Librixer Dry Grain Fractionation for Purity
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Solution Overview
Problem
Current dry milling processes for corn and other starch-bearing grains fail to achieve the same level of fractionation purity as wet milling, leading to inefficiencies and waste in ethanol production and other downstream processes due to the presence of unwanted fat and fiber.
Innovation Solution
A dry, one-pass processing method using a Librixer system with a spinnable shaft and segmented processing chambers, where the corn kernel is moisturized and comminuted to liberate components along natural boundaries, allowing for the separation of starch, protein, and fat into high-purity fractions, including Zein protein extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional dry milling techniques (roller, hammer, ball mills) are used for corn fractionation, then the process is simple and energy-efficient, but the fractionation purity is insufficient and fat/fiber cannot be effectively removed
Solution Approach 1:
The corn kernel is divided into multiple processing chambers within the mill, each chamber containing specific rotor-stator configurations tailored for different fractionation stages. This segmentation allows progressive separation of starch, protein, fat, and fiber components while maintaining overall system integration
Solution Approach 2:
The milling system employs composite rotor-stator assemblies combining different materials with specific surface properties optimized for different kernel components. The composite design enables selective liberation and separation of starch, protein, fat, and fiber based on their distinct physical and chemical characteristics
2Productivity
If traditional milling techniques are used, then equipment simplicity is maintained, but fat and fiber remain mixed with starch requiring additional removal steps
Solution Approach 1:
The mill performs preliminary liberation and separation of fat and fiber from starch in the initial fractionation stages, before downstream processing. This preliminary action prevents contamination of starch streams with unwanted components, eliminating the need for additional removal steps and preserving valuable materials
Solution Approach 2:
The system extracts and separates unwanted fat and fiber components from the starch fraction during the milling process itself. Specialized rotor-stator configurations and chamber designs enable selective removal of these components, leaving purified starch ready for downstream applications
3Quantity of substance
If conventional milling is applied, then processing cost is low, but Zein protein and other valuable components are lost in spent grain
Solution Approach 1:
Different sections of the mill are configured with specific rotor-stator geometries and operating parameters optimized for recovering different valuable components. Local variations in shear force, compression, and particle trajectory enable selective liberation and recovery of Zein protein, starch, and other valuable constituents
Solution Approach 2:
The system recovers valuable components (Zein protein, starch, fiber) that would traditionally be discarded with spent grain. Multiple separation streams are generated, each enriched in specific valuable components, transforming waste material into recoverable resources
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 enables the efficient separation and concentration of valuable components, increasing the value of Zein protein and simplifying downstream processes by removing unwanted fat and fiber, thereby enhancing ethanol production efficiency and profitability.
Implementation Method 1
liberated from the corn kernel by means of a chaotic vortex flow of the corn kernel and the liberated products generated in the processing chambers
Implementation Method 2
comminuting the corn kernel by a comminution reactor comprising a spinnable shaft and two or more processing chambers, separated by segmented plates, wherein each processing chamber comprises a rotor disc attached to the shaft and one or more vortex generators
Data Source
AI summary
A dry, one pass processing method for obtaining pre-process liberated fractions from a corn or other cereal kernel, including moisturizing (S1) the corn bran layer by a mist of small droplets of water, comminuting (S2) the corn kernel with a comminution reactor having a spinnable shaft and two or more processing chambers, separated by segmented plates, wherein each processing chamber comprises one rotor discs attached to the shaft and one or more vortex generators placed in a side wall apex corner of the processing chambers, wherein the corn kernel is fed into the comminution reactor and small and large bran sections, whole and broken germ, soft endosperm, and medium and large hard endosperm fractions are liberated from the corn kernel by means of a chaotic non-linear flow of the corn kernel and the liberated products generated in the processing chambers.