MXPA06010266A

MXPA06010266A - Methods and systems for producing ethanol using raw starch and fractionation

Info

Publication number: MXPA06010266A
Application number: MXPA/A/2006/010266A
Authority: MX
Inventors: M Lewis Steven
Original assignee: Broin And Associates Inc; M Lewis Steven
Priority date: 2004-03-10
Filing date: 2006-09-08
Publication date: 2007-04-20

Abstract

The present invention relates to methods for producing high levels of alcohol during fermentation of plant material, and to the high alcohol beer produced. The method can include fractionating the plant material. The present invention also relates to methods for producing high protein distiller’s dried grain from fermentation of plant material, and to the high protein distiller’s dried grain produced. The method can include drying a co-product by ring drying, flash drying, or fluid bed drying. The present invention further relates to reduced stack emissions from drying distillation products from the production of ethanol.

Description

METHODS AND SYSTEMS FOR PRODUCING ETHANOL USING RAW AND FRACTIONAL STARCH FIELD OF THE INVENTION The present invention relates to methods for producing high levels of alcohol during the fermentation of vegetable material, and to beer produced with high alcohol content. The method may include the fractionation of _ vegetal material. The present invention also relates to the methods for producing dry grain of high protein distiller, from the fermentation of plant material, and to the dried grain of high protein distiller, produced. The method may include the drying of a secondary product by ring drying, flash drying or fluidized bed drying. The present invention also relates to the reduced emissions of chimneys from the drying of distillation products from the production of ethanol.

BACKGROUND OF THE INVENTION There are numerous conventional methods for converting plant material to ethanol. However, these methods suffer from numerous shortcomings. There is a need for more effective additional methods to convert plant material to ethanol and to produce improved REF. 175666 fermentation products.

BRIEF DESCRIPTION OF THE INVENTION The present invention relates to methods for producing high levels of alcohol during the fermentation of vegetable material, and to beer with high alcohol content produced. The method may include the fractionation of the plant material. The present invention also relates to the methods for producing dried grain of distiller with high protein content, from the fermentation of vegetable material, and to the dry grain produced from the distiller with high protein content. The method may include drying a secondary product by ring drying, flash drying or fluidized bed drying. In one embodiment, the present invention relates to a process for producing ethanol from vegetable material (eg, fractionated plant material). This method includes the fractionation of plant material; milling of plant material (eg, fractionated plant material) to produce ground plant material (eg, fractionated plant material) which includes starch; the saccharification of the starch, without cooking, the fermentation of the incubated starch; and the recovery of ethanol from fermentation. The present method can include the variation of temperature during fermentation. The present method can include the use of plant material (for example, fractionated plant material) with a particle size such that more than 50% of the material fits through a screen with a mesh size of 0.5 mm. The present method can produce a composition that includes at least 18% by volume of ethanol. In one embodiment, the present invention relates to a process for producing tall dry distiller grain . protein content, from the plant material (for example, fractionated plant material). This method includes the fractionation of plant material; the grinding of plant material (for example, fractionated plant material) to produce the ground plant material (for example, fractionated plant material) including starch; the production of sugars from starch without cooking; the fermentation of the uncooked sugars to produce a composition that includes ethanol; and the recovery of the dried grain from the distiller from the fermentation. The dried grain 0 of the distiller may include at least about 30% protein. The dried grain of the distillers may include increased levels of the zein protein. In one embodiment, the present invention relates to a process for producing ethanol from corn. This process includes the production of starch from corn and ethanol from the starch; the production of chimney emissions from dryers, which include a significantly lower level of volatile organic compounds than conventional technologies.

BRIEF DESCRIPTION OF THE FIGURES Figure 1 schematically illustrates a fermentation system according to an embodiment of the present invention. Figures 2A to 2C illustrate schematically that the present process provides improved efficiency for the fermentation of corn fractions produced by dry milling fractionation processes. Figures 3A to 3C schematically illustrate that the present process provides improved efficiency for the fermentation of corn fractions produced by dry milling fractionation processes.

DETAILED DESCRIPTION OF THE INVENTION Definitions As used herein, the phrase "without cooking" refers to a process for converting starch to ethanol without heat treatment for gelatinization and dextrinization of starch using alpha-amylase. In general, for the process of the present invention, "without cooking" refers to the maintenance of a temperature below the gelatinization temperatures of the starch, so that saccharification occurs directly from the crude native insoluble starch, to soluble glucose , while conventional starch gelatinization conditions are diverted. The gelatinization temperatures of the starch are typically in a range of 57 ° C to 93 ° C, .depending on the source of the starch and the type of polymer.

"In the method of the present invention, the dextrinization of starch using conventional liquefaction techniques is not necessary for the efficient fermentation of the carbohydrate in the grain." As used herein, the phrase "plant material" refers to all or part of any plant (e.g., cereal grain), typically a material that includes starch.The suitable plant material includes grains such as corn (corn, e.g., whole crushed corn), sorghum (milo), barley, wheat, rye, rice and millet, and crops of starchy roots, tubers, or roots such as sweet potato and cassava.The plant material can be a mixture of such materials and secondary products of such materials, for example, corn fiber, corn cob , fodder, or other materials that contain cellulose and hemicellulose, such as wood or plant residues Suitable plant materials include corn, either standard corn or zero corn As used herein, the phrase "fractionated plant material" refers to plant material that includes only a portion or fraction of the total plant material, typically a material that includes starch.

The fractionated plant material may include fractionated grains such as fractionated corn (fractionated corn), fractionated sorghum (fractionated milo), fractionated barley, fractionated wheat, fractionated rye, fractionated rice and fractioned millet; and harvests of fractionated starchy roots, tubers or roots such as fractionated sweet potato and fractionated cassava. Suitable fractionated plant materials include fractionated corn, either fractionated standard corn or fractionated waxy corn. As used herein, the terms "saccharification" and "saccharification" refer to the process of converting starch to smaller polysaccharides, and eventually to monosaccharides, such as glucose. Conventional saccharification uses the liquefaction of the gelatinized starch to create the soluble dextrinized substrate whose glucoamylase enzyme hydrolyzes it to glucose. In the present method, saccharification refers to the conversion of crude starch to glucose with enzymes, for example glucoamylase and acid fungal amylase (AFAU). According to the present method, the crude starch is not subjected to conventional liquefaction and gelatinization, to create a conventional dextrinized substrate. As used herein, an acid fungal amylase activity unit (AFAU) refers to the standard Novozymes units for measuring the activity of the fungal amylase acid. Novozymes units are described in a technical bulletin of Novozymes SOP No .: EB-SM-0259.01 / 01. Such units can be measured by detecting products of starch degradation by iodine titration. the amount of enzyme that degrades 5,260 mg of dry matter of starch per hour under standard conditions., a glucoamylase activity unit (GAU) refers to standard Novozymes units for measuring glucoamylase activity. Novozymes units and trials to determine glucoamylase activity are described in a publicly available Novozymes technical bulletin. As used herein, a unit of amyloglucosidase (AGU) activity refers to standard Novozymes units for measuring amyloglucosidase activity. The Novozymes units are described in a technical bulletin of Novozymes SOP No. EB-SM-0131.02 / 01. Such units can be measured by detecting the conversion of maltose to glucose. Glucose can be determined using the glucose-dehydrogenase reaction. One unit is defined as the amount of enzyme that catalyzes the conversion of 1 mmol of maltose per minute under the given conditions. As used herein, the term "approximately" by modifying any quantity, refers to the variation in "that amount, found under real conditions in the world, of sugar and ethanol production, for example, in the laboratory, in a pilot plant or in production facilities. , an amount of an ingredient used in a mixture when modified by "approximately" includes the variation and degree of care typically used in the measurement in an ethanol production plant or laboratory, for example, the amount of a component of an The product when modified by "approximately" includes the variation between batches in an ethanol production plant or laboratory and the variation inherent in the analytical method, whether or not modified by "approximately" the quantities include equivalents to those quantities. The amount set forth herein and modified by "about" may also be employed in the present invention as the antity not modified by "approximately".

Conversion of Starch to Ethanol The present invention relates to methods for producing high levels of alcohol during the fermentation of vegetable material (eg, fractionated vegetable material), and to beer produced with high alcohol content. The present invention also relates to the methods for producing dry grain of distiller with high protein content, from the fermentation of the vegetable material (for example, fractionated vegetable material), to the dry grain of distiller with high protein content, produced, and the cleanest emissions from the chimneys of the dryers. The present method converts the starch from the plant material (for example, fractionated plant material) to ethanol. In one embodiment, the present method can include preparing the plant material (eg, fractionated plant material) for saccharification, converting the prepared plant material (eg, fractionated plant material) to sugars without cooking, and fermenting the sugars. Plant material (eg, fractionated plant material) can be prepared for saccharification by any of a variety of methods, for example, by milling, to make the starch available for saccharification and fermentation. In one embodiment, the plant material can be ground so that a substantial portion, for example, a greater part of the ground material, fits through a screen with a mesh of 0.1-0.5 mm. For example, in one embodiment, approximately 70% or more of the ground plant material can fit through a screen with a mesh size of 0.1 to 0.5 mm. In one embodiment, the reduced plant material (eg, fractionated plant material) can be mixed with liquid of about 20 to 50% by weight or about 25 to about 45% by dry weight of the reduced plant material (eg, fractionated plant material). ) .- The present process can include the conversion of reduced plant material (for example, fractionated plant material) sugars that can be fermented by a microorganism such as a yeast. This conversion can be effected by saccharification of the reduced plant material (eg, fractionated plant material) with an enzyme preparation, such as a saccharification enzyme composition. A saccharification enzyme composition can include any of a variety of known enzymes, suitable for converting the reduced plant material (eg, fractionated plant material) to fermentable sugars, such as amylases (eg, -amylase and / or glucoamylase). In one embodiment, the saccharification is produced at a pH of about 6.0 or less, for example, about 4.5 to about 5.0, for example, about 4.5 to about 4.8.

