CN1950514A - Methods and systems for producing ethanol using raw starch and fractionation - Google Patents

Abstract

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

Description

Use the method and system of giving birth to starch and fractionation producing and ethanol

The application applies for as a pct international patent and submitted on March 10th, 2005, for the specified applicant of the All Countries except that the U.S. is Broin and Associates, Inc., it is a tame U.S. staterun enterprise, and with Steven M.Lewis, a United States citizen is specified as only at the applicant of the U.S., and require U.S. Provisional Application sequence number Nos.60/552,108 (submitting to) on March 10th, 2004; Nos.60/614,916 (submitting to) on September 30th, 2004; And Nos.60/615, the right of priority of 155 (submitting to) on October 1st, 2004.

Invention field

The present invention relates to the method for production high levels of alcohol in the fermenting process of vegetable material, and the high pure karusen of producing.Present method can comprise the fractional separation of vegetable material.The invention still further relates to the method for producing high protein distiller's dried grain (Distiller ' s DriedGrain) from the fermentation of vegetable material, and relate to the high protein distiller's dried grain that production obtains.Present method can comprise by ring drying (ring drying), flash drying (flash drying) or fluidised bed drying comes dry joint product.The invention further relates to the fume emission that in alcohol production, reduces from the drying and distilling product.

Background of invention

Existing many traditional vegetable materials that utilizes transform production alcoholic acid method.But these methods have many defectives.Also need the other more effective method that vegetable material is changed into ethanol and produces the leavened prod of improvement.

Summary of the invention

The present invention relates to the method for production high levels of alcohol in the fermenting process of vegetable material, and the high pure karusen that relates to production.Present method can comprise the fractional separation of vegetable material.The invention still further relates to the method for producing the high protein distiller's dried grain from the fermentation of vegetable material, and relate to the high protein distiller's dried grain that production obtains.Present method can comprise by ring drying, flash drying or fluidised bed drying comes dry joint product.

In one embodiment, the present invention relates to produce the alcoholic acid method from vegetable material (for example, classified isolating vegetable material).This method comprises the fractional separation vegetable material; Grind vegetable material (for example, classified isolating vegetable material) comprises starch with generation the vegetable material that pulverizes (as, classified isolating vegetable material); The starch saccharification without boiling; This starch of hatching ferments; With from fermented product, reclaim ethanol.The inventive method can comprise and during fermentation changes temperature.The inventive method can comprise the vegetable material (for example, classified isolating vegetable material) that uses the certain granules size, and the feasible material above 50% of wherein said granular size is suitable in size having the sieve of 0.5mm mesh.The inventive method can be produced the composition that comprises at least 18% volume ethanol.

In one embodiment, the present invention relates to produce the method for high protein distiller's dried grain from vegetable material (for example, classified isolating vegetable material).This method comprises the fractional separation vegetable material; Grind vegetable material (for example, the vegetable material of fractional separation) comprises starch with production the vegetable material that pulverizes (for example, the vegetable material of fractional separation); Produce sugar without boiling from starch; This sugar without boiling that ferments comprises the alcoholic acid composition with production; And from fermented product, reclaim distiller's dried grain.Distiller's dried grain can comprise the protein at least about 30%.Distiller's dried grain can comprise the zein level of increase.

In one embodiment, the present invention relates to from Maize Production alcoholic acid method.This method comprises from Maize Production starch and from Starch Production ethanol; Generation contains the more exsiccant fume emission of obvious lower level volatile organic compounds than routine techniques.

Brief description of drawings

Fig. 1 illustrates the fermentation system according to one embodiment of the invention.

The inventive method that illustrates Fig. 2 A to 2C has improved the efficient that the corn fraction utilizing dry grinding (dry milling) fractional separation to handle to produce is fermented.

The inventive method that illustrates Fig. 3 A to 3C has improved the efficient that the corn fraction utilizing the dry grinding fractional separation to handle to produce is fermented.

Detailed Description Of The Invention

As used herein, phrase " without boiling " refers to not carry out making the heat treatment of starch gelatinization and dextrinize and utilizes AMS starch to be converted into the method for ethanol. Usually, for method of the present invention, " without boiling " refers to holding temperature below starch gelatinization temperature, generates glucose soluble and walks around conventional starch gelatinization condition thereby by natural insoluble living starch saccharification occurs directly. According to starch source and polymer type, starch gelatinization temperature is generally in 57 ℃ to 93 ℃ scopes. In the method for the invention, it is not essential utilizing conventional liquefaction technology to carry out effective fermentation that gelatinized corn starch refines for carbohydrate in the cereal.

As used herein, phrase " vegetable material " refers to all or part of (for example, cereal grain) of any plant, is typically the amyloid material of bag. Suitable vegetable material comprises cereal such as maize (corn, for example, the complete corn that grinds), Chinese sorghum (West Africa jowar (milo)), barley, wheat, rye, rice and broomcorn millet; And amyloid root crop, stem tuber or root such as sweet potato and cassava. Vegetable material can be the mixture of above-mentioned material and the joint product of above-mentioned material, and for example, zein fiber, corncob, stalk or other comprise material such as timber or the vegetable remains thing of cellulose and hemicellulose. Suitable vegetable material comprises corn, or standard corn or waxy corn.

As used herein, phrase " classification separate vegetable material " refers to only to comprise the vegetable material of a part or the fraction of whole plant, is typically the amyloid material of bag. The vegetable material that classification separates can comprise for example corn (maize) (corn (fractionated corn) that classification separates) that separates of classification of cereal that classification separates, the Chinese sorghum that classification separates (the West Africa jowar (milo) that classification separates), the barley that classification separates, the wheat that classification separates, the rye that classification separates, the rice that classification separates, and the grain of classification separation; And the amyloid root crop of classification separation, the cassava that the sweet potato that stem tuber or root such as classification separate separates with classification. The vegetable material that suitable classification separates comprises the corn that classification separates, or the waxy corn of the standard corn of classification separation or classification separation.

As used herein, term " saccharification " and " saccharification " refer to starch is converted into less polysaccharide and finally is converted into monose, such as the process of glucose. Soluble dextrinize substrate is produced in the liquefaction of the starch of traditional saccharification after by gelatinization, and this substrate is hydrolyzed to glucose by glucoamylase. In the inventive method, saccharification refers to use enzyme, and for example glucoamylase and acid fungal amylase (AFAU) will be given birth to starch and be converted into glucose. According to the inventive method, living starch produces conventional dextrinize substrate without liquefaction and the gelatinization of routine.

As use herein, acid amylomycin unit of enzyme activity (AFAU) is meant and is used for measuring the active standard of acid fungal amylase Novozymes unit.This Novozymes unit is described in Novozymes technical bulletin SOP No.:EB-SM-0259.02/01.Above-mentioned unit can measure by the product that iodometric titration detects starch degradation.1 unit definition is the enzyme amount of the 5.260mg starch dry matter of per hour degrading under standard conditions.

As use herein, glucoamylase activity unit (GAU) is meant the standard Novozymes unit that is used for measuring glucoamylase activity.The assay method that glucoamylase activity detects in this Novozymes unit and being used for is described at the Novozymes of public Ke De technical bulletin.

As use herein, amyloglucosidase activity unit (AGU) is meant the standard Novozymes unit that is used for measuring amyloglucosidase activity.This Novozymes unit is described in Novozymes technical bulletin SOP No.:EB-SM-0131.02/01.Above-mentioned unit can measure to the conversion of glucose by detecting maltose.Can utilize glucose dehydrogenase reaction assay glucose.1 unit definition is the enzyme amount that per minute catalysis 1mmol maltose transforms under specified criteria.

As use herein, modify the term of any amount " approximately " and refer in producing sugar and alcoholic acid physical condition for example change of the amount that in laboratory, pilot plant or production unit, is occurred.For example, in the mixture amount of used component when the deviation and the attention level that are included in alcohol production factory or the laboratory typical case's use when measuring by " approximately " when modifying.For example, in the product amount of component when deviation and analytical procedure intrinsic deviation between being comprised when modifying in alcohol production factory or the laboratory by " approximately " batch.Whether no matter modify with " approximately ", described amount comprises the value that is equal to of those amounts.Described herein and be used for the present invention through " approximately " modify any amount also can be used as without " approximately " amount of modification.

Starch is converted into ethanol

The present invention relates between vegetable material (for example, classified isolating vegetable material) yeast phase, produce the method for high levels of alcohol, and the high pure karusen that relates to production.The invention still further relates to from vegetable material and (for example, classified isolating vegetable material produce the method for high protein distiller's dried grain in) the fermentation, and the high protein distiller's dried grain and the cleaner more exsiccant fume emission that relate to production.

The inventive method will be converted into ethanol from the starch of vegetable material (for example, classified isolating vegetable material).In one embodiment, the inventive method can comprise that vegetable material that preparation is used for saccharification (for example, the vegetable material of fractional separation), without under the situation of boiling the vegetable material (for example, the vegetable material of fractional separation) of preparation being converted into sugar, and this sugar that ferments.

Can be through several different methods arbitrarily, for example through grinding, so that starch can be used for saccharification and fermentation, and preparation is used for the vegetable material (for example, the vegetable material of fractional separation) of saccharification.In one embodiment, can grind vegetalitas (Vegetable) material so that the material behind the mill quite most of, for example major part is in size by having the sieve of 0.1-0.5mm sieve aperture.For example, in one embodiment, the vegetalitas after the grinding (vegetable) material about 70% or more can be by having the sieve of 0.1-0.5mm sieve aperture.In one embodiment, comminuted plants material (reduced plant material) (for example, the vegetable material of fractional separation) can mix with the ratio of liquid according to about 20 to about 50wt% or about 25 to the about 45wt% dried vegetable materials of pulverizing (for example, the vegetable material of fractional separation).

The inventive method can comprise comminuted plants material (for example, the vegetable material of fractional separation) is converted into the sugar that can use microorganism such as yeast to ferment.The available enzyme preparation carries out this conversion as this comminuted plants material of saccharifying enzyme composition saccharification (for example, the vegetable material of fractional separation).The saccharifying enzyme composition can comprise that various being suitable for is converted in the known enzyme of fermentable sugars any with comminuted plants material (for example, the vegetable material of fractional separation), as amylase (for example, α-Dian Fenmei and/or glucoamylase).In one embodiment, saccharification is at pH about 6.0 or lower, and for example, about 4.5 to about 5.0 carry out, and for example, carries out in about 4.5 to about 4.8.

The inventive method comprises that with the sugar-fermenting from comminuted plants material (for example, the vegetable material of fractional separation) be ethanol.Fermentation can be carried out as yeast by microorganism.In one embodiment, fermentation is at pH about 6 or lower, and for example, about 4.5 to about 5 carry out, and for example, carries out in about 4.5 to about 4.8.In one embodiment, the inventive method comprises change pH.For example, fermentation can be included in the first half between charge period at pH about 3 to about 4.5 o'clock filling fermentor tanks and reinforced during to about 6 (for example, about 4.5 to about 4.8) at pH about 4.5 during half at fermentor tank feeding study on period back.In one embodiment, fermentation is at about 25 to about 40 ℃ or about 30 carry out to about 35 ℃ of temperature.In one embodiment, temperature is reduced to about 30 ℃ or about 25 ℃ from about 40 ℃ between yeast phase, perhaps reduces to about 30 ℃ from about 35 ℃ during the first half of fermentation, and remains on this lower temperature in back half temperature of fermentation.In one embodiment, fermentation is carried out about 25 (for example, 24) to about 150 hours, for example, carries out about 48 (for example, 47) to about 96 hours.

