WO2013180863A1 - Systèmes et méthodes de traitement de biomasse et de calcul de rendement d'éthanol - Google Patents

Systèmes et méthodes de traitement de biomasse et de calcul de rendement d'éthanol Download PDF

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Publication number
WO2013180863A1
WO2013180863A1 PCT/US2013/038252 US2013038252W WO2013180863A1 WO 2013180863 A1 WO2013180863 A1 WO 2013180863A1 US 2013038252 W US2013038252 W US 2013038252W WO 2013180863 A1 WO2013180863 A1 WO 2013180863A1
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WIPO (PCT)
Prior art keywords
slurry
fluid
vessel
starch
transport fluid
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PCT/US2013/038252
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English (en)
Inventor
Marcus Brian Mayhall Fenton
Tsz Hang Emily HO
Robert Scott
Pete Thompson
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Pursuit Dynamics Plc
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Publication date
Priority claimed from US13/486,865 external-priority patent/US20120270275A1/en
Application filed by Pursuit Dynamics Plc filed Critical Pursuit Dynamics Plc
Publication of WO2013180863A1 publication Critical patent/WO2013180863A1/fr

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    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M45/00—Means for pre-treatment of biological substances
    • C12M45/02—Means for pre-treatment of biological substances by mechanical forces; Stirring; Trituration; Comminuting
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M21/00—Bioreactors or fermenters specially adapted for specific uses
    • C12M21/12—Bioreactors or fermenters specially adapted for specific uses for producing fuels or solvents
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M45/00—Means for pre-treatment of biological substances
    • C12M45/09—Means for pre-treatment of biological substances by enzymatic treatment
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M45/00—Means for pre-treatment of biological substances
    • C12M45/20—Heating; Cooling
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
    • C12P19/00—Preparation of compounds containing saccharide radicals
    • C12P19/02—Monosaccharides
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
    • C12P7/00—Preparation of oxygen-containing organic compounds
    • C12P7/02—Preparation of oxygen-containing organic compounds containing a hydroxy group
    • C12P7/04—Preparation of oxygen-containing organic compounds containing a hydroxy group acyclic
    • C12P7/06—Ethanol, i.e. non-beverage
    • C—CHEMISTRY; METALLURGY
    • C13—SUGAR INDUSTRY
    • C13K—SACCHARIDES OBTAINED FROM NATURAL SOURCES OR BY HYDROLYSIS OF NATURALLY OCCURRING DISACCHARIDES, OLIGOSACCHARIDES OR POLYSACCHARIDES
    • C13K1/00—Glucose; Glucose-containing syrups
    • C13K1/06—Glucose; Glucose-containing syrups obtained by saccharification of starch or raw materials containing starch
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E50/00—Technologies for the production of fuel of non-fossil origin
    • Y02E50/10—Biofuels, e.g. bio-diesel

Definitions

  • the present invention relates, inter alia, to a biomass treatment process suitable for use in manufacturing alcohol, such as, for example, ethanol for biofuel production, as well as other products such as sugars, sugar syrups or products that are fed into alternative fermentation/reaction routes to make end products other than alcohol. More specifically, the present invention relates to an improved process and apparatus for converting starch-based biomass into sugars. Subsequently, the sugars may undergo a series of processes (such as saccharification, fermentation and distillation) whose end products are, e.g., an alcohol.
  • a series of processes such as saccharification, fermentation and distillation
  • the process of converting starch-based biomass into sugars in biofuel production is a multi-step process involving hydration, activation (gelatinisation) and liquefaction (conversion).
  • Hydration means the absorption of water via diffusion into the starch granule.
  • Starch activation is the swelling of starch granules by the absorption of additional water in the presence of heat such that the hydrogen bonds between the starch polymers within the granule loosen and break allowing the polymeric structure to unfold in space in the presence of water. This is an irreversible breakdown of the crystalline structure of the starch, eventually the starch granule ruptures and the starch polymers are dispersed in solution forming a viscous colloidal state.
  • the liquefaction process is the conversion of gelatinised starch into shorter chain polysaccharides (dextrins). Subsequently, the dextrins may undergo saccharification (hydrolysis to small sugar units), fermentation and distillation into alcohol such as ethanol, for example.
  • Processes used in industry for the conversion of starch-based biomass into sugars typically involve an initial hydration step of mixing ground starch-based feedstock with water to form a slurry.
  • the water may be pre-heated prior to being mixed with the feedstock.
  • the slurry may additionally be heated in a vessel in order to activate the starch, and is then heated again and mixed with a liquefaction enzyme in order to convert the starch to shorter chain sugars.
  • the activation stage typically uses steam jacketed tanks or steam sparge heating to heat the slurry to the desired temperature typically above 70°C, preferably above 85°C, and hold it at that temperature for 30 to 45 minutes in order to hydrate and gelatinise the starch.
  • a liquefaction enzyme may also be added at this stage to reduce the viscosity of the slurry.
  • agitation mixers, slurry recirculation loops, or a combination of the two mix the slurry.
  • the slurry is then pumped to a second heated vessel for the liquefaction stage where the gelatinised starch is converted to dextrins.
  • One drawback of the above process is that the temperatures reached in the first vessel are not high enough to fully gelatinise the starch, leading to a reduction in yield.
  • This first type of conventional process normally uses separate vessels for the activation and conversion stages of the process. Transfer of the slurry from the activation (and hydration) vessel to the conversion stage vessel is normally accomplished using centrifugal pumps, which impart a high shear force on the slurry and can cause further damage to the hydrated gelatinised starch as a result.
  • the conversion (liquefaction) stage may also use steam- or water- jacketed tanks, or tanks heated by sparge heaters, to raise the temperature of the slurry to the appropriate level for the optimum performance of the enzyme.
  • jet cookers are employed to heat the slurry to temperatures between 105°C and 1 10°C once it has left the activation vessel.
  • the hot slurry is then flashed into a low pressure tank and water vapour is removed.
  • the slurry is then cooled and pumped into the conversion stage vessel.
  • the high temperature regions also contribute to limiting the dextrin (sugar) yield from the process.
  • the excessive heat of these regions promotes Maillard reactions, where the sugar molecules are destroyed due to interaction with proteins also present in the slurry.
  • the combination of these Maillard losses with the shear losses from the transfer pumps limits the dextrin yield.
  • a reduced yield of dextrins from the liquefaction process obviously reduces the yields of any subsequent processing stages, such as glucose yield from the saccharification stage, and hence alcohol yield from the fermentation stage.
  • the high temperatures caused by the jet cooker denature the liquefaction enzyme such that a second dose of enzyme needs to be added to enable the liquefaction process. This increases the cost of the process as does the energy required for the extra heating and cooling stages.
  • existing liquefaction processes require a long residence time for the slurry in the conversion stage to ensure that as much starch is converted to sugars as possible. This can lead to a longer production process with increased costs.
  • one aim of the present invention is to mitigate or obviate one or more of the foregoing disadvantages.
  • a first embodiment of the present invention is a process for the treatment of a starch-based feedstock.
  • This process comprises mixing together a starch-based feedstock and a working fluid to form a slurry, hydrating the starch- based feedstock with the working fluid, adding an enzyme to the slurry, pumping the slurry into a substantially constant diameter passage of a fluid mover, and injecting a high velocity transport fluid into the slurry through a nozzle communicating with the passage, thereby heating and further hydrating the starch-based feedstock, and activating the starch content of the slurry.
  • an apparatus for treating a starch-based feedstock comprising a hydrator/mixer for mixing and hydrating the feedstock with a working fluid to form a slurry and a fluid mover in fluid communication with the first hydrator/mixer.
  • the fluid mover comprises a passage of substantially constant diameter having an inlet in fluid communication with the first hydrator/mixer and an outlet; and a transport fluid nozzle communicating with the passage and adapted to inject high velocity transport fluid into the passage.
  • a system for producing ethanol comprising an apparatus according to the present invention, which apparatus is integrated into an ethanol production plant.
  • a process for making ethanol comprising saccharifying and fermenting the activated starch content produced by carrying out a system according to the present invention on a starch-based feedstock.
  • a process for converting a starch contained within a starch-based feedstock into shorter chain polysaccharides by a process according to the present invention there is provided a process for converting a starch contained within a starch-based feedstock into shorter chain polysaccharides by a process according to the present invention.
  • processes, apparatuses and systems for the treatment of a starch-based feedstock According to certain embodiments, a starch-based feedstock and a working fluid are mixed together to form a slurry. The starch-based feedstock is hydrated with the working fluid. Such mixing and hydrating may take place in a hydrator/mixer.
  • the slurry is preferably heated and/or maintained at a temperature in the range of 55°C-85°C, and is directed to one or more fluid movers, each having a constant diameter passage, whereby a high velocity transport fluid is injected into the slurry through one or more nozzles communicating with the passage.
  • the slurry or a portion thereof ⁇ e.g., the working fluid component) is atomised to form a dispersed droplet flow regime downstream of the one or more nozzles.
  • Such processes, apparatuses, and/or systems preferably target the starch that is more difficult to gelatinise (i.e. starch that typically requires heating to a temperature that is higher than 75°C), increase yield, and can be used to produce ethanol or non- ethanol products.
  • the fluid movers discussed herein may also pump the slurry (in addition to heating it). Alternatively, a separate pump may be used to move the slurry through the system, in which case less or none of the energy of the fluid mover and corresponding reactor would be used for pumping and more - if not all - of the energy may be dedicated to heating, mixing, hydrating the starch, etc.
  • a process for calculating ethanol yield during the production of biofuels in a plant includes the steps of establishing a composition of dry matter and water making up a mass unit of mash entering into a fermenter that is part of an ethanol production system within the plant, and calculating a mass of dry matter and a mass of wet matter making up the mass unit.
  • An amount of wet corn in the mass unit may be calculated by adding the mass of dry matter and the mass of wet matter.
  • An amount of ethanol produced from the mass unit may also be calculated based on ethanol concentration measurements from the fermenter, and the yield may be determined by dividing the calculated amount of ethanol by the calculated amount of wet corn.
  • One or more of these steps may be implemented using a computer as they rely on stoichiometry and measurements of materials going into and leaving, for example, the fermenter.
  • One or more parameters such as operating conditions and inputs (e.g., ingredient balance), may be adjusted during production based on the resulting calculation to further improve yield. Examples of such parameters that may be adjusted include the temperature of the slurry, its flow rate and/or throughput, transport fluid speed , process time, pH level, the amount or ratio of feedstock/liquid present in the slurry, the amount of enzyme present and particle size.
  • FIG. 1 is a schematic view of a biofuel processing apparatus.
  • FIG. 2 is a longitudinal section view through a fluid mover suitable for use in the apparatus shown in FIG. 1 , FIG. 8, FIG. 10, or FIG. 1 1 .
  • FIG. 3 shows a graph of the temperature and pressure profile of a slurry as it passes through the device shown in FIG. 2.
  • FIG. 4 is a schematic view of part of the processing apparatus shown in FIG. 1 , FIG. 8, FIG. 10, or FIG. 1 1 , with various configurations of fluid movers included.
  • FIG. 5 is a schematic view of part of one embodiment of the processing apparatus according to the present invention.
  • FIG. 6 is a schematic view of part of another embodiment of the processing apparatus according to the present invention with a recirculation loop included.
  • FIG. 7 is a longitudinal section view through another embodiment of a fluid mover suitable for use in the apparatus shown in FIG. 1 , FIG. 8, FIG. 10, or FIG. 1 1 .
  • FIG. 8 is a schematic view of a biomass processing apparatus targeting starch that gelatinises at higher temperatures as compared to starch targeted using the apparatus of FIG. 1 .
  • FIG. 9 shows an illustrative graph that plots the temperature range over which starch granules from an exemplary feedstock may gelatinise.
  • FIG. 10 is a schematic view of a biomass processing apparatus that relies on a jet cook installation.
  • FIG. 1 1 is a schematic view of a biomass processing apparatus that relies on a hot cook installation.
  • FIG. 12 is a schematic view of a sub-system for fermenting and distilling ethanol post-liquefaction.
  • FIG. 13 is a block diagram view of a process for calculating yield.
  • the present invention relates, inter alia, to improved processes and apparatuses for converting starch-based biomass into sugars. Accordingly, the processes and apparatuses of the present invention are suitable for use in industrial processes as a first step in the production of an alcohol such as ethanol .
  • an alcohol such as ethanol
  • One such industrial process is the processing of starch-based biomass for biofuel production.
  • Other applications are the production of ethanol for a wide variety of other uses.
  • ethanol is used as a solvent in the manufacture of varnishes and perfumes; as a preservative for biological specimens; in the preparation of essences and flavourings; in many medicines and drugs; and as a disinfectant and in tinctures (e.g. tincture of iodine).
