Sugar Slip Stream Extraction in Ethanol Fermentation
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Solution Overview
Problem
Conventional ethanol fermentation processes face challenges in producing a sugar stream simultaneously with ethanol while maintaining the same ethanol titer, as fractionation equipment is expensive and affects the cost and efficiency of sugar production.
Innovation Solution
The method involves producing a slip stream of sugar by removing a first portion of the fermentable stream prior to or after saccharification in an ethanol fermentation facility, processing it to remove solids and recycle enzymes, and reintegrating these components back into the facility to maintain ethanol production at a commercially acceptable level.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fractionation equipment is used to produce a pure sugar stream while also making other components of corn available to sell, then the sugar stream purity is improved, but the cost of producing the sugar stream increases
Solution Approach 1:
The patent extracts only the necessary components (sugar and solids) from the fermentable stream for separate processing, rather than using comprehensive fractionation equipment to separate all components. The sugar stream is removed and processed independently while solids are returned to the ethanol facility, achieving sugar purity without the full cost of complete fractionation.
Solution Approach 2:
The patent makes the fermentable stream serve multiple functions: a portion is removed for sugar production while the remaining portion and returned solids continue to support ethanol production. This multi-functional approach allows simultaneous sugar and ethanol production without requiring dedicated separate facilities for each product.
2Productivity
If a slip stream of fermentable stream is removed prior to fermentation to produce sugar, then sugar production is enabled, but the ethanol titer may be affected
Solution Approach 1:
The patent removes solids from the sugar stream through filtration and recycles them back to the ethanol facility's mash or saccharified liquor. This recovery and reuse of solids ensures that nutrients and fermentable materials are returned to the ethanol production process, maintaining ethanol titer while enabling sugar production.
Solution Approach 2:
The system implements feedback by returning filtered solids from the sugar stream back to the ethanol fermentation process. This closed-loop approach ensures that the ethanol facility receives补充 nutrients and maintains optimal conditions for achieving desired ethanol titers while continuously producing sugar.
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 allows for the simultaneous production of a sugar stream for non-ethanol chemicals and ethanol with minimal impact on ethanol titer, reducing costs by recycling enzymes and utilizing existing facility capabilities.
Implementation Method 1
In the saccharification step, enzymes are added to the mash to convert the corn starch into simple sugars
Implementation Method 2
The fermentation of the sugars by an ethanologen such as yeast produces a beer
Data Source
AI summary
Methods and system for producing a slip stream of sugar, for example for use in the production of one or more chemicals, in ethanol fermentation facilities. In some embodiments, the methods and systems have little to no impact on the level of production of ethanol, despite also producing a slip stream of sugar. The methods and systems can be implemented in dry mill ethanol, wet mill ethanol, and lignocellulosic ethanol fermentation facilities and processes.