WO2019154110A1 - 一种以玉米淀粉质为原料生产燃料乙醇的工艺 - Google Patents

一种以玉米淀粉质为原料生产燃料乙醇的工艺 Download PDF

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WO2019154110A1
WO2019154110A1 PCT/CN2019/073107 CN2019073107W WO2019154110A1 WO 2019154110 A1 WO2019154110 A1 WO 2019154110A1 CN 2019073107 W CN2019073107 W CN 2019073107W WO 2019154110 A1 WO2019154110 A1 WO 2019154110A1
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wine
mash
raw material
molecular sieve
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PCT/CN2019/073107
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English (en)
French (fr)
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周宏才
姜新春
谭晓东
马建智
高志贵
唐兆兴
潘锦锋
陈留炘
区镜深
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广东中科天元新能源科技有限公司
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Publication of WO2019154110A1 publication Critical patent/WO2019154110A1/zh

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    • 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
    • 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
    • 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
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/10—Process efficiency
    • Y02P20/129—Energy recovery, e.g. by cogeneration, H2recovery or pressure recovery turbines

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  • the invention relates to the field of ethanol production, in particular to a more energy-saving process for producing fuel ethanol from corn starch as raw material.
  • the alcohol industry refers to the industry that produces cereals, potatoes, and molasses as raw materials, and produces fuel ethanol, edible alcohol, and industrial alcohol through fermentation and distillation. It is an important basic raw material industry in the national economy. In recent decades, with the soaring price of oil and the rapid development of biotechnology, the use of biomass as a raw material to produce fuel ethanol for replacing vehicle fuels and reducing harmful substances in automobile exhaust has become increasingly widespread. With the 15th ceremonies and commissions such as the National Development and Reform Commission and the Energy Bureau jointly issued the “Implementation Plan on Expanding the Production of Biofuel Ethanol and Promoting the Use of Ethanol Gasoline for Vehicles”, the domestic fuel ethanol industry will be further expanded.
  • Chinese invention patent CN102286544A discloses a clean production method of starch-based fuel ethanol.
  • the overall process steam consumption is ⁇ 3.45 tons/ton of fuel ethanol, and the energy consumption level of the method such as steam consumption. Still at a relatively high level.
  • the present invention provides a process for producing fuel ethanol using corn starch as a raw material, which improves the existing technology, thereby further reducing energy consumption, improving product quality and production efficiency.
  • the present invention adopts the following technical solutions:
  • a process for producing fuel ethanol using corn starch as a raw material includes the following sections:
  • the corn starch raw material is pulverized to a size of 1 to 3 mm, and then mixed with a certain temperature of process water and ⁇ -amylase to obtain a dry matter mass content of 20% to 34. % of the slurry, the slurry is heated by steam to 70-85 ° C through a first-stage ejector and then sent to the pre-liquefaction tank, and stirred uniformly to obtain pre-liquefied hydrazine; the pre-liquefied hydrazine is preheated to 80 by the heat exchanger.
  • the discharge temperature is controlled at 95 ⁇ 110 ° C; the heated pre-liquefaction enthalpy from the multi-stage spray liquefier, after the maintenance device, into the helium heat exchanger, The heat is exchanged with the pre-liquefied hydrazine which has not been heated by the multi-stage jet liquefier, and the temperature is lowered to about 80 to 95 ° C, after which the pre-liquefied hydrazine enters the post-liquefaction tank, and at the same time, the starch is further dispersed, the protein is further solidified, and then the starch is added.
  • the enzyme is cooked and cooked, and the obtained pre-liquefied mash is cooled to 40 to 60 ° C and then cooled to obtain liquefied mash; then the pH value of the cooled liquefied mash is adjusted, and saccharification enzyme is added to further cool to 28 to 32 ° C. After Mash, the mash and the fermentation section taken;
  • Fermentation section a part of the mashed mash that is pumped from the mashing mash enters the wine tank, and at the same time, the nutrient salt is added to the wine tank, and the sterile air is introduced.
  • the wine bred quickly multiplies and controls the appropriate flow.
  • Adding proportion, passing air volume and temperature to facilitate the growth and reproduction of the wine mother, the heat generated during the breeding process is taken away by external cooling of the mother liquor circulation; the wine mother containing a large amount of wine is pumped to the first tank of fermentation to control the tank of the wine.
  • the liquid level remains stable; there is a certain alcohol production during the breeding process; the temperature in the wine tank is maintained at 28-30 ° C;
  • Another part of the mash is directly into the fermenter.
  • a large amount of alcohol is generated through the life activity of the wine mother.
  • a certain amount of sterile air is introduced depending on the production situation;
  • the distillation workshop adopts a multi-tower combination, and is combined with a molecular sieve thermal coupling process, mainly composed of a distillation apparatus and a molecular sieve system, the distillation apparatus mainly comprises a fine tower and a coarse tower; the molecular sieve system includes an evaporator, Superheater and molecular sieve bed.
  • the fermented mature mash is preheated to the temperature above 70 °C by the uncooled liquefied mash after being cooked and cooked in the section (1), and then the fermented mature mash is sent to the distillation workshop, after the crude tower is stripped, and then refined by the refined tower, 95% (v) of alcohol was produced in the liquid phase of the column as a water-free raw material.