The present process includes the fermentation of sugars from reduced plant material (for example, fractionated plant material) to ethanol. The fermentation can be carried out by a microorganism, such as a yeast. In one embodiment, the fermentation is conducted at a pH of about 6 or less, for example, about 4.5 to about 5, for example, about 4.5 to about 4.8. In one embodiment, the present method may include the variation of pH. For example, fermentation may include filling the fermenter at a pH of about 3 to about 4.5 during the first half of the filling and at a pH of about 4.5 to about 6 (e.g., about 4.5 to about 4.8) during the second half. of the fermenter filling cycle. In one embodiment, the fermentation is conducted at a temperature of from about 25 to about 0 ° C or about 30 to about 35 ° C. In one embodiment, during fermentation the temperature is lowered from about 40 ° C to about 30 ° C or about 25 ° C, or from about 35 ° C to about 30 ° C, during the first half of the fermentation, and the temperature it is kept at the lowest temperature for the second half of the fermentation. In one embodiment, the fermentation is conducted by about 25 (eg, 24) to about 150 hours, for example, by about 48 (eg, 47) to about 96 hours. The present process may include simultaneously converting the reduced plant material (eg, fractionated plant material) to sugars, and fermenting those sugars with a microorganism such as yeast. The product of the fermentation process is referred to herein as "beer." The ethanol can be recovered from the fermentation mixture, from the beer, by any of a variety of known processes, such as by distillation. The remaining residue includes liquid material, and solid. The liquid and the solid can be separated by, for example, centrifugation.

Preparation of Vegetable Material The present method converts the starch from the plant material (for example, fractionated plant material) to ethanol. The plant material (for example, fractionated plant material) can be reduced by a variety of methods, for example by grinding, to make the starch available for saccharification and fermentation. Other methods of reducing the plant material are available. For example, the plant material, such as corn kernels, can be crushed with a ball mill, a roller mill, a hammer mill, or another known mill to crush plant material, and / or other materials for reduction purposes of the particle size. The use of emulsion technology, rotary pulsation, and other means of particle size reduction, can be employed to increase the surface area of the plant material (eg, fractionated plant material) while increasing the flow effectiveness of the plant. half liquefied. Prepared plant material (eg, fractionated plant material) can be referred to as-or as including "raw starch." A fine grind exposes more surface area of the plant material (for example, fractionated plant material), or plant material, and can facilitate saccharification and fermentation. In one embodiment, the plant material is crushed so that a substantial portion, eg, a greater part, of the crushed material fits through a screen with a mesh of 0.1 to 0.5 mm. In one embodiment, approximately 35% or more of the crushed material can fit through a screen with a mesh of 0.1 to 0.5 mm. In one embodiment, about 35% to about 70% of the crushed plant material can fit through a screen with a mesh of 0.1 to 0.5 mm. In one embodiment, approximately 50% or more of the crushed plant material can fit through a sieve with a mesh of 0.1 to 0.5 mm. In one embodiment, approximately 90% of the crushed plant material can fit through a sieve with a mesh size of 0.1 to 0.5 mm. In one embodiment, all the crushed plant material can fit through a sieve with a mesh of 0.1 to 0.5 mm. In one embodiment, the crushed plant material has an average particle size of about 0.25 mm.

Reduction of Plant Material The preparation of plant material (for example, fractionated plant material) can employ any of a variety of techniques for the reduction of plant material (for example, fractionated plant material). For example, the present method of preparing the plant material (for example, fractionated plant material) can employ emulsion technology, rotary pulsation, sonication, magnetostriction, ferromagnetic materials or the like. These methods of reducing plant material can be used for the treatment of the substrate. Although not limited to the present invention, it is believed that these methods can increase the surface area of the plant material (eg, fractionated plant material) while increasing the effectiveness of the flow of the liquified medium (eg, decreased viscosity). These methods can include electrical to mechanical, mechanical to electrical pulses, and sound-based vibrations at varying speeds. This can provide varying frequencies over a wide range of frequencies, which can be effective for pretreating plant material (eg, fractionated plant material) and / or reducing particle size. Although not limited to the present invention, it is believed that certain of these sonic methods create a low pressure around a particle of the plant material (eg, fractionated plant material) and induce particle cavitation or particle structure disintegration. . The cavitated or disintegrated particle may increase the availability of plant material (eg, starch) to an enzyme, for example, by increasing the surface area. It is believed that such pretreatment can decrease the amount of enzyme ratios in the present method for the production of ethanol. In one embodiment, the present method includes the vibration of the plant material (eg, fractionated plant material) and the cavitation of the fluid containing the plant material. This can result in the disintegration of the plant material and / or the decrease in the size of the plant material (for example, fractionated plant material). In certain embodiments, the present method includes the treatment of plant material (e.g., fractionated plant material) with emulsion technology, rotating pulsation, magnetostriction, or ferromagnetic materials. This can result in the disintegration of the plant material and / or the decrease in the size of the plant material (for example, fractionated plant material). In one embodiment, the present method includes sonication of the plant material (e.g., fractionated plant material). This can result in the disintegration of the plant material and / or the decrease in the size of the plant material (for example, fractionated plant material). In one embodiment, the present method may include the use of sound waves to reduce plant material (for example, fractionated plant material). The sound waves can be ultrasonic. The present method may include sonication of the plant material (eg, fractionated plant material). The method may include the sonication of plant material at a frequency (eg, measured in kHz), energy (eg, measured in watts) and for a time, effective in reducing (or helping to reduce) the particle size at sizes described hereinabove. For example, the method may include sonication of the plant material (eg, fractionated plant material) at 20,000 Hz and up to about 3000 W for a sufficient time and at a suitable temperature. Such sonication can be carried out with commercially available apparatuses, such as the high energy ultrasonics available from ETREMA (Ames, IA). In one embodiment, the present method may include the use of rotary pulsation to reduce plant material (eg, fractionated plant material). The method may include rotating pulsation of plant material (eg, fractionated plant material) at a frequency (eg, measured in Hz), energy (eg, measured in watts), and for an effective time to reduce (or assist) to reduce) the particle size to the sizes described hereinabove. Such pulsation-rotating can be carried out with known apparatuses, such as the apparatuses described in U.S. Patent No. 6,648,500, the description of which is incorporated by reference herein. In one embodiment, the present method may include the use of pulse wave technology to reduce plant material (eg, fractionated plant material). The method may include the rotating pulsation of plant material at a frequency (eg, measured in Hz), energy (for example, measured in watts), and for a time, effective in reducing (or helping to reduce) the particle size to the sizes described hereinabove. Such pulsation can be carried out with known apparatuses, such as the apparatuses described in U.S. Patent No. 6,726,133, the description of which is incorporated by reference herein.

Fractionation In one embodiment, the plant material can be divided into one or more components. For example, a plant material such as a cereal grain or corn may be fractionated into components such as fiber (e.g., corn fiber), germ (e.g., corn germ), and a mixture of corn and protein (e.g. example, a mixture of corn starch and corn protein). One or a mixture of these components can be fermented in a process according to the present invention. Fractionation of corn or other plant material can be accomplished by any of a variety of methods or apparatuses. For example, a system manufactured by Satake can be used to fractionate plant material such as corn. In one embodiment, the germ and the fiber components of the plant material can be fractionated and separated from the remaining portion of the plant material. In one embodiment, the remaining portion of the plant material (for example, the maize endosperm) can be further ground and reduced in particle size, and then combined with the larger pieces of the fractioned seed and the fiber components for fermentation. . In one embodiment, the plant material can be ground to access value-added products (such as nutraceuticals, leutein, carotenoids, xanthophylls, pectin, cellulose, lignin, mannose, xylose, arabinose, galactose, galacturonic acid, GABA, olive oil). corn, albumins, globulins, prolamines, gluetellins, zein and the like). Fractionation can be accomplished by any of a variety of methods and apparatuses, such as those described in U.S. Patent Application Publication No. 2004/0043117, the description of which is incorporated by reference herein. Suitable methods and apparatus for fractionation include sieving, sieving and elutriation. The suitable apparatus includes a friction mill such as a rice or grain polishing mill (for example those manufactured by Satake, Kett, or Rapsco).

Saccharification and Fermentation Sacarification The present process can include the conversion of the reduced plant material (for example, fractionated plant material) to sugars that can be fermented by a microorganism such as a yeast. This conversion can be effected by saccharification of the reduced plant material (eg, fractionated plant material) with any of a variety of known saccharification enzyme compositions. In one embodiment, the composition of the saccharification enzyme includes an amylase, such as an alpha-amylase (eg, an acid fungal amylase). The enzyme preparation can also include glucoamylase. The enzyme preparation does not need, and, in one embodiment, does not include protease. However, the ethanol production methods according to the present invention can conserve water by reusing the process waters (countercurrent) which may contain protease. In one embodiment, the present method employs acid fungal amylase to hydrolyze the crude starch. The saccharification can be conducted without cooking.

For example, saccharification can be conducted by mixing the source of saccharification enzyme composition (e.g., commercial enzyme), yeast, and fermentation ingredients with ground grain and process waters without cooking. In one embodiment, the saccharification can include mixing the reduced plant material (eg, fractionated plant material) with a liquid, which can form a suspension and adding the composition of the saccharification enzyme to the liquid. In one embodiment, the method includes mixing the produced plant material (eg, fractionated plant material) and liquid, and then adding the saccharification enzyme composition. Alternatively, the addition of the enzyme composition may precede or occur simultaneously with mixing. In one embodiment, the reduced plant material (eg, fractionated plant material) can be mixed with liquid from about 20 to about 50% by weight, about 25 to about 45% by weight (eg, 44), about 30 to about 40% by weight (eg, 39"), or about 35% by weight of the dried reduced plant material (eg, fractionated plant material) As used herein, the weight percentage of the plant material reduced in a liquid refers to the percentage of reduced plant material, dry matter, or dry solids In one embodiment, the method of the present invention can convert raw or native starch (e.g., dry reduced plant material) to ethanol at a rate faster, at higher dry solids levels compared to conventional saccharification with cooking, Although not limited to the present invention, it is believed that the present method can be activated at higher dry solids levels because, contrary to the conventional process, it does not include gelatinization, which increases the viscosity.

