The present invention generally relates to the field of biofuel and/or biochemical production, and more particularly to a system and method for isolation of protein as a co-product of alcohol (e.g., ethanol or butanol) production.
Manufacturers use two major processes to produce alcohol or other starch-based products. These two processes, dry milling (mash distillation) and wet milling are very different, as are their co-products. The primary co-products from dry milling are distillers' grains, while the primary co-products from wet milling are gluten products. Co-products from the dry milling and/or wet milling of corn have important nutritional properties that add value to feeding rations and livestock programs. However, current systems and methods of isolating co-products from dry milling and wet milling processes may require unnecessary steps and equipment, which may be time-consuming and costly. Further, current systems and methods for isolating co-products may not efficiently utilize the various co-products.
Accordingly, it would be desirable to provide a system and method for isolating protein as a co-product of alcohol (e.g., ethanol or butanol) production that addresses the above-referenced shortcomings of current solutions.
Accordingly, an embodiment of the present invention is directed to a method for protein isolation as a co-product of biofuel and/or biochemical production, including: receiving a grain product at a holding receptacle, the grain product being at least one of whole stillage, dried distillers grain and wet distillers grain; directing the grain product from the holding receptacle over a plurality of screens, thereby allowing a fiber-containing portion of the grain product to be collected on the plurality of screens and further allowing a protein-containing portion of the grain product and an oil-containing portion of the grain product to pass through the plurality of screens; directing the protein-containing portion and the oil-containing portion over a finishing screen, thereby allowing remaining fiber fractions from the protein-containing portion and the oil-containing portion to be collected on the finishing screen and further allowing the protein-containing portion and the oil-containing portion to pass through the finishing screen and centrifuging the protein-containing portion and the oil-containing portion for isolating a protein fraction and an oil, water, sugar, and minerals fraction; and recovering the isolated protein fraction.
An additional embodiment is directed to a system for protein isolation as a co-product of biofuel and/or biochemical production, including: a holding receptacle configured for receiving grain product, the grain product being at least one of whole stillage, dried distillers grain and wet distillers grain; a screen system, the screen system including a plurality of screens, the screen system being configured for receiving the grain product from the holding receptacle, each of the plurality of screens configured for retaining a fiber-containing portion of the grain product and further configured for allowing flow-through of a protein-containing portion of the grain product and an oil-containing portion of the grain product; a transfer receptacle, the transfer receptacle being configured for receiving the protein-containing portion of the grain product and the oil-containing portion of the grain product from the screen system; a finishing screen, the finishing screen being configured for receiving the protein-containing portion and the oil-retaining portion from the transfer receptacle, the finishing screen further being configured for retaining remaining fiber fractions of the protein-containing portion and the oil-containing portion, the finishing screen further being configured for allowing flow-through of the protein-containing portion and the oil-containing portion; and a centrifuge assembly, the centrifuge assembly being configured for receiving the protein-containing portion and the oil-retaining portion which pass through the finishing screen, the centrifuge assembly being further configured for centrifuging the protein-containing portion and the oil-containing portion for isolating a protein fraction and an oil, water, sugar, and minerals fraction.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not necessarily restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description, serve to explain the principles of the invention.
The numerous objects and advantages of the present invention may be better understood by those skilled in the art by reference to the accompanying figures in which:
Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings.
Referring generally to
Referring generally to
Referring generally to
In exemplary embodiments, the grain product may be pumped over the series of screens 406, with each of the plurality of screens 406 configured for retaining a fiber-containing portion of the grain product (i.e., the overflow or portion which passes over the screens 406). Further, each of the plurality of screens 406 is configured for allowing flow-through of a protein-containing portion of the grain product (i.e., the underflow) and an oil-containing portion of the grain product (i.e., the underflow). For example, approximately eighty percent (80%) of total available oil of the grain product may pass through the screens as underflow. The flow-through (ex- the oil-containing portion and the protein-containing portion) at each screen 406 may be captured by a series of transfer receptacles 408, from which, the flow-through may be directed/pumped over the next screen 406 of the screen system 404. For instance, the transfer receptacles may be a series of five thousand (5,000) gallon tanks. In current embodiments of the present invention, process water may be added to the overflow (ex- the fiber-containing portion) for hydrating the fiber overflow as may be necessary for facilitating pumping of the grain product (ex-fiber-containing portion) over the screens 406. This may be advantageous in that no fresh water may need to be added to the system 400.