  • the anhydrous raw material is preheated by the fuel ethanol wine steam and sent to the molecular sieve system. After passing through the evaporator and the superheater, it is dehydrated into the molecular sieve bed to obtain the fuel ethanol wine vapor, and the fuel ethanol wine steam heating tower and the crude tower. Finally, the fuel ethanol wine vapor is cooled to obtain fuel ethanol with a mass fraction of 99.5%.
  • a denatured fuel ethanol product is obtained by adding a denaturant to the fuel ethanol product, and the product quality conforms to the national standard GB18350-2013.
  • the starch liquefaction process of the section (1) adopts a continuous cooking process of steaming after low-pressure steam spraying, so that the mixed slurry is uniformly heated, and the starchy raw material is gelatinized thoroughly; compared with the high-temperature cooking process, the starch can be extracted.
  • the rate is 0.5%, and the energy saving is 30%; the temperature of the pre-liquefied hydrazine after the aging is cooled from 95 to 105 ° C, and the heat released by cooling is used to heat the mature mash before the fermentation mature cesium is sent to the distillation column.
  • the pre-liquefied crucible after curing in the section (1) is cooled by a two-stage cooler, and the cooler is a spiral plate or a plate cooler.
  • the mash of the mash in the section (2) is ⁇ 60 hours in the fermenter; the amount of the fermented mature mash reaches 14 to 17% (v/v); a large amount of heat is released during the fermentation.
  • the fermentation temperature is stabilized by external cooling of the tank; the fermentation temperature is 31-35 ° C; the fermenter uses a vertical stirrer, thereby greatly increasing the alcohol concentration of the fermenter.
  • the plant further comprising a distillation wash column into the wash column (2) in the tank and the yeast fermentation tank during fermentation C0 2 produced the carbon dioxide recovery section.
  • the molecular sieve bed in the section (3) comprises a molecular sieve adsorption bed and a molecular sieve analytical bed.
  • the molecular sieve system in the section (3) enables heat source coupling within the molecular sieve system.
  • the process for producing fuel ethanol using corn starch as raw material of the invention further comprises a waste processing unit and a by-product recycling section.
  • waste waste treatment is to separate solid and liquid after solid-liquid separation, and convert it into feed, organic fertilizer or other by-products.
  • the clear liquid and condensed water produced by the process are used as the mixing water for each section. After the wastewater is treated, part of the water is reused and partially discharged.
  • the waste processing unit is mainly composed of solid-liquid separation, evaporation concentration, drying, fan conveying, powder storage, packaging, etc.
  • the equipment used mainly includes: horizontal screw centrifuge, evaporation Equipment such as concentrating devices, dryers, packaging machines, etc.
  • the treatment process mainly includes: solid-liquid separation of waste waste, obtaining wet and clear liquid, partially separating the separated liquid, partially feeding the concentrated slurry into the evaporation concentrating device, mixing the thick slurry with the wet residue, and drying through the tube bundle. After the machine was dried and cooled, DDGS was obtained. The secondary condensate produced by the concentration of the clear liquid is treated, and the treated medium water is used as the mixing water for each section to realize the recycling of the production water in each section.
  • the evaporation concentrating device generates waste hot gas in the evaporation concentration process, and after the waste hot gas is treated, it is used as a heat source of the section (3) distillation device, which can save a large amount of steam.
  • the heat source of the distillation apparatus of the section (3) further comprises waste heat recovered by the vapor-heat coupling of the fuel ethanol wine in the molecular sieve system.
  • the specific corn distiller's grains processing process is as follows:
  • the advanced distiller's grains from the distiller's liquor from the distillation section are separated from the snail centrifuge by the distiller's juice pump, and the separated clear liquid flows into the separation clear liquid tank.
  • the other supernatants are passed through a pre-concentrated multi-effect evaporator (pre-concentrated evaporator using dry waste steam as a heat source) to make the concentrated liquid concentration reach 10% or more of the semi-concentrated slurry, and then continue to increase concentration.
  • a pre-concentrated multi-effect evaporator pre-concentrated evaporator using dry waste steam as a heat source
  • the thick slurry required for concentration into a dryer is sent to the mixer for mixing and drying together with the separated solid matter and the returned material after drying.
  • the dried material is collected by the wind conveying system and then enters the hopper. After the air is cooled, the material is directly sent to the baler to make the DDGS finished product.
  • Evaporation is divided into two lines, pre-concentration and enrichment; wherein pre-concentration uses dry waste steam and steam condensation water as a heat source.
  • the evaporation system is composed of multi-effect full falling film evaporator, low circulation, high vaporization rate, and end.
  • the juice steam that comes out is used as a heat source in the distillation system, while eliminating a large amount of circulating water.
  • the concentrated steam is used as a heat source, and a multi-effect falling film evaporator and a one-effect forced circulation evaporator are used according to the physical characteristics.
  • the semi-concentrated slurry from the preconcentration device is further concentrated to a desired concentration of the concentrated slurry and then dried in a dryer.
  • the by-product recycling section includes liquid carbon dioxide recovery, biogas purification and precision separation of fusel oil. Its main purpose is to increase the added value of by-products, to maximize the utilization of resources throughout the production process and to maximize economic benefits.
