Animal Feed Production from Grain Stillage via Particle Size Separation
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Solution Overview
Problem
The dry grinding ethanol process has limitations in efficiently separating and recovering oil and protein from whole stillage, resulting in low oil yields and poor quality oil due to the formation of emulsions with protein, which complicates the separation process and reduces the value of distiller's dried grains with soluble (DDGS) as an animal feed.
Innovation Solution
Implementing a backend milling process that includes selective particle separating, dewater milling, fiber washing, and oil and protein separating steps to break down germ and grit particles, release oil and protein, and separate them effectively, along with a front-end oil recovery system to enhance oil quality and yield, and using a multi-screens system for particle size separation to produce four types of animal feeds with specific nutritional profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional dry grinding ethanol process is used, then the process is simple and easy to operate, but oil yield is low (0.4 lbs/Bu) and oil quality is poor due to emulsion formation with protein
Solution Approach 1:
The patent divides the stillage processing into multiple sequential stages: initial separation to remove large solids, followed by controlled grinding to break cell walls and release oil, then fractionation to separate different particle size fractions. Each stage targets specific components, progressively isolating oil from protein and other matrix materials to prevent emulsion formation while maximizing recovery.
Solution Approach 2:
The patent applies different processing conditions to different fractions of the stillage material. Coarse fractions receive different treatment than fine fractions, with specific grinding intensity, separation conditions, and processing parameters optimized for each fraction's characteristics to maximize oil recovery while maintaining product quality.
2Quantity of substance
If backend milling process is implemented to separate oil and protein, then oil yield increases to 1.4 lbs/Bu, but the process complexity increases with multiple separation steps
Solution Approach 1:
The patent performs preliminary separation of large solids and cell debris before the main oil extraction process. This preliminary action removes materials that would interfere with subsequent oil-protein separation, making the main extraction steps more efficient and reducing the complexity burden of the overall process.
Solution Approach 2:
The patent systematically extracts different components at different stages: first removing large solids, then extracting oil from ground material, then separating protein from the remaining fraction. Each extraction step isolates a specific component, progressively purifying the oil fraction while maximizing yield.
3Adaptability or versatility
If multi-screens system is used for particle size separation, then four types of animal feeds with tailored nutritional profiles are produced, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent uses a multi-screen separation system that can produce multiple different feed products from a single feedstock stream by adjusting screen parameters and collection points. The same system infrastructure serves multiple product formulations, making the complex device versatile rather than specialized for a single function.
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 increases oil yield from 0.4 to 1.4 lbs/Bu, improves oil quality, and produces high-value animal feeds with tailored nutritional content, enhancing the economic value of DDGS and enabling its use for various animal species.
Implementation Method 1
using a multi-screens system for particle size separation to produce four types of animal feeds
Implementation Method 2
dewater milling to break down germ and grit particles, release oil and protein
Implementation Method 3
oil and protein separating steps to break down germ and grit particles, release oil and protein, and separate them effectively
Data Source
AI summary
A method of and system for making at least four types of animal feed products for various types of animals to maximize and use all of the components found in the whole stillage in an alcohol producing plant. The method includes liquefying, fermenting, distilling, performing a selective particle size separating into three streams, wherein the three streams contain a first stream of a large particle stream that is used to form a first animal feed suitable for ruminant animals, a second stream of a coarse protein stream that is used to form a second animal feed suitable for chicken and pigs, and a third stream of a fine particle stream that is used to form a third animal feed suitable for fish and pet. The third stream is further concentrated and enriched to have a syrup with 35%-80% of dry solid.