Heating Process Liquid in Slurry Stream via Steam Eductor

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Solution Overview

Problem

The alcohol production process requires significant energy and water inputs, and there is a need to conserve these resources while maintaining efficient heating of process liquids in the slurry stream.

Innovation Solution

Redirecting a portion of direct inject steam from the slurry tank to first effect evaporators, where it is converted into additional steam, which is then used to heat process liquids, including cook water and backset, at an eductor before mixing with milled corn to form a slurry stream.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If direct inject steam is used to heat slurry tank, then heating efficiency is improved, but water and energy consumption increase

Engineering Contradiction:

Improveslurry tank heating efficiencyVSAvoidwater and energy consumption

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The patent converts waste heat from stillage evaporators (which would otherwise be lost) into a useful resource by directing it through an eductor to heat process liquids and slurry streams. This transforms a harmful energy loss into a beneficial heating mechanism, reducing the need for additional steam injection and thereby lowering water and energy consumption while maintaining heating efficiency.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent merges the waste heat stream from stillage evaporators with the process liquid and slurry streams using an eductor. This combination allows the waste heat to directly warm the process liquids and slurry, eliminating the need for separate steam injection systems and reducing overall water and energy requirements while maintaining effective heating.

Inventive Principle:

Principle #5Merging (Combining)

2Loss of energy

If more steam is directed to first effect evaporators, then waste heat utilization is improved, but steam input requirements increase

Engineering Contradiction:

Improvewaste heat utilizationVSAvoidsteam input requirements

Core Design Contradiction:

Loss of energyVSUse of energy by moving object

Solution Approach 1:

The system uses waste heat from stillage evaporators to heat process liquids and slurry streams, making the system self-sufficient in terms of heating requirements. The waste heat that would otherwise be lost is reused within the process, reducing the need for external steam input while improving waste heat utilization efficiency.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent recovers waste heat from stillage evaporators that would otherwise be discarded or lost. By capturing and redirecting this waste heat through an eductor to heat process liquids and slurry streams, the system transforms a lost resource into a valuable heating medium, improving overall energy efficiency without requiring additional steam input.

Inventive Principle:

Principle #34Discarding and recovering

3Loss of energy

If process liquid is heated at eductor, then energy efficiency is improved, but device complexity increases

Engineering Contradiction:

Improveenergy efficiencyVSAvoidheating system complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The eductor serves as an intermediary device that facilitates heat transfer from waste steam to process liquids and slurry streams. This intermediary component enables efficient heat exchange without requiring complex heating systems, achieving energy efficiency through a relatively simple mechanical device that utilizes pressure differential and fluid dynamics.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 approach reduces the amount of water and energy required in the alcohol production process by utilizing waste heat from stillage evaporators to efficiently heat process liquids, leading to cost savings and improved energy efficiency.

Implementation Method 1

a process liquid is heated, which includes a mixture of a second portion of the separated thin stillage and a liquid portion, with a portion of the steam at an eductor whereat the steam mixes with and heats the process liquid

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

the steam cools and condenses to liquid thereby providing a heated process liquid

Methodology Applied

Scientific EffectCondensation: Condensation

Implementation Method 3

evaporating liquid from a first portion of the separated thin stillage via one or more evaporators to produce steam

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS20250035381A1Method and system for heating process liquid used in a slurry stream in an alcohol production process

Publication Date: 2025.01.30 FLUID QUIP TECHNOLOGIES LLC

AI summary

A method and system for heating process liquid used in a slurry stream in an alcohol production process. A portion of direct inject steam typically intended for a slurry tank, such as in a dry milling process, can be (re)directed to first effect evaporators to produce a greater steam input than is typical. The additional pounds of steam produces a corresponding additional volume of first effect evap steam that can be captured and directed to an eductor on a front end of the dry milling process. That first effect steam mixes with and further heats incoming process liquid, which now further includes condensed first effect steam. This heated mixture is combined with milled corn to provide a heated slurry stream, which is sent on to a slurry tank and further subjected to direct inject steam, in a smaller weight by volume than is typical, to provide a desired slurry temperature.