Suitable liquids include water and a mixture of water and process waters, such as sediments (countercurrent), sewage water, condensate or distillate from the evaporator, collateral sewage water from distillation, or other waters from the ethanol plant process. In one embodiment, the liquid includes water. In one embodiment, the liquid includes water in a mixture with about 1 to about 70% by volume of waste, about 15 to about 60% by volume of waste, about 30 to about 50% by volume of waste, or about 40% in volume of waste. In the conventional process employing gelatinization and liquefaction, the residue provides nutrients for the efficient fermentation of the yeast, especially the free amino nitrogen (FAN) required by the yeast. The present invention can provide effective fermentation with reduced levels of residues or sediments and even without aggregate residues. In a modality, the present method employs a preparation of the plant material (eg, fractionated plant material) that supplies the sufficient amount and quality of the nitrogen for efficient fermentation under high gravity conditions (eg, in the presence of high levels of reduced plant material) . In this way, in one modality, a zero level or only low residue levels may be sufficient. However, the present method provides the flexibility to employ high levels of waste if desired. The present method does not employ conventional liquefaction. Conventional liquefaction increases the viscosity of the fermentation mixture and the resulting residue. The present method produces lower viscosity residue. Therefore, in one embodiment, increased levels of residues may be employed in the present method, without damagingly increasing the viscosity of the fermentation mixture or the resulting residue. Furthermore, although not limited to the present invention, it is believed that conventional saccharification and fermentation processes require added FAN due to the undesirable "Maillard Reactions" that occur during gelatinization and high temperature liquefaction. The Maillard reactions consume FAN during cooking. As a result, the conventional process requires the addition of waste (or another source of FAN) to increase FAN levels in the fermentation. It is believed that the current process avoids the Maillard Reactions induced by the temperature, and provides increased levels of FAN in the reduced plant material, which are actually used by the yeast in the fermentation. Saccharification can employ any of a variety of known enzyme sources (e.g., a microorganism) or compositions for producing fermentable sugars from the reduced plant material (e.g., fractionated plant material). In one embodiment, the saccharification enzyme composition includes an amylase, such as an alpha-amylase (eg, an acid fungal amylase) or a glucoamylase. In one embodiment, saccharification is conducted at a pH of about 6.0 or less, pH from about 3.0 to about 6.0, about 3.5 to about 6.0, about 4.0"to about 5.0, about 4.0 to about 4.5, about 4.5 to about 5.0. or about 4.5 to about 4.8 In one embodiment, the saccharification is conducted at a pH of from about 4.1 to about 4.6 or about 4.9 to about 5.3 The initial pH of the saccharification mixture can be adjusted by the addition of, for example. , ammonia, sulfuric acid, phosphoric acid, process waters (eg, waste or sediment (countercurrent), evaporator condensate (distillate), bottoms of the side scrubber, and the like), and the activity of certain enzyme compositions of saccharification (for example, one that includes acidic amylase) may be increased to a pH lower than the intervals before higher.

In one embodiment, the saccharification is conducted at a temperature of about 25 to about 40 ° C or about 30 to about 35 ° C. In one embodiment, saccharification can be carried out by using amounts of the selected saccharification enzyme composition to maintain low concentrations of dextrin in the fermentation broth. For example, the present process can employ amounts of the selected saccharification enzyme composition to maintain the maltotriose (DP3) at levels of at or below about 0.2% by weight or at or below 0.1% by weight. For example, the present process may employ amounts of the selected saccharification enzyme composition to maintain the dextrin with a degree of polymerization of 4 or more (DP4 +) at levels of or below about 1% by weight or at or below about 0.5% by weight. In one embodiment, saccharification can be carried out using amounts of the selected saccharification enzyme composition to maintain low concentrations of maltose in the fermentation broth. For example, the present process can employ amounts of the selected saccharification enzyme composition to maintain the maltose at levels of or below about 0.3% by weight. To maintain low levels of maltose, adequate levels of the acid fungal amylase and glucoamylase include about 0.5 to about 3 AFAU / gram of plant material reduced in dry solids (eg, DSC) of the fungal amylase acid and about 1 to approximately 2.5 (for example, 2.4) AGU per gram of plant material reduced from dry solids (eg, DSC) of glucoamylase. In one embodiment, the reaction mixture includes about 0.1 to about 2 AFAU / gram of plant material reduced from dry solids (eg, DSC) of the fungal amylase acid and about 1 to about 2.5 AGU per gram of plant material reduced in solids * dry (for example, DSC) glucoamylase. In a modality, the reaction mixture includes about 0.3 to about 2 AFAU / gram of plant material reduced from dry solids (eg, DSC) of the fungal amylase acid and about 1 to about 2.5 AGU per gram of plant material reduced from dry solids (by example, DSC) of glucoamylase. In one embodiment, the reaction mixture includes about 1 to about 2 AFAU / gram of plant material reduced from dry solids (eg, DSC) of the fungal amylase acid and about 1 to about 1.5 AGU per gram of plant material reduced in solids. dry (for example, DSC) glucoamylase.

Glucoamylase In certain embodiments, the present method can employ a glucoamylase. Glucoamylase is also known as amyloglucosidase and has the systematic name 1,4-alpha-D-glucan-glucohydrolase (E.C. 3.2.1.3). Glucoamylase refers to an enzyme that removes successive glucose units from the non-reducing ends of the starch. For example, certain glucoamylases can hydrolyse the linear and branched glycosidic bonds of starch, amylose and amylopectin. A variety of suitable glucoamylases are known and commercially available. For example, suppliers such as Novozymes and Genencor provide glucoamylases. Glucoamylase can be of fungal origin. The amount of glucoamylase used in the present process can vary according to the enzymatic activity of the amylase preparation. Suitable amounts include about 0.05 to about 6.0 units of glucoamylase (AGU) per gram of plant material reduced to dry solids (eg, DSC). In one embodiment, the reaction mixture may include about 1 to about 6 AGU per gram of plant material reduced in dry solids (eg, DSC). In one embodiment, the reaction mixture may include about 1 to about 3 AGU per gram of plant material reduced from dry solids (eg, DSC). In one embodiment, the reaction mixture may include about 1 to about 2.5 (eg, 2.4) AGU per gram of plant material reduced in dry solids (eg, DSC). In one embodiment, the reaction mixture may include about 1 to about 2 AGU per gram of plant material reduced in dry solids (eg, DSC). In one embodiment, the reaction mixture may include about -1 to about 1.5 AGU per gram of reduced plant material of dry solids (eg, DSC). In one embodiment, the reaction mixture may include about 1.2 to about 1.5 AGU per gram of plant material reduced in dry solids (eg, DSC).

Acid Fungal Amylase In certain embodiments, the present method employs an α-amylase. The α-amylase can be one produced by fungi. The α-amylase may be one characterized by its ability to hydrolyze carbohydrates under acidic conditions. An amylase produced by fungi and capable of hydrolyzing carbohydrates under acidic conditions, is referred to herein as the fungal amylase acid, and also known as the acid-stable fungal α-amylase.

Acid fungal amylase can catalyze the hydrolysis of partially hydrolyzed starch and large oligosaccharides to sugars such as glucose. The acid fungal amylase that can be used in the present process can be characterized by its ability to aid in the hydrolysis of crude or native starch, increasing the saccharification provided by glucoamylase. In one embodiment, the fungal amylase acid produces more maltose than the conventional a-amylases (for example bacterial). The appropriate acid fungal amylase can be isolated from any of a variety of fungal species, including Aspergillus, Rhizopus, Mucor, Candida, Coriolus-, - Endothia, Enthomophtora, Irpex, Penicillium, Sclerotium and Torulopsis. In one embodiment, the fungal amylase acid is thermally stable and is isolated from Aspergillus species, such as A. niger, A. saitoi or A. oryzae, from Mucor species such as M. Pusillus or M. miehei, or from species of Endothia such as E. parasitica. In one embodiment, the fungal amylase acid is isolated from Aspergillus niger. The activity of the fungal amylase acid may be supplied as an activity in a glucoamylase preparation, or it may be added as a separate enzyme. A suitable acid fungal amylase can be obtained from Novozymes, for example in combination with glucoamylase. The amount of fungal amylase acid employed in the present process may vary according to the enzymatic activity of the amylase preparation. Suitable amounts include from about 0.1 to about 10 units of acid fungal amylase (AFAU) per gram of plant material reduced from dry solids (e.g., dry solids corn (DSC)). In one embodiment, the reaction mixture may include from about 0.05 to about 3 AFAU / gram of plant material reduced from dry solids (eg, DSC). "In one embodiment, the reaction mixture may include from about 0.1 to about 3 AFAU / gram of plant material reduced from dry solids (eg, DSC) In one embodiment, the reaction mixture may include from about 0.3 to about 3 AFAU / gram of plant material reduced from dry solids (eg, DSC). , the reaction mixture may include about 1 to about 2 AFAU / gram of plant material reduced in dry solids (eg, DSC).

Fermentation The present process includes the fermentation of sugars from reduced plant material (for example, fractionated plant material) to ethanol. The fermentation can be carried out by a microorganism, such as a yeast. The fermentation mixture does not need, and in one embodiment, does not include the protease. However, the process waters may contain protease. The amount of protease may be less than that used in the conventional process. According to the present invention, the fermentation is conducted on a starch composition that has not been cooked. In one embodiment, the present fermentation process produces potable alcohol. Drinking alcohol has only acceptable non-toxic levels of other alcohols, such as amyl alcohols. The fermentation may include contacting a mixture that includes sugars from reduced plant material (eg, fractionated plant material) with yeast under conditions suitable for yeast and growth. Ethanol production. In one embodiment, the fermentation uses the saccharification mixture. Any of a variety of yeasts can be employed as the yeast starter in the present process. Suitable yeasts include any of a variety of commercially available yeasts, such as commercial strains of Saccharomyces cerevisiae. Suitable strains include "Fali" (Fleischmann's), Thermosac (Alltech), Ethanol Network (LeSafre), BioFerm AFT (North American Bioproducts), and the like. In one embodiment, the yeast is selected to provide rapid growth and fermentation rates in the presence of high temperature and high levels of ethanol. In one embodiment, it has been found that the Fali yeast provides good performance measured by the final alcohol content greater than 17% by volume. The amount of yeast initiator employed is selected to effectively produce a commercially significant amount of ethanol in a suitable time, for example, less than 75 hours. ^ The yeast can be added to the fermentation by any of a variety of known methods to add yeast to the fermentation processes. For example, the yeast initiator can be added as a dry batch, or by conditioning / propagation. In one embodiment, the yeast-starter is added as a simple inoculation. In one embodiment, the yeast is added to the fermentation during the filling of the fermenter at a rate of 2.27 to 45.4 kg (5 to 100 pounds) of active dry yeast (ADY) by 378,540 liters (100,000 gallons) of pulpy mass of fermentation . In one embodiment, the yeast can be acclimated or conditioned by incubating 2.27 to 22.7 kg (5 to 50 pounds) of ADY per volume of 37,854 liters (10,000 gallons) of the fermenter volume in a pre-fermentation or propagation tank. The incubation can be from 8 to 16 hours during the propagation stage, which is also aerated to promote the growth of the yeast. The pre-fermentor used to inoculate the main fermenter can be of a capacity of 1 to 10% by volume of the main fermenter, for example, from 2.5 to 5% by volume of capacity in relation to the main fermenter. In one embodiment, the fermentation is conducted at a pH of about 6 or less, pH from about 3 to about 6, about 3 to about 4.5, about 3.5 to about 6, about 4 to about 5, about 4 to about 4.5, about 4.5 to about 5, or about 4.5 to about 4.8. The initial pH of the fermentation mixture can be adjusted by the addition of, for example, ammonia, sulfuric acid, phosphoric acid, process waters (eg, waste (countercurrent), evaporator condensate (distillate), bottoms of the side scrubber , and the like), and the like. Aungue is not limited to the present invention, it is believed that the known distiller's yeast develops well above the pH range of 3 to 6, but are more tolerant of lower pH's below 3.0 than most of the contaminating bacterial strains. The lactic acid and acetic acid producing bacteria develop best at pH 5.0 and above. Thus, in the pH range of 3.0 to 4.5, it is believed that ethanol fermentation will predominate because the yeast will develop better than contaminating bacteria.