The inventive method can comprise and simultaneously comminuted plants material (for example, the vegetable material of fractional separation) is converted into sugar and with microorganism such as these sugar of yeast fermentation.

The product of fermenting process is called " karusen " (beer) in this article.Ethanol can pass through various known method, for example by distilling from fermenting mixture, reclaiming from karusen.Residual stillage (stillage) comprises liquid and solid matter.This liquid can be by for example centrifugal the separation with solid.

The preparation of vegetable material

Present method will change into ethanol from the starch of vegetable material (for example, the vegetable material of fractional separation).Vegetable material (for example, the vegetable material of fractional separation) can be pulverized through the whole bag of tricks, thereby for example makes starch can be used for saccharification and fermentation through grinding.The additive method of pulverizing vegetable material also is obtainable.For example, vegetable matter such as corn grain can be used for grinding ball mill, roller mill, hammer mill or other grinding machine that vegetable matter and/or other material reach the purpose that reduces particle size and grind with known.Can reduce the utilization of the method for granular size by emulsifying technology, rotary pulsed (rotary pulsation) and other, the surface-area that increases vegetable material (for example, the vegetable material of fractional separation) improves the flow efficiency of liquefaction back medium simultaneously.The vegetable material (for example, the vegetable material of fractional separation) of preparation can be described as " giving birth to starch (raw starch) " or comprises " giving birth to starch ".

Fine grinding exposes vegetable material (for example, the vegetable material of fractional separation) or the more surface-area of vegetable matter, and can promote saccharification and fermentation.In one embodiment, thus the quite major part of grinding the material behind the feasible mill of vegetable matter, and for example major part is suitable in size having the sieve of 0.1-0.5mm sieve aperture.In one embodiment, about 35% of the ground vegetable matter or more in size can be by having the sieve of 0.1-0.5mm sieve aperture.In one embodiment, about 35% of the ground vegetable matter to about 70% in size can be by having the sieve of 0.1-0.5mm sieve aperture.In one embodiment, about 50% of the ground vegetable matter or more in size can be by having the sieve of 0.1-0.5mm sieve aperture.In one embodiment, about 90% of the ground vegetable matter in size can be by having the sieve of 0.1-0.5mm sieve aperture.In one embodiment, all ground vegetable matters in size all can be by having the sieve of 0.1-0.5mm sieve aperture.In one embodiment, the ground vegetable matter has the average particle size particle size of about 0.25mm.

Vegetable material is pulverized

The preparation of vegetable material (for example, the vegetable material of fractional separation) can be used any one in a large amount of vegetable material (for example, the vegetable material of fractional separation) crushing technology.For example, the preparation vegetable material (for example, the vegetable material of fractional separation) present method can using emulsion technique, rotary pulsed (rotary pulsation), ultrasonic, magnetostriction, ferromagnetic substance, etc.These methods of pulverizing vegetable material can be used for the pre-treatment of substrate.Though be not used for limiting the present invention, believe that surface-area that these methods can increase vegetable material (for example, the vegetable material of fractional separation) increases the flow efficiency (just, reducing viscosity) of liquefaction back medium simultaneously.These methods can comprise electricity to the vibration to friction-motion speed electricity, pulse and sound basis machinery, machinery.This can provide the different frequency in the wide frequency ranges, and these frequencies may be effective for pre-treatment vegetable material (for example, the vegetable material of fractional separation) and/or minimizing particle size.

Though be not used for limiting the present invention, it is believed that the destruction that some method in these sound wave methods can produce low pressure and cause particulate cavitation or grain pattern around vegetable material (for example, the vegetable material of fractional separation) particulate.This cavitation or the destructive particle can increase the utilization ratio that vegetable material (for example, the vegetable material of fractional separation) can be used for enzyme, for example, realize by the mode that increases surface-area.This pre-treatment is considered to reduce the quantity of enzyme ratio in the method ethanol production of the present invention.

In one embodiment, the inventive method comprises vibration vegetable material (for example, the vegetable material of fractional separation) and makes the liquid cavitation that contains vegetable material.The size that this can cause destroying vegetable material and/or reduce vegetable material (for example, the vegetable material of fractional separation).In certain embodiments, the inventive method comprises and utilizes emulsifying technology, utilizes rotary pulsed (rotary pulsation), utilizes magnetostriction or utilize ferromagnetic substance to handle vegetable material (for example, the vegetable material of fractional separation).The size that this can cause destroying vegetable material and/or reduce vegetable material (for example, the vegetable material of fractional separation).In one embodiment, the inventive method comprises sonic treatment vegetable material (for example, the vegetable material of fractional separation).The size that this can cause destroying vegetable material and/or reduce vegetable material (for example, the vegetable material of fractional separation).

In one embodiment, the inventive method can comprise and utilizes sound wave to pulverize vegetable material (for example, the vegetable material of fractional separation).This sound wave can be a ultrasonic wave.The inventive method can comprise sonic treatment vegetable material (for example, the vegetable material of fractional separation).This method can be included in and can effectively reduce frequency (for example, with kHz metric), power (for example, with watt metric) and hold time the down sonic treatment vegetable material of (perhaps assisting to reduce) particle size to top described size.For example, this method can be included in 20,000Hz and be lower than about 3000W sonic treatment vegetable material (for example, the vegetable material of fractional separation) time enough down and under suitable temperature.This sonic treatment can be utilized existing device realization on the market, for example can be available from ETREMA (Ames, high-power ultrasonics instrument IA).

In one embodiment, the inventive method can comprise the rotary pulsed vegetable material (for example, the vegetable material of fractional separation) of pulverizing of use.This method can be included in and can effectively reduce (perhaps assisting to reduce) particle size to the frequency of top described size (for example, metric with Hz), power (for example, metric with watt) and the time length rotary pulsed vegetable material (for example, the vegetable material of fractional separation) that gets off.Thisly rotary pulsedly can utilize known equipment to realize, for example U.S. Patent No. 6,648, the equipment of being introduced in 500, and its disclosed content is introduced into here as a reference.

In one embodiment, the inventive method can comprise and uses pulse wave (pulsewave) technology to pulverize vegetable material (for example, the vegetable material of fractional separation).This method can be included in and can effectively reduce (perhaps assisting to reduce) particle size to the frequency of top described size (for example, metric with Hz), power (for example, metric with watt) and the time length rotary pulsed vegetable material (for example, the vegetable material of fractional separation) that gets off.This pulse can utilize known equipment to realize, for example U.S. Patent No. 6,726, the equipment of being introduced in 133, and its disclosed content is introduced into here as a reference.

Fractional separation

In one embodiment, vegetable matter is gradable is separated into one or more components.

For example; vegetable matter such as cereal class grain or corn are gradable such as fiber (for example to be separated into; zein fiber), plumule (ferm) (for example, maize germ) and starch and proteinic mixture components such as (for example, the mixtures of W-Gum and corn protein).A kind of or the mixture of these components can be according to method fermentation of the present invention.The fractional separation of corn or other vegetable material can be finished by any diverse ways or device.For example, the system that is produced by Satake can be used for fractional separation vegetable material such as corn.

In one embodiment, plumule in can the fractional separation vegetable matter and fibre fractionation and it is separated from the remainder of vegetable matter.In one embodiment, the remainder of vegetable matter (for example, corn embryosperm) can further grind and reduce the granular size size, merges with the plumule of relatively large fractional separation and fibre fractionation then to be used for fermenting.

In one embodiment, can grind vegetable matter with obtain value-added product (such as neutraceuticals, leutein, carotenoid, xanthrophils, pectin, Mierocrystalline cellulose, xylogen, seminose, wood sugar, pectinose, semi-lactosi, galacturonic acid, GABA, Semen Maydis oil, white protein, sphaeroprotein, prolamine, gluten (gluetelins), zein etc.).

Fractional separation can be finished by any of several different methods and device, for example in U.S. patent application publication number No.2004/0043117 disclosed those, disclosed content is introduced into here as a reference in the document.The method and apparatus suitable for fractional separation comprises sieve, screening, and elutriation.Suitable device comprises frictional type grinding machine such as rice or grain polishing machine (polishing mill) (for example by Satake, Kett, or those of Rapsco manufacturing).

Saccharification and fermentation

Saccharification

The inventive method can comprise comminuted plants material (for example, the vegetable material of fractional separation) is converted into sugar that this sugar can ferment by microorganism such as yeast.Can be by transforming with this comminuted plants material of any saccharification (for example, the vegetable material of fractional separation) of any known multiple saccharifying enzyme composition.In one embodiment, the saccharifying enzyme composition comprises amylase, as αDian Fenmei (for example acid fungal amylase).This zymin can also comprise glucoamylase.This zymin needn't, and in one embodiment, do not comprise proteolytic enzyme.Yet, can water saving by utilizing the process water (returning poor) may comprise proteolytic enzyme again according to method ethanol production of the present invention.In one embodiment, the inventive method uses acid amylomycin enzymic hydrolysis to give birth to starch.

Saccharification can be carried out without boiling.For example, can carry out saccharification without boiling by cereal and process water and saccharifying enzyme source (for example, industrial enzyme), yeast and the fermentation component mixing that will grind.

In one embodiment, saccharifying comprises that it can form slurries or suspension with comminuted plants material (for example, the vegetable material of fractional separation) and liquid mixing, and adds the saccharifying enzyme composition in liquid.In one embodiment, this method comprises comminuted plants material (for example, the vegetable material of fractional separation) and liquid mixing, adds the saccharifying enzyme composition subsequently.The interpolation enzyme composition carries out when perhaps, can or mix before mixing.

In one embodiment, the comminuted plants material (for example, the vegetable material of fractional separation) can be (for example with about 20 to about 50wt%, about 25 to about 45,44) wt%, about 30 to about 40 (for example, 39) wt%, or the ratio and the liquid mixing of the dried vegetable material of pulverizing with about 35wt% (for example, the vegetable material of fractional separation).As use herein, the wt% that pulverizes vegetable material in the liquid refers to the per-cent of comminuted plants material dry-matter or dried solid substance.In one embodiment, compare the conventional saccharification of carrying out boiling, method of the present invention can be converted into ethanol with higher dried solid substance level and faster rate with giving birth to starch or native starch (for example, in the comminuted plants material of doing).Though do not limit the present invention, think that the inventive method can carry out with higher dried solid substance level, because be different from ordinary method, the inventive method does not comprise increases the gelatinization of viscosity effect.

Suitable liquid comprises the mixture of water and water and process water, described process water be for example stillage (return poor), scrubbing tower water (scrubber water), evaporator condensation liquid or distillate, from the process water of distillatory side-cut stripper (side stripper) water or other ethanol plant.In one embodiment, liquid comprises water.In one embodiment, liquid comprise with about 1 to about 70vol% stillage, about 15 to about 60vol% stillage, about 30 to about 50vol% stillage, or about 40vol% stillage blended water.

