Fractionated Stillage Separation Using Density-Shifted Solids Removal
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Solution Overview
Problem
Existing methods for separating solids from liquids in process streams are inefficient, costly, require frequent maintenance, and fail to adequately separate components, leading to high energy consumption, emissions, and increased capital and operating costs, while not easily integrating into production facilities to produce valuable products.
Innovation Solution
A mechanical device is used to separate suspended solids from liquids by adding non-condensable media to reduce liquid density, followed by mechanical separation, and further processing to produce valuable animal feed products, including wet and dried feed products, and syrup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If gravity separation is used to separate solids from liquids, then the separation process is simple, but the separation efficiency is poor and the process time is long
Solution Approach 1:
The patent replaces gravity-based mechanical separation with a biological treatment system using microorganisms to consume suspended solids and convert them into microbial biomass, thereby achieving efficient solid-liquid separation without relying on slow gravitational settling processes
Solution Approach 2:
The patent changes the separation mechanism from physical gravity-based separation to biological transformation, where microorganisms metabolically convert suspended solids into biomass that can be easily separated, fundamentally altering the separation parameter from density-based to biology-based
2Reliability
If conventional separation methods are used, then the process is established, but energy consumption is high and emissions increase
Solution Approach 1:
The patent converts the harmful suspended solids in stillage, which normally require energy-intensive removal and contribute to emissions, into a beneficial microbial biomass product through biological consumption, thereby eliminating the need for high-energy separation processes while reducing greenhouse gas emissions
Solution Approach 2:
The system uses microorganisms that autonomously consume suspended solids and generate biomass, providing self-service separation without requiring external energy input for mechanical separation equipment, thus reducing energy consumption while maintaining process reliability
3Ease of manufacture
If traditional separation equipment is used, then the infrastructure is available, but maintenance frequency is high and operating costs increase
Solution Approach 1:
The patent replaces mechanical separation equipment that requires frequent maintenance with a biological treatment system using microorganisms, eliminating moving parts and mechanical wear components that necessitate regular maintenance and repairs
4Device complexity
If solids are not adequately separated, then the process is simple, but capital costs and operating costs increase
Solution Approach 1:
The system employs microorganisms that automatically and continuously consume suspended solids and convert them to biomass, providing self-service separation that eliminates the need for complex, expensive mechanical separation infrastructure while maintaining effective solid-liquid separation
Solution Approach 2:
The patent fundamentally changes the separation approach from mechanical/physical methods requiring expensive equipment to biological transformation using microorganisms, thereby reducing both capital investment in separation infrastructure and ongoing operating costs while achieving adequate separation
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 enhances solid-liquid separation efficiency, reduces energy and emissions, lowers operating and capital costs, and produces valuable feed products, aligning with regulatory carbon intensity standards.
Implementation Method 1
separating components in a fractionated stillage process stream by enhancing solid-liquid separation... adding non-condensable media to the fractionated stillage process stream to reduce density of liquids relative to the density differential to suspended solids
Data Source
AI summary
This disclosure describes methods to separate solids from liquids in a production facility. A process separates components in the process stream by applying non-condensable media to create density differences and then using a mechanical device to separate the solids from the liquids based on the density difference. The process produces the liquids and solids, which may be further processed to create valuable animal feed products.