  • Ethanol is also used as a feedstock in the production of other chemicals, for instance in the manufacture of ethanal (i.e. acetaldehyde) and ethanoic acid (i.e. acetic acid).
  • ethanal i.e. acetaldehyde
  • ethanoic acid i.e. acetic acid
  • the processes and apparatuses of the present invention relate to an improved process for manufacturing sugars from starch-based biomass, they are also suitable for the production of sugar products, examples of which include dextrose, maltose, glucose and glucose syrup (e.g. corn syrup, widely used in processed foods, which is glucose syrup manufactured from maize), as well as other dextrins (e.g. fructose, maltodextrin, and high fructose syrup).
  • sugar alcohols e.g. maltitol, xylitol, erythritol, sorbitol, mannitol, and hydrogenated starch hydrolysate
  • Such sugar products will be produced by processes (such as controlled saccharification steps) after the liquefaction step of the present invention.
  • Corn dry grind is the most common type of ethanol production in the United States. In the dry grind process, the entire corn kernel is first ground into flour and the starch in the flour is
  • Corn wet milling is a process for separating the corn kernel into starch, protein, germ and fiber in an aqueous medium prior to fermentation.
  • the primary products of wet milling include starch and starch-derived products (e.g. high fructose corn syrup and ethanol), corn oil, and corn gluten.
  • starch and starch-derived products e.g. high fructose corn syrup and ethanol
  • corn oil e.g. corn oil
  • corn gluten e.g. high fructose corn syrup and ethanol
  • the apparatuses and processes of the present invention described in further detail below, may be integrated into any conventional bioethanol plant -either Dry Mill or Wet Mill- in order to improve the efficiency and lower the production costs of such a plant.
  • one embodiment of the present invention is a process for the treatment of a starch-based feedstock.
  • This process comprises mixing together a starch-based feedstock and a working fluid to form a slurry, hydrating the starch- based feedstock with the working fluid, adding an enzyme to the slurry, moving by, e.g., pumping the slurry into a substantially constant diameter passage of a fluid mover, and injecting a high velocity transport fluid into the slurry through one or more nozzles communicating with the passage, thereby further hydrating the starch-based feedstock and activating the starch content of the slurry.
  • the step of injecting a high velocity transport fluid into the slurry may include:
  • the first hydrating step may further include heating the slurry and/or maintaining it at a first predetermined temperature within a first vessel for a first predetermined period of time.
  • the process may further comprise recirculating the slurry through the first vessel.
  • the process may further comprise the step of transferring the slurry to a second vessel from the fluid mover, and maintaining the temperature of the slurry in the second vessel for a second predetermined period of time.
  • the step of transferring the slurry to the second vessel may include passing the slurry through a temperature conditioning unit to raise the temperature of the slurry.
  • this step may include passing the slurry through a low pressure flash tank to reduce the temperature of the slurry.
  • the process may also include the step of agitating the slurry in the first and/or second vessels for the respective first and second periods of time.
  • the transport fluid may be a hot, compressible gas, such as, e.g., steam, carbon dioxide, nitrogen, or other like gasses.
  • the transport fluid is steam.
  • the transport fluid may be injected at a subsonic or supersonic velocity.
  • the working fluid may be water as defined herein.
  • the step of injecting the transport fluid may comprise injecting the high velocity transport fluid into the slurry through a plurality of nozzles communicating with the passage.
  • the step of injecting the transport fluid into the slurry may occur on a single pass of the slurry through the fluid mover.
  • the step of injecting the transport fluid into the slurry may also include recirculating the slurry through the fluid mover.
  • the pumping of the slurry may be carried out using a pump, such as a low shear pump.
  • the feedstock may be selected from any starch-based plant material suitable for conversion to, e.g., alcohol, such as ethanol.
  • the feedstock is dry milled maize, dry milled wheat, or dry milled sorghum.
  • the feedstock could also include starch stocks derived from potato, oats, barley, rye, rice (or dry milled rice) and cassava.
  • an apparatus for treating a starch-based feedstock comprising a hydrator/mixer for mixing and hydrating the feedstock with a working fluid to form a slurry and a fluid mover in fluid communication with the first hydrator/mixer.
  • the fluid mover comprises a passage of substantially constant diameter having an inlet in fluid communication with the first hydrator/mixer and an outlet; and a transport fluid nozzle communicating with the passage and adapted to inject high velocity transport fluid into the passage.
  • the hydrator/mixer may comprise a heater to heat the working fluid and/or the slurry.
  • the hydrator/mixer may comprise a first vessel having an outlet in fluid communication with the inlet of the passage.
  • the heater may comprise a heated water jacket surrounding the first vessel. Alternatively, the heater may be remote from the hydrator/mixer.
  • the apparatus may further comprise a second vessel having an inlet in fluid communication with the outlet of the passage.
  • the second vessel may include an insulator to insulate the contents of the second vessel.
  • the insulator may comprise a heated water jacket surrounding the second vessel.
  • the insulator may comprise a layer of insulating material covering the exterior of the second vessel.
  • the apparatus may further comprise a residence tube section having an inlet in fluid communication with the outlet of the passage.
  • the residence tube may include an insulator for insulating the contents of the residence tube as it passes through.
  • Such an insulator may be a layer of insulating material covering the exterior of the residence tube section, or the residence tube may have a heated water jacket surrounding it.
  • the transport fluid nozzle may be annular and circumscribe the passage.
  • the transport fluid nozzle may have an inlet, an outlet and a throat portion intermediate the inlet and the outlet, wherein the throat portion has a cross sectional area which is less than that of the inlet and the outlet.
  • the passage may be of substantially constant diameter.
  • the apparatus may further comprise a transport fluid supply adapted to supply transport fluid to the transport fluid nozzle.
  • the apparatus may comprise a plurality of fluid movers in series and/or parallel with one another, wherein the transport fluid supply is adapted to supply transport fluid to the transport fluid nozzle of each device.
  • the apparatus may comprise a plurality of transport fluid supply lines connecting the transport fluid supply with each nozzle, wherein each transport fluid supply line includes a transport fluid conditioner.
  • the transport fluid conditioner may be adapted to vary the supply pressure of the transport fluid to each nozzle.
  • the apparatus may comprise a dedicated transport fluid supply for each transport fluid nozzle.
  • Each transport fluid supply may include a transport fluid conditioner.
  • Each conditioner may be adapted to vary the supply pressure of the transport fluid to each respective nozzle.
  • the apparatus may further comprise a temperature conditioning unit located between the fluid mover and the second vessel, the temperature conditioning unit is adapted to increase the temperature of fluid passing from the device to the second vessel.
  • the apparatus may comprise a low pressure flash tank or other device located between the fluid mover and the second vessel, the flash tank or other device is adapted to reduce the temperature of the fluid passing to the second vessel, as needed.
  • the apparatus may further comprise a recirculation pipe adapted to allow fluid recirculation between the outlet of the fluid mover and the first vessel, e.g., from downstream of the fluid mover to upstream of the fluid mover.
  • the apparatus may further comprise a pump, or other suitable device for moving the fluid.
  • the pump may or may not be a low shear pump adapted to pump fluid from the hydrator/mixer to the fluid mover.
  • the apparatus may further comprise first and second agitators located in the first and second vessels, respectively.
  • the first vessel may include a recirculator for recirculating slurry from the outlet to an inlet thereof.
  • the apparatus may be integrated into an ethanol production plant for producing ethanol from a feed stock, such as, e.g., a plant as disclosed in the Example or described herein.
  • the invention is a system for producing alcohol, e.g., ethanol.
  • the system includes an apparatus according to the present invention, which is integrated into an alcohol, e.g., ethanol, production plant.
  • the ethanol production plant may be a dry mill or a wet mill plant.
  • the plant may utilize either a dry grind based feedstock or a wet milling based feedstock.
  • the plant is a dry mill, which utilizes a dry grind based feedstock.
  • Another embodiment of the present invention is a process for making ethanol.
  • This process includes carrying out a system according to the present invention and then saccharifying and fermenting the product to produce, an alcohol, e.g., ethanol.
  • an alcohol e.g., ethanol.
  • any conventional process for carrying out the saccharifying and fermenting steps preferably commercial scale processes, are contemplated.
  • a further embodiment of the present invention is a process for converting a starch contained within a starch-based feedstock into polysaccharides, oligosaccharides and glucose.
  • This process involves carrying out a process according to the present invention, e.g., the process depicted in FIG. 1 , FIG. 8 or other similar figures.
  • the addition of, for example, alpha-amylase to make the shorter chain polysaccharides could be paired/followed with the addition of, for example gluco-amylase in order to break the polysaccharides down further to simpler sugars and monosaccharides, such as glucose.
  • the invention includes a system and process for calculating and monitoring yield (such as ethanol yield) in the production of biofuels.
  • yield such as ethanol yield
  • FIG. 1 it schematically illustrates an apparatus which hydrates and gelatinises the starch from a starch-based feedstock and then makes it more accessible so that it can be converted into shorter chain polysaccharides by, e.g., liquefaction enzymes.
  • the apparatus generally designated 1 , comprises a first vessel 2 acting as a first hydrator/mixer.
  • the first vessel 2 has a heater, which is preferably a heated water jacket 4 which surrounds the vessel 2 and receives heated water from a heated water supply (not shown).
  • the heater may be a traditional heater, a heat exchanger, sparge pipes, hot water injection systems and other like devices/systems well known to those skilled in the art.
  • the vessel 2 also includes an agitator 6 that is powered by a motor 8. The agitator 6 is suspended from the motor 8 so that it lies inside the vessel 2.
  • At the base of the vessel 2 are an outlet 10 and a valve 12 which controls fluid flow from the outlet 10.
  • a first supply line 16 Downstream of the first vessel 2 is a first supply line 16, the upstream end of which fluidly connects to the outlet 10 and valve 12 whilst the downstream end of the supply line 16 fluidly connects with a reactor 18.
  • a pump 14 may be provided in the supply line 16.
  • the pump 14 may be a centrifugal pump which has been modified in order to reduce shear as fluid is pumped through it.
  • the reactor 18 is formed from one or more fluid movers.
  • a suitable device that may act as a fluid mover is shown in detail in FIG. 2.
  • the fluid mover 100 comprises a housing 20 that defines a passage 22.
  • the passage 22 has an inlet 24 and an outlet 26, and is of substantially constant diameter.
  • the inlet 24 is formed at the front end of a protrusion 28 extending into the housing 20 and defining exteriorly thereof a plenum 30.
  • the plenum 30 has a transport fluid inlet 32.
  • the protrusion 28 defines internally thereof part of the passage 22.
  • the distal end 34 of the protrusion 28 remote from the inlet 24 is tapered on its relatively outer surface at 36 and defines a transport fluid nozzle 38 between it and a correspondingly tapered part 40 of the inner wall of the housing 20.
  • the nozzle 38 is in fluid communication with the plenum 30 and is preferably annular such that it circumscribes the passage 22.
  • the nozzle 38 has a nozzle inlet 35, a nozzle outlet 39 and a throat portion 37 intermediate the nozzle inlet 35 and nozzle outlet 39.
  • the nozzle 38 has convergent-divergent internal geometry as is known in the art, wherein the throat portion 37 has a cross sectional area which is less than the cross sectional area of either the nozzle inlet 35 or the nozzle outlet 39 and where there is a smooth and continuous decrease in cross- sectional area from the nozzle inlet 35 to the throat portion 37 and a smooth and continuous increase in cross-sectional area from the throat portion 37 to the nozzle outlet 39.
  • the nozzle outlet 39 opens into a mixing chamber 25 defined within the passage 22.
  • the reactor 18 is connected to a transport fluid supply 50 via a transport fluid supply line 48.
  • the transport fluid inlet 32 for each fluid mover 100 making up the reactor is fluidly connected with the transport fluid supply line 48 for the receipt of transport fluid from the transport fluid supply 50.
  • TCU 52 Located downstream of the reactor 18 and fluidly connected thereto is a temperature conditioning unit (TCU) 52.
  • the TCU 52 preferably comprises a fluid mover substantially identical to that illustrated in FIG. 2, and will therefore not be described again in detail here.
  • the TCU 52 can either be connected to the transport fluid supply 50 or else it may have its own dedicated transport fluid supply (not shown).
  • a second supply line 54 Downstream of the TCU 52 is a second supply line 54, which fluidly connects the outlet of the TCU 52 with a second vessel 56.
  • the second vessel 56 is similar to the first vessel 2, and therefore has a heater, such as, e.g., a heated water jacket 58 which surrounds the vessel 56 and receives heated water from a heated water supply (not shown).
  • the vessel 56 also includes an agitator 60 that is powered by a motor 62. The agitator 60 is suspended from the motor 62 so that it lies inside the vessel 56.
