Enzymatic Disassembly of Corn Kernels for Starch and Glucose Recovery
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Solution Overview
Problem
Biorefineries face challenges in diversifying their product portfolios and achieving efficient processing of corn feedstocks to reduce greenhouse gas emissions and increase revenue, as existing methods are capital- and energy-intensive and lack effective methods for processing corn kernels into valuable components like starch, pericarp, and glucose.
Innovation Solution
Enzymatic digestion of corn kernels using a composition including pectinase, cellulase, and β-glucosidase to separate solid corn starch, pericarp, and liquid glucose fractions, with physical separation techniques like filtration or centrifugation, allowing for the formation of corn kernel particles and efficient disassembly of corn kernel materials into valuable components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional petroleum refining methods are used, then fuel production is achieved, but capital costs and energy consumption are high and greenhouse gas emissions increase
Solution Approach 1:
The patent replaces conventional mechanical and chemical refining processes with enzymatic digestion using pectinase, cellulase, and beta-glucosidase enzymes. This biological substitution reduces energy consumption and greenhouse gas emissions while maintaining product feasibility through controlled enzymatic reactions that break down corn kernel components at lower temperatures and pressures
Solution Approach 2:
The patent changes the operational parameters from high-energy conventional refining to low-energy enzymatic conditions. The process operates at moderate temperatures (30-60°C) and neutral pH levels, fundamentally altering the energy and environmental parameters compared to petroleum refining while achieving comparable fuel and chemical production
2Adaptability or versatility
If corn kernels are processed into diversified products, then revenue and profit increase, but processing complexity increases
Solution Approach 1:
The patent segments the corn kernel into distinct components (starch, pericarp, proteins, lipids) through enzymatic digestion, allowing each fraction to be independently processed into different products. This segmentation enables diversified product portfolios including ethanol, animal feed, and chemical intermediates while managing complexity through modular processing streams
Solution Approach 2:
The enzymatic digestion system serves multiple functions simultaneously: it hydrolyzes starch to sugars for fermentation, separates pericarp for feed applications, and releases proteins and lipids for chemical synthesis. This multi-functionality increases product versatility while consolidating processing operations rather than requiring separate systems for each product stream
3Productivity
If corn kernels are mechanically ground into particles, then surface area increases for better processing, but energy consumption increases
Solution Approach 1:
The patent applies preliminary enzymatic treatment to soften and partially hydrolyze the corn kernel structure before mechanical processing. This preliminary action reduces the mechanical energy required for subsequent particle formation while maintaining high surface area for efficient enzymatic digestion and product recovery
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 method enables the efficient separation and recovery of high-value components such as starch and glucose, reducing energy consumption and greenhouse gas emissions, while enhancing the economic viability of biorefineries and providing a diversified product portfolio.
Implementation Method 1
enzymatically digesting corn kernels in whole or essentially whole form or in a particulate form to form a solid corn starch fraction, a solid pericarp fraction, and a liquid fraction containing dissolved glucose. The composition includes at least a pectinase, a cellulase, and a β-glucosidase
Implementation Method 2
The separating step or steps may be performed using a physical separation technique such as filtration, centrifugation, centrifugal filtration, settling, screening, flotation
Implementation Method 3
The separating step or steps may be performed using a physical separation technique such as filtration, centrifugation, centrifugal filtration, settling, screening, flotation
Data Source
AI summary
Whole corn kernels or particles thereof are enzymatically disassembled. The method can produce a solid starch fraction, a solid pericarp fraction, and a liquid fraction. A high purity starch solids product can be provided suitable for use as a feedstock in other chemical processes.