Starch-Based Ethanol Fermentation With Protease Pretreatment
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Solution Overview
Problem
Existing fermentation processes for producing ethanol from starch-containing materials are limited by slow fermentation rates, low yields, and high residual glucose concentrations, with the need for further improvements in efficiency and productivity.
Innovation Solution
A process involving liquefaction with alpha-amylase, followed by protease treatment to degrade proteins, and simultaneous or sequential saccharification and fermentation, optimized for temperature and pH conditions, to enhance fermentation performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If standard fermentation processes are used, then the process is simple and easy to operate, but the fermentation rate is slow and productivity is low
Solution Approach 1:
The patent applies preliminary action by adding protease treatment before fermentation to degrade proteins and release amino nitrogen in advance. This preparation step enhances subsequent fermentation performance by providing necessary nutrients to yeast, thereby increasing fermentation rate and productivity without significantly complicating the overall process flow.
Solution Approach 2:
The patent utilizes parameter changes by optimizing temperature and pH conditions at different process stages. Specifically, the process employs temperature cycling (e.g., 65-70°C during liquefaction, then reduced to 30-35°C for fermentation) and pH adjustment to create optimal conditions for each enzymatic and microbial step, thereby maximizing fermentation efficiency and ethanol yield.
2Productivity
If standard fermentation processes are used, then the process is simple, but ethanol yield is low and residual glucose concentration is high
Solution Approach 1:
The patent applies preliminary action by implementing protease treatment before fermentation to degrade proteins and release amino nitrogen in advance. This preparation step enhances subsequent fermentation performance by providing necessary nutrients to yeast, thereby increasing fermentation rate and productivity without significantly complicating the overall process flow.
Solution Approach 2:
The patent utilizes parameter changes by optimizing temperature and pH conditions at different process stages. Specifically, the process employs temperature cycling (e.g., 65-70°C during liquefaction, then reduced to 30-35°C for fermentation) and pH adjustment to create optimal conditions for each enzymatic and microbial step, thereby maximizing fermentation efficiency and ethanol yield.
3Speed
If protease treatment is added to degrade proteins, then amino nitrogen increases and fermentation rate accelerates, but process complexity increases
Solution Approach 1:
The patent applies merging by combining protease treatment with the existing liquefaction step. The protease is added to the mash during or after liquefaction, allowing protein degradation to occur concurrently with or immediately following starch breakdown. This integration eliminates the need for a completely separate protein degradation step, thereby accelerating fermentation rate while minimizing additional process complexity.
Solution Approach 2:
The patent utilizes parameter changes by optimizing temperature and pH conditions at different process stages. Specifically, the process employs temperature cycling (e.g., 65-70°C during liquefaction, then reduced to 30-35°C for fermentation) and pH adjustment to create optimal conditions for each enzymatic and microbial step, thereby maximizing fermentation efficiency and ethanol yield.
4Productivity
If fermentation time is extended to improve yield, then ethanol yield increases, but time consumption increases and productivity decreases
Solution Approach 1:
The patent applies preliminary action by implementing protease treatment before fermentation to degrade proteins and release amino nitrogen in advance. This preparation step enhances subsequent fermentation performance by providing necessary nutrients to yeast, thereby increasing fermentation rate and productivity without significantly complicating the overall process flow.
Solution Approach 2:
The patent utilizes parameter changes by optimizing temperature and pH conditions at different process stages. Specifically, the process employs temperature cycling (e.g., 65-70°C during liquefaction, then reduced to 30-35°C for fermentation) and pH adjustment to create optimal conditions for each enzymatic and microbial step, thereby maximizing fermentation efficiency and ethanol yield.
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 process results in significantly faster fermentation rates, higher ethanol yields, and lower glycerol/ethanol ratios, with improved productivity and reduced residual glucose concentration, demonstrating a 14% increase in ethanol yield within half the time compared to standard methods.
Implementation Method 1
liquefying starch-containing material with an alpha-amylase
Implementation Method 2
Liquefaction involves gelatinization of starch simultaneously with or followed by addition of alpha-amylase
Implementation Method 3
treating with a protease; degradation of the proteins contained in the starch-containing material
Implementation Method 4
saccharifying in the presence of a carbohydrate-source generating enzyme; dextrins are converted to low molecular DP1-3 sugars
Implementation Method 5
fermenting in the presence of a fermenting organism; converted by a yeast into ethanol
Data Source
AI summary
The present invention relates to a process for producing a fermentation product from starch-containing material, comprising liquefying said starch-containing material with an alpha-amylase; treating with a protease; saccharifying in the presence of a carbohydrate-source generating enzyme; fermenting in the presence of a fermenting organism.