Whole Stillage Separation Using Flexible Screening and 3-Phase Decanting

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Solution Overview

Problem

Existing ethanol production processes from corn fermentation mash are inefficient in separating and recovering valuable corn products due to the wide range of particle sizes in hammer milled corn, leading to high costs and low recovery rates of products like corn oil, protein meal, and fiber.

Innovation Solution

A process involving high shear milling of corn to achieve uniform particle sizes, followed by slurry processing, filtration, and centrifugation to separate ethanol, fiber-rich products, and stillage proteins, with optional recycling of solubles streams to enhance product recovery.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If hammer milling is used to grind corn, then corn processing is simple and fast, but particle size varies widely making product separation difficult

Engineering Contradiction:

Improvecorn processing speedVSAvoidparticle size uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The grinding process is divided into multiple stages using different mill types (hammer mill for initial size reduction, then roller mill or disk mill for uniform particle size achievement). This segmentation allows each mill to perform its optimal function, resolving the contradiction between processing speed and particle size uniformity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces the single mechanical hammer milling system with a combination of mechanical grinding systems (hammer mill followed by roller mill or disk mill). This substitution of mechanical systems enables both high productivity and uniform particle size control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If traditional separation methods are used for whole stillage, then process complexity is low, but product recovery rates are low

Engineering Contradiction:

Improveseparation process complexityVSAvoidproduct recovery rate

Core Design Contradiction:

Device complexityVSLoss of substance

Solution Approach 1:

The separation process is segmented into multiple stages: initial filtration to remove large particles, followed by centrifugation to separate oil and protein components. This segmentation enables recovery of multiple valuable products (fiber, oil, protein meal) that would otherwise be lost, resolving the contradiction between process complexity and product recovery rate.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes the physical parameters of the stillage through controlled dehydration and concentration processes. By adjusting moisture content and density parameters, the separation efficiency is improved, enabling better product recovery without excessive complexity.

Inventive Principle:

Principle #35Parameter changes

3Loss of substance

If corn products are separated from stillage, then product recovery increases, but separation time and cost increase

Engineering Contradiction:

Improveproduct recovery rateVSAvoidseparation time

Core Design Contradiction:

Loss of substanceVSLoss of time

Solution Approach 1:

The patent performs preliminary filtration of whole stillage before centrifugation to remove large particles and reduce the load on subsequent separation equipment. This preliminary action reduces the overall separation time while maintaining high product recovery rates.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The separation process is designed as a continuous flow system where stillage moves continuously through filtration, centrifugation, and dehydration stages. This continuity eliminates idle time between operations, reducing total separation time while maintaining high recovery rates.

Inventive Principle:

Principle #20Continuity of useful action

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

Enhances the recovery of corn oil, protein meal, and fiber products, improving the overall efficiency and yield of ethanol production by optimizing the separation process.

Implementation Method 1

The whole stillage can be separated with a fiber filter to produce a fiber rich product and a filtrate

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Implementation Method 2

The fiber rich product can be hydrolyzed to produce a saccharification mash

Methodology Applied

Scientific EffectHydrolysis: Hydrolysis

Implementation Method 3

Ethanol is removed from the corn fermentation mash by distillation to produce a whole stillage

Methodology Applied

Scientific EffectDistillation: Distillation

Data Source

PatentUS12480142B2Processes for separating whole stillage

Publication Date: 2025.11.25 POET GRAIN OCTANE LLC

AI summary

Improved processes and systems for recovering products from a corn fermentation mash. In some examples, a process recovers an oil product, a protein meal product, and a fiber product from a slurry. A process includes the following steps: introducing the slurry into a device with a flexible screen and mechanical agitation to produce a filtrate and a fibrous solid stream; and introducing the filtrate into a three-phase centrifuge to produce an oil stream, a high protein solids stream, and a water with solubles stream. The flexible screen includes a washing nozzle. The slurry is whole stillage from an ethanol process. The three-phase centrifuge is a three-phase decanter. The filtrate is heated before introducing into the three-phase centrifuge. The filtrate is optionally evaporated before introducing into the three-phase centrifuge.