  • the high-concentration slurry is sprayed and liquefied by multi-stage high-performance ejector, and combined with the ⁇ heat exchange process, and the technical means such as reconstitution of clear liquid is used to ensure the liquefaction effect and achieve the purpose of energy saving.
  • the temperature of the crude tower waste sputum can be controlled at 80-95 °C, which has obvious superior effect on the feed color index of DDGS.
  • Figure 1 is a general flow chart of the process of the present invention.
  • the discharge temperature is controlled at 95-110 ° C; the pre-liquefied helium after heating is discharged from the multi-stage jet liquefier, passes through the maintainer, and enters the helium heat exchanger, and The pre-liquefied hydrazine heated by the multi-stage jet liquefier is subjected to heat exchange, and the temperature is lowered to about 85-95 ° C, after which the pre-liquefied mash enters the post-liquefaction tank, and the starch is further dispersed, the protein is further solidified, and then the amylase is added for cooking and aging.
  • the obtained pre-liquefied hydrazine is cooled and cooled to obtain liquefied mash; then the pH value of the cooled liquefied mash is adjusted, and saccharification enzyme is added, and further cooled to 28 to 32 ° C to obtain mash, and the mash is sent to Fermentation section
  • Fermentation a part of the mashed mash that has been pumped from the mashing mash enters the wine tank, and at the same time, the nutrient salt is added to the wine tank, and the sterile air is introduced. Under the aerobic condition, the wine bred quickly multiplies and controls the appropriate flow ratio.
  • temperature in order to facilitate the growth and reproduction of the wine mother, the heat generated during the breeding process is carried away by the external cooling of the mother liquor circulation; the wine mother containing a large amount of wine mother is pumped to the first tank of fermentation, and the liquid level of the wine tank is controlled to remain stable. There is a certain amount of alcohol produced during the breeding process of the wine; the temperature in the wine tank is maintained at 28 ⁇ 35 ° C;
  • Another part of the mash is directly into the fermenter.
  • a large amount of alcohol is generated through the life activity of the wine mother.
  • a certain amount of sterile air is introduced depending on the production situation;
  • the distillation workshop adopts a multi-tower combination, which is combined with a molecular sieve thermal coupling process, and is mainly composed of a distillation apparatus and a molecular sieve system.
  • the distillation apparatus mainly comprises a fine tower and a coarse tower; the molecular sieve system includes an evaporator, a superheater and a molecular sieve. bed.
  • the fermented mature mash is preheated to the temperature above 70 °C by the uncooled liquefied mash after being cooked and cooked in the section (1), and then the fermented mature mash is sent to the distillation workshop, after the crude tower is stripped, and then refined by the refined tower, 95% (v) of alcohol was produced in the liquid phase of the column as a water-free raw material.
  • the anhydrous raw material is preheated by the fuel ethanol wine steam and sent to the molecular sieve system, and is dehydrated by the evaporator, the superheater and the molecular sieve bed to obtain the fuel ethanol wine steam, and the fuel ethanol wine steam supply heat tower and the crude tower. Finally, the fuel ethanol wine vapor is cooled to obtain fuel ethanol with a mass fraction of 99.5%.
  • the pulverization of the starchy raw material and the combined steam consumption of the liquid chemical section and the ethanol distillation dehydration section are 0.8-1.0 tons/ton of fuel ethanol.
  • Waste waste comprehensive treatment section the advanced distiller's grains from the distiller's liquor from the distillation section, after being separated from the snail centrifuge by the distiller's juice pump, the separated clear liquid flows into the separation clear liquid tank.
  • the other supernatants are passed through a pre-concentrated multi-effect evaporator (pre-concentrated evaporator using dry waste steam as a heat source) to make the concentrated liquid concentration reach 10% or more of the semi-concentrated slurry, and then continue to increase concentration.
  • a pre-concentrated multi-effect evaporator pre-concentrated evaporator using dry waste steam as a heat source
  • the thick slurry required for concentration into a dryer is sent to the mixer for mixing and drying together with the separated solid matter and the returned material after drying.
  • the dried material is collected by the wind conveying system and then enters the hopper. After the air is cooled, the material is directly sent to the baler to make the DDGS finished product.
  • Evaporation is divided into two lines, pre-concentration and enrichment; wherein the pre-concentration uses a heat source for the dry waste steam and the steam condensation water flash steam.
  • the evaporation system is composed of a multi-effect falling film evaporator, low circulation amount, high vaporization rate, and final effect.
  • the juice steam comes out to the fine tower and the thick tower as a heat source, while eliminating a lot of circulating water.
  • the enrichment uses raw steam as a heat source, and according to the physical characteristics, a multi-effect falling film evaporator and a one-effect forced circulation evaporator are used.
  • the semi-concentrated slurry from the preconcentration unit is continuously concentrated to a desired concentration of the concentrated slurry and then dried in a dryer.
  • the total steam consumption of the whole section is ⁇ 3.0 tons/ton of fuel ethanol (including the waste waste comprehensive treatment section).
  • the slurry is then pumped to the jet liquefier to control the steam injector discharge temperature to 95-105 ° C to obtain heated mash.
  • the heated mash is sent to a cooking column for cooking and aging.
