Ethanol Production via Pretreated Lignocellulosic Cattle Feed
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Solution Overview
Problem
The challenge is to expand ethanol production from corn dry-milling while maintaining adequate cattle feed supplies, as diverting corn for ethanol production leads to energy loss from starch in cattle feed and over-saturation of the animal feed market with corn dry milling by-products.
Innovation Solution
The solution involves upgrading distillers dried grains and solubles (DDG/DDGS) by mixing them with pretreated lignocellulosics, such as corn stover, wheat straw, and soybean hulls, to create a bioavailable cattle feed that replaces the energy from diverted corn starch, using thermochemical, chemical, enzymatic, and physical pretreatments to enhance digestibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If corn is diverted from cattle feed to ethanol production, then ethanol production increases, but cattle feed supply decreases and energy from starch is lost
Solution Approach 1:
The invention changes the physical and chemical parameters of lignocellulosic materials through pretreatment processes (thermal, chemical, enzymatic) to transform them from indigestible forms into bioavailable feed components that can replace starch in cattle diets
Solution Approach 2:
The invention creates a composite feed material by combining DDG/DDGS with pretreated lignocellulosics, forming a new composite product that combines the nutritional benefits of both components to replace corn starch in cattle feed
2Productivity
If corn dry milling by-products are produced in large quantities, then ethanol production increases, but the animal feed market becomes over-saturated
Solution Approach 1:
The invention applies parameter changes to DDG/DDGS by combining them with pretreated lignocellulosics, transforming the product characteristics to create a differentiated feed material that addresses market saturation
Solution Approach 2:
The invention segments the corn processing stream into multiple valuable products: ethanol from starch, DDG/DDGS protein component, and pretreated lignocellulosic fiber component, which are then combined to create an enhanced feed product
3Quantity of substance
If pretreated lignocellulosics are used to replace corn starch in cattle feed, then feed energy value is maintained, but biomass transport costs increase
Solution Approach 1:
The invention merges DDG/DDGS with pretreated lignocellulosics in a combined processing step, creating a unified feed product that integrates protein and fiber components locally, reducing the need for separate biomass transport
Solution Approach 2:
The invention uses pretreatment processes as an intermediary step that converts recalcitrant lignocellulosics into bioavailable forms, enabling their integration into cattle feed without requiring long-distance transport of raw biomass
4Quantity of substance
If recalcitrant cellulose is used in cattle feed, then feedstock availability increases, but digestibility is poor due to recalcitrance
Solution Approach 1:
The invention applies multiple parameter changes through sequential pretreatment processes (thermal, chemical, enzymatic) that progressively modify the physical and chemical structure of cellulose, breaking its recalcitrance and improving digestibility
Solution Approach 2:
The invention creates a composite material combining DDG/DDGS with pretreated lignocellulosics, where the pretreatment process transforms the recalcitrant cellulose into a digestible form that works synergistically with the DDG/DDGS component
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 increases ethanol production by 40% without increasing corn acreage, ensures adequate cattle feed supply, and addresses the recalcitrance of cellulose, high energy requirements, and economic issues associated with biomass transport, by utilizing bacterial consortium enzymes and local processing to enhance feedstock digestibility and reduce costs.
Implementation Method 1
The cellulose and hemicellulose are broken down enzymatically in the rumen of the animal as a source of mono- and di-saccharides
Implementation Method 2
These organisms ferment the starch to organic acids, which at high concentrations can lead to acidosis in the cattle
Data Source
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AI summary
A method for the production of ethanol and a modified animal feed is provided. The method replaces the starch in known corn-based animal feed with biomass fiber treated to make it more digestible by animals. The process includes wherein the pericarp and germ are removed from the corn kernel and processed for by-products. The starch and protein are also removed and separated. The starch is then fermented and distilled to ethanol and stillage. The bioavailable modified animal feed comprises the pericarp and germ removed from corn kernels and optionally by-products of the pericarp and germ processing, and lignocellulosic materials. The modified animal feed may optionally include energy materials such as animal and vegetable fats, vegetable soapstocks, or glycerin, and combinations thereof.