  • At the base of the vessel 56 are an outlet 64 and a valve 66 which controls fluid flow from the outlet 64.
  • a ground starch-based feedstock is introduced into the first vessel 2 at a controlled mass addition flow rate.
  • suitable feedstock include dry milled maize, wheat or sorghum.
  • Feedstock may be added by any method, such as manually, automatically, continuously or in batch mode. For instance, in a large production facility the feedstock may be added from a continuous belt feed whilst in a small test rig the feedstock may be added manually.
  • an enzyme that catalyzes the breakdown of the feedstock is mixed with a working fluid, preferably water, and that working fluid is then added to the feedstock in the vessel 2 to form a slurry and to start to hydrate the feedstock.
  • a working fluid preferably water
  • water in this context is not limited to pure water, but instead is intended to encompass all types of water (e.g. hard or soft water, aqueous solutions etc.) also fluids recovered from a later stage in the processing apparatus, or a combination of the above.
  • An example of a recovered fluid is 'backset' -a water-based fluid that may contain dissolved solids, solid debris and other soluble or insoluble impurities from the fermenter, which is recovered from the separator after fermentation.
  • process condensate which is water recovered from a distillation stage.
  • an "enzyme” or a “liquefaction enzyme”, which are used interchangeably herein, is a naturally occurring or genetically engineered protein that functions as a biochemical catalyst either enabling and/or accelerating a given process, e.g., the breakdown/conversion of the feedstock.
  • the enzymes may be of fungal, bacterial or plant origin.
  • catalysts such as, e.g., non-natural catalysts, such as metal ions, graphitic carbon, etc., may also be used in the present invention, as well as living organisms such as yeast or bacteria which actively produce enzymes.
  • the enzymes of the present invention are typically sourced from the fungus Aspergillis niger or bacteria Bacillus licheniformis.
  • An example of a suitable enzyme is a-amylase, for which a typical level of enzyme activity for the processes of the present invention is between 750 and 824AGU/g, where enzyme activity is given per unit mass of wet feedstock.
  • the preferred enzyme concentration in the vessel 2 is about 0.09-0.18 ml/kg.
  • the ratio of feedstock to liquid content in the slurry is 20%- 40% by weight.
  • Typical a-amylases used in the liquefaction stage have an activity optima when the pH is between about 5.5 and about 6.5.
  • one or more pH adjusters and/or surfactants may also be added to the slurry at this point. For instance, process condensate often has a low pH (e.g. 2-3) and once it and the feedstock have been mixed to form a slurry, ammonia may be added to adjust the pH to that required by the enzyme.
  • Heated water such as, e.g., recycled hot water recovered from another part of a process plant
  • Heated water is fed into the water jacket 4 surrounding the vessel 2 and the heated water jacket then heats the slurry to a temperature of typically 30° C-60° C, preferably 45° C-55° C, and holds the slurry at this temperature for 30-120 minutes so as to hydrate the crystalline regions of the starch granules.
  • the motor 8 drives the agitator 6, which stirs the slurry in the vessel 2 with gentle (i.e. low shear) agitation whilst the slurry is held in the vessel 2.
  • the working fluid may be heated prior to being mixed with the feedstock and the heater 4 in the vessel 2 may then maintain the slurry at the desired temperature.
  • the enzyme may be added into the vessel 2 separately from the working fluid. The enzyme may be added before the slurry has reached the desired temperature.
  • the slurry is held at the desired temperature in the vessel 2 for a sufficient period of time to allow the starch content to be prepared for full, or substantially full, hydration and gelatinisation.
  • “Sufficient” in this context means the time required for the crystalline, un-gelatinised starch grains in the slurry to absorb as much water as possible.
  • the water being absorbed into the crystallised starch grains acts as a plasticiser, destabilising the hydrogen bonds that help to order the crystal structure.
  • the valve 12 is opened to allow the slurry to leave the vessel via the outlet 10.
  • steering refers to the process of soaking the starch-based biomass as a slurry at a time and temperature in order to facilitate hydration of the un-gelatinised starch therein.
  • the pump 14 pumps the slurry under low shear conditions from the vessel 2 through the first supply line 16 to the reactor 18.
  • Transport fluid which in this non-limiting example is preferably steam, is fed from the transport fluid supply 50 (FIG. 1 ) at a preferred pressure of between 5-9 bar to the, or each, transport fluid inlet 32 via transport fluid supply line 48 (FIG. 1 ).
  • Transport fluid is fed from the transport fluid supply 50 (FIG. 1 ) at a preferred pressure of between 5-9 bar to the, or each, transport fluid inlet 32 via transport fluid supply line 48 (FIG. 1 ).
  • Introduction of the transport fluid through the inlet 32 and plenum 30 causes a jet of steam to issue forth through the nozzle 38 at a very high subsonic or, more preferably, supersonic velocity.
  • the nozzle outlet 39 opens into a mixing chamber 25 defined within the passage 22.
  • the angle at which the transport fluid exits the transport fluid nozzle 38 affects the degree of shear between it and the feedstock passing through the passage 22, the turbulence levels in the vapour-droplet flow regime and the further development of the fluid flow.
  • the angle a most readily defines the angle of inclination of the transport nozzle 38 to the passage 22. This angle is that formed between the leading edge of the divergent portion of the transport nozzle 38 which is the relatively outer surface 36 of the distal end 34 of the protrusion 28 and the longitudinal axis L of the passage 22.
  • the angle a is preferably between 0° and 70°, more preferably between 0° and 30°.
  • a momentum and mass transfer occurs between the two which preferably results in the atomisation of at least part of the slurry to form a dispersed droplet flow regime. This transfer is enhanced through turbulence.
  • "Atomised” in this context should be understood to mean break down into very small particles or droplets.
  • the steam preferably applies a shearing force to the slurry which not only atomises the working fluid component but also helps disrupt the ultrastructure ⁇ e.g., cellular structure) of the feedstock suspended in the slurry, such that some or all of the starch granules present are separated from the feedstock and dispersed into the slurry. Free surface area is critical in processing starch granules.
  • FIG. 3 shows the profile of the temperature and pressure as the slurry passes through various points in the fluid mover 100 of FIG. 2.
  • the graph in FIG. 3 has been divided into four sections A-D, which correspond to various sections of the fluid mover 100.
  • Section A corresponds to the section of the passage 22 between the inlet 24 and the nozzle 38.
  • Section B corresponds to the upstream section of the mixing chamber 25 extending between the nozzle 38 and an intermediate portion of the chamber 25.
  • Section C corresponds to a downstream section of the mixing chamber 25 extending between the aforementioned intermediate portion of the chamber 25 and the outlet 26, while section D illustrates the temperature and pressure of the slurry as it passes through the outlet 26.
  • the steam is injected into the slurry at the beginning of section B of the FIG. 3 graph.
  • the speed of the steam which is preferably injected at a supersonic velocity, and its expansion upon exiting the nozzle 38 may cause an immediate pressure reduction.
  • the steam may begin to condense, further reducing or continuing to maintain the low pressure and causing an increase in temperature.
  • the steam condensation may continue and form a condensation shock wave in the downstream section of the mixing chamber 25.
  • the forming of a condensation shock wave causes a rapid increase in pressure, as can be seen in section C of FIG. 3.
  • Section C also shows that the temperature of the slurry also continues to rise through the condensation of the steam.
  • the shear force applied to the slurry and the subsequent turbulent flow created by the injected steam disrupts the ultrastructure ⁇ e.g., cellular structure) of the feedstock suspended in the slurry, releasing the starch granules from the feedstock.
  • the slurry passes through the low pressure zone or partial vacuum and condensation shock wave formed in the chamber 25, it is further disrupted by the changes in pressure occurring, as illustrated by the pressure profile in sections B and C of FIG. 3.
  • the starch granules in the feedstock pass into the reactor 18 (FIG. 1 ), they are almost instantaneously heated and further hydrated resulting in gelatinisation due to the introduction of the steam.
  • the fluid mover(s) 100 making up the reactor 18 simultaneously pump and heat the slurry and complete the hydration and activate or gelatinise the starch content as the slurry passes through.
  • the reactor 18 mixes the enzyme(s) with the slurry, providing a homogenous distribution and high level of contact with the starch, which is now in a liquid phase.
  • the temperature of the slurry as it leaves the reactor 18 is preferably between 80°C- 86°C.
  • the pressure of the steam supplied to each fluid mover can be individually controlled by a transport fluid conditioner (not shown) so that the optimum temperature of the slurry for the activity and stability of the liquefaction enzymes is only reached as it exits the last fluid mover in the series.
  • the transport fluid conditioner may be attached directly to the transport fluid supply 50, or else may be located in the transport fluid supply lines 48.
  • the temperature at which the slurry leaves the reactor 18 is selected to avoid any heat damage to the slurry contents during the activation stage. However, this temperature may be below the temperature for optimal performance of the liquefaction enzyme, and so the temperature of the slurry may need to be raised without subjecting the slurry to excessively high temperatures or additional shear forces. This gentle heating is achieved using the optional TCU 52 downstream of the reactor 18.
  • the TCU 52 comprises one or more fluid movers of the type illustrated in FIG. 2. Where there is more than one fluid mover in the TCU 52, they are preferably arranged in series.
  • the pressure of the steam supplied to the fluid mover(s) of the TCU 52 is controlled so that it is comparatively low when compared to that of the steam supplied to the fluid mover(s) 100 of the reactor 18.
  • a preferred steam input pressure for the fluid mover(s) of the TCU is between about 0.5-2.0 bar. Consequently, the transport fluid velocity is much lower so no shear force or condensation shock is applied to the slurry by the injected steam as the slurry passes through the TCU 52. Instead, the TCU 52 merely uses the low pressure steam to gently raise the temperature of the slurry.
  • the slurry is preferably at a temperature of between 83°C-86°C.
  • the slurry then flows downstream through the second supply line 54 into the second vessel 56.
  • the water jacket 58 of the second vessel receives heated water, which maintains the slurry at the aforementioned temperature.
  • the slurry is held in the second vessel 56 for a sufficient residence time to allow the enzyme to convert or hydrolyse the starch content into oligosaccharides (e.g. maltodextrins).
  • the motor 62 drives the agitator 60 to gently agitate the slurry.
  • the process of the present invention may also be used to reduce the amount of enzyme required whilst maintaining the slurry in the second vessel 56 for a residence time akin to existing liquefaction processes.
  • the progress of the conversion is monitored during the residence time by measuring the dextrose equivalent (DE) of the slurry.
  • DE dextrose equivalent
  • "DE” indicates the degree of hydrolysis of starch into shorter chain polysaccharides. Calculating the DE is a simple method of estimating the efficiency of the liquefaction process. The higher the DE, the shorter the average length of the chains and the more efficient the liquefaction process.
  • the DE value is in the range 1 -10 prior to liquefaction and 6-22 after liquefaction.
  • the required DE value depends on the application, those processes that do not require a subsequent fermentation step (such as commercial processes to manufacture sugars) can tolerate much higher DE values.
  • the required DE value depends substantially on the yeast that the process will use.
  • the mash (after the liquefaction stage, the slurry is often referred to as a ' mash ' ) may be transferred to a fermentation tank (not shown) via the outlet 64 and control valve 66 of the second vessel 56.
  • pH adjustors may also be added at this point via a feed port (not shown) because the glucoamylases and yeasts used in the fermentation stage typically operate at a pH optima of 3.5-4.5.
  • the pH may be adjusted using phosphoric acid, and/or materials such as urea which also act as nutrient sources for the yeast in the saccharification/fermentation step can be added.
  • the mash may be cooled by a cooling device (not shown), such as a heat exchanger, prior to entry into the fermentation tank, because the fermentation stage typically requires much lower temperatures (e.g. 25° C-35° C) than the liquefaction stage.
  • a mash diluent e.g. water or backset
  • Using a fluid mover of the type described herein allows the present invention to heat and mix the starch content of the slurry with the enzyme while avoiding the creation of regions of extreme heat, which can damage the starch content. Prevention of these regions also reduces or eliminates Maillard effects caused by the reaction of proteins with the extracted starch. These reactions can prevent conversion of the starch to sugar and therefore reduce yields. Furthermore, the gentle agitation, mixing, and low shear pumping at a lower temperature also ensures that there are no high shear forces which may damage the enzyme or starch content of the slurry whilst held in a vessel or being transported between vessels. Such damage limits the ultimate glucose yield available from the feedstock.
  • the fluid mover(s) of the reactor also ensure that the slurry components are more thoroughly mixed than is possible using simple agitator paddles and/or recirculation loops alone.
