Ethanol Production via Raw Starch Fractionation and Enzymatic Saccharification
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Solution Overview
Problem
Conventional methods for converting plant material to ethanol are inefficient and do not effectively produce high levels of alcohol or high protein distiller's dried grain, with issues related to starch gelatinization and viscosity in fermentation processes.
Innovation Solution
A method involving fractionation of plant material, grinding to achieve specific particle sizes, saccharification without cooking, and fermentation using enzymes like glucoamylase and acid fungal amylase, with temperature and pH control, to produce high ethanol content and high protein distiller's dried grain, while reducing stack emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional starch gelatinization methods are used, then starch conversion to ethanol is achieved, but viscosity increases and fermentation efficiency decreases
Solution Approach 1:
The patent changes the temperature parameter from conventional high-temperature gelatinization (60-90°C) to low-temperature processing (below gelatinization temperature). This parameter change allows starch saccharification without the viscosity increase and energy loss associated with conventional heating methods, thereby improving fermentation efficiency while maintaining lower process temperatures.
Solution Approach 2:
The patent replaces the thermal-mechanical gelatinization process with an enzymatic saccharification process. Instead of using heat and mechanical stirring to gelatinize starch, the invention uses enzymes (amylases, glucoamylases) to convert starch to fermentable sugars at low temperatures, eliminating the harmful effects of high-temperature processing.
2Quantity of substance
If fractionation of plant material is implemented, then ethanol yield increases to over 18 vol-%, but process complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the plant material into different particle size fractions before processing. The material is ground and separated into fine particles (passing through 0.5mm sieve) and coarse particles. This segmentation increases the surface area of starch exposed to enzymes, improving saccharification efficiency and ethanol yield to over 18 vol-%, while the added complexity is managed through relatively simple mechanical grinding and screening operations.
3Loss of energy
If conventional drying methods are used for distiller's dried grain, then drying is achieved, but energy consumption increases and stack emissions increase
Solution Approach 1:
The patent changes the drying parameters by using lower temperatures and shorter drying times compared to conventional methods. The distiller's dried grain is dried at optimized temperature and time parameters that reduce energy consumption by 10-20% while maintaining drying efficiency, achieving a balance between energy savings and production productivity.
Solution Approach 2:
The patent implements continuous drying operations where the distiller's dried grain is continuously processed through the drying system, eliminating idle time and maximizing energy utilization. This continuous operation maintains high drying efficiency while reducing total energy consumption compared to batch processing methods.
4Ease of manufacture
If saccharification without cooking is used, then fermentation of uncooked starch is achieved, but enzyme requirements and process control complexity increase
Solution Approach 1:
The patent uses enzymes as intermediary substances to facilitate the saccharification of uncooked starch. Specific enzymes (amylases, glucoamylases) are added to the ground plant material to catalyze the conversion of starch to fermentable sugars without requiring thermal cooking. This enzymatic mediation simplifies the overall process by eliminating the cooking step while requiring controlled addition of enzymes and maintenance of appropriate pH and temperature conditions for enzyme activity.
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 achieves high ethanol yields of over 18 vol-% and high protein distiller's dried grain with improved physical characteristics, along with reduced volatile organic compounds and carbon monoxide emissions, compared to conventional processes.
Implementation Method 1
saccharifying the starch without cooking
Implementation Method 2
fermentation using enzymes like glucoamylase and acid fungal amylase
Implementation Method 3
fermenting the incubated starch
Implementation Method 4
recovering the ethanol from the fermentation
Implementation Method 5
drying a co-product by ring drying, flash drying, or fluid bed drying
Data Source
AI summary
The present invention relates to methods for producing high levels of alcohol during fermentation of plant material, and to the high alcohol beer produced. The method can include fractionating the plant material. The present invention also relates to methods for producing high protein distiller's dried grain from fermentation of plant material, and to the high protein distiller's dried grain produced. The method can include drying a co-product by ring drying, flash drying, or fluid bed drying. The present invention further relates to reduced stack emissions from drying distillation products from the production of ethanol.