A method involving tempering, dehulling to remove pericarps without breaking the corn grains, followed by pulverization and specific-gravity separation to extract grits and germ efficiently, with optional primary and secondary refining steps using aspirators and sifters, and a carbon-dioxide processing step to facilitate easy separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If corn grains are impact-milled and broken into multiple pieces to extract germ and bran, then the rate of recovery of grits is improved, but the germ and residual bran are mixed with crushed grits, requiring multiple separation processes
Solution Approach 1:
The patent applies preliminary action by tempering the corn grains before milling. This pre-treatment step prepares the corn grains to be broken into fewer, larger pieces during milling, which prevents the mixing of germ and residual bran with the grits. As a result, the separation process is simplified because the components remain more distinct after milling.
Solution Approach 2:
The patent changes the physical state and properties of the corn grains by tempering them with water before milling. This parameter change (moisture content increase) affects how the corn grains break during milling, resulting in larger average particle sizes and fewer pieces per grain. This parameter change directly reduces the complexity of subsequent separation processes.
2Manufacturing precision
If multiple separation processes are used to remove germ and residual bran from grits, then the purity of extracted grits is improved, but production costs and energy consumption increase
Solution Approach 1:
By tempering the corn grains before milling, the patent creates conditions where the grits break into fewer, larger pieces that remain more distinct from the germ and bran. This preliminary preparation reduces the number of separation processes needed to achieve the desired purity, thereby reducing energy consumption while maintaining manufacturing precision.
Solution Approach 2:
The patent extracts and removes the pericarp from the corn grains before milling. This extraction step eliminates the pericarp that would otherwise complicate the separation process and contaminate the grits. By removing this interfering component beforehand, the subsequent separation processes become more efficient and less energy-intensive.
3Productivity
If corn grains are broken into 3-10 pieces to improve starch-rich grits recovery, then product yield is improved, but pericarp remains on the pieces, complicating separation
Solution Approach 1:
The patent applies preliminary action by tempering the corn grains before milling. This pre-treatment step prepares the corn grains to be broken into fewer, larger pieces during milling, which prevents the mixing of germ and residual bran with the grits. As a result, the separation process is simplified because the components remain more distinct after milling.
Solution Approach 2:
The patent extracts and removes the pericarp from the corn grains before milling. This extraction step eliminates the pericarp that would otherwise complicate the separation process and contaminate the grits. By removing this interfering component beforehand, the subsequent separation processes become more efficient and less energy-intensive.
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 number of separation processes, simplifies production configuration, and enables effective extraction of grits, pericarp, and germ with reduced risk of pericarp contamination, improving efficiency and reducing production costs.
Implementation Method 1
tempering the corn grains by adding predetermined amount of moisture to the corn grains such that only pericarps of the corn grains are wetted by the moisture
Implementation Method 2
separating grits and germ from the broken pieces of the corn grains
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A processing method and an apparatus for producing ethanol that reduces the number of separation steps to the maximum extent possible and simplifies the production configuration while enabling the grits, pericarp and germ to be extracted with ease. The method includes a tempering step of wetting corn grains with a certain amount of water, a dehulling step of dehulling the corn grains while maintaining their shape without breaking the wetted grains, a pulverization step of pulverizing the dehulled corn grains into pieces, a separation step of separating grits and bran from the broken pieces, and a milling step of further milling the separated grits.