In the ordinary method of using gelatinization effect and liquification, stillage provides effective nutrient for yeast fermentation, especially the required free amino nitrogen (FAN) of yeast.The present invention can and even not add at the stillage that the reduction level is provided and realizes effectively fermentation under the situation of stillage.In one embodiment, the inventive method (is for example used vegetable material, the vegetable material of fractional separation) prepared product, wherein this prepared product is the nitrogenous source that sufficient amount and quality are provided in effective fermentation of (for example, when having high-level comminuted plants material) under the high density condition.Therefore, in one embodiment, do not need stillage or only low-level stillage just enough.

Yet if necessary, the inventive method provides the maneuvering ability of using high-level stillage.The inventive method is not used conventional liquification.Conventional liquification increases the viscosity of fermenting mixture and gained stillage.The inventive method produces more low viscous stillage.Therefore, in one embodiment, the inventive method can adopt the stillage level of raising and not cause the unfavorable increase of the viscosity of fermenting mixture and gained stillage.

In addition, though do not limit the present invention, think that conventional saccharification and fermenting process need add FAN owing to " Maillard reaction " that take place not expect during high temperature gelatinization effect and liquification.Maillard reaction consumes FAN during boiling.Therefore, ordinary method need be added stillage (the perhaps FAN in other source) to improve the level of FAN in fermentation.The inventive method is considered to avoid thermoinducible Maillard reaction and the FAN that increases level is provided in the comminuted plants material, and these FAN can effectively be utilized by yeast in fermentation.

Saccharification can use various known enzymes source (for example, microorganism) or composition any carry out, from comminuted plants material (for example, the vegetable material of fractional separation), to produce fermentable sugars.In one embodiment, the saccharifying enzyme composition comprises amylase, as αDian Fenmei (for example, acid fungal amylase) or glucoamylase.

In one embodiment, saccharification is at pH about 6.0 or lower, and pH about 3.0 to about 6.0, about 3.5 to about 6.0, about 4.0 to about 5.0, about 4.0 to about 4.5, about 4.5 is to about 5.0, or carries out in about 4.5 to about 4.8 o'clock.In one embodiment, saccharifying can or carry out at pH about 4.1 to about 4.6 in about 4.9 to about 5.3 o'clock.Can be by for example adding, ammonia, sulfuric acid, phosphoric acid, process water (for example, under stillage (returning poor (backset)), evaporator condensation liquid (distillate), the side-cut stripper raffinate (bottom) etc.) wait the initial pH that regulates the saccharification mixture.The activity of some saccharifying enzyme composition (for example, a kind of enzyme composition that comprises acid fungal amylase) can be improved when being lower than the pH of above-mentioned scope.

In one embodiment, saccharification is at about 25 to about 40 ℃ or about 30 carry out to about 35 ℃ of temperature.

In one embodiment, can select that dextrin is in lower concentration in the fermented liquid to keep to the amount of the employed saccharifying enzyme composition of saccharifying.For example, the inventive method can be used to reaching the saccharifying enzyme amount of composition that following purpose is selected, and described purpose is equal to or less than about 0.2wt% or is equal to or less than about 0.1wt% for keeping trisaccharide maltose (DP3) level.For example, the inventive method can to the amount of employed saccharifying enzyme composition select with keep have 4 or the dextrin (DP4+) of the above polymerization degree be in the level that is equal to or less than about 1wt% or is equal to or less than about 0.5wt%.

In one embodiment, can select to keep the lower concentration of maltose in the fermented liquid the amount of the employed saccharifying enzyme composition of saccharifying.For example, the inventive method can be used to reaching the saccharifying enzyme amount of composition that following purpose is selected, and described purpose is equal to or less than about 0.3wt% for keeping the maltose level.For keeping low-level maltose, suitable acid fungal amylase and glucose starch enzyme level comprise acid fungal amylase be about 0.05 to about 3AFAU/ gram do solid shape the pulverizing vegetable material (for example, DSC) and glucoamylase be about 1 to about 2.5 (for example, 2.4) AGU/ gram do solid shape the pulverizing vegetable material (for example, DSC).In one embodiment, reaction mixture comprise acid fungal amylase be about 0.1 to about 2AFAU/ gram do solid shape the pulverizing vegetable material (for example, DSC) and glucoamylase be about 1 to about 2.5AGU/ gram do solid shape the pulverizing vegetable material (for example, DSC).In one embodiment, reaction mixture comprise acid fungal amylase be about 0.3 to about 2AFAU/ gram do solid shape the pulverizing vegetable material (for example, DSC) and glucoamylase be about 1 to about 2.5AGU/ gram do solid shape the pulverizing vegetable material (for example, DSC).In one embodiment, reaction mixture comprise acid fungal amylase be about 1 to the about 2AFAU/ gram pulverizing vegetable material of doing solid shape (for example, DSC) and glucoamylase be the about 1 pulverizing vegetable material of doing shape admittedly to about 1.5AGU/ gram (for example, DSC).

Glucoamylase

In certain embodiments, present method can be used glucoamylase.Glucoamylase is also referred to as amyloglucosidase and has 1, the systematic naming method (E.C.3.2.1.3) of 4-α-D-dextran glucose lytic enzyme (1,4-alpha-D-glucan glucohydrolase).Glucoamylase is meant a kind of enzyme, and it can remove the successive glucose unit from the non-reduced end of starch.For example, some glucoamylase can hydrolyzed starch, the straight chain and the side chain glycosidic link of amylose starch and amylopectin.Many suitable glucoamylases are known and are commercial buying.For example, supplier such as Novozymes and Genencor provide glucoamylase.This glucoamylase can be an originated from fungus.

The amount of the glucoamylase of Shi Yonging can change according to the enzymic activity of diastase in the method.Suitable consumption comprises that about 0.05 does solid shape to about 6.0 glucose starch unit of enzyme (AGU)/gram and pulverizes vegetable material (for example, DSC).In one embodiment, reaction mixture can comprise that about 1 to about 6AGU/ restrains dried solid shape pulverizing vegetable material (for example, DSC).In one embodiment, can comprise in the reaction mixture that pulverizing vegetable material that about 1 to about 3AGU/ gram does solid shape (for example, DSC).In one embodiment, reaction mixture can comprise that pulverizing vegetable material that about 1 to about 2.5 (for example, 2.4) AGU/ gram does solid shape (for example, DSC).In one embodiment, reaction mixture can comprise that pulverizing vegetable material that about 1 to about 2AGU/ gram does solid shape (for example, DSC).In one embodiment, reaction mixture can comprise that pulverizing vegetable material that about 1 to about 1.5AGU/ gram does solid shape (for example, DSC).In one embodiment, reaction mixture can comprise that pulverizing vegetable material that about 1.2 to about 1.5AGU/ grams do solid shape (for example, DSC).

Acid fungal amylase

In certain embodiments, the inventive method is used α-Dian Fenmei.This α-Dian Fenmei can be by mycetogenetic.The feature of this α-Dian Fenmei can have the ability of hydrolysis carbohydrate under acidic conditions for it.Produce and amylase that can the hydrolysis carbohydrate under acidic conditions is called acid fungal amylase herein by fungi, and also claim the fungal alpha-amylase that acid is stable.But the acid fungal amylase catalysis starch of partial hydrolysis and big oligosaccharides is hydrolyzed to sugar such as glucose.Its feature of acid fungal amylase that can be used for the inventive method can be to help to give birth to starch or native starch hydrolysis, and the saccharification that is provided by glucoamylase is provided.In one embodiment, this acidity fungal amylase produces more maltose than conventional (for example, bacterium) α-Dian Fenmei.

Suitable acid fungal amylase can separate from various fungal species, comprises Aspergillus (Aspergillus), Rhizopus (Rhizopus), Mucor (Mucor), Candida (Candida), Coriolus Qu61 (Coriolus), the mould genus of eqpidemic disease (Endothia), Enthomophtora, rake Pseudomonas (Irpex), Penicillium (Penicillium), sclerotium (Sclerotium) and torulopsis (Torulopsis).In one embodiment, acid fungal amylase is heat-staple and separates from Aspergillus (Aspergillus) species, as aspergillus niger (A.niger), A.saitoi or aspergillus oryzae (A.oryzae), separation is from Mucor (Mucor) species, as Mucor pusillus (M.pusillus) or the conspicuous Mucor (M.miehei) of rice, or separate from the mould genus of eqpidemic disease (Endothia), as parasitic eqpidemic disease mould (E.parasitica).In one embodiment, acid fungal amylase separates from aspergillus niger (Aspergillusniger).Acid amylomycin enzymic activity can be used as a kind of activity in the glucose starch zymin and provides, or it can be used as independent enzyme and adds.Suitable acid fungal amylase can obtain from Novozymes, for example with glucoamylase.

The acid fungal amylase amount of using in present method can change according to the enzymic activity of diastase.Appropriate vol comprises the pulverizing vegetable material (for example, doing the corn (DSC) of solid shape) of the dried solid shape of about 0.1 to about 10 acid fungal amylase units (AFAU)/gram.In one embodiment, reaction mixture can comprise that pulverizing vegetable material that about 0.05 to about 3AFAU/ gram does solid shape (for example, DSC).In one embodiment, reaction mixture can comprise that pulverizing vegetable material that about 0.1 to about 3AFAU/ gram does solid shape (for example, DSC).In one embodiment, reaction mixture can comprise that pulverizing vegetable material that about 0.3 to about 3AFAU/ gram does solid shape (for example, DSC).Reaction mixture can comprise that pulverizing vegetable material that about 1 to about 2AFAU/ gram does solid shape (for example, DSC) in one embodiment.

Fermentation

Present method comprises being ethanol from the sugar-fermenting of pulverizing vegetable material (for example, the vegetable material of fractional separation).Fermentation can be carried out as yeast by microorganism.This fermenting mixture needn't comprise proteolytic enzyme, does not comprise proteolytic enzyme in one embodiment.Yet process water may comprise proteolytic enzyme.The amount of this proteolytic enzyme can be lower than amount used in the ordinary method.According to the present invention, fermentation is to carry out on without the starch composites of boiling.In one embodiment, this fermentation process produces drinkable alcohol (alcohol).Drinkable alcohol only has other alcohol of acceptable nontoxic level, as potato spirit.Fermentation can comprise that the mixture that will contain from the sugar of pulverizing vegetable material (for example, the vegetable material of fractional separation) contacts under the condition that is suitable for yeast growth and alcohol production with yeast.In one embodiment, the saccharification mixture is used in fermentation.

Different yeast all can be used as yeast bottle opener (starter) in the methods of the invention arbitrarily.Suitable yeast comprises various commercially available yeast, as business-like yeast saccharomyces cerevisiae (Saccharomycescerevisiae) bacterial strain.Suitable bacterial strain comprise " Fali " (Fleischmann ' s), Thermosac (Alltech), Ethanol Red (LeSafre), BioFerm AFT (North AmericanBioproducts), or the like.In one embodiment, be chosen in the yeast that quick growth and fermenting speed are provided when high temperature and high ethanol level exist.In one embodiment, find that the Fali yeast provides according to superperformance, the final ethanol content of measurement is greater than 17% volume.

The amount of selecting the used yeast bottle opener was for example produced commercial significant amount of alcohol effectively with in the suitable time in 75 hours.