  • the aged mash is pumped to the slurry preheater. After preheating the slurry that has not entered the liquefaction tank, the temperature is lowered and then enters the flash tank.
  • the temperature of the liquefied mash after flashing is 60-65 °C.
  • the liquefied mash is adjusted with sulphuric acid in a saccharification tank (equipped with a stirrer), and then saccharified by adding ⁇ -1,4-glucohydrolase.
  • the mashed mash is pumped and cooled by a two-stage plate cooler. Cool to 28 ⁇ 33 ° C, sent to the fermentation section.
  • the fermentation section uses batch fermentation, and the mash is added to the yeast from the wine tank.
  • the fermentation time is 60 h and the temperature is 33 °C.
  • the obtained fermented mature mash is sent to the distillation and dehydration section, and the tank is subjected to washing and sterilizing, and then the above operation is repeated.
  • the condenser is condensed to discharge C0 2 and non-condensable gas; the mature enthalpy after degassing is divided into two strands, one of which enters the stripping section of the crude distillation column for preliminary distillation, and the alcohol vapor is condensed by the condenser of the degassing section to obtain coarse wine.
  • the obtained waste sputum is discharged from the bottom of the crude distillation tower to the waste residue treatment section; the other degassed mature enthalpy is withdrawn from the bottom line of the degassing section, and the flow rate is 180t/h, and the combined tower is After the kettle is preheated, it enters the combined tower for re-distillation.
  • a portion of the alcohol vapor (95.8% V/V) obtained at the top of the column is condensed in a forced circulation reboiler of the crude distillation column. The latent heat of condensation is used to heat the crude distillation column and condense.
  • the liquid is refluxed as the top of the tower, and the waste enthalpy is discharged from the bottom of the combined tower to the waste disposal section; another part of the alcohol vapor is sent to the molecular sieve dehydration unit to obtain the finished product of light wine and anhydrous ethanol with a concentration of 70% V/V.
