Oxygen-Free Single-Cell Protein Process With Centrifugal Separation
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Solution Overview
Problem
Existing methods for separating solids from liquids in biofuel production facilities are inefficient, costly, and emit high levels of greenhouse gases, requiring significant energy and maintenance, and do not effectively produce valuable feed products.
Innovation Solution
A method involving mechanical separation devices and non-condensable media to enhance solid-liquid separation, followed by enzymatic hydrolysis and drying to produce high-value animal feed products, reducing energy consumption and emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional separation methods are used to separate solids from liquids in biofuel production, then separation can be achieved, but energy consumption is high and greenhouse gas emissions increase
Solution Approach 1:
The patent changes the physical parameters of the separation process by using centrifugal force (changing from gravitational to centrifugal acceleration) and controlling temperature to maintain solids in suspension during transport. This allows for more efficient separation with reduced energy consumption compared to conventional thermal evaporation methods.
Solution Approach 2:
The patent replaces conventional thermal/chemical separation methods with a mechanical centrifugal separation system. The centrifugal separator uses rotational mechanical force to separate solids from liquids, eliminating the need for energy-intensive heating and evaporation processes.
2Ease of manufacture
If conventional separation methods are used, then separation can be achieved, but equipment requires significant maintenance and has high capital costs
Solution Approach 1:
The patent employs a centrifugal separation system that avoids the need for expensive, maintenance-intensive thermal processing equipment. The mechanical centrifugal separator has simpler construction with fewer moving parts requiring maintenance, reducing both capital costs and operational maintenance requirements.
3Loss of substance
If solids are separated from liquids using conventional methods, then liquid can be recovered, but valuable feed products are not effectively produced
Solution Approach 1:
The patent recovers solids from the centrifugal separation process and converts them into valuable single-cell protein feed products through microbial fermentation. Instead of discarding the separated solids as waste or low-value byproduct, the system transforms them into high-value animal feed, thereby recovering substance value and improving productivity.
Solution Approach 2:
The patent introduces microorganisms as an intermediary to transform the separated solids into single-cell protein feed products. The microbes consume the organic matter in the solids and convert it into protein-rich biomass, creating a valuable feed product from what would otherwise be waste material.
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 improves efficiency, reduces energy and capital costs, and lowers greenhouse gas emissions by enhancing the separation of solids from liquids, producing valuable animal feed products with higher solids content.
Implementation Method 1
using a mechanical device to separate the suspended solids from the liquids
Implementation Method 2
adding non-condensable media to the fractionated stillage process stream to reduce density of liquids relative to the density differential to suspended solids
Implementation Method 3
dries the solids to create a dried feed product
Data Source
AI summary
This disclosure describes methods to separate solids from liquids in a production facility. A process separates components in the process stream by applying non-condensable media to create density differences and then using a mechanical device to separate the solids from the liquids based on the density difference. The process produces the liquids and solids, which may be further processed to create valuable animal feed products.