  • the atomisation of the liquid component of the slurry further ensures a more homogenous mixing of the constituent parts of the slurry than previously possible. This improved mixing increases the efficiency of the enzyme in converting starch to shorter dextrins, reducing the time to achieve the desired DE values in the slurry when compared with existing processes.
  • Another benefit of the processes of the present invention is that, in a continuous flow processing plant with a fixed liquefaction time, the amount of enzyme required to give the desired DE can be reduced.
  • higher DE values than possible with existing processes may be achieved.
  • the shear action and condensation/pressure shock applied to the feedstock component of the slurry when in the reactor further improves the performance of the present invention as this exposes more of the cellular structure of the feedstock.
  • This allows virtually all the starch granules in the feedstock to become accessible, thereby providing improved starch hydrolysis rates compared to conventional processes as the enzymatic reaction is supplemented by the mechanical mixing in the reactor.
  • This also allows the process to provide an accessible starch to sugar conversion ratio of substantially 100% (i.e., close to 100%).
  • the processes of the present invention therefore, may only require the slurry to pass once through the reactor before it is ready to pass to the second vessel for the conversion stage. Hence, yields are much improved as there is no loss during the process.
  • Exposing more starch also means that less of the enzyme is needed to achieve the desired DE value of 6-22 before the slurry is transferred to the saccharification and fermentation processes.
  • the high degree of dispersal of the material in combination with high temperature kills bacteria, thereby reducing losses in any subsequent fermentation process.
  • the processes and apparatuses of the present invention may also improve fermentation rates in the subsequent fermentation process.
  • the improved hydration of the present invention also hydrates some proteins in the feedstock. These hydrated proteins act as additional feedstock to the fermenting yeast, thereby improving the fermenting performance of the yeast.
  • the processes and apparatuses of the present invention have been found to provide a number of advantages over existing arrangements. These advantages include an increase of up to 14% in starch to sugar yields, a reduction of up to 50% of the amount of liquefaction enzyme required, a reduction of up to 75% in the residence time for the conversion to take place, and a reduction of up to 30% in the time taken for the subsequent fermentation of the converted sugars into alcohol.
  • the reactor 18 may comprise a plurality of fluid movers 100 arranged in series and/or parallel as shown in FIG. 4. Where the reactor comprises groups of four or more devices in series, the slurry need not be maintained in the desired 30°C-60°C temperature range whilst being developed in the first vessel. Instead, as each of the devices in the reactor injects high pressure transport fluid into the slurry, the temperature of the slurry as it leaves the first vessel may need only be 20°C-30°C in this instance.
  • An antibiotic additive may be added at the same time as the enzyme, into the first vessel 2, and/or after the liquefaction process and prior to the fermentation stage (where present), if desired.
  • an additive port could be included in the pipework after the vessel 56 (FIG. 2).
  • suitable additives are virginiamycin-based and penicillin-based antibiotics.
  • a cooling device would need to be incorporated into the pipework downstream of the vessel 56 and prior to the antibiotic additive port in order to cool the mash.
  • FIG. 8 illustrates an alternative apparatus 1000 for processing biomass in accordance with another embodiment which targets the starch that is more difficult to gelatinise (i.e. starch that typically requires heating to a temperature that is higher than 75° C).
  • apparatus 1 of FIG. 1 and the corresponding process is preferably aimed at gelatinising the majority of starch (i.e. starch that typically requires heating to a temperature in the range of 60° C-80° C).
  • FIG. 9 shows a schematic graph that plots an exemplary temperature range over which the starch within an exemplary feedstock may gelatinise and illustrates the difference between the starch targeted using apparatus 1 illustrated in FIG. 1 as opposed to the starch targeted using apparatus 1000 illustrated in FIG. 8.
  • Different feedstocks may have starch that gelatinize at different temperatures/ranges.
  • the gelatinisation temperature range of starch depends upon, among other things, the plant type from which the starch originated, the size of the starch grains, the degree of crystallinity and the proportions of amylase and amylopectin in the starch granule.
  • Some types of unmodified native starches start swelling at 55°C, whereas other types start swelling at 85°C.
  • using apparatus 1000 of FIG. 8 which preferably targets the type of starch that is more difficult to gelatinise, results in the production of additional ethanol, thereby increasing yield.
  • the alternative apparatus illustrated in FIG. 8 also hydrates and gelatinises the starch from a starch-based feedstock and then makes it more accessible so that it can be converted into shorter chain polysaccharides by, e.g., liquefaction enzymes.
  • apparatus 1000 of FIG. 8 targets starch that gelatinises at temperatures in the range of 75°C-95°C and/or higher, such as the proportion of starch crystals in ground corn that are hard to gelatinise at lower temperatures. To do so, apparatus 1000 utilizes many of the same components described in FIG. 1 . Thus, like numbers have been used for like parts.
  • element 5200 need not be a temperature conditioning unit which raises the slurry's temperature given that the temperature of the slurry leaving reactor 18 is preferably in the range of 80°C-100°C.
  • element 5200 may be a low pressure flash tank which reduces the slurry temperature from 100°C to 85°C. More details pertaining to the apparatus illustrated in FIG. 8 and corresponding process will now be described.
  • Apparatus 1000 of FIG. 8 comprises a first vessel 2 acting as a first hydrator/mixer.
  • the first vessel 2 has a heater, which is preferably a heated water jacket 4 which surrounds the vessel 2 and receives heated water from a heated water supply (not shown).
  • the heater may be a traditional heater, a heat exchanger, sparge pipes, hot water injection systems and other like devices/systems well known to those skilled in the art.
  • the vessel 2 also includes an agitator 6 that is powered by a motor 8. The agitator 6 is suspended from the motor 8 so that it lies inside the vessel 2.
  • At the base of the vessel 2 are an outlet 10 and a valve 12 which controls fluid flow from the outlet 10.
  • a first supply line 16 Downstream of the first vessel 2 is a first supply line 16, the upstream end of which fluidly connects to the outlet 10 and valve 12 whilst the downstream end of the supply line 16 fluidly connects with a reactor 18.
  • a pump 14 is provided in the supply line 16. Pump 14 may be a centrifugal pump which has been modified in order to reduce shear as fluid is pumped through it. Pump 14 may or may not consist of a low shear pump.
  • reactor 18 may be formed from one or more fluid movers, such as the one shown and described in connection with FIG. 2, which may be arranged in series, or in parallel according to any of the configurations shown in FIG. 4.
  • the reactor 18 is connected to a transport fluid supply 50 via a transport fluid supply line 48.
  • the transport fluid inlet 32 for each fluid mover 100 making up the reactor is fluidly connected with the transport fluid supply line 48 for the receipt of transport fluid from the transport fluid supply 50.
  • unit 5200 Located downstream of the reactor 18 and fluidly connected thereto is a unit 5200.
  • Unit 5200 may be a temperature conditioning unit (TCU), such as one comprising a fluid mover substantially identical to that illustrated in FIG. 2, and may either be connected to the transport fluid supply 50 or else it may have its own dedicated transport fluid supply (not shown).
  • TCU temperature conditioning unit
  • unit 5200 may be a low pressure flash tank as explained above and further below.
  • the second vessel 56 is similar to the first vessel 2, and therefore has a heater, such as, e.g., a heated water jacket 58 which surrounds the vessel 56 and receives heated water from a heated water supply (not shown).
  • the vessel 56 also includes an agitator 60 that is powered by a motor 62. The agitator 60 is suspended from the motor 62 so that it lies inside the vessel 56.
  • At the base of the vessel 56 are an outlet 64 and a valve 66 which controls fluid flow from the outlet 64.
  • a ground starch-based feedstock is introduced into the first vessel 2 at a controlled mass addition flow rate.
  • suitable feedstock include dry milled maize, wheat or sorghum.
  • the feedstock could also include starch stocks derived from potato, oats, barley, rye, rice (or dry milled rice) and cassava.
  • Feedstock may be added by any method, such as manually, automatically, continuously or in batch mode. For instance, in a large production facility the feedstock may be added from a continuous belt feed whilst in a small test rig the feedstock may be added manually.
  • an enzyme that catalyzes the breakdown of the feedstock is mixed with a working fluid, preferably water (e.g. hard or soft water, aqueous solutions, etc., fluids recovered from a later stage in the processing apparatus - e.g. backset or water condensate - or a combination of the above), and that working fluid is then added to the feedstock in the vessel 2 to form a slurry and to start to hydrate the feedstock.
  • a working fluid preferably water (e.g. hard or soft water, aqueous solutions, etc., fluids recovered from a later stage in the processing apparatus - e.g. backset or water condensate - or a combination of the above)
  • the ratio of feedstock to liquid content in the slurry is 20%- 40% by dry weight.
  • Typical a-amylases used in the liquefaction stage have an activity optima when the pH is between about 5.5 and about 6.5.
  • one or more pH adjusters and/or surfactants may also be added to the slurry at this point. For instance, process condensate often has a low pH (e.g. 2-3) and once it and the feedstock have been mixed to form a slurry, ammonia or some other appropriate base may be added to adjust the pH to that required by the enzyme.
  • Heated water such as, e.g., recycled hot water recovered from another part of a process plant
  • Heated water is fed into the water jacket 4 surrounding the vessel 2 and the heated water jacket then heats the slurry to a temperature of typically 55° C-85° C, preferably 65° C-85° C, and holds the slurry at this temperature for 30-120 minutes so as to hydrate the crystalline regions of the starch granules.
  • the motor 8 drives the agitator 6, which stirs the slurry in the vessel 2 with gentle (i.e. low shear) agitation whilst the slurry is held in the vessel 2.
  • the working fluid may be heated prior to being mixed with the feedstock and the heater 4 in the vessel 2 may then maintain the slurry at the desired temperature.
  • the enzyme may be added into the vessel 2 separately from the working fluid. The enzyme may be added before the slurry has reached the desired temperature.
  • transport fluid which in this non-limiting example is preferably steam
  • transport fluid supply 50 is fed from the transport fluid supply 50 at a preferred pressure of between 5-9 bar gauge via transport fluid supply line 48, which causes a jet of steam at a very high subsonic or, more preferably, supersonic velocity.
  • transport fluid supply line 48 which causes a jet of steam at a very high subsonic or, more preferably, supersonic velocity.
  • a momentum and mass transfer - enhanced through turbulence - occurs between the two which preferably results in the atomisation of at least part of the slurry to form a dispersed droplet flow regime.
  • the steam preferably applies a shearing force to the slurry which not only atomises the working fluid component but also disrupts some or all of the ultrastructure ⁇ e.g., cellular structure) of the feedstock suspended in the slurry, such that some or all of the starch granules present are separated from the feedstock and dispersed into the slurry.
  • a shearing force to the slurry which not only atomises the working fluid component but also disrupts some or all of the ultrastructure ⁇ e.g., cellular structure) of the feedstock suspended in the slurry, such that some or all of the starch granules present are separated from the feedstock and dispersed into the slurry.
  • Increasing the free surface area reduces the time required for homogenous heating of the granules, as well as the time required for achieving 80% of the saturated water absorption.
  • atomising the working fluid component of the slurry and the starch granules will greatly speed the rate and completeness
  • the shear force applied to the slurry and the subsequent turbulent flow created by the injected steam disrupts some or all of the ultrastructure ⁇ e.g., cellular structure) of the feedstock suspended in the slurry, releasing the starch granules from the feedstock.
  • the low pressure zone which is at least lower than system pressure and may or not be a partial vacuum
  • condensation shock wave formed in the chamber(s) of reactor 18 it is further disrupted by the changes in pressure occurring.
  • the starch granules in the feedstock pass into the reactor 18, they are almost instantaneously further hydrated and heated, resulting in gelatinisation due to the introduction of the steam.
  • the fluid mover(s) making up the reactor 18 simultaneously pump and heat the slurry and complete the hydration and gelatinisation of the starch content as the slurry passes through.
  • the reactor 18 mixes the enzyme(s) with the slurry, providing a homogenous distribution and high level of contact with the starch, which is now in a liquid phase.
  • the temperature of the slurry as it leaves the reactor 18 is preferably between 80°C-100°C in the embodiment described herein in connection with FIG. 8.
  • the pressure of the steam supplied to each fluid mover can be individually controlled by a transport fluid conditioner (not shown) so that the optimum temperature of the slurry for the activity and stability of the liquefaction enzymes is only reached as it exits the last fluid mover in the series.
  • the transport fluid conditioner may be attached directly to the transport fluid supply 50, or else may be located in the transport fluid supply lines 48.
  • the slurry then flows downstream through the second supply line 54 into the second vessel 56.
  • the water jacket 58 of the second vessel of FIG. 8 receives heated water, which maintains the slurry at the aforementioned temperature.
  • the slurry is held in the second vessel 56 for a sufficient residence time to allow the enzyme to convert or hydrolyse the starch content into shorter chain polysaccharides (e.g. dextrins).
