Pre-dissolved Antimicrobial Agents for Ethanol Mash
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In ethanol production, antimicrobial agents like pristinamycin-type and polyether ionophore-type agents are ineffective in controlling lactobacilli and other microorganisms in heat exchangers due to heat inactivation and slow dissolution in traditional powdered forms, leading to reduced ethanol yield and increased costs.
Innovation Solution
Pre-solubilization of antimicrobial agents in organic solvents like alkyl citric acid esters and glycols allows for immediate and effective delivery in a dissolved form, particularly in heat exchangers, enhancing control of microorganisms and improving ethanol production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If powdered antimicrobial agents are added to mash in traditional form, then the agents can be easily applied, but the agents are inactivated by heat and dissolve too slowly to provide effective concentration in heat exchangers
Solution Approach 1:
The antimicrobial agents are pre-dissolved in a suitable solvent before addition to the mash. This preliminary dissolution ensures that the agents are already in a bioavailable form, eliminating the slow dissolution step that occurs with powdered agents and ensuring immediate effectiveness when the mash passes through heat exchangers.
Solution Approach 2:
The patent changes the physical state of the antimicrobial agents from solid powder to dissolved solution. This parameter change (from solid to dissolved state) allows the agents to withstand heat exposure and provide immediate active concentration, resolving the contradiction between ease of application and effectiveness.
2Reliability
If antimicrobial agents are added to control lactobacilli in heat exchangers, then microorganism control is improved, but the agents are destroyed by high temperature
Solution Approach 1:
A suitable solvent acts as an intermediary medium that protects the antimicrobial agents from heat inactivation. The solvent allows the agents to remain in a stable, dissolved state during heat exposure in heat exchangers, enabling them to maintain effectiveness while withstanding temperatures that would normally destroy them.
Solution Approach 2:
The patent changes the chemical state of the antimicrobial agents from solid powder to dissolved solution in a protective solvent. This parameter change enables the agents to resist heat inactivation, as the dissolved state in the appropriate solvent provides thermal stability that allows them to survive and remain effective in heat exchanger environments.
3Ease of manufacture
If powdered antimicrobial agents are used, then application is simple, but the dissolution kinetics are too slow to provide effective concentration in the time frame of mash passage through heat exchangers
Solution Approach 1:
The dissolution process is performed in advance during the preparation of the antimicrobial solution before addition to the mash. This preliminary action eliminates the time-consuming dissolution step from the process, ensuring that the agents are immediately bioavailable when needed in the heat exchangers without delaying the overall production timeline.
Solution Approach 2:
The patent changes the physical state of the antimicrobial agents from solid powder to dissolved solution. This parameter change fundamentally reduces the dissolution time from hours or days to instantaneous upon addition, eliminating the time loss associated with slow dissolution kinetics while maintaining simplicity of application.
4Ease of operation
If traditional powdered antimicrobial agents are added to mash, then the agents can be easily distributed, but they cannot provide active concentration immediately in heat exchangers
Solution Approach 1:
The patent changes the physical state of the antimicrobial agents from solid powder to dissolved solution. This parameter change simultaneously improves both distribution ease (as the solution can be easily pumped and mixed) and the rate of active concentration availability (as the agents are already dissolved and immediately bioavailable upon contact with the mash).
Solution Approach 2:
The patent utilizes liquid solution form that can be easily pumped and distributed through the mash using standard hydraulic systems. This allows for simple and effective distribution through existing liquid handling infrastructure while ensuring immediate availability of active concentration, as the agents are already in dissolved form.
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 use of pre-solubilized antimicrobial agents results in rapid and effective control of lactobacilli, increasing ethanol yield and reducing microorganism-related losses, while minimizing residual antimicrobial agent presence in byproducts, thus improving the economic viability of ethanol production.
Implementation Method 1
wherein the solubility of the antimicrobial agent in the liquid composition is at least 10 grams per liter
Data Source
AI summary
A method of controlling microorganisms such as lactobacilli metabolism in mash in an ethanol production facility includes adding to the mash an effective amount to control such microorganisms of one or more of a substantially water insoluble pristinamycin-type antimicrobial agent, a substantially water insoluble polyether ionophore antimicrobial agent, or both, wherein the term “substantially water insoluble” means the antimicrobial agent has a solubility in pure water at 20° C. of 0.1 grams per liter or less, and wherein at least a portion of the substantially water insoluble antimicrobial agent(s) is added to the mash in the form of: 1) an organic liquid comprising at least one organic solvent having said substantially water insoluble antimicrobial agent(s) dissolved therein, said organic liquid advantageously comprising more than 1 gram per liter of said antimicrobial agent(s); 2) particles comprising said substantially water insoluble antimicrobial agent(s) and having a weight mean average diameter of less than 5 microns; or 3) both.