  • the waste slag discharged from the bottom of the crude distillation tower and the combined tower is subjected to pressure filtration treatment by a plate and frame filter press, and 30% of the separated clear liquid is used as water for the liquid chemical section, and 70% of the evaporative concentration device is used to produce thick slurry, and the thick slurry is obtained. It is mixed with the filter residue from the filter press, dried, granulated and cooled by a tube bundle dryer to obtain DDGS feed with a water content of less than 11.5%. After the waste hot gas at the outlet of the tube bundle dryer is treated, it is used as a supplementary heat source for the evaporation concentrating device.
  • the secondary condensate produced by the concentration of the clear liquid is used for sewage treatment, and the treated medium water is used as the liquid chemical section to realize the recycling of the production water of the whole plant.
  • the total steam consumption of the whole section is 3.45 tons / ton of fuel ethanol (including waste waste treatment section).
  • Example 1 Compared to Comparative Example 1, the steam consumption of the distillation and dewatering sections of Example 1 was reduced by 42% to 44%, and the total steam consumption of the entire section was reduced by 5% to 15%.

Abstract

一种以玉米淀粉质为原料生产燃料乙醇的工艺，包括淀粉质原料的粉碎及液化工段、糖化工段、发酵工段、乙醇蒸馏脱水工段、废糟综合处理工段和副产品回收利用工段。

Description

一种以玉米淀粉质为原料生产燃料乙醇的工艺 技术领域
本发明涉及乙醇生产领域，具体是涉及一种更加节能的以玉米淀粉质为原料生产燃料乙醇的工艺。
背景技术
酒精工业是指以谷类、薯类、糖蜜为原料，经发酵、蒸馏而生产燃料乙醇、食用酒精和工业酒精的工业，是国民经济重要的基础原料产业。近几十年来，随着石油价格的飞涨和生物技术的日新月异，以生物质为原料生产用于替代车用燃料、减少汽车尾气有害物质的燃料乙醇应用日益广泛。随着国家发改委、能源局等十五部委联合印发《关于扩大生物燃料乙醇生产和推广使用车用乙醇汽油的实施方案》，国内的燃料乙醇工业会进一步扩增。
中国发明专利CN102286544A公开了一种淀粉基燃料乙醇的清洁生产方法，在采用该方法生产燃料乙醇的过程中，整体工艺蒸汽消耗≥3.45吨/吨燃料乙醇，所述方法的汽耗等能耗水平还处在相对较高的水平。
发明内容
为了解决上述问题，本发明提供一种以玉米淀粉质为原料生产燃料乙醇的工艺，该工艺对现有的技术进行改进，从而进一步降低能耗，提高产品质量与生产效益。
为实现上述目的，本发明采用如下技术方案：
如图1所示，一种以玉米淀粉质为原料生产燃料乙醇的工艺，包括以下工段：
(1)淀粉质原料的粉碎及液化工段：将玉米淀粉质原料粉碎至1～3mm大小，然后与一定温度的工艺水及α-淀粉酶混合搅拌均匀，得到干物质质量含量为20％～34％的粉浆，粉浆经一级喷射器由蒸汽加热至70～85℃后送入预液化罐，搅拌均匀，得到预液化醪；预液化醪先经醪醪换热器预热至80～95℃，然后经多级喷射液化器由蒸汽加热，出料温度控制在95～110℃；加热后的预液化醪从多级喷射液化器出来，经过维持器后，进入醪醪换热器，与未经多级喷射液化器加热的预液化醪进行换热，温度降低至80～95℃左右，之后预液化醪进入后液化罐，与此同时淀粉进一步分散，蛋白进一步凝固，接着再加入淀粉酶进行蒸煮熟化，将所得熟化后的预液化醪降温至40～60℃后进行冷却，得到液化醪；然后调节冷却后的液化醪的pH值,并加入糖化酶，进一步冷却至28～32℃后得到糖化醪，并将糖化醪送往发酵工段；