  • the motor 62 drives the agitator 60 to gently agitate the slurry. It has been found that approximately 30 minutes is a sufficient residence time in the present process, compared with a typical residence time of 120 minutes in existing liquefaction processes.
  • the present invention may be used to reduce the process time.
  • the process of the present invention may be used to reduce the amount of enzyme required whilst maintaining the slurry in the second vessel 56 for a residence time akin to existing liquefaction processes.
  • the progress of the conversion is monitored during the residence time by measuring the DE of the slurry.
  • the DE value is in the range 1 -10 prior to liquefaction and 6-22 after liquefaction.
  • the required DE value depends on the application, those processes that do not require a subsequent fermentation step (such as commercial processes to manufacture sugars) can tolerate much higher DE values.
  • the required DE value depends substantially on the second enzyme used in saccharification and on the yeast used in fermentation.
  • the resulting mash may be transferred to a fermentation tank (not shown) via the outlet 64 and control valve 66 of the second vessel 56 shown in FIG. 8.
  • pH adjustors may also be added at this point via a feed port (not shown) because the glucoamylases and yeasts used in the fermentation stage typically operate at a pH optima of 3.5-4.5.
  • the pH may be adjusted using phosphoric acid, and/or materials such as urea which also act as nutrient sources for the yeast in the saccharification/fermentation step can be added.
  • the mash may be cooled by a cooling device (not shown), such as a heat exchanger, prior to entry into the fermentation tank, because the fermentation stage typically requires much lower temperatures (e.g. 25° C-35° C) than the liquefaction stage.
  • a mash diluent e.g. water or backset
  • reactor 18 of FIG. 8 performs best with slurry temperatures of 55°C and higher. Reactor 18 also performs well with slurry temperatures below 55°C.
  • reactor 18 may comprise a plurality of fluid movers 100 (FIG. 2) arranged in series and/or parallel as shown in FIG. 4. Where the reactor comprises groups of four or more devices in series, the slurry need not be maintained in the desired 55°C-85°C temperature range whilst being developed in the first vessel . Instead, as each of the devices in the reactor injects high pressure transport fluid into the slurry, the temperature of the slurry as it leaves the first vessel may need only be 20°C-30°C in this instance.
  • an antibiotic additive may be added at the same time as the enzyme, into the first vessel 2, and/or after the liquefaction process and prior to the fermentation stage (where present), if desired.
  • an additive port (not shown) could be included in the pipework after the vessel 56 .
  • suitable additives are virginiamycin-based and penicillin-based antibiotics.
  • a cooling device (not shown) would need to be incorporated into the pipework downstream of the vessel 56 and prior to the antibiotic additive port in order to cool the mash.
  • FIG. 10 illustrates an alternative apparatus 2000 for processing biomass in accordance with yet another embodiment which targets the starch that is more difficult to gelatinise (i.e. starch that typically requires heating to a temperature that is higher than 75° C) and results in the production of additional ethanol, thereby increasing yield.
  • FIG. 9 shows a graph that plots the temperatures at which different starches gelatinise and illustrates the difference between the starch targeted using apparatus 1 illustrated in FIG. 1 as opposed to the starch targeted using apparatus 2000 illustrated in FIG. 10.
  • Apparatus 2000 illustrates what may be referred to as a jet cook installation.
  • the alternative apparatus illustrated in FIG. 10 also hydrates and gelatinises the starch from a starch-based feedstock and then makes it more accessible so that it can be converted into shorter chain polysaccharides by, e.g., liquefaction enzymes.
  • apparatus 2000 of FIG. 10 targets starch that gelatinises at temperatures in the range of 75°C-95°C and/or higher. To do so, apparatus 2000 utilizes many of the same components described in FIG. 1 . Thus, like numbers have been used for like parts.
  • apparatus 2000 includes a recirculation loop 280, a strainer 330, a jet cooker 350 (hence the name of this particular type of installation), and a flash tank 520 (similar to element 5200 of FIG. 8). It is worth noting that the recirculation loop and strainer may also be included in the apparatus of FIG. 1 and/or 8.
  • the reactor configuration used in apparatus 2000 is preferably in two stages having reactor 1801 located after jet cooker 350 and reactor 1802 located before flash tank 520, whereby one or more residence tube(s) 1800 are located between reactors 1801 and 1802.
  • apparatus 2000 may include only one reactor stage, such as 1801 or reactor 1802. More details pertaining to the apparatus illustrated in FIG. 10 and corresponding process will now be described.
  • Apparatus 2000 comprises a first vessel 2 acting as a first hydrator/mixer.
  • the first vessel 2 has a heater, which is preferably a heated water jacket 4 which surrounds the vessel 2 and receives heated water from a heated water supply (not shown).
  • the heater may be a traditional heater, a heat exchanger, sparge pipes, hot water injection systems and other like devices/systems well known to those skilled in the art.
  • the vessel 2 also includes an agitator 6 that is powered by a motor 8. The agitator 6 is suspended from the motor 8 so that it lies inside the vessel 2.
  • At the base of the vessel 2 are an outlet 10 and a valve 12 which controls fluid flow from the outlet 10.
  • Pump 14 Downstream of the first vessel 2 is a first supply line 16, the upstream end of which fluidly connects to the outlet 10 and valve 12 whilst the downstream end of the supply line 16 fluidly connects with strainer 330.
  • Pump 14 may be provided in the supply line 16. Pump 14 may be a centrifugal pump which has been modified in order to reduce shear as fluid is pumped through it. Pump 14 may or may not consist of a low shear pump.
  • Apparatus 2000 preferably includes recirculation loop 280 which may consist of one or more recirculation pipes that can selectively recirculate slurry through vessel 2 so that slurry can pass through the first vessel more than once, if necessary.
  • Recirculation loop 280 recirculates the slurry through vessel 2 using a pump, which may be pump 14 or another pump that is not shown.
  • Valve 12 prevents the slurry from leaving the vessel until the appropriate conditions have been reached (e.g. slurry temperature).
  • Another valve (not shown) may be located downstream of pump 14 and may function to apportion the slurry such that some passes through the recirculation loop whilst some proceeds into the first supply line 16.
  • Recirculation loop 280 may operate similar to the description below pertaining to the first recirculation loop shown in FIG. 6(a).
  • the slurry pumped through pump 14 may be passed through strainer 330 to remove large particles and/or other debris (which may be returned to the slurry tank or may be directed to a waste bin for subsequent disposal) and then split into two streams, the first is returned to the slurry tank via recirculation loop 280, the second stream continues to the cooker/reactor(s).
  • Jet cooker 350 may already be part of the process apparatus into which the processes, systems and/or teachings of the present invention may be retrofit. Jet cooker 350 may be fully open, with or without steam addition. Alternatively a bypass can be built from the exit of strainer 330 to the inlet of reactor 1801 or from the exit of strainer 330 to the inlet of reactor 1802, as shown by the broken lines surrounding these elements in FIG. 10.
  • the reactor configuration used in apparatus 2000 is preferably in two stages, whereby part of the gelatinisation process takes place in reactor 1801 in the first stage, and another part of the gelatinisation process takes place in reactor 1802.
  • the slurry is directed to one or more residence tubes 1800 (preferably 1 tube or 2 tubes in series) where the slurry resides for some time until the appropriate conditions have been reached.
  • the slurry may cool off in residence tube(s) 1800 before being fed into reactor 1802.
  • a residence tube 1800 has a passage, as well as an inlet in fluid communication with the outlet of the passage.
  • the tube may include an insulator for insulating the contents of the residence tube as it passes through. Such an insulator may be a layer of insulating material covering the exterior of the tube section.
  • Each reactor 1801 and/or 1802 may be formed from one or more fluid movers, such as the one shown and described in connection with FIG. 2, which may be arranged in series, or in parallel according to any of the configurations shown in FIG. 4. As before, each reactor may be connected to a transport fluid supply (not shown) via one or more transport fluid supply line(s) (not shown). Reactors 1801 and 1802 may be connected to the same transport fluid supply or different transport fluid supplies.
  • flash tank 520 Located downstream of reactor 1802 and fluidly connected thereto is flash tank 520, which may be a low pressure flash tank. Downstream of flash tank 520 is a second supply line 54, which fluidly connects the outlet of flash tank 520 with second vessel 56. Moreover, steam resulting from the operation of flash tank 520 (which generally cools the slurry exiting from the two-stage reactor process and therefore results in a heat exchange producing energy that can be used to heat air) may be used to heat a side stripper (not shown) which recovers the trace amounts of ethanol off the bottoms flow.
  • a separate or direct steam source may be used for the side stripper.
  • the second vessel 56 is similar to the first vessel 2, and therefore has a heater, such as, e.g., a heated water jacket 58 which surrounds the vessel 56 and receives heated water from a heated water supply (not shown).
  • the vessel 56 also includes an agitator 60 that is powered by a motor 62. The agitator 60 is suspended from the motor 62 so that it lies inside the vessel 56.
  • At the base of the vessel 56 are an outlet 64 and a valve 66 which controls fluid flow from the outlet 64.
  • a ground starch-based feedstock is introduced into the first vessel 2 at a controlled mass addition flow rate.
  • suitable feedstock include dry milled maize, wheat or sorghum.
  • the feedstock could also include starch stocks derived from potato, oats, barley, rye, rice (or dry milled rice) and cassava.
  • Feedstock may be added by any method, such as manually, automatically, continuously or in batch mode. For instance, in a large production facility the feedstock may be added from a continuous belt feed whilst in a small test rig the feedstock may be added manually.
  • an enzyme - e.g., a-amylase - that catalyzes the breakdown of the feedstock is mixed with a working fluid, which is preferably recovered from a later stage in the processing apparatus - e.g. backset and/or water condensate - or any other suitable working fluid described above.
  • the working fluid is then added to the feedstock in the vessel 2 to form a slurry and to start to hydrate the feedstock.
  • the ratio of feedstock to liquid content in the slurry is 20%- 40% by dry weight.
  • Typical a-amylases used in the liquefaction stage have an activity optima when the pH is between about 5.5 and about 6.5.
  • one or more pH adjusters and/or surfactants may also be added to the slurry at this point. For instance, process condensate often has a low pH (e.g. 2-3) and once it and the feedstock have been mixed to form a slurry, ammonia or some other appropriate base may be added to adjust the pH to that required by the enzyme.
  • Heated water such as, e.g., recycled hot water recovered from another part of a process plant
  • Heated water is fed into the water jacket 4 surrounding the vessel 2 and the heated water jacket then heats the slurry to a temperature of typically 55° C-85° C, preferably 65° C-85° C, and holds the slurry at this temperature for 30-120 minutes so as to hydrate the crystalline regions of the starch granules.
  • recycled hot water may be used in making up the slurry.
  • the slurry may be recirculated through loop 280 into vessel 2 until the target slurry temperature has been reached and/or so as to increase the agitation within the tank whilst increasing the residence time
  • the motor 8 drives the agitator 6, which stirs the slurry in the vessel 2 with gentle (i.e. low shear) agitation whilst the slurry is held in the vessel 2.
  • the working fluid may be heated prior to being mixed with the feedstock and the heater 4 in the vessel 2 may then maintain the slurry at the desired temperature.
  • the enzyme may be added into the vessel 2 separately from the working fluid. The enzyme may be added before the slurry has reached the desired temperature.
  • valve 12 (or another valve controlling the recirculation loop) is opened to allow the slurry to be directed from vessel 2 through the first supply line 16 to the strainer 330, followed by jet cooker 350.
  • Residence tube 1800 may store and allow residence at the immediate temperature, or to increase the time to allow the full condensation of steam at high temperature.
  • transport fluid which in this non-limiting example is preferably steam
  • transport fluid supply line the transport fluid source and line are not shown in this figure but are similar to elements 50 and 48 of FIGS. 1 and 8), which causes a jet of steam at a very high subsonic or, more preferably, supersonic velocity.
  • a momentum and mass transfer - enhanced through turbulence - occurs between the two which preferably results in the atomisation of at least part of the slurry to form a dispersed droplet flow regime.
  • the steam preferably applies a shearing force to the slurry which not only atomises the working fluid component but also disrupts some or all of the ultrastructure ⁇ e.g., cellular structure) of the feedstock suspended in the slurry, such that some or all of the starch granules present are separated from the feedstock and dispersed into the slurry.
  • the shear force applied to the slurry and the subsequent turbulent flow created by the injected steam disrupts some or all of the ultrastructure ⁇ e.g., cellular structure) of the feedstock suspended in the slurry, releasing the starch granules from the feedstock.
  • the low pressure zone which is at least lower than system pressure and may or not be a partial vacuum
  • condensation shock wave formed in the chamber(s) of reactor 1801 it is further disrupted by the changes in pressure occurring.