In one embodiment, the present method may include the variation of pH. It is believed that pH variation can be conducted to reduce the likelihood of contamination early in fermentation, and / or to increase yeast growth and fermentation during the late stages of fermentation. For example, fermentation may include filling the fermenter at pH from about 3 to about 4.5 during the first half of the filling. Fermentation may include increasing the pH of the suspension to a pH of about 4.5 to about 6 during the second half of the fermenter filling cycle. Fermentation may include maintaining the pH by adding the suspension of the fresh substrate to the desired pH as described above. In one embodiment, during the fermentation (after filling), the pH is not adjusted. Rather, in this mode, the pH is determined by the pH of the components during filling. In one embodiment, the pH is decreased to approximately five (5) or below in the maize process waters. In one embodiment, the pH is about pH 4 (for example 4.1) at the start of the fermentation filling and increases up to about pH 5 (for example 5.2) towards the end of the fermentation filling. In one embodiment, the method includes stopping the pH control of the pulpy mass suspension after the yeast culture is stabilized during the initial process of filling the fermentor, and then the pH is allowed to move into the water of the fermentor. corn process during the final stages of filling the fermentor. In one embodiment, the fermentation is conducted from about 25 (e.g., 24) to about 150 hours, about 25 (e.g., 24) to about 96 hours, about 40 to about 96 hours, about 45 (e.g., 44) at about 96 hours, about 48 (e.g., 47) at about 96 hours. For example, the fermentation can be conducted for about 30, about 40, about 50, about 60, or about 70 hours. For example, the fermentation can be conducted for about 35, about 45, about 55, about 65 or about 75 hours. In one embodiment, the fermentation is conducted at a temperature of from about 25 to about 40 ° C or about 30 to about 35 ° C. In one embodiment, during fermentation the temperature is lowered from about 40 ° C to about 30 ° C or about 25 ° C, or from about 35 ° C to about 30 ° C, during the first half of the fermentation, and the temperature it is kept at the lowest temperature by the second half of the fermentation. In one embodiment, the temperature can be decreased as ethanol is produced. For example, in one embodiment, during fermentation the temperature can be as high as about 37 ° C (99 ° F) and then reduced to about 26 ° C (79 ° F). This reduction in temperature can be coordinated with the increased titers of ethanol (%) in the fermenter. In one embodiment, the present method includes the preparation or stacking of the solids. The preparation or stacking of the solids includes the filling to a disproportionately higher level of solids during the initial phase of the fermenter filling cycle, to increase the initial fermentation rates. The solids concentration of the pulpy mass entering the fermenter can then be decreased as the ethanol titres increase and / or as the fermenter filling cycle is almost complete. In one embodiment, the concentration of the solids can be about 40% (for example 41%) during the first half of the fermentation filling. This can be decreased to approximately 25% after the fermenter is 50% full and continuing until the fermenter filling cycle is completed. In the previous example, such a strategy results in a fermenter filled with 33% solids.

It is believed that the preparation or stacking of the solids can accelerate the rates of enzymatic hydrolysis and promote a rapid onset of fermentation through the use of higher, initial filling solids. It is believed that by decreasing the solids in the last half of the filling, the stress effects related to the osmotic pressure on the yeast can be reduced. By keeping the total fermentor filling solids within a specified fermentability range, the stacking of the solids improves the ability of the yeast to ferment the high gravity pulpy masses towards the end of the fermentation.

Simultaneous Saccharification and Fermentation The present process may include simultaneously converting the reduced plant material (eg, fractionated plant material) to sugars, and fermenting those sugars with a microorganism such as yeast. Saccharification and simultaneous fermentation can be conducted using the reagents and conditions described above for saccharification and fermentation. In one embodiment, saccharification and fermentation are conducted at a temperature of from about 25 to about 40 ° C or about 30 to about 35 ° C. In one embodiment, during saccharification and fermentation the ambient temperature is lowered from about 40 to about 25 ° C or from about 35 to about 30 ° C during the first half of the saccharification, and the temperature is maintained at the lowest temperature for the second half of saccharification. Although not limited to the present invention, it is believed that higher temperatures early during saccharification and fermentation can increase the conversion of starch to fermentable sugar, when the ethanol concentrations are low. This can . help increase ethanol yield At higher ethanol concentrations, this alcohol can adversely affect the yeast, thus, it is believed that lower temperatures later during saccharification and fermentation are beneficial in decreasing the strain on the yeast. ethanol yield Not even limited to the present invention, it is believed that higher temperatures early during saccharification and fermentation can reduce the viscosity during at least a portion of the fermentation.This can help in temperature control. that lower temperatures later during saccharification and fermentation are beneficial to reduce glucose formation after the yeast has stopped fermenting.The formation of glucose later in the fermentation may be harmful to the color of the secondary product of the dried grain of the distillers, in one mode, saccharification and the fermentation is conducted at a pH of about 6 or less, pH from about 3 to about 6, about 3.5 to about 6, about 4 to about 5, about 4 to about 4.5, about 4.5 to about 5, or about 4.5 to approximately 4.8. The initial pH of the saccharification mixture and fermentation can be adjusted by the addition of, for example, ammonia, sulfuric acid, phosphoric acid, process waters (eg, waste (countercurrent), evaporator condensate (distillate), bottoms of the side scrubber, and the like), and the like. In one embodiment, saccharification and fermentation are conducted for about 25 (eg, 24) to about 150 hours, about 25 (eg, 24) to about 72 hours, about 45 to about 55 hours, about 50 (e.g. , 48) to about 96 hours, about 50 to about 75 hours, or about 60 to about 70 hours. For example, it can be conducted for approximately 30, about 40, about 50, about 60, or about 70 hours. For example, saccharification and fermentation can be conducted for about 35, about 45, about 55, about 65 or about 75 hours. In one embodiment, simultaneous saccharification and fermentation can be carried out using amounts of enzyme and yeast selected to maintain the high concentrations of the yeast and the high levels of budding of the yeast in the fermentation broth. For example, the present process can employ selected amounts of enzyme and yeast to maintain the yeast at or above 200 cells / ml, at or above 300 cells / ml, or approximately 300 to approximately 600 cells / ml. In one embodiment, simultaneous saccharification and fermentation can be carried out using amounts of enzyme and yeast selected for effective fermentation without exogenous nitrogen added; without added protease; and / or without added countercurrent. The countercurrent can be added, if desired, to consume the process water and reduce the amount of wastewater produced by the process. In addition, the present process maintains the low viscosity during saccharification and fermentation.

In one embodiment, simultaneous saccharification and fermentation can be carried out using amounts of enzyme and yeast selected to maintain low concentrations of the soluble sugar in the fermentation broth. In one embodiment, simultaneous saccharification and fermentation can be carried out using amounts of enzyme and yeast selected to maintain the low concentrations of glucose in the fermentation broth. For example, the present process can employ selected amounts of enzyme and yeast to maintain glucose at levels of or below about 2% by weight, at or below about 1% by weight, at or below about 0.5. % by weight, or at or below about 0.1% by weight For example, the present process can employ selected amounts of enzyme and yeast to maintain glucose at levels of or below about 2% by weight during saccharification and fermentation For example, the present process can employ selected amounts of enzyme and yeast to maintain glucose at levels of or below about 2% by weight from 0 to 10 hours (or from 0 to about 15% of the time) of saccharification and fermentation For example, the present process can employ selected amounts of enzyme and yeast to maintain glucose at levels of or below about 1% by weight, in or below about 0.5% by weight, or at or below about 0.1% by weight of 12 to 54 hours (or about 15% to about 80% of the time) of saccharification and fermentation. For example, the present process may employ selected amounts of enzyme and yeast to maintain glucose at levels of or below about 1% by weight of 54 to 66 hours (or approximately 80% to about 100% of the time) of the saccharification and fermentation. In one embodiment, simultaneous saccharification and fermentation can be carried out using amounts of enzyme and yeast selected to maintain low concentrations of maltose (DP2) in the fermentation broth. For example, the present process can employ selected amounts of enzyme and yeast to maintain maltose at levels of at or below about 0.5% or at or below about 0.2% by weight. In one embodiment, simultaneous saccharification and fermentation can be carried out using amounts of enzyme and yeast selected to maintain low concentrations of dextrin in the fermentation broth. For example, the present process can employ selected amounts of enzyme and yeast to maintain the maltotriose (DP3) at levels of or below about 0.5% by weight, of or below about 0.2% by weight, of or below about 0.1% by weight. For example, the present process can employ selected amounts of enzyme and yeast to maintain the dextrin with a degree of polymerization of 4 or more (DP4 +) at levels of or below about 1% by weight or at or below about 0.5. % in weigh. In one embodiment, simultaneous saccharification and fermentation can be carried out using amounts of enzyme and yeast selected to maintain low concentrations of isoamyl alcohols in the fermentation broth. For example, the present process can employ selected amounts of enzyme and yeast to maintain the isoamyl alcohols at levels at or below about 0.4 to about 0.5% by weight. For example, simultaneous saccharification and fermentation can employ acid fungal amylase at about 0.05 to about 10 AFAU per gram of plant material reduced in dry solids (eg, DSC) and glucoamylase at about 0.5 to about 6 AGU per gram of material vegetable reduced in dry solids (for example, DSC). For example, simultaneous saccharification and fermentation can employ acid fungal amylase at about 0.1 to about 10 AFAU per gram of plant material reduced in dry solids (eg, DSC) and glucoamylase at about 0.5 to about 6 AGU per gram of material vegetable reduced in dry solids (eg, DSC). For example, simultaneous saccharification and fermentation can employ the acid fungal amylase at about 0.3 to about 3 AFAU per gram of plant material reduced in dry solids (eg, DSC) and the glucoamylase at about 1 to about 3 AGU per gram of reduced plant material in dry solids (eg, DSC). For example, simultaneous saccharification and fermentation can employ acid fungal amylase at about 1 to about 2 AFAU per gram of plant material reduced in dry solids (eg, DSC) and glucoamylase at about 1 to about 1.5 AGU per gram. of reduced plant material in dry solids (eg, DSC).