(2)发酵工段：自糖化醪泵送来的一部分糖化醪进入酒母罐，同时向酒母罐中加入营养盐，通入无菌空气，在有氧条件下，酒母迅速大量繁殖，控制合适的流加比例、通入空气量、温度，以利于酒母的生长繁殖，在繁殖过程中产生的热量通过母液循环外部冷却带走；含有大量酒母的酒母醪用泵送至发酵首罐，控制酒母罐的液位保持稳定；在酒母繁殖过程中有一定的酒精产生；酒母罐内的温度保持在 28～30℃；
另一部分糖化醪直接进入发酵罐，在罐内，通过酒母的生命活动，大量的酒精生成，为了保持酒母的单位体积醪液中的数量，视生产情况通入一定的无菌空气；
(3)乙醇蒸馏脱水工段：蒸馏车间采用多塔组合，配合分子筛热耦合工艺，主要由蒸馏装置和分子筛系统组成，所述蒸馏装置主要包括精塔和粗塔；所述分子筛系统包括蒸发器、过热器和分子筛床。
发酵成熟醪由工段(1)蒸煮熟化后未经冷却的液化醪预热至70℃以上，然后将发酵成熟醪送至蒸馏车间，经粗塔提馏，再经精塔精馏后，从精塔的液相中采出95％(v)的酒精作为无水原料。
无水原料经燃料乙醇酒汽预热后送至分子筛系统，经过蒸发器、过热器后进入分子筛床脱水，得到燃料乙醇酒汽，同时燃料乙醇酒汽供热精塔和粗塔。最后燃料乙醇酒汽经过冷却后即得到质量分数为99.5％的燃料乙醇。
在所述燃料乙醇产品中添加变性剂后得到变性燃料乙醇产品，产品质量符合国家标准GB18350-2013。
优选的，所述工段(1)的淀粉液化过程采用低压蒸汽喷射后蒸煮的连续蒸煮工艺,使混合粉浆受热均匀，淀粉质原料糊化彻底；与高温蒸煮工艺比较,可提髙淀粉出酒率0.5％，并节能30％；所述熟化后的预液化醪的温度从95～105℃降温冷却释放的热量用于在发酵成熟醪送入蒸馏塔前，对发酵成熟醪进行加热。
优选的，所述工段(1)中熟化后的预液化醪的冷却使用两级冷 却器，逐级进行冷却，冷却器采用螺旋板式或板式冷却器。
优选的，所述工段(2)中的糖化醪在发酵罐的时间≥60小时；发酵成熟醪的酒份达到14～17％(v/v)；在发酵过程中会有大量的热量放出，通过罐外冷却保证发酵温度的稳定；发酵温度为31～35℃；发酵罐采用立式搅拌器，从而大大提高发酵罐的酒精浓度。
优选的，所述蒸馏车间还包括洗涤塔，所述工段(2)中酒母罐和发酵罐在发酵过程产生的C0 2进入洗涤塔进行二氧化碳的回收。
优选的，所述工段(3)中的所述分子筛床包括分子筛吸附床和分子筛解析床。
所述工段(3)中的分子筛系统能实现分子筛系统内部热源耦合。
本发明的以玉米淀粉质为原料生产燃料乙醇的工艺还包括废糟综合处理工段和副产品回收利用工段。其中，废糟处理是对废醪进行固液分离后，对固体和液体分别进行处理，使之转化为饲料、有机肥料或其他副产品，过程产生的清液和冷凝水作为各工段的拌料用水，废水经过处理后，部分中水回用，部分达标排放。
例如，若以玉米为原料生产酒精，其废糟综合处理工段主要由固液分离、蒸发浓缩、干燥、风机输送、贮粉、包装等工序组成，采用的设备主要有：卧螺离心机、蒸发浓缩装置、干燥机、包装机等设备。
处理过程主要包括：对废糟进行固液分离,得到湿糟和清液，分离后的清液部分回用，部分进蒸发浓缩装置生产浓浆，将浓浆与湿糟混合后，经过管束干燥机干燥、冷却后，得到DDGS。对清液浓缩产 生的二次凝水进行处理，处理后的中水作为各工段的拌料用水，实现各工段生产用水的循环使用。所述蒸发浓缩装置在蒸发浓缩过程中产生废热气，废热气经过处理后，用做工段(3)蒸馏装置的热源，可节约大量蒸汽。
而且，所述工段(3)的蒸馏装置的热源还包括所述分子筛系统中的燃料乙醇酒汽热耦合所回收的余热。
具体的玉米酒糟处理流程如下：
从蒸馏工段来的酒糟液先进酒糟罐，经酒糟泵打到卧螺离心机分离后，分离清液流入分离清液罐。
部分清液回配后，其它清液通过一套预浓缩多效蒸发器(利用干燥废汽作为热源的预浓缩蒸发器)使浓缩液浓度达到10％以上的半浓浆液，再进增浓缩继续浓缩成干燥机所需要的浓浆，与分离所得的固形物和干燥后的返回物料一起送至混料机进行混合干燥。
干燥后的物料经风力输送系统收集后进入料斗，经空气冷却后物料直接送打包机制成DDGS成品。
蒸发分二条线，预浓缩和增浓缩；其中预浓缩用干燥废汽和汽凝水闪蒸汽作热源，此蒸发系统是由多效全降膜蒸发器组成，低循环量，高汽化率，末效出来的汁汽去蒸馏系统作热源，同时省去大量循环水。
增浓缩用生蒸汽作热源，根据物性特点，采用多效降膜式蒸发器和一效强制循环蒸发器。从预浓缩装置出来的半浓浆进增浓缩装置继续浓缩到所需要浓度的浓浆后进干燥机干燥。
而副产品回收利用工段则包括液体二氧化碳回收，沼气提纯净化 和杂醇油的精密分离。其主要目的是提高副产品的附加值，实现整个生产过程资源利用的最大化和经济效益的最大化。
本发明的有益效果在于：
1.采用高浓度粉浆经多级高性能喷射器喷射液化，同时结合醪醪换热工艺，回用清液调配等技术手段，既保证液化效果，又达到节能的目的。
2.相比于现有的工艺方法，本发明各工段采用能源优化整合技术，整体汽耗≤3.0吨汽/吨无水乙醇。
3.装置投资较传统工艺低，工艺流程简洁高效，维护方便。
4.粗塔废醪液温度可控制在80～95℃，对DDGS的饲料色泽指标有明显提优作用。
附图说明
图1为本发明的工艺总流程图。
具体实施方式
以下将结合附图对本发明作进一步的描述，需要说明的是，本实施例以本技术方案为前提，给出了详细的实施方式和具体的操作过程，但本发明的保护范围并不限于本实施例。
实施例1
以玉米淀粉为原料发酵生产燃料乙醇的工艺如下：
