Raw Starch Ethanol Production via Direct Enzymatic Saccharification

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Solution Overview

Problem

Conventional methods for converting plant material to ethanol are inefficient and fail to produce high levels of alcohol and high protein distiller's dried grain effectively, while also generating high stack emissions during the drying process.

Innovation Solution

A process involving grinding plant material to produce starch, saccharifying it without cooking, and fermenting the sugars to produce ethanol, which includes varying temperature and using a specific particle size to achieve high ethanol yields and high protein distiller's dried grain, while reducing volatile organic compounds in stack emissions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional cooking and saccharification methods are used, then starch conversion to ethanol is achieved, but process efficiency is low and alcohol levels are insufficient

Engineering Contradiction:

Improveethanol production efficiencyVSAvoidenergy consumption in cooking

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The patent applies parameter changes by modifying the saccharification process to operate at lower temperatures (50-65°C) without conventional cooking, changing the physical state parameters of starch conversion. This enables direct enzymatic hydrolysis of raw starch to fermentable sugars, eliminating the energy-intensive cooking step while maintaining efficient ethanol production

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention extracts and removes the cooking step from the conventional ethanol production process. By taking out this energy-consuming operation and replacing it with direct enzymatic saccharification of raw starch, the process achieves high ethanol yields without the associated energy losses and time requirements

Inventive Principle:

Principle #2Taking out (Extraction)

2Quantity of substance

If conventional fermentation processes are used, then ethanol is produced, but alcohol levels remain below 18 vol-%

Engineering Contradiction:

Improveethanol concentrationVSAvoidfermentation efficiency

Core Design Contradiction:

Quantity of substanceVSProductivity

Solution Approach 1:

The patent applies preliminary action by performing complete saccharification of starch to fermentable sugars before initiating fermentation. This preliminary conversion ensures that maximum substrate is available for yeast metabolism, enabling the system to achieve high ethanol concentrations (≥18 vol-%) without compromising fermentation efficiency

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention maintains continuity of useful action through optimized fermentation conditions (pH 4.0-5.0, temperatures 20-35°C) that sustain high yeast activity throughout the fermentation process. This continuous efficient conversion of sugars to ethanol maximizes alcohol yield while maintaining productive fermentation rates

Inventive Principle:

Principle #20Continuity of useful action

3Quantity of substance

If high protein distiller's dried grain is produced, then protein content increases to ≥30%, but conventional methods cannot achieve high zein levels

Engineering Contradiction:

Improveprotein contentVSAvoidmanufacturing complexity

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The patent applies parameter changes by controlling fermentation pH (4.0-5.0) and temperature (20-35°C) to optimize protein preservation and concentration in the distiller's dried grain. These parameter optimizations naturally increase zein content to ≥15% without adding complex manufacturing steps, achieving high protein content (≥30%) through process optimization alone

Inventive Principle:

Principle #35Parameter changes

4Loss of energy

If conventional drying processes are used, then distillation products are dried, but stack emissions of volatile organic compounds are high

Engineering Contradiction:

Improvedrying efficiencyVSAvoidstack emissions

Core Design Contradiction:

Loss of energyVSObject-generated harmful factors

Solution Approach 1:

The patent applies parameter changes by operating the drying process at lower temperatures and optimizing moisture content parameters to minimize thermal degradation and volatile organic compound emissions. This enables efficient drying of high-protein distiller's dried grain while significantly reducing harmful stack emissions to the environment

Inventive Principle:

Principle #35Parameter changes

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 achieves high ethanol production with high protein distiller's dried grain and significantly lowers stack emissions by optimizing fermentation conditions and enzyme usage, improving the efficiency and environmental impact of ethanol production.

Implementation Method 1

saccharifying the starch, without cooking

Methodology Applied

Scientific EffectEnzymatic hydrolysis: Hydrolysis

Implementation Method 2

employing an enzyme preparation that does not require cooking

Methodology Applied

Scientific EffectEnzyme catalysis: Enzyme

Implementation Method 3

fermenting the uncooked sugars to yield a composition including ethanol

Methodology Applied

Scientific EffectFermentation: Fermentation

Data Source

PatentUS7842484B2Method for producing ethanol using raw starch

Publication Date: 2010.11.30 POET RESEARCH INC

AI summary

Disclosed are methods for producing high levels of alcohol during fermentation of plant material, and to the high alcohol beer produced.