  • the starch granules in the feedstock pass into the reactor 1801 , they are almost instantaneously further hydrated and heated, resulting in gelatinisation due to the introduction of the steam.
  • the fluid mover(s) making up the reactor 1801 simultaneously assist in pumping and heat the slurry and complete the hydration and gelatinisation of the starch content as the slurry passes through.
  • the reactor 1801 mixes the enzyme(s) with the slurry, providing a homogenous distribution and high level of contact with the starch, which is now in a liquid phase.
  • the temperature of the slurry as it enters reactor 1801 is preferably around 85° C, and the temperature of the slurry as it leaves reactor 1801 is preferably between 85°C-105°C in the embodiment described herein in connection with FIG. 10.
  • Reactor 1802 preferably operates in a similar fashion as described in connection with reactor 180, except that the temperature of the slurry as it leaves reactor 1802 is preferably higher ⁇ e.g., between 90°C-120°C).
  • the slurry then flows downstream through the second supply line 54 into the second vessel 56.
  • the water jacket 58 of the second vessel of FIG. 10 receives heated water, which maintains the slurry at the aforementioned temperature.
  • the slurry is held in the second vessel 56 for a sufficient residence time to allow for the conversion or hydrolysation of the starch content into shorter chain polysaccharides (e.g. dextrins).
  • a-amylase may be used for this purpose.
  • a lower dose may be utilized in this step in vessel 56 as compared to earlier in the process in vessel 2.
  • no enzymes need be utilized in vessel 56.
  • the motor 62 drives the agitator 60 to gently agitate the slurry. It has been found that approximately 30 minutes is a sufficient residence time in the present process, compared with a typical residence time of 120 minutes in existing liquefaction processes. Thus, production process time may be reduced using apparatus 2000. Alternatively, using process 2000, the amount of enzyme required may be reduced whilst maintaining the slurry in the second vessel 56 for a residence time akin to existing liquefaction processes. The progress of the conversion is monitored during the residence time by measuring the DE of the slurry. As before, the higher the DE, the shorter the average length of the chains ⁇ e.g., the polysaccharide chains) and the more efficient the liquefaction process. Typically, the DE value is in the range 1 -10 prior to liquefaction and 6-22 after liquefaction.
  • reactor 1801 and 1802 of FIG. 10 perform best with slurry temperatures of about 85°C.
  • reactor 1801 and/or reactor 1802 may comprise a plurality of fluid movers 100 (FIG. 2) arranged in series and/or parallel as shown in FIG. 4.
  • an antibiotic additive may be added at the same time as the enzyme, into the first vessel 2, and/or after the liquefaction process and prior to the fermentation stage, if desired.
  • an additive port (not shown) could be included in the pipework after the vessel 56.
  • Suitable additives are virginiamycin-based and penicillin-based antibiotics.
  • a cooling device (not shown) would need to be incorporated into the pipework downstream of the vessel 56 and prior to the antibiotic additive port in order to cool the mash.
  • the resulting mash may be transferred for fermentation and/or distillation, consistent with the post-liquefaction process described in connection with FIG. 12.
  • FIG. 1 1 illustrates an alternative apparatus 3000 for processing biomass in accordance with yet another embodiment which targets the starch that is more difficult to gelatinise (i.e. starch that typically requires heating to a temperature that is higher than 75° C) and results in the production of additional ethanol, thereby increasing yield.
  • FIG. 9 shows a graph that plots the temperatures at which different starches gelatinise and illustrates the difference between the starch targeted using apparatus 1 illustrated in FIG. 1 as opposed to the starch targeted using apparatus 3000 illustrated in FIG. 1 1 .
  • Apparatus 3000 illustrates what may be referred to as a hot cook installation. Much like the apparatus illustrated in FIG. 1 , the alternative apparatus illustrated in FIG. 1 1 also hydrates and gelatinises the starch from a starch-based feedstock and then makes it more accessible so that it can be converted into shorter chain polysaccharides by, e.g., liquefaction enzymes. However, apparatus 3000 of FIG.
  • apparatus 3000 targets starch that gelatinises at temperatures in the range of 75°C-95°C and/or higher, such as ground corn, dry milled maize, dry milled wheat, or dry milled sorghum, as well as and starch stocks derived from potato, oats, barley, rye, rice (or dry milled rice) and cassava.
  • apparatus 3000 utilizes many of the same components described in FIG. 1 . Thus, like numbers have been used for like parts. The main difference is that apparatus 3000 includes a recirculation loop 480, a strainer 430, and does not include element 52 (i.e. a TCU).
  • the recirculation loop and strainer may also be included in the apparatus of FIG. 1 , FIG. 8 and/or FIG. 10. More details pertaining to the apparatus illustrated in FIG. 1 1 and corresponding process will now be described.
  • Apparatus 3000 comprises a first vessel 2 acting as a first hydrator/mixer.
  • the first vessel 2 has a heater, which is preferably a heated water jacket 4 which surrounds the vessel 2 and receives heated water from a heated water supply (not shown).
  • the heater may be a traditional heater, a heat exchanger, sparge pipes, hot water injection systems and other like devices/systems well known to those skilled in the art.
  • the vessel 2 also includes an agitator 6 that is powered by a motor 8. The agitator 6 is suspended from the motor 8 so that it lies inside the vessel 2.
  • At the base of the vessel 2 are an outlet 10 and a valve 12 which controls fluid flow from the outlet 10.
  • Pump 14 Downstream of the first vessel 2 is a first supply line 16, the upstream end of which fluidly connects to the outlet 10 and valve 12 whilst the downstream end of the supply line 16 fluidly connects with strainer 430.
  • Pump 14 may be provided in the supply line 16. Pump 14 may be a centrifugal pump which has been modified in order to reduce shear as fluid is pumped through it. Pump 14 may or may not consist of a low shear pump.
  • Apparatus 3000 preferably includes recirculation loop 480 which may consist of one or more recirculation pipes that can selectively recirculate slurry through vessel 2 so that slurry can pass through the first vessel more than once, if necessary.
  • Recirculation loop 480 recirculates the slurry through vessel 2 using a pump, which may be pump 14 or another pump that is not shown.
  • Valve 12 prevents the slurry from leaving the vessel until the appropriate conditions have been reached (e.g. slurry temperature).
  • Another valve (not shown) may be located downstream of pump 14 and may function to apportion the slurry such that some passes through the recirculation loop whilst some proceeds into the first supply line 16.
  • Recirculation loop 480 may operate similar to the description below pertaining to the first recirculation loop shown in FIG. 6(a).
  • the slurry pumped through pump 14 may be passed through strainer 430 to remove large particles and/or other debris (which may be returned to the slurry tank or may be directed to a waste bin for subsequent disposal) and then split into two streams, the first is returned to the slurry tank via recirculation loop 480, the second stream continues to the reactor.
  • Reactor 1820 used in apparatus 3000 may be formed from one or more fluid movers, such as the one shown and described in connection with FIG. 2, which may be arranged in series, or in parallel according to any of the configurations shown in FIG. 4. As before, the reactor may be connected to a transport fluid supply (not shown) via a transport fluid supply line (not shown). Slurry exiting from reactor 1820 is transported to second vessel 56 through supply line 54.
  • the second vessel 56 is similar to the first vessel 2, and therefore has a heater, such as, e.g., a heated water jacket 58 which surrounds the vessel 56 and receives heated water from a heated water supply (not shown).
  • the vessel 56 also includes an agitator 60 that is powered by a motor 62. The agitator 60 is suspended from the motor 62 so that it lies inside the vessel 56.
  • At the base of the vessel 56 are an outlet 64 and a valve 66 which controls fluid flow from the outlet 64.
  • a ground starch-based feedstock is introduced into the first vessel 2 at a controlled mass addition flow rate.
  • suitable feedstock include dry milled maize, wheat or sorghum.
  • the feedstock could also include starch stocks derived from potato, oats, barley, rye, rice (or dry milled rice) and cassava.
  • Feedstock may be added by any method, such as manually, automatically, continuously or in batch mode. For instance, in a large production facility the feedstock may be added from a continuous belt feed whilst in a small test rig the feedstock may be added manually.
  • an enzyme - e.g., a-amylase, preferably thermostable up to 95°C a-amylase - that catalyzes the breakdown of the feedstock is mixed with a working fluid, which is preferably recovered from a later stage in the processing apparatus - e.g. backset and/or water condensate - or any other suitable working fluid described above.
  • the working fluid is then added to the feedstock in the vessel 2 to form a slurry and to start to hydrate the feedstock.
  • the ratio of feedstock to liquid content in the slurry is 20%- 40% by dry weight.
  • Typical a-amylases used in the liquefaction stage have an activity optima when the pH is between about 5.5 and about 6.5.
  • one or more pH adjusters and/or surfactants may also be added to the slurry at this point.
  • process condensate often has a low pH (e.g. 2-3) and once it and the feedstock have been mixed to form a slurry, ammonia or some other appropriate base may be added to adjust the pH to that required by the enzyme.
  • Heated water such as, e.g., recycled hot water recovered from another part of a process plant
  • Heated water is fed into the water jacket 4 surrounding the vessel 2 and the heated water jacket then heats the slurry to a temperature of typically 55° C-85° C, preferably 65° C-85° C, and holds the slurry at this temperature for 30-120 minutes so as to hydrate the crystalline regions of the starch granules.
  • the slurry temperature at entry to the reactor may be 65° - 85°C, whereas the exit temperature may be 80°C-90°C.
  • the slurry may be recirculated through loop 480 into vessel 2 so that slurry until the target slurry temperature has been reached.
  • the motor 8 drives the agitator 6, which stirs the slurry in the vessel 2 with gentle (i.e. low shear) agitation whilst the slurry is held in the vessel 2.
  • the working fluid may be heated prior to being mixed with the feedstock and the heater 4 in the vessel 2 may then maintain the slurry at the desired temperature.
  • the enzyme may be added into the vessel 2 separately from the working fluid. The enzyme may be added before the slurry has reached the desired temperature.
  • transport fluid which in this non-limiting example is preferably steam
  • transport fluid supply line the transport fluid source and line are not shown in this figure but are similar to elements 50 and 48 of FIGS. 1 and 8
  • the transport fluid source and line are not shown in this figure but are similar to elements 50 and 48 of FIGS. 1 and 8
  • a jet of steam at a very high subsonic or, more preferably, supersonic velocity.
  • a momentum and mass transfer - enhanced through turbulence - occurs between the two which preferably results in the atomisation of at least part of the slurry to form a dispersed droplet flow regime.
  • the steam preferably applies a shearing force to the slurry which not only atomises the working fluid component but disrupts some or all of the ultrastructure ⁇ e.g., cellular structure) of the feedstock suspended in the slurry, such that some or all of the starch granules present are separated from the feedstock and dispersed into the slurry.
  • the shear force applied to the slurry and the subsequent turbulent flow created by the injected steam disrupts some or all of the ultrastructure ⁇ e.g., cellular structure) of a proportion of the feedstock suspended in the slurry, releasing some or all of the starch granules from the feedstock.
  • the low pressure zone which is at least lower than system pressure and may or not be a partial vacuum
  • condensation shock wave formed in the chamber(s) of reactor 1820 it is further disrupted by the changes in pressure occurring.
  • the starch granules in the feedstock pass into the reactor 1820, they are almost instantaneously further hydrated and heated, resulting in gelatinisation due to the introduction of the steam.
  • the fluid mover(s) making up the reactor 1820 simultaneously pump and heat the slurry and complete the hydration and gelatinisation of the starch content as the slurry passes through.
  • the reactor 1820 mixes the enzyme(s) with the slurry, providing a homogenous distribution and high level of contact with the starch, which is now in a liquid phase.
  • the temperature of the slurry as it enters reactor 1820 is preferably around 65° C-85° C, and the temperature of the slurry as it leaves reactor 1820 is preferably around 80°C-90°C in the embodiment described herein in connection with FIG. 1 1 .
  • the slurry then flows downstream through the second supply line 54 into the second vessel 56.
  • the water jacket 58 of the second vessel of FIG. 1 1 receives heated water, which maintains the slurry at the aforementioned temperature.
  • the slurry is held in the second vessel 56 for a sufficient residence time to allow for the conversion or hydrolysation of the starch content into shorter chain polysaccharides (e.g. dextrins).
  • no enzymes need be added in vessel 56.
  • the motor 62 drives the agitator 60 to gently agitate the slurry.
  • the production process using apparatus 3000 obviates the need to rely on enzymes whilst maintaining the slurry in the second vessel 56 for a residence time that is shorter than existing liquefaction processes.
  • the progress of the conversion is monitored during the residence time by measuring the DE of the slurry.