Can be used to add yeast to the currently known methods of fermenting process yeast is added fermented product by various.For example, the yeast bottle opener can be used as a collection of dry substance, or adds through conditioning (conditioning)/propagation.In one embodiment, the yeast bottle opener adds as single inoculum.In one embodiment, yeast adds fermented product with the speed of the dry yeast (ADY) of 5 to 100 pounds of work of per 100,000 gallons of karusens during the filling fermentor tank.In one embodiment, yeast can adapt to or nurses one's health by hatch about 5 to 50 pounds ADY with per 10,000 gallons of fermentor tank volumes in pre-fermentor tank or breeding jar.In the breeding stage, hatch and can be 8 to 16 hours, wherein also through ventilating to stimulate yeast growth.The pre-fermentor tank that is used to inoculate main fermentation tank can be 1 to 10% volume of main fermentation tank, for example, and with respect to 2.5 to 5% volume of main fermentation tank.

In one embodiment, fermentation is at pH about 6 or lower, pH about 3 to about 6, about 3 to about 4.5, about 3.5 to about 6, about 4 to about 5, about 4 to about 4.5, about 4.5 to about 5 or carried out in about 4.5 to about 4.8 o'clock.The initial pH of fermenting mixture can be by for example adding, ammonia, sulfuric acid, phosphoric acid, process water (for example, raffinate or the like under stillage (returning poor), evaporator condensation liquid (distillate), the side-cut stripper) or the like and regulate.

Although do not limit the present invention, think known distillery yeast at the scope well-grown of pH 3 to 6, it more tolerates and is low to moderate 3.0 low pH but compare most of contaminative bacterial isolateses.Contaminative lactic acid and bacterium vinegar pH 5.0 and when higher growth best.Therefore, think in the scope of pH 3.0 to 4.5 that because yeast is grown better than polluted bacteria, ethanol fermentation is occupied an leading position.

In one embodiment, the inventive method can comprise change pH.The change of carrying out pH is considered to and can strengthens zymic growth and fermentation in fermentation early stage reduction contamination of heavy and/or at the fermentation later stage.For example, fermentation can be included in the first half between charge period in pH about 3 to about 4.5 filling fermentor tanks.Fermentation can be included in the back pH to pH about 4.5 to about 6 that improves slurries during half of fermentor tank feeding study on period.Fermentation can comprise by adding as mentioned above the fresh substrate slurries of required pH keeps pH.In one embodiment, (reinforced back) do not regulate pH between yeast phase.On the contrary, in this embodiment, pH is determined by the pH of component between charge period.

In one embodiment, in the corn process water pH be reduced to about five (5) or below.In one embodiment, pH is reinforced in fermentation is about pH 4 (for example, 4.1) when initial and finishes towards fermentation is reinforced that pH is increased to about pH 5 (for example, 5.2).In one embodiment, the reinforced initial stage that this method is included in fermentor tank is set up the pH control that stops the converted mash slurries behind the yeast culture, allows pH come-up in the corn process water subsequently in the reinforced latter stage of fermentor tank.

In one embodiment, fermentation carry out about 25 (for example, 24) to about 150 hours, about 25 (for example, 24) to about 96 hours, about 40 to about 96 hours, about 45 (for example, 44) to about 96 hours, about 48 (for example, 47) to about 96 hours.For example, fermentation can carry out about 30, about 40, about 50, about 60 or about 70 hours.For example, fermentation can carry out about 35, about 45, about 55, about 65 or about 75 hours.

In one embodiment, fermentation is at about 25 to about 40 ℃ or about 30 carry out to about 35 ℃ of temperature.In one embodiment, temperature is reduced to about 30 ℃ or about 25 ℃ from about 40 ℃ between yeast phase, or reduces to about 30 ℃ from about 35 ℃ during the first half of fermentation, and remains on this lower temperature in back half temperature of fermentation.In one embodiment, temperature can produce with ethanol and reduce.For example, in one embodiment, temperature can be reduced to about 79  subsequently up to about 99  between yeast phase.This temperature descends and can coordinate mutually with the ethanol titre (%) that improves in the fermentor tank.

In one embodiment, the inventive method comprises solid substance segmentation (solidsstaging).The starting stage that the solid substance segmentation is included in the fermentor tank feeding study on period is reinforced to improve initial fermenting speed with out-of-proportion higher solid substance level.The solid concentration that adds the converted mash (mash) of fermentor tank can be subsequently along with raising of ethanol titre and/or fermentor tank feeding study on period reduce near finishing.In one embodiment, solid concentration ferments at the first half and can be about 40% (for example, 41%) between charge period.After filling 50%, fermentor tank can be reduced to about 25% and hold to continue and finish until the fermentor tank feeding study on period.In above example, above-mentioned strategy causes whole fermentor tank to have 33% solid substance.

The solid substance segmentation is considered to can be by the quick startup that utilizes more initial charge solid substance to promote enzymic hydrolysis speed and impel fermentation.Think in addition and can reduce the stress effect relevant zymic osmotic pressure at reinforced back half minimizing solid substance.Maintain in the specified fermentation capacity scope by the filling solid substance that fermentor tank is overall, the solid substance segmentation can improve and closes on fermentation ends, the ability of yeast fermentation high-concentration mash.

Synchronous glycosylation and fermentation

The inventive method can comprise and simultaneously comminuted plants material (for example, the vegetable material of fractional separation) is converted into sugar and with as those sugar of microbial fermentations such as yeast.Synchronous glycosylation and fermentation can utilize above-mentioned reagent and the condition that is used for saccharification and fermentation to carry out.

In one embodiment, saccharification and fermentation are at about 25 to about 40 ℃ or about 30 carry out to about 35 ℃ of temperature.In one embodiment, temperature is reduced to about 25 ℃ from about 40 ℃ between saccharification and yeast phase, or reduces to about 30 ℃ from about 35 ℃ during the first half of saccharification, and remains on this lower temperature in back half temperature of saccharification.

Although do not limit the present invention, think saccharification and fermentation early stage when alcohol concn hangs down higher temperature can improve the conversion of starch to fermentable sugars, this can help to improve ethanol production.When higher alcohol concn, but ethanol negative impact yeast.Therefore, think that saccharification and fermentation lower temperature of later stage help reduction zymic is coerced, this can help to improve ethanol production.

Still do not limit the present invention, think that the early stage higher temperature of saccharification and fermentation can reduce viscosity between at least a portion yeast phase, this can help temperature control.Think that also saccharification and fermentation lower temperature of later stage help stopping the generation that glucose is reduced in the fermentation back at yeast.The generation of fermentation glucose in late period is unfavorable to the color of distiller's dried grain joint product (co-product).

In one embodiment, saccharification and fermentation are at pH about 6 or lower, pH about 3 to about 6, about 3.5 to about 6, about 4 to about 5, about 4 to about 4.5, about 4.5 to about 5 or carried out in about 4.5 to about 4.8 o'clock.The initial pH of saccharification and fermenting mixture can be by for example adding, ammonia, sulfuric acid, phosphoric acid, process water (for example, raffinate or the like under stillage (returning poor), evaporator condensation liquid (distillate), the side-cut stripper) or the like and regulate.

In one embodiment, saccharification and fermentation carry out about 25 (for example, 24) to about 150 hours, about 25 (for example, 24) to about 72 hours, about 45 to about 55 hours, about 50 (for example, 48) to about 96 hours, about 50 to about 75 hours or about 60 to about 70 hours.For example, saccharification and fermentation can carry out about 30, about 40, about 50, about 60 or about 70 hours.For example, saccharification and fermentation can carry out about 35, about 45, about 55, about 65 or about 75 hours.

In one embodiment, synchronous glycosylation and fermentation can use the enzyme of selection and zymic amount to carry out sprouting with yeast and the high-caliber yeast of keeping the fermented liquid middle and high concentration.For example, the inventive method can be used to keeping yeast and be equal to or higher than about 200 cells/ml, is equal to or higher than about 300 cells/ml or equals about 300 enzyme and the zymic amounts of selecting to about 600 cells/ml.

In one embodiment, synchronous glycosylation and fermentation can use the enzyme of selected amount and yeast to carry out, not add exogenous nitrogen; Do not add proteolytic enzyme and/or do not add back when being pickled with grains or in wine and effectively ferment.If desired, can add back being pickled with grains or in wine, to consume process water and to reduce the wastewater flow rate that produces by the inventive method.In addition, the inventive method is kept low viscosity between saccharification and yeast phase.

In one embodiment, synchronous glycosylation and fermentation can use the enzyme of selected amount and yeast to carry out to keep the soluble sugar of lower concentration in the fermented liquid.In one embodiment, synchronous glycosylation and fermentation can use the enzyme of selected amount and yeast to carry out to keep the glucose of lower concentration in the fermented liquid.For example, the inventive method can use the enzyme of selected amount and yeast to be equal to or less than about 2wt% to keep glucose, to be equal to or less than about 1wt%, to be equal to or less than about 0.5wt%, or is equal to or less than the level of about 0.1wt%.For example, the inventive method can use the enzyme of selected amount and yeast to keep the level that glucose between saccharification and yeast phase is equal to or less than about 2wt%.For example, the inventive method can use the enzyme of selected amount and yeast being equal to or less than the level of about 2wt% with 0-10 hour of maintaining saccharification and fermentation time (or 0 to this time about 15%) glucose.For example, the inventive method can use the enzyme of selected amount and yeast being equal to or less than about 1wt%, being equal to or less than about 0.5wt% or being equal to or less than the level of about 0.1wt% with 12-54 hour of maintaining saccharification and fermentation time (or should time about 15% to about 80%) glucose.For example, the inventive method can use the enzyme of selected amount and yeast being equal to or less than the level of about 1wt% with 54-66 hour of maintaining saccharification and fermentation time (or should time about 80% to about 100%) glucose.

In one embodiment, synchronous glycosylation and fermentation can use the enzyme of selected amount and yeast to carry out maltose (DP2) to keep lower concentration in the fermented liquid.For example, the inventive method can use the enzyme of selected amount and yeast to keep the level that maltose is equal to or less than about 0.5wt% or is equal to or less than about 0.2wt%.

In one embodiment, synchronous glycosylation and fermentation can use the enzyme of selected amount and yeast to carry out to keep the dextrin of lower concentration in the fermented liquid.For example, the inventive method can be used the enzyme of selected amount and yeast to be equal to or less than about 0.5wt% to keep trisaccharide maltose (DP3), is equal to or less than about 0.2wt% or is equal to or less than the level of about 0.1wt%.For example, the inventive method can use the enzyme of selected amount and yeast with keep have 4 or the dextrin (DP4+) of the above polymerization degree be equal to or less than about 1wt% or be equal to or less than the level of about 0.5wt%.

In one embodiment, synchronous glycosylation and fermentation can use the enzyme of selected amount and yeast to carry out to keep the potato spirit of lower concentration in the fermented liquid.For example, the inventive method can use the enzyme of selected amount and yeast to be equal to or less than about level of 0.4 to about 0.5wt% to keep potato spirit.

