Whole Stillage Separation via Multi-Stage Process
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Solution Overview
Problem
Current ethanol manufacturing processes inefficiently separate whole stillage into valuable bio-material streams, limiting the recovery of oil, protein, and fibers, which are essential for biofuel and animal feed applications, and result in high energy consumption and carbon intensity.
Innovation Solution
A multi-stage continuous process that separates whole stillage into streams rich in fibers, oil, protein, and clean water by using oval plate separators, dissolved air flotation devices, and phase separators, with the aid of anionic and cationic acrylamide copolymers and demulsifying compositions to enhance separation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional separation methods are used for whole stillage, then the process is simple, but the recovery of valuable bio-materials (oil, protein, fibers) is limited
Solution Approach 1:
The separation process is divided into multiple stages: first separating fibers from liquid fraction, then separating oil from the remaining liquid, and finally concentrating protein. This multi-stage segmentation allows each separation step to focus on specific components, improving overall recovery efficiency while managing complexity through systematic breakdown
Solution Approach 2:
Chemical agents are introduced as intermediaries to enhance separation efficiency. These agents facilitate the separation of oil and protein from the liquid fraction by modifying surface properties and promoting phase separation, enabling better recovery of valuable bio-materials
2Loss of energy
If conventional separation methods are used for whole stillage, then the process complexity is low, but energy consumption is high
Solution Approach 1:
The patent replaces energy-intensive mechanical separation methods with chemical-based separation mechanisms. By using chemical agents to facilitate phase separation and material differentiation, the process reduces reliance on high-energy mechanical operations while achieving more efficient component separation
Solution Approach 2:
The process utilizes changes in chemical parameters (such as pH, surfactant concentration, and chemical composition) to control separation behavior. By adjusting these parameters, the system achieves efficient separation with lower energy input compared to conventional mechanical methods
3Object-generated harmful factors
If conventional separation methods are used for whole stillage, then the carbon intensity is high, but the process is simpler
Solution Approach 1:
The process maximizes the recovery and utilization of valuable components (oil, protein, fibers) from whole stillage, discarding minimal waste. By recovering these bio-materials for use as animal feed, biofuel, or other applications, the process reduces carbon intensity compared to conventional disposal or low-value utilization methods
Solution Approach 2:
The patent converts what would traditionally be waste products into valuable resources. By separating and recovering oil, protein, and fibers from whole stillage, the process transforms low-value byproducts into high-value bio-materials, thereby reducing overall carbon intensity of the ethanol production system
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
Significantly increases the recovery of valuable bio-materials, reduces energy consumption, and decreases carbon intensity by producing more concentrated protein and oil streams, which can be used as biofuels and animal feeds, while allowing for water recycling.
Implementation Method 1
passing the diluted source stream through an oval plate separator, wherein actions of the oval plate separator result in separating the diluted source stream into a fiber slurry comprising predominantly fibers and into the first liquid fraction
Implementation Method 2
passing the first liquid fraction through a first dissolved air flotation device, wherein the actions of the first dissolved air flotation device result in separating the first liquid fraction into a non-aqueous fraction and an aqueous fraction
Implementation Method 3
passing the non-aqueous fraction through a phase separator to separate out the oil stream, the protein stream and the aqueous stream
Implementation Method 4
with the aid of anionic and cationic acrylamide copolymers and demulsifying compositions to enhance separation efficiency
Implementation Method 5
with the aid of anionic and cationic acrylamide copolymers and demulsifying compositions to enhance separation efficiency
Data Source
AI summary
A multi stage process for separating oil, protein, fiber and clean water from a stream containing whole stillage byproduct from ethanol production is disclosed. In a first step, fibers are separated in a two-step process that includes a plate separator and a press. In a subsequent step, the liquid stream separated from the fibers and contains oil, protein and water is treated with a composition that causes the protein to gel. The liquid stream is then processed in a phase separator that drains the oil by gravity, removes the water by an impeller under pressure and removes the solidified protein using a scroll.