Staged Solid-Liquid Separation for High-Protein Animal Feed
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for separating solids from liquids in biofuel production processes are inefficient, costly, and energy-intensive, leading to high greenhouse gas emissions and low-quality animal feed products.
Innovation Solution
Implementing the Feed Optimization Technology (FOT) process, which uses multiple separation devices and passes to separate solids and liquids, reducing moisture content and increasing protein concentration in animal feed products to above 45%, thereby enhancing efficiency and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing separation methods are used in biofuel production, then the process can be completed, but the separation efficiency is low and energy consumption is high
Solution Approach 1:
The separation process is divided into multiple stages using different separation devices (centrifuges, filters, evaporators) in sequence. Each stage performs a specific separation function, progressively improving separation efficiency while managing energy consumption through staged processing rather than a single high-energy operation.
Solution Approach 2:
The patent changes physical parameters such as temperature, pressure, and centrifugal force at different stages of the separation process. By adjusting these parameters across multiple processing stages, the system achieves high separation efficiency while optimizing energy consumption through parameter optimization rather than constant high-energy operation.
2Productivity
If existing separation methods are used, then processing can occur, but greenhouse gas emissions are high
Solution Approach 1:
The patent captures and utilizes waste heat from the evaporation and drying processes, converting what would be waste heat into a useful resource for preheating feeds or generating power. This reduces the overall energy intensity of the process and consequently reduces greenhouse gas emissions associated with fuel combustion.
Solution Approach 2:
The patent utilizes phase transitions (evaporation, condensation, freezing) in the separation process, which are highly efficient separation mechanisms that consume less energy than conventional thermal processing. The phase change processes enable effective separation while maintaining lower energy consumption and reduced greenhouse gas emissions.
3Quantity of substance
If conventional processing is used, then animal feed can be produced, but the protein content is insufficient
Solution Approach 1:
The patent extracts and removes fiber and other non-protein components from the grain processing stream through specialized separation devices. By selectively removing these unwanted components, the concentration of protein in the remaining feed material increases, achieving high protein content (greater than 45%) while maintaining processing efficiency.
Solution Approach 2:
The patent applies different processing intensities and separation methods to different components of the feed stream. By applying localized quality control and selective separation to specific fractions, the system optimizes protein concentration in the final product while maintaining overall processing efficiency through targeted rather than uniform processing.
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 FOT process improves the separation of solids and liquids, resulting in high-protein animal feed products, reduces energy and operating costs, and lowers greenhouse gas emissions, while meeting regulatory carbon intensity standards.
Implementation Method 1
separating components in the process stream through a first separation device and through a second separation device
Implementation Method 2
separating components in the process stream through a first separation device and through a second separation device
Implementation Method 3
The process stream may then be sent to a series of evaporators
Implementation Method 4
The wet cake may then be sent to a dryer to remove moisture from the wet cake
Data Source
AI summary
This disclosure describes methods to separate solids from liquids in a production facility. A process separates components in a defiber process stream by using two or more mechanical devices to separate the solids from the liquids based on density differences. The process produces animal feed products having a protein content ranging from approximately 45% to approximately 64%.