Clarifying Thin Stillage via Insoluble Solid Extraction
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Solution Overview
Problem
Conventional biofuel production processes, such as dry grind alcohol production, face inefficiencies due to the presence of insoluble solids in the thin stillage stream, leading to fouling, reduced evaporation efficiency, and lower oil yields, as well as increased costs and capital investment.
Innovation Solution
A system and process that separates insoluble solids from the thin stillage stream using screening devices like paddle screens or centrifuges, followed by additional clarification steps to enhance the separation efficiency and reduce the viscosity of the syrup stream, thereby improving evaporation capacity and oil recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional dry grind process is used to produce alcohol, then the process is simpler and capital cost is lower, but the presence of insoluble solids in thin stillage causes fouling, reduced evaporation efficiency, and lower oil yields
Solution Approach 1:
The patent extracts and removes insoluble solids from the thin stillage stream using screening devices (paddle screens, centrifuges) before the evaporation step. This separation removes the harmful insoluble particles that cause fouling and efficiency reduction, allowing the evaporation system to operate at optimal capacity while maintaining the simpler dry grind process structure.
Solution Approach 2:
The patent applies preliminary clarification action by removing insoluble solids from thin stillage before it enters the evaporation system. This pre-treatment prevents fouling and efficiency loss during evaporation, enabling the system to achieve 20% higher evaporation capacity without changing the fundamental dry grind process design.
2Device complexity
If insoluble solids are present in thin stillage stream, then the process structure remains simple, but fouling occurs and operational costs increase
Solution Approach 1:
The patent extracts insoluble solids from the thin stillage stream using screening devices positioned before evaporation. This removal prevents fouling of heat transfer surfaces and equipment, eliminating the need for frequent cleaning shutdowns and reducing energy waste associated with inefficient heat transfer and operational interruptions.
3Device complexity
If insoluble solids are present in thin stillage, then no additional equipment is needed, but evaporation capacity is reduced by 20%
Solution Approach 1:
The patent introduces screening devices (paddle screens or centrifuges) that extract insoluble solids from the thin stillage stream. This extraction prevents the solids from interfering with evaporation heat transfer, enabling the evaporation system to operate at 20% higher capacity by eliminating the fouling effect without requiring complete system redesign.
4Productivity
If insoluble solids are removed from thin stillage, then evaporation capacity increases by 20%, but additional separation equipment is required
Solution Approach 1:
The patent uses screening devices (paddle screens or centrifuges) to extract and remove insoluble solids from the thin stillage stream. This extraction step, positioned before evaporation, clears the liquid stream of fouling particles, allowing the evaporation system to achieve 20% higher capacity by operating without the detrimental effects of solid particle interference.
5Ease of manufacture
If insoluble solids are present in thin stillage, then oil yields are reduced, but the process remains unchanged
Solution Approach 1:
The patent extracts insoluble solids from the thin stillage stream using screening devices before the stream enters downstream processing. This removal prevents the solids from interfering with oil separation and recovery processes, allowing oil yields to increase by eliminating the fouling and emulsion formation that insoluble particles cause in conventional unchanged processes.
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
The removal of insoluble solids results in a 20% increase in evaporation capacity, improved oil yields, reduced fouling, and lower operational costs, with the potential for increased syrup dry solids and natural gas savings.
Implementation Method 1
separates insoluble solids from the thin stillage stream using screening devices like paddle screens or centrifuges
Implementation Method 2
improving evaporation capacity and oil recovery
Data Source
AI summary
The present invention is directed to improved systems and processes for clarifying a thin stillage stream in a biofuel production process, such as a dry grind alcohol production process, that removes desirable amounts of insoluble solids from at least a portion of the thin stillage stream, thereby realizing any number of process enhancements.