For example, synchronous glycosylation and fermentation can be used about 0.05 to about 10AFAU/ gram to do solid shape to pulverize vegetable material (for example, acid fungal amylase DSC) and about 0.5 is done shape pulverizing vegetable material (for example, glucoamylase DSC) admittedly to about 6AGU/ gram.For example, synchronous glycosylation and fermentation can be used about 0.1 to about 10AFAU/ gram to do solid shape to pulverize vegetable material (for example, acid fungal amylase DSC) and about 0.5 is done shape pulverizing vegetable material (for example, glucoamylase DSC) admittedly to about 6AGU/ gram.For example, synchronous glycosylation and fermentation can be used about 0.3 to about 3AFAU/ gram to do solid shape to pulverize vegetable material (for example, acid fungal amylase DSC) and about 1 is done shape pulverizing vegetable material (for example, glucoamylase DSC) admittedly to about 3AGU/ gram.For example, synchronous glycosylation and fermentation can be used about 1 to about 2AFAU/ gram to do solid shape to pulverize vegetable material (for example, acid fungal amylase DSC) and about 1 is done shape pulverizing vegetable material (for example, glucoamylase DSC) admittedly to about 1.5AGU/ gram.

Other component that is used for saccharification and/or fermentation

Saccharification and/or fermenting mixture can comprise that other component is to improve the efficient of this method.For example, mixture can comprise extra nutrient (for example, yeast micronutrient), microbiotic, salt, extra enzyme, or the like.Nutrient can derive from the stillage that adds to this liquid or return poor.Suitable salt comprises zinc or magnesium salts, as zinc sulfate, sal epsom, or the like.Suitable extra enzyme comprises that those add to the enzyme of ordinary method, as proteolytic enzyme, phytase, cellulase, hemicellulase, circumscribed-and inscribe-dextranase, zytase, or the like.

From karusen, reclaim ethanol

The products known as of fermenting process " karusen (beer) " herein.For example, fermented maize produces " corn fermentation wine with dregs ".Ethanol can be by various known methods from fermenting mixture, reclaim from karusen.For example, ethanol can reclaim by distillation.

Residual stillage comprises liquid and solid material.This liquid and solid can pass through, for example centrifugation.The liquid---spent wash (thin stillage)---that reclaims can be used as at least a portion of the liquid that forms saccharification and fermenting mixture, is used for subsequently batch fermentation or running.

The solid substance---distiller's dried grain---that reclaims comprises the yeast solid substance of unfermentable cereal solid substance and consumption.Spent wash (thin stillage) but simmer down to syrup (syrup), it can add to distiller's dried grain and this mixture can dry add solvend (distiller ' s dried grain plus solubles) to form distiller's dried grain subsequently.Distiller's dried grain and/or distiller's dried grain add solvend and can be used as the animal-feed sale.

After-flame (burn-out) residual starch is used for Secondary Fermentation subsequently

In one embodiment, the inventive method can comprise the thermal treatment of karusen or stillage, for example between fermentation vat (beer well) and distillation.In one embodiment, the inventive method can comprise the thermal treatment of karusen or stillage and the interpolation of enzyme, for example between fermentation vat (beer well) and distillation.In the process that is called after-flame (burn-out), this thermal treatment can be converted into starch dextrin and the sugared fermentation that is used for subsequently.Described treatment step can also reduce silt up (fouling) of distilling tray and vaporizer heat exchange surface.In one embodiment, can carry out segmentation thermal treatment to whole stillage or spent wash.After the enzyme of residual starch is handled, in one embodiment, the dextrin of gained and sugar can be used as that returning of recirculation is pickled with grains or in wine in Primary Fermentation process fermentation or the fermentation series (fermentation train) of separating in processing with generation ethanol.In one embodiment, distillation can be accelerated liquefaction and the saccharification to the spent wash of whole stillage or centrifugal generation afterwards.

From fermented product fractional separation solid substance

The plumule of bulk and fiber can be at the residual starch of fermentation cylinder for fermentation.After the fermentation, these fractions can be removed before distillation or afterwards.Can before distillation, implement to remove with surperficial skimmer.In one embodiment, can sieve to karusen.Material after sieving can separate from the mixture of ethanol/water with rotation steam oven drying (rotary steam drum drying) by for example centrifugal subsequently, and this can remove residual ethanol from this cake (cake).In the embodiment that bigger fiber and plumule piece are removed, can use the stripping tower that separates at this fiber/plumule stream before large quantities of karusens distillations.Perhaps, can remove fiber and plumule by after distillation, whole stillages being sieved.

In one embodiment, with all component mixing and dry together.Fiber and plumule can be by selection by winnowing (aspiration) and/or screenings (size classification) and remove from the finished product.Can be from DDGS the selection by winnowing fiber.Remove fiber by selection by winnowing after the drying and can make oil and proteinic amount raising 0.2 to 1.9% and 0.4 to 1.4% among the residual DDGS respectively.The amount of NDF for example can reduce by 0.1 to 2.8% among the residual DDGS.

In one embodiment, fractional separation can use bigger fiber and plumule piece to come from that part of granular size and the raising syrup supporting capacity of the DDGS of endosperm with raising.Festoon drier pulverizer (ring dryer disintegrator) can cause certain particle to reduce and homogenization.

Be used for the method and system of dry wet cake (wet cake) with the preparation distiller's dried grain

The karusen that produces by fermentation comprises ethanol, other liquid and solid material.Centrifugal and/or the distillation of karusen can produce the solid substance of the wet cake of being known as and the liquid of the spent wash of being known as.Can the dry wet cake to produce distiller's dried grain.Spent wash can be condensed into syrup (syrup), and it can be added in wet cake or the distiller's dried grain, can add solvend to form distiller's dried grain by dry this mixture then.The inventive method can comprise that the dry wet cake is to produce distiller's dried grain.The inventive method can comprise that dry syrup adds distiller's dried grain and adds solvend to produce distiller's dried grain.Distiller's dried grain can produce from whole cereal (for example, corn) or produce the cereal (for example, corn) of the fractional separation of hanging oneself.The inventive method can produce high protein distiller's dried grain and/or the improved distiller's dried grain of physical property.This distiller's dried grain is described below.

Conventional alcohol production technology is used rotary drum dryer (drum dryer).Advantageously, in one embodiment, the inventive method and system can use hurried or festoon drier.Hurried or festoon drier before never had been used to such as in the such technology of the present invention.Hurried and configuration festoon drier is known.Briefly, hurried or festoon drier can comprise vertical pillar, and pre-heated air draught makes wet cake move through this post.For example, hurried or festoon drier can comprise one or more imports, so that the air of warm air or heating enters in the moisture eliminator thus.This drying wet cake.Be transported to the top of pillar through the wet cake of exsiccant.In festoon drier, can carry out further drying by making wet cake move through one or more rings that are connected to pillar.For example, festoon drier can comprise one or more imports, by described import, and the air admission ring structure of heating, it makes wet cake reach or circulation in this ring structure or around this ring structure.The wet cake of exsiccant can be transported to downstream separation equipment such as rotoclone collector or particle collector by air effect subsequently.

The inventive method can comprise to be used the wet cake of flash dryer dry (flash drying just) and produces distiller's dried grain.The inventive method can comprise that using dry (the flash drying just) syrup of flash dryer to add distiller's dried grain adds solvend to produce distiller's dried grain.Use flash dryer can produce high protein distiller's dried grain and/or the improved distiller's dried grain of physical property.This distiller's dried grain is described below.

The inventive method can comprise to be used the wet cake of festoon drier dry (ring drying just) and produces distiller's dried grain.The inventive method can comprise that using festoon drier (ring drying just) to come dry syrup to add distiller's dried grain adds solvend to produce distiller's dried grain.Use festoon drier can produce high protein distiller's dried grain and/or the improved distiller's dried grain of physical property.This distiller's dried grain is described below.

The inventive method can comprise to be used the wet cake of fluidized bed dryer dry (fluidised bed drying just) and produces distiller's dried grain.The inventive method can comprise that using fluidized bed dryer (fluidised bed drying just) to come dry syrup to add distiller's dried grain adds solvend to produce distiller's dried grain.Use fluidized bed dryer can produce high protein distiller's dried grain and/or the improved distiller's dried grain of physical property.This distiller's dried grain is described below.

Before the inventive method can be included in drying, syrup (returning poor or spent wash) was added in the drying or dry back in wet cake.In one embodiment, the inventive method is included in and adds syrup (returning poor or spent wash) in the drying process in wet cake.For example, present method can be included in and mix wet cake and syrup in the moisture eliminator.For example, present method can comprise and syrup flowed into or syrup is injected in hurried, annular or the fluidized bed dryer.In one embodiment, the inventive method is included under the situation that wet cake and/or distiller's dried grain exist in the post of moisture eliminator or ring and adds syrup.

Though be not used for limiting the present invention, to think hurried and/or festoon drier is different from rotation or rotary drum dryer, it has reduced wet cake and has contacted with pyritous in the drying process.Rotation or rotary drum dryer have the hot metal that contacts for a long time with wet cake product usually.This hot metal and wet cake long-term contact be considered to cause to become palm fibre, distiller's dried grain or distiller's dried grain pyrogenic or sex change add solvend.And the Inside Air Temperature in rotation or the rotary drum dryer may be higher.

Therefore, in one embodiment, the inventive method can comprise comparing with rotation or rotary drum dryer uses less time to come dry wet cake or wet cake to add syrup, and obtains that the distiller's dried grain or the distiller's dried grain of thorough drying add solvend.Therefore, in one embodiment, the inventive method can comprise that comparing the lower temperature of use with rotation or rotary drum dryer comes dry wet cake or wet cake to add syrup, and obtains that the distiller's dried grain or the distiller's dried grain of thorough drying add solvend.In one embodiment, the inventive method is included in and changes drying temperature in the drying process.

Though be not used for limiting the present invention, in certain embodiments, this dehumidification system and method can provide one or more advantages, for example reduce the energy consumption in the drying, reduce the leakage of self-desiccation system.

One embodiment of the invention are to use hurried or festoon drier changes the condition of dryer system inside to increase or to reduce temperature.One embodiment of the invention are to use hurried or festoon drier changes the condition of dryer system inside to increase or to reduce humidity.One embodiment of the invention are to use hurried or festoon drier changes the condition of dryer system inside to increase or to reduce recirculation rate (recycle speed).One embodiment of the invention are to use hurried or festoon drier changes the condition of dryer system inside to increase or to reduce the speed of charging in dryer system.

Continuously ferment

The inventive method can be by method running in batches or continuously.Continuous processing comprises makes saccharification and/or fermenting mixture move through (pump is crossed) a series of container (for example, groove) so that this process is held the time enough that continues.For example, continuous processing can be used multistage segmentation fermentation system, the 48-96 hour residence time.For example, comminuted plants material (for example vegetable material of fractional separation) can be put into the top of first container that is used for saccharification and fermentation.Part is hatched and the mixture that ferments can shift out from the bottom of first container subsequently and send the top of second container to, or the like.

Though do not limit the present invention, think that the inventive method is more suitable for turning round with continuous processing than ordinary method.Think that the inventive method can reduce the growth machine meeting of polluting organism when moving in a continuous manner.At present, most of drying and crushing alcohol production factory uses the batch fermentation technology.Partly cause is to be difficult to prevent the loss that causes because of the pollution in these ordinary methods.For utilizing effectively continuously fermenting of traditional liquefaction technology, it is generally acknowledged saccharification stage of separating before the fermentation in advance-karusen that saccharification is used to ferment is essential.This pre--saccharification guaranteed to have enough fermentable glucose to be used to the process of continuously fermenting.

