Pulse Dosing Cleaning Formulation for Ethanol Plant Deposits
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Solution Overview
Problem
Current cleaning-in-place (CIP) methods in ethanol, protein, and corn oil processing plants require frequent shutdowns, significant labor, and chemical usage, reducing plant efficiency and increasing maintenance costs due to continuous dosing of cleaning formulations which may not be economically feasible.
Innovation Solution
Implementing pulse dosing of cleaning formulations into fluid process streams at specific intervals and concentrations within processing facilities, such as ethanol and corn oil plants, to control deposit and bacterial buildup, thereby enhancing production efficiency and extending cleaning cycle intervals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuous dosing of cleaning formulation is used, then deposit and bacterial buildup is controlled, but chemical consumption increases and production efficiency decreases
Solution Approach 1:
The patent applies periodic action by dosing the cleaning formulation in pulses at specific intervals (e.g., every 15-60 minutes) rather than continuously. This periodic dosing maintains effective cleaning concentrations while significantly reducing overall chemical consumption compared to continuous dosing methods.
Solution Approach 2:
The patent implements dynamic dosing where the cleaning formulation concentration is adjusted based on process conditions such as flow rate, temperature, and deposit buildup rates. This dynamic approach optimizes chemical usage by providing higher concentrations when needed and lower concentrations when process conditions are favorable.
2Reliability
If frequent CIP shutdowns are implemented, then cleaning effectiveness is maintained, but plant productivity decreases
Solution Approach 1:
The patent applies preliminary action by continuously dosing cleaning formulation during operation to prevent deposit and bacterial buildup before it becomes severe. This preventive approach extends the time between required CIP shutdowns, maintaining cleaning effectiveness while preserving plant productivity.
Solution Approach 2:
The patent implements continuity of useful action by maintaining cleaning formulation presence in the process stream throughout operation. This continuous protective action prevents fouling accumulation, allowing the plant to operate at full capacity for longer periods without interruption for cleaning.
3Reliability
If high concentration of cleaning formulation is dosed, then cleaning performance is improved, but chemical cost and environmental impact increase
Solution Approach 1:
The patent applies parameter changes by adjusting the cleaning formulation concentration based on process conditions such as flow rate, temperature, and observed deposit buildup. This dynamic parameter adjustment maintains optimal cleaning performance while minimizing chemical consumption and associated costs.
Solution Approach 2:
The patent implements local quality by dosing the cleaning formulation at specific locations within the process system where deposit buildup is most problematic. This targeted approach concentrates cleaning action where needed most, reducing overall chemical usage while maintaining effective cleaning performance.
Data Source
AI summary
Pulse dosing is used to administer a cleaning formulation into a fluid process stream flowing through structural components of a processing facility. The fluid process stream may contain corn, corn-derived products, or a combination thereof, or the fluid process stream may contain a process condensate, a rinse fluid, a cleaning fluid or any combination thereof. The processing facility may be an ethanol processing plant, a protein processing plant, a corn oil processing plant, an ethanol and corn oil processing plant, an ethanol and protein processing plant, or an ethanol, corn oil and protein processing plant. Pulse dosing may include administering the cleaning formulation into the fluid process stream for a period of x seconds every y minutes, with no administration of the cleaning formulation between the periods of x seconds.