In additional embodiments, the grain product may be fed to/pumped to/pumped over the screens 406 at a header pressure, for example, of at least sixty (60) pounds per square inch (psi). In another example, the grain product may be fed to/pumped to/pumped over the screens 406 at a header pressure of between one hundred (100) psi and one hundred and twenty (120) psi. Further, as the grain product is pumped through/over the series of screens, it may be maintained at a temperature of at least or approximately one hundred eighty (180) degrees Fahrenheit. In current embodiments of the present invention, one or more heat exchangers 410 may be included/connected in-line for promoting maintenance of the temperature of the grain product at the desired temperature (ex-one hundred eighty (180) degrees Fahrenheit up to about two hundred forty (240) degrees Fahrenheit). Also, as the grain product is pumped over/through the series of screens 406, a continuous flow counter current may be created meaning that the flow-through (ex-protein containing portion and oil-containing portion) moves backward (ex-to a preceding transfer receptacle 408), while the overflow (ex-fiber-containing portion) moves forward (to a next screen 406) (as shown in
In exemplary embodiments, once the grain product and/or fiber-containing portion/overflow has been pumped over all of the screens 406 of the screen system 404, the fiber-containing portion which had been collected on and pumped over the screens 406 may be directed to/pumped back to the ethanol plant. For example, once at the ethanol plant, the fiber-containing portion may be: a) placed in a decanting centrifuge and dried; b) sold as a wet product or c) further processed for conversion to sugars for biofuel and/or biochemical production. The feed value of the fiber-containing portion/overflow/feed stock/feed product may be approximately 20% protein, 15% fiber and 5% fat.
In further embodiments, the system 400 may include a finishing screen 412. The finishing screen 412 may be configured for receiving the protein-containing portion and the oil-containing portion from one of the transfer receptacles 408. Further, the finishing screen 412 may be a gravity-fed or pressure screen (e.g., a PS-Triple pressure screen available from Fluid-Quip of Springfield, Ohio). In exemplary embodiments, the finishing screen 412 is further configured for retaining remaining fiber fractions of the protein-containing portion and the oil-containing portion which were not retained/captured by the screens 406 of the screen system 404. The finishing screen 412 is also configured for allowing flow-through of the protein-containing portion of the grain product and the oil-containing portion of the grain product. For promoting its fiber fraction retention functionality, the finishing screen 412 may have a smaller slot width than the screens 406 of the screen system 404. For example, the finishing screen 412 may be a seventy-five (75) micron screen, but may also be any size included in the range of fifty (50) microns through two hundred fifty (250) microns. In additional embodiments, the finishing screen 412 may be a one hundred and eighty (180) degree screen. Further, one or more of the heat exchangers 410 may be included/connected in-line for promoting maintenance of the temperature of the protein-containing portion and/or the oil-containing portion at the desired temperature (ex-one hundred eighty (180) degrees Fahrenheit), or for increasing temperature. The protein-containing portion and the oil-containing portion, which flow-through the finishing screen, may be received in a receiving vessel or tank 414.
In additional embodiments, the system 400 includes a centrifuge assembly 416. The centrifuge assembly 416 may be a 2-stage centrifuge assembly configured for receiving the protein-containing portion and the oil-containing portion which pass through the finishing screen 412. In exemplary embodiments, the protein-containing portion and the oil-containing portion may be directed or pumped from the receiving vessel/tank 414 to the centrifuge assembly 416. The centrifuge assembly 416 may be further configured for centrifuging the protein-containing portion and the oil-containing portion for isolating a protein fraction and an oil, water, sugar, and minerals fraction. In current embodiments of the present invention, the isolated oil, water, sugar, and minerals fraction may pass from/exit the centrifuge assembly 416 as centrifuge overflow.
The oil, water, sugar and minerals fraction may be directed/pumped to the ethanol plant where it may be used as backset, used to hydrate new grain/corn before processing and/or evaporated via an evaporator of the ethanol plant. The evaporator can concentrate the fraction to about 35% solids, or higher or lower. The concentrated stream can be further processed to separate the oil from the water, sugar, and minerals to produce a pure oil fraction of 96% or greater concentration. Still further, the oil, water, sugar, and minerals fraction may be recycled/pumped back through the system 400 and used as process water, which may be used to hydrate the fiber overflow as discussed above. Surfactant and/or flocculant may be added prior to or during evaporation and before oil separation to improve oil separation efficiency and/or yield.
