Automated Ethanol Production via Segmented Tank Control
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Solution Overview
Problem
Conventional ethanol production methods using large tanks are inefficient and economically unfeasible due to high manual labor requirements and lack of automation, resulting in lower conversion efficiency and higher production costs.
Innovation Solution
A method utilizing a series of small tanks automated by a PLC system with distributed I/O points, allowing for precise control of temperature, agitation, and ingredient addition, enabling continuous processing and reducing manual labor through a scalable, modular setup that can be adapted for various grain types and production scales.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If large tanks are used for ethanol production, then automation is more economical, but conversion efficiency decreases and manual labor requirements increase
Solution Approach 1:
The system divides the fermentation process into multiple smaller tanks (first fermentation tank, second fermentation tank, etc.) instead of using a single large tank. Each tank can be independently controlled and automated, allowing for better agitation and distribution of fermentation activation agents while maintaining economical automation through modular PLC control systems.
2Extent of automation
If large tanks are used for ethanol production, then automation is more economical, but manual labor requirements increase
Solution Approach 1:
The PLC control system serves multiple functions across different tanks and process stages (cooking, fermentation, distillation). The control system can automatically manage ingredient addition, temperature control, agitation, and timing for multiple tanks, eliminating the need for manual intervention while maintaining flexibility for different grain types and production scales.
3Productivity
If small tanks are used for ethanol production, then conversion efficiency improves, but automation becomes less economical
Solution Approach 1:
The system segments the automation control into modular PLC units that can independently control each small tank. This modular approach makes automation economical by allowing incremental implementation and reducing the complexity burden on any single control unit while maintaining efficient conversion through proper agitation and temperature control in each small tank.
4Quantity of substance
If conventional large tank methods are used, then production scale is achieved, but production costs increase
Solution Approach 1:
The system achieves production scale through parallel processing in multiple small tanks rather than one large tank. This segmentation allows for better conversion efficiency in each tank, lower automation complexity per unit, and reduced production costs while maintaining overall production volume through coordinated operation of multiple tanks.
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 significantly reduces production costs to approximately $0.55 per gallon of ethanol, increases feed byproduct value, and eliminates the need for EPA permits due to minimal pollution, while allowing for flexible operation and efficient ethanol production in various settings, including repurposed buildings.
Implementation Method 1
precise control of temperature
Implementation Method 2
greater agitation of the product and more uniform distribution of fermentation activation agents
Implementation Method 3
The cooking, fermenting and distilling is accomplished in small tanks
Data Source
AI summary
The present invention provides a method of automating the production of ethanol in an economical method yet maximizing the conversion of grains into ethanol in an even greater conversion efficiency with a greatly improved feed value byproduct.