Additional Ingredients for Saccharification and Fermentation The saccharification and / or fermentation mixture may include additional ingredients to increase the effectiveness of the process. For example, the mixture may include added nutrients (e.g., yeast micronutrients), antibiotics, salts, added enzymes, and the like. The nutrients can be derived from the waste or the countercurrent added to the liquid. Suitable salts may include zinc or magnesium salts, such as zinc sulfate, magnesium sulfate and the like. Suitable aggregated enzymes include those added to conventional processes, such as protease, phytase, cellulase, hemicellulase, exo- and endo-glucanase, xylanase and the like.

Recovery of Ethanol from Beer The product of the fermentation process is referred to herein as "beer". For example, the fermentation of corn produces "corn beer". Ethanol can be recovered from the fermentation mixture from beer, through a variety of known processes. For example, ethanol can be recovered by distillation. The remaining residue includes liquid and solid material. The liquid and the solid can be separated by, for example, centrifugation. The recovered liquid, the thin residue, can be used as at least part of the liguid to form the saccharification and fermentation mixture for the subsequent batches or runs. The recovered solids, the dried grain from the distiller, include unfermented grain solids and spent yeast solids. The thin residue can be concentrated to a syrup, which can be added to the dry grain of the distiller, and the mixture is then dried to form the dry grain of the distiller plus the soluble materials. The dry grain from the distiller and / or the dried grain from the distiller plus the soluble ones can be sold as animal feed.

Consumption of Residual Starches for Subsequent Secondary Fermentation In one embodiment, the present method may include heat treatment of beer or. the residue, for example, between the beer well and the distillation. In one embodiment, the present method may include heat treatment of the beer or the residue and addition of enzyme, for example, between the beer well and the distillation. This heat treatment can convert the starches to dextrins and sugars for subsequent fermentation in a process known as consumption or depletion. Such a treatment step can also reduce the fouling of the distillation trays and the heat exchange surfaces of the evaporator. In one embodiment, the heat treatment of the stages or platforms can be performed on the entire waste or the thinned waste. After the enzymatic treatment of the residual starches, in one embodiment, the resulting dextrins and sugars can be fermented within the main fermentation process as recycled countercurrent, or processed in a separate fermentation train to produce ethanol. In one embodiment, liquefaction and saccharification on the entire waste or the thin waste produced by the centrifugation can be accelerated after distillation.

Fractionation of the Solids from the Fermentation Large pieces of germ and fiber can ferment the residual starch in the fermenter. After fermentation, the fractions could be eliminated before or after the distillation. The removal can be done with a surface skimmer before distillation. In one embodiment, screening can be performed on the beer. The screened material can then be separated from the ethanol / water mixture by, for example, centrifugation and drying with a rotating steam drum, which can remove residual ethanol from the cake. In embodiments in which larger pieces of fiber and germ are removed prior to the bulk distillation of the beer, a separate filter column for the fiber / germ stream can be used. Alternatively, the fiber and germ could be removed by sieving the entire residue after distillation.

In one embodiment, all components are mixed and dried together. The fiber and germ can be removed from the finished product by aspiration and / or size classification. DGS fiber can be aspirated. Removal of the fiber by aspiration after drying may increase the amount of oil and protein in the residual DGS, for example, by 0.2 to 1.9% and 0.4 to 1.4%, respectively. The amount of NDF in the residual DGS may decrease, for example, by 0.1 to 2.8%. In one embodiment, the fractionation can employ larger pieces of fibers and germs to increase the particle size of that part of the DGS derived from the endosperm, as well as to improve the syrup transportation capacity. some reduction and homogenization of the particle size.

Methods and Systems for Drying the Filter Cake Press to Make the Dry Grains of the Distiller The beer produced by the fermentation includes ethanol, other liquids, and solid material. The centrifugation and / or distillation of the beer can produce solids known as wet cake or press filter cake and liquids known as thin or thin waste. The wet cake can be dried to produce the dried grain of the distiller. The thin residue can be concentrated to a syrup, which can be added to the wet cake or dry grain of the distiller, and the mixture then dried to form the dried grain of the distiller plus soluble materials. The present method may include drying the wet cake to produce the dried grain of the distiller. The present method can include the drying of the syrup plus the dry grain of the distiller to produce the dry grain of the distiller plus the soluble materials. The dried grain of the distiller can be produced from "whole grain (for example, corn) or from fractionated grain (for example, corn) .The present method can produce the dry grain from the distiller with high protein content and / or the dried grain of the distiller with improved physical characteristics Such dry grains of the distiller are described hereinafter.The conventional ethanol production processes used drum dryers.Usefully, in one embodiment, the present method and the system can employ an instant or ring dryer instant or ring dryers have been previously used in processes such as the current one, instantaneous and ring dryer configurations are known.Briefly, an instant or ring dryer can include a vertical column through which a stream of preheated air shows the wet cake, for example, an instant or pu ring dryer ede include one or more inputs that provide the entry of heat or hot air into the dryer. This dries the wet cake. The dried wet cake is transported to the top of a column. In a ring dryer, additional drying can be achieved by moving the wet cake through one or more rings connected to the column. For example, a ring dryer may include one or more entries through which hot air enters a ring structure that urges or circulates the wet cake in or around the ring structure. The dried wet cake can then be permanently transported to the downstream separation equipment, such as a cyclone or dust collector. The present method may include the use of an instant dryer to dry (eg, flash dry) the wet cake and to produce the dried grain from the distiller. The present method may include the use of an instant dryer to dry (eg, flash dry) the syrup plus the dried grain from the distiller to produce the dried grain from the distiller plus soluble materials. The use of an instant dryer can produce the dry grain of the distiller with high content of protein and / or dry grain of the distiller with improved physical characteristics. Such dry grains of the distiller are described hereinafter. The present method may include the use of a ring dryer to dry (e.g., dried in ring) the wet cake and to produce the dry grain of the distiller. The present method may include the use of a ring dryer (eg, ring drying) to dry the syrup plus the dried grain from the distiller to produce dry granule from the distiller plus soluble materials. The use of a ring dryer can produce dry grain from the distiller with high protein content, and / or dry grain from the distiller with improved physical characteristics. Such dried grains of the distiller are described hereinafter. The present method can include the use of a fluidized bed dryer to dry (eg, fluidized bed drying) the wet cake and to produce the dried grain from the distiller. The present method may include the use of a fluidized bed dryer to dry (eg, fluidized bed drying) the syrup plus the dry grain of the distiller to produce the distiller grain plus the soluble materials. The emlpeo of a fluidized bed dryer can produce the dry grain of the distiller with high protein content and / or the dried grain of the distiller with improved physical characteristics. Such dried grains of the distiller are described hereinafter. The present method can include the addition of syrup (countercurrent or thin residue) to the wet cake before, during or after drying. In one embodiment, the present method includes adding the syrup (countercurrent or thin residue) to the wet cake during drying. For example, the method may include mixing the wet cake and the syrup in the dryer. For example, the method can include the flow or injection of the syrup into the instant ring or fluidized bed dryer. In one embodiment, the present method includes the addition of the syrup into the column or the dryer ring, in the presence of the wet cake and / or the dried grain of the distiller. Although not limited to the present invention, it is believed that instant and / or ring dryers differ from rotary or drum dryers by providing decreased exposure of the wet cake to the high temperatures of the drying process. A rotary or drum drum generally has high temperature metal that is in prolonged contact with the wet cake product. It is believed that prolonged contact of this metal at high temperature with the wet cake can result in dried, burnt or denatured distiller's grains or dried grains of the distiller plus soluble materials. In addition, the internal air temperature may be higher in a rotary or drum dryer.

Accordingly, in one embodiment, the present method may include drying the wet cake or the wet cake plus syrup for a shorter period of time than that employed with a rotary or drum dryer, and obtaining the dried grain from the distiller or the dry grain of the distiller plus the soluble materials, which has been sufficiently dried. Accordingly, in one embodiment, the present method may include drying the wet cake or the wet cake plus syrup at a lower temperature than that used with a rotary or drum dryer, and obtaining the dry grain from? distiller or the dry grain of the distiller plus the soluble materials, which has been sufficiently dried. In one embodiment, the method includes changing the temperature during drying. Although not limited to the present invention, in certain embodiments, such systems and methods of drying may provide one or more advges such as decreased energy consumption in drying, decreased leakage from the drying system. One embodiment of this invention is the use of the instor ring dryer to change the conditions within the dryer system to increase or decrease the temperature. One embodiment of this invention is the use of the instor ring dryer to change the conditions within the dryer system to increase or decrease the humidity. One embodiment of this invention is the use of the instor ring dryer to change the conditions within the dryer system to increase or decrease the recycling speed. One embodiment of this invention is the use of the instor ring dryer to change conditions within the dryer system to increase or decrease the feed rate within the dryer system.

Continuous Fermentation The present process can be run through a batch or continuous process. A continuous process includes the movement (pumping) of saccharification and / or fermentation mixtures through a series of containers (e.g., tanks) to provide a sufficient duration for the process. For example, a multi-stage fermentation system can be used for a continuous process with residence time of 48 to 96 hours. For example, reduced plmaterial (eg, fractionated plmaterial) can be fed into the top of a first container for saccharification and fermentation. The partially incubated and fermented mixture can then be extracted from the bottom of the first container and fed to the top of the second container, and so on. Although not limited to the present invention, it is believed that the present method is more suitable than conventional methods for running as a continuous process. It is believed that the present process provides reduced opportunity for the development of contaminating organisms in a continuous process. To date, most dry mill ethanol facilities use batch fermentation technology. This is partly due to the difficulty of preventing losses due to contamination in these conventional processes. For efficient continuous fermentation using traditional liquefaction technology, the conventional belief is that a separate saccharification stage prior to fermentation is necessary to pre-saccharify the pulpy mass for fermentation. Such pre-saccharification ensures that there is adequate fermentable glucose for the continuous fermentation process. The present method achieves the efficient production of high concentration of ethanol without a stage of liquefaction or saccharification before fermentation. This is surprising since this conventional wisdom teaches that it is necessary to have adequate levels of fermentable sugar available during the fermentation process, when practiced in a continuous mode. By contrast, the present method can provide low concentrations of glucose and efficient fermentation. In the present method, it appears that glucose is rapidly consumed by fermenting yeast cells. It is believed that such low levels of glucose reduce the stress on the yeast, such as the stress caused by the osmotic inhibition and the pressures by bacterial contamination. According to the present invention, ethanol levels greater than 18% by volume can be achieved in about 45 to about 96 hours.