The inventive method realized high concentration ethanol effective production and before fermentation aneroid turn into and the saccharification stage.Because conventional knowledge is taught in and must has enough horizontal available fermentable sugars in the process of fermenting in a continuous manner, so this is wonderful.On the contrary, the inventive method can provide the glucose of lower concentration and effectively fermentation.In the methods of the invention, glucose it seems that the yeast cell that is just being fermented has consumed fast.This low dextrose level is considered to reduce coerces zymic, as coercing of being caused by osmotic pressure inhibition and bacterial contamination pressure.According to the present invention, in about 45 to about 96 hours, can reach greater than 18% volume of ethanol level.

Endosperm, fiber and plumule fermentation

In one embodiment, the inventive method for example part of corn of the vegetable material pulverized of can fermenting.For example, can ferment at least a in endosperm, fiber or the plumule of this method.The inventive method can increase the ethanol production from this part of corn.In one embodiment, but the inventive method saccharification and the fermentation endosperm.Owing to contain the removal of the plumule of free amino nitrogen (FAN), the endosperm fermentation has lower FAN near the fermentation beginning time.For example, the inventive method is compared the FAN quality that can keep endosperm with conventional high temperature liquefaction.One embodiment of the invention comprise uses endosperm FAN, and this can increase the handiness and the efficient of fermentation.

In one embodiment, the inventive method can be used the endogenous enzyme activity in the cereal.In one embodiment, compare the remarkable increase of in the fermentation of full corn and the corn that removes fiber, reaching FAN with initial converted mash slurries.

Conventional cereal dry ginding operation is used a series of step and operation to isolate plumule and wheat bran from endosperm (starch and the albumen) part of cereal or is planted skin (fiber fraction).These steps and operation comprise: cereal cleans, regulate (tempering), degerming, reduce granularity, roll powder (roller milling), air draught (aspirating) and screening.This method is different from traditional wet milling process of cereal (logical see be corn), and wet milling process is costliness and water loss more, but can make grain component realize more purified separation.The dry grinding method provides a kind of mode of using low cost of capital to come separated portion for factory.And these methods need less water to be used for running.With water ratio required in the wet-milling, in dry grinding, regulate the less water of arts demand.

When method of the present invention was used for the ethanol conversion of these components, the competitiveness of dried grain fractional separation method was strengthened.Traditional dry grinding method produces every kind of fraction (plumule, wheat bran and endosperm) of various grades.In one embodiment, the inventive method provides wheat bran and the endosperm fraction that can more easily ferment.According to the expectation purity of every kind of fraction, fraction can be merged to produce the mixture of every kind of logistics, perhaps can handle each fraction individually respectively.

Yeast utilizes FAN in the methods of the invention.In the liquefaction process of routine, because yeast cell assimilates and the available FAN of metabolism during the fermentation, the FAN level is all dropping in whole fermentation process.During near fermentation ends, the FAN level raises, and the release of cell FAN is described in ordinary method, and this conforms to cracking with the death of yeast cell.By contrast, the kinetics that FAN utilizes in the living starch technology of the present invention is more quick.The FAN level at least early reached Schwellenwert in 24 hours, began remarkable increase then.A part of reason that FAN increases is to quicken the yeast cell death that fermentation causes.

High ethanol fermentation wine with dregs

The invention still further relates to high ethanol fermentation wine with dregs.In one embodiment, method of the present invention produces the karusen that comprises greater than 18% volume ethanol.The inventive method can produce this high ethanol fermentation wine with dregs in about 40 to about 96 hours or about 45 to about 96 hours.In one embodiment, karusen comprises 18% volume to about 23% volume of ethanol.For example, the inventive method can produce 18 to 23% volume of ethanol content in fermentor tank in about 45 to 96 hours.

As another example, the inventive method can produce 18 to 23% volume of ethanol content in fermentor tank in about 45 to 96 hours.In certain embodiments, most of ethanol (final concentration 80% or more than) produce in initial 45 hours.Subsequently, 2 to 5% volume ethanol in addition produced in final 12-48 hour.When reaching 96 hours, fermentation time can reach 23% volume of ethanol concentration.Results are to improve the productivity of fermentor tank after 48 to 72 hours in fermentation, and this may be favourable economically.

Karusen of the present invention can comprise this high-caliber ethanol, even also like this when it comprises high-level residual starch.For example, karusen of the present invention can comprise 18 to 23% volume of ethanol when comprising 0 to 30% residual starch.This karusen can comprise and low reaches 0% to up to 20% residual starch.

Use conventional means, the residual starch of high level shows the fermentation of poor efficiency, and this only produces low-level ethanol., though do not limit the present invention, think that the inventive method produces less Mei Lade type reaction product and more effective yeast fermentation (for example, the secondary metabolite level of reduction).This is considered to, and the inventive method has the low dextrose level and low temperature is caused owing to comparing with liquification with conventional saccharification.Therefore, even the residual starch of higher level is arranged, the inventive method still can produce more ethanol.

In one embodiment, karusen of the present invention comprises less residual joint product (byproduct) than conventional karusen, although residual starch may be many.For example, compare with the amount in the conventional karusen that produces under similar fermentation condition, residual glucose, maltose and senior dextrin (DP3+) can hang down nearly 0.8wt%.As another example, residual glycerine can hang down nearly 0.7wt%.Lactic acid and potato spirit also significantly reduce.For example, karusen of the present invention can comprise the glucose that is less than or equal to about 0.2wt%, about 0.4wt%, about 0.1wt% DP3, detect less than glycerine, the lactic acid of about 0.01wt% and/or the potato spirit of about 0.4wt% of DP4+, 0.7wt%.

Distiller's dried grain

The high protein distiller's dried grain

The invention still further relates to the distiller's dried grain product.Distiller's dried grain can also comprise one or more protein, fat, fiber (for example, the neutral detergent fiber (neutral detergentfiber, NDF)) and the starch of improving the standard.For example, distiller's dried grain of the present invention can comprise 34wt% or higher protein, about protein of 25 to about 60wt%, about protein of 25 to about 50wt% or about protein of 30 to about 45wt%.In some cases, proteinic amount than the protein mass much about 1 of producing by ordinary method to about 2wt%.For example, distiller's dried grain can comprise 15wt% or higher fat, about 13 to about 17wt% fat or than about 1 to about 6wt% the fat that manys by ordinary method production.For example, distiller's dried grain can comprise 31wt% or higher fiber, about fiber of 23 to about 37wt% or than about fiber of 3 to about 13wt% that manys of producing by ordinary method.For example, distiller's dried grain can comprise 12wt% or higher starch, many about starch of 1 to about 23wt% or about starch of 1 to about 18wt% than what produce by ordinary method.

In one embodiment, compare conventional distiller's dried grain product, distiller's dried grain of the present invention comprises vitamins B, vitamins C, vitamin-E, folic acid and/or the vitamin A that level improves.Distiller's dried grain of the present invention is compared conventional distiller's dried grain product and is had more bright-coloured gold.

Distiller's dried grain with physical properties of improvement

The invention still further relates to the distiller's dried grain of physical properties, as reducing caking (caking) or compacting (compaction) or strengthening mobile with one or more improvement.The inventive method can produce the distiller's dried grain of this improvement.

Though do not limit the present invention, think that the inventive method can produce and comprise the more fermentation solid substance of the carbohydrate of high molecular form.Compare with the solid substance from ordinary method, this fermentation solid substance it is believed that and can show high glass transition (that is, higher Tg value).For example, residual starch can have high Tg value.Therefore, by starch content among control DDG and the DDGS, the inventive method can prepare DDG or the DDGS with target Tg value.

In addition, according to the present invention, the alkaline syrup mixture of interpolation (for example, syrup adds lime or other basic materials of interpolation) can make distiller's dried grain add solvend (DDGS) minimizing caking or compacting or strengthen mobile in fermentation solid substance (for example, distiller's dried grain).

Though do not limit the present invention, think that the organic acid such as lactic acid, acetic acid and the succsinic acid that produce in the fermentation have lower Tg value than its corresponding calcium salt.Keep the residual carbon hydrate of higher molecular weight form or add lime to form the organic acid calcium salt, for forming two kinds of strategies of higher Tg value joint product, these joint product will have low possibility generation glass transition, and the latter causes being called harmful phenomenon of caking.

In one embodiment, of the present invention or be easier to flow than the DDG or the DDGS that produce by ordinary method by DDG or DDGS that the inventive method produces.

Though do not limit the present invention, think that method of the present invention needn't destroy the protein in the vegetable material of fermentation (for example, the vegetable material of fractional separation).Corn contains prolamine, as zein.For example, Chinese sorghum comprises a class zein sample protein that is called kafirin, and its amino acid composition is similar to zein.The thermal destruction that takes place during liquefaction, distillation and the high temperature drying causes comprising the DDG and the DDGS of quite a large amount of degrade proteins.Method of the present invention is considered to improve the level of the prolamine fraction of Cereals (cereal grain).

It is believed that, prolong and to be exposed to the high determining alcohol of realizing by the inventive method and can to regulate protein in the vegetable material (for example, the vegetable material of fractional separation).Some protein of this solubilized.For example, it is believed that in distillation alcohol concn can reach the level of prolamine in the solubilized karusen (for example, zein).Behind removal or " sloughing (stripping) " ethanol from karusen, prolamine (as zein) is recyclable to be concentrated among DDG and the DDGS.The DDG of gained high protein content and DDGS are useful for the various whole purposes of DDG and DDGS, for example in other processing or cooperation (compounding).

In one embodiment, the component such as the starch of non-zein has been removed in effective fermentation of the inventive method from DDG or DDGS.The fractional separation vegetable material, for example corn also can improve protein among DDG or the DDGS, as the level of zein.For example, remove bran and plumule (germ) fraction before the fermentation and can in substrate, concentrate zein.Zein in the corn is isolated in the endosperm.The fermentation of the endosperm of zein enrichment causes concentrating of zein in the fermentation residue.

In one embodiment, the inventive method can go up at the vegetable material (for example, the other parts of endosperm, fiber, cereal grain) of fractional separation and implement, so that the solid substance product of rich in proteins to be provided from fermentation.For example, the inventive method of implementing on the vegetable material of fractional separation can produce the enrichment prolamine, for example the DDG of zein.

In one embodiment, method of the present invention can provide DDG and the DDGS with different predetermined Tg values.Method of the present invention can ferment comprise height, in or the fraction of low-level zein, change the second-order transition temperature of gained DDG or DDGS thus.The Tg of gained joint product can be directly proportional with the content of prolamine (as zein).Method expectation of the present invention is used for the fermentation of Quality Protein Maize.This also allows to have the DDG of higher prolamine (zein) content and the production of DDGS.

The last residual starch preferable separation of fermentation is in the spent wash fraction, and this fraction is evaporated subsequently to produce syrup.By the wet cake fraction that the inventive method produces, it can be dry separately with generation DDG, and comparable conventional DDG has higher prolamine (as zein).The inventive method allows to change the ratio of mixture of syrup and wet cake.This generation has the prolamine (as zein) of different ratios and the DDG/DDGS of residual starch.Residual starch reduces in wet cake, and protein just increases in the wet cake.This indicates a kind of inverse relationship.Similarly effect occurs in the syrup fraction.

