Grain Oil Emulsion Stabilization Through Alkaline Soap Formation
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Solution Overview
Problem
Existing grain material-based emulsions derived from distiller's corn oil (DCO) are unstable and tend to separate into multiple phases when stored at ambient temperatures, limiting their use in various applications.
Innovation Solution
A method to stabilize and homogenize emulsions by combining grain oil compositions with water, adjusting pH, and treating with an alkali or alkaline metal base to form a stable, single-phase emulsion with specific soap and viscosity characteristics, maintaining stability for at least two weeks at ambient temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If grain material-based emulsions are derived from distiller's corn oil (DCO) through conventional methods, then the emulsion can be produced for various applications, but the emulsion becomes unstable and separates into multiple phases when stored at ambient temperatures
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition of the emulsion through controlled alkaline hydrolysis. By adjusting parameters such as pH (to approximately 7-9), temperature (50-100°C), and reaction time, free fatty acids are converted into soap molecules that act as natural emulsifiers. This chemical transformation changes the emulsion's stability parameters, allowing it to maintain a single-phase homogeneous structure during storage while remaining adaptable for various applications such as defoaming.
2Duration of action of stationary object
If the emulsion is stored at ambient temperatures for extended periods, then the emulsion maintains its usability, but it separates into at least two phases and becomes unstable
Solution Approach 1:
The patent applies preliminary action by performing alkaline treatment and soap formation before storage. The emulsion is pre-treated with an alkaline agent (such as sodium hydroxide, potassium hydroxide, or calcium hydroxide) to generate soap molecules that provide long-term stabilizing effects. This preliminary chemical modification ensures that when the emulsion is stored at ambient temperatures for extended periods (at least two weeks), the soap molecules continuously maintain the emulsion in a stable single-phase state, preventing separation.
3Ease of manufacture
If conventional DCO-based emulsions are produced, then they can be used in applications, but they require additional stabilization treatments and have limited shelf life
Solution Approach 1:
The patent applies self-service by utilizing the emulsion's own components to achieve stabilization. The alkaline hydrolysis process converts free fatty acids already present in the DCO-based emulsion into soap molecules that serve as natural emulsifiers. This self-service approach transforms the emulsion's inherent components into stabilizing agents, eliminating the need for additional external stabilizers or complex preservation treatments, thereby extending shelf life reliably while maintaining production simplicity.
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
The method produces a stable and homogeneous emulsion that remains a single phase for an extended period, enhancing its usability and value in applications such as defoamers.
Implementation Method 1
treating with an alkali or alkaline metal base to form a stable, single-phase emulsion with specific soap and viscosity characteristics
Implementation Method 2
a soap content of about 500 ppm or greater, wherein the soap content includes a salt of a fatty acid and an alkali or an alkaline-earth metal
Data Source
AI summary
The present disclosure relates methods and systems for refining grain oil compositions using water, and related compositions produced therefrom. The present disclosure also relates to methods of using said compositions. The present disclosure also relates to methods of using grain oil derived from a fermentation product in an anti-foam composition. The present disclosure further relates to stabilized emulsion products and methods for forming thereof.