Grain Drying Using Fermentation CO2 Byproduct
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Solution Overview
Problem
Current methods for grain moisture removal and disease control in ethanol plants rely on high energy usage and harmful chemicals, leading to increased greenhouse gas emissions and inefficiencies, particularly with the venting of CO2 byproducts and reliance on propane and natural gas for drying processes.
Innovation Solution
A system and method utilizing CO2 as a byproduct from alcohol fermentation or thermal energy generation for grain drying and disease control, where captured CO2 is directed through grain storage facilities to reduce moisture and inhibit fungal growth, leveraging the CO2 refrigeration cycle for cooling and fumigation to control pests and fungi.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If CO2 is vented into the atmosphere from ethanol fermentation and thermal energy generation, then greenhouse gas emissions increase, but the CO2 that could be used for grain drying and treatment is wasted
Solution Approach 1:
The patent converts the harmful CO2 emissions into a beneficial drying and treatment agent for grain. CO2 generated from ethanol fermentation and thermal energy generation is captured and directed through grain storage facilities, where it serves to dry grain, control moisture, and inhibit fungal and pest growth. This transforms a greenhouse gas problem into a valuable processing resource, eliminating emissions while providing drying functionality.
Solution Approach 2:
The patent recovers CO2 that would otherwise be discarded into the atmosphere. By capturing CO2 from fermentation processes and thermal energy generation, the system recovers this byproduct and reuses it for grain drying and storage treatment, preventing waste and reducing the need for external drying energy inputs.
2Use of energy by stationary object
If propane and natural gas are used for grain drying, then moisture removal is effective, but energy consumption and greenhouse gas emissions increase
Solution Approach 1:
The patent enables the ethanol plant to serve its own grain drying needs using internally generated CO2. Instead of relying on external propane or natural gas sources, the system uses CO2 produced during the plant's own fermentation and thermal processes, creating a self-sufficient drying system that eliminates the need for purchased fossil fuels.
3Reliability
If chemical treatments are used for grain disease and pest control, then protection is effective, but harmful chemical residues and environmental pollution occur
Solution Approach 1:
The patent uses CO2 to create an inert atmosphere within grain storage facilities. By increasing CO2 concentration in the storage environment, the system creates conditions that are hostile to fungal growth and pest survival without introducing harmful chemicals. The CO2 atmosphere physically suppresses biological contaminants through displacement of oxygen and direct toxic effects on organisms.
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 reduces energy consumption by 15-50% for grain drying, decreases pesticide use, and recycles CO2, lowering greenhouse gas emissions while improving grain quality and flowability, enabling safer animal feed production and streamlined operations.
Implementation Method 1
leveraging the CO2 refrigeration cycle for cooling and fumigation to control pests and fungi
Implementation Method 2
releasing CO2 in a grain storage facility, wherein the CO2 is a byproduct of alcohol fermentation or thermal energy generation
Data Source
AI summary
The present disclosure provides methods for treating one or more grains in an ethanol plant or alcohol brewery, methods of drying, cooling, disease control of dried distillers grains with soluble (DDG), barley, or brewer's spent grain (BSG), and a system for treating one or more grains in an ethanol plant or alcohol brewery by these disclosed methods.