Fermentation of Endosperm, Fiber and Germ In one embodiment, the present process can ferment a portion of a reduced plant material, such as corn. For example, the process can ferment at least one of the endosperm, the fiber or the germ. The present method can increase the production of ethanol from such a portion of corn. In one embodiment, the present process can saccharify and ferment the endosperm. Fermentation of the endosperm is lower in free amino nitrogen (FAN) towards the beginning of fermentation due to the elimination of the germ, which contains FAN. The present process can, for example, preserve the quality of the endosperm FAN, compared to conventional high temperature liquefaction. One embodiment of the present invention includes the use of the F7? N of the endosperm, which can increase the flexibility and efficiency of the fermentation. In one embodiment, the present process can employ endogenous enzymatic activity in the grain. In one modality, the dramatic increase in FAN in fermentations with whole corn and defibrated corn is achieved in comparison to the suspension of initial pulpy mass. Conventional dry milling operations of the grains separate the germ (which contains oil) and the bran or pericarp (fiber fraction) from the endosperm portion (starch and protein) of the grain using a series of steps and procedures. These steps and procedures include: grain cleaning, tempering, de-germination, particle size reduction, roller milling, vacuuming and siphoning. This process differs from the traditional wet milling of grains (commonly corn) that are more expensive and occupy more water, but are able to achieve cleaner clearances of grain components. Dry milling processes offer a separation version of the components using lower capital costs for the facilities. Also, these processes require less water for the operation. The process of tempering in dry milling requires less water than that required in wet milling.

The competitiveness of dry grain fractionation processes is improved when the process of the present invention is used for the conversion of ethanol from these fractions. Traditionally, dry milling processes produce varying degrees of each fraction (germ, bran and endosperm). In one embodiment, the present method provides bran and endosperm fractions that can be more easily fermented. Depending on the desired purity of each fraction, the fractions can either be combined to create compounds of each stream, or the fractions can be processed individually. The yeast uses FAN in the present process. In the conventional liquefaction process, the FAN levels fall throughout the fermentation as the yeast cells assimilate and metabolize the available FAN during the course of the fermentation. Towards the end of the fermentation in the conventional process, FAN levels rise illustrating the release of cellular FAN that coincides with the death and lysis of the yeast cells. In contrast, the kinetics of using FAN in the raw starch process is faster. FAN levels reach a minimum of at least 24 hours before, and then begin to increase dramatically. Some of the increase in FAN is due to the death of the yeast cells resulting from accelerated fermentation.

Beer with High Alcohol Content The present invention also relates to a beer with a high alcohol content. In one embodiment, the process of the present invention produces beer containing more than 18% by volume of ethanol. The present process can produce such beer with a high alcohol content in about 40 to about 96 hours or about 45 to about 96 hours. In a modality, beer includes 18% by volume .. up to approximately 23% by volume of ethanol. For example, the present method can produce alcohol contents in the fermenter from 18 to 23% by volume in about 45 to 96 hours By way of further example, the present method can produce the alcohol content in the fermenter of 18 to 23% by volume in approximately 45 to 96 hours In certain embodiments, most of the alcohol (80% or more of the final concentration) is produced in the first 45 hours, then it can be produced 2 to 5% by volume additional alcohol in the final 12 to 48 hours.Ethanol concentrations up to 23% by volume can be achieved with fermentation time up to 96 hours.It can be economically advantageous to harvest after 48 to 72 hours of fermentation to increase the fermenter productivity The present beer can include this high level of ethanol even when it includes high levels of residual starch For example, the present beer can include ethanol in 18 to 23% by volume in when it contains 0 to 30% residual starch. The present beer may contain residual starches as low as 0% at as high as 20% residual starch. By conventional measures, the high levels of residual starch indicate inefficient fermentation, which produces only low levels of ethanol.In contrast, although not limited to the present invention, it is believed that the present method results in fewer reaction products of type Maillard and more efficient yeast fermentation (eg, reduced levels of secondary metabolites) This is believed to be due to the high glucose levels and low temperatures of the current method compared to conventional saccharification and liquefaction. , the present method can produce more alcohol even with higher levels of residual starch In one embodiment, the present beer includes fewer residual byproducts than conventional beers, even though the residual starch may be higher, for example, residual glucose , the maltose and the higher dextrins (DP3 +) can be as much as 0.8% by weight less r than in conventional beers produced under similar fermentation conditions. By way of further example, the residual glycerol can be as much as 0.75 by weight less. Lactic acid and isoamyl alcohols can also be significantly reduced. For example, the present beer may include less than or equal to about 0.2 wt% glucose, about 0.4 wt%, about 0.1 wt% DP3, not detectable DP4 +, 0.7 wt% glycerol, about 0.01% by weight weight of lactic acid, and / or about 0.4% by weight of isoamyl alcohols.

Dry Grain of the Distiller Dry Grain of the Distiller with High Protein Content The present invention also relates to a dry grain product of the distiller. The dried grain of the distiller may also include elevated levels of one or more of protein, fat and fiber (eg, neutral detergent fiber (NDF)), and starch. For example, the present dry grain of the distiller may include 34 or more% by weight of protein, about 25 to about 60% by weight of protein, about 25 to about 50% by weight of protein, or about 30 to about 45% by weight. protein weight. In certain circumstances, the amount of protein is from about 1 to about 2% by weight more protein than that produced by the conventional process. For example, the dried grain of the distiller may include 15% by weight or more of fat, about 13 to about 17% by weight of fat, or about 1 to about 6% by weight more fat than that produced by the conventional process. For example, the dry grain of the distiller may include 31% by weight or more of fiber, approximately 23 to approximately 37%. in weight of fiber, or about 3 to about 13% by weight more fiber than that produced by the conventional process For example, the dried grain of the distiller can include 12 or more% by weight of starch, about 1 to about 23% of starch, or about 1 to about 18% more starch than that produced by the conventional process In one embodiment, the present dry grain of the distiller includes high levels of vitamins B, vitamin C, vitamin E, folic acid and / or vitamin A , compared to the conventional dry distiller dry grain products.The present dry bead of the distiller has a richer gold color compared to conventional distiller dry grain products.

Dry Distiller Grain with Enhanced Physical Characteristics The present invention also relates to a dry bean of the distiller with one or more improved physical characteristics, such as decreased cake formation or compaction or increased ability to flow. The present process can produce such dry grain from the improved distiller. Although not limited to the present invention, it is believed that the present process can produce fermentation solids that include higher molecular weight forms of the carbohydrates. Such fermentation solids may, it is believed, show a higher vitreous transition temperature (eg, higher Tg values) compared to the solids of the conventional process. For example, residual starches may have a high Tg value. In this way, through the control of the starch content in the DDG and DGS, the present process can manufacture DDG or DGS with target Tg values. Furthermore, according to the present invention, the addition of an alkaline syrup mixture (eg, syrup plus added limestone or other alkaline material) to the fermentation solids (eg, dry grains of the distiller) can provide decreased formation of the cake or cappactación or increase the ability to flow into the dry grain of the distiller with soluble materials (DGS).

Although not limited to the present invention, it is believed that organic acids such as lactic, acetic and succinic acids that are produced in fermentation have a lower Tg value than their corresponding calcium salts. The maintenance of residual carbohydrate in the form of higher molecular weight, or ... the addition of limestone to form calcium salts of organic acids, are two strategies to form co-products with higher T3 value that will be less likely to suffer the glass transition, resulting in the harmful phenomenon known as cake formation. In one embodiment, DDG or DGS produced by the method of the present invention flows more rapidly than DDG or DGS produced by the conventional process. Although not limited to the present invention, it is believed that the process of the present invention may not need to destroy the protein in the fermented plant material (eg, fractionated plant material). Corn contains prolamines, such as zein. Sorghum grain, for example, contains a class of zein-like proteins known as kafirins, which resemble zein in the amino acid composition. The thermal degradation that occurs during liquefaction, distillation and drying at high temperature, produces DDG and DGS that include significant amounts of degraded protein. It is believed that the process of the present invention can provide improved levels of prolamin fraction of the cereal grains. It is believed that prolonged exposure to the high concentrations of alcohol that can be achieved by the present process can condition the proteins in the plant material (for example, fractionated plant material).

This can solubilize some of the proteins. For example, it is believed that in the distillation the ethanol concentration reaches levels that can solubilize the prolamines (for example, zein) in beer. - After the elimination, or "depuration", of the ethanol from the beer, the prolamines (such as - zein) can be recovered in concentrated form in DDG and DGS. The high protein content resulting from DDG and DGS can be advantageous for various end uses of DDG and DGS, for example in the further processing or composition. In one embodiment, efficient fermentation of the present process removes non-zein components such as starch from DDG or DGS. Fractionation of plant material, for example, corn, can also increase protein levels, such as zein, in DDG or DGS. For example, the removal of bran and germ fractions prior to fermentation may concentrate the zein in the substrate. Zein in corn is isolated in the endosperm. Fermentation of the endosperm enriched with zein results in the concentration of the zein in the residues of the fermentation. In one embodiment, the present method can operate on fractionated plant material (such as the endosperm, fiber, other parts of the cereal grain) to provide a solid product enriched in protein, from fermentation. For example, the present method operated on the fractionated plant material, can produce a DDG-enriched in prolamine, such as zein. In one embodiment, the process of the present invention can provide "DDG and DDGS with different predetermined Tg values." The process of the present invention can ferment fractions containing high, medium or low levels of zein, thereby varying the temperature of vitreous transition of the resulting DDG or DGS The Tg of the resulting co-product can be directly proportional to the protein content of prolamine (such as zein) The process of the present invention is desirable for the fermentation of high protein corn. This also allows the production of DDG and DGS with a higher content of prolamin (zein) .The residual starch remaining at the end of the fermentation is preferably segregated within the fraction of the thin residue, which is subsequently evaporated to produce syrup. of wet cake produced by the present method, which can be dried separately to produce DDG, can be s high in prolamin protein (such as zein) than conventional DDG. The present process allows the syrup and wet cake to be mixed in varying proportions. This results in DDG / DGS with varying proportions of prolamin protein (such as zein) and residual starch. According to the residual starch in the wet cake is reduced, the protein in the wet tota is increased. This indicates an inverse relationship. A similar response occurs in the fraction of the syrup. It is believed that starch can segregate within the liquid fraction. The amount of starch in the DGS can be varied by mixing the syrup to proportions in the range of 0 kg dry weight of the syrup solids to 544 g (1.2 pounds) of syrup solids per 454 g (1 pound) of wet cake solids before and various times during drying, to create the DGS product. The disproportionate segregation of the residual starches within the countercurrent or the thin slurry fraction can provide the aforementioned consumption and the secondary fermentation to be carried out on these fractions. Since the thin waste is evaporated to produce syrup, the centrifugal mass balance also makes it possible to produce DGS at various values of Tg depending on the desired properties and its dependence on the Emissions The present invention has benefits in emissions. The benefits in the emissions result in the reduction in by-products created in the ethanol manufacturing process. There is a -reducción marked in the extraction of fats and oils in the pulpy mass from the germ fraction of cereal grains. There is a reduction of secondary products from the Maillard reactions, typically formed during the portion and liquefaction. And there is a reduction in the fermentation byproducts. These observations result in reduced emissions during the recovery of the co-products. The concentration and emission rates of volatile organic compounds (VOC), carbon monoxide (CO) compounds of nitric oxide (NOx), sulfur oxides (S02) and other emissions, are considerably lower. See Table 1. Note that other manufacturers have tried to reduce emissions by making the wet cake instead of drying out DDG or DGS. The present invention also relates to volatile organic compounds (VOC), such as those produced by drying the products of a fermentation process. The present method includes the production of ethanol, the dried grain of the distiller, and the additional useful fermentation products with production of lower levels of VOC, in comparison to the conventional processes. For example, in the present method, the drying of distillation products (eg, spent grain) produces reduced levels of VOC. Conventional fermentation processes using corn, for example, produce approximately 952 g (2.1 pounds) of VOC's from the drying of the distillation products for each ton of processed corn. Current chimney emissions may be lower due to pollution control equipment. The present method results in at least 30% reduction in VOC production to approximately 666 g (1.47 pounds) or less per ton of processed corn. These reductions in emissions are unexpected and even highly significant, and provide more efficient use of emission reduction control technology, such as thermal oxidants. The VOC produced by the fermentation processes include ethanol, acetic acid, formaldehyde, methanol, acetaldehyde, acrolein, furfural, lactic acid, formic acid and glycerol. The present invention also relates to carbon monoxide (CO), such as those produced by drying the products of a fermentation process. The present method includes the production of ethanol, dried grain from the distiller and additional useful fermentation products with production of lower CO levels compared to conventional processes. For example, in the present method, the drying of the distillation products (eg, spent grain) produces reduced levels of CO. Conventional fermentation processes using corn, for example, produce approximately 635 g (1.4 pounds) of CO from the drying of the distillation products for each ton of processed corn. Effective chimney emissions may be lower due to pollution control equipment. The present method results in a 30% reduction in CO production to approximately 444 g (0.98 pounds) or less per ton of processed corn. These reductions in emissions are unexpected and even highly significant, and provide more efficient use of control technology to reduce emissions, such as thermal oxidants.