In further embodiments of the present invention, the isolated protein fraction may pass from/exit the centrifuge assembly 416 as centrifuge underflow. For example, the protein fraction may be approximately 75% moisture, approximately 40-55% protein, approximately 20% dry solids, approximately 5% fiber, and approximately 3% fat. Because free oil, water, sugar, and minerals have been removed from the protein fraction via centrifugation, the protein fraction may be a “purified” protein stream and may contain yeast and yeast protein. In additional embodiments, the system 400 may include a conveyer 420, such as a heavy conveyer, for transporting the protein fraction from the centrifuge assembly 416 to a dryer 422. For instance, the dryer 422 may be a rotary, ring or drum dryer. In exemplary embodiments, the dryer 422 may be configured for drying/removing moisture from the isolated protein fraction. For example, the isolated protein fraction may be dried to approximately 10% moisture and stockpiled for shipping as a high feed value product. Further processing of the protein fraction may include the separation of specific amino acids, the separation of zein protein and/or the separation of the yeast components within the protein fraction by processes known in the art. The isolated protein fraction may also be utilized as a feed source to produce corn protein concentrates or isolates.
Referring now to
With further reference now to
With continuing reference to
The remainder of the oil, water, sugar and minerals fraction can be piped and subjected to an additional evaporator(s) 260 whereat the liquid portion is further evaporated to ultimately yield a soluble solids portion. While the oil, water, sugar and minerals fraction is subjected to at least two evaporators 260, it should be understood that the number of evaporators or sets thereof can be varied, i.e., can be more or less, from that shown depending on the particular application and result desired.
The resulting soluble solids portion may be combined with the fiber-containing portion or overflow which had been collected on and pumped over the screens 406 to provide distillers wet grains with solubles (DWGS), which may be further dried by a drier, as is known in the art, to provide distillers dry grains with solubles (DDGS), both of which can be sold to dairy and beef feedlots. In another example, the soluble solids portion may be used as a natural fertilizer.
Accordingly, in this dry mill process, neither the DDGS nor DWGS receive the typical concentrated syrup from the evaporators 260. While this change from the typical dry mill process results in a lower crude protein content in the DDGS and DWGS, this decrease is insubstantial, particularly when the economic advantages of producing the high protein corn meal are realized. And, despite the lower protein content, the DDGS and DWGS may still be sold to beef and dairy feedlots as cattle feed.
Referring generally to
In additional embodiments, the method 500 may further include drying the isolated protein fraction 510. In exemplary embodiments, the dried isolated protein fraction includes between five percent (5%) and fifteen (15%) moisture. The method 500 may further include pumping the fiber-containing portion to an ethanol plant 512. The method 500 may further include providing the isolated water and minerals fraction to an ethanol plant for being at least one of: used as backset and evaporated via an evaporator of the ethanol plant 514.
In further embodiments, the method 500 may include adding process water for hydrating the fiber-containing portion collected on the plurality of screens 516. In exemplary embodiments, at least one of the grain product, the protein-containing portion and the oil-containing portion is maintained at a temperature of at least one hundred eighty (180) degrees Fahrenheit. In additional embodiments, the step of directing the grain product over the plurality of screens 504 and/or the step of directing the protein-containing portion and the oil-containing portion over a finishing screen 506 includes pumping the grain product to the plurality of screens at a header pressure of at least sixty (60) pounds per square inch (psi), but preferably between one hundred (100) pounds per square inch (psi) and one hundred twenty (120) pounds per square inch (psi).
It is noted that in embodiments in which the grain product is wet distillers grain or dried distillers grain, water may need to be added during the process to facilitate pumping of the wet distillers grain or dried distillers grain through the system 400.
It is believed that the system and method for isolation of protein as a co-product of biofuel and/or biochemical production of the present invention and many of its attendant advantages will be understood by the forgoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components and steps thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely an explanatory embodiment thereof.
Number | Date | Country | |
---|---|---|---|
62293107 | Feb 2016 | US |