  • the DE value is in the range 1 -10 prior to liquefaction and 6-22 after liquefaction.
  • Reactor 1820 of FIG. 1 1 performs best with slurry temperatures of about 85°C.
  • reactor 1820 may comprise a plurality of fluid movers 100 (FIG. 2) arranged in series and/or parallel as shown in FIG. 4.
  • an antibiotic additive may be added at the same time as the enzyme, into the first vessel 2, and/or after the liquefaction process and prior to the fermentation stage, if desired.
  • an additive port (not shown) could be included in the pipework after the vessel 56.
  • Suitable additives are virginiamycin-based and penicillin-based antibiotics.
  • a cooling device (not shown) would need to be incorporated into the pipework downstream of the vessel 56 and prior to the antibiotic additive port in order to cool the mash.
  • the resulting mash may be transferred for fermentation and/or distillation, consistent with the post-liquefaction process described in the section that follows in connection with FIG. 12.
  • sub-system 600 may be part of - or added to - any apparatus 1 , 1000, 2000, and/or 3000 illustrated in FIGS. 1 , 8, 10 and 1 1 , respectively.
  • the output of vessel 56 used in any of the processes depicted in these figures may be fed into sub-apparatus 600 of FIG. 12.
  • Sub-apparatus 600 includes, inter alia, mash cooler 1210, fermenter 1220, yeast prop tank 1230, beer well 1240, beer column 1250, centrifuge 1260, and thin stillage tank 1270.
  • the mash resulting from the liquefaction in vessel 56 is fed into mash cooler 1210.
  • the mash which is fed from vessel 56 may be introduced via an outlet and control valve (such as outlet 64 and control valve 66 shown in FIGS. 1 , 8, 10 or 1 1 ) disposed on vessel 56.
  • vessel 56 depicted in FIGS. 10 and 1 1 may include similar control valves.
  • Mash cooler 1210 may be a heat exchanger which cools the mash content because the fermentation stage typically requires much lower temperatures (e.g. 25° C-35° C) than the liquefaction stage.
  • Fermenter 1220 which is a vessel in which saccharification/fermentation of the mash content may take place, is located downstream of mash cooler 1210.
  • Yeast prop tank 1230 which is also coupled to fermenter 1220, supplies yeast (or any other fermenting microorganism(s)) in order for the saccharification/fermentation processes to take place in fermenter 1220.
  • yeast or any other fermenting microorganism(s)
  • Other additives well known in the fermentation arts may also be provided.
  • a mash diluent e.g. water or backset
  • Well 1240 is preferably a beer well that feeds into beer column 1250, so as to distil the alcohol, i.e., separate the ethanol and most of the water from the other fermentation products.
  • the stillage is processed by centrifuge 1260 which produces solid distillers grains and thin stillage.
  • the resulting distillers grains can be used as livestock (animal) feed.
  • the thin stillage it is be fed to thin stillage tank 1270 from where it is recycled as backset used in vessel 2 in any of apparatus 1 , 1000, 2000 or 3000 as discussed above.
  • Another aspect of the present invention pertains to improved systems and methods for measuring yield (such as ethanol yield) in the production of biofuels using any apparatus or related process described above and in connection with FIGS. 1 , 8, and 10-12.
  • yield such as ethanol yield
  • These systems and methods result in yield calculations that are more accurate than traditional methods.
  • these systems and methods allow plant operators to respond and make adjustments on a relatively quick basis in order to improve yield.
  • the systems and methods of the present invention rely on stoichiometric computations based on other parameters, such as lab measurements, that can be ascertained at different stages of the process.
  • the yield calculations are accurate, quick and can be made often given that they can be calculated using one or more computers in real-time (or near real-time) based on actual process measurements taken repetitively at frequent intervals, or even continuously.
  • the basis for the yield calculation is each unit of mass going into the fermenter (e.g. component 1220 of FIG. 12) before the fermentation process begins.
  • the process 1 300 depicted in FIG. 1 3 for calculating yield can be performed using a computing device (e.g. a general purpose - or specially tailored - computer programmed to perform the steps identified herein), and can be summarized as follows.
  • a computing device e.g. a general purpose - or specially tailored - computer programmed to perform the steps identified herein
  • step 1 31 the composition of dry matter and water making up each mass unit of mash going into the fermenter is established, and the calculation of various masses of dry matter (D) and water (W) may be implemented using equations [1 ] - [9] below.
  • the mash is hydrolysed prior to entering into the fermenter that is part of the production system.
  • step 1 320 This enables the calculation of the amount of wet corn in each unit of mash going into the fermenter (X C ), which is performed at step 1 320 based on the equation [1 1 ] below.
  • step 1 330 which can be performed concurrently with, after, or before step 1 320, the amount of ethanol that can be produced from each mass unit of mash going into the fermenter (XEIOH) can be calculated based on the equations [1 2] - [1 6] below.
  • These equations involve stoichiometric determinations and rely on measurements of materials going into and leaving, for example, the fermenter. The measurements relied on preferably include ethanol and dissolved solids concentration, water mass balances and beer density.
  • yield can be calculated at step 1 340 based on the amount of wet corn determined at step 1 320 and the amount of ethanol produced at step 1 330 based on the equation [1 7] below.
  • Process 1 300 relies on actual process measurements taken at different stages of the biomass treatment process.
  • steps 1 31 0 through 1 340 and the corresponding equations below rely on various parameters, which are identified in List 1 below and which can be ascertained at different stages in FIGS. 8 and 1 0-1 2, e.g., through sensors and/or appropriate measuring devices.
  • List 1 identifies each point in FIGS. 8 and 1 0-1 2 at which the corresponding parameter that is listed adjacent to that point can be measured. For example, as can be seen below, W PC - i.e.
  • the mass of water in the process condensate (which is part of the composition making up each mass unit of mash going into the fermenter and which is used first for calculating the remainder of the composition) can be measured at point 91 5.
  • W YP - i.e. the mass of fresh water added to yeast prop tank 1 230 - can be measured at point 955.
  • 910 Corn composition starch & moisture
  • W is the mass of water
  • pc is from process condensate
  • yp is from yeast prop
  • a2 is %starch in wet maize
  • a n are constants from dry matter measurements, that is measured by 3 hours loss on drying in an oven of 105-1 10°C; and from the ratio of different streams making up the water going into the slurry tank.
  • M wa ter,finai The mass of water in the fermenter at the end of fermentation, M wa ter,finai can be estimated from the mass of water added into the fermenter, and the mass of water consumed during fermentation (based on stoichiometry to be explained in equations [18] to [20]).
  • the volume of liquid, V be er, at the end of fermentation, is the sum of the volumes of the liquids and the volume of the dissolved solids:
  • V stands for volume in litre
  • C stands for concentration in kg/litre or g/m litre
  • beer stands for the ethanol and water liquid mixture at the end of fermentation
  • W stm An estimation of steam addition, W stm , if required, can be performed based energy balance.
  • the steam addition W stm depends on the initial and final (e.g. 85° C) temperatures of the slurry, and the thermal properties of the slurry, which in turn can be derived from the %corn in the slurry.
  • process 1300 may include additional optional steps which allow plant operators to respond and make adjustments during plant operation to improve yield based on the calculation produced in step 1340.
  • operating conditions and/or materials inputs may be adjusted.
  • operating conditions include the temperature exit of the slurry from the reactor, the mash process flow rate and/or throughput, the transport fluid speed, the process time and the pH level .
  • materials/ingredient inputs include the amount or ratio of feedstock/liquid present in the slurry, the solids content or the working fluid content of the slurry/mash, the amount of enzyme present and particle size.
  • the present invention is not so limited, and in fact, can be used to produce a variety of polysaccharides and sugars from starch-based biomass.
  • the processes and apparatuses of the present invention are also suitable for the production of a wide variety of commercially useful chemicals derived from starch.
  • Products that are made from starch include: dextrins (e.g. fructose, maltodextrin, glucose syrups, corn syrups), dextrose, maltose, and sugar alcohols (e.g.
  • starch-derived sugar/oligosaccharide mixture is corn syrup, which is made from maize, and is widely used in food products as a natural sweetener.
  • Corn syrup is used in, for example, cookies, crackers, sauces, cereals, flavoured yogurts, ice cream, preserved meats, canned fruits and vegetables, soups, beers, soft drinks, and many others.
  • Sugar alcohols are popular for use as sweeteners, particularly since they aren't usually absorbed in the bloodstream, so they are widely used in diet foods and foods for diabetics. They are also used to mask the taste of some high-intensity sweeteners.
  • the apparatus 1000 depicted in FIG. 8 may be used to produce such non-ethanol products from starch.
  • the process described above in connection with FIG. 8 can be largely relied on for such production, although the enzymatic breakdown of starch to sugars in the liquefaction step (i.e. in vessel 56) may involve the use of one or more enzymes, such as a-amylase to break the starch into shorter chains of sugars, and then glucoamylase to break it down to even simpler sugars such as glucose.
  • non-ethanol compounds may require further processing after the liquefaction step.
  • starch-derived sugars and/or polysaccharides may be further chemically, enzymatically, and/or biologically treated to create other commercially useful compounds.
  • glucose can be converted to a variety of compounds: cyclic and acyclic polyols, aldehydes, ketones, acids, esters, and ethers which can then be used industrially.
  • Polyols such as sorbitol, on the other hand, can be made by fermentation processes similar to that used to make ethanol . Sorbitol is widely used to make surfactants and emulsifiers, which are used in a wide variety of applications, including food products.
  • Starch-derived products are not just used in the food industry, they may be used to manufacture synthetic polymers including plastics, ingredients in detergents, etc. Of significant interest to many manufacturers is that such starch- derived compounds can be biodegradeable.
  • Glucose may also be derived from the liquefaction and saccharification of starch to act as the carbon feedstock for biological fermenters used to culture microorganisms (e.g. bacterial, fungal, heterotrophic algae) both native and bio- engineered (GMO) for the ultimate production of a wide range of chemical and biochemical products, such as enzymes, functional proteins, carbohydrates, biopolymers, pharmacological compounds, pigments, oils and lipids, alcohols other than ethanol, polyols, isoprene, flavourings, fragrances, and long chain hydrocarbons.
  • biological fermenters used to culture microorganisms (e.g. bacterial, fungal, heterotrophic algae) both native and bio- engineered (GMO) for the ultimate production of a wide range of chemical and biochemical products, such as enzymes, functional proteins, carbohydrates, biopolymers, pharmacological compounds, pigments, oils and lipids, alcohols other than ethanol, polyols, isoprene, flavourings
  • FIG. 4 depicts various configurations of the reactor 18 in FIG. 1 , FIG. 8, FIG. 10, or FIG. 1 1 .
  • reactor 18 consists of a single fluid mover 100.
  • reactor 18 consists of three fluid movers 100 in series.
  • FIG. 4(c) shows two fluid movers 100 in parallel and
  • FIG. 4(d) shows two parallel legs, each consisting of two fluid movers 100 in series.
  • FIG. 5 shows the configuration depicted in FIG. 4(b) in more detail and incorporates the transport fluid supply 50 and the transport fluid supply line 48 that connects the transport fluid supply 50 to the three fluid movers 100.
  • each transport fluid supply line 48 prior to each individual fluid mover 100 is a transport fluid conditioner 80.
  • the transport fluid conditioner 80 may be adapted to vary the supply pressure of the transport fluid to each nozzle.
  • Alternative transport fluid conditioners may be, e.g., a heating device to create superheated steam or a condensation trap to remove condensate from the transport fluid supply line 48.
  • Similar pipework and transport fluid conditioners may be incorporated for any reactor 18 consisting of any configuration of fluid movers in parallel and/or in series. Additionally, one or more transport fluid supplies 50 may be utilised.
  • FIG. 7 An alternative embodiment of a device according to the present invention that may act as a fluid mover is shown in detail in FIG. 7.
  • the fluid mover 101 is substantially the same as the fluid mover 100 shown in FIG. 2, so like numbers have been used for like parts.
  • the main difference is that the fluid mover 101 has an additional transport fluid inlet 320, transport fluid plenum 300 and transport fluid nozzle 380.
  • the transport fluid nozzle 380 is a convergent-divergent nozzle similar to the transport fluid nozzle 38 described in FIG. 1 and operates in the same manner.
  • the transport fluid nozzles 38 and 380 are shown directly adjacent to each other, but they may be spaced apart along the length of the mixing region 25 in any manner.
  • the angle ⁇ defines the angle of inclination of the leading edge of the divergent portion of the transport fluid nozzle 380 relative to the longitudinal axis L of the passage 22 as shown in FIG. 7.
  • the angle a and the angle ⁇ are different in this embodiment, with angle a more acute than angle ⁇ . This relationship is not fixed, and one or other angle could be more acute, or they could be the same, depending on the requirements of the application.