Starch is considered to separable and goes in the liquid fraction.Amount of starch among the DDGS can change by the ratio mixing molasses of time different before dry or between dry epoch with 0 pound of syrup solid substance of every pound of wet cake solid substance dry weight to 1.2 pound syrup solid substance, thereby produces final DDGS product.Residual starch is out-of-proportion to be segregated into back poor or the timesharing of spent wash level can be carried out above-mentioned burnouting and Secondary Fermentation to these fractions.Because spent wash evaporation produces syrup, centrifugal material balance (massbalance) also makes and can produce the DDGS with different Tg values to the dependency of Tg according to desired characteristic and they.

Discharging

The present invention has the discharging advantage.The discharging advantage causes that the joint product that produced in the ethanol manufacturing processed reduce.The extraction of oil and fat significantly reduces in from the converted mash of grain plumule fraction.Generally the joint product of the Maillard reaction that forms during boiling and liquefaction reduce.And the minimizing of the joint product that ferment in addition.These phenomenons cause the minimizing of joint product discharge between payback period.The concentration and the drainage rate of volatile organic matter (VOC), carbon monoxide (CO), oxynitride (NOx), sulfur oxide (SO2) and other discharges significantly reduce, referring to table 1.It is to be noted that other manufacturers attempts that wet cake replaces being dried to DDG or DDGS reduces discharging by producing.

The invention still further relates to the volatile organic matter (VOC) of volatile organic compounds (VOC) as producing by dry tunning.The inventive method comprises producing compares ethanol, distiller's dried grain and other the useful leavened prod that ordinary method produces low VOC level.For example, the VOC that drying and distilling product (for example, exhausted cereal) generation level reduces in the inventive method.

For example, the conventional fermentation process that utilizes corn produces about 2.1 pounds of VOC by the corn of processing per ton from the drying and distilling product.Actual smoke stack emission amount can be lower because of pollution control equipment.The inventive method produces the minimizing of 30%VOC output at least, about 1.47 pounds or lower to the corn of processing per ton.The minimizing of this discharge be unexpected but be very significant, and make discharge reduce control techniques such as hot oxidant is able to more efficient use.

The VOC that is produced by fermenting process comprises ethanol, acetate, formaldehyde, methyl alcohol, acetaldehyde, propenal, furfural, lactic acid, formic acid and glycerine.

The invention still further relates to carbon monoxide (CO) as producing by the product of dry fermenting process.The inventive method comprises producing compares ethanol, distiller's dried grain and other the useful leavened prod that ordinary method produces low CO level.For example, the CO that drying and distilling product (for example, exhausted grain) generation level reduces in the inventive method.

For example, the conventional fermentation process that utilizes corn produces about 1.4 pounds of CO by the corn of processing per ton from the drying and distilling product.Actual smoke stack emission amount can be lower because of pollution control equipment.The inventive method produces the minimizing of 30%CO output, reaches about 0.98 pound or lower of the corn of processing per ton.The minimizing of this discharge is unexpected and very meaningful, and makes discharge reduce control techniques, is used more effectively as hot oxidant.

Table 1: the minimizing of discharge

The discharge type		Unit	Conventional running	Method of the present invention	Discharge reduces %
						VOC	Concentration	ppmv lb/dscf	663	459.65	30.67
Drainage rate	lb/hr	13.35	7.91	40.75
					CO		Concentration	ppmv lb/dscf	434	234.13	46.05
Drainage rate	lb/hr	9.1	4.94	45.71

The alcohol production system

In one embodiment, the present invention relates to produce the alcoholic acid system.System of the present invention can comprise sacchariferous equipment 1, fermentation equipment 2, distillation equipment 3 and moisture eliminator equipment 4.

Sacchariferous equipment 1 can be to be applicable to comprise or carry out any equipment in the various device of saccharification.Sacchariferous equipment 1 can be, for example, and a kind of container that the comminuted plants material can be changed into the sugar that can ferment by microorganism such as yeast therein.Can be provided with sacchariferous equipment 1, so that the saccharification mixture is maintained under the condition that is suitable for saccharification.Can be provided with sacchariferous equipment 1, so that provide condition for transforming the comminuted plants material by the interpolation enzyme.In one embodiment, sacchariferous equipment 1 is set to and is used for liquid is mixed with the comminuted plants material and adds the saccharifying enzyme composition to this liquid.In one embodiment, sacchariferous equipment 1 is configured to be used for carrying out saccharification under different pH values and temperature, but preferred pH is 6.0 or lower, and temperature is about 25 to about 40 ℃.

Fermentation equipment 2 can be any equipment that is applicable in the various device that comprises or ferment.Sacchariferous equipment 1 can be, for example, a kind ofly the sugar-fermenting that comes from the comminuted plants material can be become the alcoholic acid container therein.Fermentation equipment 2 can be set, so that fermenting mixture is maintained under the condition that is suitable for fermenting.In one embodiment, fermentation equipment 2 can be set at and be used for by using microorganism such as yeast to ferment.In one embodiment, fermentation equipment 2 can be set at the starch composites of fermentation without boiling, particularly saccharification mixture.In one embodiment, this equipment can use the yeast that can produce any kind of of commercial significant amount of alcohol in the suitable time.Yeast can add in the equipment by any method that becomes known in system's interpolation zymic the whole bag of tricks of carrying out fermentation.Fermentation equipment 2 can be set at and be used for to about 40 ℃ temperature, carrying out fermentation in about 25 to 150 hours about 25.

Sacchariferous equipment 1 and fermentation equipment 2 can be integral device.In one embodiment, this equipment is set and provides higher temperature in early days at the same time the comminuted plants material is transformed in saccharogenesis and these sugared processes of fermenting.In one embodiment, this equipment is set, to provide lower temperature in the later stage in the process of carrying out saccharification and fermentation at the same time.This equipment also can use above-mentioned reagent and the condition that is used for saccharification and fermentation, comprises enzyme and yeast.

Distillation equipment 3 can be any equipment that is applicable in the various device of distillation leavened prod.Of course, for example, distillation equipment 3 is set so that from fermenting mixture (" karusen "), reclaim ethanol.In one embodiment, fermenting mixture was heat-treated before entering distillation equipment 3.In another embodiment, before or after entering distillation equipment 3, remove the plumule and the fiber fraction of bulk with surperficial skimmer or sieve.

Moisture eliminator equipment 4 can be any equipment that is applicable in the various device of dry distillation (and optional centrifugal, for example, in centrifugation systems) the remaining solid substance in back.In one embodiment, moisture eliminator equipment 4 is set so that the solid substance of dried recovered, this can cause the generation of distiller's dried grain.Behind the karusen separating alcohol, stay the solid substance of recovery in the distillation system.The solid substance of these recovery then can be dry in moisture eliminator equipment 4.This produces distiller's dried grain and/or distiller's dried grain adds solvend.In one embodiment, moisture eliminator equipment 4 can be or comprise ring-like moisture eliminator.In one embodiment, moisture eliminator equipment 4 can be or comprise flash dryer.In one embodiment, moisture eliminator equipment 4 can be or comprise fluidized bed dryer.

The present invention can understand better according to the following example.These embodiment are intended to represent specific embodiment of the present invention, and do not attempt to limit the scope of the invention.

Embodiment

Embodiment 1-present method is for coming from cereal dry ginding operation (endosperm, fiber, and plumule)

Substrate improved effect is provided

The invention provides fermentation and come from the improved method that cereal grinds the substrate of (doing fractional separation) technology.Because having removed plumule has caused reducing the FAN level in the converted mash, makes the present invention can be used for the endosperm that ferments.Present method helps the endogenous enzyme activity in the cereal.Compare the remarkable increase that has reached FAN in full corn and the defiber corn fermentation with primary converted mash slurries.

Result and discussion

Present method can be used for the endosperm fermentation, because the removal of plumule has caused reducing the FAN level in the converted mash, shown in Fig. 2 A.FAN provides required nitrogenous source for yeast growth and has reduced the relevant pressure of ethanol in high density (gravity) ethanol fermentation.Fig. 2 A has reflected that liquefaction is to reducing the counter productive of available FAN amount in the fermentation.Dextrin and production of dissolved sugars cause producing Mei Lade (Maillard) condensation reaction between the amino group of the carbonyl group of sugar and amino acid and peptide in the high temperature liquefaction process.This has caused the loss (because carbohydrate can not obtain) of potential production and has reduced the converted mash nutritional quality (nutritional quality) (because reduction of FAN) that is used to keep effective high gravity fermentation.Present method also makes the endogenous enzyme activity in the cereal can help the generation of soluble sugar and amino nitrogen in the converted mash.These useful activity do not have in the liquefaction stage of routine.Shown among Fig. 2 B that the FAN that carries out the fermentation of different dry grain milling thing fraction utilizes kinetics.

Notice that very meaningfully the FAN kinetics in the common process all follows the similar approach that utilizes to each cereal level part.At the first half of fermentation, FAN is consumed in the process of yeast growth.Subsequently, observe the increase of FAN level, the chances are owing to release with the death of yeast cell and the corresponding cell FAN of cracking causes.Observe that initial FAN utilizes much quick in giving birth to starch technology.Be also noted that FAN significantly increased when living amylofermentation finished.The increase of this FAN may be the result of yeast cell death, because the alcoholic acid throughput rate is faster in the living amylofermentation.Also may be owing to come from the FAN generation of endogenous enzyme in the cereal.Notice that when plumule is removed the growth of FAN has reduced in the latter half of fermentation.These observationss have been pointed out another aspect of living starch technology.

Fig. 2 C has shown FAN in the influence of not using back the cereal fraction fermentation of carrying out in poor, relatively and contrast the sensitivity of two kinds of methods to extra interpolation FAN.Clearly, method of the present invention has significantly been improved the potential substrate quality that is used for fermenting from dry grinding fractional separation equipment, has reduced the importance of extra FAN.Present method is better than conventional liquifying method, because conventional liquifying method is more responsive to the decomposition effect of carrying out metric substrate quality by the FAN level.

Embodiment 2-present method has been produced high protein DDG from the plant prod of fractional separation

Before the present invention has proved and fermented corn is carried out fractional separation and can in the DDG that produces, provide high-level albumen.

Material and method

Before fermentation, corn is carried out fractional separation by use Satake fractional separation system.After the fractional separation, using glucose amylase and acid fungal amylase carry out saccharification and according to the present invention corn are fermented under the situation of not boiling.Fermentation is to carry out under 5 the situation at 90  and pH.After corn solids was fermented, distillation obtained ethanol.Remaining solid carries out drying subsequently, and obtains fiber, plumule and starch sample.All fractional separation samples ground on Knifetec 20 seconds.To these sample subsequent analysis starch, albumen, fat and neutral detergent fiber (neutral detergent fiber) content.Calculate the ethanol percentage output of each sample simultaneously.About the out of Memory how these tests are carried out, also can be with reference to material and the method part of other embodiment.

Result and discussion

Present method is compared with common process and has been produced high protein DDG and high-level ethanol (table 2).

Table 2 has shown the ethanol that produced and the result of DDG from two representative samples of every kind of fiber, starch and plumule sample.Fermentation B and C are representational starch sample, have produced the ethanol of production peak and have produced the DDG (table 2) with maximum albumen per-cent.Two plumule samples have produced minimum ethanol production and the highest percent fat (table 2).Fiber sample has produced minimum protein content (table 2).Generally speaking, this table understands that for example fractional separation has increased the albumen retention rate (table 2) in whole fermentation and the still-process.

