Pulse Combustion Dryer for Distiller Solubles
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Solution Overview
Problem
The challenge lies in effectively drying stillage from ethanol production facilities without oxidizing or denaturing the suspended fraction, which contains valuable components like proteins and oils, as existing methods often fail to preserve these materials in their nutritional form.
Innovation Solution
The introduction of condensed distiller's solubles (CDS) into a high-velocity, pulsed drying gas stream with controlled temperature and turbulence, allowing for continuous drying into dried distiller's solubles (DDS) with a moisture content of 0.5-10%, using a pulse combustion dryer system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional drying methods are used to dry stillage, then drying can be achieved, but the suspended fraction containing proteins and oils is oxidized and denatured
Solution Approach 1:
The patent applies periodic pulsed action by introducing CDS into intermittent pulses of hot drying gas rather than continuous exposure. This periodic introduction allows rapid drying while limiting the total thermal exposure time, thereby preventing oxidation and denaturation of the suspended fraction containing proteins and oils
Solution Approach 2:
The patent implements rushing through by using high-velocity drying gas pulses that rapidly evaporate water from CDS before the material can be significantly exposed to oxidative conditions. The rapid transit time through the drying zone minimizes harmful thermal and oxidative effects while achieving efficient drying
2Speed
If high temperature drying is used to remove water quickly, then drying speed increases, but thermal efficiency decreases due to energy loss
Solution Approach 1:
The pulsed drying gas introduction system provides high drying speed during active pulses while allowing heat recovery during idle periods. The periodic operation enables better thermal management and reduces continuous energy loss compared to sustained high-temperature drying
Solution Approach 2:
The patent utilizes phase transition of water from liquid to vapor during rapid evaporation in the pulsed hot gas stream. This phase change occurs quickly, achieving high drying speed while the brief exposure time minimizes overall energy consumption compared to prolonged heating
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 efficiently preserves the nutritional value of the suspended fraction by rapidly evaporating water while maintaining the integrity of proteins and oils, achieving high thermal efficiency and reducing capital costs through rapid drying processes.
Implementation Method 1
introducing condensed distiller's solubles (CDS) into a drying gas stream and recovering dried distiller's solubles (DDS) from the drying gas stream
Implementation Method 2
the gas stream may be a pulsed gas stream... having a temperature between about 600° F. and 1800° F.
Implementation Method 3
The drying gas stream may have a high velocity in the range of about 60 meters per second to about 260 meters per second
Data Source
AI summary
Dried distiller's solubles is described. Methods for drying condensed distiller's solubles into dried distiller's solubles are presented. The methods may include introducing the condensed distiller's solubles into a drying gas stream and recovering dried distiller's solubles from the drying gas stream.