Yeast Stage Tank for Ethanol Fermentation

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Solution Overview

Problem

Continuous fermentation systems in ethanol production face challenges such as lower alcohol yield, high sugar content, longer startup times, infection issues, and unstable operations, leading to increased costs and inefficiencies, prompting the need for improved yeast management in batch fermentation processes.

Innovation Solution

The implementation of a dual-function Yeast Stage Tank (YST) that optimizes yeast cell counts by serving as both a propagation and fermentation tank, ensuring maximum yeast cell counts are maintained during the filling period through continuous propagation and recycling, thereby stabilizing operations and reducing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If continuous fermentation system is used, then operation simplicity is improved, but alcohol yield decreases and infection risk increases

Engineering Contradiction:

Improveoperation simplicityVSAvoidalcohol yield

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The fermentation process is segmented into distinct batch cycles rather than continuous operation. Each batch is independently controlled and completed within a defined time frame, allowing for better management of yeast cell counts and infection prevention while maintaining operational simplicity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Yeast propagation is performed in advance in a separate propagation tank before the main fermentation batch. This preliminary action ensures optimal yeast cell counts are achieved before fermentation begins, improving alcohol yield while keeping the main fermentation process simple and batch-based.

Inventive Principle:

Principle #10Preliminary action

2Ease of operation

If continuous fermentation system is used, then operation simplicity is improved, but startup time increases

Engineering Contradiction:

Improveoperation simplicityVSAvoidstartup time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

Yeast propagation is conducted in advance in a dedicated propagation tank before the main fermentation batch is initiated. This preliminary preparation of yeast ensures that optimal yeast cell counts are achieved quickly, reducing the startup time of the fermentation process while maintaining simple batch operation.

Inventive Principle:

Principle #10Preliminary action

3Device complexity

If traditional yeast propagation method is used, then device complexity is reduced, but yeast cell count consistency decreases

Engineering Contradiction:

Improvesystem complexityVSAvoidyeast cell count consistency

Core Design Contradiction:

Device complexityVSStability of the object's composition

Solution Approach 1:

The yeast management system is segmented into two distinct functional units: a propagation tank for yeast multiplication and a fermentation tank for alcohol production. This segmentation allows independent optimization of yeast cell count in the propagation tank, ensuring consistency while keeping the overall system relatively simple.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The propagation tank continuously maintains optimal yeast cell counts through controlled propagation conditions, ensuring consistent yeast quality is supplied to the fermentation tank. This continuous useful action of yeast propagation ensures cell count consistency without requiring complex control systems in the fermentation tank itself.

Inventive Principle:

Principle #20Continuity of useful action

4Device complexity

If yeast propagation is not optimized, then device complexity is reduced, but fermentation cycle time increases

Engineering Contradiction:

Improvesystem complexityVSAvoidfermentation cycle time

Core Design Contradiction:

Device complexityVSDuration of action of moving object

Solution Approach 1:

Yeast propagation is performed as a preliminary step before fermentation in a dedicated propagation tank. This advance preparation ensures optimal yeast cell counts are achieved before fermentation begins, shortening the overall fermentation cycle time without requiring complex integrated systems.

Inventive Principle:

Principle #10Preliminary 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

This approach enhances yeast cell count consistency, decreases yeast and enzyme costs, shortens fermentation cycles, and minimizes the risk of infections, resulting in increased alcohol production efficiency and operational stability.

Implementation Method 1

The yeast metabolizes carbohydrates (primarily monosaccharides and disaccharides) to produce ethanol (liquid) and the byproduct carbon dioxide (gas).

Methodology Applied

Scientific EffectFermentation: Fermentation

Data Source

PatentUS11680278B2Yeast stage tank incorporated fermentation system and method

Publication Date: 2023.06.20 LEE TECH LLC

AI summary

Methods of and system for growing and maintaining an optimized/ideal active yeast solution in the yeast tank and fermenter tank during the fermentation filling cycle are provided. A new yeast stage tank is used between the yeast tank and the fermenter tank allowing yeast to rapidly produce a huge amount of active young yeast cells for a fermenter during the filling period. A measurable and useful controlling factor, % DT/% Yeast by weight ratio (or “food” to yeast ratio), is used (e.g., % DT=glucose), which offers information on the health status of the yeast. The controlling factor is used to control the status of the yeast throughout the entire process.