Table 1: Reductions in Emissions System for Producing Ethanol In one embodiment, the invention relates to a system that produces ethanol. The present system may include a saccharification apparatus 1, a fermentation apparatus 2, a distillation apparatus 3, and a drying apparatus 4. The saccharification apparatus 1 may be any of a variety of apparatuses suitable for containing or conducting saccharification. The saccharification apparatus 1 can be, for example, a container in which the reduced plant material can be converted to a sugar, which can be fermented by a microorganism such as a yeast. The saccharification apparatus 1 can be configured to maintain a saccharification mixture under conditions suitable for saccharification. The saccharification apparatus 1 can be -configured to provide the conversion of the reduced plant material with the addition of enzymes. In one embodiment, the saccharification apparatus 1 is configured to mix reduced plant material with a liquid, and add a saccharification enzyme composition to the liquid. In one embodiment, the saccharification apparatus 1 is configured for saccharification at a variety of pH's and temperatures, but preferably at a pH of 6. 0 or less, and at a temperature of about 25 to about 40 ° C. The fermentation apparatus 2 may be any of a variety of suitable apparatuses for containing or conducting the fermentation. The fermentation apparatus 2 can be, for example, a container in which the sugar from the reduced plant material can be fermented to ethanol. The fermentation apparatus 2 can be configured to maintain a fermentation mixture under conditions suitable for fermentation. In one embodiment, the fermentation apparatus 2 can be configured to ferment through the use of a microorganism, such as a yeast. In one embodiment, the fermentation apparatus 2 can be configured to ferment a starch composition that has not been cooked, specifically the saccharification mixture. In one embodiment, the apparatus may employ any variety of "yeasts that produce a quantity commercially. - significant ethanol at an appropriate time. The yeast can be added to the appliance by any of a variety of known methods to add yeast to a system that conducts fermentation. The fermentation apparatus 2 can be configured for fermentation for approximately 25 to 150 hours at a temperature of about 25 to about 40 degrees C. The saccharification apparatus 1 and fermentation apparatus 2 can be a simple integrated apparatus. In one embodiment, this apparatus is configured to provide higher temperatures early during the simultaneous conversion of the reduced plant material, to sugars and the fermentation of those sugars. In one embodiment, this apparatus is configured to provide lower temperatures later during simultaneous saccharification and fermentation. The apparatus may also utilize the reagents and conditions described above for saccharification and fermentation, including enzymes and yeast. The distillation apparatus 3 can be any of a variety of apparatuses suitable for distilling fermentation products. The distillation apparatus 3 can be, for example, configured to recover ethanol from the fermentation mixture ("beer"). In one embodiment, the fermentation mixture is heat treated before entering the distillation apparatus 3. In yet another embodiment, the fractions of large pieces of germ and fiber are removed with a surface skimmer or screen before or after entering. to the distillation apparatus 3. The drying apparatus 4 can be any of a variety of apparatuses suitable for drying solids remaining after distillation (and optional centrifugation, for example, in a centrifuge system). In one embodiment, the drying apparatus 4 is configured to dry the recovered solids, which can result in the production of the dried grain from the distiller. Then the distillation system separates the ethanol from the beer, and the recovered solids remain. These recovered solids can then be dried in the drying apparatus 4. This produces the dry grain from the distiller and / or the dried grain from the distiller plus soluble materials. In one embodiment, the dryer apparatus 4 can be or include a ring dryer. In one embodiment, the dryer apparatus 4 can be or include an instant dryer. In one embodiment, the drying apparatus 4 can be or include a fluidized bed dryer. The present invention can be better understood with reference to the following examples. These examples are intended to be representative of the specific embodiments of the invention, and are not intended to limit the scope of the invention.

EXAMPLES Example 1 - The Present Process Provides Improved Efficiency with Derived substrates d. Dry Grain Milling Operations (Endosperm, Fiber and Germ) The present invention provides an improved method for the fermentation of substrates derived from grain grinding processes (dry fractionation). The present process is useful for the fermentation of the endosperm, since the levels of FAN in the pulpy mass are reduced to the elimination of the germ. The present process contributes to the activity of the endogenous enzymes in the grain. The dramatic increase in FAN in the whole corn and the fermentations in the defibrated corn, are reached in comparison to the suspension of initial pulpy mass.

Results and Discussion The present process is useful for fermentation of the endosperm since the levels of FAN in the pulpy mass are reduced due to the elimination of the germ, as shown in Figure 2A. The FAN supplies the necessary nitrogen for the development of the yeasts and reduces the tension related to ethanol in fermentations of high gravity ethanol. Figure 2A also reveals the negative impact of liquefaction on the reduction of the amount of FAN available in the fermentation. The generation of dextrins and sugars "soluble during high temperature liquefaction, results in Maillard condensation reactions between the carbonyl groups on sugars and amino groups on amino acids and peptides. This results in a loss in potential yield (due to unavailable carbohydrate) as well as a reduction in the nutritional quality of the pulpy mass to sustain high-gravity efficient fermentation (due to the reduction in FAN). The present process also makes it possible for the activity of the endogenous enzyme in the grain to contribute to the generation of soluble sugars and amino nitrogen in the pulpy mass. These charitable activities are lost during the conventional liquefaction stage. The kinetics of the use of FAN is illustrated in Figure 2B for the fermentation of various fractions of dry milled grain.

It is interesting to note that the FAN kinetics in the conventional process all follow a similar guide for each corn fraction. During the first half of the fermentation, the FAN is consumed in the course of yeast development. Subsequently, it is observed that the levels of FAN increase, presumably due to the release of cellular FAN corresponding to the death and cell lysis of "the yeasts." It is observed that the initial use of FAN in the raw starch process is much faster Also note the dramatic increase in F ^ at the end of the raw starch fermentations.This increase in FAN could be the result of the death of the yeast cells, since the speed of ethanol production is much higher. This could also be due to the generation of FAN from the endogenous enzymes in the grain.Note that when the germ is eliminated, there is less than an increase in FAN during the last half of the fermentation. These observations suggest an additional aspect of the raw starch process, Figure 2c illustrates the impact of FAN on the fermentations of the maize fraction run in au. countercurrent sequence, in comparison and contrasting with the sensitivity of the two processes to the addition of additional FAN. It is apparent that the process of the present invention significantly improves the potential quality of the substrate from a dry milling fractionation facility for fermentation, reducing the importance of the additional FAN. The present process is superior to the conventional liquefaction process, since the conventional liquefaction process is more sensitive to the disturbing impact of the quality of the substrate as measured by the levels of FAN.- Example 2 - The present method produced high protein DDG from Fractionated Vegetable Product The present invention demonstrated that fractionation of maize before fermentation provides high levels of protein in the resulting DDG.

Materials and Methods Corn was fractionated before fermentation through the use of a Satake fractionation system. After the fractionation, the corn was fermented according to the present invention using for the saccharification the glucoamylase and the fungal amylase acid without cooking. The fermentation was conducted at 32 ° C (90 ° F) and at a pH of 5. After the corn solids were fermented, the ethanol was distilled. The remaining solids were then dried, and samples of fiber, germ and starch were taken. All fractionation samples were crushed for twenty seconds in a Knifetec. These samples were then analyzed for starch, protein, fat and neutral detergent fiber content. The percentage yield of ethanol was also calculated for each sample. See also the Materials and Methods sections for the other examples for additional information regarding how these experiments were conducted.

Results and Discussion The present method produced DDG of high protein and high levels of ethanol compared to a conventional process (Table 2). Table 2 shows the results for ethanol and DDG produced from two representative samples of each of the fiber, starch and germ samples. Fermentations B and C, the representative starch samples, resulted in the highest ethanol yield and produced DDG with the highest percentage of protein (Table 2). The two germ samples generated the lowest ethanol yield and the highest percentage of fat (Table 2). The fiber samples produced the lowest amount of protein (Table 2). In general, this table illustrates that the fractionation increased the retention rate of the protein throughout the fermentation and distillation process (Table 2).

Table 2 - Approximate Levels of Ethanol and DDG Produced from Corn Fractions Example 3 - The Present Process Provided Improved Fermentation of Corn Fiber The present invention provides an improved method for the fermentation of corn fiber substrates derived from grain milling processes (dry fractionation). The present process was useful to remove milder starch from the corn fiber fractions via fermentation. Typically, corn fiber fractions contain recalcitrant starch deposits. The present method provided improved access to the starch present in the corn fiber.

