Single-Cell Protein Separation Using Density-Shifted Stillage
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Solution Overview
Problem
Existing methods for separating solids from liquids in biofuel production facilities are inefficient, costly, and energy-intensive, leading to high greenhouse gas emissions and capital costs, and do not effectively produce valuable feed products.
Innovation Solution
A mechanical device is used to separate components in the fractionated stillage process stream by adding non-condensable media to reduce liquid density, followed by mechanical separation, and further processing to produce valuable animal feed products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If gravity separation is used to separate solids from liquids, then equipment complexity is reduced, but separation efficiency is poor and processing time is long
Solution Approach 1:
The patent replaces gravity-based mechanical separation with a biological system (microorganisms) that naturally consume organic compounds and convert them to biomass. This substitution resolves the contradiction by achieving high separation efficiency through biological action rather than complex mechanical means, while maintaining relatively simple equipment requirements.
Solution Approach 2:
The patent introduces microorganisms as an intermediary between the liquid mixture and separation process. These microorganisms selectively consume organic compounds and convert them to cellular biomass, which can then be easily separated from the liquid phase. This intermediary approach achieves efficient separation without requiring complex mechanical separation equipment.
2Ease of manufacture
If conventional separation methods are used, then capital costs are reduced, but energy consumption is high and operating costs increase
Solution Approach 1:
The patent changes the fundamental parameter of separation from physical/chemical methods to biological transformation. By allowing microorganisms to naturally consume organic compounds and grow as biomass, the process eliminates energy-intensive heating, evaporation, and mechanical separation steps, thereby reducing both capital costs and ongoing energy consumption while maintaining low operating costs.
3Device complexity
If traditional processing methods are used, then process simplicity is maintained, but greenhouse gas emissions increase
Solution Approach 1:
The patent converts harmful organic compounds that would otherwise be wasted or require energy-intensive treatment into beneficial microbial biomass (single-cell protein). The microorganisms consume these organic compounds through metabolism, transforming potential pollutants into high-value feed products, thereby reducing greenhouse gas emissions while maintaining process simplicity.
4Speed
If mechanical separation devices are used, then separation speed is improved, but equipment complexity and maintenance requirements increase
Solution Approach 1:
The patent employs a self-service approach where microorganisms automatically perform the separation function by consuming organic compounds and converting them to biomass. This eliminates the need for complex mechanical separation devices that require maintenance, while achieving rapid separation through the natural metabolic activity of the microorganisms.
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 reduces energy and operating costs, decreases greenhouse gas emissions, and increases the efficiency of biofuel production by enhancing solid-liquid separation, producing valuable animal feed products such as Distiller's Dried Grains with Solubles (DDGS) and Single Cell Protein (SCP).
Implementation Method 1
separating the components in the fractionated stillage process stream by adding non-condensable media to the fractionated stillage process stream to reduce density of liquids relative to the density differential to suspended solids and by 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
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.