将130吨/h玉米(淀粉含量为65％，水分质量含量为14％)粉碎至1～3mm大小，随后与水及α-淀粉酶混合搅拌均匀，得到干物质 质量含量为20％～34％的粉浆，粉浆经一级喷射器由蒸汽加热70～85℃后送入预液化罐，搅拌均匀，得到预液化醪，预液化醪先经醪醪换热器预热至80～95℃，然后经多级喷射液化器由蒸汽加热，出料温度控制在95～110℃；加热后的预液化醪从多级喷射液化器出来，经过维持器后，进入醪醪换热器，与未经多级喷射液化器加热的预液化醪进行换热，温度降低至85～95℃左右，之后预液化醪进入后液化罐，同时淀粉进一步分散，蛋白进一步凝固，接着加入淀粉酶进行蒸煮熟化，将所得熟化后的预液化醪降温冷却，得到液化醪；然后调节冷却后的液化醪的pH值,并加入糖化酶，进一步冷却至28～32℃后，得到糖化醪，并将糖化醪送往发酵工段；
发酵：自糖化醪泵送来的一部分糖化醪进入酒母罐，同时向酒母罐中加入营养盐，通入无菌空气，在有氧条件下，酒母迅速大量繁殖，控制合适的流加比例、通入空气量、温度，以利于酒母的生长繁殖，在繁殖过程中产生的热量通过母液循环外部冷却带走；含有大量酒母的酒母醪用泵送至发酵首罐，控制酒母罐的液位保持稳定；在酒母繁殖过程中有一定的酒精产生；酒母罐内的温度保持在28～35℃；
另一部分糖化醪直接进入发酵罐，在罐内，通过酒母的生命活动，大量的酒精生成，为了保持酒母的单位体积醪液中的数量，视生产情况通入一定的无菌空气；
蒸馏和脱水：蒸馏车间采用多塔组合，配合分子筛热耦合工艺，主要由蒸馏装置和分子筛系统组成，所述蒸馏装置主要包括精塔和粗塔；所述分子筛系统包括蒸发器、过热器和分子筛床。
发酵成熟醪由工段(1)蒸煮熟化后未经冷却的液化醪预热至70℃以上，然后将发酵成熟醪送至蒸馏车间，经粗塔提馏，再经精塔精馏后，从精塔的液相中采出95％(v)的酒精作为无水原料。
无水原料经燃料乙醇酒汽预热后送至分子筛系统，经蒸发器、过热器后进分子筛床脱水得到燃料乙醇酒汽，同时燃料乙醇酒汽供热精塔和粗塔。最后燃料乙醇酒汽经过冷却后即得到质量分数为99.5％的燃料乙醇。淀粉质原料的粉碎及液化工段、乙醇蒸馏脱水工段合并蒸汽消耗0.8～1.0吨/吨燃料乙醇。
废糟综合处理工段：从蒸馏工段来的酒糟液先进酒糟罐，经酒糟泵打到卧螺离心机分离后，分离清液流入分离清液罐。
部分清液回配后，其它清液通过一套预浓缩多效蒸发器(利用干燥废汽作为热源的预浓缩蒸发器)使浓缩液浓度达到10％以上的半浓浆液，再进增浓缩继续浓缩成干燥机所需要的浓浆，与分离所得的固形物和干燥后的返回物料一起送至混料机进行混合干燥。
干燥后的物料经风力输送系统收集后进入料斗，经空气冷却后物料直接送打包机制成DDGS成品。
蒸发分二条线，预浓缩和增浓缩；其中预浓缩用干燥废汽和汽凝水闪蒸汽用热源，此蒸发系统是由多效降膜蒸发器组成，低循环量，高汽化率，末效出来的汁汽去精塔和粗塔作热源，同时省去大量循环水。
增浓缩用生蒸汽做热源，根据物性特点，采用多效降膜式蒸发器和一效强制循环蒸发器。从预浓缩装置出来的半浓浆进增浓缩装置继 续浓缩到所需要浓度的浓浆后进干燥机干燥。
副产品回收利用：对液体二氧化碳回收，进行沼气提纯净化和杂醇油精密分离。
全工段总的蒸汽消耗为≤3.0吨/吨燃料乙醇(含废糟综合处理工段)。
对照例1
以玉米淀粉为原料发酵生产燃料乙醇的工艺如下：
将71.6吨/h玉米(淀粉含量为65％，水分质量含量为14％)粉碎至平均粒径为2mm送入预液化罐，加入拌料水，α-淀粉酶，得到干物质质量含量为26.5％的粉浆，为使粉浆混合均匀，罐内配有搅拌器，将粉浆预热后送入预液化罐，在预液化罐中，上述粉浆由直接蒸汽加热至80～90℃。
然后粉浆通过泵送去喷射液化器，控制蒸汽喷射器出料温度为95～105℃，得到加热后的醪液。将加热后的醪液送入蒸煮柱进行蒸煮熟化。熟化后的醪液被泵送至粉浆预热器，对未进入液化罐的粉浆进行预热后，降低温度后进入闪蒸罐，闪蒸后液化醪的温度为60～65℃。
液化醪在糖化罐(配备搅拌器)内用硫酸调节pH值，然后加入α-1,4-葡萄糖水解酶进行糖化，糖化后的醪液由泵输送经两级板式冷却器进行逐级冷却，冷却至28～33℃，送往发酵工段。
发酵工段采用间歇式发酵，醪液加入从酒母罐过来的酵母，发酵时间为60h，温度为33℃。发酵结束后，得到的发酵成熟醪送去蒸馏 和脱水工段，罐体经洗刷灭菌后再重复以上操作。
发酵成熟醪经粗馏塔酒精蒸汽、无水乙醇成品蒸汽、粗馏塔塔底废醪三级预热后进入粗馏塔脱气段进行脱气，脱出的CO 2随酒精蒸汽进入脱汽段冷凝器冷凝，排出C0 2及不凝气体；脱气后的成熟醪分成两股，一股进入粗馏塔提馏段进行初步蒸馏，得到酒精蒸汽经脱汽段冷凝器冷凝后得到粗酒，进入粗酒精罐，得到的废醪由粗馏塔底部排出，去往废糟处理工段；另一股脱气后的成熟醪从脱气段底部侧线抽出，流量为180t/h，经组合塔塔釜废醪预热后进入组合塔进行再次蒸馏，塔顶得到的酒精蒸汽(95.8％V/V)一部分进入粗馏塔的强制循环再沸器中冷凝，冷凝潜热用于加热粗馏塔，冷凝液作为塔顶回流，得到废醪由组合塔底部排出，去往废糟处理工段；另一部分酒精蒸汽送往分子筛脱水机组，得到浓度为(70％V/V)的淡酒和无水乙醇成品蒸汽，淡酒进入粗酒精罐，无水乙醇成品蒸汽冷凝后得到燃料乙醇产品；质量流量为25.2吨/h，产品质量分数为99.2％，含水量＜0.5％，酸含量46ppm,满足国家标准GB18350-2013，蒸馏和脱水工段蒸汽消耗为1.4～1.8吨/吨燃料乙醇。