Materials and Methods The final fiber obtained from Broin Enterprises, Inc.

(BEI) in Scotland, South Dakota in the US, was used in this experiment. The gauging water used was deionized water. The 2,081,970 liters (550,000 gallons) were adjusted to a pH of 4.5 with sulfuric acid (0.5 ml per lOx solution required). The wet fiber was crushed in the Knifetech mill twice for ten seconds.

The temperature of a yeast propagator of 75,708 liters (20,000 gallons) was maintained at 32 ° C (90 ° F) with a propagation time of eight (8) hours and the pH adjusted to 5.0 with sulfuric acid. La-Fali, obtained from Fleischmann's Yeast was prepared using reconstitution water or capacity from the operations of the plant. A commercially available glucoamylase with a dose of 400 liters was used.

Results and Discussion Table 3 The present process provided effective fermentation of the corn fiber (Table 3). The data in Table 3 indicate the positive impact of fiber fermentation as measured by ethanol yield using the present method. The variation in temperature shows the effect on the recovery of ethanol, with efficient recovery of ethanol produced at lower temperatures. The present method effectively fermented a corn fiber fraction which in a conventional process typically retards fermentation.

Example 4 - The Present Process Provided Improved Kinetics of Ethanol in Endosperm Fermentation Via Additional Germ or Germ Flour The present invention provides an improved method for fermenting fractionated grain, such as fractionated corn derived from a grain milling process (fractionation dry) .

Materials and Methods Standard Ingredients for Cooking at a Vegetable Equivalent (Laboratory Dose) dose of 308 liters of Liquizyme SC AA (0.30 ml of a 25X solution) were used. Standard ingredients of fermentation at the equivalent plant dose (laboratory dose) included 660 liters of the Spirizyme Plus glucoamylase (0.25 ml of a 10X solution), 33 liters of protease (0.13 ml of a 100X solution), 2 kg (4.4 pounds) ) of Lactrol (0.16 ml of a 2,000X solution), and liquor without urea. Conditions in stages at the fermentation temperature included 32 ° C (90 ° F) from 0 to 24 hours, 29 ° C (84 ° F) from 24 to 48 hours, and 28 ° C ~ (82 ° F) from 48 to 65: hours. The ingredients of the standard yeast propagator at the laboratory dose included 230 ml of deionized water, 100 ml of countercurrent, 70 grams of maltodextrin MO40, 0.44 ml of 5x, 1.76 ml of 100X, 1.07 grams, 1.07 grams, 1.70 ml of 1000X , 0.13 grams of zinc sulfate, 0.48 grams of Fali Yeast for a propagation of eight (8) hours, propagation temperature of 52 ° C (90 ° F) with a transfer of 2.88 ml of yeast propagator for each fermenter for the inoculation. Plant-scale doses refer to 2,081,970 liters (550,000 gallons) with 80 ml laboratory thermenters used. The grams of the flour used and the water of reconstitution added were adjusted for each fermenter, to keep the starch content consistent. The pH of all the fermenters was adjusted to 6.0 with sulfuric acid. All the endosperm flour used was harvested from the ground BEI, and all the germ meal was crushed in a KnifeTech mill (3 x 10 seconds). The whole corn used as control was crushed through a 1.0 mm Laboratory Sieve. The pH of all the samples was adjusted to less than 3.50 with sulfuric acid to deactivate the residual enzyme activity before drying the samples for approximate analysis.

Results and Discussion At the beginning of the fermentation there was a difference measured in the percentage of ethanol in the germ produced according to the present method, in comparison to the liquefied germ. This difference continues throughout the forty-seven hours of fermentation. A similar trend was observed between the germ meal of the present invention and the liquefied germ meal. The present process provided improved kinetics of the ethanol in the fermentation of the endosperm via the additional germ or germ meal. These results are illustrated in Figures 3A, 3B and 3C. It should be noted that, as used in this specification and in the appended claims, the singular forms "a," "an," and "the," include plural referents, unless the content clearly dictates otherwise. . Thus, for example, reference to a composition containing "a compound" includes a mixture of two or more compounds. It should also be noted that the term "or" is generally used in its sense that includes "and / or" unless the content clearly dictates otherwise. All publications and patent applications in this specification are indicative of the level of ordinary experience in the art to which this invention pertains. The invention has been described with reference to various specific and preferred modalities and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention. It is noted that in relation to this date, the best known method for carrying out the said invention is that which is clear from the present description of the invention.

Claims

CLAIMS Having described the invention as above, the content of the following claims is claimed as property: 1. A process for producing ethanol from plant material, characterized in that it comprises: the fractionation of plant material; the reduction of plant material, to produce material that includes starch; the reduced plant material. it has a particle size such that at least about 50% x of the particles fit through a sieve with a mesh of 0.1 to 0.5 ml; the saccharification of the starch, without cooking, with an enzyme composition; the fermentation of the incubated starch, to produce a composition comprising at least 15% by volume of ethanol; the fermentation comprising the reduction of the temperature of the fermentation mixture; and the recovery of ethanol and the co-products of fermentation.
2. The process according to claim 1, characterized in that the plant material comprises corn, which comprises starch with high content of amylopectin.
3. The process according to claim 1, characterized in that the plant material comprises corn, sorghum, millet, wheat, barley, rye or mixtures thereof. .
The process according to claim 3, characterized in that the corn comprises waxy corn.
5. The process according to claim 3, characterized in that the corn comprises corn of high protein content.
6. The process of conformity with claim 3, characterized in that the corn comprises yellow cogged maize # 2.
The process according to claim 1, characterized in that it comprises the reduction of the plant material with a hammer mill, roller mill, or both mills: hammer mill and roller mill.
8. The process according to claim 7, characterized in that it comprises reducing the plant material to produce plant material of a size such that at least 35% of the reduced plant material fits through a mesh screen of 0.1-0.5 mm.
9. The process according to claim 1, characterized in that it comprises the reduction of the plant material with emulsion technology of particle size reduction.
10. The process according to claim 1, characterized in that it simultaneously comprises saccharification and fermentation.
11. The process according to claim 1, characterized in that it comprises the reduction of the temperature during saccharification, fermentation or simultaneous saccharification and fermentation.
12. The process according to claim 1, characterized in that it comprises saccharification, fermentation or simultaneous saccharification and fermentation at a temperature of 25 to 40 ° C.
13. The process according to claim 1, characterized in that it comprises simultaneous saccharification, fermentation or saccharification and fermentation at a temperature of 27 to 35 ° C. 1 .
The process according to claim 1, characterized in that it comprises the reduction of the temperature of about 40 ° C and up to about 25 ° C during saccharification, fermentation or simultaneous saccharification and fermentation.
15. The process according to claim 1, characterized in that it comprises simultaneous saccharification, fermentation or saccharification and fermentation at pH from about 3.0 to about 6.0.
16. The process according to claim 1, characterized in that it comprises saccharification, • * - fermentation or simultaneous saccharification and fermentation at pH from about 4.1 to about 5.3.
17. The process of compliance with claim 1, characterized in that it comprises a pH of about 4 to about 4.5 at the start of the fermentation filling.
18. The process according to claim 1, characterized in that it comprises a pH of about 5 to about 5.5 as the ethanol production reaches the maximum level.
19. The process according to claim 1, characterized in that it comprises increasing the pH from about 4 to about 5.3 during simultaneous saccharification, fermentation or saccharification and fermentation.
The process according to claim 1, characterized in that it comprises the reduction of the solids content from about 40% to about 15% during simultaneous saccharification, fermentation or saccharification and fermentation.
21. The process according to claim 1, characterized in that the enzyme composition comprises alpha-amylase, glucoamylase, protease, or mixtures thereof.
22. The process according to claim 1, characterized in that saccharification, fermentation or saccharification and simultaneous fermentation, comprise the addition of protease.
23. The process according to claim 1, characterized in that saccharification, fermentation or simultaneous saccharification and fermentation comprise countercurrent addition.
24. The process according to claim 1, characterized in that saccharification, fermentation or simultaneous saccharification and fermentation comprise the addition of nitrogen.
25. The process according to claim 1, characterized in that it comprises saccharification and fermentation at rates that maintain the glucose concentration at less than 3% by weight in the fermentation.
26. The process according to claim 1, characterized in that it comprises saccharification, fermentation or saccharification and fermentation with about 0.1 to about 10 units of acid fungal amylase (AFAU) per gram of plant material reduced in dry solids, and about 0.1 to about 6 units of glucoamylase (AGU) per gram of plant material reduced in dry solids.
27. The process according to claim 1, characterized in that it comprises the initiation, saccharification, fermentation or saccharification and fermentation with about 25 to about 45% by weight of reduced plant material, in water.
28. The process according to claim 1, characterized in that it comprises the initiation of saccharification, fermentation or saccharification and fermentation with residual starch up to 20%.
29. The process according to claim 1, characterized in that it comprises the production of more than 18% by volume of ethanol in about 48 to 96 hours.
30. The process according to claim 1, characterized in that it comprises the production of 18% by volume up to about 23% by volume of ethanol.
31. The process according to claim 1, characterized in that it also comprises the recovery of the solids from the fermentation.
32. The process according to claim 31, characterized in that it comprises the recovery before, during and after the recovery of the ethanol.
33. The process according to claim 31, characterized in that it comprises the recovery of the dried grain from the distiller.
34. The process according to claim 31, characterized in that the dried grain of the distiller comprises about 30 to 38% by weight of protein, about 11 to 19% by weight of fat, about 25 to 37% by weight of fiber.
35. The process according to claim 31, characterized in that the dried grain of the distiller comprises at least about 30% protein.
36. The process according to claim 1, characterized in that it comprises the running of the process as a batch process or as a continuous process.
37. A process for the production of ethanol from vegetable material, characterized in that it comprises: the fractionation of the plant material; the reduction of plant material to produce material comprising starch; saccharification of the starch, without cooking, with an enzymatic composition comprising the fungal amylase acid; the fermentation of the incubated starch, to produce a composition comprising at least about 18 volume% ethanol; the recovery of ethanol from fermentation.
38. A dried grain of the distiller, characterized in that it comprises at least about 40% by weight of protein.
39. A process for producing ethanol from the plant material, characterized in that it comprises: reduction of the plant material, to produce material comprising starch; the reduced plant material having a particle size such that at least about 50% of the particles fit through a sieve with a mesh of 0.1 to 0.5 ml; the saccharification of the starch, without cooking, with an enzyme composition; the fermentation of the incubated starch, to produce a composition comprising at least 15% by volume of ethanol; the fermentation comprising the reduction of the temperature of the fermentation mixture; and the recovery of ethanol and the co-products of fermentation. the drying of a co-product by ring drying, flash drying or fluidized bed drying.