Thin Stillage Fermentation for Algae Oil Recovery
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Solution Overview
Problem
Conventional ethanol production methods leave important oils, biomass, and other byproducts unprocessed, leading to inefficiencies in the production process.
Innovation Solution
A novel process that involves processing thin stillage to produce algae oil and protein-rich biomass by removing suspended solids and corn oil, followed by batch fermentation with algae seeds, and subsequent heating to liberate oil, which is then centrifuged and evaporated to produce energy-rich byproducts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional ethanol production methods are used, then ethanol is produced through distillation and evaporation, but important oils, biomass and other byproducts remain unprocessed and are wasted
Solution Approach 1:
The patent recovers oils and biomass from thin stillage that would otherwise be discarded. The process extracts corn oil through centrifugation and converts remaining thin stillage into algae biomass through fermentation, transforming waste streams into valuable products and eliminating substance loss
Solution Approach 2:
The patent converts the harmful waste stream of thin stillage into beneficial products. By fermenting thin stillage with algae seeds, the process transforms what was previously a disposal problem into a source of protein-rich biomass and energy-rich byproducts, improving overall production efficiency
2Quantity of substance
If thin stillage is processed through the new process, then valuable algae oil and biomass are produced, but additional processing steps and equipment are required
Solution Approach 1:
The patent segments the thin stillage processing into distinct stages: first removing suspended solids and corn oil through centrifugation, then fermenting the clarified liquid with algae seeds, and finally harvesting the algae biomass. This segmentation allows each step to be optimized independently while managing overall process complexity
Solution Approach 2:
The patent employs multi-functional equipment that performs multiple operations. For example, the centrifuge both removes suspended solids and extracts corn oil, while the evaporator concentrates both the thin stillage and the algae biomass, reducing the number of separate devices needed
3Reliability
If mid-stillage is subjected to batch fermentation with algae seeds, then oil-rich algae biomass is produced, but the fermentation process requires precise control of parameters
Solution Approach 1:
The patent implements feedback control in the fermentation process by monitoring parameters such as pH, temperature, and dissolved oxygen levels, and automatically adjusting them to maintain optimal conditions for algae growth and oil production, ensuring consistent results
Solution Approach 2:
The patent performs preliminary preparation of the thin stillage before fermentation by removing suspended solids and adjusting chemical parameters. This pre-treatment ensures that the fermentation process starts with optimized conditions, reducing the complexity of control during the actual fermentation
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 enhances the efficiency of ethanol production by converting thin stillage into valuable algae oil and biomass, reducing waste and increasing the output of animal feed co-products, as demonstrated in multiple test settings.
Implementation Method 1
the mid-stillage is subject to a batch fermentation process with algae 'seed' fed from an algae inoculation system
Implementation Method 2
the oil-rich algae/mid-stillage is then preferably heated to rupture the cells and liberate the oil
Implementation Method 3
the oil-rich algae/mid-stillage is preferably processed by a centrifuge which produces solids, a light phase oil and a 'clean' mid-stillage stream
Implementation Method 4
a 'clean' mid-stillage stream that can be evaporated to a very high level of solids
Data Source
AI summary
The present invention generally relates to a novel process in which thin stillage is processed to produce algae oil and protein rich biomass as well as other energy rich byproducts. In accordance with a preferred embodiment, thin stillage is removed from an evaporator during the evaporation process to produce mid-stillage. This mid-stillage is preferably routed to a new process where it is directed to a pre-treatment centrifuge to remove suspended solids, sludge and corn oil. Thereafter, the mid-stillage is preferably cooled and then directed to a fermentation tank where the mid-stillage is subject to a batch fermentation process with algae “seed” fed from an algae inoculation system. Once the batch is harvested, the oil-rich algae/mid-stillage is then preferably heated to rupture the cells and liberate the oil. Thereafter, the oil-rich algae/mid-stillage is preferably processed by a centrifuge which produces solids, a light phase oil and a “clean” mid-stillage stream that can be evaporated to a very high level of solids.