Ethanol and DDG composition level that table 2-produces from the corn fraction

Fermentation	Ethanol vol-%	Starch %dw	Albumen %dw	Fat %dw	NDR％dw	Sample type
							A	8.10	0.00	22.51	17.93	30.90	Fiber
B	12.11	3.58	42.46	5.66	12.99	Starch
							C	11.75	0.55	43.83	7.73	13.84	Starch
D	6.39	0.57	26.18	26.81	13.33	Plumule
							E	6.58	0.00	18.31	14.43	42.34	Fiber
F	4.68	0.34	22.70	29.49	17.63	Plumule

Embodiment 3-present method provides improved zein fiber fermentation

The invention provides improved fermentation and grind the method for the zein fiber substrate of (doing fractional separation) technology from cereal.Present method can be used for leniently removing starch in the zein fiber fraction by fermentation.Typically, comprise reluctant (recalcitrant) starch sedimentation thing in zein fiber level part.Present method provides the improved method of utilizing for the starch that exists in the zein fiber.

Material and method

Use available from Broin Enterprises the final fiber of Inc. (BEI) (Scotland, South Dakota U.S.A.) in this experiment.Employed supplementary feed (makeup water) is a deionized water.Utilize the pH regulator to 4.5 of sulfuric acid (0.5ml 10 * required solution) with 550,000 gallons of fermentor tanks.Wet fiber ground on the Knifetech mill twice 10 seconds.20,000 gallons yeast propagator temperature are remained on 90 Fahrenheit degrees (90 ), and the breeding jar time is eight (8) hours and utilizes sulfuric acid that the pH value is adjusted to 5.0.Use the supplementary feed that comes from factory's operation to be prepared available from Fali yeast in Fleischmann ' s Yeast.Use the commercial glucoamylase of buying of 400L dosage.

Result and discussion

Table 3

GA(L)	Temperature ()	0 hour (% ethanol)	16 hours (% ethanol)	24 hours (% ethanol)	40 hours (% ethanol)
						400	98	0	4.685	6.141	7.328
400	95	0	4.349	5.649	6.961
						400	101	0	4.897	6.351	7.265
400	104	0	5.005	6.419	7.565

Present method provides effective zein fiber fermentation (table 3).Measure by ethanol production, the data presentation in the table 3 use the positive effect of present method fiber fermentation.Variation of temperature has shown the influence that ethanol is reclaimed, and the ethanol recovery is effective under lower temperature.Present method makes the zein fiber fraction that typically hinders fermentation in ordinary method obtain fermentation effectively.

Embodiment 4-the inventive method is carried in the endosperm fermentation by extra plumule or germ meal

Supplied improved ethanol kinetics

Present method provides a kind of cereal of improved fermentation fractional separation, for example comes from the method that cereal grinds the fractional separation cereal of (doing fractional separation) technology.

Material and method

Use the boiling standard analysis (Lab Dose) of factory's DE of 308L Liquizyme SC AA (25X of 0.30ml).The fermentation standard analysis of factory's DE (lab dose) comprises the Spirizyme Plus glucoamylase (10X of 0.25ml) of 660L, the proteolytic enzyme of 33L (100X of 0.13ml), 4.4 (2 of 0.16ml 000X), does not have urea soln to the Lactrol of lbs.The segmentation condition of leavening temperature comprises from 0-24 hour 90 , from 24-48 hour 84 , and from 48-65 hour 82 .The yeast propagator standard analysis of laboratory dosage comprises the 230mL deionized water, 100mL returns poor, 70 gram maltodextrin MO40, the 5X of 0.44mL, 1.76mL 100X, 1.07 gram, 1.07 grams, the 1000X of 1.70mL, 0.13 gram zinc sulfate, 0.48 gram Fali yeast carries out eight (8) hours breeding, the breeding temperature is 90 degree (90 ), shifts 2.88mL and inoculate in each fermentor tank from yeast propagator.

Plant size dosage is meant 550,000 gallons of fermentor tanks, and uses 80mL laboratory ferment jar.The supplementary feed of adjusting employed flour gram number and adding makes each fermentor tank keep starch content consistent.Utilize sulfuric acid that the pH value of all fermentor tanks is adjusted to 6.0.Employed whole endosperm powder comes from the BEI that has ground, and all germ meals (3 * 10 seconds) on the KnifeTech mill.Grinding the full corn that uses in contrast makes it screen by Lab 1.0mm.Utilize sulfuric acid that all become are dripped samples (drop sample) thus the pH value adjust to and be less than 3.50 before dry sample, to make remaining enzymic activity inactivation carry out proximate analysis.

Result and discussion

In the beginning of fermentation, compare with the liquefaction plumule, have difference clocklike according to ethanol percentage in the plumule of present method generation.This species diversity continues to exist in whole 47 hours fermentation.Between germ meal of the present invention and liquefaction germ meal, observe similar trend.Present method provides improved ethanol kinetics by extra plumule or germ meal in the endosperm fermentation.These the results are shown among Fig. 3 A, 3B and the 3C.

Should be noted in the discussion above that as employed in specification sheets and accompanying Claim unless clearly regulation is arranged in addition, singulative " ", " one " and " this " comprise plural indication things.Therefore, for example, when mentioning the composition that comprises " a kind of compound ", comprise the mixture of two or more compounds.Unless be also noted that has clearly regulation in addition, term " perhaps " use usually it comprise " and/or " the meaning.

All publication and patent application have shown under the present invention the level of those of ordinary skill in the field in the specification sheets.

The present invention is with reference to various concrete being described with embodiment preferred and technology.Yet, be understood that still belonging in the spirit and scope of the present invention and can make many changes and improvements.

Claims (39)

1, a kind of from vegetable material production alcoholic acid method, comprising:

This vegetable material of fractional separation;

Pulverize this vegetable material contains starch with generation material; The suitable sieve of the particle of the particle diameter that the comminuted plants material has feasible about at least 50% by the 0.1-0.5mm sieve aperture;

Come this starch of saccharification with enzyme composition without boiling;

This starch through hatching that ferments comprises at least 15 volume % alcoholic acid compositions with generation; Fermentation comprises the temperature that reduces fermenting mixture; And from fermented product, reclaim ethanol and joint product.

2, the process of claim 1 wherein that vegetable material comprises corn, it comprises high amylopectin starch.

3, the process of claim 1 wherein that vegetable material comprises corn, Chinese sorghum, grain, wheat, barley, naked barley or their mixture.

4, the method for claim 3, wherein corn comprises waxy corn.

5, the method for claim 3, wherein corn comprises the high protein corn.

6, the method for claim 3, wherein corn comprises the yellow dent corn of #2.

7, the method for claim 1 comprises and utilizes hammer mill, roller mill or hammer mill and roller mill to pulverize vegetable material.

8, the method for claim 7 comprises and pulverizes vegetable material to produce a certain size vegetable material, the feasible suitable sieve by 0.1-0.5mm of at least 35% comminuted plants material.

9, the method for claim 1 comprises and utilizes the particle size reduction emulsifying technology to pulverize vegetable material.

10, the method for claim 1 comprises synchronous glycosylation and fermentation.

11, the method for claim 1 is included between saccharification, fermentation or synchronous glycosylation and yeast phase and reduces temperature.

12, the method for claim 1 is included under 25-40 ℃ the temperature and carries out saccharification, fermentation or synchronous glycosylation and fermentation.

13, the method for claim 1 is included under 27-35 ℃ the temperature and carries out saccharification, fermentation or synchronous glycosylation and fermentation.

14, the method for claim 1 is included between saccharification, fermentation or synchronous glycosylation and yeast phase temperature is reduced to about 25 ℃ from about 40 ℃.

15, the method for claim 1 is included under about 3.0 to about 6.0 pH and carries out saccharification, fermentation or synchronous glycosylation and fermentation.

16, the method for claim 1 is included under about 4.1 to about 5.3 pH and carries out saccharification, fermentation or synchronous glycosylation and fermentation.

17, the method for claim 1, be included in the fermentation filler when beginning pH be about 4 to about 4.5.

18, the method for claim 1 comprises that pH is about 5 to about 5.5 when alcohol production reaches maximum horizontal.

19, the method for claim 1 is included between saccharification, fermentation or synchronous glycosylation and yeast phase the pH value is increased to about 5.3 from about 4.

20, the method for claim 1 is included between saccharification, fermentation or synchronous glycosylation and yeast phase solid content is reduced to about 15% from about 40%.

21, the process of claim 1 wherein that enzyme composition comprises α-Dian Fenmei, glucoamylase, proteolytic enzyme or their mixture.

22, the process of claim 1 wherein that saccharification, fermentation or synchronous glycosylation and fermentation comprise interpolation proteolytic enzyme.

23, the process of claim 1 wherein saccharification, fermentation or synchronous glycosylation and fermentation comprise add back poor.

24, the process of claim 1 wherein that saccharification, fermentation or synchronous glycosylation and fermentation comprise interpolation nitrogen.

25, the method for claim 1 comprises that glucose concn carries out saccharification and fermentation less than the speed of 3wt% in the fermented product to keep.

26, the method for claim 1 comprises that using dried solid shape pulverizing vegetable material about 0.1 to the about 10 acid fungal amylase units (AFAU) of every gram and every gram to do solid shape pulverizing vegetable material about 0.1 to about 6 glucose starch unit of enzyme (AGU) carries out saccharification, fermentation or saccharification and fermentation.

27, the method for claim 1 comprises with about 25 to about 45wt% pulverizing vegetable material in water beginning saccharification, fermentation or saccharification and fermentation.

28, the method for claim 1 comprises that the remaining starch with maximum 20% begins saccharification, fermentation or saccharification and fermentation.

29, the method for claim 1 is included in and produces the ethanol that is higher than 18vol% in about 48 to 96 hours time.

30, the method for claim 1 comprises producing the ethanol of 18vol% to about 23vol%.

31, the method for claim 1 further comprises and reclaim solid substance from fermented product.

32, the method for claim 31, be recovered in reclaim before the ethanol, during and carry out afterwards.

33, the method for claim 31 comprises the recovery distiller's dried grain.

34, the method for claim 31, wherein distiller's dried grain comprises the protein of about 30-38wt%, the fat of about 11-19wt%, the fiber of about 25-37wt%.

35, the method for claim 31, wherein distiller's dried grain comprises the protein at least about 30%.

36, the method for claim 1 comprises with batch process or continuous processing and implements this method.

37, a kind of from vegetable material production alcoholic acid method, comprising:

This vegetable material of fractional separation;

Pulverize this vegetable material contains starch with generation material;

Come this starch of saccharification with the enzyme composition that comprises acid fungal amylase without boiling;

This starch through hatching that ferments comprises at least about 18vol% alcoholic acid composition with generation;

From fermented product, reclaim ethanol.

38, comprise proteinic distiller's dried grain at least about 40wt%.

39, a kind of from vegetable material production alcoholic acid method, comprising:

Pulverize this vegetable material contains starch with generation material; The particle of the particle diameter that this comminuted plants material has feasible about at least 50% is fit to the sieve by the 0.1-0.5mm sieve aperture;

Come this starch of saccharification with enzyme composition without boiling;

This starch through hatching that ferments comprises 15vol% alcoholic acid composition at least with generation; Fermentation comprises the temperature that reduces fermenting mixture; And from fermented product, reclaim ethanol and joint product;

Come dry joint product by ring drying, flash drying or fluidised bed drying.

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