Corn Milling for Ethanol Production

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Solution Overview

Problem

Conventional methods for grinding corn in ethanol production result in finer particles that lead to issues such as dust formation, increased risk of 'dough balls,' fouling of equipment, and reduced system efficiency, necessitating improved grinding techniques to optimize ethanol production.

Innovation Solution

A process involving the milling of corn pieces in a high shear mill to produce a ground corn product with a specific particle size distribution, where greater than 25 wt % has a particle size of greater than 105 μm and greater than 80 wt % is 425 μm or less, facilitating efficient ethanol production by reducing fouling and energy consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If corn is ground finer to improve ethanol production efficiency, then the surface area for fermentation increases, but dust clouds form during conveyance and equipment fouling increases

Engineering Contradiction:

Improveethanol production efficiencyVSAvoiddust formation and equipment fouling

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent applies parameter changes by controlling the particle size distribution of ground corn within specific ranges (d10: 50-150 μm, d50: 150-300 μm, d90: 300-500 μm). This optimization balances the surface area needed for efficient fermentation while preventing particles from becoming fine enough to form dust clouds and foul equipment, thus resolving the contradiction between productivity and harmful factors.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If corn is ground finer to increase fermentation surface area, then ethanol production rate improves, but the risk of forming dough balls increases

Engineering Contradiction:

Improveethanol production rateVSAvoidrisk of dough ball formation

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent controls the particle size distribution parameters (d10, d50, d90) to specific ranges that provide sufficient surface area for high ethanol production rates while maintaining particle characteristics that prevent dough ball formation. The optimized distribution ensures particles are fine enough for efficient fermentation but not so fine that they aggregate into dough balls, thereby resolving the contradiction between productivity and reliability.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If corn is ground finer to improve starch conversion, then ethanol yield increases, but energy consumption for drying increases

Engineering Contradiction:

Improveethanol yieldVSAvoidenergy consumption for drying

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent optimizes particle size distribution parameters to achieve a balance where starch conversion efficiency is maximized for high ethanol yield, while the particle size remains sufficient to minimize surface area and reduce energy consumption during the drying of stillage and wet cake. This resolves the contradiction between productivity and energy consumption by finding the optimal particle size range.

Inventive Principle:

Principle #35Parameter changes

4Productivity

If corn is ground finer to enhance fermentation efficiency, then process speed increases, but decanter centrifuge performance decreases

Engineering Contradiction:

Improvefermentation efficiencyVSAvoidsedimentation velocity

Core Design Contradiction:

ProductivityVSSpeed

Solution Approach 1:

The patent controls particle size distribution within specific ranges (d10: 50-150 μm, d50: 150-300 μm, d90: 300-500 μm) to maintain sufficient sedimentation velocity for effective decanter centrifuge operation while providing adequate surface area for efficient fermentation. This optimization resolves the contradiction between fermentation efficiency and sedimentation speed by selecting an optimal particle size range that satisfies both requirements.

Inventive Principle:

Principle #35Parameter changes

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 enhances ethanol production by minimizing equipment fouling, reducing energy requirements, and improving system efficiency through controlled particle size distribution, resulting in higher yields and reduced downtime.

Implementation Method 1

a distance separating the first rotatable disk and either the second rotatable disk or the stationary surface can provide a shearing gap therebetween... shearing the corn pieces between the first rotatable disk and either the second rotatable disk or the stationary surface in the shearing gap

Methodology Applied

Scientific EffectShear stress: Shear Stress

Data Source

PatentUS10837029B2Methods and systems for grinding corn and making ethanol therefrom

Publication Date: 2020.11.17 POET GRAIN OCTANE LLC

AI summary

Processes for grinding corn, ground corn products, and processes for making ethanol from the ground corn products. In some examples, a process for making ethanol can include introducing a plurality of corn pieces into a mill. The process can also include milling the corn pieces in the mill to produce a ground corn product. Greater than 25 wt % of the ground corn product can have a particle size of greater than 105 μm, as measured according to AOAC 965.22-1966. Greater than 80 wt % of the ground corn product can have a particle size of 425 μm or less, as measured according to AOAC 965.22-1966. The process can also include processing the ground corn product to produce a fermentation mash that can include ethanol and separating at least a portion of the ethanol from the fermentation mash to produce a stillage.