从粗馏塔和组合塔塔底排放的废醪经板框压滤机压滤处理，分离出的清液30％回用作液化工段用水，70％进蒸发浓缩装置生产浓浆，将浓浆与压滤机出来的滤渣混合，经管束干燥机干燥、造粒、冷却得到水分小于11.5％的DDGS饲料。管束干燥机出口的废热气处理后，用于蒸发浓缩装置的补充热源。清液浓缩产生的二次凝水进行污水处理，处理后的中水用做液化工段用水，实现全厂生产用水的循环使 用。全工段总的蒸汽消耗为3.45吨/吨燃料乙醇(含废糟综合处理工段)。
相比于对照例1，实施例1蒸馏和脱水工段的蒸汽消耗降低了42％～44％，全工段总的蒸汽消耗降低了5％～15％。
对于本领域的技术人员来说，可以根据以上的技术方案和构思，作出各种相应的改变和变形，而所有的这些改变和变形都应该包括在本发明权利要求的保护范围之内。

Claims (9)

  1. 一种以玉米淀粉质为原料生产燃料乙醇的工艺，其特征在于，包括以下工段：
    (1)淀粉质原料的粉碎及液化工段：将玉米淀粉质原料粉碎，然后与水及α-淀粉酶混合搅拌均匀，得到干物质质量含量为20％～34％的粉浆，粉浆经一级喷射器由蒸汽加热至70～85℃后送入预液化罐，搅拌均匀，得到预液化醪；预液化醪先经醪醪换热器预热至80～95℃，然后经多级喷射液化器由蒸汽加热；加热后的预液化醪从多级喷射液化器出来，经过维持器后，进入醪醪换热器，与未经多级喷射液化器加热的预液化醪进行换热，温度降低至80～95℃，之后预液化醪进入后液化罐，再加入淀粉酶进行蒸煮熟化，将所得熟化后的预液化醪降温至40～60℃后进行冷却，得到液化醪；然后调节冷却后的液化醪的pH值,并加入糖化酶，进一步冷却至28～32℃后，得到糖化醪，并将糖化醪送往发酵工段；
    (2)发酵工段：自糖化醪泵送来的一部分糖化醪进入酒母罐，同时向酒母罐中加入营养盐，通入无菌空气，在有氧条件下，酒母迅速繁殖，控制流加比例、空气通入量和温度，以利于酒母的生长繁殖，酒母在繁殖过程中产生的热量通过母液循环外部冷却带走；含有酒母的酒母醪用泵送至发酵首罐，控制酒母罐的液位保持稳定；控制酒母罐内的温度保持在28～30℃；
    另一部分糖化醪直接进入发酵罐，在罐内，通过酒母的生命活动，发酵生成酒精，为了保持酒母的单位体积醪液中的数量，通入无菌空气；
    (3)乙醇蒸馏脱水工段：蒸馏车间主要由蒸馏装置和分子筛系统组成，并配合热耦合工艺；所述蒸馏装置主要包括精塔和粗塔；所述分子筛系统包括蒸发器、过热器和分子筛床；发酵成熟醪由工段(1)蒸煮熟化后未经冷却的液化醪预热至70℃以上，然后将发酵成熟醪送至蒸馏车间，经粗塔提馏，再经精塔精馏后，从精塔的液相中采出体积分数为95％的酒精作为无水原料；
    无水原料经燃料乙醇酒汽预热后送至分子筛系统，经过蒸发器、过热器后进入分子筛床脱水，得到燃料乙醇酒汽，燃料乙醇酒汽经过冷却后即得到质量分数为99.5％的燃料乙醇。
  2. 根据权利要求1所述的以玉米淀粉质为原料生产燃料乙醇的工艺，其特征在于，所述工段(1)的淀粉液化过程采用多级低压蒸汽喷射后蒸煮的连续蒸煮工艺；所述的多级蒸汽喷射为一级或一级以上蒸汽喷射；所述熟化后的预液化醪降温冷却释放的热量用于在发酵成熟醪送入蒸馏车间之前，对发酵成熟醪进行加热。
  3. 根据权利要求1所述的以玉米淀粉质为原料生产燃料乙醇的工艺，其特征在于，所述工段(1)中熟化后的预液化醪的冷却使用两级冷却器，逐级进行冷却，冷却器采用螺旋板式或板式冷却器。
  4. 根据权利要求1所述的以玉米淀粉质为原料生产燃料乙醇的工艺，其特征在于，所述工段(2)中的糖化醪在发酵罐的时间≥60小时，发酵温度为31～35℃；发酵罐采用立式搅拌器。
  5. 根据权利要求1所述的以玉米淀粉质为原料生产燃料乙醇的工艺，其特征在于，所述蒸馏车间还包括洗涤塔，所述工段(2)中 酒母罐和发酵罐在发酵过程产生的C0 2进入洗涤塔进行二氧化碳的回收。
  6. 根据权利要求1所述的以玉米淀粉质为原料生产燃料乙醇的工艺，其特征在于，所述工段(3)中的分子筛系统实现分子筛系统内部热源耦合；所述分子筛床包括分子筛吸附床和分子筛解析床。
  7. 根据权利要求1所述的以玉米淀粉质为原料生产燃料乙醇的工艺，其特征在于，还包括废糟综合处理工段，所述废糟综合处理工段的处理过程包括：对废糟进行固液分离,得到湿糟和清液，分离后的清液部分回用，部分进蒸发浓缩装置生产浓浆，将浓浆与湿糟混合后，经过管束干燥机干燥、冷却后，得到DDGS；对清液浓缩产生的二次凝水进行处理，处理后的中水作为各工段的拌料用水；所述蒸发浓缩装置在蒸发浓缩过程中产生废热气，废热气经过处理后，用做工段(3)蒸馏装置的热源。
  8. 根据权利要求1或7所述的以玉米淀粉质为原料生产燃料乙醇的工艺，其特征在于，所述工段(3)蒸馏装置的热源还包括所述分子筛系统中的燃料乙醇酒汽热耦合所回收的余热。
  9. 根据权利要求1所述的以玉米淀粉质为原料生产燃料乙醇的工艺，其特征在于，还包括后续的副产品回收利用工段，所述副产品回收利用工段包括液体二氧化碳回收、沼气提纯净化和杂醇油的精密分离。
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CN111440828A (zh) * 2020-04-09 2020-07-24 吉林中粮生化有限公司 调浆液和液化淀粉质原料的方法及制备乙醇的方法
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