  • the angle ⁇ is preferably between 0° and 70°, more preferably between 0° and 30°.
  • the embodiment shown in FIG. 7 has one additional transport fluid nozzle 380, however this is not limiting and more than one additional transport fluid nozzle may be included along the length of the mixing chamber.
  • Transport fluid nozzles may be arranged in any configuration appropriate to accomplishing the desired task, e.g., liquefaction of starch-based biomass.
  • all transport fluid nozzles may be immediately adjacent to each other, or spaced along the length of the mixing chamber, or other arrangements (e.g. a series of pairs) as would occur to one skilled in the art.
  • each transport fluid nozzle may have its own transport fluid supply and transport fluid plenum, or some or all of the transport fluid nozzles may share these features.
  • the reactor may comprise a combination of fluid movers in series and/or parallel . This may also be the case with the temperature conditioning unit made up of one or more of such fluid movers.
  • the apparatus may also include one or more recirculation pipes which can selectively recirculate slurry from downstream of the fluid mover to upstream of the device, so that the slurry can pass through the device more than once, if necessary.
  • the first vessel may also include such an arrangement so that slurry can pass through the first vessel more than once, if necessary.
  • FIG. 6 shows part of the fluid processing apparatus 1 or 1000 of FIG. 1 or FIG. 8, respectively, with representative recirculation loops shown as dash-dot lines. For clarity, several of the features relevant to the vessel 2 as shown in FIG. 1 or FIG. 8 are omitted. In FIG. 6(a), there are two recirculation loops, either or both of which may be incorporated in the fluid processing apparatus.
  • the first recirculation loop 68 recirculates the slurry through the vessel 2 using a pump 69, the valve 12 prevents the slurry from leaving the vessel until the appropriate conditions have been reached (e.g. slurry temperature).
  • the valve 12 may also function to apportion the slurry such that some passes through the recirculation loop whilst some proceeds into the first supply line 16.
  • Such a recirculation loop may be in addition to the motor 8 and agitator 6 shown in FIG. 1 or FIG. 8 or instead of them.
  • An additional port (not shown) in the recirculation loop may be used to add the enzyme into the slurry rather than adding the enzyme to the first vessel 2 or mixing it with the working fluid prior to adding the working fluid to the first vessel 2.
  • the second recirculation loop 74 in FIG. 6(a) is driven by a pump 72.
  • Valves 70 and 76 close the recirculation loop 74 off from the pipework 16 and TCU 52 (not shown) so that slurry can be passed through the reactor 18 for a desired time or until a desired condition (e.g. slurry temperature or viscosity) is reached.
  • the valve 76 may also apportion the slurry such that some continues to the TCU 52 (not shown) whilst the rest recirculates through the recirculation loop 74.
  • FIG. 6(b) shows an alternative recirculation loop 78 that returns the slurry to the first vessel 2 after it has passed through the reactor 18.
  • the first and/or second vessel may alternatively comprise an insulation layer on the exterior surface thereof.
  • the insulation layer keeps the temperature of the slurry inside the vessel in the desired ranges stated above.
  • the working fluid may be pre-heated by an external heater (not shown) prior to being mixed with the feedstock.
  • the temperature of the slurry is maintained at the desired temperature in vessel 2 by either using the heated water jacket 4 or the insulation layer.
  • the second vessel may comprise a large number of internal baffles such that slurry is directed in a convoluted continuous flow path that slowly takes it through the vessel .
  • the low shear centrifugal pump which moves the slurry from the first vessel into the reactor may be replaced with any other suitable pump, such as either a membrane pump or a peristaltic pump, for example.
  • the TCU described above comprises one or more fluid movers of the type shown in FIG. 2, they may be replaced by a heat exchanger.
  • the heat exchanger may be a shell and tube heat exchanger with the slurry passing through a tube and heated water passing through the shell surrounding the tube.
  • the TCU may be replaced by a direct steam injection ' sparge heater * or a jacketed liquefaction tank.
  • the preferred concentration of the liquefaction enzyme in the slurry during development in the first vessel assumes an average of 10%-15% feedstock moisture content and an average starch content of 70%-75% dry weight.
  • the enzyme Whilst the enzyme is preferably introduced to the slurry upstream of the fluid mover, the enzyme may also be introduced in the device or else, downstream of the device following activation of the starch content.
  • first and second vessels for handling the slurry
  • the invention need not include the vessels to provide the advantages highlighted above.
  • the first hydrator may be a pipe or an in-line mixing device into which the feedstock, working fluid and enzyme are introduced upstream of the fluid mover.
  • the second vessel may be replaced by pipework in which the conversion of the activated starch to sugar takes place.
  • Maize is supplied to the plant as grain and then ground to a flour.
  • a conveyor feeds the flour to the slurry tank, where it is mixed with working fluid and continuously agitated (stirred).
  • the plant working fluid is a combination of backset (approx. 25%) and process condensate (approx. 75%).
  • the process condensate is heated before it enters the slurry tank in order to maintain the temperature of the slurry at 85°C-88°C.
  • Aqueous ammonia is added to the slurry tank in order to maintain a pH of approximately 6.0. This temperature range and pH are the preferred conditions for the enzyme a-amylase, which is also added to the slurry tank.
  • the slurry is pumped from the slurry tank, passed through a strainer to remove large particles (which are returned to the slurry tank) and then split into two streams, the first is returned to the slurry tank via a recirculation loop, the second stream continues to the liquefaction tank.
  • the temperature and pH in the liquefaction tank are the same as those in the slurry.
  • the liquefaction tank is divided into compartments with baffles so that the slurry passes slowly through the tank over a period of 90-120 minutes.
  • a mash dilute may be added to maintain a consistent density.
  • the mash is then cooled to about 32°C in a mash cooler and then pumped to a fermenter.
  • a yeast prop is added. This is a pre-prepared mixture of 35% water and 65% mash to which is added yeast, gluco-amylase, urea (nitrogen to feed the yeast), zinc sulphate (speeds fermentation) and magnesium sulphate (aids yeast health), the proportions of each depend on the needs of the yeast.
  • the yeast prop is held in a yeast mix tank with air bubbling through it for 10 hours prior to being added to the fermenter. During this time, a strong yeast mix forms containing a large number of colony forming units (approx. 500-600 million colony forming units per millilitre).
  • the plant uses a fermentation process known as Simultaneous Saccharification and Fermentation (SSF) whereby gluco-amylase is added to perform the saccharification step (breaking the dextrin and other short polysaccharide chains down to smaller sugar units such as glucose) the yeast then consumes the glucose to make ethanol. Too high a level of glucose stresses the yeast, and too low a level starves it, so gluco-amylase is added gradually (at the rates given in Table 2) throughout the fermenter fill time in order to maintain a constant glucose level in the mash.
  • the total fermentation time (including 12 hours of fill time) is about 45-55 hours, after which the fermentation tank is drained and further treatment processes such as distillation occur.
  • the above plant was modified so that the apparatus of the present invention was installed after the slurry tank recirculation loop and before the liquefaction tank.
  • the reactor 18 consisted of two parallel legs, each of which contained five in-series fluid movers of the type shown in FIG. 2, of which the last was operating as a TCU. Each leg fed separately into the liquefaction tank. Steam was injected into the slurry as it passed through the reactor 18 at a rate of 88.6 kg/min (195 Ib./min.) at a maximum steam pressure of 6.5 bar gauge (94 psig) 7.5 bar absolute. The temperature of the slurry entering the reactor 18 was 48°C and on entering the liquefaction tank was 84°C.
  • the temperature of the mash was 83°C and the DE value was 13.4 (compared to a typical value for this plant without the process of the present invention of 12.7).
  • the process of the present invention achieved a higher DE value than the typical process with a lower level of dosing with a-amylase.
  • Corn contains a certain amount of water (typically about 15%).
  • the reason for the lower level of wet corn in the process of the present invention is that because it is able to activate more of the available starch, less corn is required for a given ethanol yield.
  • the conditions in the fermenter are given in Table 2.
  • the gluco- amylase dosing level is initially higher for the process of the present invention (though both processes use the same total amount of the enzyme). This is because the altered proportions of solids and liquids and the balance of sugars in the mash suited the yeast, such that the rates of yeast growth and ethanol production at the start of the fermentation process were accelerated.
  • the yeast therefore, required a faster rate of glucose release to feed it, so the initial dosing levels of gluco-amylase compared to the typical process were increased.
  • a typical ethanol plant producing 40 million gallons of ethanol per year has to purchase 15.94 million bushels of corn.
  • Table 2 shows that the process of the present invention gives a higher ethanol yield per bushel of corn, so less corn is required (15.33 million bushels) to produce the same amount of ethanol. At a purchase price of $4 per bushel of corn, this is a saving of $2.44 million per year.
  • the process of the present invention also required less a-amylase for the liquefaction stage, providing a further cost saving. Energy savings due to the reduced heat requirements of the slurry tank are also possible.

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Abstract

La présente invention concerne des processus, entre autres, de traitement de charge d'alimentation à base d'amidon. Les processus consistent à mélanger ensemble une charge d'alimentation à base d'amidon et un fluide actif pour former une bouillie, hydrater la charge d'alimentation à base d'amidon avec le fluide actif, ajouter un enzyme à la bouillie, pomper la bouillie dans un passage de diamètre pratiquement constant d'un système de déplacement de fluide, et injecter un fluide de transport à haute vitesse dans la bouillie par une ou plusieurs buses en communication avec le passage, ce qui hydrate et chauffe davantage la charge d'alimentation à base d'amidon et disperse l'amidon contenu dans la bouillie. L'invention concerne aussi des appareils permettant d'effectuer de tels processus. L'invention concerne aussi des processus de conversion de l'amidon dans des charges d'alimentation en oligosaccharides et des systèmes de production de sucres et d'éthanol utilisant les processus et les appareils de l'invention. L'invention concerne aussi des processus de calcul du rendement d'éthanol en utilisant les appareils.
PCT/US2013/038252 2012-06-01 2013-04-25 Systèmes et méthodes de traitement de biomasse et de calcul de rendement d'éthanol WO2013180863A1 (fr)

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GB2527317A (en) * 2014-06-17 2015-12-23 Nch Corp Microbial fermentation system for growing and discharging a biological material
US9239063B2 (en) 2004-07-29 2016-01-19 Pursuit Marine Drive Limited Jet pump
WO2016109590A1 (fr) * 2014-12-31 2016-07-07 Poet Research, Inc. Utilisation d'un flux de sucre dans la fermentation de l'éthanol pour produire d'autres produits
US10793879B2 (en) 2014-12-31 2020-10-06 Poet Research, Inc. High purity starch stream methods and systems

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US20070196907A1 (en) * 2003-03-10 2007-08-23 Broin & Associates, Inc. Method For Producing Ethanol Using Raw Starch
US20080103748A1 (en) * 2006-10-31 2008-05-01 Celso Axelrud Integrated model predictive control of distillation and dehydration sub-processes in a biofuel production process
US20100129888A1 (en) * 2004-07-29 2010-05-27 Jens Havn Thorup Liquefaction of starch-based biomass

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US20070196907A1 (en) * 2003-03-10 2007-08-23 Broin & Associates, Inc. Method For Producing Ethanol Using Raw Starch
US20100129888A1 (en) * 2004-07-29 2010-05-27 Jens Havn Thorup Liquefaction of starch-based biomass
US20080103748A1 (en) * 2006-10-31 2008-05-01 Celso Axelrud Integrated model predictive control of distillation and dehydration sub-processes in a biofuel production process

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Publication number Priority date Publication date Assignee Title
US9239063B2 (en) 2004-07-29 2016-01-19 Pursuit Marine Drive Limited Jet pump
GB2527317A (en) * 2014-06-17 2015-12-23 Nch Corp Microbial fermentation system for growing and discharging a biological material
GB2527317B (en) * 2014-06-17 2020-12-02 Nch Corp Microbial fermentation system for growing and discharging a biological material
WO2016109590A1 (fr) * 2014-12-31 2016-07-07 Poet Research, Inc. Utilisation d'un flux de sucre dans la fermentation de l'éthanol pour produire d'autres produits
US10233466B2 (en) 2014-12-31 2019-03-19 Poet Research, Inc. Economic ethanol fermentation sugar stream, processes and systems of producing same
US10793879B2 (en) 2014-12-31 2020-10-06 Poet Research, Inc. High purity starch stream methods and systems
US11060116B2 (en) 2014-12-31 2021-07-13 Poet Research, Inc. Economic ethanol fermentation sugar stream, processes and systems of producing same
US11795480B2 (en) 2014-12-31 2023-10-24 Poet Research, Inc. High purity starch stream methods and systems

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