Multi-Stage Grain Stillage Separation for High-Protein Feed
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Solution Overview
Problem
Existing methods for separating solids from liquids in biofuel production facilities are inefficient, costly, and energy-intensive, leading to high greenhouse gas emissions and increased operating costs, while failing to effectively produce high-protein animal feed products.
Innovation Solution
Implementing a multi-stage separation process using at least two passes through separation devices to separate solids and liquids, followed by dilution and further separation to create high-protein animal feed products, reducing energy consumption and emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing separation methods are used to separate solids from liquids in biofuel production, then the separation process can be performed, but the process is inefficient, costly, and energy-intensive with high greenhouse gas emissions
Solution Approach 1:
The patent divides the separation process into multiple sequential stages: first separation device separates whole stillage into solids and liquids, second separation device further separates the liquid stream, and third separation device processes the second liquid stream. This multi-stage segmentation achieves thorough separation while optimizing energy efficiency at each stage, resolving the contradiction between separation efficiency and energy consumption.
Solution Approach 2:
The patent applies preliminary action by performing initial separation of solids from liquids at the first separation device before subsequent processing. This preliminary separation removes bulk solids early in the process, reducing the energy required for downstream processing and improving overall separation efficiency while lowering energy consumption.
2Productivity
If existing separation methods are used, then solids and liquids can be separated, but operating costs increase and high-protein animal feed products cannot be effectively produced
Solution Approach 1:
The patent applies discarding and recovering by separating and removing fiber components at the second separation device while recovering and concentrating protein-rich streams at the third separation device. This selective discarding of low-value fiber and recovery of high-value protein streams enables effective production of high-protein animal feed products while reducing operating costs through targeted processing.
3Manufacturing precision
If multi-stage separation process is implemented to produce high-protein feed, then protein content increases to 45-64%, but process complexity increases
Solution Approach 1:
The patent applies universality by designing each separation device to perform multiple functions: the first separation device separates solids from liquids and begins concentration, the second separation device separates fiber while concentrating proteins, and the third separation device further purifies and concentrates the protein stream. This multi-functionality achieves high protein content (45-64%) while managing process complexity through integrated device design.
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 process enhances the efficiency of solid-liquid separation, decreases energy and operating costs, and produces high-protein animal feed with protein content ranging from 45% to 64%, thereby reducing greenhouse gas emissions and improving overall facility efficiency.
Implementation Method 1
separating components in a defiber process stream through a first separation device and through a second separation device to create solids of a first wet cake and liquids of a first liquid stream
Data Source
AI summary
This disclosure describes methods to separate solids from liquids in a production facility. A process separates components in a defiber process stream by using two or more mechanical devices to separate the solids from the liquids based on density differences. The process produces animal feed products having a protein content ranging from approximately 45% to approximately 64%.