Microfiltration for Aqueous Fermentation Feedstock Production
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Solution Overview
Problem
The high cost of fermentation feedstock is a significant contributor to the overall cost of fermentation products, necessitating the development of low-cost methods for producing fermentation feedstock.
Innovation Solution
A dry-milling method involving corn-processing filtration feed, where corn kernels are comminuted and treated with enzyme compositions to form liquefied corn mash, followed by microfiltration to separate water-soluble carbohydrates and water-insoluble matter, and subsequent washing and saccharification steps to produce an aqueous fermentation feedstock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional fermentation feedstock production methods are used, then the process is simpler and more established, but the cost of fermentation feedstock is high
Solution Approach 1:
The patent extracts water-soluble carbohydrates from corn-processing filtration feed using microfiltration membranes, separating the valuable fermentable sugars from water-insoluble matter to create a concentrated fermentation feedstock stream that reduces overall feedstock costs
Solution Approach 2:
Instead of discarding the filtration feed from corn processing, the patent recovers valuable water-soluble carbohydrates through microfiltration, treating what would be waste material as a valuable feedstock source for fermentation
2Quantity of substance
If microfiltration is used to separate water-soluble carbohydrates, then feedstock concentration is improved, but process complexity increases
Solution Approach 1:
The patent replaces conventional mechanical filtration methods with microfiltration membrane technology, achieving superior separation of water-soluble carbohydrates from filtration feed with higher concentration and purity in a single processing step
3Loss of substance
If multiple washing and saccharification steps are performed on retentate, then glucose recovery is improved, but processing time increases
Solution Approach 1:
The patent implements continuous washing of the retentate with fresh water to extract additional water-soluble carbohydrates, maintaining continuous flow and processing to maximize glucose recovery without significant time penalty
Solution Approach 2:
The patent performs saccharification of the retentate before final drying, converting any remaining starches to fermentable sugars in advance to ensure maximum glucose recovery in the final feedstock product
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 reduces the cost of fermentation feedstock by efficiently processing corn to produce a high-concentration glucose solution suitable for fermentation, while minimizing waste and operational costs.
Implementation Method 1
filtering at least a fraction of the filtration feed on a microfiltration membrane; whereby an aqueous filtration permeate, comprising the water-soluble carbohydrates, and a filtration retentate comprising the water-insoluble matter, are formed
Implementation Method 2
treating the liquefied corn mash with an enzyme composition comprising gluco-amylase enzymes, whereby a saccharified corn mash is formed
Data Source
AI summary
Provided are dry-milling methods for producing an aqueous fermentation feedstock ingredient. The methods include providing a corn-processing filtration feed; filtering at least a fraction of said filtration feed on a microfiltration membrane, whereby an aqueous filtration permeate and a filtration retentate are formed; separating said filtration permeate from said filtration retentate, to form separated permeate and separated retentate; forming a fermentation feedstock comprising said separated permeate, and saccharifying and/or washing said separated retentate.